Daelim S4 50cc Service Manual - Mojo

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SERVICE INFORMATIONTORQUE VALUESENGINEITEMQ’TYTHREAD DIA(mm)TORQUE VALUEREFERENCETAPPET ADJUSTING ROLL CAPOIL DRAIN PLUG BOLTVALVE ADJUST SCREW LOCK NUTCYLINDER HEAD BOLTFLYWHEEL NUTDRIVE FACE NUTCLUTCH OUTER BOLTSPARK PLUGDRIVE PLATECAM SHAFT HOLDER NUTCAM CHAIN TENSIONER FLANGE BOLTCAM CHAIN TENSIONER PAN SCREWCYLINDER HEAD COVER BOLTMISSION COVER BOLTMISSION COVER DRAIN BOLTMISSION COVER CHECK BOLTCOOLING FAN BOLTSTARTER MOTOR FLANGE BOLT11221111142148113230125612121010287666688661.5 kgf·m2.5 kgf·m1.1 kgf·m1.1 kgf·m5.5 kgf·m5.5 kgf·m4.0 kgf·m1.2 kgf·m5.5 kgf·m2.0 kgf·m1.0 kgf·m0.4 kgf·m1.1 kgf·m1.2 kgf·m1.0 kgf·m0.9 kgf·m1.0 kgf·m0.9 kgf·mApply the engine oilApply the engine oilFRAMEITEMQ’TYTHREAD DIA(mm)TORQUE VALUEREFERENCESTEERING LOCK NUTSTEERING TOP NUTHANDLE BAR LOCK NUTFRONT AXLE NUTFRONT CALIPER BRACKET BOLTFRONT MASTER CYLINDER HOLDER BOLTFRONT DISK PLATE BOLTFRONT FORK BOLTREAR WHEEL AXLE NUTREAR CUSHION UPPER BOLTREAR CUSHION UNDER BOLTREAR CUSHION UPPER METAL LOCK NUTENGINE HANGER UPPER BOLTMAIN STAND BOLTSIDE STAND PIVOT SCREWSIDE STAND PIVOT NUT111112321111111126261012106822168810101010107.0 kgf·m0.25 kgf·m4.5 kgf·m6.0 kgf·m3.0 kgf·m1.2 kgf·m4.25 kgf·m2.25 kgf·m12 kgf·m4.0 kgf·m4.0 kgf·m3.5 kgf·m4.5 kgf·m4.0 kgf·m1.5 kgf·m4.5 kgf·mTorque values listed above are for specific tightening points. Torque values for other items are listed in the following table.ITEMTORQUE VALUEITEMTORQUE VALUE5mm BOLT, NUT6mm BOLT, NUT8mm BOLT, NUT10mm BOLT, NUT12mm BOLT, NUT0.5 kgf·m1.0 kgf·m2.2 kgf·m3.5 kgf·m5.5 kgf·m5mm SCREW6mm SCREW6mm SCREW BOLT, NUT8mm SCREW BOLT, NUT10mm SCREW BOLT, NUT0.4 kgf·m0.9 kgf·m1.2 kgf·m2.7 kgf·m4.0 kgf·m
SYMBOLS / ABBREVIATIONSThe following symbols are used in this manual to represent job-related warnings or cautions.SYMBOLWARNINGMEANINGIndicates dangerous area. Seriousaccident may result if instructions are notfollowed.SYMBOLCAUTIONNOTESERVICE INFORMATIONMEANINGIndicates important work. Minor injury orvehicle part damage may result if instructionare not followed.Indicates general safety matters. Providessafety and appropriate handling procedures.The following abbreviations are used in this manual.ASS’YASSEMBLYLH.LeftRH.RightThe following symbols indicate oil adding, oil change, or parts.SYMBOLCAUTIONUse recommended engine oil, unless otherwise specified.Use molybdenum oil solution (mixture of the engine oil and molybdenum grease with the ratio 1:1)Use multi-purpose grease (Lithium based multi-purpose grease NLG #2 or equivalent)Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2or equivalent)Use molybdenum disulfide paste containing more than 40% molybdenum disulfide, NLGI #2 orequivalent)Use silicone greaseApply a locking agent. Use the agent of the middle strength, unless otherwise specifiedApply sealantReplace the parts with new ones before assemblyUse brake fluid, DOT3 or DOT4. Use the recommended brake fluid, unless otherwise specifiedUse Fork or Suspension FluidUse special toolUse option tool. These tools are obtained as you order parts.(3-1) Indicates reference page. (Example : Refer to page 3-1)Special grease, etc. that do not correspond to the above are indicated without using symbols.
Page 3: CONTENTS Contents of this manual an
Page 6 and 7: SERVICE INFORMATIONSPECIFICATIONDIM
Page 10 and 11: SERVICE INFORMATIONLUBRICATION OILE
Page 12 and 13: SERVICE INFORMATIONWINKER RELAYHORN
Page 14 and 15: SERVICE INFORMATIONBATTERY CABLESAI
Page 16 and 17: SERVICE INFORMATION3. Store the par
Page 18 and 19: SERVICE INFORMATION19. Install the
Page 20 and 21: SERVICE INFORMATION•Turn off the
Page 22 and 23: SERVICE INFORMATION•In case that
Page 24 and 25: INSPECTIONS / ADJUSTMENTSTORQUESPAR
Page 26 and 27: INSPECTIONS / ADJUSTMENTSFUEL STRAI
Page 28 and 29: INSPECTIONS / ADJUSTMENTSTURNCAUTIO
Page 30 and 31: INSPECTIONS / ADJUSTMENTSBRAKE FLUI
Page 32 and 33: INSPECTIONS / ADJUSTMENTSWHEELS / T
Page 34 and 35: MEMO
Page 36 and 37: EXTERNAL PARTSMAINTENANCE PROCEDURE
Page 38 and 39: EXTERNAL PARTSTAPPING SCREWS● Loo
Page 40 and 41: EXTERNAL PARTSFLOOR PANEL● Untie
Page 42 and 43: EXTERNAL PARTSWASHER BOLTFRONT UNDE
Page 46 and 47: LUBRICATION SYSTEMTROUBLE SHOOTINGO
Page 48 and 49: LUBRICATION SYSTEMOIL PUMPINSPECTIO
Page 50 and 51: LUBRICATION SYSTEMASSEMBLY● Clean
Page 54 and 55: FUEL SYSTEMTROUBLESHOOTINGThe vehic
Page 56 and 57: FUEL SYSTEM● Untie screws install
Page 58 and 59:
FUEL SYSTEMSLOW JET● Remove the m
Page 60 and 61:
FUEL SYSTEM● Assemble acceleratin
Page 62 and 63:
FUEL SYSTEMTHROTTLE STOP SCREW Exte
Page 64 and 65:
MEMO
Page 66 and 67:
ENGINE REMOVAL/INSPECTIONCARBURETOR
Page 68 and 69:
BELT TYPE CONTINUOUSLY VARIABLE TRA
Page 70 and 71:
Page 72 and 73:
Page 74 and 75:
Page 76 and 77:
Page 78 and 79:
Page 80 and 81:
Page 82 and 83:
Page 84 and 85:
A.C. GENERATOR /RH. CRANK CASE COVE
Page 86 and 87:
Page 88 and 89:
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
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TRANSMISSION/CRANKSHAFT/CRANKCASETO
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TRANSMISSION/CRANKSHAFT/CRANKCASEIN
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TRANSMISSION/CRANKSHAFT/CRANKCASECR
Page 124 and 125:
FRONT WHEEL / FRONT BRAKE / FRONT F
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REAR WHEEL / REAR BRAKE / REAR CUSH
Page 150 and 151:
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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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