Daelim SL125 SERVICE MANUAL

HOW TO USE THIS MANUAL

This manual describes effective maintenance procedure
for the SL125 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
LUBRICA TION
INSPECTIONS / ADJUSTMENTS
EXTERNAL P ARTS
FUEL SYSTEM
ENGINE REMOV AL

LH.CRANK CASE COVER / KICK ST ARTER /
CONTINUOUSL Y V ARIABLE TRANSMISSION

A.C.GENERA TOR / ST ARTER CLUTCH
CYLINDER HEAD / V ALVE
CYLINDER / PISTON
TRANSMISSION/CRANKSHAFT/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

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

WIRING DIAGRAM

17

TROUBLESHOOTING

18

19

20

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

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

ITEM SPECIFICATIONS

1,965 mm
690 mm
1,230 mm
1,350 mm
780 mm
120 mm
125 kg
255 kg

Underbone
Telescopic / 77mm
Swing arm / 66mm
120 / 70 - 12 53k / Tubeless
130 / 70 - 12 62k / Tubeless

2.00 Kgf / ㎠ (200 kPa)

2.00 Kgf / ㎠ (200 kPa)

2.00 Kgf / ㎠ (200 kPa)

2.25 Kgf / ㎠ (225 kPa)
Hydraulic disk
Drum brake

8.0ℓ

1.7ℓ
25。
86 mm
90 ㎠

Oil cooled / air cooled 4 cycle SOHC engine
1(Single cylinder), front angle 80。
56

×50.7 mm

124.9 ㏄

10.8 : 1
SOHC chain drive

1.1ℓAfter disassembly

0.75ℓAfter Oil change

0.8ℓAfter Oil filter change

0.9ℓAfter Oil change with Oil in the Oil hose removed
Forced pressure splash type
Wet sump

14.0 kgf / ㎠ (550 rpm)
5。BTDC
14。ABDC
18。BBDC
1。BTDC

0.12±0.12 mm

0.12±0.12 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
TRAIL
FRONT FORK OIL CAPACITY

TYPE
CYLINDERS / ARRANGEMENT
BORE AND STROKE
DISPLACEMENT
COMPRESSION RATIO
VALVE TRAIN
OIL CAPACITY

LUBRICATION SYSTEM
AIR CLEANER TYPE
CYLINDER COMPRESSION
INTAKE VALVE OPEN

CLOSED

EXHAUST VALVE CLOSED

CLOSED

VALVE CLEARANCE (COOLING-OFF PERIOD)

INTAKE
EXHAUST

DIMENSIONS

FRAME

ENGINE

SPECIFICA TIONS

1-11

SERVICE INFORMATION

ITEM SPECIFICATIONS

CV type ( vacuum ) 24.2 mm
BDS 26 - 112
Auto-bystarter
# 95
1 and ½ trust out
13 mm

1.800±100 ( rpm )

Automatic Transmission

3.231 (42/13)

2.786 (39/14)

C.D.I Ignition
15。BTDC / 1.800 ( rpm )
12V 10A / 5,000 ( rpm )
Closed type (MF) 12V 8AH
CR8EH - 9 (NGK)

0.8 - 0.9 mm
15A
Kick / starter motor
12V 60 / 55W
12V 5W
12V 10W

×4

12V 21 / 5W
14V 3W
14V 3W

×2

12V 1.7W

×2

14V 1.4W
12V 5W
14V 3W

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
AC GENERATOR CAPACITY
BATTERY TYPE / CAPACITY
SPARK PLUG
SPARK PLUG GAP
FUSE CAPACITY
STARTING SYSTEM
HEADLIGHT ( HIGH / LOW )
POSITION LIGHT
WINKER LIGHTS ( FR / RR )
TAIL / STOP LIGHT
HIGH-BEAM PILOT
WINKER PILOT
METER LIGHTS
TRUNK LAMP
LICENSE LAMP
PARKING BRAKE PILOT

CARBURETOR

DRIVE TRAIN

ELECTRICAL

SYSTEM

1-12

SERVICE INFORMATION

ITEM REFERENCETORQUE VALUE

THREAD DIA

(mm)

Q’TY

1.1 kgf·m

2.5 kgf·m

0.8 kgf·m

1.0 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

2.0 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

9.5 kgf·m

0.9 kgf·m

3.2 kgf·m

1.0 kgf·m

1.0 kgf·m

Apply engine oil

20
12

5

6
12
12
12

8
12
30

8

6

6

6

6

8

8

6
22

6
12

6

6

1
1
4
2
1
1
1
1
1
1
4
2
1
4
8
1
1
3
1
2
4
3
1

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
RADIATOR OIL BOLT
OIL PUMP FLAT SCREW
OIL PUMP DRIVEN GEAR NUT

TORQUE V ALUES

ENGINE

ITEM REFERENCETORQUE VALUE

THREAD DIA

(mm)

Q’TY

7.0 kgf·m

0.20 kgf·m

6.0 kgf·m

7.5 kgf·m

2.0 kgf·m

5.0~7.0 kgf·m

4.0~4.5 kgf·m

4.0~4.5 kgf·m

6.0~8.0 kgf·m

4.5 kgf·m

4.0 kgf·m

1.5 kgf·m

Initial torque

Apply locking agent

26
26
10
10

8
12

8

8
14
10
10
10

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

STEERING STEM NUT
STEERING TOP THREAD NUT
HANDLE POST NUT
FRONT FORK BOTTOM BRIDGE BOLT
FRONT FORK SOCKET BOLT
FRONT AXLE NUT
FRONT BRAKE DISK BOLT
REAR BRAKE DISK BOLT
REAR AXLE NUT
ENGINE HANGER NUT
MAIN STAND BOLT
SIDE STAND PIVOT BOLT

FRAME

1-13

SERVICE INFORMATION

ITEM REFERENCETORQUE VALUE

THREAD DIA

(mm)

Q’TY

4.5 kgf·m

2.7 kgf·m

0.6 kgf·m

2.3 kgf·m

1.8 kgf·m

1.8 kgf·m

0.15 kgf·m

3.0 kgf·m

1.0 kgf·m

1.0 kgf·m
10 kgf·m

0.4 kgf·m

4.0 kgf·m

4.0 kgf·m

4.0 kgf·m

Apply locking agent

Apply locking agent

10

8
8
8
8
8
4

10

6
6
6

5
10
10
10

1
2/2
1/1
1/1
1/1
2/2
2/2
2/2
1/1
1/1

1

1

1

1

1

SIDE STAND PIVOT NUT
FRONT / REAR BRAKE CALIPER BRACKET BOLT
FRONT / REAR BRAKE CALIPER BLEEDER VALVE
FRONT / REAR BRAKE CALIPER SLIDE PIN
FRONT / REAR BRAKE CALIPER BRACKET PIN BOLT
FRONT / REAR BRAKE HANGER PIN
FRONT / REAR MASTER CYLINDER RESERVOIR CAP SCREW
FRONT / REAR BRAKE HOSE OIL BOLT
FRONT / REAR MASTER CYLINDER LEVER PIVOT BOLT
FRONT / REAR MASTER CYLINDER LEVER PIVOT LOCK NUT
REAR BRAKE ARM FLANGE BOLT
SPEEDOMETER GEAR BOX OVAL SCREW
REAR CUSHION UPPER BOLT
REAR CUSHION LOWER BOLT
REAR CUSHION DAMPER ROD LOCK NUT

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

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

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.BRAKEHOSE

FRAMEEARTHCONNECTOR

(TIGHTATTHESAMETIMEWITHTHEREG.REC.)

THROTTLECABLE

STARTERS/WUNIT

FR.STOPS/WCONNECTOR

FR.BRAKEHOSE

SEATOPENCABLE

REG.RECTIFIER

MAINS/W

SPEEDOMETERCABLE

CABLEGUIDE

RR.BRAKEHOSE

RR.STOPS/WCONNECTOR

HAZARDS/WUNIT

HORNS/WUNIT

RR.BRAKEHOSE
LH.FR.WINKERLIGHT

CONNECTINGCONNECTOR

CABLEGUIDE

RESISTOR
30W5.9

LIGHTINGS/WUNIT

HEADPIPE

SPEEDOMETER

CABLEGUIDE

SOCKETCOMP.

A.P.WINKERRELAY

DIMMERS/WUNIT

WINKERS/WUNIT

FRONTFENDER

CABLEGUIDE

THROTTLECABLE

PRESSTOATTACHTHE
SEL.SECTIONTOTHEPIPE

FR.BRAKEHOSE

HORNCOMP.

SPEEDOMETERCABLE

Y

SEATLOCKCABLE

THROTTLECABLE

BREATHERTUBE

DRAINTUBE(CARB.)

AIRCLEANERINLETDUCT

FUELUNIT

FUELTUBE

FUELTANK

FUELPUMP

TUBECLAMP

CABLECLIP

CABLESETT.PIPE

LH.RR.WINKERCORD

LH.RR.WINKERLIGHT

FUELUNITCORD

LH.RADIATORHOSE

BATTERY

DETAILOF"Z"

THROTTLECABLE

FULETUBE(INSU)

FULETUBE(CARB)

CORDCLIP

PLUNGERASS'Y.

DRAINTUBE

BREATHERTUBE

FUSE

BREATHERTUBE

STARTERMAGNETICBATTERY+CABLE

BATTERYEARTHCABLE

RR.BRAKEHOSEB

RH.RADIATORHOSE

RR.BRAKEHOSEB

WIREHARNESS

WIRECLIP

HOSECLAMP

WIREHARNESS

HOSECLAMP

RH.RR.WINKERCORD

RH.RR.WINKERLIGHT

WIRECLIP

WIRECLIP

WIRECLIP

TAILLIGHTCORD

LICENSELIGHTCORD

I/G.COIL

RR.BRAKEHOSEB

STARTERMOTORCABLE

HIGHTENTIONCORD

STARTERMAGNETICS/W

PLUNGERASS'Y

1-16

SERVICE INFORMATION

MASTERCYLINDERASS'Y

FR.BRAKEHOSE

SPEEDOMETERCABLE

THROTTLECABLE

MAINS/W

SEATLOCKCABLE

WIREHARNESS

AIRCLEANER

TRUNKLAMP

TRUNKLAMPS/W

PARKINGBRAKECABLE

RR.BRAKEHOSEB

BLEEDERTUBE

BATTERYEARTHCABLE

HIGHTENSIONCORD

THROTTLECABLE

WIREHARNESS

RH.RADIATORHOSE

STARTERMAGNETICBATTERY+CABLE

STARTERMOTORCABLE

I/G.COIL

CDIUNIT

FUELTANK

TAILLIGHT

RH.RR.WINKERLIGHT

LICENSELIGHT

RR.BRAKEHOSEB

WIREHARNESS

REGULATERECTIFIER

SPEEDOMETERCABLE

HEADLIGHT

MASTERCYLINDERASS'Y

RR.BRAKEHOSEA

SOCKETCOMP.

CHARGESOCKETASS'Y
WIREHARNESS

HEADLIGHTCORD

INNERBOX

DETAILOF"A"

HEADLIGHT

HEADLIGHTCONNECTING
COUPLER(4P.FEMAIL)

THROTTLECABLE

AIRCLEANER

FUELTUBE(CARB')

FUELTUBE(INSU.)

FUELPUMPASS'Y

FUELSTRAINERCOMP.

FUELTUBE(TANK)

TAILLIGHT

LH.RR.WINKERLIGHT

LICENSELIGHT

BREATHERTUBE

PARKINGBRAKECABLE

CABLESETTINGPIPE

RR.BRAKEHOSEB

X

A

DRAINTUBE

SIDESTANDS/W

SEATLOCKCABLE

THROTTLECABLE

CABLECLAMP

BREATHERCABLE

RR.BRAKEHOSEB

RH.RADIATORHOSE

LH.RADIATORHOSE

SPEEDOMETERCABLE

SPEEDOMETERCABLE

SPEEDOMETERCABLE

SOCKETCOMP.

WIRECLAMP
(SOCKETCOMP.)

SEATLOCKCABLE

THROTTLECABLE

WIREHARNESS

WIRECLAMP

HORNCOMP.

RESISTOR30W5.9

VIEW"X"

2-1

2. LUBRICATION

SERVICE INFORMATION

GENERAL SAFETY

WARNING

1.The exhaust gas contains poisonous substance. Do not keep engine idling in a closed or poorly ventilated place for a
long period of time.

2.Used engine oil may cause skin cancer if repeatedly left in contect 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.

3.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 FILTER COVER BOL T

1.1㎏f·m

OIL PUMP MOUNTING BOLT

1.1㎏f·m

OIL DRAIN PLUG BOLT

2.5㎏f·m

2

SERVICE INFORMATION

······

2-1

TROUBLESHOOTING

··········

2-2
ENGINE OIL LEVEL INSPECTION··2-3
ENGINE OIL CHANGE

········

2-3
OIL FILTER ELEMENT CHANGE··2-4

OIL PUMP

··················

2-4

RADIATOR

··················

2-7
TRANSMISSION OIL INSPECTION··2-8
LUBRICATION POINTS

······

2-9

OIL CAP ACITY

RECOMMENDED

OIL

1.1ℓ (After disassembly)

0.9ℓ (After Oil change with Oil in the Oil hose removed)

0.8ℓ (After Oil filter change)

0.75ℓ (After Oil change)
API service classification : SE, SF, SH grade
Viscosity : SAE10W-30
(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 CAP ACITY

RECOMMENDED OIL

0.15ℓ (Full capacity)

0.14ℓ (After oil change)
DMC Pure mission oil or SAE 80W/90

-10 0 10 20 30 40℃

2-2

LUBRICA TION

TROUBLESHOOTING

Oil level low

•Oil consumption.

•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 check the oil level line on the
sight-glass installed on the LH. crank case cover .

● If the oil level is between the lower and higher sight­glass oil level line, oil level is satisfactory. If the oil
level is below or near the lower level mark, add the
recommended engine oil.

ENGINE OIL CHANGE

NOTE

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

● Loosen the oil drain plug bolt and drain engine oil.

● Operate the kick starter arm several times to remove

the remaining oil from the engine.

● Tighten the oil drain plug bolt.

TORQUE VALUE : 2.0-3.0 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.

•Tighten the hole cap with specified tightening torque.

TORQUE VALUE : 1.5 kgf·m

● Loosen the special screw, remove the plug maintenance
cover.

● Fill the recommended oil after opening oil filter cap of
cylinder head cover .

OIL CAPACITY : 1.1ℓ(After disassembly)

0.9ℓ(After Oil change with Oil in
the Oil hose removed)

0.8ℓ(After Oil filter change)

0.75ℓ(After Oil change)

● API service classification : SE, SF , SH 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

LUBRICA TION

UPPER LINE
PROPER LINE
LOWER LINE

SIGHT GLASS

OIL DRAIN PLUG

TAPPET ADJUSTING
HOLE CAP

OIL PICK
UP COLLAR

OIL FILTER
SCREEN

OIL FILTER CAP

OIL FILTER ELEMENT CHANGE

●Drain engine oil. (⇨2-3)

●Loosen the 3 flange bolts securing the oil filter cover,
remove the oil filter cover.

●Remove the oil filter element and oil filter spring.

●Change the oil filter element with a new one.

●Check if the oil filter seal is in good condition.

●Assemble the filter element spring and filter cover, and

tighten bolts.

TORQUE VALUE : OIL FILTER COVER 1.1kgf·m

NOTE

•Always use a genuine oil filter element.

•Be sure to replace the oil filter seal when removing oil

filter element.

•Be careful not to lose the oil filter spring when
assembling the oil filter element.

OIL PUMP

REMOV AL

●Remove the following parts :

-Rear cushion lower bolt (⇨13-7)

-Muffler (⇨4-12)

-Rear swing arm (⇨13-8)

-Rear caliper (⇨14-6)

-Shroud (⇨8-2)

-Cooling fan (⇨8-2)

-A.C. generator (⇨8-2)

-RH. crankcase cover (⇨8-4)

-Starter driven gear (⇨8-6)

-Reduction gear (⇨8-5)

-Starting clutch assembly (⇨8-6)

●Loosen the oil pump driven gear setting nut.

●Remove the oil pump driven gear.

●Remove the oil pump drive gear.

●Loosen the 3 flat screws securing the oil pump.

●Remove the oil pump.

2-4

LUBRICA TION

OIL FILTER COVER

DRIVE
GEAR

NUT

ELEMENT

OIL FILTER SEAL

DRIVEN GEAR

FLAT SCREW

OIL PUMP 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.

OIL PUMP INSPECTION

●Assemble the inner and outer rotors to the oil pump
body .

●Measure the pump body clearance.

SERVICE LIMIT : 0.23mm
TOOL : FEELER GAUGE

●Measure the rotor tip clearance.

SERVICE LIMIT : 0.18mm

●Measure the pump side clearance

SERVICE LIMIT : 0.12mm

2-5

LUBRICA TION

PUMP PLATE

PUMP BODY

OUTER ROTOR

INNER ROTOR

PUMP SHAFT

ROLLER2.5x11.8

FEELER GAUGE

INNER ROTOR

OUTER ROTOR

2-6

LUBRICA TION

OIL PUMP ASSEMBLY

●Clean all parts with fresh cleaning oil.

●Install the inner and outer rotors to the pump body.

●Assemble the pump shaft with setting pin.

●Install the oil pump plate to the pump body.

●Tighten the pan screw.

NOTE

•After installing, check the oil pump to operate
smoothly .

OIL PUMP INST ALLATION

●Install the oil pump to the RH. crankcase.

●Install the following parts.

-Oil pump drive gear and driven gear .

-Starting clutch assembly . (⇨8-8)

-Starter driven gear and reduction gear (⇨8-6)

-A.C. generator (⇨8-2)

-RH. crank case cover (⇨8-6)

-Shroud and cooling fan (⇨8-2)

-Rear swing arm (⇨13-8)

-Rear caliper (⇨14-6)

-Muffler (⇨4-12)

PUMP PLATE

PUMP BODY

OUTER ROTOR

INNER ROTOR

PUMP SHAFT

ROLLER2.5x11.8

INNER ROTOR

OUTER ROTOR

PUMP PLATE

PAN SCREW

FLAT SCREW

RADIATOR

REMOV AL

●Remove the front cover. (⇨4-3)

●Remove the front wheel. (⇨12-5)

●Loosen the 2 oil bolts and the 4 drain cock packings

from the main pipe bracket.

●Loosen the 3 flange bolts securing the radiator.

●Remove the radiator.

CAUTION

•Be careful not to damage the radiator when removing it.

•Pay attention not to turn over the vehicle.

INSPECTION

●Check the oil line connections for leaks.

●Check the oil cooler for bent or collapsed fins.

Straighten the bent or collapsed fins with a suitable,
small, blade-type screw driver if necessary .

●Check the air passages for clogging or restriction. Blow
dirt out from between core fins with compressed air or
wash off dirt with water .

●After installing, start the engine and check for leak. Stop
the engine and check the oil level.

2-7

LUBRICA TION

FLANGE

BOLT

RADIATOR

FIN

OILRADIATOR

RADIATORRUBBER

RADIATORCOLLAR

FLANGEBOLT

RADIA T OR INSTALLATION

●Tighten the 3 radiator setting flange bolts to the main
pipe bracket.

●Tighten the drain cock packings and oil bolts.

TORQUE VALUE : 3.2kgf·m

●Install the front wheel. (⇨12-9)

●Install the front cover. (⇨4-3)

CAUTION

•Pay attention not to turn over the vehicle.

•When installing the radiator, tighten the oil bolts with

specified tightening torque.

TRANSMISSION OIL INSPECTION

●Remove the LH. crankcase cover. (⇨7-2)

●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 .

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.

●Install the LH. crankcase cover. (⇨7-2)

2-8

LUBRICA TION

FLANGE

BOLT

RADIATOR

OIL BOLT

OIL CHECK BOLT

A.C.GENERATOR CAP

BREATHER TUBE

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 LUBRICA TION

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

2-9

LUBRICA TION

FRONTBRAKELEVERPIVOT

THROTTLEGRIP

STEERINGHEADBEARING

FRONTFORK
DUSTSEAL

WHEELBEARING/SPEEDOMETERGEAR

BRAKECALIPERBRACKET

SIDE/MAINSTANDPIVOT

WHEELBEARING

MEMO

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.

SPECIFICA TIONS

TIRES

3

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

················

3-7

BRAKE PAD/SHOE

··········

3-7

BRAKE SYSTEM

············

3-7

BRAKE LEVER FREE PLAY

··

3-8

HEADLIGHT AIM

············

3-8

SIDE STAND

················

3-8

SUSPENSION

··············

3-9

BOLTS, NUTS, FASTENERS

····

3-9

WHEELS/TIRES

··············

3-10

STEERING HEAD BEARING

··

3-10

THROTTLE GRIP PLA Y 2- 6mm
SP ARK PLUG CR8EH-9
SP ARK PLUG GAP 0.8-0.9mm

IN 0.12±0.02mm

EX 0.12±0.02mm
CARBURETOR IDLE SPEED 1,800±100rpm
CYLINDER COMPRESSION PRESSURE 14±2kgf/㎠㎠( 550rpm )

NOTE

•For information on engine oil and oil filter, refer to sections 2-3 and 2-4

•Stand the main stand prior to beginning work.

VALVE CLEARANCE

COLD TIRE

PRESSURE

TIRE SIZE

MIN, TREAD
DEPTH “”

DRIVER ONL Y

DRIVER AND A

PASSENGER

FRONT TIRE

REAR TIRE

FRONT TIRE

REAR TIRE

FRONT TIRE

REAR TIRE

FRONT TIRE

REAR TIRE

200kPa (2.00kgf/㎠㎠)
200kPa (2.00kgf/㎠㎠)
200kPa (2.00kgf/㎠㎠)
225kPa (2.25kgf/㎠㎠)
120/70 - 12 53k(Tubeless)
130/70 - 12 62k(Tubeless)

0.5mm

0.5mm

TORQUE VALUES

SPARK PLUG 1.1kgf·m
CYLINDER HEAD COVER BOLTS 1.0kgf·m
VALVE ADJUSTING NUTS 1.1kgf·m
TIMING HOLE CAP 0.6kgf·m

TOOLS

WRENCH 8X9mm
ADJUST WRENCH
COMPRESSION GAUGE

3-2

INSPECTIONS / ADJUSTMENTS