User manual DAELIM S2-250 SERVICE MANUAL

[. . . ] HOW TO USE THIS MANUAL This manual describes effective maintenance procedure for the S2-250 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. [. . . ] : 22. 15mm replace if over O. D. : 41. 50mm replace if below STARTER REDUCTION GEAR STARTER REDUCTION GEAR STARTER REDUCTION GEAR Inspect the starter reduction gear and shaft for wear or damage. 9-3 A. C GENERATOR/STARTER CLUTCH Remove the starter one-way clutch rollers, plungers and springs. START REDUCTION GEAR START REDUCTION GEAR START REDUCTION GEAR INSTALLATION Install the starting clutch gear comp onto the crankshaft. Install the starter reduction gear and shaft. START CLUTCH GEAR COMP START CLUTCH GEAR COMP START CLUTCH GEAR COMP FLYWHEEL INSTALLATION FLYWHEEL FLYWHEEL FLYWHEEL KEY KEY KEY Install the flywheel onto the crankshaft by aligning the key on the crankshaft with the groove in the flywheel. GROOVE GROOVE GROOVE GROOVE FLYWHEEL FLYWHEEL FLYWHEEL Hold the flywheel with the flywheel holder and tighten the flywheel nut. TORQUE VALUE : 5. 39~6. 37kgf·m 9-4 A. C GENERATOR/STARTER CLUTCH PULSE COIL PULSE COIL PULSE COIL STATOR INSTALLATION Install the A. C. CRANKCASE COVER INSTALLATION Install the 2 dowel pins and a new gasket. RH. crankcase cover over the crankcase, aligning the water pump shaft groove with the oil pump shaft. Fill the cooling system with the specified coolant. ALIGNING ALIGNING ALIGNING OIL PUMP SHAFT OIL PUMP SHAFT OIL PUMP SHAFT WATER PUMP SHAFT WATER PUMP SHAFT WATER PUMP SHAFT ·Be sure to bleed air from the water jacket after filling the coolant. 9-5 CYLINDER HEAD / VALVE 10-0 10. CYLINDER HEAD/CYLINDER/PISTON · SERVICES INFORMATION······· · 10-1 · CYLINDER HEAD COVER········ 10-1 · CAM SHAFT·············· 10-2 · CYLINDER HEAD············ 10-4 SERVICE INFORMATION Drain the coolart from the radiator and water. Apply oil to valve guide and valve arm when assemblying. SPECIFICATIONS ITEM STANDARD (mm) SERVICE LIMIT(mm) IN VALVE CLEARANCE (COLD) EX CYLINDER HEAD COMPRESSION PRESSURE CYLINDER HEAD WARPAGE IN CAMSHAFT CAM HEIGHT EX IN VALVE ROCKER ARM I. D. EX IN VALVE STEM-TO-GUIED CLEARANCE EX 0. 10 0. 10 15kg/cm2 _ 34. 2987 34. 1721 10. 00~10. 015 10. 00~10. 015 9. 972~9. 987 9. 972~9. 987 1. 2 1. 2 4. 990~4. 975 4. 970~4. 955 5. 00~5. 012 5. 00~5. 012 0. 010~0. 037 0. 030~0. 057 0. 05 34. 14 34. 02 10. 10 10. 10 9. 9 9. 9 1. 8 1. 8 4. 925 4. 915 5. 03 5. 03 0. 08 0. 10 10 TORQUE VALUES CYLINDER HEAD CAP NUT : 2. 45kgf·m VALVE CLEARANCE ADJUSTING NUT : 0. 88kgf·m CYLINDER HEAD COVER BOLT : 0. 78~1. 18kgf·m 10-1 CYLINDER HEAD / VALVE CYLINDER HEAD COVER REMOVAL Remove the center cover. Remove the cylinder head cover 4 bolts and then remove the cylinder head cover. CAM CHAIN TENSIONER CAM CHAIN TENSIONER CAM CHAIN TENSIONER CAMSHAFT REMOVAL Turn the A. C. generator flywheel so that the "T" mark on the flywheel aligns with the index mark on the crankcase. Hold the round hole on the camshaft gear facing up and the location is the top dead center on the compression stroke. Remove the 2 bolts attaching cam chain tensioner and the tensioner. ROUND HOLE ROUND HOLE ROUND HOLE CAMSHAFT HOLDER CAMSHAFT HOLDER CAMSHAFT HOLDER First remove the 2 bolts between the cylinder head and cylinder. Remove the 4 cap nuts securing cylinder head. ·Diagonally loosen the cylinder head cap nuts in 2 or 3 times. BOLTS BOLTS BOLTS CAP NUTS CAP NUTS CAP NUTS CAMSHAFT HOLDER CAMSHAFT HOLDER CAMSHAFT HOLDER Remove the camshaft holder and dowel pins. 10-2 CYLINDER HEAD / VALVE CAM CHAIN CAM CHAIN CAM CHAIN Remove the camshaft gear from the cam chain to remove the camshaft. CAMSHAFT GEAR CAMSHAFT GEAR CAMSHAFT GEAR INSPECTION Check each cam lobe for wear or damage. Measure the cam lobe height. SERVICE LIMITS: IN : 34. 14mm replace if below EX: 34. 02mm replace if below CAMSHAFT BEARING CAMSHAFT BEARING CAMSHAFT BEARING Check each camshaft bearing for play or damage. Replace the camshaft assembly with a new one if the bearings are noisy or have excessive play. CAMSHAFT HOLDER DISASSEMBLY VALVE ROCKER ARMS VALVE ROCKER ARMS VALVE ROCKER ARMS Remove the valve rocker arms. ROCKER ARM SHAFT ROCKER ARM SHAFT ROCKER ARM SHAFT 10-3 CYLINDER HEAD / VALVE CAMSHAFT HOLDER CAMSHAFT HOLDER CAMSHAFT HOLDER CAMSHAFT HOLDER CAMSHAFT HOLDER INSPECTION Inspect the camshaft holder, valve rocket arms and rocker arm shafts for wear or damage. ·If the valve rocker arm contact surface is worn, check each cam lobe for wear or damage. ROCKER ARM SHAFT ROCKER ARM SHAFT ROCKER ARM SHAFT Measure the I. D. of each valve rocket arm. SERVICE LIMITS: IN : 10. 10mm replace if over EX: 10. 10mm replace if over Measure each rocker arm shaft O. D. SERVICE LIMITS: IN : 9. 90mm replace if below EX: 9. 90mm replace if below CYLINDER HEAD REMOVAL First drain the coolant from the radiator and water jacket, then remove the thermostat water hose. Loosen the bolt securing the thermostat housing and the thermostat housing. Remove the cylinder head. BOLT BOLT BOLT CYLINDER HEAD GASKET CYLINDER HEAD GASKET CYLINDER HEAD GASKET CYLINDER CYLINDER CYLINDER CYLINDER Remove the dowel pins and cylinder head gasket. Remove all gasket material from the cylinder head mating surface. CAM CHAIN TENSIONER SLIPPER CAM CHAIN TENSIONER SLIPPER CAM CHAIN TENSIONER SLIPPER 10-4 CYLINDER HEAD / VALVE CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD DISASSEMBLY Remove the valve spring cotters, retainers, springs, spring seats and valve stem seals using a valve spring compressor. ·Be sure to compress the valve springs with a valve spring compressor. ·Mark all disassembled parts to ensure correct reassembly. VALVE SPRING COMPRESSOR VALVE SPRING COMPRESSOR VALVE SPRING COMPRESSOR COMBUSTION CHAMBER COMBUSTION CHAMBER COMBUSTION CHAMBER COMBUSTION CHAMBER Remove carbon deposits fron the exhaust port and combustion chamber. ·Be careful not to damage the cylinder head mating surface. STRAIGHT EDGE STRAIGHT EDGE STRAIGHT EDGE STRAIGHT EDGE INSPECTION Check the spark plug hole and valve areas for cracks. Check the cylinder head for warpage with a straight edge and feeler gauge. SERVICE LIMITS : 0. 05mm replace or replace if over FEELER GAUGE FEELER GAUGE FEELER GAUGE Measure the free length of the inner and outer valve springs. SERVICE LIMITS: INNER (IN, EX) : 29. 5mm replace if below OUTER(IN, EX) : 39. 5mm replace if below 10-5 CYLINDER HEAD / VALVE Inspect each valve for bending, burning, scratches or abnormal stem wear. Measure each valve stem O. D. SERVICE LIMITS: IN : 4. 925mm replace if below EX : 4. 925mm replace if below ASSEMBLY Install the valve spring seats and stem seals. [. . . ] Start engine and if the temperature of heater controller unit is under 0° C Check if the white/yellow wire of heater controller unit has output voltage. If it has not any voltage, it is damaged. 19-4 LIGHTS/SWITCH/HORN HEADLIGHT CONTROLLER When the main switch turns ON, the headlight (low), meter illumination, taillight, position light and license light turns on during a second and turns off. If the engine RPM becomes over 1, 100rpm, the headlight (low), the meter illumination, taillight, position light and license light turns on CORD A TERMINAL : EARTH B TERMINAL : NONE C TERMINAL : NONE D TERMINAL : SW. 1 E TERMINAL : BATTERY F TERMINAL : PULSER(INPUT) SZ1-LC COOLANT TEMPERATURE GAUGE If the gauge needle indicates the red zone when idling or running, turn the main switch OFF. [. . . ]