Daelim S4 50cc Service Manual - Mojo

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FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEMDUST SEAL● Remove the dust seal.● Remove the fork pipe from the bottom case.● Remove the piston and rebound spring from thefork pipe.OIL SEAL STOP RING● Remove the oil seal stop ring.● Remove the oil seal.OIL SEALNOTE•Take precaution not to damage the interior andexterior rim of the bottom case.
FRONT WHEEL / FRONT BRAKE / FRONT FORK / STEERING STEMINSPECTION● Place the fork spring on a level place, and measurethe free length.● If the free length deviates from the service limit,replace the springs with now ones.SERVICE LIMIT: 232 MMFRONT FORK SPRINGBOTTOM CASEOIL SEALDUST SEAL● Check components for damage or abnormal wear.Replace defective parts with new ones.OIL LOCK PEACEREBOUND SPRINGOIL SEAL STOP RINGSOCKETBOLTPIPE SEATCUSHION SPRINGFORK PIPE● Set the fork pipe on a V-blocks, and measure forkpipe deflection by rotating with a dial gauge.● Replace if the defletion is greater than 0.2mm.● Check the contact side of slider bush.● Replace bottom case when serisously damaged.FORK PIPEBOTTOM CASEFORK SEAL DRIVEASSEMBLY● Wash parts with clean oil prior to assembling.● Assemble the rebound spring and fork piston to thefork pipe.● Assemble oil seal● Assemble oil seal stop ring● Apply ATF to the new oil seal.● Assemble the oil seal to the bottom case.● Insert the oil seal with special tools until theattachment groove of the bottom case set ring isexposed.TOOL: FORK SEAL DRIVERFORK SEAL DRIVER BODY
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CONTENTS Contents of this manual an
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SERVICE INFORMATIONSPECIFICATIONDIM
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SERVICE INFORMATIONTORQUE VALUESENG
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SERVICE INFORMATIONLUBRICATION OILE
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SERVICE INFORMATIONWINKER RELAYHORN
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SERVICE INFORMATIONBATTERY CABLESAI
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SERVICE INFORMATION3. Store the par
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SERVICE INFORMATION19. Install the
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SERVICE INFORMATION•Turn off the
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SERVICE INFORMATION•In case that
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INSPECTIONS / ADJUSTMENTSTORQUESPAR
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INSPECTIONS / ADJUSTMENTSFUEL STRAI
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INSPECTIONS / ADJUSTMENTSTURNCAUTIO
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INSPECTIONS / ADJUSTMENTSBRAKE FLUI
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INSPECTIONS / ADJUSTMENTSWHEELS / T
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MEMO
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EXTERNAL PARTSMAINTENANCE PROCEDURE
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EXTERNAL PARTSTAPPING SCREWS● Loo
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EXTERNAL PARTSFLOOR PANEL● Untie
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EXTERNAL PARTSWASHER BOLTFRONT UNDE
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MEMO
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LUBRICATION SYSTEMTROUBLE SHOOTINGO
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LUBRICATION SYSTEMOIL PUMPINSPECTIO
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LUBRICATION SYSTEMASSEMBLY● Clean
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MEMO
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FUEL SYSTEMTROUBLESHOOTINGThe vehic
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FUEL SYSTEM● Untie screws install
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FUEL SYSTEMSLOW JET● Remove the m
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FUEL SYSTEM● Assemble acceleratin
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FUEL SYSTEMTHROTTLE STOP SCREW Exte
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MEMO
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ENGINE REMOVAL/INSPECTIONCARBURETOR
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BELT TYPE CONTINUOUSLY VARIABLE TRA
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A.C. GENERATOR /RH. CRANK CASE COVE
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Page 90 and 91: CYLINDER HEAD / VALVES
Page 92 and 93: CYLINDER HEAD / VALVESTOOL-VALVE GU
Page 94 and 95: CYLINDER HEAD / VALVESCAM SHAFTCAM
Page 96 and 97: CYLINDER HEAD / VALVES● Remove th
Page 98 and 99: CYLINDER HEAD / VALVESVALVE GUIDE R
Page 100 and 101: CYLINDER HEAD / VALVESCYLINDER HEAD
Page 102 and 103: CYLINDER HEAD / VALVES● Install f
Page 104 and 105: CYLINDER / PISTON
Page 106 and 107: CYLINDER / PISTONCYLINDERCYLINDERRE
Page 108 and 109: CYLINDER / PISTONPISTON RINGFEELER
Page 110 and 111: CYLINDER / PISTON● Install the ne
Page 112 and 113: TRANSMISSION/CRANKSHAFT/CRANKCASE
Page 114 and 115: TRANSMISSION/CRANKSHAFT/CRANKCASETO
Page 116 and 117: TRANSMISSION/CRANKSHAFT/CRANKCASEIN
Page 122 and 123: TRANSMISSION/CRANKSHAFT/CRANKCASECR
Page 124 and 125: FRONT WHEEL / FRONT BRAKE / FRONT F
Page 148 and 149: REAR WHEEL / REAR BRAKE / REAR CUSH
Page 156 and 157: CHARGING SYSTEMWINKER RELAYMAGNETIC
Page 158 and 159: CHARGING SYSTEMTROUBLE SHOOTINGNo p
Page 160 and 161: CHARGING SYSTEMBATTERY TERMINALCAUT
Page 162 and 163: IGNITION SYSTEMWINKER RELAYFUEL TAN
Page 164 and 165: IGNITION SYSTEMTROUBLE SHOOTINGSpar
Page 166 and 167: IGNITION SYSTEMIGNITION COIL INSPEC
Page 168 and 169: STARTING SYSTEMWINKER RELAYMAGNETIC
Page 170 and 171: STARTING SYSTEMTROUBLE SHOOTINGStar
Page 172 and 173: STARTING SYSTEMBRUSH● the brush s
Page 174 and 175: STARTING SYSTEMSTARTER MAGNETIC SWI
Page 176 and 177: LIGHTS// SWITCHES / HORNHEADLIGHT B
Page 178 and 179: LIGHTS// SWITCHES / HORNSPEEDOMETER
Page 180 and 181: LIGHTS// SWITCHES / HORNRELEASE THE
Page 182 and 183: ENGINE STALLS, HARD TO START, ROUGH
Page 184 and 185: POOR OPERATIONCLUTCH DRIVE / DRIVEN
Page 186 and 187: MEMO
Page 188: SM62-1003-01E
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Daelim S4 50cc Service Manual - Mojo

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