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DAELIM NS125DLX Service Manual Download Page 33

External Parts

4-1

4. External Parts

Service Information

NOTE

●

This section describes external parts removal/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.

Service Information

4-1

Maintenance Procedure

4-2

External Parts Removal/Installation 4-3

Muffler

4-9

Front Fender

4-10

4

Summary of Contents for NS125DLX

Page 1: ...SERVICE MANUAL...

Page 2: ...annot 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...

Page 3: ...ll ventilated area 5 Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods It is desirable not to handle used oil frequently however wash your hands t...

Page 4: ...Service Information 1 2 Identification Numbers Frame serial number Engine serial number...

Page 5: ...Drum brake Fuel tank capacity Full capacity 7 5 Reserve capacity 1 2 Caster angle 25 Trail 84 7 Front fork oil capacity 80 Type Oil cooled air cooled 4 cycle SOHC engine Cylinders Arrangement 1 Singl...

Page 6: ...eduction 2 786 39 14 Ignition system C D I lgnition Ignition timing F mark 8 BTDC 1 600 rpm Full advance 19 AC generator capacity 125W 5 000 rpm Battery type capacity Closed type MF 12V 6AH Spark plug...

Page 7: ...8 6 1 2 12 8 Transmission cover drain bolt 1 8 1 0 10 7 Transmission cover check bolt 1 8 0 9 9 6 Cooling fan bolt 3 6 1 0 10 7 Starting clutch nut 1 22 9 5 95 67 Starter motor terminal nut 2 6 0 9 9...

Page 8: ...ck absorber upper bolt 1 10 2 7 27 20 Rear shock absorber lower bolt 1 10 4 0 40 29 Rear shock absorber damper rod lock nut 2 10 3 8 38 27 Apply locking agent Torque values listed above are for specif...

Page 9: ...Add oil If there is no specific oil indicated use the designated or recommended engine oil Apply grease 3 1 Indicates reference page example Refer to page 3 1 Symbol Meaning Symbol Meaning OIL GREASE...

Page 10: ...g tape Do not use a wire or harness with a broken insulator Repair by wrapping them with protective tape or replace them Route wire harnesses to avoid sharp edges or corners Avoid the projected ends o...

Page 11: ...ctor Side stand switch connector Charge socket connector Front brake hose Horn Chage socket Radiator Packing lever Front brake hose Speedometer cable Rear brake cable Side stand switch Radiator hose T...

Page 12: ...1 10 Service Information CDI unit Ignition coil Radiator hose CDI unit Ignition coil Throttle cable Rear brake cable Side stand switch Fuel pump Fuel filter...

Page 13: ...oil with viscosity satisfying the atmospheric temperature In your riding area based on the table shown on the right side 1 1 After disassembly Oil capacity 0 75 After Oil change 0 8 After Oil filter...

Page 14: ...ough Head gasket faulty Worn piston rings Low oil pressure Oil level now Pressure relief valve stuck open Plugged oil pick up screen Oil pump worn External oil leaks High oil pressure Pressure relief...

Page 15: ...er 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...

Page 16: ...ent spring and filter cover and tighten bolts Torque value Oil filter cover 1 1kg m 11N m 8ft lb Oil Pump Remove the following parts Luggage box 4 5 Rear cushion bolt 6 2 RH floor side cover 4 5 Exhau...

Page 17: ...ip clearance Service limit 0 18mm 0 007in Inspection Assemble the inner and outer rotors to the oil pump Measure the pump body clearance Service limit 0 23mm 0 009in Measure the pump side clearance Se...

Page 18: ...pump to the R crank case cover Install the following parts Oil pump drive gear and driven gear Starter clutch Starter driven gear and reduction gear A C generator R crank case cover Shroud and coolin...

Page 19: ...lation Remove the front wheel Remove the front cover front side cover and inner box Loosen the flange bolt 3EA oil bolt and remove the radiator from the main pipe bracket Radiator Radiator bracket Rad...

Page 20: ...Inspection Check the damage or oil leaks from the radiator Radiator Installation Assemble the radiator to the main pipe bracket Tighten the oil bolt Install the inner box Install the front side cover...

Page 21: ...rease Control Cable Lubrication Remove and clean the upper assembly of the throttle cable and apply oil If the cable has expanded replace it Wheel bearing Side main stand pivot Brake caliper bracket W...

Page 22: ...MEMO...

Page 23: ...e idling in a closed or poorly ventilated place for a long period of time NOTES Driver only Front tire 175kPa 1 75kg Rear tire 200kPa 2 00kg Cold tire pressure Driver and Front tire 225kPa 2 25kg a pa...

Page 24: ...Torque Values Spark plug 1 1kg m 11N m 8ft lb Cylinder head cover bolts 1 0kg m 10N m 7ft lb Valve adjusting nuts 1 1kg m 11N m 8ft lb Timing hole cap 0 6kg m 6N m 4 3ft lb Tools Wrench 8 9mm Adjusti...

Page 25: ...each scheduled maintenance period based on the information described in the owner s manual I Inspect and clean adjust lubricate or replace if necessary R Replace L Lubricate C Clean Frequency Odometer...

Page 26: ...the throttle grip does not operate properly lubricate the throttle cable If the throttle grip does not operate properly check the throttle cable for aging damage or kinking Check the throttle grip fre...

Page 27: ...e Genuine plug CREH 9 Spark plug clearance 0 8 0 9mm Torque value 1 1kg m 11N m 8ft lb NOTE Valve Tappet Clearance Remove the following parts Center cover 4 4 Loosen the 4 cylinder head bolts NOTE Mea...

Page 28: ...a compression gauge Open the throttle completely and crank the engine with the starter motor until the gauge reading rising Tool Compression gauge NOTE Compression pressure 13 8kg cm2 If the pressure...

Page 29: ...ake pads for wear If the red mark on the pad reaches the brake disk replace the pads Rear brake pad replacement Replace in the some method as that of front brake pad replacement NOTE Rear brake fluid...

Page 30: ...level by operating the adjusting screw located on the upper side of the front fender NOTE Side Stand Erect the main stand Pull the lower end of the side stand and see if it moves freely If the side st...

Page 31: ...ting conditions Check the front fork for oil leakage parts damage or looseness Rear wheel Compress the near cushion up and down several times to check the operating conditions Check the rear fork for...

Page 32: ...7 5mm 0 3in Steering Head Bearing NOTE Lift the front wheel and check if the handle moves right and left smoothly If the handles move heavily check if the cable or electric cord interferes with the ha...

Page 33: ...moval 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 Service Information 4...

Page 34: ...g covers Front cover Inner box Front side cover Floor side cover Maintenance cover Center cover Rear under cover Rear handle cover Body cover Floor panel Front handle cover Luggage box Rear carrier Ta...

Page 35: ...e reverse order of removal Front Side Cover Removal Installation Remove the front fender 4 10 Remove the front wheel 12 5 Remove the 2 front lower flange bolts and the 2 upper screws Remove the 2 inne...

Page 36: ...to unlock and remove the main key cover Remove the charge socket from the inner box Remove the inner box Install in the reverse order of removal Center Cover Loosen the 4 setting screws assembled to...

Page 37: ...l Remove R L side covers Install in the reverse order of removal Luggage Box Unlock the system with the main key and open the seat Loosen the 4 cap nuts Remove the fuel tank cap NOTE Remove the luggag...

Page 38: ...nter cover 4 4 Loosen 2 each of the R L body cover grill screws set with the floor panel Loosen 1 each of the R L body cover clips assembled to the rear fender Loosen 1 each of the R L flange bolts se...

Page 39: ...r Panel Battery Cover Remove the center cover 4 4 Loosen 2 each of the R L pillion step cover setting screws of the floor mat and remove the floor mat Loosen the 2 battery cover setting screws and rem...

Page 40: ...the front handle cover forward and remove the wiring Remove the front handle cover Install in the reverse order of removal Rear Handle Cover Loosen the 3 screws assembled to the handle bar Loosen the...

Page 41: ...EX muffler connect the EX pipe and install the 2 flange nuts temporarily Install the 2 flange bolts on the R crankcase temporarily Tighten the 3 flange nuts to install the EX muffler and EX pipe Inst...

Page 42: ...fender A and B Loosen the 2 setting screws of the front fender A and remove the front fender A Loosen 1 setting screw of the front fender B Remove the speedometer cable guide Remove the front fender...

Page 43: ...MEMO...

Page 44: ...Fuel System 5 0 Fuel tank Fuel strainer Fuel pump Carburetor...

Page 45: ...AUTION Do not excessively bend or twist cable Distorted or damaged cable may lead to mechanical malfunctions Pay particular attention to the position of O ring Replace with new ones when disassembled...

Page 46: ...tory rotation Unsatisfactory idling adjustment Mixture too lean or rich Air cleaner clogged Secondary air absorbed into the intake system Fuel system clogged Mixture too lean Carburetor jets clogged F...

Page 47: ...bottom fuel tank bracket bolts Remove the fuel tank bracket Remove the fuel tank Installation Install in the reverse order of removal NOTES 5 3 Check for gasoline leakage Gasoline mark is on the fuel...

Page 48: ...aner Install in the reverse order of removal Carburetor Remove Remove the air cleaner 5 4 Loosen the throttle cable lock nut and remove the throttle cable from the carburetor Remove the auto cock cord...

Page 49: ...e the jet needle holder spring and jet needle Inspection Check the vacuum piston for wear cracks scratches or other damage Check the jet needle edge for extensive wear twist or damage Check if the dia...

Page 50: ...or damage Check the float valve operation Remove the main jet needle jet holder and needle jet and remove the slow jet NOTE Prior to unfastening the pilot screws count the number of turns until the sc...

Page 51: ...l System Clean all jets and holes with an air hose 5 7 Assemble the needle jet needle jet holder main jet and slow jets Assemble and turn the pilot screw to the number of turns memorized Carburetor bo...

Page 52: ...the jet needle and spring to the piston and install the holder NOTE Install the compression spring and vacuum chamber Carburetor Installation Assemble the air vent fuel tubes and drain tubes to the c...

Page 53: ...10 Adjust the throttle operation Adjust the carburetor idling Adjust the pilot screws Check on oil leakage Pilot Screw Adjustment NOTE Gently tighten the pilot screw clockwise and unscrew in reverse...

Page 54: ...MEMO...

Page 55: ...linder and piston Section 9 and 10 Carburetor Section 5 Oil pump Section 2 Items to be worked after removing engine Crankshaft crankshaft bearing crank case bearing Engine oil capacity 1 0 when disass...

Page 56: ...Disconnect the high tension cord from the engine Remove the negative pressure tube from the caburetor insulator Remove the EX muffler 4 9 Remove the rear brake caliper Remove the L floor side cover 4...

Page 57: ...everse order of removal NOTE Toque Engine hanger bolt Front 2 7kg m 27N m 20ft lb Rear 3 5kg m 35N m 25ft lb Check the following after the engine is assembled Engine oil Electric systems 6 3 Take prec...

Page 58: ...L Crank Case Cover Kick Starter Continuously Variable Transmission 7 0 L crank case cover...

Page 59: ...Drive face boss outer diameter 23 980 23 993 0 9441 0 9446 23 960 0 9433 Drive belt width 22 0 8661 20 5 0 8071 Weight roller outer diameter 10 95 20 05 0 4311 0 7893 19 5 0 7677 Clutch outer and inn...

Page 60: ...gasket and install a new gasket and dowel pin L Crank Case Cover Removal Loosen the kick starter pedal bolt Remove the kick starter pedal Remove the cover side cooling hose Loosen the L crank case co...

Page 61: ...ission Tighten the L crank case cover bolt Assemble the cooling hose to the cover Install the kick starter pedal and tighten bolts Torque value 2 2kg m 22N m 16ft Ib Feed the DAELIM genuine oil to the...

Page 62: ...oval Remove the L crank case cover 7 2 Remove the kick starter spring from the kick return stopper plate on the L crank case cover Remove the kick starter spindle Remove the kick driven gear Remove th...

Page 63: ...rter driven gear Disassemble the kick starter idle shaft Kick Starter Inspection Check the kick starter spindle for wear or damage Check the return spring for defects or damage Check the kick starter...

Page 64: ...Case Cover Kick Starter Continuously Variable Transmission Check the kick starter driven gear for wear and damage Check the friction spring for defects and damage 7 6 Friction spring Kick starter driv...

Page 65: ...ith the L crank case cover groove and assemble Match the kick starter spindle with the idle gear punch mark and assemble Hold and turn in reverse the kick return spring arm Assemble the kick stopper p...

Page 66: ...ven pulley to the drive shaft As shown in the right side figure turn the movable driven face clockwise and assemble the drive belt to the driven pulley while widening the driven pulley belt contact pa...

Page 67: ...Assemble the clutch outer to the drive shaft Fix the clutch outer with the universal holder and fasten with the setting nuts Torque value 5 5kg m 55N m 40ft Ib Tool Universal holder Assemble the L cr...

Page 68: ...r wear or damage Check the weight roller outer diameter Service limit 19 5mm 0 767in Movable Drive Face Assembly Supply grease on the inner side of the movable drive face boss part Assemble oil seal i...

Page 69: ...semble the movable drive face boss and the movable drive face to the crank shaft Assemble the assembly drive belt to the crank shaft Tighten the drive pulley nut with a drive holder Torque value 5 5kg...

Page 70: ...7 7 Use a universal holder to hold the clutch outer and remove the clutch outer after disassembling the 12mm flange nut Remove the movable driven face and the clutch from the drive shaft Driven Face D...

Page 71: ...r Remove the guide roller and its pin Remove the movable driven face Remove the O ring from the movable drive face Remove the oil seal from the movable driven face Remove the inner bearing Seal collar...

Page 72: ...sure the free length of the driven face spring Service limit 97 23mm 3 822in Check the clutch outer for wear or damage Measure the inner diameter of the clutch outer Service limit 120 5mm 4 736in Chec...

Page 73: ...ck the guide globe for wear or damage Check the oil seal for wear damage or other defects Driven Face Assembly Assemble the outer bearing to the movable driven face NOTE Insert the circlip into the gr...

Page 74: ...ndle until the lock nut can be installed Clamp the clutch spring compressor in a vise and tighten the lock nut to the specified torque using the lock nut wrench Remove the spring compressor Torque val...

Page 75: ...Variable Transmission Assemble the clutch outer Hold the clutch outer and tighten nuts with the prescribed torque Torque value 5 5kg m 55N m 40ft lb Tool Universal holder Assemble the drive face Asse...

Page 76: ...Generator Starter Clutch 8 0...

Page 77: ...d without removing the engine Specifications Item Standard value service Limit Starter driven gear O D 39 622 39 635 1 5599 1 5604 39 53 1 556 I D 32 000 32 025 1 2578 1 2588 32 10 1 2618 Reduction ge...

Page 78: ...e 3 shroud R L setting bolts Loosen the shroud L setting screw Remove the shroud R L Install in the reverse order of removal A C Generator Removal Remove the following parts Luggage box 4 5 Body cover...

Page 79: ...Tool Fly wheel puller holder Remove the woodruff key from the crankshaft Stator Removal Installation Loosen the pulse generator screw and remove the pulse generator Loosen the 3 stator setting screws...

Page 80: ...ighten the rotor bolts after fixing the flywheel with the holder Tool Flywheel holder Torque value 5 5kg m 55N m 40ft lb Connect the A C generator wire Assemble the cooling fan with bolts Assemble shr...

Page 81: ...l seals if necessary Starter Reduction Gear 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 1...

Page 82: ...etting bolts Assemble the A C generator 8 2 Assemble the R L shroud 8 2 Assemble the luggage box 4 5 Assemble the body cover 4 6 Starter Clutch Removal Remove the shroud 8 2 Remove the A C generator 8...

Page 83: ...her Remove the starter driven gear Check the starter driven gear and starter clutch for proper operation Remove the starter clutch Inspection Check the starter driven gear for wear of damage Measure t...

Page 84: ...ghten the starter driven gear with lock nuts Torque value 9 0kg m 90N m 65ft lb Tool Special socket 12 7 28 120 Assemble the washer Assemble the R crank case cover 8 4 Assemble the A C generator 8 2 A...

Page 85: ...diameter 11 982 12 000 0 4717 0 4724 11 950 0 4705 Cam height IN 33 835 33 995 1 321 1 3384 33 625 1 3234 Camshaft EX 33 984 34 144 1 380 1 3443 33 765 1 3293 Camshaft inner diameter 15 005 15 018 0 5...

Page 86: ...s Faulty hydraulic tappet Burned or bent valves Incorrect valve timing Broken valve spring Cylinder head Leaking or damaged head gasket Warped or cracked cylinder head Cylinder and piston Refer to Sec...

Page 87: ...R crank case cover Verify 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 an...

Page 88: ...er arm and rocker arm shaft for wear or damage Measure the inner diameter of the rocker arm Service limit 12 060mm 0 4748in Measure the outer diameter of the rocker arm shaft Service limit 11 950mm 0...

Page 89: ...Removal Remove the engine from the frame section 5 Remove the camshaft Remove the cylinder head from the cylinder Remove the gasket dowel pin and cam chain guide from the cylinder Cylinder Head Disas...

Page 90: ...he valve spring Service limit 36 90mm 1 4528in NOTE Clearance Between Valve Steam and Guide Check the valve for bend seizure or damage and check the stem for abnormal wear Insert the valve into the va...

Page 91: ...the service limit replace the valve Valve Guide Replacement NOTE Heat all cylinder heads uniformly to approximate levels of 130 140 NOTE NOTE 9 7 After changing the valve guide make sure to adjust the...

Page 92: ...alve Seat Inspection Adjustment Remove carbon deposits from the valve Apply a light coating of prussian blue to the cylinder head valve seat Gently strike the valve with the valve guide reamer without...

Page 93: ...ndard value 0 8 1 0mm 0 031 0 039in Service limit 1 4mm 0 055in Valve Seat Cutter Repair the damaged valve seat by using valve seat cutters and grinders NOTE Valve Seat Repair If the seat surface is r...

Page 94: ...at Gently strike the valve with a valve guide reamer to check the status of contact without turning the valve If the contact surface is too high grind the surface with a 37 cutter and finish to the pr...

Page 95: ...acing the cylinder head Assemble the spring retainer Compress the valve spring and install the valve cotter NOTE Tool Valve spring compressor 9 11 Do not excessively press and turn the valve to set it...

Page 96: ...chain tensioner and assemble pivot bolts Torque valve 1 0kg m 10N m 7ft lb Assemble spark plugs Torque valve 1 1kg m 11N m 8ft lb Cylinder Head Installation Clean the gasket marks from the cylinder he...

Page 97: ...side of the rocker arm shaft check the camshaft assembly for abnormal condition and place it on the cylinder head Put the cam chain on the cam sprocket Slowly turn the crankshaft to the left and alig...

Page 98: ...der nut and bolts and tighten them driving with 2 or 3 times Torque values 8mm nut 2 9kg m 29N m 21ft lb Remove the sealing screws and washers from the cam chain tensioner lifter Turn the tensioner sh...

Page 99: ...screws to the tensioner lifter Torque values 0 4kg m 4N m 3ft lb Fill clean engine oil into the operating parts of the cylinder head Adjust the valve clearance 3 5 Remove oil from the cylinder head co...

Page 100: ...Cylinder Piston 10 0 O I L O I L Piston pin clip Piston top ring Piston pin clip Piston 2ND ring Piston Oil ring...

Page 101: ...ylinder Excessive carbon build up Low octane fuel Item Standard value Service limit Inner diameter 56 000 56 010 2 2047 2 2051 56 100 2 2087 Cylinder Cylindricality 0 050 0 002 Out of roundness 0 005...

Page 102: ...nner diameter Service limit 56 100mm 2 2087in Measure the piston outer diameter Subtract the piston outer diameter value from the cylinder inner diameter value and measure the clearance between the cy...

Page 103: ...ing Remove the piston ring NOTE Check the clearance between the piston ring and groove Service limit Top 0 110mm 0 0043in Second 0 080mm 0 003in Oil 0 280mm 0 0110in Check the piston for wear or damag...

Page 104: ...r diameter of the piston pin hole Service limit 15 038mm 0 5920in Measure the outer diameter of the piston pin Service limit 14 960mm 0 5890in Check the clearance between the piston and piston pin Ser...

Page 105: ...sembling verify the ring is rotating smoothly 10 5 Top ring Second ring The ring is easily broken Take necessary precautions not to break it and not to damage the piston during assembly Assemble the r...

Page 106: ...the cam chain guide by aligning the tangs with the cylinder slots Assemble the cylinder head 9 10 6 Let the IN mark face towards the intake valve side Place a piece of cloth over the crank case to pr...

Page 107: ...MEMO...

Page 108: ...Transmission Crankshaft Crank Case 11 0 R Crank Case Crankshaft L Crank Case...

Page 109: ...n 7 Clutch driven pulley section 7 The following parts must be removed prior to changing the L crank case Follow the removal procedure specified in each section Transmission section 11 Rear brake sect...

Page 110: ...mover shaft Remover head Sliding weight Assembly shaft Troubleshooting Engine noise Connecting rod big and small ends loose Crank pin bearing loose Engine started but unable to move out Transmission d...

Page 111: ...Remove the rear wheel section 13 Loosen the 8 transmission cover bolts Remove the transmission cover Remove the gasket and dowel pin Remove the drive shaft from the transmission cover by using a hydra...

Page 112: ...Crank Case Check the final shaft for wear or damage Check the countershaft for wear or damage Remove the final shaft and the countershaft comp Inspection Check the drive shaft for wear or damage 11 4...

Page 113: ...special tools to push in the bearing into the case Tools Driver handle A Outer Driver Driver pilot Check the L crank case oil seal for wear or damage 11 5 Installation Install the drive shaft on the...

Page 114: ...Remove the parts to disassemble crank case Loosen the seven R L crank case setting bolts Install a new gasket and dowel pin Tighten the transmission cover with setting bolts Assemble the rear wheel s...

Page 115: ...y Remove the R crank case cover 8 4 Remove the L crank case cover 7 2 Remove the crankshaft from the R crank case by using a crankshaft remover If there is the bearing left in the L crank case use the...

Page 116: ...hly Check the outer race to see if it is accurately pressed into the case If the outer race is excessively loose or is loosely pressed into the case remove it and replace with a new one Inspection Pla...

Page 117: ...g Driver Attachment 32 35mm Countershaft bearing Driver Attachment 42 47mm Pilot 20mm Install a new final shaft oil seal 11 9 Crankshaft Assembly Apply clean engine oil to the new R crankshaft bearing...

Page 118: ...R crank case to the L crank case NOTE Tighten the crank case bolts Torque value 1 0kg m 10N m 7ft lb Install the R L crank case cover Assemble the disassembled parts Install the engine on the frame 1...

Page 119: ...his section describes how to remove and maintain front wheels front fork and steering system For information on the front brake system refer to section 14 Place a jack underneath the engine to support...

Page 120: ...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 flui...

Page 121: ...Fix it to the vehicle while maintaining the correct assembled location Loosen the throttle housing fixing screw remove the upper under housing Remove the throttle cable from the throttle grip remove t...

Page 122: ...l grease or gasoline from the contact surface the LH handle pipe and apply molybdenum to the handle grip contact surface and install the LH handle grip Bond ROYAL BOND 1300 NOTE Accurately install the...

Page 123: ...e and tighten with screws NOTE Install the LH RH front handle side cover Install the front cover 4 3 Install the back mirror Front Wheel Removal Loosen axle nut Support bottom of engine with a Jack un...

Page 124: ...im runout with a dial gauge Service limit Radial 2 0mm 0 08in Axial 2 0mm 0 08in Bearing inspection Manually turn the bearing inner race and replace if it makes noise or is worn Check if the bearing o...

Page 125: ...OTE Tools Bearing remover head Bearing remover Apply sufficient amount of grease to the bearing Insert the right bearing with its seal surface facing outside Do not tilt the bearing Insert accurately...

Page 126: ...ling Assembly Apply grease to the right side dust seal rim Install the right side dust seal Install the brake disk Install disk bolts Torque value 4 0 4 5kgf m Install the right side collar 12 8 Right...

Page 127: ...ront forks Insert the disk taking precautions not to damage the pad and assemble the wheel Align the slots of the speedometer gear with the tangs of the left fork slider Insert the front axle into the...

Page 128: ...the fork tube Disassembly Remove the fork tube cap bolt NOTE Wrap the bottom case with a piece of cloth and remove the socket bolt 12 10 Loosen the fork tube cap bolt but do not remove it If the screw...

Page 129: ...the socket bolt turns idle but 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...

Page 130: ...ear Replace defective parts with new ones Service limit 230 8mm 9 087in Place the fork tube on a V block and measure deflection with a dial gauge Service limit Replace if the deflection is greater tha...

Page 131: ...ols until the attachment groove of the bottom case set ring is exposed Tools Fork seal driver Fork seal driver body Install the set ring Accurately assemble the set ring to the bottom case Install the...

Page 132: ...ly Installation Assemble the front fork to the steering stem Assemble the front fork setting bolt Torque value 1 1kg m 11N m 8ft lb Install the following parts Front wheel 12 5 Brake caliper 14 6 Fron...

Page 133: ...18 4 Front wheel 12 5 Front fork 12 10 Loosen the 2 headlight stay bolts and remove the stay Remove the front wiring and coupler Remove the steering stem lock nut Tools Lock nut wrench Extension bar...

Page 134: ...steering bottom cone race dust seal dust seal washer Remove the top ball race and the bottom ball race into the steering head pipe Tool Ball race driver Assembly Insert the top ball race and the bott...

Page 135: ...after applying grease thereto Install the top cone race and the top thread nut over the steering head Tighten the top thread nut completely and loosen by 1 8 turn Torque value 0 2 0 3kg m 2 3N m 2ft l...

Page 136: ...heel Front Fork Steering Readjust and clamp the speedometer cable Install the front fork Install the headlight stay Install the following parts Front fork Front wheel Main switch Handle bar Front cove...

Page 137: ...ontaminated with oil clean the brake drum and replace the brake shoe Item Standard value Service limit Axle shaft run out 0 2 0 008 Rear wheel rim runout Radical 2 0 0 08 Axial 2 0 0 08 Rear cushion s...

Page 138: ...sure incorrect Faulty tire Bent rim Loose wheel bearing Swing arm bushing worn Wheel out of balance Soft suspension Weak springs Shock absorber improperly adjusted Hard suspension Shock absorber impro...

Page 139: ...sen the rear axle nut remove the rear swing arm Remove the rear wheel inside collar Remove the rear wheel mud guard Remove the rear wheel Inspection Turn the wheel and check the rim for wobbles Servic...

Page 140: ...m 43 58ft lb Install the rear caliper assembly to the rear swing arm Install the muffler 4 9 Rear Cushion Removal Remove the body cover 4 6 Remove the luggage box 4 5 Loosen the top and bottom rear c...

Page 141: ...Apply thread locking agent to the lock nut and install the rear cushion compressor attachment on the damper rod Fix the upper joint and tighten the lock nut Torque value 2 0kg m 20N m 14ft lb Tools R...

Page 142: ...brake caliper Loosen the axle nut remove the rear swing arm Disassemble the rear wheel outside collar to the rear swing arm Disassemble the oil seal and radial ball bearing Install in the reverse ord...

Page 143: ...tisfactory Air in the brake system Moisture in brake fluid Brake pad and disk contaminated Caliper piston seal worn Master cylinder piston seal worn Brake pad worn Caliper inside contaminated Unsatisf...

Page 144: ...the above operation until there is no air flowing out of the bleeder hose Squeeze the bleeder valve and operate the brake lever to check the ingress of air 14 2 A contaminated disk or pad reduces bra...

Page 145: ...ar the lower level If no air leaks out of the bleeder hose operate the brake lever to check the presence of air Assemble the bleeder valve Torque 0 4 0 7kgf m Add brake fluid up to upper level Install...

Page 146: ...press the piston to return to the original position Remove the pad pin bolt lock plate and brake pad Verify that the pad spring is installed in specific position Install a new brake pad lock plate an...

Page 147: ...ve the rear brake caliper from the rear swing arm To install a new brake pad into the brake press the piston to return to the original position Remove the pad pin bolt lock plate and brake pad Verify...

Page 148: ...and the pin bolt from the caliper If there is any wear or damage in the boot replace it with the new one Wind the caliper with cloth to prevent the piston or brake fluid from leaking Remove the piston...

Page 149: ...he brake fouid and install them in the caliper Install the piston in the caliper with the groove side of the piston facing the pad NOTE 14 7 Make sure that each part is free from dust or dirt before r...

Page 150: ...ose bolt Torque 3 5kgf m Install the slide pin cap Fill the brake fluid and bleed air Rear brake caliper removal Remove the brake oil bolt and the brake hose from the brake caliper Remove the EX muffl...

Page 151: ...er Clean the master cylinder reserve master piston with the recommended brake fluid Master cylinder inspection Check the piston periphery for kink or scratch Check the primary and secondary cups for w...

Page 152: ...it may indicate the side wear of the cylinder by the direction of the piston contacting face In this case the master cylinder must be replaced also Replace the piston spring cups and snap ring as a s...

Page 153: ...sealing washers and the hose bolt Torque 3 5kgf m Connest the brake stop switch wire Fill the brake fluid and bleed air Install the rear handle cover 4 8 Install the front handle cover 4 8 Install the...

Page 154: ...MEMO...

Page 155: ...ime specified on top of the battery Use a tester to check the charging status open voltage Do not replace the battery with a general type battery Check the charging system in sequence based on trouble...

Page 156: ...pecific gravity Charging system failure Loose battery connection Low power engine running Battery undercharged Low fluid level One or more dead cells Charging system failure Intermittent power Loose b...

Page 157: ...Turn off the main switch and remove the earth cable from the battery Connect an ampere meter between the battery terminal and the earth cable and check current when the main switch is turned off NOTE...

Page 158: ...ews and remove the headlight NOTE Start engine turn the light switch on set the dimmer switch to Hi and check voltage between the blue and green lamp side NOTE If the digital tester used 10 0 13 0V 5...

Page 159: ...e main switch is turned Lead black ON between the black and green Regulator Rectifier Inspection If the inspection of the harness side proves to be satisfactory check the regulator rectifier coupler f...

Page 160: ...Generator Inspection NOTE Disconnect the 4P coupler of the generator cord Measure the resistance between the yellow leads Resistance value 0 1 1 0 20 68 Measure the resistance between the yellow lead...

Page 161: ...ervoltage may occur on the unit leading to circuit damage Always turn off the main switch prior to servicing Ignition timing cannot be adjusted because the ignition system is of CDI type Spark plug ch...

Page 162: ...gnition coil and plug Faulty main switch Faulty ignition coil Faulty CDI unit Faulty A C generator Faulty pulse generator Poor Engine Running Primary ignition circuit Faulty ignition coil Faulty wire...

Page 163: ...TE Replace defective CDI unit 16 3 Inspection item Terminal Standard value Pulse generator Blue yellow and green white 50 170 20 68 Ignition coil primary coil Black yellow and earth 3 6 4 6 20 68 A C...

Page 164: ...the ignition coil spark plug cap and earth Standard value 7 3 11K If the measured value deviates from the prescribed value remove the plug cap from the high tension cord and measure the secondary res...

Page 165: ...lack red Measure the resistance between the black red wire and the earth Standard value 50 350 20 68 NOTE 16 5 Read the tester manual carefully prior to using the tester Even if the resistance value s...

Page 166: ...t the engine speed greater than 3 900 rpm it indicates the advance system is correct Side Stand Ignition Cut off Switch Inspection Remove the front cover 4 3 Remove the headlight 18 2 Remove the coupl...

Page 167: ...dlight 18 2 Remove the coupler of the side stand switch Remove the L side cover 4 5 Loosen the side stand switch mounting 2 bolts Release the wire clamps and remove the side stand switch Installation...

Page 168: ...MEMO...

Page 169: ...sion 680g Unit mm in Troubleshooting Starter motor will not turn Battery discharged Faulty ignition switch Faulty starter switch Faulty starter magnetic switch Loosen or disconnected wire or cable Sta...

Page 170: ...with a tester to determine if power is connected Tester PVA multi tester Installation Install a new O ring and apply oil Insert the starter motor and tighten the 2 bolts completely NOTE Assemble the l...

Page 171: ...ates operation condition is satisfactory Earth Circuit Inspection Disconnect the green yellow wire connector of the starter magnetic switch If power is connected between the harness terminal and the v...

Page 172: ...MEMO...

Page 173: ...continuity test on circuits or parts to diagnose electric systems The continuity test on normal parts can be carried out without removing the parts from the vehicle Simply disconnect the wires and con...

Page 174: ...replace the light bulb Install in the reverse order of removal Front Winker Bulb Replacement Remove the front handle cover 4 8 Remove the R L winker light bulb socket from the handle cover and replac...

Page 175: ...the speedometer setting screws and remove the front wheel side speedometer Remove the speedometer cable from the meter and remove the speedometer To disassemble the meter release the hook from the me...

Page 176: ...removal Handle Bar Switch Remove the front handle cover 4 8 Loosen the headlight and remove the handle bar switch terminals Carry out inspection based on the following table Dimmer switch 18 4 Color B...

Page 177: ...uel sensor from the fuel tank Fuel gauge Turn the ignition switch on Remove the fuel tank 5 3 NOTE Check the fuel gauge while moving the fuel sensor float up and down Up No fuel Down Fuel amount suffi...

Page 178: ...tery Check the sound quality for any abnormalities Clock The current time is displayed at the bottom of the combination meter If the time is incorrect make adjustments with the setting rubber Replacem...

Page 179: ...Light Switch Horn 18 7 Trunk Lamp Replace bulb Remove the luggage box 4 5 Replace the trunk lamp bulb socket from the trunk lamp of out side Color Green Red Terminal G R Push Projection...

Page 180: ...MEMO...

Page 181: ...Br SB G O G Br Br L W B SB G B LG LG B B G Y G Y G O R B L Y Y 12V MF6AH BATTERY ST MOTOR A C G R H RR WINKER LIGHT 12V 10W STOP AND TAIL LIGHT 12V 21W 5W L H RR WINKER LIGHT 12V 10W R H FR WINKER LI...

Page 182: ...MEMO...

Page 183: ...ged 2 Check spark plugs weak or no spark 1 Faulty spark plug 2 Contaminated spark plug 3 Faulty CDI unit 4 Faulty A C generator 5 Disconnected or shorted high tension cord 6 Disconnected or shorted ig...

Page 184: ...arburetor for clogging Clogged 1 Unsatisfactory Carburetor maintenance 5 Remove spark plugs Contaminated or 1 Unsatisfactory plug maintenance discolored 2 Plugs with incorrect heat value used 6 Check...

Page 185: ...ng 4 Check sparks Weak or intermittent 1 Carbon deposited on spark plugs sparks or spark plugs contaminated 2 Faulty CDI unit 3 Faulty ignition coil 4 Faulty A C generator 5 Disconnected or shorted hi...

Page 186: ...r worn 3 Drive pulley bearing worn 5 Abnormal noise or odor 1 Oil or grease spilled on the drive belt and inside pulley 2 Drive belt worn 3 Weak drive face spring 4 Driven pulley bearing worn or seize...

Page 187: ...e and cam contact surface worn 4 Brake drum worn 2 Brake noise 1 Brake shoe worn 2 Foreign matter in the brake lining 3 Brake drum and shoe contact surface curved 3 Poor braking 1 Brake wire defective...

Page 188: ...Ignition switch ON 1 Operate the turn signal to check Signal continuously 1 Fuse cut the battery circuit operates dim or does 2 Battery weak or totally discharged not operate at all 3 Ignition switch...

Page 189: ...ot activated 2 Rotor winding damaged or shorted 3 Starter motor subwire damaged 4 Terminal loose 1 Wire harness damaged Starter Motor turns slow or fails to crank motor 1 Operate the turn signal to ch...

Page 190: ...2001 4 PRINTED 2001 4 PUBLICATION SERVICE MANUAL NO COPY...

Page 191: ...0104 01E HEAD OFFICE FACTORY 58 Sungsan dong Changwon Kyungnam Korea Tel 82 55 279 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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