DAELIM HISTORY 125 - SERVICE Service Manual Download

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8-5

A.C GENERATOR / STARTER CLUTCH

OIL SEAL

RH. CRANKCASE COVER

REDUCTION GEAR

SHAFT

STARTER
REDUCTION GEAR

SHAFT

DOWEL PIN

●

Loosen the 9 RH. crankcase cover setting bolts.

●

Remove the RH. crankcase cover.

●

Remove the gasket and dowel pin.

●

Remove the RH. crankcase cover oil seal.

●

Check the oil seal for wear or damage and replace with
a new one as necessary.

STARTER REDUCTION GEAR

REMOVAL

●

Remove the starter reduction gear and shaft.

INSPECTION

●

Check the reduction gear for wear or damage.

●

Measure the inner diameter of the gear.

SERVICE LIMIT : 12.10 mm

●

Measure the outer diameter of the gear shaft.

SERVICE LIMIT : 11.97 mm

Summary of Contents for HISTORY 125 - SERVICE

Page 1: ......

Page 2: ...ot 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 thi...

Page 3: ...n 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 spa...

Page 4: ...e 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 compresse...

Page 5: ...ection in case of the single sided sealed ball bearing Install the open direction or double sided sealed bearing in the way that the face marked with manufacturer and size should direct to the outer a...

Page 6: ...ll 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...

Page 7: ...er 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 co...

Page 8: ...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 t...

Page 9: ...ng 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 fro...

Page 10: ...ess 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...

Page 11: ...1 9 SERVICE INFORMATION SERIAL NUMBER LOCATION ENGINE SERIAL NUMBER LOCATION FRAME SERIAL NUMBER LOCATION...

Page 12: ...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...

Page 13: ...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...

Page 14: ...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...

Page 15: ...REARMASTERCYLINDERRESERVOIRCAPSCREW FRONT REAR BRAKE HOSE OIL BOLT FRONT REARMASTERCYLINDERLEVERPIVOTBOLT FRONT REARMASTERCYLINDERLEVERPIVOTLOCKNUT REAR BRAKE ARM FLANGE BOLT SPEEDOMETER GEAR BOX OVAL...

Page 16: ...ing 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 Indic...

Page 17: ...TION 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 CABL...

Page 18: ...TER 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...

Page 19: ...5 f m OIL FILTER COVER BOLT 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 F...

Page 20: ...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...

Page 21: ...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...

Page 22: ...ilter seal when removing oil filter element Be careful not to lose the oil filter spring when assembling the oil filter element OIL PUMP REMOVAL Remove the following parts Rear cushion lower bolt 13 7...

Page 23: ...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...

Page 24: ...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 INSTALLATION Install the oil pump to the...

Page 25: ...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 Ch...

Page 26: ...y 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 re...

Page 27: ...add oil or grease CONTROL CABLE LUBRICATION Remove and clean the upper assembly of the throttle cable and apply oil If the cable has expanded replace it 2 9 LUBRICATION FRONT BRAKE LEVER PIVOT THROTTL...

Page 28: ...MEMO...

Page 29: ...HT 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 PLAY 2 6mm SPARK PLUG CR8EH 9 SPARK PLUG GAP 0 8 0 9mm IN 0 12 0 02mm EX 0...

Page 30: ...ORQUE 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 ADJUSTMENT...

Page 31: ...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 ridi...

Page 32: ...d recheck the throttle grip free play AIR CLEANER Release the seat lock by turning the main switch key to open the seat Loosen the 6 screws securing the air cleaner case cover remove it Loosen the 2 s...

Page 33: ...wire brush to clean the plug Always use a feeler gauge to check the gap GENUINE PLUG CR8EH 9 SPARK PLUG GAP 0 8 0 9mm TORQUE VALUE 1 1 kgf m CAUTION Make sure there is no dirt or debris on the seat of...

Page 34: ...until the gauge reading rising TOOL COMPRESSION GAUGE NOTE The maximum reading is usually reached within 4 7 seconds COMPRESSION PRESSURE 13 8 kg cm2 If the pressure is low check the following Inadequ...

Page 35: ...in the brake system can lead to reduced braking effiency and possible loss of braking ability BRAKE PAD SHOE BRAKE PAD REPLACEMENT Check the brake pads for wear If the red mark on the pad reaches the...

Page 36: ...cated on the upper side of the front fender NOTE Adjust the beam level according to local laws and regulations Improper beam level adjustment may blind oncoming drivers or may incorrectly light the ro...

Page 37: ...n efficiency FRONT WHEEL Hold the brake lever and compress the front cushion up and down several times to check the operating conditions Check the front fork for oil leakage parts damage or looseness...

Page 38: ...SERVICE LIMIT 0 5mm STEERING HEAD BEARING NOTE Check the cable if it interferes with the handle operation Lift the front wheel and check if the handle moves right and left smoothly If the handles move...

Page 39: ...emoval installation Do not apply unreasonable force when disassembling covers to prevent possible damage A muffler is hot Do not service it immediately after the engine is stopped 4 SERVICE INFORMATIO...

Page 40: ...in the order of disassembling covers FRONT COVER FRONT FENDER FRONT WHEEL FRONT UNDER COVER REARCOMBINATION LIGHT SEAT LUGGAGE BOX REAR CENTER COVER REAR CARRIER BACK REST UPPER BODY COVR BODY COVER C...

Page 41: ...emove it Disconnect the headlight wiring and remove the front cover Loosen the 4 flange bolts securing the headlight remove the headlight Loosen the 4 tapping screws securing the top cover remove the...

Page 42: ...floor panel Loosen the 2 flange bolts securing the frame under cover bracket Remove the front under cover Install in the reverse order of removal NOTE Pay attention not to turn over the vehicle LUGGAG...

Page 43: ...the plug maintenance cover setting special screw securing the center cover remove the plug maintenance cover Loosen the 2 washer screws securing the body cover Loosen the special screw securing the f...

Page 44: ...key to open the seat Remove the following parts Luggage box 4 4 Center cover 4 5 Rear center cover 4 5 Rear carrier 4 6 Back rest 4 6 Loosen the 4 special screw R L securing the floor panel Loosen th...

Page 45: ...6 Back rest 4 6 Body cover 4 6 Loosen the 2 washer screws securing the body cover remove the rear combination light Install in the reverse order of removal FLOOR SIDE COVER Remove the floor mat Loosen...

Page 46: ...UTION Be sure to remove the negative pole side cord first and the position pole side cord next Make sure that terminals do not contact with other adjacent parts when handling terminal Contact with oth...

Page 47: ...emove the inner box Loosen the 2 tapping screws remove the parking brake lever seal Remove the inner box lid from the inner box Remove the lock key setting spring and remove the inner box lid key Inst...

Page 48: ...e the front handle cover 4 10 Loosen the 2 tapping screws securing the steering handle Remove the speedometer cable from the meter Disconnect the stop switch wiring of the RH LH master cylinder assemb...

Page 49: ...kcase Loosen the washer bolt securing EX muffler bracket Remove the rear wheel mud guard Install in the reverse order of removal NOTE Never perform the maintenance of the muffler right after stopping...

Page 50: ...asket to the EX pipe Insert the EX pipe to the cylinder comp and tighten the 2 flange nuts with specified torque Install the plug maintenance cover NOTE Tighten the flange nuts diagonally and alternat...

Page 51: ...MEMO...

Page 52: ...FUEL SYSTEM 5 0 FUEL TANK FUEL STRAINER FUEL PUMP CARBURETOR...

Page 53: ...O ring Replace with new ones when disassembled If it is desired to store a vehicle for a period longer than 1 month drain gasoline out of the carburetor float chamber Gasoline left in the float chamb...

Page 54: ...perly Air screw is adjusted improperly Compression pressure is low Air Fuel mixture is either too lean or rich Carburetor is blocked Mis firing occurs when driving at high speeds Ignition system is da...

Page 55: ...4 5 Rear carrier Back rest 4 6 Body cover 4 6 Remove the fuel tube from the fuel tank NOTE Use the tube clip or the cap to prevent the gasoline from leaking Remove the fuel unit wire coupler Remove t...

Page 56: ...ng the air cleaner After pressing the duct clip securing the air cleaner remove the air cleaner inlet duct Loosen the 3 flange bolts left 1 right 2 securing the frame body Remove the air cleaner Insta...

Page 57: ...r Remove the diaphragm spring diaphragm assembly Turn the jet needle with a screwdriver and remove the needle spring spring holder and jet needle from the vacuum piston CARBURETOR INSPECTION Check the...

Page 58: ...nd float value Check the float valve and valve seat for scores scratches clogging and damage Replace if necessary Check the float valve operation Remove the main jet main jet holder holder washer jet...

Page 59: ...ow open air and fuel passages in the carburetor body with compressed air CAUTION Cleaning the air and fuel passages with a piece of wire will damage the carburetor body or fuel pump FLOAT CHAMBER FLOA...

Page 60: ...an rich Install the float body assembly install the bracket and 4 pan screws NOTE Be sure to replace the float chamber body O ring with the new one Insert the jet needle needle spring holder needle sp...

Page 61: ...Install the air cleaner 5 4 Install the center cover 4 5 Install the luggage box 4 4 NOTE After adjusting the carburetor check the throttle grip free play CABURETOR INSULATOR REMOVAL Remove the lugga...

Page 62: ...leaning and gap adjusting Valve clearance for adjusting CAUTION Tightening the pilot screw against its seat will damage the seat Rev the engine up slightly from the idle speed and make sure that engin...

Page 63: ...engine from the vehicle body TRANSMISSION SECTION 11 STARTING CLUTCH SECTION 8 OIL PUMP SECTION 2 A C GENERATOR SECTION 8 STARTER MOTOR SECTION 17 KICK STARTER CONTINUOUSLY VARIABLE TRANSMISSION SECT...

Page 64: ...C generator coupler and connector wiring connected to the A C generator disconnect the starter motor wiring cable Remove the battery earth cable from the RH shroud groove Disconnect the high tension c...

Page 65: ...8 Remove the rear wheel 13 3 Remove the rear wheel mud guard 4 11 ENGINE INSTALLATION Install in the reverse order of removal NOTE Take precautions not to damage wiring and cable Take precautions not...

Page 66: ...7 0 LH CRANKCASECOVER KICKSTARTER CONTINUOUSLYVARIABLE TRANSMISSION LH CRANKCASE COVER...

Page 67: ...mm DRIVE FACE BOSS OUTER DIAMETER 23 980 23 993mm 23 96mm DRIVE BELT WIDTH 22mm 20 50mm WEIGHT ROLLER OUTER DIAMETER 19 95 20 02mm 19 50mm CLUTCH OUTER INNER DIAMETER 120 0 120 2mm 120 50mm DRIVEN FAC...

Page 68: ...kcase surface NOTE Align the bolts to uniform the tightening location before tightening then when you don t know the bolt length Tighten the bolts diagonally with specified tightening torque Be sure t...

Page 69: ...e kick driven gear and 13mm thrust washer Loosen the kick starter pedal bolt Remove the kick starter pedal Remove the 14mm external circlip Remove the kick spindle washer 7 3 LH CRANKCASECOVER KICKSTA...

Page 70: ...pindle for wear or damage Check the return spring for defects or damage Check the kick starter bush for damage Check the kick starter driven gear for wear and damage Check the friction spring for defe...

Page 71: ...ng the kick starter pedal install the kick driven gear and 13mm thrust washer Install the LH crankcase cover 7 2 NOTE When installing the 14mm external circlip keep holding the spindle manually and in...

Page 72: ...y groove as shown so that it slackens enough to remove the driven pulley from the drive shaft Loosen the drive face setting nut 12mm with the clutch center holder Remove the kick starter ratchet and d...

Page 73: ...ulley sub assembly on the drive shaft Turn the pulley clockwise and spread the faces apart while installing the drive belt Remove the pulley assembly once with the drive belt installed Put the drive b...

Page 74: ...lder and remove the nut TOOL DRIVE FACE HOLDER Remove the kick starter ratchet and drive face If the drive face holder cannot be used remove the cooling fan at the right side of the crankshaft and hol...

Page 75: ...e service limit is exceeded Movable drive face boss outer diameter SERVICE LIMIT 23 960mm Movable drive face inner diameter SERVICE LIMIT 24 025mm MOVABLE DRIVE FACE INSTALLATION Install the weight ro...

Page 76: ...8 0 kgf m TOOL DRIVE FACE HOLDER NOTE Tighten the drive face nut to the specified torque Correctly match the drive face and crank shaft serration when assembling If the drive face holder cannot be use...

Page 77: ...ft Remove the drive belt DISASSEMBLY Install a clutch spring compressor on the pulley assembly and tighten the tool to gain access to the nut NOTE Do not overtighten the compressor Hold the clutch spr...

Page 78: ...pulley Remove the guide pins and guide pin rollers and the movable driven face Remove the O ring and oil seals from the movable driven face Remove the movable driven face 7 12 LH CRANKCASECOVER KICKST...

Page 79: ...fits securely Replace the bearing if necessary Movable Driven Face Spring Inspection Measure the free length of the driven pulley spring and replace if the service limit is exceeded SERVICE LIMIT 97...

Page 80: ...first then remove the bearing Remove the snap ring then drive out the outer bearing toward the inner bearing side Drive a new outer bearing into place with the sealed end toward the outside Install th...

Page 81: ...the driven pulley spring and clutch in the clutch spring compressor Compress the assembly by turning the tool handle until the lock nut can be installed Clamp the clutch spring compressor in a vise an...

Page 82: ...W Ye eW Y e W Yf W Y f W Yg Y g Yh 7 6 Install the drive face Xh X g V Xg V X f V Xf hfV X e hf V Xe N1e J5e hf W Ye eW Y e W Yf W Y f W Yg Y g Yh 7 8 Install the LH crankcase cover Xh X g V Xg V X f...

Page 83: ...MEMO...

Page 84: ...8 0 FLYWHEEL STATOR COMP RH SHROUD COOLING FAN A C GENERATOR STARTER CLUTCH...

Page 85: ...IONS TORQUE VALUES FLY WHEEL BOLT 5 5 kgf m STARTER CLUTCH LOCK NUT 9 5 kgf m RH CRANKCASE COVER BOLT 1 1 kgf m TOOLS SPECIAL SOCKET 12 7 x 28 x 120 A C G ROTOR PULLER 8 SERVICE INFORMATION 8 1 SHROUD...

Page 86: ...shroud Install in the reverse order of removal NOTE Before removing the RH shroud be sure to remove the RH floor side cover and rear cushion upper bolt A C GENERATOR REMOVAL Loosen the rear cushion u...

Page 87: ...ert the puller shaft and remove the flywheel after inserting the A C G rotor puller and securing it with spanner The flywheel may easily removed if you rotate the puller while tapping the roller shaft...

Page 88: ...OLDER NOTE If the universal holder cannot be used remove the LH crankcase cover and hold the drive face with the drive face holder TORQUE VALUE 0 8 1 2 kgf m TOOL DRIVE FACE HOLDER Install the RH shro...

Page 89: ...the gasket and dowel pin Remove the RH crankcase cover oil seal Check the oil seal for wear or damage and replace with a new one as necessary STARTER REDUCTION GEAR REMOVAL Remove the starter reducti...

Page 90: ...RH shroud 8 2 Rear swing arm 13 8 Rear caliper 14 6 EX muffler 4 12 RH floor side cover 4 7 Luggage box 4 4 Tighten the rear cushion under bolt STARTER CLUTCH REMOVAL Loosen the rear cushion under bol...

Page 91: ...r clutch Check the starter driven gear and starter clutch for proper operation Remove the starter clutch STARTER CLUTCH INSPECTION Remove the starter driven gear needle bearing and starter oneway clut...

Page 92: ...e accurately Install the thrust washer Temporarily install the starter clutch lock nut Hold the drive face with the drive face holder Tighten the starter clutch lock nut with a special socket NOTE Tig...

Page 93: ...MEMO...

Page 94: ...9 0 CYLINDER HEAD VALVES CAM COVER PLATE IN VALVE ROCKER ARM EX VALVE ROCKER ARM CAM SHAFT HOLDER CAM SHAFT COMP CARBURETOR INSULATOR CYLINDER HEAD COMP CYLINDER HEAD GASKET INLET VALVE EX VALVE...

Page 95: ...f m SPARK PLUG 1 2 kgf m CAMSHAFT HOLDER 8mm NUT 2 0 kgf m CAM CHAIN TENSIONER MOUNTING BOLT 1 2 kgf m CAM CHAIN TENSIONER SEALING SCREW 0 4 kgf m CYLINDER HEAD COVER BOLT 0 9 kgf m CYLINDER HEAD BOLT...

Page 96: ...urned or bent valves Incorrect valve timing Broken valve spring Uneven valve seating Cylinder head Leaking or damage head gasket Warped or cracked cylinder head Cylinder piston see section 10 Excessiv...

Page 97: ...erify that the piston is located at the top dead center Make all camshaft lobes face downward If all camshaft lobes face upward rotate the crankshaft to the left for 1 turn 360 and align the T mark wi...

Page 98: ...shaft and rocker arm in the same sequence CAMSHAFT INSPECTION Check the rocker arm and rocker arm shaft for wear or damage Measure the inner diameter of the rocker arm SERVICE LIMIT 12 060 mm Measure...

Page 99: ...he frame 6 2 Remove the cylinder head cover Remove the RH LH shroud 8 2 Remove the camshaft 9 3 Remove the EX pipe 4 12 Remove the cylinder head Remove the cylinder head gasket dowel pin and cam chain...

Page 100: ...assembling hole and the valve seat for cracks Using a square and a feeler gauge check the cylinder head distortion SERVICE LIMIT 0 1 mm VALVE SPRINGS Measure the free length of the inner and outer va...

Page 101: ...tem clearance with a dial indicator while rocking the stem in the direction of normal thrust SERVICE LIMIT IN 0 090 mm EX 0 120 mm Measure the inner diameter of the new valve guide If the clearance is...

Page 102: ...ve is installed slanted that causes oil leaks from the stem seal and improper valve seat contact and results in the valve seat refacing not able to be performed Use cutting oil on the reamer during th...

Page 103: ...ust be replaced Measure the valve seat width STANDARD VALUE 0 8 1 0 mm SERVICE LIMIT 1 4 mm VALVE SEAT REFACING Reface the worn valve seat by using valve seat cutters and grinders NOTE Follow the refa...

Page 104: ...wered using a 37 degree flat cutter Refinish the seat to specifications using a 45 degree finish cutter If the contact area is too low on the valve the seat must be raised using a 55 degree inner cutt...

Page 105: ...ace the stem seals with new ones whenever a stem seal is removed Lubricate each valve stem with molybdenum disulfide grease and insert the valve into the valve guide CAUTION Turning a valve too fast c...

Page 106: ...groove Tighten the carburetor insulator with mounting bolts Install the cam chain tensioner and assemble pivot bolts TORQUE 1 0 kgf m Install the spark plug TORQUE 1 2 kgf m Cleananygasketmaterialfro...

Page 107: ...ndition and place it on the cylinder head Put the cam chain on the cam sprocket Slowly rotate the crankshaft counterclockwise and align the T mark of the flywheel with the index mark of the RH crank c...

Page 108: ...section must be in alignment Of IN and EX the shorter rocker arm should be installed on the IN side Install the cam cover plate Apply engine oil to the threaded part install the camshaft holder nut an...

Page 109: ...LUE 0 4 kgf m Fill clean engine oil into the operating parts of the cylinder head Adjust the valve clearance 3 5 Remove oil from the cylinder head cover grooves and accurately assemble the gasket to t...

Page 110: ...10 0 CYLINDER PISTON CYLINDER CYLINDER GASKET PISTON TOP RING SECOND RING OIL RING...

Page 111: ...piston ring Scored or scratched piston or cylinder wall Excessive carbon build up on top of piston 10 SERVICE INFORMATION 10 1 TROUBLESHOOTING 10 1 CYLINDER 10 2 PISTON PISTON RING 10 3 CYLINDER INSTA...

Page 112: ...nder wall for scratches and wear Measure and record the cylinder inner diameter at three levels in both an X and Y axis Take the maximum reading to determine the cylinder wear SERVICE LIMIT 56 100 mm...

Page 113: ...crankcase Remove the piston pin clip using a pair of pliers Press the piston pin out of the piston NOTE Do not damage or scratch the piston Do not apply side force to the connecting rod Do not let the...

Page 114: ...SERVICE LIMIT 55 825 mm PISTON PIN INSPECTION Measure the piston pin bore inner diameter in an X and Y axis Take the maximum reading to determine the inner diameter Replace the piston if the inner di...

Page 115: ...assembly Do not confuse the top and second rings Space the ring end gaps 120 degrees apart Space the side rail gaps 40mm or more apart as shown After installing the rings they should rotate freely wit...

Page 116: ...t material from the cylinder head mating surface Do not scratch the surface Install a new cylinder gasket and dowel pins NOTE Take care not to damage the cylinder mating surface Coat the cylinder wall...

Page 117: ...MEMO...

Page 118: ...11 0 TRANSMISSION CRANKSHAFT CRANK CASE RH CRANKCASE LH CRANKCASE CRANKSHAFT...

Page 119: ...following parts must be removed prior to changing the LH crank case Follow the removal procedure specified in each section TRANSMISSION SECTION 11 PARKING BRAKE SECTION 14 To assemble the crank case...

Page 120: ...SSEMBLY SHAFT TROUBLESHOOTING Engine Noise Connecting rod big and small ends loose Crank pin bearing loose Engine started but unable to move out Transmission damage Transmission seized Noise during op...

Page 121: ...el 13 3 Loosen the rear cushion upper bolt Remove the transmission bleeder tube from the mission cover groove Loosen the 8 transmission cover bolts Remove the transmission cover Remove the gasket and...

Page 122: ...RANSMISSION INSPECTION Check the drive shaft for wear or damage Check the final shaft for wear or damage Check the counter shaft for wear or damage 11 4 TRANSMISSION CRANKSHAFT CRANK CASE FINAL SHAFT...

Page 123: ...DRIVE HANDLE A OUTER DRIVER DRIVER PILOT Check the LH crankcase oil seal for wear or damage TRANSMISSION ASSEMBLY Install the drive shaft on the transmission cover Install a new drive shaft oil seal T...

Page 124: ...bolt release the transmission oil filler ACG cap or the LH crankcase until the oil overflow through oil hole and fill the recommended oil slowly Install the oil check bolt and the cap RECOMMENDED OIL...

Page 125: ...REMOVAL Remove the crankshaft from the RH crankcase by using a crankshaft remover If the bearing is left on the RH crankcase use the driver handle and the outer driver to remove it TOOLS DRIVER ATTAC...

Page 126: ...the connecting rod radial clearance in both X and Y directions Replace the crankshaft if the service limit is exceeded SERVICE LIMIT 0 05 mm TRANSMISSION BEARING Remove the transmission and crankshaft...

Page 127: ...VER HANDLE A DRIVER PILOT OUTER DRIVER Install a new final shaft oil seal CRANKSHAFT INSTALLATION Apply clean engine oil to the new RH crankshaft bearing and press in the bearing into the RH crankcase...

Page 128: ...Make sure that the gasket is completely attached without any clearance Install the RH LH radiator hose Install the bleeder tube to the LH crankcase Install the removed parts Install the engine on the...

Page 129: ...MEMO...

Page 130: ...12 0 FRONT WHEEL FRONT FORK STEERING STEERING HANDLE STEERING STEM FRONT DISK FORNT TIRE FRONT CASTING WHEEL FORNT FORK...

Page 131: ...10 Place a jack underneath the engine to support the 2 wheeled vehicle SPECIFICATIONS TORQUE VALUES STEERING STEM NUT 6 8 f m STEERING TOP THREAD 0 15 0 25 f m BOTTOM BRIDE 7 0 8 0 f m FRONT BRAKE DIS...

Page 132: ...axle wheel installed incorrectly Front wheel wobbling Bent rim Worn front wheel bearings Faulty tire Axle nut not tightened properly Wheel out of balance Soft suspension Weak fork springs Insufficient...

Page 133: ...and remove the RH grip from the handlebar Remove the winker relay from the steering handle Remove the front top cover Remove the front rear brake hose speedometer cable throttle cable from the handle...

Page 134: ...st the throttle grip free play 3 4 Apply DAELIM Bond A to the inside surface of the grip and to the clean surface of the left handle bar Wait 3 6 minutes and install the grip Bond A ROYAL BOND 1300 NO...

Page 135: ...LH winker wiring NOTE Check to see if the cylinder is passing each cable and wire harness directly and make sure that there is any interference by rotating the handle to the right and left Install the...

Page 136: ...front wheel on an inspection stand Slowly turn the wheel and check the rim for wobbles with a dial gauge SERVICE LIMIT Radial 2 0mm Axial 2 0mm Bearing Inspection Manually turn the bearing inner race...

Page 137: ...bearings in pairs and never use old bearings TOOLS BEARING REMOVER HEAD BEARING REMOVER Apply sufficient amount of grease to the bearing Insert the right bearing with its seal surface facing outside D...

Page 138: ...Apply grease to the speedometer gear prior to assembling FRONT WHEEL ASSEMBLY Apply grease to the right side dust seal rim Install the right side dust seal Install the brake disk Install disk bolts T...

Page 139: ...r groove to assemble the speedometer gear box FRONT WHEEL INSTALLATION Insert the front wheel between the front forks Insert the disk taking precautions not to damage the pad and assemble the wheel Al...

Page 140: ...he engine not to turn over it Loosen the fork pipe bolt but do not remove it Loosen the 4 setting bolts securing the RH LH front fork remove the RH LH front fork Loosen the washer bolt securing the RH...

Page 141: ...cannot be removed temporarily assemble the spring and the fork tube cap bolt first Hold the bottom case firmly with a vise taking precautions not to distort or damage it Remove the dust seal Remove t...

Page 142: ...springs with new ones Check components for damage or abnormal wear Replace defective parts with new ones SERVICE LIMIT FORK SPRING 258 3mm REBOUND SPRING 21 2mm Set the fork pipe on a V blocks and mea...

Page 143: ...om case do not insert the case itself but insert the bracket Apply ATF to a new oil seal Assemble the oil seal to the bottom case Insert the oil seal with special tools until the attachment groove of...

Page 144: ...he spring with the smaller pitch side facing downward Assemble the fork bolt to the fork pipe FRONT FORK INSTALLATION Install the front fork to the steering stem Install the front fork setting bolts T...

Page 145: ...ont fender 12 3 Front wheel 12 5 Front fork 12 10 Loosen the front brake hose clamp setting bolt securing the steering stem remove the front brake hose from the brake hose guide on the steering stem R...

Page 146: ...E Place a shop towel under the steering stem to catch the steel balls Check the upper ball assembly top cone race for damage or abnormal wear and replace as necessary Remove the under ball assembly fr...

Page 147: ...ace using the steering stem driver Apply grease to the bottom cone race Install the under ball assembly onto the bottom cone race making sure you have the correct amount TOOL STEERING STEM DRIVER Inst...

Page 148: ...rake hose Install the front fork TORQUE VALUE 7 0 kgf m Install the following parts Front wheel 12 9 Front fender 4 3 Front caliper 14 6 Steering handle 12 3 Rear handle cover 4 10 Front handle cover...

Page 149: ...gned to minimize the hazard caused by airborne asbestos fibers SPECIFICATIONS TORQUE VALUES REAR CUSHION UPPER BOLT 3 5 4 5 f m REAR CUSHION LOWER BOLT 3 5 4 5 f m REAR CUSHION ROD LOCK NUT 3 0 4 5 f...

Page 150: ...se wheel bearing Swing arm bushing worn Wheel out of balance Soft suspension Weak springs Rear damper improperly adjusted oil leakage Hard suspension Rear damper improperly adjusted Bent shock absorbe...

Page 151: ...4 12 Remove the rear brake caliper assembly from the rear swing arm Loosen the rear axle nut Remove the rear swing arm 13 8 Remove the rear wheel inside collar Remove the rear wheel mudguard 4 11 Rem...

Page 152: ...ecified torque TORQUE VALUE 6 0 8 0 kgf m Install the rear brake caliper assembly to the rear swing arm Install the EX muffler 4 12 Install the rear wheel mudguard 4 11 Insert the brake arm joint B in...

Page 153: ...14 6 Remove the rear swing arm 13 8 Remove the rear wheel 13 3 INSPECTION Measure the brake drum for inner diameter SERVICE LIMIT 111mm Measure the brake lining for thickness SERVICE LIMIT 2 0mm 13 5...

Page 154: ...small amount of grease to the brake cam Install the brake cam Install the rear brake dust seal indicator rear brake arm NOTE Align the punch marks of the brake arm and the brake cam before assembly Re...

Page 155: ...AR CHUSION COMPRESSOR ATTACHMENT REAR CHUSION COMPRESSOR Fix the upper metal and loosen the hex nut Remove the upper metal Remove the hex nut stopper rubber spring from the rear damper component INSPE...

Page 156: ...s TORQUE VALUE UPPER SIDE 3 5 4 5kgf m LOWER SIDE 3 5 4 5kgf m Install the luggage box 4 4 REAR SWING ARM REMOVAL Remove the EX muffler 4 12 Remove the rear brake caliper 14 6 Loosen the flange bolt s...

Page 157: ...MEMO...

Page 158: ...BRAKE SYSTEM 14 0...

Page 159: ...brake hose Warped deformed brake disk Caliper not sliding properly Clogged restricted brake hose joint Brakes drag Contaminated brake pad disk Misaligned wheel Worn brake pad disk Warped deformed brak...

Page 160: ...flowing out of the bleeder valve stop pumping the brake lever AIR BLEEDING When the brake bleeder is available Fill the reservoir with DOT 3 or 4 brake fluid up to the upper level CAUTION To prevent...

Page 161: ...bleeding the system to prevent air from being pumped into the system Release the brake lever slowly and wait several seconds after it reaches the end of its travel Repeat the above steps and until bub...

Page 162: ...rake hose when replacing brake pads Open the lock plate tangs and loosen the hanger pin Loosen the 2 front brake caliper setting bolts from the front fork Remove the front caliper from the RH front fo...

Page 163: ...not remove the brake hose when replacing brake pads Open the lock plate tangs and loosen the pad pin bolt Loosen the rear brake hose setting clamp bolt securing the EX muffler Remove the EX muffler 4...

Page 164: ...ke fluid from leaking Clean the removed parts with the brake fluid and make sure that the each port isn t clogged with the compressed air Keep the removed parts in order to avoid dust from adhering DI...

Page 165: ...th the brake fluid and install them in the caliper Install the piston in the caliper with the groove side of the piston facing the pad NOTE Make sure that each part is free from dust or dirt before re...

Page 166: ...he wind screen 4 10 Remove the front handle cover 4 10 Remove the rear handle cover 4 10 Disconnect the front brake switch wire Drain the brake fluid Remove the front rear brake hoses from the master...

Page 167: ...ry and secondary cups for wear NOTE If there is any leak of fluid when installing new piston it may indicate the side wear of the cylinder by the direction of the piston contacting face In this case t...

Page 168: ...ATION Install the front rear master cylinder to the handle bar NOTE Install the holder with its UP mark facing upwards and align the holder joint with the punch mark on the handle bar Tighten the hold...

Page 169: ...screw securing the parking brake lever remove the parking brake grip Remove the front cover 4 3 Loosen the parking brake rod adjust nut B remove the parking brake cable After releasing the lock by ro...

Page 170: ...MEMO...

Page 171: ...charged state the battery can be damaged its life can be reduced or it can lose some of its strength It is important to note here that the battery will naturally last 2 3 years of normal use and altho...

Page 172: ...TIFIER A C GENERATOR HEADLIGHT IC MAIN SWITCH HI LO 12V 60 55W TAILLIGHT 12V 5W FUSE RED YELLOW YELLOW YELLOW METERLIGHT DIMMER SWITCH LIGHTING SWITCH BLACK BROWN PINK GREEN GREEN GREEN GREEN GREEN GR...

Page 173: ...horted wire or connection Loose battery connection Faulty regulator rectifier Faulty A C generator CHARGING SYSTEM Measure battery current leakage 15 5 Check the regulator rectifier 15 7 Battery is fa...

Page 174: ...spark could ignite or damage the battery To prevent shorting always connect the positive cable first BATTERY OPEN CIRCUITVOLTAGE INSPECTION Remove the battery cover Disconnect the battery terminals f...

Page 175: ...ow may change abruptly if not sufficiently charged Use a battery whose voltage between its terminals is 13 0 13 2V When the engine is started using the starter motor a large amount of current may flow...

Page 176: ...agnosis above check the following Battery wire Broken wire harness repair or replace Ground wire Broken wire harness repair or replace Charging coil wire Check the charging coil of the A C generator I...

Page 177: ...the 2 regulator rectifier setting nut securing the horn stay remove the regulator rectifier Install in the reverse order of removal A C GENERATOR CHARGING COIL INSPECTION NOTE This test is done with t...

Page 178: ...MEMO...

Page 179: ...plers A faulty ignition system is often related to poorly connected connectors Check those connections before proceeding This manual gives explanations on inspections to receive peak voltage As inspec...

Page 180: ...GNITION COIL MAIN SWITCH A C GENERATOR DC CDI UNIT BLUE YELLOW BLACK YELLOW BLACK GREEN GREEN GREEN CDI UNIT IGNITION COIL SPARK PLUG GREEN RED BLACK BLUE SIDE STAND SWITCH GREEN PULSE GENERATOR MAIN...

Page 181: ...nnected CDI unit connector 4 Open circuit or poor connection in ground cord of the CDI unit 5 Faulty ignition system control circuit such as side stand switch 6 Faulty peak voltage adaptor 7 Faulty CD...

Page 182: ...Remove the luggage box 4 4 Disconnect the A C generator 4P coupler and the blue yellow wire connector Measuretheresistancebetweenthegreenandblue yellow STANDARD VALUE 90 150 20 PVA MEASUREMENT Discon...

Page 183: ...SECONDARY COIL INSPECTION With the spark plug cap on measure the resistance between the primary coil terminal and the spark plug cap If the resistance value is within the specified range then the coi...

Page 184: ...ng speed then the timing is correct IDLING SPEED 15 BTDC 1 800 rpm Increase engine speed by rotating the stop screw on the carburetor At the engine speed greater than 4 000rpm the ignition timing is c...

Page 185: ...Loosen the side stand switch mounting 2 bolts Release the wire clamps and remove the side stand switch INSTALLATION Install in the reverse order of removal Check the side stand ignition cut off switch...

Page 186: ...MEMO...

Page 187: ...ble to turn the starter motor quickly enough or supply adequate ignition current The starter motor may be damaged if current is allowed to flow to it when the engine cannot turn over The engine may no...

Page 188: ...SWITCH STARTER MOTOR STARTER MAGNETIC SWITCH M RED MAIN SWITCH FUSE FRONT STOP SWITCH RED WHITE STARTER SYSTEM CIRCUIT STARTER MOTOR STARTER SWITCH GREEN GREEN STARTER MAGNETIC SWITCH REAR STOP SWITCH...

Page 189: ...at starter magnetic switch coupler Faulty starter magnetic switch Disconnect starter magnetic switch coupler and check the starter magnetic switch coil ground wire 17 7 Connect the starter magnetic s...

Page 190: ...ssembling the starter motor mark the position of the case and cover so the starter can be assembled correctly later Loosen the starter motor case bolts and remove the motor cover INSPECTION Check for...

Page 191: ...e Discoloration of the commutator bar Replace with a new one Metallic debris between commutator bars Clean it off Check for continuity between pairs of commutator bars Make a continuity check between...

Page 192: ...5t thrust washer 0 2t slip washer and thrust support CAUTION The sliding surfaces of the brushes can be damaged if they are not installed properly When inserting the armature into the case hold the a...

Page 193: ...urned ON Clicks Poorly connected battery terminal and motor terminal of the switch Check the starter magnetic switch No clicks No starter magnetic switch input voltage Faulty relay ground line and sta...

Page 194: ...witch wire connector Apply battery voltage between terminals when the yellow red wire is connected to the positive battery terminal and the green yellow wire to the negative battery terminal If there...

Page 195: ...ks prior to disassembling and insert these tabs all the way until locked when assembling Carry out continuity test on circuits or parts to diagnose electric systems The continuity test on normal parts...

Page 196: ...WARNING Headlight bulbs become very hot while the headlight is ON and remain hot for a while after they are turned OFF Be sure to turn the ignition switch OFF and let the bulb cool down before replac...

Page 197: ...the reverse order of removal NOTE Check the each switch for proper operation SPEEDOMETER REMOVAL Remove the wind screen 4 10 Remove the front handle cover 4 10 Remove the front cover 4 10 Remove the f...

Page 198: ...er of removal INSPECTION Check for continuity between the terminals There should be continuity between the O O positions on the continuity chart HANDLE BAR SWITCH INSPECTION Remove the back mirror Rem...

Page 199: ...pulled CONTINUITY When the brake lever is released NOCONTINUITY Install in the reverse order of removal STARTER SWITCH LIGHTING SWITCH HORN SWITCH DIMMER SWITCH WINKER SWITCH HAZARD SWITCH TRUNK LAMP...

Page 200: ...set cap component to the left and remove it Remove the fuel unit from the fuel tank NOTE Be careful not to damage the wire Be careful not to damage the float arm Check the base packing for damage INS...

Page 201: ...ULSE GEN P PINK LIGHT GREEN LG SKY BLUE SB ORANGE O BROWN Br RED R GREEN G BLUE L YELLOW Y B BLACK GRAY Gr W WHITE 14V 3W HIGH BEAM PILOT 14V 3W L H WINKER PILOT 14V 3W R H WINKER PILOT 12V 1 7W x 2 M...

Page 202: ...d misadjusted Faulty ignition timing Clogged air cleaner Lean fuel mixture Flooded carburetor Throttle valve excessively opened Contaminated or clogged air cleaner Rich fuel mixture Recheck the engine...

Page 203: ...r O ring Faulty insulator band tightening Faultyinsulator Lean fuel mixture Rich fuel mixture Slow circuit clogged Open the drain screw and check fuel flow to the carburetor Check the spark plug Inser...

Page 204: ...k plug with an incorrect heat range Lean mixture Worn cylinder or piston Lean fuel mixture Poor quality fuel being used Excessive carbon build up on combustion chamber Incorrect ignition timing Damage...

Page 205: ...seized driven pulley bearing Steering top thread too tight Insufficient tire pressure Damaged steering bearing Damaged ball race Faulty tire Insufficient tire pressure Worn or faulty tire Faulty wheel...

Page 206: ...TROUBLE Weak cushion spring Overloaded Oil leakage from damper unit Bent fork pipe or cushion rod Worn slider Damaged cushion stopper rubber Soft suspension Hard suspension Suspension noisy POOR FRON...

Page 207: ...SERVICEMANUAL 2001 11 PRINTED 2001 11 PUBLICATION NO COPY...

Page 208: ...111 01E HEAD OFFICE FACTORY 58 SUNG SAN DONG CHANGWON KYUNGNAM KOREA TEL 82 55 239 7000 FAX 82 55 239 7524 OVERSEAS SALES OFFICE 16 6 PIL DONG 2KA CHUNG KU SEOUL KOREA TEL 82 2 2274 3171 FAX 82 2 2269...

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