DAELIM S2-250 User 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. If you cannot find the cause of
trouble, refer to Section 18: 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
INSPECTIONS/ADJUSTMENTS
EXTERNAL PARTS
LUBRICATION SYSTEM
FUEL SYSTEM
GENERAL
ENGINE
1
2
3
4
5
COOLING SYSTEM
6
ENGINE REMOVAL/INSTALLATION
LH.CRANK CASE COVER/TRANSMISSION
A.C. GENERATOR/STARTING CLUTCH
CYLINDER HEAD/VALVE
CYLINDER/PISTON
7
8
9
10
11
FRAME
ELECTRICAL SYSTEM
CRANK SHAFT/CRANK CASE
FINAL REDUCTION
FRONT WHEEL / FRONT FORK
/ STEERING / BRAKE
REAR WHEEL / BRAKE
/ SUSPENSION / REAR SWING ARM
IGNITION SYSTEM
STARTING SYSTEM
CHARGING SYSTEM
12
13
14
15
16
17
18
LIGHTS / SWITCHES / HORN
19
WIRING DIAGRAM
20

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
STANDARD TORQUE VALUES 1-13
SYMBOLS 1-13
LUBRICATION OIL 1-14
WIRING DIAGRAM 1-15
GENERAL SAFETY
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 chassis.
1
1-1

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
be 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 expended
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
SPECIFICATIONS
ITEM SPECIFICATIONS
2,110 mm
745 mm
1,356 mm
1,481 mm
760 mm
121 mm
164 kg
294 kg
Underbone
Telescopic
Swing arm
120 / 70 - 12 / Tubeless
140 / 60 - 13 / Tubeless
2.00 Kgf / ㎠
2.00 Kgf / ㎠
2.00 Kgf / ㎠
2.25 Kgf / ㎠
Hydraulic disk
Hydraulic disk
11ℓ
2.8ℓ
27。
87.1 mm
100/65 ㎠
Water cooled 4 cycle SOHC engine
1(Single cylinder), front angle 80。
72.7×60 mm
249 ㏄
10.3 : 1
SOHC chain drive
1.1ℓAfter disassembly
0.95ℓAfter Oil filter change
0.9ℓAfter Oil change
Forced pressure splash type
Paper Filter
15 kgf / ㎠(600 rpm)
8。BTDC
42。ABDC
33。BBDC
1。ATDC
0.1 mm
0.1 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 BRAKE
REAR BRAKE
FUEL TANK CAPACITY FULL CAPACITY
RESERVE CAPACITY
CASTER ANGLE
TRAIL
FRONT FORK /REAR 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 OPEN
CLOSED
VALVE CLEARANCE (COOLING-OFF PERIOD)
INTAKE
EXHAUST
DIMENSIONS
FRAME
ENGINE

1-11
SERVICE INFORMATION
ITEM SPECIFICATIONS
CVK type/30 mm
Butterfly
# 102
2 ½
18.5 mm
1,700±100 rpm
Automatic Transmission
2.8 (42/15)
2.79 (39/14)
Full-Transistor
BTDC 5。/ 1,700 ( rpm )
12V 10AH (MF type)
NGK DPR 7EA-9
0.9 mm
Starter motor
55/ 55W
5W
10W×2/10W×2
5/21W
3W
1.7W×2
3W×2
1.4W×1
5W×1
LG-Caltex Oil CX AF EQUIV/40%
1.4ℓ/1.0ℓ
80 2 C
0.9 0.15kgf/cm2
Motor / 90 3 C
43km/ (50km/h)
22PS/7000rpm
2.2kgf m
SAE:15W 40# or 10W 30, API:SJ
Triple phase wave
100 5dB
TYPE / VENTURI BORE
CHOKE TYPE
MAIN JET
PILOT SCREW INITIAL SETTING
FLOAT LEVEL
IDLE SPEED
CLUTCH TYPE
PRIMARY REDUCTION
SECONDARY REDUCTION
IGNITION SYSTEM
IGNITION TIMING F MARK
BATTERY TYPE / CAPACITY
SPARK PLUG
SPARK PLUG GAP
STARTING SYSTEM
HEADLIGHT ( HIGH / LOW )
POSITION LIGHT
WINKER LIGHTS ( FR / RR )
TAIL / STOP LIGHT
HIGH-BEAM PILOT
SPEEDOMETER LAMP
WINKER PILOT
TRUNK LAMP
LICENSE LAMP
COOLANT/MIXTURE RATIO
COOLANT CAPACITY RADIATOR AND ENGINE/AT REPLACING
THERMOSTAT VALVE OPEN
RADIATOR CAP VALVE OPEN PRESSURE
COOLING FAN DRIVING METHOD/OPERATING TEMPERATURE
FUEL CONSUMPTION RATIO
ENGINE MAXIMUM POWER
ENGINE MAXIMUM TORQUE
ENGINE OIL
GENERATOR TYPE
HORN
CARBURETOR
DRIVE TRAIN
ELECTRICAL
SYSTEM
COOLING
SYSTEM
THE
OTHERS

1-12
SERVICE INFORMATION
ITEM REFERENCETORQUE VALUE
THREAD DIA
(mm)
Q’TY
3.0 kgf·m
3.0 kgf·m
1.47 kgf·m
2.2 kgf·m
2.45 kgf·m
1.1 kgf·m
1.0 kgf·m
1.27 kgf·m
5.5 kgf·m
5.5 kgf·m
5.88 kgf·m
0.5 kgf·m
1.18 kgf·m
1.72 kgf·m
1.18 kgf·m
1.18 kgf·m
2.8 kgf·m
4.0 kgf·m
8
8
30
8
8
5
6
12
12
12
14
5
6
10
6
8
8
10
2
2
1
2
4
2
1
1
1
1
1
2
4
1
1
1
2
1
CYLINDER HEAD BOLT A
CYLINDER HEAD BOLT B
OIL FILTER SCREEN CAP
EXHAUST MUFFLER JOINT LOCK NUT
CYLINDER HEAD CAP NUT
VALVE ADJUST LOCK NUT
CAM CHAIN TENSIONER SLIPER BOLT
OIL BOLT
CLUTCH OUTER NUT
CLUTCH DRIVE PLATE NUT
FLYWHEEL NUT
OIL PUMP BOLT
CYLINDER HEAD COVER BOLT
SPARK PLUG
WATER PUMP IMPELLER
CAM CHAIN TENSIONER BOLT
MUFFLER TORQUE BOLT
TORQUE VALUES
ENGINE
ITEM REFERENCETORQUE VALUE
THREAD DIA
(mm)
Q’TY
7.0 kgf·m
0.25 kgf·m
7.5 kgf·m
6.0 kgf·m
6.0 kgf·m
3.1 kgf·m
1.2 kgf·m
4.25 kgf·m
12.5 kgf·m
3.1 kgf·m
1.2 kgf·m
4.25 kgf·m
0.43 kgf·m
2.25 kgf·m
4.0 kgf·m
4.0 kgf·m
3.5 kgf·m
5.25 kgf·m
4.5 kgf·m
4.0 kgf·m
1.5 kgf·m
4.5 kgf·m
Initial torque
26
26
10
10
12
8
6
8
16
8
6
8
5
22
10
10
10
12
10
10
10
10
1
1
1
2
1
2
2
3
1
2
2
3
1
2
2
2
2
2
1
2
1
1
STEERING STEM NUT
STEERING TOP THREAD NUT
FORK PIPE BOTTOM BRIDGE
HANDLE POST
FRONT AXLE NUT
FRONT CALIPER BRACKET BOLT
FRONT MASTER CYLINDER HOLDER BOLT
FRIBT DISK PLATE BOLT
REAR AXLE NUT
REAR CALIPER BRACKET BOLT
REAR MASTER CYLINDER HOLDER BOLT
REAR DISK PLATE BOLT
SPEEDOMETER GEARBOX SCREW
FRONT FORK BOLT
REAR CUSHION UPPER BOLT
REAR CUSHION UNDER BOLT
REAR CUSHION LOCK NUT
ENGINE HANGER UPPER BOLT
ENGINE HANGER LOWER BOLT
MAINSTAND BOLT
SIDESTAND PIVET SEREW
SIDESTAND PIVET NUT
FRAME
Torque values listed above are for specific tightening points. Torque values for other items are listed in the following table.

1-13
SERVICE INFORMATION
STANDARD TORQUE VALUES
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
SYMBOL
SYMBOL
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
OIL
GREASE

1-14
SERVICE INFORMATION
LUBRICATION OIL
LUBRICATION POINTS REFERENCE
SAE15W-40 or SAE10W 30#
API SE, SF or SG
HEAT-RESISTANT GREASE
LOCTITE APPLIES
GLUE
VALVE GUIDE/VALVE STEM OPERATING PARTS
CAM SHAFT CONTACT AREA
CAM SHAFT DRIVE CHAIN
CYLINDER LOCK BOLT AND NUT
PISTON AROUND AND PISTON RING GROOVE
PISTON PIN AROUND
CONNECTING ROD, PISTON PIN HOLE
CONNECTING ROD BIG END
CRANK SHAFT
CRANK SHAFT ONE-WAY CLUTCH OPERATING PARTS
OIL PUMP DRIVE CHAIN
STARTER REDUCTION GEAR PARTS
COUNTER SHAFT GEAR PARTS
FINAL GEAR PARTS
BEARING OPERATING PARTS
O-RING SURFACE
OIL SEAL RIP
STARTER IDLE GEAR
FRICTION SPRING OPERATING PARTS/SHAFT OPERATING PARTS
SHAFT OPERATING PARTS
STARTER SPINDLE OPERATING PARTS
STARTER ONE-WAY CLUTCH THREAD
A.C. GENERATOR CONNECTOR
TRANSMISSION CASE BLEEDER TUBE
ENGINE

1-15
SERVICE INFORMATION
WIRING DIAGRAM
WATER PASS TUBE A
FUEL NECK EARTH WIRE
BATTERY (12V 10AH)
RESISTER COMP.
HEATER CONTROLLER
IGNITION UNIT COMP.
L. SEAT LOCK CABLE
THROTTLE POSITION
SENSER COUPLER
I.G COIL
TRANK LAMP WIRE
FUEL UNIT COUPLER AIR CLEANER TUBE(AIR CLEANER)
DRAIN TUBE
AUTO CHOCK COUPLER
SIDE STAND SWITCH COUPLER
WATER PASS TUBE A
WATER PASS TUBE B
FUEL BREATHER TUBE
HOSE CLIP
WATER PASS TUBE C
E.M.I. UNIT COMP.
E.M.I. CORD (WIRE)
E.M.I. CORD (FAN MOTOR)
RADIATOR HOSE A
HORN
LICENSE LAMP WIRE
REGULATOR RECTIFIER
HEADLIGHT CONTROL UNIT
STARTER MAGNETIC SWITCH
FUELTUBE (CARBURETOR)
FUELTUBE (FUELTANK)
FUELTUBE (INSULATOR)
RADIATOR HOSEA
FR. BRAKE HOSE
RR. STAY
WATER PIPEA
WATER PIPE B
WATER HOSE C
A.C.G CORD
STARTER MOTOR CABLE
RR. BRAKE HOSE
WATER PASS TUBE A
SPEEDOMETER CABLE
THEROMO SWITCH WIRE
RADIATOR HOSE B
RADIATOR CAP HOSE
FUEL STRAINER
A.C.G. COUPLER
EARTH CABLE
STARTER MAGNETIC
SWITCH WIRE
WATER HOSE A
WATER HOSE B
WATER HOSEA
WATER HOSE B

1-16
SERVICE INFORMATION
FUELTUBE (INSULATOR)
FUELTUBE (INSULATOR)
FUELTUBE
FUEL STRAINER COMP.
FUEL WATER PASS TUBE B
FUELTUBE (FUELTANK)
TUBE CLIP
RR. STAY
WATER HOSE B
WATER HOSEA
WATER HOSE CLAMP
WATER PIPEA
WATER PIPE B
RR. BRAKE HOSE PIPE
WATER PASS TUBE B
E.M.I. UNIT COMP.
WATER PASS TUBE B
THROTTLE CABLE
RADIATOR CAP HOSE
RADIATOR HOSEA
RADIATOR HOSEA
RADIATOR HOSE B
THERMO SWITCH WIRE
THERMO SWITCH WIRE
SEAT LOCK CABLE
WATER PASS TUBE A
WATER PASS TUBE B
WATER PASS TUBE B
RR. BRAKE HOSE PIPE
LH. SEAT LOCK CABLE
SEAT LOCK CABLE
COMB METER COUPLER
RH. SEAT LOCK CABLE
WATER PIPEA
WATER PIPE B
WATER PASS TUBE A
HORN WIRE
E.M.I. CORD(FAN MOTOR)
E.M.I. CORD(WIRE HARNESS)

1-17
SERVICE INFORMATION
HEAD LIGHT CONTROLLER
REGULATOR RECTIFIER
START MAGNETIC
SWITCH
BATTERY EARTH CABLE
HEADLIGHT CONTROLLER CODE
REGULATOR
COUPLER 2EA
HEAD LIGHT RELAY
THERMO SWITCH RELAY
WINKER RELAY
EARTH CABLE
BATTERY BOX
COUPLER
*NOTE
- WHITE COLOR : EXPORT USE ONLY
- BLACK COLOR :DOMESTIC USE ONLY