DAELIM HISTORY 125 - SERVICE User manual

HOW TO USE THIS MANUAL
This manual describes effective maintenance procedure
for the SL125 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. If you cannot find the cause of
trouble, refer to Section 20: Troubleshooting.
Contents of this manual and specifications are
subject to change without prior notice for
improvement of vehicle quality.
No part of this publication may be reproduced
without written permission of DAELIM Motor Co.,
Ltd.,
CONTENTS
SERVICE INFORMATION
LUBRICATION
INSPECTIONS / ADJUSTMENTS
EXTERNAL PARTS
FUEL SYSTEM
ENGINE REMOVAL
LH.CRANK CASE COVER / KICK STARTER /
CONTINUOUSLY VARIABLE TRANSMISSION
A.C.GENERATOR / STARTER CLUTCH
CYLINDER HEAD / VALVE
CYLINDER / PISTON
TRANSMISSION/CRANKSHAFT/CRANK CASE
FRONT WHEEL / FRONT FORK / STEERING
REAR WHEEL / BRAKE / SUSPENSION /
REAR SWING ARM
BRAKE SYSTEM
GENERAL
ENGINE
FRAME
ELECTRICAL SYSTEM
CHARGING SYSTEM / BATTERY
STARTER SYSTEM
LIGHTS/METER/SWITCHES
IGNITION SYSTEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
WIRING DIAGRAM
17
TROUBLESHOOTING
18
19
20

1-1
1. SERVICE INFORMATION
GENERAL SAFETY ················1-1
SERVICE RULES····················1-1
CAUTION WHEN WIRING··········1-5
SERIAL NUMBER LOCATION······1-9
SPECIFICATIONS ··················1-10
TORQUE VALUES··················1-12
SYMBOLS / ABBREVIATIONS ······1-14
WIRING DIAGRAM ················1-15
GENERAL SAFETY
WARNING
1. Do not run the engine for a long time in closed or not well-ventilated area because the exhaust gas contains toxic
substances such as carbon monoxide, hydrocarbon, nitric oxide.
2. The battery fluid(lean sulfuric acid) is extremely toxic. It is dangerous if skin is exposed to it or if it enters into the eye.
Be careful in handling. When exposed to the battery fluid, wash it with water and get a medical check up.(store the
battery fluid in a safe place to avoid touching by the children)
3. Pay attention not to be burned and always put on the protection gears because the engine or the muffler is hot right after
engine stops.
4. Gasoline is extremely flammable. Maintenance must performed in the place free of the open fire or electric spark.
5. When more than two person are working, always pay attention to other worker’s action and alway have safety in mind.
6. The skin exposed to used engine oil can be a major reason of the skin cancer. Pay attention not to exposed and wash
carefully with soap and water after handling.
7. If compressed air is used to clean the brake, dust scattered in the air can be breathed in by workers. Please take action not
to scatter dust in the brake cleaner, etc.
8. Flammable nitrogen gas is generated during charging the battery so charging must be performed in well-ventilated area
and free of the open fire and spark.
SERVICE RULES
1. Parts and lubrication oil must be DAELIM genuine or
recommended parts. 2. Before maintenance, remove deposit or dust from the chasis.
1

1-2
SERVICE INFORMATION
9. Check to see if the rubber part is worn out when
removing it and replace it if necessary. Some rubber part
is weak to gasoline and kerosene, so pay attention not to
soak with gasoline or oils.
10. Recommended grease must be applied to or filled in
the specified place.
7. Align the bolts to uniform the tightening points before
tightening them when you don’t know the bolt length. 8. Bolts, nuts and pieces must be tightened from the bigger diameter to the smaller one, from inside to outside and
diagonally with the specified torque.
5. Clean the parts after the overhaul and before the test and
remove the cleaning oil with compressed air. Apply oil
to seal face during installation.
6. Check necessary place and measure necessary data
during installation. When installing, return to the state
before removing.
3. Store the parts of each system discriminatively to install
each part in the right place. 4. After removing gasket, O-ring, piston pin clip and cotter pin, always replace them with the new one. When
removing the snap ring, it can be easily missed after
transformation or installation.

1-3
SERVICE INFORMATION
11. Maintenance needed to use the specialized tools must
performed with the right tool. 12. Never reuse the ball bearing removed with the ball applied pressure when removing press-fitted the
bearing.
13. Check the smooth rotation of inner or outer race of the
ball bearing by rotating it manually.
•Replace the ball bearing having excessive axial/
longitudinal hanging.
•Wipe the ball bearing likely to have hanging with
cleaning oil.(except double-sided sealed type ball
bearing)
•Replace the ball bearing of which press-fitted part is
slacked at the case or shaft.
14. Pay attention to installation direction in case of the
single-sided sealed ball bearing. Install the open-
direction or double-sided sealed bearing in the way
that the face marked with manufacturer and size
should direct to the outer axle.
15. When blowing the ball bearing with compressed air
after cleaning, keep the race from rotating. High speed
rotation of the race may damage the bearing. Prior to
installation, apply oil or grease to the bearing.
16. Install the snap ring so that chamfered side directs to
the load-applied side. After installation, check the
proper installation by rotating the snap ring.
17. Check each part for proper tightening and operation
after installation. 18. The brake fluid and coolant can damage the painted plastic or rubber parts. Keep these parts from
contacting with them and wash these parts with water
in case of contact.
’

1-4
SERVICE INFORMATION
21. Keep the pneumatic system interior or the engine
interior from the infiltration of dust. 22. Install the gasket mounted in the contact surface of each case of the engine while removing gasket
material completely. Remove damaged contact surface
by wiping with the oil stone equally.
19. Install the oil seal so that the manufacturer marked
surface directs outer surface.(direction not covered
with oil)
•Pay attention not to bend or damage the lip
•Apply the grease to the lip
20. Connect the tube until the tube fully inserted in the
joint. Install the clip if it is supplied. Replace the tube
having slacked end.
23. Pay attention not to bend the cable excessively.
Transformed or damaged cable may cause malfunction
or damage.
24. Install the boots with the installing groove by inserting
the boots into the groove.
’

1-5
SERVICE INFORMATION
•Each cord must be connected depending on its color.
When connecting different cord, attach color tube
around the connector. Connect the coupler to the
connector with same color and same pin number.
•Identify the two-colored cord by main color first and
then spriped color .
•When measuring voltage or resistance of the cord
terminal using tester, contact the tester plug behind of
the coupler. Pay attention not to open the cord terminal
and contact the tester plug from the front of the coupler
in case of water-proof coupler.
•Recheck the condition of contact, securing and
continuity of each part after maintenance.
•When connecting the battery, the plus terminal must be
connected first.
•After connecting the terminal, apply the grease to the
terminal.
•When disconnecting the battery, the minus terminal
must be disconnected first.
•Make sure that the tool such as spanner do not contact
with the frame.
•Connect covers to the terminal after maintenance.
•If the fuse is short-circuited, find out the cause and
repair. Replace with the fuse having the specified
capacity.
•If there is rust in the terminal, remove the rust with sand
paper prior to connecting.
CAUTION WHEN WIRING
VALIDATION
OF CAPACITY! REMOVE
THE
RUST!

1-6
SERVICE INFORMATION
•Insert the lock of the coupler until the lock is fully
secured.
•Turn off the main switch before connecting/dis-
connecting.
•Release the lock to disconnect the lock of the coupler.
•The lock of the coupler has two types according to
releasing method(press type and pull type) so release it
properly according to the shape.
- Typical releasing method of the coupler is illustrated in
the following.
•When disconnecting the coupler, disconnect it while
holding the coupler body. Pull while holding the wire
harness cord and do not remove the coupler connection.
•Release the lock by inserting the coupler slightly and
then narrowing connection to remove the coupler. •Pay attention not to damage the vinyl cover of the coupler.
•Check to see if there is bended terminal and secure it to
avoid disconnecting. •If the wire harness coating is damaged, repair by winding vinyl tape or replace it.
•Prior to connecting the connector, make sure that the
cover is not damaged and the mess terminal is not
opened.

1-7
SERVICE INFORMATION
•Wire band must be secured firmly in the specified
location of the frame. In case of aluminium band,
secure the wire harness to the coated part.
•Secure the wire harness firmly using the clamp.
•Insert the connector until the vinyl cover is fully
inserted into the terminal.
•The opening of the vinyl cover must face at the ground
direction but in case of the plain connector, the draining
opening must face at the sky direction.
•When removing T-start, broaden the groove of T-start
using the wiring driver and release the torque.
•Connect the harness and the hose to T-start and then
insert until the groove is locked.
•When removing T-start from the frame, replace it with
the new one.
•In case of the weld clamp, do not clamp in the welded
part. •When clamping the wire harness, make sure that the harness is not contacted with the shaft or rotating part.
•When clamping the wire, pay attention not to contact
with hot part. •The wire harness must be routed without contacting with the end of the lamp or any sharp edge.
•The wire harness must be routed without contacting
with the end of the bolt or the piece.

1-8
SERVICE INFORMATION
•If necessary, lock the wire harness properly. •When mounting parts, make sure that the wire harness
is not pressed by the parts.
•In case that the wire harness is contacted with the end or
the sharp edge, protect both parts with tube or tape. •The wire must not hang down or be pulled excessively.
•Do not twist the wire harness. •Wire the wire harness not to be pulled or expanded
when the handle is turned to the right or the left
completely. Avoid excessive bending or chewing and
interference with the engine.
•Prior to using the tester, please read the manual care-
fully and understand the contents.
•When testing the resistance of the tester, the zero
adjustment must be performed before testing.
•Do not drop or throw the parts especially
semiconductor contained parts because these parts may
be damaged by the impact of the drop.
NOT TO
PULL!
Is this
measurement range or
configuration in accord
with the manual?

1-9
SERVICE INFORMATION
SERIAL NUMBER LOCATION
ENGINE SERIAL NUMBER LOCATION FRAME SERIAL NUMBER LOCATION

1-10
SERVICE INFORMATION
ITEM SPECIFICATIONS
1,965 mm
690 mm
1,230 mm
1,350 mm
780 mm
120 mm
125 kg
255 kg
Underbone
Telescopic / 77mm
Swing arm / 66mm
120 / 70 - 12 53k / Tubeless
130 / 70 - 12 62k / Tubeless
2.00 Kgf / ㎠(200 kPa)
2.00 Kgf / ㎠(200 kPa)
2.00 Kgf / ㎠(200 kPa)
2.25 Kgf / ㎠(225 kPa)
Hydraulic disk
Drum brake
8.0ℓ
1.7ℓ
25。
86 mm
90 ㎠
Oil cooled / air cooled 4 cycle SOHC engine
1(Single cylinder), front angle 80。
56×50.7 mm
124.9 ㏄
10.8 : 1
SOHC chain drive
1.1ℓAfter disassembly
0.75ℓAfter Oil change
0.8ℓAfter Oil filter change
0.9ℓAfter Oil change with Oil in the Oil hose removed
Forced pressure splash type
Wet sump
14.0 kgf / ㎠(550 rpm)
5。BTDC
14。ABDC
18。BBDC
1。BTDC
0.12±0.12 mm
0.12±0.12 mm
OVERALL LENGTH
OVERALL WIDTH
OVERALL HEIGHT
WHEEL BASE
SEAT HEIGHT
GROUND CLEARANCE
DRY WEIGHT
GROSS WEIGHT
TYPE
FRONT SUSPENSION / STROKE
REAR SUSPENSION / STROKE
FRONT TIRE SIZE / TYPE
REAR TIRE SIZE / TYPE
TIRE PRESSURE 1 PERSON FRONT
REAR
2 PERSON FRONT
REAR
FRONT / REAR BRAKE
PARKING BRAKE
FUEL TANK CAPACITY FULL CAPACITY
RESERVE CAPACITY
CASTER ANGLE
TRAIL
FRONT FORK OIL CAPACITY
TYPE
CYLINDERS / ARRANGEMENT
BORE AND STROKE
DISPLACEMENT
COMPRESSION RATIO
VALVE TRAIN
OIL CAPACITY
LUBRICATION SYSTEM
AIR CLEANER TYPE
CYLINDER COMPRESSION
INTAKE VALVE OPEN
CLOSED
EXHAUST VALVE CLOSED
CLOSED
VALVE CLEARANCE (COOLING-OFF PERIOD)
INTAKE
EXHAUST
DIMENSIONS
FRAME
ENGINE
SPECIFICATIONS

1-11
SERVICE INFORMATION
ITEM SPECIFICATIONS
CV type ( vacuum ) 24.2 mm
BDS 26 - 112
Auto-bystarter
# 95
1 and ½trust out
13 mm
1.800±100 ( rpm )
Automatic Transmission
3.231 (42/13)
2.786 (39/14)
C.D.I Ignition
15。BTDC / 1.800 ( rpm )
12V 10A / 5,000 ( rpm )
Closed type (MF) 12V 8AH
CR8EH - 9 (NGK)
0.8 - 0.9 mm
15A
Kick / starter motor
12V 60 / 55W
12V 5W
12V 10W×4
12V 21 / 5W
14V 3W
14V 3W×2
12V 1.7W×2
14V 1.4W
12V 5W
14V 3W
TYPE / VENTURI BORE
MODEL MARK
CHOKE TYPE
MAIN JET
PILOT SCREW INITIAL SETTING
FLOAT LEVEL
IDLE SPEED
CLUTCH TYPE
PRIMARY REDUCTION
SECONDARY REDUCTION
IGNITION SYSTEM
IGNITION TIMING F MARK
AC GENERATOR CAPACITY
BATTERY TYPE / CAPACITY
SPARK PLUG
SPARK PLUG GAP
FUSE CAPACITY
STARTING SYSTEM
HEADLIGHT ( HIGH / LOW )
POSITION LIGHT
WINKER LIGHTS ( FR / RR )
TAIL / STOP LIGHT
HIGH-BEAM PILOT
WINKER PILOT
METER LIGHTS
TRUNK LAMP
LICENSE LAMP
PARKING BRAKE PILOT
CARBURETOR
DRIVE TRAIN
ELECTRICAL
SYSTEM

1-12
SERVICE INFORMATION
ITEM REFERENCETORQUE VALUE
THREAD DIA
(mm)
Q’TY
1.1 kgf·m
2.5 kgf·m
0.8 kgf·m
1.0 kgf·m
5.5 kgf·m
7.5 kgf·m
5.5 kgf·m
1.0 kgf·m
1.2 kgf·m
5.5 kgf·m
2.0 kgf·m
1.0 kgf·m
0.4 kgf·m
0.9 kgf·m
1.2 kgf·m
1.0 kgf·m
0.9 kgf·m
1.0 kgf·m
9.5 kgf·m
0.9 kgf·m
3.2 kgf·m
1.0 kgf·m
1.0 kgf·m
Apply engine oil
20
12
5
6
12
12
12
8
12
30
8
6
6
6
6
8
8
6
22
6
12
6
6
1
1
4
2
1
1
1
1
1
1
4
2
1
4
8
1
1
3
1
2
4
3
1
OIL FILTER CAP
OIL DRAIN PLUG BOLT
VALVE ADJUST SCREW LOCK NUT
CYLINDER HEAD BOLT
FLYWHEEL BOLT
DRIVE FACE NUT
CLUTCH OUTER BOLT
CAM CHAIN TENSIONER PIVOT BOLT
SPARK PLUG
DRIVE PLATE
CAM SHAFT HOLDER NUT
CAM CHAIN TENSIONER FLANGE BOLT
CAM CHAIN TENSIONER PAN SCREW
CYLINDER HEAD COVER BOLT
MISSION COVER BOLT
MISSION COVER DRAIN BOLT
MISSION COVER CHECK BOLT
COOLING FAN BOLT
STARTING CLUTCH NUT
STARTER MOTOR FLANGE BOLT
RADIATOR OIL BOLT
OIL PUMP FLAT SCREW
OIL PUMP DRIVEN GEAR NUT
TORQUE VALUES
ENGINE
ITEM REFERENCETORQUE VALUE
THREAD DIA
(mm)
Q’TY
7.0 kgf·m
0.20 kgf·m
6.0 kgf·m
7.5 kgf·m
2.0 kgf·m
5.0~7.0 kgf·m
4.0~4.5 kgf·m
4.0~4.5 kgf·m
6.0~8.0 kgf·m
4.5 kgf·m
4.0 kgf·m
1.5 kgf·m
Initial torque
Apply locking agent
26
26
10
10
8
12
8
8
14
10
10
10
1
1
1
4
2
1
3
3
1
2
2
1
STEERING STEM NUT
STEERING TOP THREAD NUT
HANDLE POST NUT
FRONT FORK BOTTOM BRIDGE BOLT
FRONT FORK SOCKET BOLT
FRONT AXLE NUT
FRONT BRAKE DISK BOLT
REAR BRAKE DISK BOLT
REAR AXLE NUT
ENGINE HANGER NUT
MAIN STAND BOLT
SIDE STAND PIVOT BOLT
FRAME

1-13
SERVICE INFORMATION
ITEM REFERENCETORQUE VALUE
THREAD DIA
(mm)
Q’TY
4.5 kgf·m
2.7 kgf·m
0.6 kgf·m
2.3 kgf·m
1.8 kgf·m
1.8 kgf·m
0.15 kgf·m
3.0 kgf·m
1.0 kgf·m
1.0 kgf·m
10 kgf·m
0.4 kgf·m
4.0 kgf·m
4.0 kgf·m
4.0 kgf·m
Apply locking agent
Apply locking agent
10
8
8
8
8
8
4
10
6
6
6
5
10
10
10
1
2/2
1/1
1/1
1/1
2/2
2/2
2/2
1/1
1/1
1
1
1
1
1
SIDE STAND PIVOT NUT
FRONT / REAR BRAKE CALIPER BRACKET BOLT
FRONT / REAR BRAKE CALIPER BLEEDER VALVE
FRONT / REAR BRAKE CALIPER SLIDE PIN
FRONT / REAR BRAKE CALIPER BRACKET PIN BOLT
FRONT / REAR BRAKE HANGER PIN
FRONT / REAR MASTER CYLINDER RESERVOIR CAP SCREW
FRONT / REAR BRAKE HOSE OIL BOLT
FRONT / REAR MASTER CYLINDER LEVER PIVOT BOLT
FRONT / REAR MASTER CYLINDER LEVER PIVOT LOCK NUT
REAR BRAKE ARM FLANGE BOLT
SPEEDOMETER GEAR BOX OVAL SCREW
REAR CUSHION UPPER BOLT
REAR CUSHION LOWER BOLT
REAR CUSHION DAMPER ROD LOCK NUT
ITEM ITEMTORQUE VALUE TORQUE VALUE
0.5 kgf·m
1.0 kgf·m
2.2 kgf·m
3.5 kgf·m
5.5 kgf·m
0.4 kgf·m
0.9 kgf·m
1.2 kgf·m
2.7 kgf·m
4.0 kgf·m
5mm BOLT, NUT
6mm BOLT, NUT
8mm BOLT, NUT
10mm BOLT, NUT
12mm BOLT, NUT
5mm SCREW
6mm SCREW
6mm FLANGE BOLT, NUT
8mm FLANGE BOLT, NUT
10mm FLANGE BOLT, NUT
Torque values listed above are for specific tightening points. Torque values for other items are listed in the following table.
SH (Small Head) : Indicates 6mm bolt of 8mm flange head.

SYMBOL
CAUTION
NOTE
SYMBOL
1-14
SERVICE INFORMATION
SYMBOLS / ABBREVIATIONS
The following symbols are used in this manual to represent job-related warnings or cautions.
MEANING
Indicates dangerous area. Serious
accident may result if instructions are not
followed.
The following symbols indicate oil adding, oil change, or parts.
MEANING
Add oil. If there is no specific oil indicated, use the designated or recommended engine oil.
Apply grease
Indicates reference page. (example : Refer to page 3-1)
MEANING
Indicates important work. Minor injury or
vehicle part damage may result if instruction
are not followed.
Indicates general safety matters. Provides
safety and appropriate handling procedures.
(⇨3-1)
ASS’Y
The following abbreviations are used in this manual.
ASSEMBLY
Left
Right
LH.
RH.
SYMBOL
WARNING
OIL
GREASE

1-15
SERVICE INFORMATION
WIRING DIAGRAM
FR.BRAKEHOSE
FRAMEEARTHCONNECTOR
(TIGHTATTHESAMETIMEWITHTHEREG.REC.)
THROTTLECABLE
STARTERS/WUNIT
FR.STOPS/WCONNECTOR
FR.BRAKEHOSE
SEATOPENCABLE
REG.RECTIFIER
MAINS/W
SPEEDOMETERCABLE
CABLEGUIDE
RR.BRAKEHOSE
RR.STOPS/WCONNECTOR
HAZARDS/WUNIT
HORNS/WUNIT
RR.BRAKEHOSE
LH.FR.WINKERLIGHT
CONNECTINGCONNECTOR
CABLEGUIDE
RESISTOR
30W5.9
LIGHTINGS/WUNIT
HEADPIPE
SPEEDOMETER
CABLEGUIDE
SOCKETCOMP.
A.P.WINKERRELAY
DIMMERS/WUNIT
WINKERS/WUNIT
FRONTFENDER
CABLEGUIDE
THROTTLECABLE
PRESSTOATTACHTHE
SEL.SECTIONTOTHEPIPE
FR.BRAKEHOSE
HORNCOMP.
SPEEDOMETERCABLE
Y
SEATLOCKCABLE
THROTTLECABLE
BREATHERTUBE
DRAINTUBE(CARB.)
AIRCLEANERINLETDUCT
FUELUNIT
FUELTUBE
FUELTANK
FUELPUMP
TUBECLAMP
CABLECLIP
CABLESETT.PIPE
LH.RR.WINKERCORD
LH.RR.WINKERLIGHT
FUELUNITCORD
LH.RADIATORHOSE
BATTERY
DETAILOF"Z"
THROTTLECABLE
FULETUBE(INSU)
FULETUBE(CARB)
CORDCLIP
PLUNGERASS'Y.
DRAINTUBE
BREATHERTUBE
FUSE
BREATHERTUBE
STARTERMAGNETICBATTERY+CABLE
BATTERYEARTHCABLE
RR.BRAKEHOSEB
RH.RADIATORHOSE
RR.BRAKEHOSEB
WIREHARNESS
WIRECLIP
HOSECLAMP
WIREHARNESS
HOSECLAMP
RH.RR.WINKERCORD
RH.RR.WINKERLIGHT
WIRECLIP
WIRECLIP
WIRECLIP
TAILLIGHTCORD
LICENSELIGHTCORD
I/G.COIL
RR.BRAKEHOSEB
STARTERMOTORCABLE
HIGHTENTIONCORD
STARTERMAGNETICS/W
PLUNGERASS'Y

1-16
SERVICE INFORMATION
MASTERCYLINDERASS'Y
FR.BRAKEHOSE
SPEEDOMETERCABLE
THROTTLECABLE
MAINS/W
SEATLOCKCABLE
WIREHARNESS
AIRCLEANER
TRUNKLAMP
TRUNKLAMPS/W
PARKINGBRAKECABLE
RR.BRAKEHOSEB
BLEEDERTUBE
BATTERYEARTHCABLE
HIGHTENSIONCORD
THROTTLECABLE
WIREHARNESS
RH.RADIATORHOSE
STARTERMAGNETICBATTERY+CABLE
STARTERMOTORCABLE
I/G.COIL
CDIUNIT
FUELTANK
TAILLIGHT
RH.RR.WINKERLIGHT
LICENSELIGHT
RR.BRAKEHOSEB
WIREHARNESS
REGULATERECTIFIER
SPEEDOMETERCABLE
HEADLIGHT
MASTERCYLINDERASS'Y
RR.BRAKEHOSEA
SOCKETCOMP.
CHARGESOCKETASS'Y
WIREHARNESS
HEADLIGHTCORD
INNERBOX
DETAILOF"A"
HEADLIGHT
HEADLIGHTCONNECTING
COUPLER(4P.FEMAIL)
THROTTLECABLE AIRCLEANER
FUELTUBE(CARB')
FUELTUBE(INSU.)
FUELPUMPASS'Y
FUELSTRAINERCOMP.
FUELTUBE(TANK)
TAILLIGHT
LH.RR.WINKERLIGHT
LICENSELIGHT
BREATHERTUBE
PARKINGBRAKECABLE
CABLESETTINGPIPE
RR.BRAKEHOSEB
X
A
DRAINTUBE
SIDESTANDS/W
SEATLOCKCABLE
THROTTLECABLE
CABLECLAMP
BREATHERCABLE
RR.BRAKEHOSEB
RH.RADIATORHOSE
LH.RADIATORHOSE
SPEEDOMETERCABLE
SPEEDOMETERCABLE
SPEEDOMETERCABLE
SOCKETCOMP.
WIRECLAMP
(SOCKETCOMP.)
SEATLOCKCABLE
THROTTLECABLE
WIREHARNESS
WIRECLAMP
HORNCOMP.
RESISTOR30W5.9
VIEW"X"

2-1
2. LUBRICATION
SERVICE INFORMATION
GENERAL SAFETY
WARNING
1.The exhaust gas contains poisonous substance. Do not keep engine idling in a closed or poorly ventilated place for a
long period of time.
2.Used engine oil may cause skin cancer if repeatedly left in contect with the skin for prolonged periods. It is desirable
not to handle used oil frequently; however, wash your hands thoroughly with soap and water immediately after
handling the used oil.
3.The oil pump can be serviced without removing the engine from the frame.
ENGINE OIL
TRANSMISSION OIL
TORQUE VALUES
OIL FILTER SCREEN CAP
1.5㎏f·m
OIL FILTER COVER BOLT 1.1㎏f·m
OIL PUMP MOUNTING BOLT
1.1㎏f·m
OIL DRAIN PLUG BOLT
2.5㎏f·m
2
SERVICE INFORMATION······2-1
TROUBLESHOOTING
··········2-2
ENGINE OIL LEVEL INSPECTION
··2-3
ENGINE OIL CHANGE········2-3
OIL FILTER ELEMENT CHANGE
··2-4
OIL PUMP ··················2-4
RADIATOR··················2-7
TRANSMISSION OIL INSPECTION
··2-8
LUBRICATION POINTS ······2-9
OIL CAPACITY
RECOMMENDED
OIL
1.1ℓ(After disassembly)
0.9ℓ(After Oil change with Oil in the Oil hose removed)
0.8ℓ(After Oil filter change)
0.75ℓ(After Oil change)
API service classification : SE, SF, SH grade
Viscosity : SAE10W-30
(Use appropriate type of oil with viscosity satisfying
the atmospheric temperature
In your riding area based on the table shown on the
right side.)
OIL CAPACITY
RECOMMENDED OIL
0.15ℓ(Full capacity)
0.14ℓ(After oil change)
DMC Pure mission oil or SAE 80W/90
-10 0 10 20 30 40℃

2-2
LUBRICATION
TROUBLESHOOTING
Oil level low
•Oil consumption.
•External oil leaks.
•Worn piston ring or incorrect piston ring installation.
•Worn valve guide or seal.
Oil contamination
•Oil or filter not changed often enough.
•Faulty head gasket.
•Worn piston rings.
Low or no oil pressure
•Clogged oil orifice.
•Incorrect oil being used.