DAELIM S2-250 Скачать руководство пользователя страница 112

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10-5

CYLINDER HEAD / VALVE

Be careful not to damage the cylinder head mating
surface.

Be sure to compress the valve springs with a valve
spring compressor.

Mark all disassembled parts to ensure correct
reassembly.

●

Remove carbon deposits fron the exhaust port and
combustion chamber.

DISASSEMBLY

●

Remove the valve spring cotters, retainers, springs,
spring seats and valve stem seals using a valve spring
compressor.

INSPECTION

●

Check the spark plug hole and valve areas for cracks.

●

Check the cylinder head for warpage with a straight
edge and feeler gauge.

SERVICE LIMITS : 0.05mm replace or replace if
over

●

Measure the free length of the inner and outer valve
springs.

SERVICE LIMITS:

INNER (IN, EX) : 29.5mm replace if below
OUTER(IN, EX) : 39.5mm replace if below

CYLINDER HEAD

VALVE SPRING COMPRESSOR

COMBUSTION CHAMBER

STRAIGHT EDGE

FEELER GAUGE

Содержание S2-250

Страница 1: ......

Страница 2: ...f 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 vehicle quality No p...

Страница 3: ......

Страница 4: ...ays 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 fire or ele...

Страница 5: ...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...

Страница 6: ...rection 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...

Страница 7: ...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...

Страница 8: ...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...

Страница 9: ...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...

Страница 10: ...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...

Страница 11: ...ess not to be pulled or expended 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...

Страница 12: ...1 9 SERVICE INFORMATION SERIAL NUMBER LOCATION ENGINE SERIAL NUMBER LOCATION FRAME SERIAL NUMBER LOCATION...

Страница 13: ...rpm 8 BTDC 42 ABDC 33 BBDC 1 ATDC 0 1 mm 0 1 mm OVERALL LENGTH OVERALL WIDTH OVERALL HEIGHT WHEEL BASE SEAT HEIGHT GROUND CLEARANCE DRY WEIGHT GROSS WEIGHT TYPE FRONT SUSPENSION STROKE REAR SUSPENSIO...

Страница 14: ...ET PILOT SCREW INITIAL SETTING FLOAT LEVEL IDLE SPEED CLUTCH TYPE PRIMARY REDUCTION SECONDARY REDUCTION IGNITION SYSTEM IGNITION TIMING F MARK BATTERY TYPE CAPACITY SPARK PLUG SPARK PLUG GAP STARTING...

Страница 15: ...gf m 0 25 kgf m 7 5 kgf m 6 0 kgf m 6 0 kgf m 3 1 kgf m 1 2 kgf m 4 25 kgf m 12 5 kgf m 3 1 kgf m 1 2 kgf m 4 25 kgf m 0 43 kgf m 2 25 kgf m 4 0 kgf m 4 0 kgf m 3 5 kgf m 5 25 kgf m 4 5 kgf m 4 0 kgf...

Страница 16: ...rnings or cautions MEANING Indicates dangerous area Serious accident may result if instructions are not followed The following symbols indicate oil adding oil change or parts MEANING Add oil If there...

Страница 17: ...ROOVE PISTON PIN AROUND CONNECTING ROD PISTON PIN HOLE CONNECTING ROD BIG END CRANK SHAFT CRANK SHAFT ONE WAY CLUTCH OPERATING PARTS OIL PUMP DRIVE CHAIN STARTER REDUCTION GEAR PARTS COUNTER SHAFT GEA...

Страница 18: ...HOSE CLIP WATER PASS TUBE C E M I UNIT COMP E M I CORD WIRE E M I CORD FAN MOTOR RADIATOR HOSE A HORN LICENSE LAMP WIRE REGULATOR RECTIFIER HEADLIGHT CONTROL UNIT STARTER MAGNETIC SWITCH FUEL TUBE CAR...

Страница 19: ...PIPE WATER PASS TUBE B E M I UNIT COMP WATER PASS TUBE B THROTTLE CABLE RADIATOR CAP HOSE RADIATOR HOSE A RADIATOR HOSE A RADIATOR HOSE B THERMO SWITCH WIRE THERMO SWITCH WIRE SEAT LOCK CABLE WATER P...

Страница 20: ...LATOR RECTIFIER START MAGNETIC SWITCH BATTERY EARTH CABLE HEADLIGHT CONTROLLER CODE REGULATOR COUPLER 2EA HEAD LIGHT RELAY THERMO SWITCH RELAY WINKER RELAY EARTH CABLE BATTERY BOX COUPLER NOTE WHITE C...

Страница 21: ...1 18 SERVICE INFORMATION HEADLIGHT RELAY BATTERY EARTH CABLE RESERVE FUSE BATTERY BOX FUSE BOX WINKER RELAY THERMO SWITCH RELAY HEADLIGHT RELAY FUSE BOX ASS Y BATTERY BOX...

Страница 22: ...L TANK FUEL TUBE CARBURETOR TRUNK LAMP WIRE THERMO SENSOR WIRE NOISE SUPPRESSOR CAP AUTO CHOCK CORD I G COIL SIDE STAND SWITCH COUPLER THROTTLE POSITION COUPLER RR BRAKE HOSE WATER HOSE B WATER HOSE A...

Страница 23: ...MEMO...

Страница 24: ...RCOMPRESSIONPRESSURE 2 6 CARBURETOR IDLING 2 6 FINAL REDUCTION GEAR OIL 2 6 GEAR OIL REPLACEMENT 2 7 DRIVE BELT 2 7 COOLING LEVEL INSPECTION 2 8 COOLANT REPLACEMENT 2 8 BRAKE FLUID 2 9 BRAKE PAD 2 9 B...

Страница 25: ...ADJUSTMENTS TIRES COLD TIRE PRESSURE TIRE SIZE DRIVER ONLY DRIVER AND A PASSENGER FRONT TIRE REAR TIRE FRONT TIRE REAR TIRE FRONT TIRE REAR TIRE 2 00kgf 2 00kgf 2 00kgf 2 25kgf 120 70 12 Tubeless 140...

Страница 26: ...ceeds 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 more frequently 3 Replace every 2 ye...

Страница 27: ...djustment loosen the lock nut and turn adjuster After adjusting tighten lock nut After adjustment is completed recheck the throttle grip free play For simple adjustment use the adjuster under the thro...

Страница 28: ...aner and wire brush to clean the plug Always use a feeler gauge to check the gap GENUINE PLUG DPR7EA9 SPARK PLUG 0 9 1 0mm TORQUE VALUE 1 47 1 96kgf m Remove the air cleaner element Wash away any accu...

Страница 29: ...er Stop engine and remove the spark plug cap and spark plug Install a compression gauge Open the throttle completely and crank the engine with the starter motor until the gauge reading rising TOOL COM...

Страница 30: ...rpm Verify all engine adjustments satisfy specifications Make adjustments if necessary Heat the engine to make accurate idling inspection and adjustment Stand the vehicle on the main stand Turn the th...

Страница 31: ...ature too high or low Fill to the F UPPER LEVEL line Start the engine Bleed air from the coolant and check the level of coolant Install the radiator cap Fill the coolant with the reserve tank up to th...

Страница 32: ...e pads for wear If the red mark on the pad reaches the brake disc replace the pads Replace the brake pads in sets Brake fluid will damage painted plastic or rubber parts Mixing incompatible fluids can...

Страница 33: ...nsion parts will lead to deterioration in the vehicle s safety and operation efficiency 2 10 SIDE STAND Erect the main stand Pull the lower end of the side stand and see if it moves freely If the side...

Страница 34: ...Check all nuts and bolts of the frame during the regular maintenance to check if they meet the prescribed torque value Check all pins clips hose clamps and cable stays FRONT WHEEL 2 00 200 2 00 200 R...

Страница 35: ...MEMO...

Страница 36: ...EXTERNAL PARTS 3 SERVICE INFORMATION 3 1 SEAT 3 2 PILLION SEAT 3 2 LUGGAGE BOX TOP COVER 3 2 REAR GRIP 3 2 LUGGAGE BOX 3 3 CENTER COVER 3 3 BODY SIDE COVER 3 3 BODY COVER 3 4 REAR FENDER 3 4 FLOOR SI...

Страница 37: ...R GRIP Remove the rear grip cap R L Loosen the 4 special bolts Install in the reverse order of removal LUGGAGE BOX TOP COVER Loosen the 5 Tapping screws and remove the top cover Install in the reverse...

Страница 38: ...amp Install in the reverse order of removal CENTER COVER Remove the floor mat Loosen the 2 washer screws and 1 special screw Install in the reverse order of removal BODY SIDE COVER Remove the center c...

Страница 39: ...er of removal REAR FENDER Remove the body cover Loosen the 4 washer bolts and remove the Rr fender Install in the reverse order of removal FLOOR SIDE COVER Remove the center cover Loosen the 3 body co...

Страница 40: ...the 4 special screws R L 2Ea for each to remove the under cover Install in the reverse order of removal HANDLE COVER Loosen the washer screw and tapping screw securing the under handle cover Loosen t...

Страница 41: ...al FRONT UNDER COVER A Remove the front cover and windscreen Loosen the 7 tapping screws securing the inner cover Install in the reverse order of removal FRONT UNDER COVER B Loosen the 2 flange bolts...

Страница 42: ...be clip Remove the breather tube Loosen the 3 screws securing the inner cover Remove the bag holder Loosen the 2 tapping screws securing the speedometer cover Install in the reverse order of removal S...

Страница 43: ...curing Ex pipe comp Loosen the 3 bolts securing the Rr Fork Remove the Ex muffler comp REAL WHEEL MUDGUARD Loosen the 2 flange bolts of RH Loosen the flange bolt securing the air cleaner and mudguard...

Страница 44: ...MEMO...

Страница 45: ...4 0 LUBRICATION SYSTEM ROCKER ARM SHAFT CRANK SHAFT OIL FILTER SCREEN OIL PUMP...

Страница 46: ...contect with the skin for prolonged periods It is desirable not to handle used oil frequently however wash your hands thoroughly with soap and water immediately after handling the used oil 3 The oil...

Страница 47: ...ption External oil leaks Worn piston ring or incorrect piston ring installation Worn valve guide or seal Oil contamination Oil or filter not changed often enough Faulty head gasket Worn piston rings L...

Страница 48: ...filter screen every 4 000Km Clean the filter screen with fresh cleaning oil Check the hole cap O ring for satisfactory condition Tighten the hole cap with specified tightening torque TORQUE VALUE 1 5...

Страница 49: ...PERATOR COVER OIL SEPERATOR COVER OIL SEPERATOR COVER OIL SEPERATOR COVER OIL SEPERATOR COVER OIL SEPERATOR COVER OIL PUMP DRIVE SPROCKET OIL PUMP DRIVE SPROCKET OIL PUMP DRIVE SPROCKET OIL PUMP DRIVE...

Страница 50: ...ump body clearance SERVICE LIMIT 0 25mm TOOL FEELER GAUGE Measure the rotor tip clearance SERVICE LIMIT 0 20mm Measure the pump side clearance SERVICE LIMIT 0 12mm OIL PUMP ASSEMBLY Clean all parts wi...

Страница 51: ...R OIL SEPERATOR COVER OIL SEPERATOR COVER OIL SEPERATOR COVER OIL SEPERATOR COVER OIL SEPERATOR COVER OIL SEPERATOR COVER OIL SEPERATOR COVER OIL SEPERATOR COVER OIL SEPERATOR COVER OIL PUMP DRIVE SPR...

Страница 52: ...MEMO...

Страница 53: ...5 0 FUEL SYSTEM...

Страница 54: ...e for a period longer than 3 weeks 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...

Страница 55: ...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...

Страница 56: ...ring coupler of the auto bystarter After removing the fuel tank be sure to close the fuel tank cap Gasoline is extremely flammable Avoid fire during work and pay particular attention to electric spark...

Страница 57: ...r cleaner connecting tube band and the carburetor intake manifold band Remove the carburetor Remove the two vacuum chamber cover screws and the cover Remove the compression spring and vacuum piston VA...

Страница 58: ...VALVE FLOAT VALVE FLOAT VALVE FLOAT VALVE FLOAT VALVE FLOAT VALVE FLOAT VALVE FLOAT VALVE FLOAT VALVE FLOAT VALVE FLOAT VALVE FLOAT PIN FLOAT PIN FLOAT PIN FLOAT PIN FLOAT PIN FLOAT PIN FLOAT PIN FLOA...

Страница 59: ...PILOT SCREW P S PILOT SCREW P S PILOT SCREW P S PILOT SCREW P S PILOT SCREW P S PILOT SCREW P S PILOT SCREW P S PILOT SCREW P S PILOT SCREW P S PILOT SCREW P S PILOT SCREW P S PILOT SCREW P S SLOW JET...

Страница 60: ...TARTER AUTO BYSTARTER AUTO BYSTARTER AUTO BYSTARTER AUTO BYSTARTER AUTO BYSTARTER AUTO BYSTARTER AUTO BYSTARTER AUTO BYSTARTER AUTO BYSTARTER AUTO BYSTARTER AUTO BYSTARTER AUTO BYSTARTER AUTO BYSTARTE...

Страница 61: ...VALVE COVER AIR CUT OFF VALVE COVER AIR CUT OFF VALVE COVER AIR CUT OFF VALVE COVER DIAPHRAGM DIAPHRAGM DIAPHRAGM DIAPHRAGM DIAPHRAGM DIAPHRAGM DIAPHRAGM DIAPHRAGM DIAPHRAGM DIAPHRAGM DIAPHRAGM DIAPH...

Страница 62: ...S SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS SCREWS O RING O RING O...

Страница 63: ...VACUUM PISTON VACUUM PISTON VACUUM PISTON VACUUM PISTON VACUUM PISTON VACUUM PISTON JET NEEDLE JET NEEDLE JET NEEDLE JET NEEDLE JET NEEDLE JET NEEDLE JET NEEDLE JET NEEDLE JET NEEDLE JET NEEDLE JET NE...

Страница 64: ...CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE INTAKE MANIFOLD BAND INTAKE...

Страница 65: ...or foreign matters Install in the reverse order of removal OUTPUT 40CC 1 700rpm 10 seconds Measure the fuel pump output Start the engine and disconnect the fuel outlet fube and place a clean containe...

Страница 66: ...MEMO...

Страница 67: ...6 0 COOLING SYSTEM...

Страница 68: ...the radiator cap if the coolant temperature is over 100 C Removing the cap while the engine is hot and the coolant is under pressure may cause serious scalding When the temperature is below carefully...

Страница 69: ...d in radiator hoses or water jacket Faulty fan motor switch Faulty water pump Engine temperature too low or unstable Faulty temperature gauge or thermo sensor Faulty thermostat stuck Thermostat stuck...

Страница 70: ...of coolant is 2000cc RADIATOR COOLANT MIXTURE CHART ANTICORROSIVE AND ANTIFREEZE COOLANT GRAVITY CHART Minimum temperature 9 C 16 C 25 C 37 C 44 5 C Mixture 20 30 40 50 60 Ratio 400 600 800 1 000 1 10...

Страница 71: ...ube from the radiator filler Remove the overflow tube clamp and disconnect the overflow tube Inspect the radiator soldered joints and seams for leaks Blow dirt out from between core fins with compress...

Страница 72: ...R HOSE LOWER HOSE LOWER HOSE LOWER HOSE LOWER HOSE LOWER HOSE LOWER HOSE LOWER HOSE BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS NUT NUT...

Страница 73: ...he radiator on the radiator bracket with the 2 bolts and 1 nut Connect the upper and lower hoses and secure them with hose bands Connect the thermostatic switch wire and fan motor wire couplers Instal...

Страница 74: ...owed out from the air vent tube 3 Put the air vent tube on TELLTALE HOLE TELLTALE HOLE TELLTALE HOLE TELLTALE HOLE TELLTALE HOLE TELLTALE HOLE TELLTALE HOLE TELLTALE HOLE TELLTALE HOLE TELLTALE HOLE T...

Страница 75: ...crankcase cover BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOL...

Страница 76: ...assembly from the inside Drive in a new mechanical seal using a mechanical seal driver WATER PUMP SHAFT WATER PUMP SHAFT WATER PUMP SHAFT WATER PUMP SHAFT WATER PUMP SHAFT WATER PUMP SHAFT WATER PUMP...

Страница 77: ...R BEARING INNER BEARING INNER BEARING INNER BEARING INNER BEARING WATER PUMP SHAFT WATER PUMP SHAFT WATER PUMP SHAFT WATER PUMP SHAFT WATER PUMP SHAFT WATER PUMP SHAFT WATER PUMP SHAFT WATER PUMP SHAF...

Страница 78: ...DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN BOLTS BOLTS BOLTS BOLTS BOLTS BOLTS BOL...

Страница 79: ...t and the thermostat housing from the cylinder head Remove the 2 bolts and separate the thermostat housing halves Remove the thermostat from the thermostat housing Be sure to bleed air from the coolin...

Страница 80: ...er and gradually raise the water temperature to check its operation Technical Data Do not let the thermostat touch the pan as it will give a false reading Replace the thermostat if the valve stays ope...

Страница 81: ...MEMO...

Страница 82: ...n the coolant before removing the engine After the engine is installed fill the cooling system with coolant and be sure to bleed air from the water jacket Start the engine to check for coolant leaks T...

Страница 83: ...d connectors Disconnect the engine fuel tube Drain the coolant Disconnect the water hose Disconnect the starter motor wire from the starter relay Disconnect the fuel tube and vacuum tube Disconnect th...

Страница 84: ...REAR SHOCK ABSORBER UPPER MOUNT BOLTS REAR SHOCK ABSORBER UPPER MOUNT BOLTS REAR SHOCK ABSORBER UPPER MOUNT BOLTS REAR SHOCK ABSORBER UPPER MOUNT BOLTS REAR SHOCK ABSORBER UPPER MOUNT BOLTS REAR SHOC...

Страница 85: ...t bolts TORQUE VALUE 3 92kgf m After installation inspect and adjust the following Throttle grip free play Fill the rear brake reservoir with brake fluid and bleed air from the rear brake Fill the coo...

Страница 86: ...MEMO...

Страница 87: ...8 0 LH CRANKCASECOVER CONTINUOUSLYVARIABLE TRANSMISSION...

Страница 88: ...40 000 40 025mm 40 06mm DRIVE FACE COLLAR OUTER DIAMETER 39 965 39 955mm 39 85mm DRIVE BELT WIDTH 23 6 24 4mm 22 0mm CLUTCH LINING WICTH 3 963 4 037mm 2 0mm CLUTCH OUTER AND INNER DIAMETER 153 0 153 2...

Страница 89: ...R TUBE BAND AIR TUBE BAND AIR TUBE BAND AIR TUBE BAND AIR TUBE BAND AIR TUBE BAND AIR TUBE BAND AIR TUBE BAND LH COVER LH COVER LH COVER LH COVER LH COVER LH COVER LH COVER LH COVER LH COVER LH COVER...

Страница 90: ...from the movable drive face Remove the movable drive face assembly Remove the drive pulley collar INSPECTION Check the drive bolt for cracks sepuration or abnormal or excessive wear Inspect the drive...

Страница 91: ...heck the pump shaft to rotate smoothly RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PL...

Страница 92: ...SEMBLY RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP PLATE RAMP P...

Страница 93: ...ey collar Install the washer and drive nut into the drive pulley face temperarilly DRIVE PULLEY COLLAR DRIVE PULLEY COLLAR DRIVE PULLEY COLLAR DRIVE PULLEY COLLAR DRIVE PULLEY COLLAR DRIVE PULLEY COLL...

Страница 94: ...Hold the clutch outer with the universal holder and remove the clutch outer nut Remove the clutch outer INSPECTION Inspect the clutch outer for wear or damage Measure the clutch outer I D SERVICE LIMI...

Страница 95: ...clutch spring compressor and disassemlble the clutch driven pulley assembly Remove the seal collar Pull out the guide roller pins and guide rollers Remove the movable driven face from the driven face...

Страница 96: ...D SERVICE LIMIT 40 06mm replace if over DRIVEN PULLEY FACE BEARING REPLACEMENT Remove the inner needle bearing out of the driven pulley face Remove the snap ring and drive the outer bearing out of th...

Страница 97: ...the retainer plate and secure with the circlips Keep grease off the clutch linings BALL BEARING OUTER CIRCLIPS CIRCLIPS CIRCLIPS CIRCLIPS CIRCLIPS CIRCLIPS CIRCLIPS CIRCLIPS CIRCLIPS CIRCLIPS CIRCLIPS...

Страница 98: ...er pins and then install them into the holes of the driven face Install new seal collar Remove any excessive grease Tighten the drive flate nut temperily Set teh tool invise and righten the drive plat...

Страница 99: ...ch driven pulley onto the drive shaft Install the clutch outer Hold the clutch outer with the universal holder Install and tighten the clutch outer nut TORQUE VALUE 4 9 5 88kgf m Install the drive bel...

Страница 100: ...MEMO...

Страница 101: ...9 0 A C GENERATOR STARTER CLUTCH...

Страница 102: ...ase cover When the right crankcase cover is installed fill with the recommended engine oil and coolant Then bleed air from the water jacket SPECIFICATIONS 9 SERVICE INFORMATION 9 1 R CRANKCASE COVER R...

Страница 103: ...PULSE COIL PULSE COIL PULSE COIL PULSE COIL PULSE COIL PULSE COIL PULSE COIL PULSE COIL PULSE COIL PULSE COIL PULSE COIL PULSE COIL A C GENERATOR STATOR A C GENERATOR STATOR A C GENERATOR STATOR A C...

Страница 104: ...START CLUTCH GEAR COMP START CLUTCH GEAR COMP START CLUTCH GEAR COMP START CLUTCH GEAR COMP START CLUTCH GEAR COMP START CLUTCH GEAR COMP START CLUTCH GEAR COMP START CLUTCH GEAR COMP START CLUTCH GEA...

Страница 105: ...CTION GEAR START REDUCTION GEAR START REDUCTION GEAR START REDUCTION GEAR START REDUCTION GEAR START REDUCTION GEAR START REDUCTION GEAR START REDUCTION GEAR START REDUCTION GEAR START REDUCTION GEAR...

Страница 106: ...PUMP 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 OIL PUMP SHAFT OIL PUMP SHAFT OIL PUMP SHAFT OIL PUMP SHAFT ALIGNING...

Страница 107: ...10 0 CYLINDER HEAD VALVE...

Страница 108: ...ARPAGE CAMSHAFT CAM HEIGHT VALVE ROCKER ARM I D VALVE ROCKER ARM SHAFT O D VALVE SEAT WIDTH VALVE STEM O D VALVE GUIDE I D VALVE STEM TO GUIED CLEARANCE IN EX IN EX IN EX IN EX IN EX IN EX IN EX IN EX...

Страница 109: ...TENSIONER CAM CHAIN TENSIONER CAM CHAIN TENSIONER CAM CHAIN TENSIONER CAM CHAIN TENSIONER CAM CHAIN TENSIONER CAMSHAFT HOLDER CAMSHAFT HOLDER CAMSHAFT HOLDER CAMSHAFT HOLDER CAMSHAFT HOLDER CAMSHAFT H...

Страница 110: ...FT ROCKER ARM SHAFT ROCKER ARM SHAFT ROCKER ARM SHAFT ROCKER ARM SHAFT ROCKER ARM SHAFT ROCKER ARM SHAFT ROCKER ARM SHAFT CAMSHAFT GEAR CAMSHAFT GEAR CAMSHAFT GEAR CAMSHAFT GEAR CAMSHAFT GEAR CAMSHAFT...

Страница 111: ...HAFT ROCKER ARM SHAFT ROCKER ARM SHAFT ROCKER ARM SHAFT ROCKER ARM SHAFT ROCKER ARM SHAFT ROCKER ARM SHAFT ROCKER ARM SHAFT ROCKER ARM SHAFT ROCKER ARM SHAFT ROCKER ARM SHAFT ROCKER ARM SHAFT ROCKER A...

Страница 112: ...NG COMPRESSOR VALVE SPRING COMPRESSOR VALVE SPRING COMPRESSOR VALVE SPRING COMPRESSOR VALVE SPRING COMPRESSOR VALVE SPRING COMPRESSOR VALVE SPRING COMPRESSOR VALVE SPRING COMPRESSOR VALVE SPRING COMPR...

Страница 113: ...HAIN GUIDE CAM CHAIN GUIDE CAM CHAIN GUIDE CAM CHAIN GUIDE CAM CHAIN GUIDE CAM CHAIN GUIDE CAM CHAIN GUIDE CAM CHAIN GUIDE CAM CHAIN GUIDE CAM CHAIN GUIDE VALVE SPRING COMPRESSOR VALVE SPRING COMPRESS...

Страница 114: ...M CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN CAM CHAIN DOWEL PINS DOWEL PINS DOWEL PINS DOWEL PINS DOWEL PINS DOWEL PINS DOWEL PINS DOWEL PINS DOWEL PINS DOWEL PINS DOWEL PINS D...

Страница 115: ...e O ring into the groove properly WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS WASHERS BOLTS BOLTS BOLTS BOLT...

Страница 116: ...MEMO...

Страница 117: ...11 0 CYLINDER PISTON...

Страница 118: ...ICITY TRUE ROUNDNESS RING TO GROOVE TOP CLEARANCE SECOND TOP RINGENDGAP SECOND OIL RING PISTON O D PISTON TO CYLINDERCLEARANCE PISTON PIN HOLE I D 72 705 72 715 0 01 0 01 0 01 0 2 0 015 0 050 0 1 0 25...

Страница 119: ...CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER DOWEL PINS DOWEL PINS DOWEL PINS DOWEL PINS DOWEL PINS DOWEL PINS DOWEL PINS DOWEL PINS DOWEL PINS DO...

Страница 120: ...emove the piston rings and insert each piston ring into the cylinder bottom Measure the piston ring end gap SERVICE LIMITS 0 5mm replace if over Measure the piston pin hole I D SERVICE LIMITS 17 04mm...

Страница 121: ...ar or damage SERVICE LIMITS 72 80mm replace or replace if over Measure the cylinder to piston clearance SERVICE LIMITS 0 1mm replace or replace if over The true roundness is the difference between the...

Страница 122: ...thlout sticking stagger the ring end gaps as the figure shown Inspect the top of the cylinder for warpage SERVICE LIMITS 0 05mm replace or replace if over Measure the connecting rod small end I D SERV...

Страница 123: ...TON PIN CLIP PISTON PIN CLIP PISTON PIN CLIP PISTON PIN CLIP PISTON PIN CLIP PISTON PIN CLIP PISTON PIN CLIP PISTON PIN CLIP PISTON PIN CLIP PISTON PIN CLIP PISTON PIN CLIP PISTON PIN CLIP PISTON PIN...

Страница 124: ...to the cylinder Install the cylinder head Tighten the cylinder base bolt DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL P...

Страница 125: ...12 0 CRANKSHAFT CRANKCASE...

Страница 126: ...be removed before separating the crakcase Cylinder head Cylinder piston Right crankcase cover drive and driven pulley A C generator starter clutch Rear wheel rear shock absorber Starter motor Oil pum...

Страница 127: ...l bearing puller Bearing remover set Remover ass y Remover shaft Remover head Slieding weight Assembly shaft TROUBLESHOOTING Excessive engine noise Excessive bearing play Excessive crankpin bearing pl...

Страница 128: ...CRANKCASE LEFT CRANKCASE LEFT CRANKCASE LEFT CRANKCASE LEFT CRANKCASE LEFT CRANKCASE LEFT CRANKCASE LEFT CRANKCASE LEFT CRANKCASE LEFT CRANKCASE LEFT CRANKCASE LEFT CRANKCASE LEFT CRANKCASE LEFT CRAN...

Страница 129: ...place if over Measure the crankshaft runout SERVICE LIMITS 0 10mm replace if over LH CRANKCASE LH CRANKCASE LH CRANKCASE LH CRANKCASE LH CRANKCASE LH CRANKCASE LH CRANKCASE LH CRANKCASE LH CRANKCASE L...

Страница 130: ...et material from the crankcase mating surfaces Place the LH crankcase down and install the crankshaft into the LH crankcase Avoid damaging the oil seal Apply grease to the lip of the oil seal PLAY AXI...

Страница 131: ...ioner slipper Install the tighten the cam chain tensioner slipper bolt TORQUE VALUE 0 78 1 18kgf m Install the two dowel pins and a new gasket Install the RH crankcase squarely and do not tap it with...

Страница 132: ...MEMO...

Страница 133: ...13 0 FINAL REDUCTION...

Страница 134: ...CIAL TOOLS Bearing remover 12mm Bearing remover 15mm Pilot 12mm Pilot 15mm TROUBLESHOOTING Engine starts but motorcycle won t move Damaged transmission Seized or burnt transmission Abnormal noise Worn...

Страница 135: ...GEAR FINAL GEAR FINAL GEAR FINAL GEAR FINAL GEAR FINAL GEAR FINAL GEAR FINAL GEAR FINAL GEAR FINAL GEAR FINAL GEAR FINAL GEAR FINAL GEAR FINAL GEAR FINAL GEAR FINAL GEAR FINAL GEAR FINAL GEAR COUNTER...

Страница 136: ...FINAL SHAFT BEARING FINAL SHAFT BEARING FINAL SHAFT BEARING FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SHAFT FINAL SH...

Страница 137: ...l shaft into the left crankcase FINAL REDUCTION ASSEMBLY Install the drive shaft into the left crankcase Drive new bearings into the left crankcase Install a new drive shaft oil seal DRIVE SHAFT DRIVE...

Страница 138: ...removal Install the transmission case cover Place the motorcycle on its main stand on level ground Check the oil sealing washer for wear or damage COUNTERSHAFT COUNTERSHAFT COUNTERSHAFT COUNTERSHAFT...

Страница 139: ...14 0 FRONT WHEEL FRONT FORK STEERING BRAKE...

Страница 140: ...BER BOLT 1 98 2 45 f m FRONT AXLE NUT 4 41 4 9 f m BRAKE CALIPER BOLT 2 45 3 43 f m 14 SERVICE INFORMATION 14 1 TROUBLESHOOTING 14 2 STEERING HANDLE 14 3 FRONT WHEEL 14 4 FRONT WHEEL BEARING 14 5 SPEE...

Страница 141: ...uide bushings Insufficient fluid in forks Loose front fork fasteners Lack of grease in speedometer gear box Brake lever soft or spongy Air in hydraulic system Mixed brake fluid and wet Contaminated br...

Страница 142: ...e the throttle grip from the handlebar Remove the handlebar lock nut and take out the bolt Remove the handlebar INSTALLATION Install the handlebar onto the steering stem and install the handlebar coll...

Страница 143: ...e actual runout is 1 2 of the total indicator reading SERVICE LIMIT 0 2mm replace if over Adjust the throttle grip free play to the specified range of 2 6mm Install the brake master cylinders by align...

Страница 144: ...y sufficient amount of grease to the bearing Insert the right bearing with its seal surface facing outside Do not tilt the bearing Insert accurately Upon assembling the distance collar insert the left...

Страница 145: ...GEAR BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR BOX SPEEDOMETER GEAR SPEEDOMETER GEAR SPEEDOMETER GEAR SPEEDOMETER GEAR SPEEDOMETER GEAR SPEEDOMETER GEAR SPEEDOMETER GEAR SPEEDOMETER GEAR SPEEDOMETER G...

Страница 146: ...rst drain the brake fluid from the hydraulic brake system Disconnect the front stop switch wire connector Remove the brake fluid tube bolt Remove the two bolts securing the brake master cylinder Remov...

Страница 147: ...INDER SET MASTER CYLINDER SET MASTER CYLINDER SET MASTER CYLINDER SET MASTER CYLINDER SET MASTER CYLINDER BODY MASTER CYLINDER BODY MASTER CYLINDER BODY MASTER CYLINDER BODY MASTER CYLINDER BODY MASTE...

Страница 148: ...SPRING Replace the piston spring cups and snap ring as a set Be sure that each part is free from dust or dirt before reassembly When cleaning with the brake fluid use the specified brake fluid Instal...

Страница 149: ...lable Fill the reservoir with DOT 3 or 4 brake fluid up to the upper level Connect the recommended brake bleeder to the bleeder valve Loosen the bleeder valve while pumping the brake lever Repeat this...

Страница 150: ...evel is near the lower level If no air leaks out of the bleeder hose operate the brake lever to check the presence of air Tighten the bleeder valve TORQUE VALUE 0 4 0 7 kgf m Be sure that the brake fl...

Страница 151: ...caliper with cloth to prevent the piston or brake fluid from leaking Remove the piston from the caliper while blowing the low pressure air in the opening of the brake hose 14 12 FRONT WHEEL FRONT FOR...

Страница 152: ...N PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON SEAL PISTON SEAL PISTON SEAL PISTON SEAL PISTON SEAL PISTON SEAL PISTON...

Страница 153: ...ghten the oil bolt to the specified torque TORQUE VALUE 3 4kgf m Fill the brake fluid to the upper limit line and bleed air FRONT FORK REMOVAL Remove the following parts Front under cover Front brake...

Страница 154: ...lt 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 SPRING VISE...

Страница 155: ...if the deflection is greater than 0 2mm 14 16 FRONT WHEEL FRONT FORK STEERING BRAKE Take precautions not to damage the interior and exterior rim of the bottom case OIL SEAL STOPPER RING OIL SEAL STOPP...

Страница 156: ...ew locking agent to the socket bolt thread and assemble the socket bolt to the fork piston TORQUE VALUE 2 0kgf m Apply ATF to a new oil seal Assemble the oil seal to the bottom case Insert the oil sea...

Страница 157: ...L STOPPER RING OIL SEAL STOPPER RING OIL SEAL STOPPER RING OIL SEAL STOPPER RING OIL SEAL STOPPER RING OIL SEAL STOPPER RING OIL SEAL STOPPER RING OIL SEAL STOPPER RING OIL SEAL STOPPER RING OIL SEAL...

Страница 158: ...ball assembly top cone race and ball race for damage or abnormal and replace as necessary Check the bottom cone race for wear and damage STEERING STEM REMOVAL Remove the following parts Handle cover...

Страница 159: ...ring top thread onto the steering head Tighten the top thread to specified torque then loosen the top thread 1 8 turn TORQUE VALUE 0 15 0 25kgf m Recheck that the steering stem moves smoothly without...

Страница 160: ...MEMO...

Страница 161: ...15 0 REAR WHEEL BRAKE SUSPENSION REAR SWING ARM...

Страница 162: ...LOCK BOLT 2 94 3 92 f m REAR AXLE NUT 7 84 9 8 f m REAR SHOCK ABSORBER LOWER MOUNT BOLT 1 96 2 94 f m REAR SHOCK ABSORBER UPPER MOUNT BOLT 3 92 f m REAR BRAKE CALIPER BOLT 1 96 2 94 f m 15 SERVICE INF...

Страница 163: ...re pressure incorrect Faulty tire Bent 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...

Страница 164: ...in caliper bracket and boot from the caliper body Check the boot for wearand damage and replace if necessany INSPECTION Inspect break pad and disk Measure the break disk thickness SERVICE LIMIT 3mm 15...

Страница 165: ...PER PISTON SEAL PISTON SEAL PISTON SEAL PISTON SEAL PISTON SEAL PISTON SEAL PISTON SEAL PISTON SEAL PISTON SEAL PISTON SEAL PISTON SEAL PISTON SEAL PISTON SEAL PISTON SEAL PISTON SEAL PISTON SEAL PIST...

Страница 166: ...exhaust muffler Remove the rear brake caliper Remove the rear fork Remove the rear axle collar Remove the rear wheel Rotate the inner bearing with finger and check it for smooth operation Check the ma...

Страница 167: ...shion lower bolt 1 96 2 94kgf m Rear axle nut 7 84 9 8kgf m REAR CUSHION ADJUST Adjust the cushion spring according to the load condition The rear cushion can be adjusted as below 1 2 3 4 5 soft mediu...

Страница 168: ...INSTALLATION Install in the reverse order of removal TORQUE VALUE 3 92kgf m 15 7 REAR WHEEL BRAKE SUSPENSION SWING ARM...

Страница 169: ...16 0 CHARGING SYSTEM REGULATOR RECTIFIER MAIN SWITCH A C GENERATOR...

Страница 170: ...tedly lose all its charge is repeatedly over charged or if it is left in an un charged state the battery can be damaged its life can be reduced or it can lose some of its strength It is important to n...

Страница 171: ...oose broken or shorted wire or connection Loose battery connection Faulty regulator rectifier Faulty A C generator CHARGING SYSTEM Measure battery current leakage Check the regulator rectifier Battery...

Страница 172: ...the charger negative cable to the battery negative terminal When disconnecting the battery positive cable do not touch the frame with tool otherwise it will cause short circuit and sparks to fire the...

Страница 173: ...erminal and ground cable With the ignition switch off measure the leakage current LEAK CURRENT Not to exceed 0 5A max TOOL DIGITAL TESTER A C GENERATOR INSPECTION AMPERE METER EARTH CABLE BATTERY TERM...

Страница 174: ...move the regulator rectifier coupler Measure each terminal Replace the regulator rectifier unit if the resistance value between the terminals is abnormal RESISTANCE VALUE Tester Tester Unit 20 R B Y Y...

Страница 175: ...17 0 IGNITION SYSTEM BATTERY REGULATOR RECTIFIER IGNITION UNIT A C GENERATOR MAIN SWITCH IGNITION UNIT...

Страница 176: ...to removing wiring Connect the same color couplers A faulty ignition system is often related to poorly connected connectors Check those connections before proceeding This manual gives explanations on...

Страница 177: ...cted ignition unit connector 4 Open circuit or poor connection in ground cord of the CDI unit 5 Faulty peak voltage adaptor 6 Faulty ignition unit in case when above No 1 5 are normal 1 Faulty spark p...

Страница 178: ...If the resistance is open wire disconnect the spark plug cap and measure the secondary coil resistance STANDARD VALUE 17 21 Measure resistance between the primary coil terminal and high tension cord...

Страница 179: ...esistance between the blue white and green white wire terminals Black white Ground 23 35 L Y B Y G GR G W B W G B V R V B V G G 11 22M 67 125K 11 22M 36 67K 110 200K 36 67K 36 67K 0 5 2K 67 125K 11 22...

Страница 180: ...MEMO...

Страница 181: ...18 0 STARTER SYSTEM BATTERY MAIN SWITCH STARTER MOTOR STOP SWITCH CABLE STARTER MOTOR STOP LAMP BATTERY CABLE...

Страница 182: ...engine cannot turn over The engine may not be turned over if the stop switch is faulty SPECIFICATION 18 SERVICE INFORMATION 18 1 TROUBLESHOOTING 18 2 STARTER MOTOR 18 3 STARTER MAGNETIC SWITCH 18 5 I...

Страница 183: ...at starter magnetic switch coupler Faulty starter magnetic switch Disconnect starter magnetic switch coupler and check the starter magnetic switch coil ground wire 17 7 Connect the starter magnetic s...

Страница 184: ...al powder between the seaments Check for continuity between pairs of the commutator segments and there should be continuity STARTER MOTOR Release the seat lock with the main key Remove the luggage box...

Страница 185: ...low Check the continuity between brush and cord terminal Normal if there is continuity Check the continuity between cord terminal and case Normal if there is no continuity Make a continuity check betw...

Страница 186: ...se with the groove on the front cover Tighten the starter motor case screws STARTER MAGNETIC SWITCH INSPECTION Check if the starter magnetic switch clicks when it is turned ON Clicks Poorly connected...

Страница 187: ...ery voltage between terminals when the yellow red wire is connected to the positive battery terminal and the green yellow wire to the negative battery terminal If there is continuity between battery a...

Страница 188: ...MEMO...

Страница 189: ...MEMO...

Страница 190: ...these tabs all the way until locked when assembling Carry out continuity test on circuits or parts to diagnose electric systems The continuity test on normal parts can be carried out without removing...

Страница 191: ...ove the headlight Disconnect the connector of handle switch Check for continuity between teminals Remove the Fr cover Remove the coupler wire Test each teminal of handle switch HEADLIGHT SWITCH RED WH...

Страница 192: ...s FUEL UNIT Remove the foor panel Be cover full not to be damaged for the wire Check the base packing for damage Measure the resistance between the fuel unit upper and lower BAT3 HI BLACK BLUE HI COLO...

Страница 193: ...voltage Start engine and if the temperature of heater controller unit is under 0 C Check if the white yellow wire of heater controller unit has output voltage If it has not any voltage it is damaged...

Страница 194: ...meter illumination taillight position light and license light turns on COOLANT TEMPERATURE GAUGE If the gauge needle indicates the red zone when idling or running turn the main switch OFF Wait until t...

Страница 195: ...e taillight bulb and winker bulb When replacing the bulb be sure not to put finger and contaminated gloves prints on the headlight bulb as they may create hot spots on the bulb and cause is to fail No...

Страница 196: ...dlight switch in mounted wiht the vehicle connect the white colored coupler only If hazard switch is mounted with the vehicle connect the black colored coupler only FUSE CAPACITY Fuse A 30A Charging c...

Страница 197: ...MEMO...

Страница 198: ...g 9P MINI O Gr B G Y G Y B BAT TRUNK LAMP FREE IGN BAT 2 2 OFF UNIT THERMO G L G Lg O Gr Br L G Y THERMO SW RELAY B G L B Lg R Sb G Y Br L Br Br L Y R P G Y MINI 6P Y R G Y R Br P Br L Br P Br L G G B...

Страница 199: ...MEMO...

Страница 200: ...SERVICEMANUAL 2004 9 PRINTED 2004 9 PUBLICATION NO COPY...

Страница 201: ...01E HEAD OFFICE FACTORY 58 SUNG SAN DONG CHANGWON KYUNGNAM KOREA TEL 82 55 239 7000 FAX 82 55 239 7524 OVERSEAS SALES OFFICE 13 5 SUNG SOO 1DONG 1GA SUNG DONG GU SEOUL KOREA TEL 82 2 498 6465 FAX 82 2...

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