DAELIM S1 125 - SERVICE Service Manual Download

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HEAD OFFICE(FACTORY)

#58, SUNG SAN-DONG, CHANG WON, KYUNGNAM, KOREA
TEL: (82-55) 239-7000 / FAX: (82-2) 467-9997

Summary of Contents for S1 125 - SERVICE

Page 1: ......

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Page 3: ...rvice information and troubleshooting guide Contents of this manual and specifications are subject to change without prior notice for improvement of vehicle quality No part of this publication may be...

Page 4: ......

Page 5: ...SERVICE INFORMATION 1 1 1...

Page 6: ...1 2 SERVICE INFORMATION...

Page 7: ...SERVICE INFORMATION 1 3...

Page 8: ...1 4 SERVICE INFORMATION...

Page 9: ...1 5 SERVICE INFORMATION...

Page 10: ...1 6 SERVICE INFORMATION...

Page 11: ...1 7 SERVICE INFORMATION...

Page 12: ...1 8 SERVICE INFORMATION...

Page 13: ...1 9 SERVICE INFORMATION ENGINE SERIAL NUMBER LOCATION FRAME SERIAL NUMBER LOCATION ENGINE SERIAL NUMBER LOCATION FRAME SERIAL NUMBER LOCATION...

Page 14: ...1 10 SERVICE INFORMATION 9 6 2 2 stroke SOHC ATDC 1 965mm 743mm 1 120mm 1 350mm 770mm 126mm 127kg 277kg 60 1 75 2 25 25 80 90 70 13 8 380...

Page 15: ...1 11 SERVICE INFORMATION 30A LED LED LED...

Page 16: ...1 12 SERVICE INFORMATION...

Page 17: ...1 13 SERVICE INFORMATION...

Page 18: ...E FRAME EARTH THROTTLE CABLE NOISE SUPPRESSOR CAP TRUNK LAMP COUPLER HARNESS POSITION CLAMP TAIL STOP RR WINKER R L REGULATE RECTIFIER COUPLER Z X FRM EARTH CORD ECU UNIT THROTTLE CABLE SEAT LOCK CABL...

Page 19: ...CTOR FUEL HOSE TO INJECTOR TRUNK LAMP COUPLER CAN CORD WIRING COUPLER TAIL STOP RR WINKER R L REGULATE RECTIFIER REGULATE RECTIFIER SEAT LOCK CABLE THROTTLE CABLE SIDE STAND SWICH COUPLER HAZARD RELAY...

Page 20: ...E CABLE SEAT LOCK CABLE RR BRAKE HOSE PIPE JUNCTION VALVE FR BRAKE HOSE C MAIN WIRE HARNESS THROTTLE CABLE COMB LOCK SW COMB METER SOCKET HARNESS x_1 _5 5 R P CLAMP VIEW Y FR BRAKE HOSE RR BRAKE HOSE...

Page 21: ...AT COUPLER INJECTOR ISA RH LH RADIATOR HOSE FUEL PUMP TO INJECTOR FUEL HOSE TO INJECTOR MAIN WIRE HARNESS RR BRAKE HOSE PIPE FRAME EARTH HORN m_ J P _5 B_ 3 3 O2 SENSOR COUPLER O2 SENSOR CORD BATTERY...

Page 22: ...MEMO...

Page 23: ...2 1 INSPECTIONS ADJUSTMENTS 2...

Page 24: ...2 2 INSPECTIONS ADJUSTMENTS...

Page 25: ...2 3 INSPECTIONS ADJUSTMENTS...

Page 26: ...2 4 INSPECTIONS ADJUSTMENTS NUTS NUTS NUTS NUTS NUTS NUTS NUTS NUTS NUTS NUTS NUTS NUTS NUTS NUTS NUTS NUTS NUTS NUTS NUTS NUTS NUTS NUTS NUTS NUTS NUTS NUTS NUTS NUTS NUTS NUTS NUTS NUTS NUTS NUTS...

Page 27: ...2 5 INSPECTIONS ADJUSTMENTS...

Page 28: ...OLING FAN COOLING FAN COOLING FAN COOLING FAN COOLING FAN COOLING FAN ADJUST WRENCH ADJUST WRENCH ADJUST WRENCH ADJUST WRENCH ADJUST WRENCH ADJUST WRENCH ADJUST WRENCH ADJUST WRENCH ADJUST WRENCH ADJU...

Page 29: ...CE DRIVE FACE DRIVE FACE DRIVE FACE DRIVE FACE DRIVE FACE DRIVE FACE DRIVE FACE DRIVE BELT DRIVE BELT DRIVE BELT DRIVE BELT DRIVE BELT DRIVE BELT DRIVE BELT DRIVE BELT DRIVE BELT DRIVE BELT DRIVE BELT...

Page 30: ...IVEN LEVER DRIVEN LEVER DRIVEN LEVER DRIVEN LEVER DRIVEN LEVER DRIVEN LEVER DRIVEN LEVER DRIVEN LEVER DRIVEN LEVER DRIVEN LEVER DRIVEN LEVER DRIVEN LEVER DRIVEN LEVER DRIVEN LEVER DRIVEN LEVER DRIVEN...

Page 31: ...STAND SWITCH SIDE STAND SWITCH SIDE STAND SWITCH SIDE STAND SWITCH SIDE STAND SWITCH SIDE STAND SWITCH SIDE STAND SWITCH SIDE STAND SWITCH SIDE STAND SWITCH SIDE STAND SWITCH SIDE STAND SWITCH SIDE ST...

Page 32: ...PRESSURE GANGE TIRE PRESSURE GANGE TIRE PRESSURE GANGE TIRE PRESSURE GANGE TIRE PRESSURE GANGE TIRE PRESSURE GANGE TIRE PRESSURE GANGE TIRE PRESSURE GANGE TIRE PRESSURE GANGE TIRE PRESSURE GANGE TIRE...

Page 33: ...3 1 EXTERNAL PARTS 3...

Page 34: ...WIRE GROMMET WIRE GROMMET WIRE GROMMET WIRE GROMMET WIRE GROMMET WIRE GROMMET WIRE GROMMET WIRE GROMMET WIRE GROMMET WIRE GROMMET WIRE GROMMET WIRE GROMMET WIRE GROMMET WIRE GROMMET WIRE GROMMET WIRE...

Page 35: ...IL COVER REAR HANDIL COVER REAR HANDIL COVER REAR HANDIL COVER REAR HANDIL COVER REAR HANDIL COVER REAR HANDIL COVER REAR HANDIL COVER REAR HANDIL COVER REAR HANDIL COVER REAR HANDIL COVER REAR HANDIL...

Page 36: ...IAL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW BATTERY COVER BATTERY COVER BATTERY COVER BATTERY COVER BATTERY COVER BATTERY COVER BATTERY COVER BATTERY COVER BATTERY COVER BATTERY...

Page 37: ...he 4 washer bolts Rear fender Tail right wiring Install in the reverse order of removal REAR FENDER REAR FENDER REAR FENDER REAR FENDER REAR FENDER REAR FENDER REAR FENDER REAR FENDER REAR FENDER REAR...

Page 38: ...ER FLOOR PANEL COVER FLOOR PANEL COVER FLOOR PANEL COVER FLOOR PANEL COVER FLOOR PANEL COVER FUEL CAP NECK FUEL CAP NECK FUEL CAP NECK FUEL CAP NECK FUEL CAP NECK FUEL CAP NECK FUEL CAP NECK FUEL CAP...

Page 39: ...HOLDER BACK HOLDER BACK HOLDER BACK HOLDER BACK HOLDER BACK HOLDER BACK HOLDER BACK HOLDER BACK HOLDER BACK HOLDER BACK HOLDER BACK HOLDER BACK HOLDER BACK HOLDER BACK HOLDER BACK HOLDER BACK HOLDER...

Page 40: ...UT EX CAP NUT EX CAP NUT EX CAP NUT EX CAP NUT EX CAP NUT EX CAP NUT EX CAP NUT EX CAP NUT EX CAP NUT EX CAP NUT EX CAP NUT EX CAP NUT EX CAP NUT EX CAP NUT EX CAP NUT EX CAP NUT EX CAP NUT EX CAP NUT...

Page 41: ...4 1 LUBRICATION SYSTEM 4 1 4 2 4 3 4 3 4 4 4 7 4 8 4 9 4 4 4...

Page 42: ...4 2 LUBRICATION SYSTEM...

Page 43: ...PER ADJUST HOLE CAP TAPPER ADJUST HOLE CAP TAPPER ADJUST HOLE CAP TAPPER ADJUST HOLE CAP TAPPER ADJUST HOLE CAP OIL FILTER SCREN OIL FILTER SCREN OIL FILTER SCREN OIL FILTER SCREN OIL FILTER SCREN OIL...

Page 44: ...OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL OIL SEAL START DRIVEN GEAR START DRIVEN GEAR S...

Page 45: ...4 5 SERVICE LUBRICATION SYSTEM...

Page 46: ...MP SHAFT OIL PUMP SHAFT OIL PUMP SHAFT OIL PUMP SHAFT OIL PUMP SHAFT OIL PUMP SHAFT OIL PUMP SHAFT OIL PUMP SHAFT OIL PUMP SHAFT OILPUMP SHAFT OILPUMP SHAFT OILPUMP SHAFT OILPUMP SHAFT OILPUMP SHAFT O...

Page 47: ...4 7 LUBRICATION SYSTEM...

Page 48: ...BOLT OIL CHECK BOLT OIL CHECK BOLT OIL CHECK BOLT OIL CHECK BOLT OIL CHECK BOLT OIL CHECK BOLT OIL CHECK BOLT OIL CHECK BOLT OIL CHECK BOLT OIL CHECK BOLT OIL CHECK BOLT OIL CHECK BOLT OIL CHECK BOLT...

Page 49: ...4 9 LUBRICATION SYSTEM PILLION STEP REAR BRAKE DISK MUFFLER BATTERY FR BRAKE LEVER REAR VIEW MIRROR TIRE BAG HOLDER...

Page 50: ...MEMO...

Page 51: ...How to read the fault code 5 8 Fault code table 5 9 How to remove the fault code 5 10 EMS trouble shooting 5 10 6 INJECTOR 5 11 7 MAPAT 5 14 8 TPS 5 17 9 ETS 5 20 10 ISA 5 23 11 O2 Oxygen SENSOR 5 26...

Page 52: ...ause these parts may be damaged by the impact of the drop Do not touch the ECU terminal because it may be damaged by the static The ignition key off when assembly and disassembly of the ECU coupler ot...

Page 53: ...ipe and injector The fuel in tank being high pressed by fuel pump moves to the division pipe through fuel filter Next the fuel is supplied to injector being highly maintained as regulated pressure abo...

Page 54: ...5 4 EMS Engine Management System 3 TERMINAL ARRANGEMENT OF THE ECU Remarks ECU PIN NO 6 7 8 11 13 14 15 16 21 29 32 36 38 were not connected 4 WIRING DIAGRAM OF THE ECU...

Page 55: ...temporary when that happen Normally the MIL illuminates for 3 seconds when the main key is turned on Remarks 1 If the EMS has some problem and the MIL on and off engine starting and driving are tempo...

Page 56: ...inimum driving of vehicle MILon off INTAKE MIL INTAKE MILon on INTAKE INTAKE The value of intake pressure is fixed as the pressure just before when the intake pressure sensor is out of order intake in...

Page 57: ...r to check the malfunction of vehicle is placed in the rh side cover Turn on the ignition key Press the power button of diagnostic tool Checks according to diagnostic procedure of diagnostic tool The...

Page 58: ...ect information to driver If the MILon when engine is working engine is able to be operated by fail safe However in the event that Injector Fuel pump Ignition coil has something wrong vehicle may not...

Page 59: ...re ISA Electrical fuel pump failure EFP Intake Manifold absolute pressure signal failure IMP Throttle position signal failure TPS O2 sensor heater output failure LSH Lambda signal failure VLS Engine t...

Page 60: ...e ignition key on off If many problems happened in the EMS parts at the same time only one defect code will is displayed by the priority order Even thought repair a fault and remove the memorized faul...

Page 61: ...nagement System Remove Connector Connector bolt Injector and injector cap Replace the injector 6 INJECTOR NOTICE Before disassemble the key is off CAUTION Make sure that dust does not enter the thrott...

Page 62: ...istance of injector 14 5 0 7 20 Remarks measuring unit for resistance resistance R 4 If there is no problem check the continuity between each terminal and ground The resistance between each terminal a...

Page 63: ...U coupler are a bad contact ECU terminal No 40 If there is no problem in the electric wires ECU is broken Replace the ECU with new one it rechecks 8 If the measured voltage is not normal Check the Bla...

Page 64: ...the coupler is toward to insulator CAUTION Located on the left side of the throttle body Before disassembly the key is off CAUTION 5 14 EMS Engine Management System ISA ISA ISA ISA ISA ISA ISA ISA IS...

Page 65: ...y 4 Measure the input voltage of MAPAT intake pressure sensor intake temperature sensor s coupler Input voltage 4 5 5 5 V Measuring terminal MAPAT 3 terminal MAPAT 1 terminal Remarks Measuring unit of...

Page 66: ...electricwire P G electricwire P L electricwireto see if they have been broken orhave short circuited if there is a bad contact badnessofterminalNo 3 No 26 No 27ofECU coupler If the electric wire is n...

Page 67: ...asuring voltage 0 1 V 4 9 V Remarks Measuring unit of voltage Voltage V 6 If the measured voltage is not normal Check the P electric wire P G electric wire P L electric wire to see if they have been b...

Page 68: ...N KEY Input voltage 4 5 5 5 V Measuring terminal ECU NO 18 Gr B GRAY BLACK ECU NO 4 W R WHITE RED Measure the terminal voltage of TPS s coupler Measuring voltage 4 5 V 5 5 V Remarks Measuring unit of...

Page 69: ...eck 9 If resistance and continuty are normal connect the TPS coupler 10 Turn on the ignition key 11 Measure the TPS voltage of wire harness check the ECU Rotate the throttle lever measure the voltage...

Page 70: ...rder of removal Situated on the Right hand side of cylinder head Before disassembly the key is off CAUTION 5 20 EMS Engine Management System ETS torque 3 0 3 kgf m CAUTION PUSH PUSH PUSH PUSH PUSH PUS...

Page 71: ...GREEN BLUE ECU No 4 W R WHITE RED Measure the terminal voltage of ETS s coupler Measuring voltage 4 5 V 5 5 V Remarks Measuring unit for voltage voltage V If the voltage value is not normal Check to...

Page 72: ...k the ETS Engine Temperature Sensor Connect two terminals of ETS to the probe of the tester and insert even its screw point of ETS into oil Read the temperature of thermometer depending upon oil tempe...

Page 73: ...Maintenance cover ISA connector It is located upwards on the throttle body Before disassembly the key is off CAUTION O Ring O Ring O Ring O Ring O Ring O Ring O Ring O Ring O Ring O Ring O Ring O Rin...

Page 74: ...f ISA measure the resistance between ISA terminals ISA resistance 31 5 38 5 20 remarks Measuring unit of resistance Resistance R 4 If there is not problem check about the level of electricity flow bet...

Page 75: ...suring unit Voltage V If the measured voltage is normal Checkthe B R electricwire L G electricwire W R electricwireto see if they have been broken or have short circuited if there is a bad contact of...

Page 76: ...re disassembly the key is off CAUTION Beware of muffler after driving as it is still hot to be burnt Warning 11 O2 Oxygen SENSOR 5 26 EMS Engine Management System O2 Sensor O2 Sensor O2 Sensor O2 Sens...

Page 77: ...urn off the ignition key 2 Check the O2 oxygen coupler is loose or bad If there is no defect measure the input voltage of O2 oxygen 3 Disassemble the coupler of oxygen O2 sensor and turn on ignition k...

Page 78: ...ODE BY OXYGEN O2 SENSOR LAMBDA SIGNAL 1 Turn off the ignition key 2 Check the O2 oxygen coupler is loose or bad If there is no defect measure the input voltage of O2 oxygen 3 The wire harness to check...

Page 79: ...ltage Measuring terminal ECU No 24 L B BLUE BLACK EARTH output voltage battery voltage Remarks measuring unit of voltage voltage V If the measured voltage is normal Checkthe L B electricwire B electri...

Page 80: ...e the LH side cover CAUTION Be sure to assemble the ECU ground wire The color is green CAUTION 13 ECU ELECTRONIC CONTROL UNIT Make sure that the key is off before disassembly ECU ground wire ECU groun...

Page 81: ...N Be sure to assemble the IG coil Ground wire Be sure to check the high tension cord is assembly like a picture Install in the reverse order of removal CAUTION 14 IGNITION COIL IG coil ground wire IG...

Page 82: ...Cooling fan Flywheel Stator CPS screw Replace the CPS ENG RH crankcase cover Before disassembly the key is off CAUTION Install in the reverse order of removal 15 CRANK POSITION SENSOR CPS CPS wire CPS...

Page 83: ...is stored Always replace the packing when the fuel pump is removed Before disconnecting the fuel hose release the fuel pressure by loosing the fuel hose banjo bolt at the fuel tank Always replace the...

Page 84: ...EMS Engine Management System 5 34 The terminal arrangement of the fuel pump The following color chart is the internal color of the fuel pump 16 FUEL PUMP...

Page 85: ...r assemble Measure the resistance between Y W YELLOW WHITE wire and G GROUND wire of fuel unit terminal Remark measuring unit of resistance resistance If the measured resistance value is out of standa...

Page 86: ...TLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY THROTTLE BODY ISA ISA I...

Page 87: ...speed actuator Disconnect theMAPAT Do not disconnect the throttle valve CAUTION Check Throttle shaft Throttle valve MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT MAPAT...

Page 88: ...e o ring to insulator CAUTION INSULATOR INSULATOR INSULATOR INSULATOR INSULATOR INSULATOR INSULATOR INSULATOR INSULATOR INSULATOR INSULATOR INSULATOR INSULATOR INSULATOR INJECTOR INJECTOR INJECTOR INJ...

Page 89: ...e insulator gasket ADJUSTMENT OF THROTTLE CABLE INSPECTION OF SENSOR AND ACTUATOR Assemble the throttle cable Adjust the free play of the throttle grip 4 Connecteachsensorandtheactuator scoupler Check...

Page 90: ...eignitionkey Pressthepower buttonofdiagnostictool SUPPLEMENT TheECU isalwaysinitialized before theengine isstarting Thevehicleiswarmsupenoughto adjustthe idlingspeed CAUTION If the ETS temperature is...

Page 91: ...rbuttonofthediagnostic tool Pressthe enterbuttonintheinitial screen Pressthe enterinthevehiclediagnosisscreen PresstheenterbuttonontheresettingECU values Presstherest buttononthe followingscreen If th...

Page 92: ...Presstheenterbuttonwhenitisready WhentheECUwasinitialized turnoffthe lgnition keyandthenturn onthe ignitionkey EMS Engine Management System 5 42...

Page 93: ...rbuttonofthediagnosistool Presstheenterbuttonontheinitial screen Pressthebutton at thevehiclediagnosticscreen Pressthe enterbuttononthecurrentdata By looking the displayed figure on the ISA PWM adjust...

Page 94: ...stictool Turnthelgnitionkey Starttheengine Pressthepowerbuttonofthediagnosistool Presstheenterbuttonon the initialscreen Presstheenterbuttonon the vehiclediagnosis screen Presstheenterbutton onthe cur...

Page 95: ...ic tool Turnthelgnitionkey Starttheengine Pressthepowerbuttonofthediagnosistool Presstheenterbuttonontheinitialscreen Presstheenterbuttononthevehiclediagnosisscreen Presstheenterbuttononthecurrentdata...

Page 96: ...MEMO...

Page 97: ...6 1 FUEL SYSTEM ENGINE 6 4 6 6 6 6...

Page 98: ...6 2 FUEL SYSTEM ENGINE...

Page 99: ...6 3 FUEL SYSTEM ENGINE...

Page 100: ...MEMO...

Page 101: ...7 1 ENGINE REMOVAL INSTALLATION 7 7 7 1 7 2...

Page 102: ...ARM REAR SWING ARM REAR SWING ARM REAR SWING ARM REAR SWING ARM REAR SWING ARM REAR SWING ARM REAR SWING ARM REAR SWING ARM REAR SWING ARM REAR SWING ARM REAR SWING ARM REAR SWING ARM REAR SWING ARM...

Page 103: ...ON UNDER BOLT REAR CUSHION UNDER BOLT REAR CUSHION UNDER BOLT REAR CUSHION UNDER BOLT REAR CUSHION UNDER BOLT REAR CUSHION UNDER BOLT REAR CUSHION UNDER BOLT REAR CUSHION UNDER BOLT REAR CUSHION UNDER...

Page 104: ...8 0 LH CRANKCASE COVER CONTINUOUSLY VARIABLE TRANSMISSION LH CRANK CASE COVER...

Page 105: ...8 1 LH CRANKCASE COVER CONTINUOUSLY VARIABLE TRANSMISSION 8 8 8 8 8 8 8 8...

Page 106: ...LH COVER GASKET LH COVER GASKET LH COVER GASKET LH COVER GASKET LH COVER GASKET LH COVER GASKET LH COVER GASKET LH COVER GASKET LH COVER GASKET LH COVER GASKET LH COVER GASKET LH COVER GASKET LH COVER...

Page 107: ...VE BELT DRIVE BELT DRIVE BELT DRIVE BELT DRIVE BELT DRIVE BELT DRIVE BELT DRIVE BELT DRIVE BELT DRIVE BELT DRIVE BELT DRIVE BELT DRIVE BELT DRIVE BELT DRIVE BELT DRIVE BELT DRIVE BELT DRIVE BELT DRIVE...

Page 108: ...HOLE CLUTCH OUTER HOLE CLUTCH OUTER HOLE CLUTCH OUTER HOLE CLUTCH OUTER HOLE DRIVE BELT DRIVE BELT DRIVE BELT DRIVE BELT DRIVE BELT DRIVE BELT DRIVE BELT DRIVE BELT DRIVE BELT DRIVE BELT DRIVE BELT D...

Page 109: ...DRIVE FACE MOVABLE DRIVE FACE MOVABLE DRIVE FACE MOVABLE DRIVE FACE MOVABLE DRIVE FACE MOVABLE DRIVE FACE MOVABLE DRIVE FACE MOVABLE DRIVE FACE MOVABLE DRIVE FACE MOVABLE DRIVE FACE MOVABLE DRIVE FACE...

Page 110: ...8 6 LH CRANKCASE COVER CONTINUOUSLY VARIABLE TRANSMISSION...

Page 111: ...AR REAR AXCEL COLLAR REAR AXCEL COLLAR REAR AXCEL COLLAR REAR AXCEL COLLAR REAR AXCEL COLLAR REAR AXCEL COLLAR REAR AXCEL COLLAR REAR AXCEL COLLAR REAR AXCEL COLLAR REAR AXCEL COLLAR REAR AXCEL COLLAR...

Page 112: ...EY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY D...

Page 113: ...8 9 LH CRANKCASE COVER CONTINUOUSLY VARIABLE TRANSMISSION...

Page 114: ...8 10 LH CRANKCASE COVER CONTINUOUSLY VARIABLE TRANSMISSION...

Page 115: ...8 11 LH CRANKCASE COVER CONTINUOUSLY VARIABLE TRANSMISSION...

Page 116: ...8 12 LH CRANKCASE COVER CONTINUOUSLY VARIABLE TRANSMISSION...

Page 117: ...PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PUL...

Page 118: ...9 0 A C GENERATOR STARTER CLUTCH...

Page 119: ...9 9 9 9 9 9 9 9 1 A C GENERATOR STARTER CLUTCH 9...

Page 120: ...H SHROUD LH SHROUD LH SHROUD LH SHROUD LH SHROUD LH SHROUD LH SHROUD LH SHROUD LH SHROUD LH SHROUD LH SHROUD LH SHROUD LH SHROUD LH SHROUD LH SHROUD LH SHROUD LH SHROUD LH SHROUD LH SHROUD LH SHROUD L...

Page 121: ...INDER HEAD COVER CYLINDER HEAD COVER CYLINDER HEAD COVER CYLINDER HEAD COVER CYLINDER HEAD COVER CYLINDER HEAD COVER CYLINDER HEAD COVER CYLINDER HEAD COVER CYLINDER HEAD COVER CYLINDER HEAD COVER CYL...

Page 122: ...9 4 A C GENERATOR STARTER CLUTCH...

Page 123: ...9 5 A C GENERATOR STARTER CLUTCH...

Page 124: ...9 6 A C GENERATOR STARTER CLUTCH...

Page 125: ...9 7 A C GENERATOR STARTER CLUTCH...

Page 126: ...9 8 A C GENERATOR STARTER CLUTCH...

Page 127: ...MEMO...

Page 128: ...INJECTOR ASSY ENGINE TEMP SENSOR 10 0 CYLINDER HEAD VALVE...

Page 129: ...10 10 1 10 2 10 3 10 5 10 6 10 6 10 7 10 8 10 11 10 13 10 1 CYLINDER HEAD VALVE 10...

Page 130: ...10 2 CYLINDER HEAD VALVE...

Page 131: ...10 3 CYLINDER HEAD VALVE...

Page 132: ...10 4 CYLINDER HEAD VALVE...

Page 133: ...10 5 CYLINDER HEAD VALVE...

Page 134: ...10 6 CYLINDER HEAD VALVE...

Page 135: ...10 7 CYLINDER HEAD VALVE...

Page 136: ...10 8 CYLINDER HEAD VALVE...

Page 137: ...10 9 CYLINDER HEAD VALVE...

Page 138: ...10 10 CYLINDER HEAD VALVE...

Page 139: ...10 11 CYLINDER HEAD VALVE...

Page 140: ...10 12 CYLINDER HEAD VALVE...

Page 141: ...10 13 CYLINDER HEAD VALVE...

Page 142: ...10 14 CYLINDER HEAD VALVE...

Page 143: ...throttle body 10 15 CYLINDER HEAD VALVE...

Page 144: ...CYLINDER PISTON 11 0...

Page 145: ...11 1 11 11 11 1 11 1 11 2 11 3 11 5...

Page 146: ...11 2 CYLINDER PISTON...

Page 147: ...11 3 CYLINDER PISTON...

Page 148: ...11 4 CYLINDER PISTON...

Page 149: ...11 5 CYLINDER PISTON...

Page 150: ...11 6 CYLINDER PISTON...

Page 151: ...MEMO...

Page 152: ...12 0 TRANSMISSION CRANKSHAFT CRANKCASE...

Page 153: ...12 12 1 12 2 12 3 12 6 12 7 12 8 12 9 12 10 12 1 TRANSMISSION CRANKSHAFT CRANKCASE 12...

Page 154: ...12 2 TRANSMISSION CRANKSHAFT CRANKCASE...

Page 155: ...12 3 TRANSMISSION CRANKSHAFT CRANKCASE...

Page 156: ...12 4 TRANSMISSION CRANKSHAFT CRANKCASE...

Page 157: ...12 5 TRANSMISSION CRANKSHAFT CRANKCASE...

Page 158: ...12 6 TRANSMISSION CRANKSHAFT CRANKCASE...

Page 159: ...12 7 TRANSMISSION CRANKSHAFT CRANKCASE...

Page 160: ...12 8 TRANSMISSION CRANKSHAFT CRANKCASE...

Page 161: ...12 9 TRANSMISSION CRANKSHAFT CRANKCASE...

Page 162: ...12 10 TRANSMISSION CRANKSHAFT CRANKCASE...

Page 163: ...MEMO...

Page 164: ...13 0 FRONT WHEEL FRONT FORK STEERING BRAKE...

Page 165: ...14 24 935mm 25 25 039mm 25 27mm 25 07mm 25 278 25 328mm 25 44 25 41mm 25 27mm 25 42mm 33 914 33 935mm 34 34 039mm 33 87mm 34 01mm FRONT COMBI BRAKE CALIPER CYLINDER I D REAR REAR 13 13 1 13 2 13 3 13...

Page 166: ...13 2 FRONT WHEEL FRONT FORK STEERING BRAKE...

Page 167: ...R MASTER CYLINDER HOLDER MASTER CYLINDER HOLDER MASTER CYLINDER HOLDER MASTER CYLINDER HOLDER MASTER CYLINDER HOLDER MASTER CYLINDER HOLDER MASTER CYLINDER HOLDER MASTER CYLINDER HOLDER MASTER CYLINDE...

Page 168: ...NUT AXLE NUT AXLE NUT AXLE NUT AXLE NUT AXLE NUT AXLE NUT AXLE NUT AXLE NUT AXLE NUT AXLE NUT AXLE NUT AXLE NUT AXLE NUT AXLE NUT AXLE NUT AXLE NUT AXLE NUT AXLE NUT AXLE NUT AXLE NUT AXLE NUT AXLE N...

Page 169: ...BEARING BEARING BEARING BEARING BEARING BEARING BEARING BEARING BEARING BEARING BEARING BEARING BEARING BEARING BEARING BEARING BEARING BEARING BEARING BEARING BEARING BEARING BEARING BEARING BEARING...

Page 170: ...13 6 FRONT WHEEL FRONT FORK STEERING BRAKE...

Page 171: ...CYLINDER SPEEDOMETER CABLE SPEEDOMETER CABLE SPEEDOMETER CABLE SPEEDOMETER CABLE SPEEDOMETER CABLE SPEEDOMETER CABLE SPEEDOMETER CABLE SPEEDOMETER CABLE SPEEDOMETER CABLE SPEEDOMETER CABLE SPEEDOMETER...

Page 172: ...13 8 FRONT WHEEL FRONT FORK STEERING BRAKE...

Page 173: ...13 9 FRONT WHEEL FRONT FORK STEERING BRAKE...

Page 174: ...13 10 FRONT WHEEL FRONT FORK STEERING BRAKE BRAKE BLEEDER...

Page 175: ...13 11 FRONT WHEEL FRONT FORK STEERING BRAKE...

Page 176: ...ng and place a shop towel under the caliper to avoid contamination caused by the removed piston Check the piston cylinder for scratches or wear and replace if necessary Push the piston oil seal outwar...

Page 177: ...se to the brake caliper seat pin and caliper inside Install the brake caliper seat INSTALLATION Install the brake caliper to the shock absorber and tighten the two bolts Torque 24 5 34 3N m Check the...

Page 178: ...LE FRONT WHEEL AXLE FRONT WHEEL AXLE FRONT WHEEL AXLE FRONT WHEEL AXLE STEERING STEM COMP STEERING STEM COMP STEERING STEM COMP STEERING STEM COMP STEERING STEM COMP STEERING STEM COMP STEERING STEM C...

Page 179: ...13 15 FRONT WHEEL FRONT FORK STEERING BRAKE...

Page 180: ...SE FORK PIPE FORK PIPE FORK PIPE FORK PIPE FORK PIPE FORK PIPE FORK PIPE FORK PIPE FORK PIPE FORK PIPE FORK PIPE FORK PIPE FORK PIPE FORK PIPE FORK PIPE FORK PIPE FORK PIPE FORK PIPE FORK PIPE FORK PI...

Page 181: ...E BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM CASE BOTTOM...

Page 182: ...13 18 FRONT WHEEL FRONT FORK STEERING BRAKE...

Page 183: ...LE BAR HANDLE BAR HANDLE BAR HANDLE BAR HANDLE BAR HANDLE BAR HANDLE BAR HANDLE BAR HANDLE BAR HANDLE BAR HANDLE BAR HANDLE BAR HANDLE BAR HANDLE BAR HANDLE BAR HANDLE BAR HANDLE BAR HANDLE BAR HANDLE...

Page 184: ...PPER BALL STEERING UPPER BALL STEERING UPPER BALL STEERING UPPER BALL STEERING UPPER BALL STEERING UPPER BALL STEERING UPPER BALL STEERING UPPER BALL STEERING UPPER BALL STEERING UPPER BALL TOP THREAD...

Page 185: ...MEMO...

Page 186: ...REAR WHEEL BRAKE SUSPENSION REAR SWING ARM 14 0...

Page 187: ...14 1 14 14 14 1 14 2 14 3 14 5 14 7 14 7...

Page 188: ...14 2 REAR WHEEL BRAKE SUSPENSION REAR SWING ARM...

Page 189: ...14 3 REAR WHEEL BRAKE SUSPENSION REAR SWING ARM...

Page 190: ...14 4 REAR WHEEL BRAKE SUSPENSION REAR SWING ARM...

Page 191: ...EAR SWING ARM REAR SWING ARM REAR SWING ARM REAR SWING ARM REAR SWING ARM REAR SWING ARM REAR SWING ARM REAR SWING ARM REAR SWING ARM REAR SWING ARM REAR SWING ARM REAR SWING ARM REAR SWING ARM REAR S...

Page 192: ...KE DISK REAR BRAKE DISK REAR BRAKE DISK REAR BRAKE DISK REAR BRAKE DISK REAR BRAKE DISK REAR BRAKE DISK REAR BRAKE DISK REAR BRAKE DISK REAR BRAKE DISK REAR BRAKE DISK REAR BRAKE DISK REAR BRAKE DISK...

Page 193: ...SION FREE TENSION FREE TENSION FREE TENSION FREE TENSION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION...

Page 194: ...ARM REAR SWING ARM REAR SWING ARM REAR SWING ARM REAR SWING ARM REAR SWING ARM REAR SWING ARM REAR SWING ARM REAR SWING ARM REAR SWING ARM REAR SWING ARM REAR SWING ARM REAR SWING ARM REAR SWING ARM R...

Page 195: ...MEMO...

Page 196: ...15A 15 0 CHARGING SYSTEM A C GENERATOR IGNITION COIL BATTERY MAIN KEY C D I UNIT REGULATOR RECTIFIER...

Page 197: ...15 15 1 15 2 15 2 15 3 15 4 15 5 15 1 15...

Page 198: ...14 15V 13 5V 15 2 CHARGING SYSTEM 14 15V...

Page 199: ...RY COVER CABLE CABLE CABLE CABLE CABLE CABLE CABLE CABLE CABLE CABLE CABLE CABLE CABLE CABLE CABLE CABLE CABLE CABLE CABLE CABLE CABLE CABLE CABLE CABLE CABLE CABLE CABLE CABLE CABLE CABLE CABLE CABLE...

Page 200: ...15 4 CHARGING SYSTEM...

Page 201: ...RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR RECTIFIER REGULATOR...

Page 202: ...MEMO...

Page 203: ...0 73 0 08 23 5 80 150 15K 16 16 1 16 3 16 4 16 5 16 6 16 6 16 1 16...

Page 204: ...16 2 IGNITION SYSTEM...

Page 205: ...pulser pulser 16 3 IGNITION SYSTEM...

Page 206: ...Thesecondarycoilresistancemightnotmeasurecause bythehighvoltagediodeinsidetheignitioncoil 16 4 IGNITION SYSTEM...

Page 207: ...SWITCH SIDE STAND SWITCH SIDE STAND SWITCH SIDE STAND SWITCH SIDE STAND SWITCH SIDE STAND SWITCH SIDE STAND SWITCH SIDE STAND SWITCH SIDE STAND SWITCH SIDE STAND SWITCH SIDE STAND SWITCH SIDE STAND SW...

Page 208: ...RE D 3 0 17 0 STARTER SYSTEM...

Page 209: ...17 17 1 17 4 17 7 17 2 17 3 17 1 17...

Page 210: ...17 2 STARTER SYSTEM...

Page 211: ...R MOTOR STARTER MOTOR CABLE STARTER MOTOR CABLE STARTER MOTOR CABLE STARTER MOTOR CABLE STARTER MOTOR CABLE STARTER MOTOR CABLE STARTER MOTOR CABLE STARTER MOTOR CABLE STARTER MOTOR CABLE STARTER MOTO...

Page 212: ...17 4 STARTER SYSTEM...

Page 213: ...17 5 STARTER SYSTEM...

Page 214: ...17 6 STARTER SYSTEM...

Page 215: ...17 7 STARTER SYSTEM...

Page 216: ...MEMO...

Page 217: ...18 18 1 18 1 18 4 18 2 18 2 18 3 18 3 18 4 18 4 18 1 18...

Page 218: ...SWITCH START SWITCH START SWITCH START SWITCH START SWITCH START SWITCH START SWITCH START SWITCH START SWITCH START SWITCH START SWITCH START SWITCH START SWITCH START SWITCH START SWITCH START SWIT...

Page 219: ...TCH HORN SWITCH HORN SWITCH HORN SWITCH HORN SWITCH HORN SWITCH HORN SWITCH HORN SWITCH HORN SWITCH HORN SWITCH HORN SWITCH HORN SWITCH HORN SWITCH HORN SWITCH HORN SWITCH HORN SWITCH HORN SWITCH HORN...

Page 220: ...HEADLIGHT BULB LOW HEADLIGHT BULB LOW HEADLIGHT BULB LOW HEADLIGHT BULB LOW HEADLIGHT BULB LOW FRONT COVER FRONT COVER FRONT COVER FRONT COVER FRONT COVER FRONT COVER FRONT COVER FRONT COVER FRONT COV...

Page 221: ...MEMO...

Page 222: ...MEMO...

Page 223: ...19 CIRCUIT DIAGRAM...

Page 224: ...19 1 rhN rrN winker 19...

Page 225: ...SERVICEMANUAL 2007 04 PRINTED 2007 04 PUBLICATION N NO O C CO OP PY Y...

Page 226: ......

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