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Manual Mecanico Daelim s1 125
Manual Mecanico Daelim s1 125
General
This manual explains how to maintain procedure for the S2-125 manufactured by DAELIM MOTOR CO., LTD. To ensure safety and optimal operating conditions of the vehicle, carry out regular inspections according to the maintenance schedule(Section 2). Sections 1 through 2 provide information on overall vehicle; section 3, assembly and disassembly procedures for external components, and section 4 describes maintenance procedure for the engine, frame and electrical systems. To facilitate use of this manual, each page starts with disassembly and system diagrams, each page starts with disassembly and system diagrams, service 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 reproduced without written permission of DAELIM Motor Co.,Ltd.,
Contents
Service Information Inspections / Adjustments External Parts Lubrication System EMS(Engine Management System)
Fuel System
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
A.C Generator / Starter Clutch Cylinder Head / Valves Cylinder Head / Piston
Transmission / Crank Shaft Crank Case Front Wheel / Front Fork / Steering / Brake Rear Wheel / Rear Brake / Suspension / Rear Swing Arm
Charging System Ignition System Starter System Lights / Switches / Horn Wiring diagram
SERVICE INFORMATION
1-1
SERVICE INFORMATION
1-2
SERVICE INFORMATION
1-3
SERVICE INFORMATION
1-4
SERVICE INFORMATION
1-5
SERVICE INFORMATION
1-6
SERVICE INFORMATION
1-7
SERVICE INFORMATION
1-8
SERVICE INFORMATION
1-9
SERVICE INFORMATION
60 1.75 2.25
13.8
380
ATDC
1-10
SERVICE INFORMATION
, 30A
1-11
SERVICE INFORMATION
1-12
SERVICE INFORMATION
1-13
SERVICE INFORMATION
Y
HEAD LIGHT
(COUPLER)
RR.BRAKE HOSE A RR. BRAKE HOSE PIPE FR.BRAKE HOSE C THROTTLE CABLE SEAT LOCK CABLE FUEL BREATHER TUBE FUEL SUPPLY TUBE LH. RADIATOR HOSE THROTTLE CABLE BREATHER TUBE
RADIATOR ASS'Y.
X
TRUNK LAMP COUPLER
IGNITION COIL EARTH CORD EARTH CABLE BATTERY + CABLE RR. BRAKE HOSE PIPE RADIATOR ASS'Y. MAIN WIRE HARNESS FUEL SUPPLY TUBE FUEL BREATHER TUBE CHARGE SOCKET COUPLER JUNCTION VALVE
1-14
FRAME EARTH
O2 SENSOR COUPLER
SERVICE INFORMATION
MAIN WIRE HARNESS FUEL BREATHER TUBE RR. BRAKE HOSE PIPE O2 SENSOR COUPLER FUEL HOSE(TO. INJECTOR) FUEL PUMP RELAY RR.BRAKE HOSE
SPEEDO METER ASS'Y A.P. WINKER RELAY LIGHTING S/W UNIT STARTER S/W UNIT DIMMER S/W UNIT WINKER S/W UNIT HORN S/W UNIT
RR. STOP SW. HAZARD S/W UNIT FR. STOP SW. THROTTLE CABLE SEAT LOCK CABLE HORN COMP. COMB. & LOCK SW.
HAZARD RELAY RR.BRAKE HOSE A
FR.BRAKE HOSE C
SPEEDOMETER CABLE
1-15
SERVICE INFORMATION
THROTTLE CABLE
JUNCTION VALVE
FR.BRAKE HOSE C
VIEW Y
RR.BRAKE HOSE A
THROTTLE CABLE
SPEEDOMETER CABLE
VIEW X
HORN COMP.
1-16
SERVICE INFORMATION
THROTTLE CABLE
RH/LH RADIATOR HOSE FUEL PUMP(TO. INJECTOR)
O2 SENSOR CORD
INJECTOR ISA MAPAT COUPLER ECU UNIT FRM.EARTH CORD THROTTLE CABLE
FUEL HOSE(TO. INJECTOR) BATTERY + CABLE START-MAGNET SW. ASS'Y. MAIN WIRE HARNESS
ACG. & CPS CORD BREATHER TUBE START MOTOR CABLE RR.BRAKE HOSE
TPS
VIEW Z
DETAIL OF SENSORS PART
1-17
MEMO
INSPECTIONS/ADJUSTMENTS
2-1
INSPECTIONS/ADJUSTMENTS
2-2
INSPECTIONS/ADJUSTMENTS
2-3
INSPECTIONS/ADJUSTMENTS
2-4
INSPECTIONS/ADJUSTMENTS
2-5
INSPECTIONS/ADJUSTMENTS
TIMINCT HOlLE CAP TIMINCT HOlLE CAP TIMINCT HOlLE CAP COOLING FAN COOLING FAN COOLING FAN
2-6
INSPECTIONS/ADJUSTMENTS
UPPER UPPER UPPER UPPER UPPER UPPER MIDDIE MIDDIE MIDDLE MIDDIE MIDDIE MIDDIE MIDDIE LOWER LOWER LOWER LOWER LOWER LOWER
DRIVE BELT DRIVE BELT DRIVE BELT DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY
2-7
INSPECTIONS/ADJUSTMENTS
0IL CUP CAP 0IL CUP CAP 0IL CUP CAP
BRAK FLUID
Remove the brake fluid cover. Check the oil level inside the front brake reservoir. If the oil level is near the lower limit line, remove the reservoir diaphrag mand fill DOT3 and DOT 4 brake fluid to the top limit line. If the brake fluid reaches the lower limit line, check the entire brake system for leaks.
BRAKE FLUID BRAKE FLUID BRAKE FLUID CHECK WINDOW CHECK WINDOW CHECK WINDOW
BRAKE PAD/SHOE
ROD MARK ROD MARK
BRAKE PAD
BRAKE PAD
BRAKE SYSTEM
Check the front brake hose for cracks or damage. If any leaks are found,replace immediately Check the brake rod for looseness or damage, and replace it if necessary.
REAR CALLIPE REAR CALLIPE REAR CALLIPE
FRONT CALLIPE FRONT CALLIPE FRONT CALLIPE FRONT BRAKE HOSE FRONT BRAKE HOSE FRONT BRAKE HOSE
2-8
INSPECTIONS/ADJUSTMENTS
2-9
INSPECTIONS/ADJUSTMENTS
TIRE PRESSURE GANGE TIRE PRESSURE GANGE TIRE PRESSURE GAUGE GANGE
2-10
EXTERNAL PARTS
3-1
EXTERNAL PARTS
TAPPING SCREN TAPPING SCREN TAPPING SCREN
FRONT COVER
Loosen the 4tapping screws securing the front cover
Loosen the tapping screw securing the front cover Disconnect the headlight wiring and winker 00wiring0right and left) ( Install in the reverse order of removal
SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW ERONT COVER FRONT COVER ERONT COVER ERONT
FRONT COVER
Disconnect the wire grommet Disconnect the front fender Install in the reverse order of removal
TNNER BOX TNNER BOX TNNER BOX FRONT UNDER COVER FRONT UNDER COVER FRONT UNDER COVER FRONT UNDER COVER
Remove - Front fender - Front wheel - The 4 tapping screw securing the underside of inner box - The 2 flange bolts and 2 special screw securing front under cover - The screw (right and left) securing the front side of floor side cover - Front under cover - Install in the reverse order of removal
3-2
EXTERNAL PARTS
Loosen the 5 tapping screw and remove the handle cover Loosen the 1 tapping screw securing front handle cover and 2 tapping screw securing rear handle cover Remove the front handle cover Install in the reverse order of removal
3-3
EXTERNAL PARTS
FLANGE NET FLANGE NET FLANGE NET
LUGGAGE BOX LUGGAGE BOX LUGGAGE BOX SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW
LUGGAGE BOX
Release the seat lock. Release the seat . Loosen the special screw and remove the battery cover.
CENTER COVER
Release the seat lock by turning the main key. Loosen the special screw. Remove the center cover. Install in the reverse order of removal.
3-4
EXTERNAL PARTS
REAR CARRIER
Loosen the washer bolt(4). Remove the rear carrier. Install in the reverse order of removal.
BODY COVER
UPPER UPPER HANDLE COVER HANDLE COVER
Loosen the 2 tapping screw securing RH/LH body side cover and 2 special screw
Loosen the body cover clip(R/L). Disconnect the rear winker wiring and the body cover opens with right and left and pull to backside and remove it. Install in the reverse order of removal
REAR FENDER
4WASHER BOLTS 4WASHER BOLTS 4WASHER BOLTS 4WASHER BOLTS
Remove - Luggage box. - Body cover. - Loosen the 4 washer bolts. - Rear fender. - Tail right wiring. Install in the reverse order of removal.
3-5
EXTERNAL PARTS
FLOOR SIDE COVER FLOOR SIDE COVER FLOOR SIDE COVER CENTER COVER CENTER COVER CENTER COVER FLOOR PANEL COVER FLOOR PANEL COVER FLOOR PANEL COVER
FLOOR PANER
Remove - Center cover. - Body cover. - Floor panel cap. - Floor side cover. - 4 washer bilts. - pull the floor panel backward to remove it. - Install in the reverse order of removal.
INTER BOX
TAPPING SCREN TAPPING SCREN TAPPING SCREN
FUEL CAP NECK FUEL CAP NECK FUEL CAP NECK FUEL SUPPLY TUBE FUEL SUPPLY TUBE FUEL SUPPLY TUBE
Remove - Front fender. - Front wheel. - Front under cover. - Floor side cover. - Floor panel. Loosen. - 4 tapping screw securing fuel cap neck.
3-6
EXTERNAL PARTS
CHARGE SOCKER CAP CHARGE SOCKER CAP CHARGE SOCKER CAP
Loosen the special screw securing back holder. Remove the charge socket cap by turing the socket cap to loosen the lock securing mainkey. Remove the inner box. Install in the reverse order of removal.
UNDER COVER
Remove the floor side cover. Loosen the special screw (R/L) and remove the under cover. Install in the reverse order of removal.
Loosen the brake hose clamp and washer bolt securing. Remove the air cleaner and washer bolt. securing mud guard. Remove the rear wheel mud guard. Install in the reverse order of removal.
SPEEDO METER
Remove - The speedometer. - Coupler and wire. - Rear handle cover.
3-7
EXTERNAL PARTS
3-8
LUBRICATION SYSTEM
4-1
LUBRICATION SYSTEM
4-2
LUBRICATION SYSTEM
OIL SIGHT GLASS OIL SIGHT GLASS OIL SIGHT GLASS
UPPER UPPER UPPER UPPER UPPER MIDDLE MIDDLE MIDDIE MIDDLE MIDDLE MIDDLE MIDDLE LOWER LOWER LOWER LOWER LOWER LOWER
OIL DRAIN PLUG BOLT OIL DRAIN PLUG BOLT OIL DRAIN PLUG BOLT
TAPPER ADJUST HOLE CAP TAPPER ADJUST HOLE CAP TAPPER ADJUST HOLE CAP
TAPPER ADJUST HOLE CAP TAPPER ADJUST HOLE CAP TAPPER ADJUST HOLE CAP
4-3
LUBRICATION SYSTEM
FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS
OIL FILTER ELEMENT OIL FILTER ELEMENT OIL FILTER ELEMENT OIL SEAL OIL SEAL OIL SEAL
START DRIVEN GEAR START DRIVEN GEAR START DRIVEN GEAR OIL PUMP OIL PUMP OIL PUMP
4-4
LUBRICATIONSERVICE SYSTEM
4-5
LUBRICATION SYSTEM
OUTER ROTOR OUTER ROTOR OUTER ROTOR INNER ROTOR INNER ROTOR INNER ROTOR
4-6
LUBRICATION SYSTEM
4-7
LUBRICATION SYSTEM
RADIATOR RADIATOR RADIATOR
4-8
LUBRICATION SYSTEM
BAG HOLDER
MUFFLER
TIRE
PILLION STEP
4-9
MEMO
5-1
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. otherwise, it might be damage to ECU.
Do not connect adversely the polarity of battery. otherwise, It may be broken the EMS parts
While engine operating, do not disassembly the battery terminal. otherwise, it might cause damaged the EMS parts.
5-2
2) FUEL SYSTEM
As a system to supply required fuel for consumption in engine combustion chamber from fuel tank to injector, this Fuel system is composed of fuel tank, fuel pump, fuel filter, fuel pressure regulator, division pipe 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 about the pressure of intake system. Injector sprays fuel into the intake system by injection signals of ECU.
3) IGNITION SYSTEM
The ignition system is composed of spark plug which makes ignition spark, a spark timing control part to control proper spark time in cylinder, high-voltage system, and so forth.
4) CONTROL SYSTEM
Various sensors to move electric signals converted by checking the current engine status Input interface which works various processes like regulating voltage levels, removal of noise, A/D conversion, amplifying of inputted signals from above sensors. Micro-computer which decides output value through various calculating, arithmetic and logic processing. Output interface to amplify the above output signals. Actuator being mechanically worked by receiving the amplified output signals.
5-3
Remarks
ECU PIN NO. 6,7,8,11,13,14,15,16,21,29,32,36,38 were not connected.
5-4
MIL OFF
Starting and driving are temporary
ON
Unable
Remarks 1
If the EMS has some problem and the MIL on and off, engine starting and driving are temporary by the EMSs fail safe function. But the EMS is not normal condition, so check the vehicle and repair soonest.
Remarks 2
It might not be able to starting and driving when following problems happen. - Crankposition sensor - Injector - Fuel pump
The MIL on and blink(when this function detects a malfunction in the system)
MIL
ON Blink
MIL on continuously, when the engine operating MIL blinks, when the main key is turn on (engine is stop)
5-5
If there is something wrong in the EMS, it has fail safe function in order for engine to work and to cover a minimum driving of vehicle.
intake intake
INTAKE
The value of intake pressure is fixed as the pressure just before when the intake pressure sensor is out of order. The value of intake temperature is fixed as a temperature just before when the intake pressure sensor is out of order.
INTAKE
CAUTION
If the MIL on and blink, starting and driving are temporary by fail safe function, but, because the conditions of engine operation are not perfect, this can be used in an urgent case. In this case, safe repairing of vehicle shall be required.
5-6
The diagnostic Tool. The wireharness to check the ECU This wireharness is connected with the ECU and main wireharness It has two couplers to check the terminals. First coupler) ECU no.1~20 Second coupler) ECU no.21~40 Arrangement of ECU PIN First coupler) ECU no.1,2,3,4,5,9,10,12,17,18,19,20 were connected Second coupler) ECU no.36,38 were not connected
5-7
CAUTION
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 been driven and engine not started
ON
If many problems will happened in the EMS parts at the same time only one fault code is displayed by the priority, however, the ECU is remembers all the fault codes. After revise the code, remove the memorized fault code by the method of warm up.(5-10) (Refer to remove the fault codes) When the vehicle is checked using the diagnosis tool. - If the vehicle is check using the malfunction diagnosis tool, all fault code check is possible.
5-8
No failure
5-10
6.INJECTOR
Remove
Connector Connector bolt Injector and injector cap. Replace the injector
CAUTION
NOTICE
Make sure that dust does not enter the throttle body insulator.
5-11
Checking Circuit
ECU 40 : INJECTOR control 39 : FUEL PUMP control
INJECTOR
5-12
5-13
ISA ISA
CAUTION
Remove
MAPAT connector (Push by hand and pull to the front-side) Loosen the flange bolt 2EA.
CAUTION
5-14
Checking circuit
MAPAT
ECU
3 : Intake pressure sensorpressure ground 3 : Inhalation 26 : sensor GROUND 5V voltage 27 : 26 : 5V voltage IMP 28 : TBA 27 : IMP 28 : TBA Coupler terminal is based on the side of wire-harness
Checking Procedure
1) Turn off the ignition key . 2) Check to see if the MAPAT coupler has come loose or the wire is peeling off. If there is normal, measured the input voltage of MAPATs coupler. 3) Disassemble the coupler of MAPAT and turn on the ignition key 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 voltage : voltage [V] If voltage value is not normal, Check to see if the ECU coupler is loose or if there is a bad contact. Check the P electric wire, P/G electric wire, P/L to see if they have been broken short-circuited Remark : refer to (5-16) if the intake pressure sensor is broken refer to (5-16) if the intake temperature sensor is broken 5)After fault repaired, To erase the memorized fault code in the ECU is refer to how to remove the fault code(5-10).
5-15
5-16
CAUTION
Remove
Lh.side cover Air cleaner TPS connector TPS screw Replace the TPS
5-17
Checking circuit
TPS
ECU
Checking Procedure
1) Turn off ignition key . 2) Check the TPS(Throttle Position Sensor) coupler is loose, or bad. If there is no defect, measure the input voltage of TPS. 3) Disassemble the TPS coupler 4) Turn on the IGNITION 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 TPSs coupler. Measuring voltage : 4.5[V] ~ 5.5[V] Remarks : Measuring unit of voltage : voltage [V] If voltage value is not normal, Check to see if the ECU coupler is loose if there is bad contact. Check the GR/B electric wire, W/R electric wire, GR /L electric wire to see if they have been broken or have short- circuited. 5) If the value of voltage is normal, turn off the ignition key.
5-18
5-19
CAUTION
PUSH PUSH
Remove
Rh.shroud comp Connector by hand ETS Replace the ETS
PULL PULL
CAUTION
ETS torque:30.3[kgf m]
5-20
CHECKING CIRCUIT
ETS
ECU
Checking Procedure
1) Turn off the ignition key . 2) Check the ETS(Throttle Position Sensor) coupler is loose, or bad. If there is no defect, measure the input voltage of ETS. 3) Disassemble the coupler of ETS 4) Turn on ignition key. Measuring terminal : ECU No. 20 (Gr/L: GREEN/BLUE) ~ ECU No.4 (W/R : WHITE/RED) Measure the terminal voltage of ETSs 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 see if the ECU coupler is loose if there is bad contact. Check the G/L electric wire, W/R electric wire, W/R electric wire to see if they have been broken or have short- circuited. 5) If the voltage value is normal, turn off the ignition key. 6) Disassemble the coupler of ETS, and measure the resistance of ETS. Resistance of ETS :1.6[k ]~10.6[k ],20 ~80 Measuring terminal : Each terminal of ETS Remarks : Measuring unit for resistance : Resistance R [k ]
5-21
Checking Procedure
1) Disassembly Disassemble the ETS(Engine Temperature Sensor) : (Refer to 4-20) 2) Check 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 temperatures change and testers value. Characters of ETS
Temperature 20 80 110
Measuring unit of resistance : Resistance R [k ] If the value of resistance is high or out of the standard value, replace the ETS with the new one.
CAUTION
1)Be careful do not fell down the ETS, because its weakness. 2)Be careful the ETS and the thermometer do not to touched to oil bowl. 3)Be careful oil temperature will not raised more than measurement temperature. 3) Install Install in the reverse order of removal with standard torqve.
5-22
Remove
SEAT Maintenance cover ISA connector
O-Ring O-Ring
5-23
CHECKING CIRCUIT
ECU
33 : ISA CONTROL 39:FUEL PUMP
ISA
CHECK PROCEDURE
1) Turn off ignition key . 2) Check the ISA(Throttle Position Sensor) coupler is loose, or bad. If there is no defect, measure the input voltage of ISA 3) Disassemble the coupler of 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 between each terminal, and between each ground. Resistance between each terminal , and between each ground : [ ] If measure resistance value is not normal, replace with the new one Disassembly and Assembly : refer to ( 5-23 ) remarks : Measuring unit for resistance : Resistance R[ ]
5-24
5-25
11.O2(Oxygen) SENSOR
Located on the exhaust pipe
CAUTION
Remove
O2 Sensor O2 Sensor O2 Sensor O2 Sensor
Warning
5-26
CHECKING CIRCUIT
OXYGEN SENSOR
ECU
5-27
5-28
CHECKING CIRCUIT
ECU 24 : MALFUNCTION INDICATOR LAMP OUTPUT
CHECK PROCEDURE
1) Turn off ignition key. 2) Check the ESS coupler is loose, or bad. If there is no problem. 3) Turn on the ignition key. 4) Check the MIL on for 3 seconds when turn on the ignition key at the same time. If there is no lighting, check the lamp. But If the lamp is working for 3 second, 5) Measure the MIL voltage of wire harness to check ECU. Measuring terminal : B electric wire ~ EARTH => Output voltage: battery voltage 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, Check the L/B electric wire, B electric wire, Br/L electric wire to see if they have been broken or have short- circuited if there is a bad contact of terminal No. 24 of ECU coupler. If there is no problem in wires, ECU has is broken. Replace the ECU with new one, and rechecks it. If the measured voltage is abnormal, Check the L/B electric wire, B electric wire, Br/L electric wire to see if they have been broken or have short- circuited. 6) After fault repaired, To erase the memorized fault code in the ECU is refer to how to remove the fault code(5-10)
5-29
CAUTION
Remove
Body cover Connector (A display portion is pulled behind) Flange bolt 4 EA Replace the ECU
CAUTION
5-30
14.IGNITION COIL
Locate on the RH.body cover
CAUTION
Be sure to check the engine is cooling. because a little gasoline remains, it is still hot.
Remove
SEAT Body cover Ignition coil -Connector -Spark plug cap -Ignition coil bolt 2EA -Ignition coil
CAUTION
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.
5-31
CAUTION
Remove
Connector - CPS connector(BLUE, LIGHT GREEN) - ACG connector(YELLOW) RH.shroud Cooling fan Flywheel Stator CPS screw Replace the CPS
5-32
16.FUEL PUMP
Located below the floor panel
!
CAUTION
Remove
Fuel pump nut 4EA Replace the fuel pump injector cap
NOTICE
Do not push the fuel pump base under the fuel tank when the fuel tank 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 sealing washers when the fuel hose banjo bolt is removed or loosened.
5-33
16.FUEL PUMP
The terminal arrangement of the fuel pump (The following color chart is the internal color of the fuel pump)
5-34
The float position is based on the tank bottom plate after 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 standard at float position, replace the fuel unit.
5-35
17.THROTTLE BODY
ISA ISA
MAPAT
TPS
5-36
CAUTION
Do not disconnect both the throttle adjust screw and adjusting nut
CAUTION
MAPAT MAPAT
5-37
CAUTION
5-38
CAUTION
CAUTION
Replace the gasket with new one. The assembled insulator and throttle body assemble to cylinder head. Torque : 1.2 kgf m
CAUTION
Be sure to the value of TPS is whether the standard value after it became assembly. Check the MAPAT sensor ( -14)
5-39
SUPPLEMENT
ADJUSTMENT OF THROTTLE ADJUST SCREW A vehicle is assembled in the state which engine operation is possible. Loosen the maintenance cover and the adjust-screw is makes possible to adjust. The coupler to check the malfunction of vehicle is connected to the coupler of diagnostic tool. Turn on the ignition key. Press the power-button of diagnostic tool.
!
CAUTION
The ECU is always initialized, before the engine is starting. The vehicle is warms up enough to adjust the idling speed.
CAUTION
By adjusting the throttle adjust screw. Adjust the value of ISA PWM to standard value, among the service data of diagnostic tool. ISA PWM : 12 2%, 1600 100RPM After the ISA PWM became adjusted, fix the throttle adjust screw with adjusting nut.
5-40
5-41
When the ECU was initialized. turn off the lgnition key and then turn on the ignition key.
5-42
By looking the displayed figure on the ISA PWM, adjust the throttle adjust screw.
5-43
5-44
5-45
MEMO
6
6
6
6-1
6-2
6-3
MEMO
ENGINE REMOVAL/INSTALLATION
7
7-1 7-2
7-1
ENGINE REMOVAL/INSTALLATION
REAR SWING ARM REAR SWING ARM REAR SWING ARM MUFFLER MUFFLER MUFFLER MUFFLER
7-2
ENGINE REMOVAL/INSTALLATION
REAR CUSHION REAR CUSHION REAR CUSHION
REAR CUSHION REAR CUSHION REAR CUSHION UNDER BOLT UNDER BOLT UNDER BOLT
7-3
8-0
8
8 8 8 8 8 8
8-1
LH. CRANK CASE COVER LH. CRANK CASE COVER LH. LH. CRANK CASE COVER
8-2
8-3
DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY SUB ASSY SUB ASSY SUB ASSY
DRIVE BELT DRIVE BELT DRIVE BELT DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY
8-4
MOVABLE DRIVE FACE MOVABLE DRIVE FACE MOVABLE DRIVE FACE DRIVE FACE BOSS DRIVE FACE BOSS DRIVE FACE BOSS
8-5
8-6
8-7
8-8
8-9
8-10
8-11
8-12
8-13
9-0
9
9 9 9 9 9 9
9-1
LH. SHROUD LH. SHROUD LH. SHROUD SETTING SCREW SETTING SCREW SETTING SCREW
9-2
9-3
9-4
9-5
9-6
9-7
9-8
MEMO
INJECTOR ASSY
ENGINE TEMP.SENSOR
10-0
10
10-1 10-2 10-3 10-5 10-6 10-6 10-7 10-8 10-11 10-13
10
10-1
10-2
10-3
10-4
10-5
10-6
10-7
10-8
10-9
10-10
10-11
10-12
10-13
10-14
throttle body
10-15
CYLINDER/PISTON
11-0
11
11-1 11-1 11-2 11-3 11-5
11
11-1
CYLINDER/PISTON
11-2
CYLINDER/PISTON
11-3
CYLINDER/PISTON
11-4
CYLINDER/PISTON
11-5
CYLINDER/PISTON
11-6
MEMO
TRANSMISSION/CRANKSHAFT/CRANKCASE
12-0
TRANSMISSION/CRANKSHAFT/CRANKCASE
12
12-1 12-2 12-3 12-6 12-7 12-8 12-9 12-10
12
12-1
TRANSMISSION/CRANKSHAFT/CRANKCASE
12-2
TRANSMISSION/CRANKSHAFT/CRANKCASE
12-3
TRANSMISSION/CRANKSHAFT/CRANKCASE
12-4
TRANSMISSION/CRANKSHAFT/CRANKCASE
12-5
TRANSMISSION/CRANKSHAFT/CRANKCASE
12-6
TRANSMISSION/CRANKSHAFT/CRANKCASE
12-7
TRANSMISSION/CRANKSHAFT/CRANKCASE
12-8
TRANSMISSION/CRANKSHAFT/CRANKCASE
12-9
TRANSMISSION/CRANKSHAFT/CRANKCASE
12-10
MEMO
13-0
13
13-1 13-2 13-3 13-4 13-5 13-6 13-7 13-7 13-10 13-12 13-14 13-19
13
FRONT FRONT REAR REAR FRONT COMBI BRAKE CALIPER PISTON O.D FRONT COMBI BRAKE CALIPER CYLINDER I.D
13-1
13-2
13-3
13-4
13-5
13-6
13-7
13-8
13-9
BRAKE BLEEDER
13-10
13-11
BRAKE CALIPER
REMOVAL
First drain the baeke fluid from the hdraulic brake system. Remove the brake fluid tube bolt. Remove the two bolts attaching the brake caliper. Remove the brake caliper.
DISASSEMBLY
REmove the two brake pads dowelpins and three bolts from the brake caliper. Remove the brake pads.
Remove the piston from the brake caliper. If necessary, use compressed air to squeeze out the piston through the brake fluid inlet opening 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.
!
WARNING
Push the piston oil seal outward to remove it. Clean the oil seal groove with brake fluid.
13-12
Check the caliper cylider for scratches or wear and measure the cylinder bore. Top service limit : 27.05mm Under service limit:34.01mm
ASSEMBLY
Clean all removed parts. Apply silicon grease to the psiton and oil seal. Lubricate the brake caliper cylinder inside wall with brake fluid. Install the brake caliper piston with grooved side facing out. Install the piston with its outer end protruding 3~5mm beyond the brake caliper. Wipe off excessive brake fluid with a clean shop towel. Appiy silicon grease 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 When installing the brake caliper. be sure to position the brake disk betwee the two brake pads.
Piston Oil Seal Piston Oil Seal Piston Oil Seal
13-13
13-14
13-15
13-16
13-17
13-18
13-19
13-20
MEMO
14-0
14
14-1 14-2 14-3 14-5 14-7 14-7
14
14-1
14-2
14-3
14-4
REAR SWING ARM REAR SWING ARM REAR SWING ARM REAR AXLE NUT REAR AXLE NUT REAR AXLE NUT NUT
14-5
14-6
REAR CUSHION COMP REAR CUSHION COMP REAR REAR CUSHION COMP
14-7
14-8
MEMO
CHARGING SYSTEM
C.D.I UNIT
REGULATOR RECTIFIER
IGNITION COIL
BATTERY
MAIN KEY
A.C GENERATOR
15A
15-0
15
15-1 15-2 15-2 15-3 15-4 15-5
15
15-1
CHARGING SYSTEM
13.5V
14~15V 14~15V
15-2
CHARGING SYSTEM
15-3
CHARGING SYSTEM
15-4
CHARGING SYSTEM
15-5
MEMO
16
16-1 16-3 16-4 16-5 16-6 16-6
0.730.08(235) (15K)
80~150
16
16-1
IGNITION SYSTEM
16-2
IGNITION SYSTEM
pulser
pulser
16-3
IGNITION SYSTEM
The secondary coil resistance might not measure cause by the high voltage diode inside the ignition coil.
16-4
IGNITION SYSTEM
16-5
STARTER SYSTEM
17-0
17
17-1 17-2 17-3 17-4 17-7
17
17-1
STARTER SYSTEM
17-2
STARTER SYSTEM
STARTER MOTOR STARTER MOTOR STARTER MOTOR STARTER MOTOR CABLE STARTER MOTOR CABLE STARTER MOTOR CABLE
17-3
STARTER SYSTEM
17-4
STARTER SYSTEM
17-5
STARTER SYSTEM
17-6
STARTER SYSTEM
17-7
MEMO
18
18-1 18-1 18-2 18-2 18-3 18-3 18-4 18-4 18-4
18
18-1
LIGHTS/SWITCH/HORN
BAT 1 COLOR
BAT 2
Br/W P
GRAY
18-2
LIGHTS/SWITCH/HORN
18-3
LIGHTS/SWITCH/HORN
HEADLIGHT COUPLER HEADLIGHT COUPLER HEADLIGHT COUPLER
TAIL & STOP BULB TAIL & STOP BULB TAIL & STOP BULB TAIL & STOP BULB
18-4
MEMO
MEMO
19
19-1
SERVICE MANUAL
2007. 04 PRINTED 2007. 04 PUBLICATION
NO COPY
HEAD OFFICE(FACTORY) #58, SUNG SAN-DONG, CHANG WON, KYUNGNAM, KOREA TEL: (82-55) 239-7000 / FAX: (82-2) 467-9997