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. [. . . ] 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. Do not match the oil ring side rail ends with each other. Side rail R Mark Top ring Second ring Spacer 20mm(3/4in) Oil ring Side rail After assembling, verify the ring is rotating smoothly. Top ring Second ring Piston/Cylinder Assembly Remove the gasket from the crank case. · Place a piece of cloth over the crank case to prevent the gasket from falling into the crank case. 10-5 Cylinder/Piston Assemble the piston, and piston pin to the connecting rod. NOTE ·Let the "IN" mark face towards the intake valve side. ·Place a piece of cloth over the crank case to prevent the piston pin clips from falling into the crank case. ·Make sure the piston pin clip joint is not aligned with the piston groove. Assemble new gaskets and dowel pins. Gasket Dowel pin Piston pin Piston Apply engine oil to the cylinder inside and the piston ring, and assemble the piston ring. ·Take precautions to prevent the cam chain from falling into the crank case. Cam chain Cylinder Assemble the lower part of the cam chain guide to the crank case lost, and install the cam chain guide by aligning the tangs with the cylinder slots. ( 9) Cam chain guide 10-6 MEMO Transmission/Crankshaft/Crank Case R. Crank Case L. Crank Case Crankshaft 11-0 Transmission/Crankshaft/Crank Case 11. Transmission/Crankshaft/Crank Case Service Information Troubleshooting Transmission Crank Case Disassembly 11-1 11-2 11-3 11-6 Crankshaft Disassembly Crankshaft Bearing Crankshaft Assembly Crank Case Assembly 11-7 11-8 11-9 11-10 Service Information General Safety This section describes how to remove the crank case and to maintain the transmission and the crankshaft. crank case, remove the engine and disassemble the rear brake prior to changing the L. [. . . ] Fuel flows Insufficient fuel supply (1) Fuel tank empty (2) Fuel tube or fuel filter clogged (3) Fuel tank cap air hole clogged 3. Not clogged Clogged (1) Clean 20-3 Troubleshooting Unsatisfactory Operation Clutch Drive/Driven Pulley 1. Engine starts but motorcycle does not move. Cause of Trouble (1) Drive belt worn or slips (2) Ramp plate damaged (3) Drive face spring damaged (4) Clutch lining came off (5) Driven pulley shaft spline damaged (6) Faulty transmission (7) Transmission seized (1) Shoe spring damaged (2) Clutch outer and weight seized (3) Pivot seized (1) Drive belt worn or slips (2) Weight roller worn (3) Drive pulley bearing seized (4) Weak drive face spring (5) Drive pulley bearing worn or seized (1) Drive belt worn or slips (2) Weight roller worn (3) Drive pulley bearing worn (1) Oil or grease spilled on the drive belt and inside pulley (2) Drive belt worn (3) Weak drive face spring (4) Driven pulley bearing worn or seized Check tire pressure 2. Steering is heavy Cause of Trouble (1) Steering head adjuster excessively tightened (2) Steering cone race or steel ball damaged (1) Excessive wheel bearing play (2) Rim bent (3) Axle nut loose (1) Front wheel and rear wheel not aligned (2) Front fork bent Check tire pressure 2. [. . . ]