DAELIM DAYSTAR - Service Manual Download Page 199 | Manualshive

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19-2

Lights/Switches/Horn

Speedometer/Tachometer/Fuelmeter

Removal

Loosen the speedometer cable nut and remove
the cable from the meter.
Remove the cable guide and meterstay from
top bridge.
Remove the seat and fuel tank, and separate
the meter code from wire harness.

Bulb Replacement

Remove the headlight rim and unit.
Remove the spring.
Remove the headlight socket and position light
socket and replace the headlight bulb.

Installation

Install the headlight in the reverse order of
removal.

•

Align the index mark on the headlight case
with the index mark on the bracket.

Headlight

Removal

Remove the two headlight mounting bolts and
remove the headlight from the bracket.
Remove the individual code from the wire.

!

CAUTION

△

Screw

Screw

Screw

Screw

Screw

Screw

Screw

Screw

Screw

Screw

Screw

Screw

Screw

Headlight Socket

Headlight Socket

Headlight Socket

Headlight Socket

Headlight Socket

Headlight Socket

Headlight Socket

Headlight Socket

Headlight Socket

Headlight Socket

Headlight Socket

Headlight Socket

Headlight Socket

Meter Cable Nut

Meter Cable Nut

Meter Cable Nut

Meter Cable Nut

Meter Cable Nut

Meter Cable Nut

Meter Cable Nut

Meter Cable Nut

Meter Cable Nut

Meter Cable Nut

Meter Cable Nut

Meter Cable Nut

Meter Cable Nut

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Summary of Contents for DAYSTAR -

Page 1: ...SERVICE MANUAL...

Page 2: ...ed on the latest product information avaliable at the time of approval for printing DAELIM reserves the right to make changes at any time without notice and without incurring any obligation whatever N...

Page 3: ...oughly wash your hands with soap and water as soon as possible after handling used oil Service Rules 1 Use genuine DAELIM or DAELIM recommended parts and lubricants or their equivalents 2 Use the spec...

Page 4: ...fication Frame No Frame No Frame No Frame No Frame No Frame No Frame No Frame No Frame No Frame No Frame No Frame No Engine No Engine No Engine No Engine No Engine No Engine No Engine No Engine No Eng...

Page 5: ...l Capacity 17 3 Fuel Reserve Capacity 2 9 Caster Angle 32 Trail Length 147mm Front Fork Oil Capacity 280cm3 Type Oil Air Cooled 4 stroke SOHC Engine Cylinder Number arrangement 1 Cylinder 15 Bore and...

Page 6: ...ar Ratio 2nd 1 882 32 17 Gear Ratio 3rd 1 380 29 21 Gear Ratio 4th 1 095 23 21 Gear Ratio 5th 0 923 24 26 Gearshift Pattern Left foot operated return system 1 N 2 3 4 5 Ignition CDI Ignition Ignition...

Page 7: ...ne Oil Cam Chain Tensioner Mounting Bolt 2 6 1 2 12 Cam Chain Tensioner Sealing Screw 1 6 0 4 4 Cylinder Head Cover Bolt 2 6 1 0 10 Crank Shaft Hole Cap 1 30 0 8 8 Timing Hole Cap 1 14 0 6 6 L Crank C...

Page 8: ...24 30 12mm Bolt nut 5 0 6 0 50 60 10mm flange bolt nut 3 5 4 5 35 45 Item Q ty Thread dia Torque Remark Brake Caliper Bracket Bolt 2 8 3 0 30 Brake Caliper Bleed Valve 1 8 0 6 6 Brake Pad pin Bolt 2 8...

Page 9: ...e ratio 1 1 Use multi purpose grease Lithium based multi purpose grease NLGI 2 or equivalent Use molybdenum disulfide grease containing more than 3 molybdenum disulfide NLGI 2 or equivalent Use molybd...

Page 10: ...10 Driver 10 13 14 Remover Assy 15mm 10 Attachment 32 35mm 10 14 Remover Shaft 15mm 10 Attachment 42 47mm 10 13 14 Remover Head 10 Attachment 62 68mm 10 Sliding Weight 10 Attachment 72 78mm 10 Thread...

Page 11: ...Adapter Spark Adapter 3 16 17 16 17 17 17 Remark Description Reference section Valve Seat Cut Valve Seat Cutter 45 Valve Seat Cutter 35 Valve Seat Cutter 35 Valve Seat Cutter 60 Cutter Holder 5mm 8 8...

Page 12: ...e thoroughly before applying tape Do not use a wire or harnesse with a broken insulator Repair by wrapping then with protective tape or replace them Route wire harnesses to avoid sharp edges or corner...

Page 13: ...lay Regulator Rectifier Starter Magnetic Cable Starter Motor Cable Fuel Meter Code Horn Sub Harness Clutch Cable L Front Winker Cord Winker Switch Cord L Horn Cord Horn High Head Light Cord L Front Wi...

Page 14: ...t A C G Cord Fuel Tube Choke Cable High Tension Cord Ignition Coil Choke Cable Clutch Cable Engine breather tube Battery Earth Cable Clutch Cable Noise Supperssor High Tension Cord Clutch Cable Front...

Page 15: ...Information 2 1 Specifications 2 1 Troubleshooting 2 2 Engine Oil Level Check 2 3 Engine Oil Change 2 3 Engine Oil Filter Element Change 2 4 Oil Pump 2 4 Lubrication Points 2 7 Engine oil 1 2 all cap...

Page 16: ...ck open Plugged oil pick up screen Oil pump worm External oil leaks High oil pressure Pressure relief valve stuck closed Plugged oil filter gallery or metering orifice In correct oil being used No oil...

Page 17: ...ELIM genuine oil API service classification SE or SH Viscosity SAE 10W 30 Install the oil level gauge Start the engine and let it idle for a few minutes Stop the engine and check that the oil level is...

Page 18: ...body Measure the pump body clearance Service Limit 0 25mm 0 010 in Oil Filter Cover Oil Filter Cover Oil Filter Cover Oil Filter Cover Oil Filter Cover Oil Filter Cover Oil Filter Cover Oil Filter Co...

Page 19: ...r Outer Rotor Outer Rotor Outer Rotor Outer Rotor Outer Rotor Outer Rotor Outer Rotor Inner Rotor Inner Rotor Inner Rotor Inner Rotor Inner Rotor Inner Rotor Inner Rotor Inner Rotor Inner Rotor Inner...

Page 20: ...n the bolt Torque 1 1kgf m 11N m 8ft lb Install the right crank case cover Oil Pump Plate Oil Pump Plate Oil Pump Plate Oil Pump Plate Oil Pump Plate Oil Pump Plate Oil Pump Plate Oil Pump Plate Oil P...

Page 21: ...ables at their upper ends Thoroughly lubricate the cables and their pivot points with a commercially available cable lubricant or a light weight oil Check the cable for loose replace them if necessary...

Page 22: ...MEMO...

Page 23: ...f 550rpm Drive chain free play 50 60mm 1 968 2 362 in Rear brake pedal free play 20 30mm 0 787 1 181 in Clutch lever free play 10 20mm 0 393 0 787 in Specifications Tires Driver only Front 200kPa 2 0...

Page 24: ...f m 11N m Cylinder Head Cover Bolt 1 0 kgf m 10N m Valve Adjusting Nut 1 1 kgf m 11N m Timing Hole Cap 0 6 kgf m 6N m Crankshaft Hole Cap 0 8 kgf m 8N m Rear Axle Nut 8 8kgf m 88N m Tools Common Tool...

Page 25: ...Steering Head Bearing I I 3 15 Maintenance Schedule Perform the Pre ride inspection in the Owner s manual at each scheduled maintenance period I Inspect and clean adjust lubricate or replace if neces...

Page 26: ...by loosening the lock nut and turning the adjuster Tighten the lock nut Recheck the throttle free play Fuel Cock Fuel Cock Fuel Cock Fuel Cock Fuel Cock Fuel Cock Fuel Cock Fuel Cock Fuel Cock Fuel C...

Page 27: ...hecking the operation between the choke arm and cable cover Recheck the carburetor choke free play Air Cleaner Loosen the four screw and remove the air cleaner case cover Loosen the three screw and re...

Page 28: ...inger Tighten it with plug wrench Torque 1 1kgf m 11N m Install the spark plug caps Valve Clearnance Perform valve inspection adjustment with the engine at normal operating temperature Below 35 95 Rem...

Page 29: ...ds Compression Pressure 14 0 f 550rpm If compression is low check the following Incorrect valve clearance adjustment Valve for leakage Exposed cylinder head from the gasket Worn piston cylinder If com...

Page 30: ...check if the chain free play is within recommended range Free Play 50 60mm If necessary adjust the drive chain free play Adjust by loosening the axle nut and lock nuts in the right left chain adjuster...

Page 31: ...rollar for wear and damage and remove the chain tensioner Service limit 30 5mm RR Brake Pedal Return Spring RR Brake Pedal Return Spring RR Brake Pedal Return Spring RR Brake Pedal Return Spring RR Br...

Page 32: ...void spilling the fluid of battery on other parts The battery contains sulfuric acid electrolyte Contact with skin or eyes may cause severe burns If electrolyte gets on your eyes flush with water for...

Page 33: ...switch operation and adjust it if necessary Mark Mark Mark Mark Mark Mark Mark Mark Mark Mark Mark Mark Mark Arrow Arrow Arrow Arrow Arrow Arrow Arrow Arrow Arrow Arrow Arrow Arrow Arrow Brake Hose Br...

Page 34: ...nd adjust them if necessary Brake Stop Switch Adjust the brake light switch so that the brake light may come on when the brake pedal is depressed and brake engagement begin Hold the switch body and tu...

Page 35: ...t up the main stand Check of smooth operation when pulling the low end part of the side stand If the side stand is hard coat the pivot with grease If the side stand moves too freely inspect the side s...

Page 36: ...ess is noted Tighten all nuts and bolts of the rear suspension Bolts Nuts Fasteners Check that all nuts and bolts are tightened to correct torque values Check that all cotter pins safety clips hose cl...

Page 37: ...3 in Steering Head Bearings Check that the control cables do not interfere with handle bar rotation Raise the front wheel off the ground Check that the handle bar moves freely from side to side If the...

Page 38: ...Fuel System 4 0...

Page 39: ...ess and lead to death Run the engine in an open area or with an exhausted evacuation system in an enclosed area Bending or twisting the control cables will impair smooth operation and may cause the ca...

Page 40: ...n mixture rich mixture Clogged air cleaner Faulty air cut off valve Clogged fuel system Lean mixture Clogged carburetor jets Clogged fuel tank breather Clogged fuel strainer screen Restricted fuel tub...

Page 41: ...el cock Installation Install the fuel tank in the reverse order of removal Check for the oil leakage When the fuel is needed the fuel alarm lamp is lighted Fill the fuel at gas station Fuel Tube Fuel...

Page 42: ...aner side Remove the battery Remove the air cleaner mounting bolt Remove the air cleaner case Installation Installation is essentially the reverse order of removal Install the air cleaner case cover s...

Page 43: ...Throttle Valve Throttle Valve Throttle Valve Throttle Valve Throttle Valve Throttle Valve Throttle Valve Throttle Valve Throttle Valve Throttle Valve Carburetor Top Carburetor Top Carburetor Top Carb...

Page 44: ...Carburetor Top Carburetor Top Carburetor Top Carburetor Top Carburetor Top Carburetor Top Carburetor Top Carburetor Top Carburetor Top Carburetor Top Carburetor Top Lean Mixture First Level Standard...

Page 45: ...e Drain Tube Drain Tube Drain Tube Drain Tube Drain Tube Drain Tube Diaphragm Diaphragm Diaphragm Diaphragm Diaphragm Diaphragm Diaphragm Diaphragm Diaphragm Diaphragm Diaphragm Diaphragm Diaphragm Sp...

Page 46: ...rojecting Part Screws Screws Screws Screws Screws Screws Screws Screws Screws Screws Screws Screws Screws Float Chamber Float Chamber Float Chamber Float Chamber Float Chamber Float Chamber Float Cham...

Page 47: ...edle Jet Holder Needle Jet Holder Needle Jet Holder Needle Jet Holder Needle Jet Holder Needle Jet Holder Needle Jet Holder Needle Jet Holder Needle Jet Holder Slow Jet Slow Jet Slow Jet Slow Jet Slow...

Page 48: ...rew Throttle Stop Screw Throttle Stop Screw Throttle Stop Screw Throttle Stop Screw Throttle Stop Screw Throttle Stop Screw Throttle Stop Screw Throttle Stop Screw Main Jet Main Jet Main Jet Main Jet...

Page 49: ...e Fuel Tube Drain Tube Drain Tube Drain Tube Drain Tube Drain Tube Drain Tube Drain Tube Drain Tube Drain Tube Drain Tube Drain Tube Drain Tube Drain Tube Connecting Tube Connecting Tube Connecting Tu...

Page 50: ...erature Adjust the number of turns to the 1 400 100rpm with the throttle stop screw 3 Turn the pilot screws out by turn each until engine speed does not increase 4 Perform steps 2 and 3 5 Adjust the i...

Page 51: ...5 1 Engine Removal Installation 5 Engine Removal Installation Service Information 5 2 Engine Removal 5 3 Engine Installation 5 4 5...

Page 52: ...ystem The following parts or components can not be served with the engine installed in the frame Cylinder head valve Chapter 8 Cylinder piston Chapter 9 Transmission kick starter Chapter 10 Crank shaf...

Page 53: ...w Screw Screw Screw Drive Sprocket Drive Sprocket Drive Sprocket Drive Sprocket Drive Sprocket Drive Sprocket Drive Sprocket Drive Sprocket Drive Sprocket Drive Sprocket Drive Sprocket Drive Sprocket...

Page 54: ...d cables Be careful not to damage any part of the frame and bolt nuts Be sure to install the cables tubes and wires to their correct positions 1 11 13 Torque Engine hanger bolts Front 1 2 7kgf m 27N m...

Page 55: ...MEMO...

Page 56: ...6 0 Clutch Gearshift...

Page 57: ...the clutch slips check the fluid level before servicing the clutch system Specifications Item Standard Service Limit Spring Free 35 5 1 40 34 2 1 35 Disk Thickness 2 9 3 0 0 114 0 118 2 6 0 10 Clutch...

Page 58: ...ate warpage Clutch lock nut loose High fluid level or high fluid weight Clutch disengages Sticking lifter hydraulic system Worn disks Weak spring Too small clutch lever free play Difficult to thrust t...

Page 59: ...Case Cover Right Crank Case Cover Right Crank Case Cover Right Crank Case Cover Right Crank Case Cover Right Crank Case Cover Right Crank Case Cover Right Crank Case Cover Right Crank Case Cover Righ...

Page 60: ...ring Bolt Clutch Spring Bolt Clutch Spring Bolt Lifter Plate Lifter Plate Lifter Plate Lifter Plate Lifter Plate Lifter Plate Lifter Plate Lifter Plate Lifter Plate Lifter Plate Lifter Plate Lifter Pl...

Page 61: ...Clutch Center Clutch Center Clutch Center Clutch Center Clutch Center Clutch Center Clutch Center Clutch Center Clutch Center Clutch Center Pressure Plate Pressure Plate Pressure Plate Pressure Plate...

Page 62: ...litude Service Limit 2 6mm 0 10 in Check the plate for warpage on a surface plate using a feeler gauge Service Limit 0 2mm 0 01 in If any of the disk and plate requires replacement it must be replaced...

Page 63: ...ear Change Pedal Gear Change Pedal Gear Change Pedal Gear Change Pedal Thrust Washer Thrust Washer Thrust Washer Thrust Washer Thrust Washer Thrust Washer Thrust Washer Thrust Washer Thrust Washer Thr...

Page 64: ...n with the gear shift hole Install the thrust washer into the gear shift spindle Install the gear shift spindle into the crank case aligning the teeth of the return spring with the tappet of the right...

Page 65: ...Outer Guide Clutch Outer Guide Clutch Outer Guide Clutch Outer Guide Clutch Outer Guide Clutch Outer Guide Clutch Outer Guide Clutch Outer Guide Clutch Outer Guide Clutch Outer Guide Thrust Washer Th...

Page 66: ...lt Lifter Plate Lifter Plate Lifter Plate Lifter Plate Lifter Plate Lifter Plate Lifter Plate Lifter Plate Lifter Plate Lifter Plate Lifter Plate Lifter Plate Lifter Plate Extension Bar Extension Bar...

Page 67: ...kshaft Crankshaft Crankshaft Crankshaft Crankshaft Crankshaft Crankshaft Crankshaft Woodruff Key Woodruff Key Woodruff Key Woodruff Key Woodruff Key Woodruff Key Woodruff Key Woodruff Key Woodruff Key...

Page 68: ...f m 22N m Fill the crankcase with the recommended oil 2 3 Dowel Pin Dowel Pin Dowel Pin Dowel Pin Dowel Pin Dowel Pin Dowel Pin Dowel Pin Dowel Pin Dowel Pin Dowel Pin Dowel Pin Dowel Pin Clutch Cable...

Page 69: ...7 0 A C Generator Starter Clutch...

Page 70: ...em Standards Service Unit O D 42 195 42 208 1 6612 1 6617 42 180 1 658 Starter Driven Gear I D 22 022 22 010 0 8670 0 8665 22 100 0 870 Starter Idle Gear I D 10 045 10 028 0 3942 0 3948 10 100 0 393 S...

Page 71: ...ar Cover L Rear Cover L Rear Cover L Rear Cover L Rear Cover L Rear Cover L Rear Cover L Rear Cover Drive Chain Guide Drive Chain Guide Drive Chain Guide Drive Chain Guide Drive Chain Guide Drive Chai...

Page 72: ...Gear Starter Reduction Gear Starter Reduction Gear Shaft Shaft Shaft Shaft Shaft Shaft Shaft Shaft Shaft Shaft Shaft Shaft Shaft L Clank Case Cover L Clank Case Cover L Clank Case Cover L Clank Case...

Page 73: ...druff Key Starter Driven Gear Collar Starter Driven Gear Collar Starter Driven Gear Collar Starter Driven Gear Collar Starter Driven Gear Collar Starter Driven Gear Collar Starter Driven Gear Collar S...

Page 74: ...side magnet of rotor is attached by the bolts and nuts install them If installing the rotor with the foreign material the starter coil is damaged Install the rotor bolt temporally After fixing the fly...

Page 75: ...aft Shaft Shaft Shaft Shaft Shaft Shaft Shaft Shaft Shaft L Crank Case Cover L Crank Case Cover L Crank Case Cover L Crank Case Cover L Crank Case Cover L Crank Case Cover L Crank Case Cover L Crank C...

Page 76: ...he flywheel 7 4 If the starter driven gear turns to the right when pressing the flywheel as shown it is in good condition Disassembly Remove the three socket bolts and remove the one way clutch from t...

Page 77: ...ven gear I D and O D Service Limit O D 42 180mm 1 658in I D 22 100mm 0 870in Assembly Inspect the one way clutch for wear and damage Install the way clutch fringe onto the clutch outer After coating t...

Page 78: ...MEMO...

Page 79: ...8 0 Cylinder Head Valve...

Page 80: ...spection 8 9 Cylinder Head Assembly 8 11 Cylinder Head Assembly 8 13 Cylinder Heand Installation 8 13 Item Standard Service Limit Rocker Arm Rocker Arm I D 12 016 12 034 0 4731 0 4738 12 060 0 4748 Ro...

Page 81: ...stment Broken or damaged valve spring Incorrect valve timing Faulty valve seat adherence Cylinder head Leaking or damaged head gasket Warped or cracked cylinder head Cylinder and piston Refer to secti...

Page 82: ...ng Hole Cap Timing Hole Cap Timing Hole Cap Timing Hole Cap Timing Hole Cap Timing Hole Cap Timing Hole Cap Timing Hole Cap Timing Hole Cap Timing Hole Cap Crank Shaft Hole Cap Crank Shaft Hole Cap Cr...

Page 83: ...aft Cam Shaft Cam Shaft Cam Shaft Cam Shaft Cam Shaft Cam Shaft Cam Shaft Cam Shaft Rocker Arm Spring Rocker Arm Spring Rocker Arm Spring Rocker Arm Spring Rocker Arm Spring Rocker Arm Spring Rocker A...

Page 84: ...0mm 0 4505in Inspect the cam lobe of the camshaft for wear and damage Measure the height of the cam lobe Service Limit IN 37 420mm 1 4732in EX 37 300mm 1 4685in Turn the outer race of each bearing wit...

Page 85: ...pivot bolt and remove the cam chain tensioner Remove the carburetor insulator Remove the spark plug from the cylinder head Remove the spark plug cover from the cylinder head NOTE CAUTION CAUTION Cam C...

Page 86: ...ide diameter and record it Service Limit IN 4 925mm 0 1939in EX 4 905mm 0 1931in After inserting the valve guide reamer to the combustion chamber remove the carbon deposits The incoming and outgoing o...

Page 87: ...valve guide Insert the valve guide in the top of the cylinder head Tool Valve guide driver After inserting the valve guide install the valve guide reamer in the combustion chamber of the cylinder hea...

Page 88: ...uide reamer using a valve guide dreamer without turning the valve and align the position exactly Tale off the valve inspect the opposite side of the seat with the ink attachment of valve pace side If...

Page 89: ...replacing the valve guide cut the seat part Amend the flat using a 35 cutter side by side Amend the inside using a 60 cutter side by side Amend the seat part with a standard width using a 45 cutter 35...

Page 90: ...Head Assembly Install the valve spring seat and a new stem seal Lubricate each valve stem with molybdenum disulfide grease and insert the valve into the valve guide To avoid damage to the stem seal tu...

Page 91: ...NOTE For Cylinder Head For Cylinder Head For Cylinder Head For Cylinder Head For Cylinder Head For Cylinder Head For Cylinder Head For Cylinder Head For Cylinder Head For Cylinder Head For Cylinder H...

Page 92: ...Guede Cam Chain Guede Cam Chain Guede Cam Chain Guede Cam Chain Guede Cam Chain Guede Cam Chain Guede Cam Chain Guede Cam Chain Guede Cam Chain Guede Cam Chain Guede Cam Chain Guede Cam Chain Guede D...

Page 93: ...m chain does not come off from the crankshaft timing gear Coat the camshaft with engine oil and install the cam lobe on the cylinder head with the cam lobe facing down With the timing marks on the cam...

Page 94: ...ove the shaft from the body by turning the tensioner shaft to the right with a small driver When dropping the cam chain tensioner lifter the shaft is proceeded by the spring power CAUTION Sealing Scre...

Page 95: ...ank shaft hole cap 0 8kgf m 8N m Timing hole cap 0 6kgf m 6N m Clean oil in the slot part of the cylinder head cover Place the gasket on the correct position in the cover Install the cylinder head cov...

Page 96: ...MEMO...

Page 97: ...9 0 Cylinder Piston...

Page 98: ...ve carbon deposits on piston head Troubleshooting Item Standard Service Unit I D 56 500 56 510 2 2244 2 2248 56 60 2 228 Cylinder Outer of round 0 1 0 004 Taper 0 05 0 002 Warpage 0 1 0 004 Piston O D...

Page 99: ...on and Y direction and out of round inside diameter balance of the top middle bottom parts by X or Y direction Choose the maximum value regardless of any one and settle the taper and out of round Serv...

Page 100: ...iston pin out and remove the piston Check the piston ring for damage or deterioration Remove the piston rings Be careful when removing the rings Measure the piston ring to groove clearance Service Lim...

Page 101: ...ng 90 direction Service Limit 56 37mm 2 219in Measure the piston pin hole inside diameter Service Limit 15 04mm 0 592in Measure the piston pin outside diameter Service Limit 14 96mm 0 589in Figure out...

Page 102: ...econd Ring Piston Cylinder Installation Piston Ring Installation Clean the piston domes ring lands and skirts and install the piston ring Be careful not to damage the piston and piston rings during as...

Page 103: ...n engine oil and install the piston ring Be careful not to damage piston rings Be careful to prevent cam chain from falling into the crankcase NOTE NOTE Cam Chain Cam Chain Cam Chain Cam Chain Cam Cha...

Page 104: ...lot of the cylinder Install the cylinder head refer to section 8 Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Chain Guide Cam Cha...

Page 105: ...10 0 Crank Case Transmission Crankshaft 1 2kgf m 12N m 1 1kgf m 11N m...

Page 106: ...0 4731 12 05 0 474 Shaft Pole thickness 4 93 5 00 0 194 0 197 4 5 0 18 Shaft O D 11 976 11 994 0 4715 0 4722 11 96 0 471 Main shaft O D M3 M5 19 959 19 980 0 7858 0 7866 19 930 0 7846 C1 16 466 16 48...

Page 107: ...uide grooves worn Gear shift fork slot worn Engine noise Connecting rod big end bearing worn Connecting rod bent Crank shaft main bearing worn Transmission gear worn Poor kick starter operation Kick s...

Page 108: ...e Set Plate Set Plate Set Plate Set Plate Set Plate Set Plate Set Plate Set Plate Gear Change Switch Gear Change Switch Gear Change Switch Gear Change Switch Gear Change Switch Gear Change Switch Gear...

Page 109: ...Main Shaft Main Shaft Main Shaft Main Shaft Main Shaft Main Shaft Main Shaft Main Shaft Main Shaft Main Shaft Main Shaft Main Shaft Shift Drum Shift Drum Shift Drum Shift Drum Shift Drum Shift Drum S...

Page 110: ...ear bush inside diameter and outside diameter Service Limit M5 M3 M2 outside diameter 22 950mm 0 9035in C1 outside diameter 19 930mm 0 7846in M3 C2 inside diameter 20 050mm 0 7894in C1 inside diameter...

Page 111: ...iver Attachment 42 47mm Remove the remaining bearings in the crankshaft with a bearing puller Tool Universal bearing puller If the crankshaft is removed from the left crankcase a new left crankshaft b...

Page 112: ...dle oil seal for wear and damaging must be replaced if necessary CAUTION X X Y Y Main Shaft Bearing Main Shaft Bearing Main Shaft Bearing Main Shaft Bearing Main Shaft Bearing Main Shaft Bearing Main...

Page 113: ...t the socket bolt screw part with oil and install the main shaft bearing set plate Torque 1 2kg m Crankshaft Installation Coat a new light crankshaft bearing with clean engine oil and install new bear...

Page 114: ...aft Main Shaft Main Shaft Main Shaft Main Shaft Main Shaft Main Shaft Main Shaft Main Shaft Main Shaft Main Shaft Main Shaft Main Shaft Counter Shaft Counter Shaft Counter Shaft Counter Shaft Counter...

Page 115: ...Right Fork Right Fork Right Fork Right Fork Right Fork Right Fork Right Fork Shift Drum Shift Drum Shift Drum Shift Drum Shift Drum Shift Drum Shift Drum Shift Drum Shift Drum Shift Drum Shift Drum S...

Page 116: ...Ratchet Ratchet Ratchet Ratchet Ratchet Ratchet Ratchet 16mm Thrust Washer 16mm Thrust Washer 16mm Thrust Washer 16mm Thrust Washer 16mm Thrust Washer 16mm Thrust Washer 16mm Thrust Washer 16mm Thrus...

Page 117: ...her 16mm Thrust Washer 16mm Thrust Washer 16mm Thrust Washer Dowel Pins Dowel Pins Dowel Pins Dowel Pins Dowel Pins Dowel Pins Dowel Pins Dowel Pins Dowel Pins Dowel Pins Dowel Pins Dowel Pins Dowel P...

Page 118: ...Turn the ratchet and ratchet guide plate to the right and place them as shown NOTE Guide Plate Guide Plate Guide Plate Guide Plate Guide Plate Guide Plate Guide Plate Guide Plate Guide Plate Guide Pl...

Page 119: ...e Breather Tube Breather Tube Breather Tube Breather Tube Breather Tube Breather Tube Breather Tube Breather Tube Breather Tube Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Gear Sh...

Page 120: ...11 1 Cooling System 11 Cooling System Service Information 11 1 Radiator 11 2 Service Information General The engine must be cool before servicing the cooling system 11...

Page 121: ...ver 20 of radiant heat area Radiator Grill Radiator Grill Radiator Grill Radiator Grill Radiator Grill Radiator Grill Radiator Grill Radiator Grill Radiator Grill Radiator Grill Radiator Grill Radiato...

Page 122: ...Exhaust Muffler Service Information 12 1 Side Cover Seat 12 2 Grab Rail 12 2 Rear Fender 12 3 Muffler 12 3 Tool Box 12 4 Service Information Muffler is very hot after engine stops Avoid inspection ri...

Page 123: ...move the rear winker and tail light code Remove the left right cap nut bolts each 4EA of the grab rail After removing push the stay pinch bolt to the inside Assembly Assembly is done in the reverse or...

Page 124: ...Rail R Grab Rail R Grab Rail R Grab Rail R Grab Rail L Grab Rail L Grab Rail L Grab Rail L Grab Rail L Grab Rail L Grab Rail L Grab Rail L Grab Rail L Grab Rail L Grab Rail L Grab Rail L Grab Rail L G...

Page 125: ...er comp Muffler Bend Muffler Bend Muffler Bend Muffler Bend Muffler Bend Muffler Bend Muffler Bend Muffler Bend Muffler Bend Muffler Bend Muffler Bend Muffler Bend Muffler Bend Tool Box Tool Box Tool...

Page 126: ...12 5 MEMO...

Page 127: ...13 0 Front Wheel Front Fork Steering...

Page 128: ...during removal and installation A jack or other support is required to support the motorcycle during front end service Specification Torque Steering Handle Bolt 2 6kgf m Brake Disk Nut 4 2kgf m Front...

Page 129: ...e worn damage Insufficient tire pressure Worn Tire Steers to one side Steering head bearing damage loose Unevenly adjusted right and left cushions Bent front fork Bent front axle shaft wheel installed...

Page 130: ...witch Engine Stop Switch Engine Stop Switch Engine Stop Switch Choke Lever Choke Lever Choke Lever Choke Lever Choke Lever Choke Lever Choke Lever Choke Lever Choke Lever Choke Lever Choke Lever Choke...

Page 131: ...ter attaching leave it over 1hour until drying the adhesives CAUTION Top Bridge Connecting Hole Top Bridge Connecting Hole Top Bridge Connecting Hole Top Bridge Connecting Hole Top Bridge Connecting H...

Page 132: ...le and tighten the mounting bolt Throttle Cable Throttle Cable Throttle Cable Throttle Cable Throttle Cable Throttle Cable Throttle Cable Throttle Cable Throttle Cable Throttle Cable Throttle Cable Th...

Page 133: ...e Remove the axle nut front axle and front wheel and right side collar Do not operate the front brake lever after removing the front wheel NOTE Screw Screw Screw Screw Screw Screw Screw Screw Screw Sc...

Page 134: ...r Remove the right side collar NOTE Speedometer Grar Retainer Speedometer Grar Retainer Speedometer Grar Retainer Speedometer Grar Retainer Speedometer Grar Retainer Speedometer Grar Retainer Speedome...

Page 135: ...rom the speedometer gear box Check the gear for wear and damage Install the washer Coat the speedometer gear with grease and install it NOTE NOTE Brake Disk Brake Disk Brake Disk Brake Disk Brake Disk...

Page 136: ...side collar Dust Seal Dust Seal Dust Seal Dust Seal Dust Seal Dust Seal Dust Seal Dust Seal Dust Seal Dust Seal Dust Seal Dust Seal Dust Seal Right Side Collar Right Side Collar Right Side Collar Righ...

Page 137: ...ter Gear Retainer Speedometer Gear Retainer Speedometer Gear Retainer Speedometer Gear Retainer Speedometer Gear Retainer Speedometer Gear Retainer Speedometer Gear Retainer Speedometer Gear Box Speed...

Page 138: ...r Front Fender Front Fender Front Fender Front Fender Front Fender Front Fender Fork Top Socket Bolt Fork Top Socket Bolt Fork Top Socket Bolt Fork Top Socket Bolt Fork Top Socket Bolt Fork Top Socket...

Page 139: ...Remove the piston rebound spring from fork tbue Remove the dust Seal CAUTION Fork Tube Bottom Case Fork Tube Fork Tube Fork Tube Fork Tube Fork Tube Fork Tube Fork Tube Fork Tube Fork Tube Fork Tube F...

Page 140: ...Case Bottom Case Bottom Case Bottom Case Bottom Case Bottom Case Bottom Case Bottom Case Bottom Case Bottom Case Bottom Case Bottom Case Piston Ring Piston Ring Piston Ring Piston Ring Piston Ring Pis...

Page 141: ...slider bush Bottom case must be replaced if the copper portion is shown over three of quarter in teflon coating part or remarkably damaging Assembly Before installing clean each part with clean oil Sl...

Page 142: ...ly Install the back up ring Coat the ATF with the new oil seal Insert the oil seal until showing the assembling groove of bottom case set ring using the tools Tools Fork seal driver Fork seal driver b...

Page 143: ...owly Check the oil level in state of compression Oil Level 250mm Install the spring into the fork tube Make a spring face down the small side of pitch CAUTION Set Ring Fork Oil Fork Oil Oil Level Lowe...

Page 144: ...ate CAUTION NOTE Fork Tube Cap Bolt Fork Tube Fork Top Socket Bolt Fork Top Socket Bolt Fork Top Socket Bolt Fork Top Socket Bolt Fork Top Socket Bolt Fork Top Socket Bolt Fork Top Socket Bolt Fork To...

Page 145: ...Fender Front Fender Front Fender Front Fender Front Fender Front Fender Front Fender Front Fender Lock Nut Wrench Lock Nut Wrench Lock Nut Wrench Lock Nut Wrench Lock Nut Wrench Lock Nut Wrench Lock...

Page 146: ...r bearing Bearing Replacement Always replace the bearing and races as a set Tool Ball race driver To protect the nuts install the stem nut into the steering stem and remove the steering under bearing...

Page 147: ...nut wrench 30 32mm Extension bar After arranging the cable install the cable guide Install the front fork 13 11 NOTE Steering Stem Socket Top Bridge Top Bridge Top Bridge Top Bridge Top Bridge Top Bri...

Page 148: ...ble Guide Cable Guide Cable Guide Cable Guide Cable Guide Cable Guide Cable Guide Cable Guide Install the parts as the below Head light Front emblem stay Brake caliper Front fender Front wheel 13 6 Ca...

Page 149: ...14 0 Rear Wheel Rear Brake Suspension...

Page 150: ...fications Torque Values Rear Brake Arm Bolt 1 0kgf m Rear Axle Nut 8 8kgf m Rear Shock Absorber Mounting Upper Bolt 3 4kgf m Rear Shock Absorber Mounting Lower Bolt 3 4kgf m Rear Fork Pivot Bolt 4 5kg...

Page 151: ...ent rim Worn rear wheel bearings Faulty tire Loose axle Incorrect tire pressure Worn rear fork bush Soft suspension Weak spring Incorrect rear cushion adjuster Faulty rear damper Hard suspension Incor...

Page 152: ...aft Service Limit 0 2mm Inspect by the oscillation of rim in turning the wheel Service Limit Radial 2 0mm 0 008in Axial 2 0mm 0 008in Replace the worn bearing by turning the bearing Chain Adjuster Cha...

Page 153: ...Tools Bearing remover shaft Remover head NOTE NOTE Driven Sprocket Driven Sprocket Driven Sprocket Driven Sprocket Driven Sprocket Driven Sprocket Driven Sprocket Driven Sprocket Driven Sprocket Drive...

Page 154: ...tooper with the slot of the brake panel Install the drive chain into the sprocket Assembly Install the dust seal after applying the grease If the damper rubber was removed install the damper rubber NO...

Page 155: ...Service Limit 131mm 5 16in Measure the rear brake lining thickness Service Limit 2 0mm 0 08in Disassembly Open the brake shoe with hands and remove it from the brake panel Separate the split pin from...

Page 156: ...Indicator Wear Indicator Wear Indicator Wear Indicator Wear Indicator Wear Indicator Wear Indicator Wear Indicator Brake Cam Brake Cam Brake Cam Brake Cam Brake Cam Brake Cam Brake Cam Brake Cam Brake...

Page 157: ...20 30mm 20 30mm 20 30mm 20 30mm 20 30mm 20 30mm 20 30mm 20 30mm 20 30mm 20 30mm 20 30mm 20 30mm Stopper Bolt Stopper Bolt Stopper Bolt Stopper Bolt Stopper Bolt Stopper Bolt Stopper Bolt Stopper Bolt...

Page 158: ...se of the strong tension of spring Inspection Measure the free length of rear cushion spring Inspect the damper rod for winding and damaging Inspect the damper unit for oil leakage Inspect the damper...

Page 159: ...joint and tighten the lock nut Torque 3 8kgf m 38N m Tools Rear cushion compressor Rear cushion compressor attachment Installation Install the rear cushion Install the bolt Torque Upper bolt 3 4kgf m...

Page 160: ...on Install the rear fork and tighten the pivot bolt Torque 4 5kgf m Install the following Rear cushion Chain cover Rear wheel R L lower cover CAUTION Chain Slider Chain Slider Chain Slider Chain Slide...

Page 161: ...15 0 Hydraulic Brake...

Page 162: ...ads can be removed without disconnecting the hydraulic system Bleed the hydraulic system if it has been disassembled A contaminated brake disk or pad reduces stopping power Discard contaminated pads a...

Page 163: ...disk worn Low fluid level Clogged hydraulic system Disc bent Sticking worn caliper piston Disc Worn Contaminated master cylinder inner part Brake lever bent Brake drag Clogged hydraulic system Stickin...

Page 164: ...e while pumping the brake bleeder Repeat the above procedures until brake fluid appear in the brake bleeder Add brake fluid Check the fluid level often Add fluid when the fluid level in the master cyl...

Page 165: ...e fluid Install the diaphragm set the master cylinder cap Torque 0 13kgf m Brake Pad Replacement Always replace the brake pads in pairs to assure even disc pressure Replace the brake pads without remo...

Page 166: ...ke Hose Bolt Brake Hose Bolt Brake Hose Bolt Brake Pad Brake Pad Brake Pad Brake Pad Brake Pad Brake Pad Brake Pad Brake Pad Brake Pad Brake Pad Brake Pad Brake Pad Brake Pad Hanger Pin Hanger Pin Han...

Page 167: ...ake Caliper Brake Caliper Brake Caliper Brake Caliper Brake Caliper Brake Caliper Brake Caliper Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt Brake Ho...

Page 168: ...y part of brake hose and remove the piston from caliper Do not use the high pressure air or do not close the air conditioner Do not put the hand into the caliper inside Remove the piston seal and dust...

Page 169: ...Clean the piston seal dust seal with brake fluid and install of caliper into the part Install the piston into the caliper by the groove side of piston faces the pad Coat the boot with the silicon grea...

Page 170: ...ose Bolt Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt...

Page 171: ...Spring Spring Spring Spring Spring Secondary Cope Secondary Cope Secondary Cope Secondary Cope Secondary Cope Secondary Cope Secondary Cope Secondary Cope Secondary Cope Secondary Cope Secondary Cope...

Page 172: ...linder Master Cylinder Master Cylinder Master Cylinder Master Cylinder Master Cylinder Master Cylinder Master Cylinder Master Cylinder Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt Brake Hose Bolt B...

Page 173: ...16 0 Charging System Battery Regulator Rectifier Fuse Battery AC Generator...

Page 174: ...rk flame and cigarettes away The battery fluid level should be checked regularly Fill with distilled water when necessary Quick charge a battery only in an emergency slow charging is preferred Charge...

Page 175: ...failure Charging system failure Loose battery connection Low power Engine running Low fluid level One or more dead cells Battery undercharged Faulty battery Charging system failure Intermittent power...

Page 176: ...gravity is below 1 230 The specific gravity changes according to the battery temperature as shown Replace the battery with a new battery when it has white cells Replace the battery with a new one when...

Page 177: ...not at the battery terminals to prevent spark Discontinue charging if the electrolyte temperature exceeds 45 113 Quick charging should only be done in an emergency slow charging is preferred Assembly...

Page 178: ...A check the wire harness to be sure the connection is good and the wires are not damaged Recheck the Charging Output Inspection As voltage is changeable according to the charging state inspect the cha...

Page 179: ...ing the inspection the resistance of the human body is indicated Therefore be careful of that Must inspect using the defined tester as the below If being inspected by different tester can not be inspe...

Page 180: ...connectors Remove the voltage regulator rectifier by removing the two flange bolts Installation is the reverse order of removal A C Generator Inspection Disconnect the 3P coupler of the generator code...

Page 181: ...17 0 Ignition System A C Generator Spark Plug Ignition Coil CDI Unit...

Page 182: ...the main switch OFF while serving C D I ignition system is used and it can not be adjusted Couplers are connected to other couplers which have same colour Coil standard resistance may not be obtained...

Page 183: ...Between ignition coil and plug Faulty main switch Faulty ignition coil Faulty C D I unit Faulty A C generator Faulty pulse generator Engine starts but runs poorly Ignition primary circuit Faulty ignit...

Page 184: ...y CDI Tester Measure the resistance using the DAELIM PVA multi tester PVA multi tester Well read the instruction manual of tester and handle it Replace the CDI unit if necessary Inspection Item Termin...

Page 185: ...the two bolts and remove the ignition coil Installation is the reverse order of removal NOTE Ignition Coil Ignition Coil Ignition Coil Ignition Coil Ignition Coil Ignition Coil Ignition Coil Ignition...

Page 186: ...nd blue yellow Standard Resistance 95 135 20 68 Voltage Over 0 7V If the standard resistance is not obtained check all the related parts for the troubleshooting Replacement of the pulse generator refe...

Page 187: ...tion Remove the timing hole cap from the left crank case cover and start the engine Align the F mark on the rotor with the index mark on the case cover when specified idle rotates Idle Speed 1 400 100...

Page 188: ...MEMO...

Page 189: ...18 0 Electric Starter Starter Motor Battery Starter Magnetic Switch...

Page 190: ...starter magnetic switch Loose or disconnected wire cable Starter motor turns engine slowly Battery discharged Excessive resistance in circuit Binding in starter motor Starter motor turns but crank sha...

Page 191: ...ssembly Remove the following parts Motor case Front cover rear cover Armature Check the trust washer for position and number of sheet Inspection Measure the brush length Service Limit 8 5mm 0 33in Mea...

Page 192: ...y between the cable terminal and Brush Case side it is OK Replace or repair them if necessary Inspect the commutator part of the armature for discoloration If over 2 segments are discolored must be re...

Page 193: ...h holder center with driving each brush into the brush holder inside Install the holder into the case aligning the projecting part of brush holder with the part of case Rear Cover Armature Brush Brush...

Page 194: ...the setting bolts exactly O Ring O Ring O Ring O Ring O Ring O Ring O Ring O Ring O Ring O Ring O Ring O Ring O Ring Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Starter Magnetic...

Page 195: ...nuity Ground Circuit Inspection Disconnect the green red wire connector of the starter magnetic switch There should be continuity between the starter magnetic wire terminals at the harness side and gr...

Page 196: ...MEMO...

Page 197: ...19 0 Lights Switches Horn...

Page 198: ...nnecting and aligned when reconnecting To isolate an electrical failure check the continuity of the electrical path through the part A continuity check can usually be made without removing the part fr...

Page 199: ...the headlight case with the index mark on the bracket Headlight Removal Remove the two headlight mounting bolts and remove the headlight from the bracket Remove the individual code from the wire CAUTI...

Page 200: ...pper Cover Combination S W Upper Cover Combination S W Upper Cover Combination S W Upper Cover Combination S W Upper Cover Combination S W Upper Cover Combination S W Upper Cover Combination S W Under...

Page 201: ...Assembly is done in the reverse order of disassembly Fuel Meter Bulb Replacement Remove the hax socket bolt 3 of fuel meter Tail Light Lens Tail Light Lens Tail Light Lens Tail Light Lens Tail Light L...

Page 202: ...lb in bulb socket by turning toward anti clockwise Take off the bulb by turning toward anti clockwise and replace it Assembly is done in the reverse order of disassembly Bulb Bulb Bulb Bulb Bulb Bulb...

Page 203: ...Remove the winker coupler socket grab rail ass y Push the winker wire clamp and loosen the nut Remove the winker coupler socket Assembly is done in the reverse order of disassembly When assembling ali...

Page 204: ...happening the urgent situation during driving it is equipment for operating the engine stop to OFF position and braking the engine After checking for being RUN position before starting start the main...

Page 205: ...tch Starter Switch Starter Switch Starter Switch Starter Switch Starter Switch Starter Switch Starter Switch Starter Switch Starter Switch Starter Switch Starter Switch Starter Switch Starter Switch D...

Page 206: ...it released Rear Remove the R side cover 12 2 Disconnect the rear brake light switch wire coupler and check for continuity between terminals The switch should have continuity with the rear brake appli...

Page 207: ...ction Connect wire coupler of fuel unit and put the main switch on Check the position of the meter indicator moving float up and down Float Position Resistance High 0 02 0 1 Low 13 25 5 Float Position...

Page 208: ...20 1 Wiring Diagram 20 Wiring Diagram 20...

Page 209: ...MEMO...

Page 210: ...d high tension wires Faulty pulse generator Faulty main switch 3 Test cylinder compression Low compression Low speed of starter crank Incorrect valve clearance Faulty valve seat Worn cylinder and pist...

Page 211: ...logged air cleaner Clogged jets Clogged fuel tank breather Clogged muffler 5 Check ignition timing Incorrect Faulty CDI unit Faulty pulse generator Flywheel is not installed properly 6 Test cylinder c...

Page 212: ...essive carbon build up in combustion chamber Ignition timing too advanced Faulty CDI unit or pulse generator Valve train lubricated properly Correct Poor Performance At Low and Idle Speed 1 Check the...

Page 213: ...k for clogged jets 4 Check valve timing Incorrect Cam sprocket not installed properly 5 Check valve spring tension Weak Faulty spring Correct Correct Fuel flows freely No clogged Poor Performance At H...

Page 214: ...SM38 9911 01E HEAD OFFICE 16 6 PIL DONG 2KA CHUNG KU SEOUL KOREA TEL 82 2 2267 6111 FAX 82 2 2269 7997 FACTORY 58 SUNG SAN DONG CHANG WON KYUNGNAM KOREA TEL 82 551 279 1000 FAX 82 551 263 9761...

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