L.

Crank Case Cover/Kick Starter/Continuously Variable Transmission

L. crank case cover

7-0
 L. Crank Case Cover/Kick Starter/Continuously Variable Transmission

7. L. Crank Case Cover/Kick Starter/Continuously variable transmission

Service Information 7-1 Drive Belt 7-7

Troubleshooting 7-1 Movable Drive Face 7-9
L. Crank Case Cover 7-2 Clutch/Disassembly 7-12
Kick Starter 7-4 Driven Face Disassembly 7-12

Service Information
General Safety
ƃ Take precautions not to apply grease or oil to the drive belt and pulley surface.

NOTE 
ҮTake precautions not to apply the grease oil to the movable drive face or weight roller.

Specifications Unit:mm(in)

Item Standard Service Limit

Movable drive face bushing inner diameter 24.000-24.013(0.9449-0.9454) 24.040(0.9465)
Drive face boss outer diameter 23.980-23.993(0.9441~0.9446) 23.960(0.9433)
Drive belt width 22(0.8661) 20.5(0.8071)
Weight roller outer diameter 10.95-20.05(0.4311-0.7893) 19.5(0.7677)
Clutch outer and inner diameter 120.0-120.5(4.7244-4.7441) 120.5(4.7441)
Driven face spring play 97.85(3.8524) 97.23(3.8279)
Driven face outer diameter 37.965-37.985(1.4946-1.4955) 37.911(1.4926)
Driven face inner diameter 38.0-38.025(1.4961-1.4970) 38.060(1.4984)

Troubleshooting
Engine starts but motorcycle does not Vehicle unable to run at the maximum
work. speed, or lack of output
ƃ Drive belt worn. ƃ Drive belt worn.
ƃ Ramp plate damaged. ƃ Defective movable driven face spring.
ƃ Clutch shoe worn or damaged. ƃ Weight roller worn.
ƃ Movable driven face spring cut. ƃ Pulley face contaminated.
Engine stops, or the vehicle runs suddenly,
after starting.
ƃ Clutch shoe spring cut.

7-1
L. Crank Case Cover/Kick Starter/Continuously Variable Transmission

L. Crank Case Cover

Removal
ƃ Loosen the kick starter pedal bolt.
ƃ Remove the kick starter pedal.

Kick starter pedal

ƃ Remove the cover side cooling hose.

ƃ Loosen the L. crank case cover bolt, and remove
the cover.

Crank case cover

ƃ Remove the gasket and dowel pin.

Installation
ƃ Remove the crank case gasket, and install a new
gasket and dowel pin.

7-2
 L. Crank Case Cover/Kick Starter/Continuously Variable Transmission

ƃ Tighten the L. crank case cover bolt.

ƃ Assemble the cooling hose to the cover.

Crank case cover

ƃ Install the kick starter pedal and tighten bolts.

Torque value: 2.2kg-m (22N.m, 16ft-Ib)
ƃ Feed the DAELIM genuine oil to the cylinder
head cover.

Kick starter pedal

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L. Crank Case Cover/Kick Starter/Continuously Variable Transmission

Kick Starter Stopper plate

Removal
ƃ Remove the L. crank case cover.(ऻ 7-2)
ƃ Remove the kick starter spring from the kick
return stopper plate on the L. crank case cover.
ƃ Remove the kick starter spindle.

ƃ Remove the kick driven gear.

Kick driven gear

ƃ Remove the kick starter idle shaft.

Kick start idle shaft

7-4
 L. Crank Case Cover/Kick Starter/Continuously Variable Transmission

ƃ Disassemble the kick starter driven gear. Driven gear

OIL
Idle gear

ƃ Disassemble the kick starter idle shaft.

Kick Starter Inspection

ƃ Check the kick starter spindle for wear or
damage.
ƃ Check the return spring for defects or damage.

ƃ Check the kick starter spindle bushing and the

idle gearshaft assembly for damage.

7-5
L. Crank Case Cover/Kick Starter/Continuously Variable Transmission

ƃ Check the kick starter driven gear for wear and

damage. Check the friction spring for defects and Kick starter
driven gear
damage.
Friction
spring

7-6
 L. Crank Case Cover/Kick Starter/Continuously Variable Transmission

Kick Starter Assembly Driven gear

ƃ Assemble the kick starter idle gear shaft and the

OIL
kick driven gear comp to the left cover.

NOTE
ҮApply grease to the spring groove, kick driven
gear, and idle gear wedge.

ƃ As shown in the figure, match the kick driven

gear friction spring with the L. crank case cover
groove, and assemble. Idle gear

ƃ Match the kick starter spindle with the idle gear

punch mark, and assemble.

ƃ Hold, and turn, in reverse, the kick return spring

arm.
ƃ Assemble the kick stopper plate.

Drive Belt
Removal
ƃ Remove L. crank case cover. (ऺ 7-2)
ƃ Loosen the clutch outer setting nut with a
universal holder.
Tool: Universal holder

Setting nut

7-7
L. Crank Case Cover/Kick Starter/Continuously Variable Transmission

ƃ Remove the drive belt from the clutch / driven Drive belt
pulley, as shown in the figure.

Clutch/driven pulley

Drive Belt Inspection

ƃ Check the drive belt for cracks, deterioratect and Teeth type
abnormal wear. Replace the defective drive belt.
ƃ Check the drive belt width.
Width
Service limit: 20.5mm (0.8071in)

NOTE
Ү Use Daelim genuine parts.
Ү Be careful not to apply oil to the belt pulley
contact.

Drive Belt Assembly

ƃ Temporarily assemble the clutch / driven pulley
to the drive shaft.
ƃ As shown in the right side figure, turn the
Movable
movable driven face clockwise, and assemble the driven face
drive belt to the driven pulley while widening
the driven pulley belt contact part.

ƃ Assemble the clutch / driven pulley to the drive

shaft.

NOTE Drive
shaft
ҮMake sure that the movable drive face do not
return to the original position until the
clutch/driven pulley are completely assembled
to the drive shaft.

7-8
 L. Crank Case Cover/Kick Starter/Continuously Variable Transmission

ƃ Assemble the clutch outer to the drive shaft.

ƃ Fix the clutch outer with the universal holder, and
fasten with the setting nuts.
Torque value: 5.5kg-m (55N.m,40ft-Ib)
Tool: Universal holder
ƃ Assemble the L. crank case cover.

Setting nut

Movable Drive Face Nut Drive face

Removal
ƃ Remove the L. crank case cover.
ƃ Fix the drive pulley holder to the crank shaft.
ƃ Remove the drive pulley nut, washer and drive
face.
Tool: Drive pulley holder

Drive pulley holder

ƃ Remove the movable drive face and the drive

face boss.

Drive face boss

ƃ Remove the ramp plate, weight roller, and O-ring

Face boss Weight roller Ramp plate
from the movable drive face.

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L. Crank Case Cover/Kick Starter/Continuously Variable Transmission

Movable Drive Face Inspection

ƃ Check the weight roller for wear or damage. Weight roller
ƃ Check the weight roller outer diameter.
Service limit: 19.5mm (0.767in)

ƃ Check the movable drive face boss for wear or Movable drive face
damage.
ƃ Check the outer diameter of the movable drive
face boss.
Service limit: 23.96mm (0.943in) Drive face boss
ƃ Check the inner diameter of the movable drive
face.
Service limit: 24. 043mm (0.946in)

Movable Drive Face Assembly

ƃ Supply grease on the inner side of the movable Ramp plate
drive face boss part.
ƃ Assemble oil seal in the both sides of the
movable drive face boss part.
ƃ Assemble the weight roller.
ƃ Assemble the ramp plate.
ƃ Connect the movable drive face boss together.

NOTE

Ү Do not apply the grease to the pully surface of

the movable drive face.
Ү If grease is applied, remove the grease.

Drive face boss

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 L. Crank Case Cover/Kick Starter/Continuously Variable Transmission

ƃ Assemble the movable drive face boss and the

movable drive face to the crank shaft.

ƃ Assemble the assembly drive belt to the crank

shaft.

Drive belt

ƃ Tighten the drive pulley nut with a drive holder.

Torque value: 5.5kg-m (55N.m,40ft-Ib)
Tool: Drive pulley holder

Setting nut

7-11
L. Crank Case Cover/Kick Starter/Continuously Variable Transmission

Clutch Disassembly
ƃ Remove the L. crank case cover. (ऺ 7-2)
ƃ Disassemble the movable drive face. (ऺ 7-9)
ƃ Disassemble the drive belt. (ऺ 7-7)
ƃ Use a universal holder to hold the clutch outer,
and remove the clutch outer after disassembling
the 12mm flange nut.

Setting nut

ƃ Remove the movable driven face and the clutch

Movable drive
from the drive shaft. face.clutch

Driven Face Disassembly Drive

Drive
ƃ Disassemble the 30mm special nut.

Drive

Clutch shoe
Clutch spring

Drive plate

Face nut

Rubber Spring collar

Clutch spring

7-12
 L. Crank Case Cover/Kick Starter/Continuously Variable Transmission

ƃ Remove the seal collar.

Seal collar

ƃ Remove the guide roller and its pin.

ƃ Remove the movable driven face. Movable
Guide roller driven face
ƃ Remove the O-ring from the movable drive face.

ƃ Remove the oil seal from the movable driven Movable

face. driven face
Oil seal

O-ring Guide pin

ƃ Remove the inner bearing.

Inner bearing

7-13
L. Crank Case Cover/Kick Starter/Continuously Variable Transmission

ƃ Disassemble the circlip and remove the outer

bearing. Outer bearing

Clutch/Driven Face Inspection

ƃ Measure the free length of the driven face spring.
Service limit: 97.23mm (3.822in)

Free length

ƃ Check the clutch outer for wear or damage.

ƃ Measure the inner diameter of the clutch outer.
Service limit: 120.5mm(4.736in)

Clutch outer

ƃ Check the clutch shoe for wear or damage.

ƃ Measure the thickness of each shoe. Lining

Service limit: 2.0mm(0.078in)

Clutch shoe

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 L. Crank Case Cover/Kick Starter/Continuously Variable Transmission

ƃ Check the driven face assembly for wear or

damage.
ƃ Measure the outer diameter of the driven face.
Service limit: 37.94mm(1.491in)

Movable face Guide pin globe

ƃ Check the movable driven face for wear or

damage.
ƃ Measure the inner diameter of movable driven
face.
Service limit: 38.06mm(1.496in)
ƃ Check the guide globe for wear or damage.
ƃ Check the oil seal for wear, damage or other
defects.

Driven Face Assembly

ƃ Assemble the outer bearing to the movable
driven face. Outer bearing

NOTE
ҮAssemble the bearing so that the sealed edge
faces outward.

ƃ Insert the circlip into the groove.

ƃ Fill the grease into all bearing grooves.
Grease application: 9.0-9.5g

ƃ Assemble inner bearing.

NOTE Inner bearing

ҮAssemble the bearing so that the sealed edge
faces outward.

Tool: - Bearing driver attachment

- Driver pilot

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L. Crank Case Cover/Kick Starter/Continuously Variable Transmission

ƃ Assemble the movable driven face, guide roller

Movable
and roller pin driven face
Guide roller

ƃ Assemble the seal collar.

Seal collar

ƃ Assemble the driven pulley, spring and clutch in Lock nut Lock nut wrench
the clutch spring compressor. Compress the
assembly by turning the tool handle until the
lock nut can be installed.
ƃ Clamp the clutch spring compressor in a vise and
tighten the lock nut to the specified torque using
the lock nut wrench. Remove the spring
compressor.
Torque value: 5.5kg-m(55N.m, 40ft-lb)
Tool: - Lock nut wrench
- Clutch spring compressor Clutch spring compressor

Clutch/Driven Pulley Assembly Movable driven

ƃ Assemble the driven pulley to the drive shaft. face/clutch

7-16
 L. Crank Case Cover/Kick Starter/Continuously Variable Transmission

ƃ Assemble the clutch outer. Hold the clutch outer,

and tighten nuts with the prescribed torque.
Torque value: 5.5kg-m(55N.m, 40ft-lb)
Tool: Universal holder
ƃ Assemble the drive face.
ƃ Assemble the L. crank case cover.

Setting nut

7-17