User manual DAELIM SJ50 SERVICE MANUAL

[. . . ] HOW TO USE THIS MANUAL This manual describes effective maintenance procedure for the S-Five 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, service information, and troubleshooting guide. [. . . ] ·Do not align the clip's end gap with the piston cutout. CYLINDER/ CYLINDER HEAD INSTALLATION Coat the cylinder wall and piston ring with clean engine oil and install the cylinder. CYLINDER HEAD NOTE ·Be careful not to damage the piston ring. Install the cylinder head. 8-7 TRANSMISSION/CRANKSHAFT/CRANKCASE 9-0 9. TRANSMISSION/CRANKSHAFT/CRANKCASE SERVICE INFORMATION TROUBLESHOOTING TRANSMISSION 9-1 9-1 9-2 CRANKSHAFT REMOVAL 9-5 CRANKCASE BEARING REMOVAL 9-6 CRANKSHAFT INSTALLATION 9-7 SERVICE INFORMATION GENERAL SAFETY This section describes how to remove the crank case and to maintain the transmission and the crankshaft. Always use special tools to change the drive shaft. Fix the bearing inner race, andn install the shaft. The following parts must be removed prior to removing the crank case. Follow the removal procedure specified in each section. -OIL PUMP ( SECTION 4 ) -CARBURETOR ( SECTION 5 ) -ENGINE ( SECTION 6 ) -CYLINDER HEAD/ CYLINDER/ PISTON ( SECTION 8 ) -AC GENERATOR ( SECTION 13 ) -DRIVE PULLEY ( SECTION 7 ) -CLUTCH/DRIVEN PULLEY ( SECTION 7 ) -REED VALVE ( SECTION 5 ) The following parts must be removed prior to changing the L. Follow the removal procedure specified in each section. -TRANSMISSION ( SECTION 9 ) -REAR BRAKE ( SECTION 12 ) To assemble the crank case and crankshaft, set the special tool to the inner race of the crankshaft bearing, and push and assemble. Remove the bearing from the crankshaft during disassembling work, and insert a new bearing in the case. Install the oil seal after the case is assembled. 9 SPECIFICATIONS ITEM STANDARD VALUE SERVICE LIMIT Large end side clearance CRANK SHAFT Connecting rod large end right angle direction clearance Crank shaft shaking Right Left 0. 15~0. 55mm 0. 010~0. 02mm 0. 03mm 0. 05mm 0. 60mm 0. 04mm 0. 15mm 0. 10mm TROUBLESHOOTING Engine Noise Clearance in the connecting rod large end portion/small end portion bearing. Clearance in the crankshaft bearing. 9-1 TRANSMISSION/CRANKSHAFT/CRANKCASE TRANSMISSION DISASSEMBLY Remove the L. ( 7-2 ) Remove the continuously variable transmission. ( SECTION 7 ) Remove the exhaust muffler. ( 11-3) Install the oil sump under the cover of transmission. Loosen the 6 transmission cover flange bolts. Remove the drive shaft from the transmission cover by using a hydraulic press. NOTE ·Take precautions not to damage the cover joints. Remove the oil seal of the drive shaft. Remove the final shaft gear. Remove the side washer. INSPECTION Inspect the drive shaft for wear or damage. 9-2 TRANSMISSION/CRANKSHAFT/CRANKCASE Inspect the final shaft for wear or damage. Inspect the countershaft for wear or damage. Bearing Inspection Manually turn the bearing inner race installed inside the transmission cover, and check if the race is turning smoothly. Verify the outer race is accurately installed in the case. Replace the bearing, if necessary. NOTE ·Install the bearing with the carved mark directing to the outside. Use special tools to push in the bearing into the case. TOOLS : DRIVER HANDLE A OUTER DRIVER 52X55mm DRIVER PILOT 20mm Check the L. [. . . ] (1) Faulty fuel level sensor connection. Signal continuously operates dim or does not operate at all. 2. Remove the tank and operate the float. Needle moving. Needle not moving. 3. One up/down motion per second. Needle moving. Needle not moving. (1) Damper oil inside the meter insufficient. 4. Start the engine, and measure the fuel level sensor resistance. Resistance not changed. Resistance changed significantly. (1) Faulty connection between the sliding arm and the resistance. 5. [. . . ]