User manual DAELIM NS125DLX SERVICE MANUAL

[. . . ] SERVICE MANUAL Engine How to use this manual This manual describes effective maintenance procedure for the NS125DLX 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 3). Sections 1 through 3 provide information on overall vehicle; section 4, assembly and disassembly procedures for external components, and section 5 describes maintenance procedure for the engine, frame and electrical systems. To facilitate use of this manual, each page starts with disassembly and system diagrams, service information, and troubleshooting guide. [. . . ] Check parts after disassembling, and clean and dry with an air hose prior to taking measurements. Specifications Item Inner diameter Cylinder Cylindricality Out of roundness Head contact warpage Piston skirt outer diameter Piston pin hole inner diameter Piston, Piston pin, Piston ring Piston pin outer diameter Piston-to-piston pin clearance Piston ring-to groove clearance Piston ring joint gap Cylinder-to piston clearance Connecting rod small end inner diameter Gap between connecting rod small end and piston pin Top Second Top/second Oil(side rail) Unit: mm(in) Standard value 56. 000-56. 010(2. 2047-2. 2051) 55. 925-55. 945(2. 2018-2. 2026) 15. 002-15. 008(0. 5906-0. 5909) 14. 994-15. 000(0. 5903-0. 5906) 0. 002-0. 140(0. 0001-0. 0006) 0. 040-0. 057(0. 0016-0. 0026) 0. 025-0. 052(0. 0010-0. 020) 0. 10-0. 25(0. 004-0. 010) 0. 20-0. 70(0. 008-0. 028) 0. 055-0. 085(0. 0022-0. 0033) 15. 010-15. 028(0. 5909-0. 5917) 0. 010-0. 034(0. 004-0. 0013) Service limit 56. 100(2. 2087) 0. 050(0. 002) 0. 005(0. 0002) 0. 020(0. 0008) 54. 832(2. 1587) 15. 038(0. 5920) 14. 960(0. 5890) 0. 020(0. 0008) 0. 110(0. 0043) 0. 080(0. 0031) 0. 50(0. 020) 1. 10(0. 040) 0. 340(0. 0134) 15. 060(0. 5930) 0. 040(0. 0020) 10 Troubleshooting Compression low Worn cylinder or piston rings Leaking valve seats Overheating Excessive carbon build-up on the piston combustion Incorrect spark plug Excessive smoke Worn cylinder or piston Improper installation of piston rings Scored or scratched piston or cylinder wall Knocking or abnormal noise Worn piston and cylinder Excessive carbon build-up Low octane fuel 10-1 Cylinder/Piston Cylinder Removal Remove the cylinder head. ( 9-5) Remove the cam chain guide from the cylinder. Remove the cylinder. Cam chain guide Remove the gasket and dowel pin. Remove the gasket residues attached to the cylinder. NOTE ·Take precautions not to damage the gasket. Gasket Inspection Measure, and record, the cylinder inner diameter from the 6 top, middle and bottom places in the piston direction and the perpendicular axial (X and Y direction) direction. The maximum value shall be the cylinder inner diameter. Service limit: 56. 100mm(2. 2087in) Measure the piston outer diameter. Subtract the piston outer diameter value from the cylinder inner diameter value, and measure the clearance between the cylinder and piston. Service limit: 0. 340mm(0. 0134in) Based on each measured value, calculate the out of roundness (difference between X direction and Y direction) and cylindericality (Difference of top, middle and bottem inner diameter in the direction of X or Y). Service limit: Out of roundness 0. 005mm(0. 0002in) Cylindricality 0. 05mm(0. 002in) Cylinder gauge Top Middle Bottom 10-2 Cylinder/Piston Check the cylinder distortion. Service limit: 0. 02mm (0. 0008in) Piston Disassembly Remove the piston pin clip NOTE Piston Piston pin ·Take precautions not to drop the piston pin clip into the crank case. Remove the piston pin, and separate piston. Check the piston ring. NOTE ·Be careful not to damage the piston with the piston ring while removing the ring. Check the clearance between the piston ring and groove. Service limit: Top 0. 110mm(0. 0043in) Second 0. 080mm (0. 003in) Oil 0. 280mm(0. 0110in) Check the piston for wear or damage. Piston ring 10-3 Cylinder/Piston Insert the piston ring into the inside of the cylinder, and check the piston ring clearance. NOTE ·Use the piston head to insert the piston ring so that the piston can be level. Service limit: Top/second 0. 50mm (0. 020in) Oil (side rail) 1. 10mm (0. 040in) Feeler gauge Measure the piston outer diameter at a point 10mm from the piston bottom in the direction of 90 the piston pin to Service limit: 55. 82mm (2. 198in) Measure the inner diameter of the piston pin hole. Service limit: 15. 038mm (0. 5920in) Measure the outer diameter of the piston pin. Service limit: 14. 960mm (0. 5890in) Check the clearance between the piston and piston pin. Service limit: 0. 020mm (0. 00008in) Measure the inner diameter of the connecting rod small end. Service limit: 15. 060mm (0. 5930in) Check the clearance between inner diameter of the connecting rod small end and the piston pin. Service limit: 0. 040mm (0. 0020in) 10-4 Cylinder/Piston Piston/Cylinder Assembly Piston Ring Assembly Clean the piston ring groove with oil, and assemble the piston ring. Take necessary precautions not to break it, and not to damage the piston during assembly. [. . . ] Poor braking 20-5 Troubleshooting Fuel Gauge Gauge Reading Inaccurate (Ignition switch ON) 1. Operate the turn signal to check the battery circuit. Signal operates satisfactorily Signal continuously operates dim or does not operate at all Cause of Trouble (1) Fuse cut (2) Battery weak or totally discharged (3) Faulty ignition switch (4) Faulty terminal connection (5) Wire harness damaged (1) Faulty float 2. Remove the fuel level sensor, and move float to check the status of operation Float up : Full position Float down : Empty position Needle not moving 3. [. . . ]