User manual DAELIM S1 125 SERVICE MANUAL

[. . . ] How to use this manual 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. [. . . ] 4) Measure the voltage of intake pressure sensor for ECU check. Measuring the voltage of intake pressure sensor. 27(P/L:PINK/BLUE) ~ ECU No. 3(P/G : PINK/GREEN) Measuring voltage : 0. 1[V] ~ 4. 8[V] Remarks : Measuring unit of voltage : Voltage [V] The voltage of air pressure; 20[kPa]: 0. 719 ~ 0. 859[V] 107[kPa]: 4. 154 ~ 4. 294[V] 5) 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 broken or have short- circuited. Replace the MAPAT sensor with the new one and it rechecks. If measuring voltage is normal, Check the `P' electric wire, `P/G' electric wire, `P/L' electric wire to see if they have been broken or have short- circuited if there is a bad contact. If the electric wire is no problem, ECU is broken. Replace the ECU with the new one, it rechecks. 6) After repaired, refer to the fault code removal method to erase the memorized fault code in the ECU. Checking of the intake temperature sensor 1) If voltage value is normal, turn off ignition key. 2) Disassemble the MAPAT coupler and measure the resistance of intake temperature sensor. Resistance of intake pressure sensor : 2000±100[], 25±1 Measuring terminal : ECU No. 3(P/G : PINK/GROUND) Remarks : Measuring value for resistance : Resistance[ ] The Voltage of air pressure; 24 ~ 26[ ] : 1800~2200[ ] 99 ~ 101[ ] : 161~206[ ] 3) If measuring resistance is not normal, Replace the MAPAT sensor with new one and it rechecks. If the measured voltage is normal, Check the `P' electric wire, `P/G' electric wire, `P/L' electric wire to see if they have been broken or have short- circuited if there is a bad contact of terminal No. If the electric wire is no problem, ECU is broken. Replace the ECU with the new one, it rechecks. 5-16 EMS(Engine Management System) Checking of intake temperature sensor 4) Turn on the ignition key. 5) Measure the voltage of intake pressure sensor for ECU check. Measuring the voltage of intake pressure sensor - Measuring terminal: ECU No. 28(TBA) ~ ECU No. 3(IMP GROUND) - Measuring 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 broken or have short- circuited. Replace the MAPAT sensor with new one and it rechecks. If the measured voltage is normal, Check the `P' electric wire, `P/G' electric wire, `P/L' electric wire to see if they have been broken or have short- circuited if there is a bad contact of terminal No. If the electric wire is no problem, ECU is broken. Replace ECU with the new one, it rechecks. 7) After fault repaired, To erase the memorized fault code in the ECU is refer to how to remove the fault code(5-10). 8. TPS(THROTTLE POSITION SENSOR) It is Located on the right side of throttle body ! CAUTION Before disassembly, the key is off. Remove Lh. side cover Air cleaner TPS connector TPS screw Replace the TPS 5-17 EMS(Engine Management System) CHECKING THE TPS(Throttle Position Sensor) CIRCUIT DIAGRAM Fault code number displayed by MIL Checking circuit TPS ECU 4 : SENSOR GROUND 18 : 5V SUPPLY VOLTAGE 19 : TPS The coupler terminal is based on the side of wire-harness Checking Procedure 1) Turn off ignition key . 2) Check the TPS(Throttle Position Sensor) coupler is loose, or bad. [. . . ] Press the enter button on the vehicle diagnosis screen. Press the enter button on the current data. Check the engine rpm on the engine speed 5-45 MEMO FUEL SYSTEM / ENGINE 6 6 6 6 6 4 6-1 FUEL SYSTEM / ENGINE 6-2 FUEL SYSTEM / ENGINE 6-3 MEMO ENGINE REMOVAL/INSTALLATION 7 7-1 7-2 7 7-1 ENGINE REMOVAL/INSTALLATION DRAIN FRUG BOLT DRAIN FRUG BOLT DRAIN FRUG BOLT REAR BRAKE CALLIPER REAR BRAKE CALLIPER REAR BRAKE CALLIPER REAR SWING ARM REAR SWING ARM REAR SWING ARM MUFFLER MUFFLER MUFFLER MUFFLER REAR WHEEL REAR WHEEL REAR WHEEL REAR WHEEL RH / LH RADIATER HOSE RH // LH RADIATER HOSE RH LH RADIATER HOSE 7-2 ENGINE REMOVAL/INSTALLATION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION REAR CUSHION UNDER BOLT UNDER BOLT UNDER BOLT ENGINE HANGER BOLT ENGINE HANGER BOLT ENGINE HANGER BOLT 7-3 LH. CRANKCASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION LH. CRANK CASE COVER 8-0 LH. CRANKCASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION 8 8 8 8 8 8 8 8 8-1 LH. CRANKCASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION AIR CLEANER AIR CLEANER AIR CLEANER LH. COVER GASKET DRIVE FACE DRIVE FACE DRIVE FACE DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DOWEL PIN DOWEL PIN DOWEL PIN 8-2 LH. CRANKCASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION DRIVE FACE DRIVE FACE DRIVE FACE DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVE BELT DRIVE BELT DRIVE BELT DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVE BELT DRIVE BELT DRIVE BELT 8-3 LH. CRANKCASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY SUB ASS'Y SUB ASS'Y SUB ASS'Y DRIVE BELT DRIVE BELT DRIVE BELT DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY CLUTCH OUTER HOLE CLUTCH OUTER HOLE CLUTCH OUTER HOLE 8-4 LH. CRANKCASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION REAR AXCEL COLLAR REAR AXCEL COLLAR REAR AXCEL COLLAR MOVABLE DRIVE FACE MOVABLE DRIVE FACE MOVABLE DRIVE FACE DRIVE FACE BOSS DRIVE FACE BOSS DRIVE FACE BOSS 8-5 LH. CRANKCASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION 8-6 LH. CRANKCASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION DRIVE FACE DRIVE FACE DRIVE FACE DRIVE FACE REAR AXCEL COLLAR REAR AXCEL COLLAR REAR AXCEL COLLAR FLANGE NUT FLANGE NUT FLANGE NUT 8-7 LH. CRANKCASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY 8-8 LH. CRANKCASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION 8-9 LH. CRANKCASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION 8-10 LH. CRANKCASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION 8-11 LH. CRANKCASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION 8-12 LH. CRANKCASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVE BELR DRIVE BELR DRIVE BELR DRIVE FACE DRIVE FACE DRIVE FACE DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY 8-13 A. C GENERATOR / STARTER CLUTCH 9-0 A. C GENERATOR / STARTER CLUTCH 9 9 9 9 9 9 9 9 9-1 A. C GENERATOR / STARTER CLUTCH RH. SHROUD SETTING SCREW SETTING SCREW SETTING SCREW 9-2 A. C GENERATOR / STARTER CLUTCH CYLINDER HEAD COVER CYLINDER HEAD COVER CYLINDER HEAD COVER 9-3 A. C GENERATOR / STARTER CLUTCH 9-4 A. C GENERATOR / STARTER CLUTCH 9-5 A. C GENERATOR / STARTER CLUTCH 9-6 A. C GENERATOR / STARTER CLUTCH 9-7 A. C GENERATOR / STARTER CLUTCH 9-8 MEMO CYLINDER HEAD / VALVE INJECTOR ASSY ENGINE TEMP. SENSOR 10-0 CYLINDER HEAD / VALVE 10 10-1 10-2 10-3 10-5 10-6 10-6 10-7 10-8 10-11 10-13 10 10-1 CYLINDER HEAD / VALVE 10-2 CYLINDER HEAD / VALVE 10-3 CYLINDER HEAD / VALVE 10-4 CYLINDER HEAD / VALVE 10-5 CYLINDER HEAD / VALVE 10-6 CYLINDER HEAD / VALVE 10-7 CYLINDER HEAD / VALVE 10-8 CYLINDER HEAD / VALVE 10-9 CYLINDER HEAD / VALVE 10-10 CYLINDER HEAD / VALVE 10-11 CYLINDER HEAD / VALVE 10-12 CYLINDER HEAD / VALVE 10-13 CYLINDER HEAD / VALVE 10-14 CYLINDER HEAD / VALVE 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 FRONT WHEEL/FRONT FORK/STEERING/BRAKE 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 33. 914~33. 935mm 34~34. 039mm 25. 278~25. 328mm 25. 44~25. 41mm 24. 914~24. 935mm 25~25. 039mm 33. 87mm 34. 01mm 25. 27mm 25. 42mm 25. 27mm 25. 07mm 13-1 FRONT WHEEL/FRONT FORK/STEERING/BRAKE 13-2 FRONT WHEEL/FRONT FORK/STEERING/BRAKE FRONT UNDER COVER FRONT UNDER COVER FRONT UNDER COVER MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER HOLDER HOLDER HOLDER THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE THROTTLE CABLE U NUT U NUT U NUT 13-3 FRONT WHEEL/FRONT FORK/STEERING/BRAKE AXLE NUT AXLE NUT AXLE NUT AXLE NUT 13-4 FRONT WHEEL/FRONT FORK/STEERING/BRAKE DIAL GAUGE DIAL GAUGE DIAL GAUGE BEARING BEARING BEARING BEARING TURN TURN TURN BEARING BEARING BEARING 13-5 FRONT WHEEL/FRONT FORK/STEERING/BRAKE 13-6 FRONT WHEEL/FRONT FORK/STEERING/BRAKE SPEEDOMETER CABLE SPEEDOMETER CABLE SPEEDOMETER CABLE FRONT WHEEL AXLE FRONT WHEEL AXLE FRONT WHEEL AXLE MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER 13-7 FRONT WHEEL/FRONT FORK/STEERING/BRAKE 13-8 FRONT WHEEL/FRONT FORK/STEERING/BRAKE 13-9 FRONT WHEEL/FRONT FORK/STEERING/BRAKE BRAKE BLEEDER 13-10 FRONT WHEEL/FRONT FORK/STEERING/BRAKE 13-11 FRONT WHEEL/FRONT FORK/STEERING/BRAKE BRAKE CALIPER REMOVAL First drain the baeke fluid from the h¥draulic brake system. 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