DAELIM S-FIVE - Service Manual Download

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Summary of Contents for S-FIVE -

Page 1: ......

Page 2: ...hooting guide If you cannot find the cause of trouble refer to Section 18 Troubleshooting Contents of this manual and specifications are subject to change without prior notice for improvement of vehic...

Page 3: ...ed and always put on the protection gears because the engine or the muffler is hot right after engine stops 4 Gasoline is extremely flammable Maintenance must performed in the place free of the open f...

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: ...SPEEDREDUCTIONRATIO SECONDARYSPEED REDUCTIONRATIO TRANSMISSION TRANSMISSIONRATIO1STGEAR FRAME NUMBER ENGINE NUMBER UNDER BONE 8 0m 30km h VELOCITY 1 800mm AIR COOLED STARTER MOTOR KICK 2 CYCLE 1 CYLIN...

Page 13: ...DIAMETER OUTSIDE DIAMETER ID MARK A ID MARK B NO ID MARK CYLINDER AND PISTON CLEARANCE PISTON PIN HOLE INSIDE DIAMETER PISTON PIN OUTSIDE DIAMETER PISTON AND PISTON PIN CLEARANCE PISTON RING GAP TOP...

Page 14: ...HICKNESS DISK THICKNESS DISK SHAKING DISK WEAR LINE MASTER CYLINDER INSIDE DIAMETER MASTER PISTON OUTSIDE DIAMETER CALIPER CYLINDER INSIDE DIAMETER CALIPER PISTON OUTSIDE DIAMETER REAR BRAKE LEVER FRE...

Page 15: ...TE COIL PULSE GENERATOR IGNITION COIL RESISTANCE VALUES 20 PRIMARY COIL SECONDARY COIL PLUGCAPCONNECTION SECONDARY COIL PLUGCAPDISCONNECTION EXCITE COIL RESISTANCE VALUE 20 PLUSE GENERATOR RESISTANCE...

Page 16: ...LT NUT TWIST TORQUE 0 4 f m 0 9 f m 1 2 f m 2 7 f m 4 0 f m TWIST PART FLY WHEEL NUT DRIVE FACE NUT CYLINDER HEAD BOLT SPARK PLUG DRIVEN FACE NUT CLUTCH OUTER NUT OIL LEVEL CHECK BOLT EXHAUST PIPE JOI...

Page 17: ...UT REAR AXLE NUT SPEEDOMETER CABLE SETTING SCREW REAR BRAKE ARM BOLT FRONT BRAKE DISK BOLT REAR CUSHION UPPER BOLT REAR CUSHION LOWER BOLT ENGINE HANGER BRACKET NUT FRAME SIDE EXHAUST PIPE JOINT NUT M...

Page 18: ...00 07960 KM10000 0723 03900 07724 0050001 07725 0030000 0740 00001 0749 0010000 07746 0010200 07746 0040400 0755 00001 0751 00003 0740 00001 07746 0010400 07746 0040500 07749 0010000 0740 00001 07916...

Page 19: ...Cycle Oil Separation Lubrication Use SAE 80W 90 Multi Purpose Grease Molybdenum Grease FRAME PARTS APPLICATION AREAS FRONT WHEEL DUST SEAL EDGES FRONT PIVOT ARM BUSH FRICTION FACE FRONT PIVOT ARM SEAL...

Page 20: ...made by mixing molybdenum grease with engine oil at a 1 1 ratio Indicates needed application of a multi purpose grease NLG 1 2 using a lithium soap base Example brand Shell Albania EP 2 Fire proof She...

Page 21: ...ER HEADLIGHT TIE DOWN COUPLER ROLL THE HES CLAMP WITH THE CORD SECURELY RESISTER CONNECTING COUPLER HORN COMP TIGHT AT THE SAME TIME WITH THE HORN FRAME EARTH CDI UNIT ASS Y STARTER REALY ASS Y PRESS...

Page 22: ...AUTO BY STARTER CORD THROTTLE CABLE BATTERY ASS Y THIS SECTION SHOULD NOT BE PROJECTED THAN THE FRONT OF THE FRAME AND NOT HAVE ANY LOOSENESS AUTO BY STARTER 5W 6 7 FR BRAKE HOSE RESISTER RR BRAKE CAB...

Page 23: ...RR WINKER LIGHT TAIL LIGHT ASS Y FUEL UNIT TAIL LIGHT CONNECTING CONNECTOR CDI UNIT ASS Y OIL LEVEL S W AUTO BY STARTER CONNECTING COUPLER ACG CONNECTING COUPLER ACG CORD CLAMP ROLL THE WHITE TAPE ARE...

Page 24: ...MEMO...

Page 25: ...R CLOGGING 2 3 THROTTLE GRIP OPERATION 2 3 AIR CLEANER 2 4 SPARK PLUG 2 5 CYLINDERCOMPRESSIONPRESSURE 2 5 CARBURETOR IDLING 2 6 AIR SCREW ADJUSTMENT 2 6 BRAKE FLUID 2 6 BRAKE PAD SHOE 2 7 BRAKE SYSTEM...

Page 26: ...OTE 1 After the odometer reading exceeds 12 000km repeat maintenance service at intervals indicated in the table 2 After riding in areas with high humidity or pollution carry out maintenance service m...

Page 27: ...to install it as shown in the drawing i e with the cup facing down Fuel flows even though the strainer is installed upside down but it contaminates the inner wall of the strainer and prevents visual...

Page 28: ...ile type oil may cause improper ignition deterioration of the element or a loosening of the element adhesive Be sure to allow the element to dry thoroughly before applying oil Otherwise the oil will b...

Page 29: ...before using a wrench to tighten to the specified torque torque 14kgf m Do not overtighten the spark plug CYLINDERCOMPRESSIONPRESSURE Start and warm up the engine Remove the plug maintenance cover Sto...

Page 30: ...just by turning the air screw in or out within a 1 4 turn if necessary If the engine cannot be adjusted by turning the air screw within a 1 4 turn check for other engine problems CAUTION Excessive air...

Page 31: ...ar brake lever is fully pressed it indicates the brake lining has reached the service limit Replace the brake shoes BRAKE SYSTEM Check the front brake hose for cracks or damage If any leaks are found...

Page 32: ...nd oncoming drivers or may incorrectly light the road ahead SIDE STAND Erect the main stand Pull the lower end of the side stand and see if it moves freely If the side stand does not move smoothly app...

Page 33: ...the operating conditions Check the rear fork for oil leakage parts damage or looseness BOLTS NUTS FASTENERS Check all nuts and bolts of the frame during the regular maintenance to check if they meet t...

Page 34: ...t the steering head bearing BATTERY Remove a tapping screw securing the battery cover from the floor panel Check if the terminal is loose If the terminal is loose check and clean the contacting surfac...

Page 35: ...y after the engine is stopped 3 SERVICE INFORMATION 3 1 MAINTENANCE PRECEDURE 3 2 LUGGAGE BOX 3 3 PLUG MAINTENANCE COVER CENTER COVER 3 3 REAR CARRIER 3 3 BODY COVER 3 3 TAILLIGHT BASE 3 4 FLOOR SIDE...

Page 36: ...This chart shows arrows connected in the order of disassembling covers LUGGAGE BOX PLUGMAINTENANCE COVER CENTER COVER REAR CARRIER BODY COVER TAILLIGHT BASE FLOORSIDECOVER FLOOR PANEL ENGINE HANGER SI...

Page 37: ...e washer bolt securing the luggage box Loosen the special screw to remove the plug maintenance cover Loosen 2 tapping screw securing the floor panel Loosen 2 special screw R L securing the body cover...

Page 38: ...L securing the lower and rear end of the floor panel Pull the front part of the floor side cover to remove the floor panel Remove the floor side cover Install in the reverse order of removal FLOOR PAN...

Page 39: ...Install in the reverse order of removal NOTE Check for proper alignment of the connection hook before performing installation FRONT FENDER Loosen the flange bolts R L securing the front fork Remove th...

Page 40: ...crews securing the rear handle cover Remove the front handle cover while pull the cover to the front slightly Install in the reverse order of removal REAR HANDLE COVER Remove the back mirror Remove th...

Page 41: ...nstall 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 the EX pipe Install the 2 flange bolts on the rea...

Page 42: ...rse order of removal NOTE Never perform the maintenance of the muffler right after stopping the vehicle because the muffler is extremely hot UNDER COVER Remove the floor side cover 3 4 Remove the engi...

Page 43: ...BLESHOOTING Overheating or engine clogging Faulty adjustment of oil pump insufficient amount pumped Bad quality of engine oil Engine oil not being injected or blocked bent strainer screen or oil tube...

Page 44: ...4 2 LUBRICATION SYSTEM OIL SYSTEM DRAWING OIL TANK OIL TUBE CARBURETOR OIL PASS TUBE OIL PUMP OIL PUMP CONTROL CABLE OIL PUMP ANCHOR PLATE...

Page 45: ...tering the engine and oil tube by cleaning around the oil pump If the air enters into the oil line it may cause faulty lubrication or engine sticking Always remove the air in the oil line after mainte...

Page 46: ...g the engine Make sure that the open axis stays within an 1mm sphere The following occurs when the oil pump is adjusted incorrectly When the oil pump lever is excessively opened Emitting of white exha...

Page 47: ...to locate the oil pump shaft at the angle of 45 from the mark with oil tube connected In this state locate the oil pump in the level lower than the oil tank and drain the oil to bleed the air Install...

Page 48: ...idle for 2minutes to bleed the air remained in the oil pass tube with the oil drained from the oil pump NOTE Do not increase the engine RPM more than required Connect the oil control cable NOTE Adjus...

Page 49: ...component for any leak Remove the oil check bolt and check to see if the oil overflows from the oil check hole If only the small amount of oil overflows fill the recommended transmission oil through t...

Page 50: ...l level switch Remove the oil tube Remove the oil strainer INSPECTION Check the oil level switch and the oil tube for proper installation Install in the reverse order of removal CAUTION If the oil ent...

Page 51: ...ON POINTS LUBRICATIAON SYSTEM THROTTLE GRIP STEERING BEARING WHEEL BEARING SPEEDOMETER GEAR BOX SIDE STAND PIVOT WHEEL BEARING THROTTLE SPEEDOMETER BRAKE HOSE GREASE GREASE GREASE GREASE GREASE GREASE...

Page 52: ...FUEL SYSTEM 5 0 CARBURETOR FUEL STRAINER FUEL TUBE AUTO COCK FUEL TANK...

Page 53: ...e for a period longer than 1 month drain gasoline out of the carburetor float chamber Gasoline left in the float chamber will be deteriorated causing the slow jet to be clogged with deposits and idlin...

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: ...Plug maintenance cover 3 3 Center cover 3 3 Rear carrier 3 3 Body cover 3 3 Taillight base 3 4 Remove the fuel tube from the fuel auto cock NOTE Use the tube clip or the cap to prevent the gasoline fr...

Page 56: ...cleaner element Install in the reverse order of disassembly CARBURETORREMOVAL INSTALLATION NOTE Keep the fire away Open the drain screw to drain the gasoline in the carburetor chamber Remove the lugg...

Page 57: ...o by starter Remove the auto by starter O ring Assemble in the reverse order of disassembly NOTE Install the auto by starter in the carburetor body after applying grease to the starter O ring and then...

Page 58: ...carburetor body are replaced with the new ones adjustment is necessary CARBURETOR INSPECTION Connect an ohmmeter to the auto bystarter wire connector terminals and measure the resistance If the resist...

Page 59: ...n and starting will be difficult THROTTLE VALVE DISASSEMBLY Remove the throttle valve Remove the throttle cable Remove the throttle valve spring Remove the needle clip Remove the seal cap Remove the c...

Page 60: ...gasoline and wipe up spilled gasoline at once CAUTION Be sure to remove the diaphragms from the fuel auto valve before using compressed air to blow out the air passages Compressed air wil damage the d...

Page 61: ...Remove the oil pump anchor plate Remove the inlet pipe Remove the reed valve Install in the reverse order of removal NOTE Do not remove the reed valve and replace the assembly if necessary Keep the f...

Page 62: ...ENGINE REMOVAL INSTALLATION 6 0...

Page 63: ...following works can be carried out without removing the engine from the vehicle body TRANSMISSION SECTION 9 A C GENERATOR SECTION 13 KICK STARTER CONTINUOUSLY VARIABLE TRANSMISSION SECTION 7 CYLINDER...

Page 64: ...e carburetor Loosen the carburetor cap top remove the throttle valve Loosen the rear brake adjust nut remove the brake arm joint B and rear brake cable Remove the bottom rear cushion under bolt Loosen...

Page 65: ...Adjust of the rear brake free play Inspection of the throttle cable operation Inspection of the oil pump cable operation ENGINEHANGERLINKREMOVAL Remove the luggage box 3 3 Remove the center cover 3 3...

Page 66: ...ACE GUIDE PIN DRIVEN FACE RAMP PLATE WEIGHT ROLLER MOVABLE DRIVE FACE DRIVE FACE BOSS DRIVE FACE KICK STARTER SPINDLE KICK DRIVEN GEAR KICK STARTER RETURN SPRING KICK SPINDLE BUSH DRIVE BELT MOVABLE D...

Page 67: ...VE FACE BOSS OUTER DIAMETER 20 011 20 025mm 19 97mm DRIVE BELT WIDTH 17 5mm 16 50mm WEIGHT ROLLER OUTER DIAMETER 15 920 16 080mm 15 40mm CLUTCH OUTER AND INNER DIAMETER 107 0 107 2mm 107 50mm DRIVEN F...

Page 68: ...kick starter ratchet and the thrust washer while rotating the kick starter arm Loosen the flange bolt securing the kick starter arm remve the kick starter arm Remove the 14mm external circlip Remove...

Page 69: ...te the kick starter spindle using the kick starter arm draw the spindle to the L side cover and assemble the kick starter ratchet NOTE When installing the 14mm external circlip keep holding the spindl...

Page 70: ...eduction system Squeeze the drive belt into the pulley 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 clutc...

Page 71: ...rarily install the driven pulley clutch 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...

Page 72: ...rankshaft and hold the flywheel with the universal holder TOOL UNIVERSAL HOLDER MOVABLE DRIVE FACE DISASSEMBLY Remove the dirve 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...

Page 73: ...ice limit is exceeded Measure the I D of the drive face Replace it if the service limit is exceeded Movable drive face boss outer diameter SERVICE LIMIT 19 97mm Movable drive face inner diameter SERVI...

Page 74: ...ng If the universal holder cannot be used remove the cooling fan and hold the flywheel with the universal holder Install the L side cover CLUTCH DRIVEN PULLEY DISASSEMBLY Remove the L side cover Xh X...

Page 75: ...m the clutch spring compressor TOOL CLUTCH SPRING COMPRESSOR SOCKET WRENCH 39 41mm Assembly is done in the reverse order of disassembly Remove the seal collar from the driven pulley Remove the guide p...

Page 76: ...asure the O D of the driven face and the I D of the movable driven face Replace either part if the service limit is exceeded Drivenfaceouterdiameterservicelimit 33 94mm Movabledrivenfaceinnerdiameters...

Page 77: ...or deformation replace as necessary Apply a small amount of grease on the pivot pins Install new clutch shoes on the pivot pins and push them into place Use a small amount of grease on the pivot pin...

Page 78: ...en 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 the snap ring securely NOTE Apply the specified amount...

Page 79: ...l the seal collar Assemble 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 spr...

Page 80: ...8 0 CYLINDER HEAD CYLINDER PISTON CYLINDER HEAD BOLT CYLINDER HEAD CYLINDER HEAD GASKET TOP RING SECOND RING EXPANDER STOPPER PIN PISTON PIN NEEDLE BEARING CYLINDER GASKET PISTON CLIP CYLINDER...

Page 81: ...ton Improper installation of piston rings Scored or scratched piston or cylinder wall Overheating Excessive carbon build up on the piston combustion Incorrect spark plug Knocking or abnormal noise Wor...

Page 82: ...he floor panel 3 4 Remove the plug cap Remove the engine hanger side cover RH Loosen the 3 fan cover cover comp washer screws Remove the fan cover element B Remove the fan cover rubber Loosen the 2 fa...

Page 83: ...l 3 4 Remove the exhaust muffler assembly 3 7 Remove the fan cover shroud 3 2 Cylinder Head Loosen the 4 cylinder head bolts NOTE Bolts are loosened by rotating 2 3 times and alternating to a diagonal...

Page 84: ...in case of 2 cycle engine than 4 cycle engine because the engine oil is burnt in the 2 cycle engine Excessive carbon deposit may cause self ignition by the overheating of the carbon in the combustion...

Page 85: ...ing Measure the piston O D SERVICE LIMIT 39 05mm Calculate the piston to cylinder clearance Take the maximum reading to detemine the clearance Piston Outer Diameter Inspection Measure and record the p...

Page 86: ...n rings and ring grooves with clean 2 stroke oil Install the piston rings on the piston with the marks facing up NOTE Do not confuse the top and second rings Be sure to install them in the proper groo...

Page 87: ...stamped on the piston head should be facing the correct direction IN MARK TO INTAKE SIDE EX or MARK TO EXHAUST SIDE Install new piston pin clips CAUTION Always use new piston pin clips Reinstalling us...

Page 88: ...9 0 TRANSMISSION CRANKSHAFT CRANKCASE...

Page 89: ...l procedure specified in each section TRANSMISSION SECTION 9 REAR BRAKE SECTION 12 To assemble the crank case and crankshaft set the special tool to the inner race of the crankshaft bearing and push a...

Page 90: ...ts Remove the transmission cover Remove the mission cover guide ruber Remove the drive shaft from the transmission cover by using a hydraulic press NOTE Take precautions not to damage the cover joints...

Page 91: ...the race is turning smoothly Verify the outer race is accurately installed in the case Replace the bearing if necessary NOTE Install the bearing with the carved mark directing to the outside Use spec...

Page 92: ...mission cover Install the transmission cover Tighten the transmission cover with the flange bolts NOTE Tighten bolts diagobally and alternately and tighten with specified torque in the end Remove the...

Page 93: ...ring disassembly Do not force to disassemble by pounding on the crankshaft TOOL CRANKCASE PULLER 0751 00003 Remove the oil seal from the R and L crankcases Remove the dowel pin CRANKSHAFT BEARING REMO...

Page 94: ...ally turn the bearing inner race to see if it rotates smoothly 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 t...

Page 95: ...L crank case TOOLS DRIVER HANDLE A OUTER DRIVER 52x55mm DRIVER PILOT 20mm Clean the crankcase using cleaning oil and check for rack and damage to each area NOTE After removing the liquid gasket from t...

Page 96: ...ANKSHAFT ASSEMBLER CAUTION Make sure that the crankshaft is rotated smoothly after installation prior to oil seal installation If the smooth rotation is not acquired tap the crankshaft bearing part of...

Page 97: ...MEMO...

Page 98: ...10 0 FRONT WHEEL FRONT FORK STEERING...

Page 99: ...in front wheels front fork and steering system For information on the front brake system refer to section 10 Place a jack underneath the engine to support the 2 wheeled vehicle SPECIFICATIONS TORQUE V...

Page 100: ...t 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 fluid in front forks Hard suspension...

Page 101: ...ng If the master cylinder is dropped upside down air may enter the hydraulic system Fix it to the vehicle while maintaining the correct assembled location Loosen the handle bracket fixing washer bolt...

Page 102: ...le hole and install the L handle bracket TORQUE 1 2kgf m Clean the throttle grip surface apply the grease and install the grip Connect the throttle cable to the groove of the grip Tighten the pin scre...

Page 103: ...le nut Remove the front axle Remove the front wheel NOTE Do not operate brake lever after the front wheel is removed Remove the speedometer gear box INSPECTION Check the front axle for deflection Plac...

Page 104: ...Check if the bearing outer race is accurately fitted into the wheel hub and replace worn ones NOTE Replace bearings in pairs left and right set FRONT WHEEL DISASSEMBLY Remove the speedometer gear box...

Page 105: ...facing outside Do not tilt the bearing Insert accurately Upon assembling the distance collar insert the left bearing with its seal surface facing outside TOOLS DRIVER ATTACHMENT 32x35mm PILOT 15mm CAU...

Page 106: ...the right side dust seal rim Install the right side dust seal Install the brake disk Install disk bolts TORUE VALUE 3 9kgf m Install the front brake collar A Align the wheel hub tangs with the slots o...

Page 107: ...ith the other disk facing up Remove the valve cap and bleed air by pressing the valve core Remove the valve core after bleeding air completely Remove the valve stem nut and push the valve stem lightly...

Page 108: ...m when using the tire lever always use rim protectors NOTE Be sure to use motorcycle tire levers Do not apply the mild detergent solution to the rim and tire mating surfaces of low pressure tire Apply...

Page 109: ...sive force to cause serious injury or death CAUTION Always change rims which have been bent or have cracks as they may cause air leakage Always change the rim if there are any flaws over 0 5mm in dept...

Page 110: ...sy assembly apply a mild detergent solution to the tire and rim mating surfaces Do not use the detergent solution on the tire and rim mating surfaces of the low pressure tires Use water only Install t...

Page 111: ...tion to the bead again WARNING Use only water as a lubricant when removing or mounting tires Soap or other tire lubricants may leave a slippery residue which can cause the tire to shift on the rim Tap...

Page 112: ...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 spee...

Page 113: ...MBLY Remove the fork tube cap bolt NOTE If the screw is completely loosened the fork tube cap bolt may spring out by the force fo the spring Take due precautions Remove the fork spring and expand and...

Page 114: ...ily 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 the oil seal stopper ring Re...

Page 115: ...eck components for damage or abnormal wear Replace defective parts with new ones SERVICE LIMIT 256 0mm Place the fork tube on a V block and measure deflection with a dial gauge SERVICE LIMIT Replace i...

Page 116: ...e 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 the bottom case set ring is e...

Page 117: ...the smaller pitch side facing downward Assemble the fork bolt to the fork tube FRONT FORK INSTALLATION Install the front fork to the steering stem Install the front fork setting bolt TORQUE VALUE 4 0...

Page 118: ...14 Loosen the steering stem lock nut Remove the speedometer cable and front brake hose from the steering stem bracket Loosen the steering top cone race Remove the steering stem NOTE Place steel ball...

Page 119: ...age or abnormal wear and replace as necessary If the vehicle has been involved in a collision the steering stem may be damaged STEERING STEM INSTALLATION Insert the upper under ball race into the stee...

Page 120: ...play and check for smooth left and right movement Temporarily install the R L front forks first and tighten the steering stem nuts TORQUE VALUE 7 0kgf m TOOLS LOCK NUT WRENCH EXTENSION BAR Install the...

Page 121: ...a brake cleaner designed to minimize the hazard caused by airborne asbestos fibers SPECIFICATIONS TORQUE VALUES AXLE SHAFT RUN OUT 10 0 12 0 f m REAR CUSHION UPPER BOLT 3 5 4 5 f m REAR CUSHION LOWER...

Page 122: ...rim Loose 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...

Page 123: ...fler 3 7 Remove the rear wheel mud guard Loosen the rear wheel U nut Remove the washer Remove the rear wheel INSPECTION Turn the wheel and check the rim for wobbles SERVICE LIMIT Radical 2 0mm Axial 2...

Page 124: ...rear brake rod adjusting nut Install the rear wheel mud guard Install the muffler REAR BRAKE Remove the rear wheel 11 3 INSPECTION Measure the brake drum of inner diameter SERVICE LIMIT 111mm Measure...

Page 125: ...ke 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 Remove the excessive grease after a...

Page 126: ...hown in the figure Install the cushion on the cushion compressor and compress the spring TOOLS COMPRESSOR ATTACHMENT REAR COMPRESSOR Fix the bottom metal and loosen the lock nut Remove the bottom meta...

Page 127: ...lock nut and install the rear cushion compressor attachment on the damper rod Fix the upper joint and tighten the lock nut TORQUE VALUE 4 0kgf m TOOLS REAR CUSHION COMPRESSOR REAR CUSHION COMPRESSOR A...

Page 128: ...BRAKE SYSTEM 12 0...

Page 129: ...ized or worn Brake lever bent Brake drag Brake pad and disk contaminated Improper wheel alignment Lopsided wear of brake pad and disk Disk bent or distorted Unsatisfactory caliper sliding part operati...

Page 130: ...drum Worn brake shoes at cam contact areas Improper engagement between brake arm and camshaft serrations Brake lever hard or slow to return Worn broken return spring Improperly adjusted brake Sticking...

Page 131: ...is no more fluid flowing out of the bleeder valve stop pumping the brake lever AIR BLEEDING Fill the reservoir with DOT 3 or 4 brake fluid up to the upper level CAUTION To prevent chemical changed do...

Page 132: ...extent and leave it unattended for a few seconds Repeat the process specified in item and until there is no more air bubbles coming out of the bleeder valve Check the fluid level often and add fluid i...

Page 133: ...lts from the front fork Remove the front caliper To install a new brake pad into the brake press the piston to return to the original position Remove the hanger pin pad shim and brake pad Verify that...

Page 134: ...TORQUE 2 7kgf m Tighten the hanger pin BRAKE DISK INSPECTION Measure the thickness of the disk SERVICE LIMIT 3 0mm NOTE Measure the brake disk thickness at the several points and replace if the small...

Page 135: ...ith the compressed air Keep the removed parts in order to avoid dust from adhering DISASSEMBLY Remove the slide pin the L bracket the pin bush the boot and the pin boot and the pin bolt from the calip...

Page 136: ...t is less than the specified service limit SERVICE LIMIT 26 84 mm BRAKE CALIPER ASSEMBLY INSTALLATION Clean the piston seal and the dust seal with the brake fluid and install them in the caliper Insta...

Page 137: ...id Remove the brake hose from the master cylinder CAUTION Brake fluid causes damage to the painted plastic or rubber parts Do not spill fluid on these parts If contaminated gently wipe off the fluid w...

Page 138: ...side wear of the cylinder by the direction of the piston contacting face In this case the master cylinder must be replaced also Check the master cylinder for scores scratches or nicks and replace if n...

Page 139: ...g is seated firmly in the groove Install the rubber boot in the groove properly Install the master cylinder to the handle bar NOTE Install the holder with its UP mark facing upwards and align the hold...

Page 140: ...MEMO...

Page 141: ...2 3 years of noromal use and although it will re charge its load is reduced leading to a loss in battery strength It is possible for the battery to become overcharged from battery body load If a batt...

Page 142: ...ERY FUSE RESISTER REGULATOR RECTIFIER A C GENERATOR WHITE YELLOW GREEN GREEN BATTERY LIGHTING SWITCH REGULATOR RECTIFIER BROWN BROWN GREEN BLACK RESISTER 5W 6 7 RESISTER 30W 5 9 HEADLIGHT 12V 35 35W M...

Page 143: ...Damaged regulator rectifier darkened headlight Damaged headlight register Damaged regulator rectifier Damaged Battery Check charge level Check the voltage of the regulator rectifier battery lines and...

Page 144: ...RGING SYSTEM INSPECTION LEAK TEST Trun 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 t...

Page 145: ...rminals Never open the sealed filler cap WARNING The battery generates hydrogen gas which can be highly explosive Do not smoke or allow flames or sparks near the battery easpecially while charging it...

Page 146: ...check the regulator rectifier coupler for faulty connection and measure the resistance between the terminals of the regulator rectifier 13 6 BATTERY CHARGING SYSTEM REGULATOR RECTIFIER COUPLER ITEM BA...

Page 147: ...0750 00004 Remove the connector coupler on the wire harness or starter motor Remove the ground wires Loosen the 2 pulse generator fixing flange bolts remove the pulse generator Loosen the 2 stator fix...

Page 148: ...the woodruff key and install the flywheel on the crankshaft Tighten the flywheel bolt or nut with your fingers CAUTION Before installing the flywheel check that no nuts or bolts are magnetically atta...

Page 149: ...en the yellow wire and ground STANDARD RESISTANCE 20 BETWEEN WHITE WIRE AND GROUND 0 3 1 2 BETWEEN YELLOW WIRE AND GROUND 0 1 1 0 RESISTER INSPECTION Remove the front cover 3 5 Measure the resistance...

Page 150: ...MEMO...

Page 151: ...en appear to be malfuctioning when the couplers or connectors are disconnected Check these connections before working on Use recommended spark plug Using incorrect spark plug may make the engine run b...

Page 152: ...14 2 IGNITION SYSTEM SPARK PLUG IGNITION MAIN SWITCH I I V V SIDE STAND SWITCH BLUE YELLOW PULSE GENERATOR AC GENERATOR MAIN SWITCH SIDE STAND SWITCH IGNITION COIL SPARK PLUG BLACK YELLOW BLACK WHITE...

Page 153: ...emitted from spark plug 1 Damage to spark plug or leakage of ignition coil secondary current 2 Damaged ignition coil 1 Using a tester with a low internal resistance 2 Cranking speed is too low Batter...

Page 154: ...cle body Turn the main swtich ON operate the starter motor and measure the ignition coil initial side peak voltage CONTACT POINTS BLACK YELLOWTERMINAL BODYEARTH PEAK VOLTAGE OVER 120V CAUTION When mea...

Page 155: ...age in the CDI unit coupler portion is abnormal Disconnect the AC generator cord coupler and connect the adaptor In the same manner as with the unit coupler side measure peak voltage and compare with...

Page 156: ...h tension code and green code terminals RESISTANCE VALUE 2 6 1 25 20 EXCITE COIL INSPECTION NOTE Assembly the spark plug to the cylinder head and inspect in an state having compression pressure Remove...

Page 157: ...if the F mark and crank case index mark are aligned IGNITION TIMING 17 DEGREES 2 BTDC 1 800 rpms NOTE Index mark must face the spark plug CDI UNIT REMOVAL INSTALLATION Remove the luggage box 3 3 Disco...

Page 158: ...aintenance cover center cover 3 3 Remove 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 14 8 SIDE...

Page 159: ...main switch is not turned to OFF First check connection with battery and battery charge level before beginning maintenance on the starter motor It is possible for the starter motor coil to become dam...

Page 160: ...S TIR E APPL KOREA BATTERY STARTER RELAY FUSE 7A MAIN SWITCH STARTER SWITCH STARTER MOTOR RED WHITE YELLOW RED GREEN YELLOW GREEN YELLOW BATTERY FRONT STOP SWITCH STARTER RELAY MAIN SWITCH RED GREEN G...

Page 161: ...in starter switch wire Loose or poor contact at starter relay switch connector Faulty starter relay switch Remove the coupler from the starter replay and inspect the relay coil ground wire Check the...

Page 162: ...arter motor If power is connected the starter motor may be activated and damaged DISASSEMBLY Remove the starter motor screws and remove the motor cover NOTE Record the order so the parts can be instal...

Page 163: ...ndividual commutator bars and the armature shaft There should be no continuity Check the bearings Do not rotate smoothly Replace with a new one Loose bearing Replace with a new one STARTER MOTOR ASSEM...

Page 164: ...does not lean in the holder Apply grease to both ends of the armature shaft Install the starter motor cover NOTE The coil may be damaged if the magnet pulls the armature against the case Align the fr...

Page 165: ...corresponding wire color of the wire harness connector STARTERPINIONGEARINSPECTION Remove the L side cover 7 2 Remove the drive face 7 6 Remove the starter pinion gear Install in the reverse order of...

Page 166: ...MEMO...

Page 167: ...l switch damaged Loose connector Harness disconnection Oil indicator does not turn off when oil is out Oil level switch damaged Green red wire joined SERVICE INFORMATION GENERAL SAFETY Refer to tester...

Page 168: ...LLATION Install the base packing to the fuel tank Install the fuel unit NOTE Install it aligning the part of the fuel unit with the loop part of fuel tank Check the fuel leakage INSPECTION Move the fl...

Page 169: ...the terminals It s normal state if there is no continuity when the float is up but continuity when it is down MAIN SWITCH REMOVAL INSTALLATION Remove the front cover 3 5 Remove the inner box 3 5 Disc...

Page 170: ...brake lever is pulled continuity When the brake lever is released nocontinuity 16 4 LIGHTS METER SWITCHES STARTER SWITCH LIGHTING SWITCH WINKER SWITCH HORN SWITCH HAZARD SWITCH DIMMER SWITCH FRONT STO...

Page 171: ...light 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 replacement CAUTION If you touch the bulb with your bare hand...

Page 172: ...ot to damage the tail light lens when removing it METER BULB REPLACEMENT Remove the front handle cover 3 6 Remove the bulb socket replace with new bulb METERS REPLACEMENT Remove the front cover 3 5 Re...

Page 173: ...assembly Install in the reverse order of removal NOTE Check the each switch for proper operation The wire and cable must be connected accurately HORN INSPECTION Remove the front cover 3 5 Remove the h...

Page 174: ...MEMO...

Page 175: ...FREE R LOCK IG OFF ON E BA1 BA2 R CORD COLOR B W G B IG E BA2 BA1 SIDE STAND S W Br G Br G 12V 5W LICENSE LAMP IG E R R B W B G B B W G G B W G B W SB O SB Br O G G Y COLOR PUSH CORD B W FREE IG G E R...

Page 176: ...d cracked 4 Crank case air leaks 5 Cylinder head gasket damaged 1 Manifold air leaks 2 Inadequate ignition timing 1 Carburetor flooded 2 Faulty control box 3 Throttle valve excessively opened 1 Open t...

Page 177: ...re 3 Poor quality fuel used 4 Carbon deposit inside the combustion chamber excessive 5 Ignition timing incorrect 1 Carbon deposit inside the combustion chamber excessive 2 Poor quality fuel used 3 Lea...

Page 178: ...ulty A C generator 5 Faulty main switch 1 Check ignition timing 2 Check the carburetor air screw 3 Check the area around the manifold for air leakage 4 Check sparks Abnormal Incorrect Leaking Weak or...

Page 179: ...e pulley bearing worn 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 seized Check tire pressure CAUSE OF TROUBLE...

Page 180: ...lay or moisture inside the brake drum 4 Brake lining contaminated by grease or oil 1 If the arrow were mark and the brake panel mark match with each other 2 Brake noise 3 Poor braking POOR BRAKE PERFO...

Page 181: ...orily Check Needle not moving Needle not moving CAUSE OF TROUBLE 1 Fuse cut 2 Battery weak or totally discharged 3 Ignition switch damaged or shorted 4 Terminal loose of faulty connection 5 Wire harne...

Page 182: ...k operation Light not activated Light not activated Signal continuously operates dim or does not operate at all Unsatisfactory Starter does not turn Light is activated Signal operates satisfactorily 6...

Page 183: ...MEMO...

Page 184: ...SERVICE MANUAL 2001 3 PRINTED 2001 3 PUBLICATION NO COPY...

Page 185: ...103 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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DAELIM S-FIVE -, Service Manual

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