User manual DAELIM VL125E SERVICE MANUAL

[. . . ] How to use this manual General This manual explains how to maintain the Daystar of the DAELIM MOTOR CO. , LTD. Follow the maintenance schedule (Section 3) recommendations to ensure that the vehicle is in peak operating condition. Section 1 through 3 apply to the whole motorcycle, while sections 4 through 18 describe parts of the motorcycle, grouped according to location. Most sections start with an assembly or system illustration, service information and trouble shooting for the section. [. . . ] When heating the cylinder Head, do not heat it sectionally using a gas burner. It is caused the twist of cylinder Head. Hold the cylinder head, and remove the valve guide from the combustion chamber using valve guide driver. Tool : Valve guide driver ! Valve Guide Driver Valve Guide Driver Valve Guide Driver CAUTION Avoid the cylinder head from damaging. After inserting the valve guide, install the valve guide reamer in the combustion chamber of the cylinder head and trim the valve guide. Valve Guide Driver Valve Guide Driver Valve Guide Driver 9-8 Cylinder Head / Valve ! CAUTION Trim the reamer not to lean. If cutting the reamer by leaning, the valve hole is inclined, the step seal is leaked, and the around of valve seat is enlarged. The entrance of reamer is always performed by turning the reamer to the right. Tool: Valve guide reamer Clean the cylinder head and remove the foreign substances. Check the around of valve seat and amend them. Valve Seat Inspection Remove the carbon deposits of valve. Trim valve guide reamer using a valve guide dreamer without turning the valve, and align the position exactly. Tale off the valve, inspect the opposite side of the seat with the ink attachment of valve pace side. If the valve is inclined, inspect the valve guide-to-step gap and replace valve guide if necessary. ! Valve CAUTION It is impossible to amend the valve. If the valve pace clogging, wear and connection are bad, the valve must be replaced. Standard Value : 0. 7~0. 9(0. 028~0. 035) Service Limit : 1. 3mm(0. 05in) 60 35 IN : 22mm Ex : 22mm IN : 23mm EX : 20mm Valve Seat Cutter Amend the worn valve seat using a valve seat cutter and a grinder. ! CAUTION Perform them according to the instruction manual. IN : 24. 5mm Ex : 24. 5mm 9-9 Cylinder Head / Valve Valve Seat Amendment If the Seat part is damaged or rough, cut them using 45 cutter. !Damaged or Rough CAUTION After replacing the valve guide, cut the seat part. Valve Seat 45 Amend the flat using a 35 cutter side by side. Cut The Seat Part 35 Amend the inside using a 60 cutter side by side. Seat Width Before Cutting 60 Amend the seat part with a standard width using a 45 cutter. 0. 7~0. 9mm (0. 028~0. 035 in) 45 9-10 Cylinder Head / Valve Coat the valve seat with the compound. Use the valve guide reamer without turning the Valve, check the attached state by hitting against lightly. If the position of contacting side is high, cut it using a 35 cutter, and then cut it using a 45 cutter according to the standard width. Contact Part is Hight Seat Width Before Cutting 35 If the position of contacting side is low, cut it using a 60 cutter, and then cuts by 45 cutter according to the standard width. Contact Part is Low Seat Width Before Cutting 60 After amending, coat the valve seat with a compound and align the valve using a valve guide reamer. ! CAUTION If it is turned by pressing the valve to seat strongly when aligning the valve, it is damaged. If aligning the valve in same position, it is caused that seat is worn partly. Avoid putting compound in the gap of step and guide while aligning the Valve. Cylinder Head Assembly Install the valve spring seat and a new stem seal. Lubricate each valve stem with molybdenum disulfide grease and insert the valve into the valve guide. To avoid damage to the stem seal, turn the valve slowly when inserting. Check the valve for freedom of up-down movement. Spring Seat Spring Seat Spring Seat Valve Valve Valve Spring Spring Spring Cotter Cotter Cotter Stem Seal Stem Seal Stem Seal Retainer Retainer 9-11 Cylinder Head / Valve Install the valve springs. The springs tightly would coils should face toward the cylinder head. For Cylinder Head For Cylinder Head For Cylinder Head Install the springs retainer. Compress the valve spring and install the valve cotters. NOTE Valve Spring Compressor Valve Spring Compressor Valve Spring Compressor To prevent the loss of tension, do not compress the valve springs more than necessary to install the valve cotters. [. . . ] If the continuity is between o-o, it is correct. Light Switch Light Switch Light Switch Engine Stop Switch Engine Stop Switch Engine Stop Switch Starter Switch ST1 Free Push Color Code ST2 Starter Switch Starter Switch Starter Switch Black/Green Yellow/Red Light Switch BAT OFF P H Color Code TL HL Black Brown Blue/White Winker Switch R R N L Color Code W L Dimmer Switch Dimmer Switch Dimmer Switch Sky Blue Gray Orange Dimmer Switch HI LO HI Color Code HL LO Blue Blue/White White Winker Switch Winker Switch Winker Switch Horn Switch Horn Switch Horn Switch Horn Switch HO Free Push Color Code BAT Engine Stop Switch Engine Stop Switch Engine Stop Switch Light Green Black Engine Stop Switch EXT RUN OFF Color Code Black/White E BAT2 ST1 Green Black Black/Green 20-8 Lights/Switches/Horn Gear Chain Switch Disconnect the gear change switch wire coupler. Gear Position Neutral 3Position gear Terminal Light green/Red White/Blue Brake Light Switch Front Remove the headlight case. Disconnect the front brake light switch wire connectors and check for continuity between the connector terminals. The switch should have continuity with the front brake applied and no continuity with it released. Rear Remove the R. [. . . ]