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. [. . . ] 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. 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. crank case oil seal for wear or damage. 9-3 TRANSMISSION/CRANKSHAFT/CRANKCASE TRANSMISSION ASSEMBLY Install the drive shaft on the transmission cover. Install a new drive shaft oil seal. TOOL : CRANK ASSEMBLY Install the thrust washer, final gear and counter gear, side washer on the L. Tighten the transmission cover with the flange bolts. NOTE ·Tighten bolts diagobally and alternately and tighten with specified torque in the end. Remove the oil check bolt, release the transmission oil filler ACG cap or the L. crankcase until the oil overflow through oil hole and fill the recommended oil slowly. Install the oil check bolt and the cap . RECOMMENDED OIL : SAE #80~90 TRANSMISSION OIL AMOUNT : 0. 09 9-4 TRANSMISSION/CRANKSHAFT/CRANKCASE CRANKSHAFT REMOVAL Loosen the 6 R. crankcase. TOOL : CRANKCASE PULLER(0751-00003) Secure a crankcase puller on the L. crankcase. NOTE ·Be careful not to distort the mating surface of the crank case during disassembly. ·Do not force to disassemble by pounding on the crankshaft. TOOL : CRANKCASE PULLER(0751-00003) Remove the oil seal from the R. Remove the dowel pin. CRANKSHAFT BEARING REMOVAL If the radial ball bearing is left on the crankshaft, remove the bearings out of the crankshaft using a bearing puller. TOOL : UNIVERSAL BEARING PULLER(0755-00001) CRANKSHAFT INSPECTION Place the crankshaft on a stand or V-block, and check the journal vibration. SERVICE LIMIT : RIGHT SIDE 0. 1mm LEFT SIDE 0. 1mm 9-5 TRANSMISSION/CRANKSHAFT/CRANKCASE Measure the side gap between the connecting rod big end and the crank weight. SERVICE LIMIT : 0. 6mm Check the vertical shaft play of the connecting rod big end from the X and Y direction. SERVICE LIMIT : 0. 05mm CRANKCASE BEARING REMOVAL Remove the transmission and crankshaft. INSPECTION Manually turn the bearing inner race to see if it rotates smoothly. Check the outer race to see if it is accurately pressed into the case. If the outer race is excessively loose, or is loosely pressed into the case, remove in and replace with a new one. REPLACEMENT L. Crankcase Use special tools to remove the drive shaft bearing. TOOLS : BEARING REMOVER SET REMOVER SHAFT REMOVER HEAD Remove the final gear bearing and oil seal. Remove the counter gear bearing. 9-6 TRANSMISSION/CRANKSHAFT/CRANKCASE Apply clean engine oil to a new bearing, and assemble it to the crank case. Install a new final gear oil seal. CRANKSHAFT INSTALLATION Apply clean engine oil to the new R. crank case. TOOLS : DRIVER HANDLE A OUTER DRIVER 52x55mm DRIVER PILOT 20mm Use special tools to assemble the crankshaft bearing to the L. crank case. TOOLS : DRIVER HANDLE A OUTER DRIVER 52x55mm DRIVER PILOT 20mm Clean the crankcase using cleaning oil, and check for rack and damage to each area. NOTE ·After removing the liquid gasket from the joining face of the crankcase, amend the scratched areas using oil ston. ·Apply 2-cycle oil to the radial ball bearings and the connecting rod large end portion. crankcase. NOTE ·Install not to interfere with the case with being careful of connecting rod location. TOOL : CRANKSHAFT ASSEMBLER 9-7 TRANSMISSION/CRANKSHAFT/CRANKCASE Apply a liquid gasket to the L. Install the 6 flange bolts. NOTE ·Make sure that there is no adhesion of gasoline to the R. , L. [. . . ] Poor braking. 18-5 TROUBLESHOOTING FUEL GAUGE GAUGE READING INACCURATE (IGNITION SWTICH ON) 1. Operate the turn signal to check the battery circuit. Signal operates satisfactorily. CAUSE OF TROUBLE (1) Fuse cut. (1) Faulty float. Signal continuously operates dim or does not operate at all. 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. Needle moves. 3. [. . . ]