User manual DAELIM NS125III SERVICE MANUAL

[. . . ] SERVICE MANUAL SERVICE MANUAL HEAD OFFICE (FACTORY) #58, SUNG SAN-DONG, CHANGWON, KYUNGNAM, KOREA TEL : (82-55) 239-7000 / FAX : (82-55) 239-7524 OVERSEAS SALES OFFICE #13-5, SUNG SOO 1DONG 1GA, SUNG DONG GU, SEOUL, KOREA TEL : (82-2) 498-6465 / FAX : (82-2) 467-9997 SM37-0211-01E Engine How to use this manual This manual describes effective maintenance procedure for the NS125 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. [. . . ] assemble a new gasket to the tensioner lifter, and install the tensioner lifter on the cylinder. Torque values: 1. 2kg-m (12N. m, 9ft-lb) Remove the tensioner shaft clip from the tensioner lifter. Torque values: 0. 4kg-m(4N. m, 3ft-lb) Cam chain tensioner Sealing screw Fill clean engine oil into the operating parts of the cylinder head. ( 3-5) Gasket Remove oil from the cylinder head cover grooves, and accurately assemble the gasket to the cover. ( 4-4) Cylinder head cover 9-15 Cylinder/Piston Piston top ring Piston 2ND ring Piston Oil ring Piston pin clip Piston pin clip OIL OIL 10-0 Cylinder/Piston 10. Cylinder/Piston Services information Troubleshooting Cylinder 10-1 10-1 10-2 Piston Piston/Cylinder assembly 10-3 10-5 Service Information General Safety Take precautions not to damage the joint part with a driver when removing the cylinder, or not to damage the cooling pin by striking the cylinder too hard. Take precautions not to damage the inside of the cylinder or the exterior part of the piston. 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) 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) Unit: mm(in) Standard value 56. 000-56. 010(2. 2047-2. 2051) 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) 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. Remove the cylinder. Cam chain guide Remove the gasket and dowel pin. 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. 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. 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 to the piston pin 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. [. . . ] Check ignition timing Correct Incorrect Cause of Trouble (1) Faulty CDI unit (2) Faulty A. C. 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. [. . . ]