SM63-1010-01E

SERVICE INFORMATION

GENERAL
INSPECTION / ADJUSTMENT

EXTERNAL PARTS

LUBRICATION SYSTEM

EMS

COOLING SYSTEM

ENGINE REMOVAL/INSTALLATION

ENGINE LH. CRANK CASE COVER / CONTINOUSLYVARIABLE TRANSMISSION

AC GENERATOR / FLY WHEEL

CYLINDER HEAD / VALVE

CYLINDER / PISTON

CRANKCASE / TRANSMISSION/ CRANK SHAFT

FRONT WHEEL / FRONT FORK / STEERING

FRAME

REAR WHEEL / REAR CUSHION

BRAKES

CHARGING SYSTEM
ELECTRICAL SYSTEM

IGNITION SYSTEM

STARTER SYSTEM

LIGHTS / SWITCHES / HORN

TROUBLE SHOOTING

Copyright 2010. DAERIM MOTOR Co., LTD. WIRING DIAGRAM

All Rights Reserved
SERVICE INFORMATION

SERIAL NUMBER LOCATION 1-1 SYMBOLS / ABBREVIATIONS 1-12

SPECIFICATION 1-2 CAUTIONS AT WORK 1-13
TWIST TORQUE 1-4 CAUTIONS AT ASSEMBLY,
SPECIAL TOOL 1-6 DISASSEMBLY 1-13
PARTS COMPOSITION MAP 1-8 CAUTIONS AT WIRING 1-17

SERIAL NUMBER LOCATIONS

SERVICE INFORMATION

SPECIFICATION

OVERALLLENGTH 2,110 mm 2,140 mm

OVERALLWIDTH 750 mm 750 mm
OVERALLHEIGHT 1,200 mm 1,215 mm
WHEEL BASE 1,500 mm 1,500 mm
DIMENSIONS
SEAT HEIGHT 745 mm 762 mm
GROUND CLEARANCE 136 mm 143 mm
DRYWEIGHT 159 kgs 159 kgs
GROSS WEIGHT 170 kgs 170 kgs

TYPE Underbone Underbone

FRONT SUSPENSION/ STROKE Telescopic / 85mm Telescopic/ 85mm
REAR SUSPENSION/ STROKE Unit Swing Arm/ 80mm Unit Swing Arm/80mm
FRONT TIRE SIZE 120/70-13 (tubeless) 120/70-14(tubeless)
REAR TIRE SIZE 140/60-13 (tubeless) 140/60-13(tubeless)
TIRE PRESSURE 1 person FRONT 2.00kgf/cm2(200kpa) 2.00kgf/cm2(200 kpa)
REAR 2.40kgf/cm2(240kpa) 2.40kgf/cm2(200 kpa)
FRAME 2 persons FRONT 2.00kgf/cm2(200kpa) 2.00kgf/cm2(200 kpa)
REAR 2.50kgf/cm2(250kpa) 2.50kgf/cm2(200 kpa)
FRONT BRAKE Hydraulic Disk Hydraulic Disk
REAR BRAKE Hydraulic Disk Hydraulic Disk
FUELTANK CAPACITY Full capacity 11.5L 11.5L
Reserve capacity 1.9L 1.9L
CASTER ANGLE 27 27
TRAIL 94.5mm 94.5mm

TYPE Air cooled 4cycle DOHC engine (4 valves)

CYLINDERS, ARRANGEMENT 1(single cylinder), front angle 80
BORE X STROKE 56.5mm 49.5mm
DISPLACEMENT 124cm3
COMPRESSION RATIO 11.8:1
COMPRESSION PRESSURE 13.0kg/cm2(600 rpm)
OIL CAPACITY FULL 1.30L(Full capacity)
REPLACEMENT 1.10L(at changing)
LUBRICATION 0.1L(Full capacity)
AIR CLEANER Forced pressure splash type
ENGINE VALVES Dry filter paper
VALVE SYSTEM DOHC chain operation
INTAKE VALVE IN VALVE OPEN DOHC 4 Valves
CLOSE 15 BTDC
EX VALVE OPEN 39 ABDC
CLOSE 57.4 BBDC
12.6 ATDC
VALVE CLEARANCE INTAKE 0.15 0.02mm
EXHAUST 0.23 0.02mm
ENGINE DRYWEIGHT 38kg
 SERVICE INFORMATION

CLUTCH DRY PLATE SHOE TYPE

TRANSMISSION
Automatic Transmission(V-belt type)
TRANSMISSION TRANSMISSION PRIMARYREDUCTION RATIO
TRANSMISSION SECONDARYREDUCTION 2.786(39T/14T)
RATIO 3.462(45T/13T)

IGNITION SYSTEM TRANSISTOR

IGNITION TIMING IDLE 0 BTDC / 1,600(rpm)
AC GENERATOR 12V-17A/ 5,000(rpm)
BATTERY CAPACITY 12V 10AH
SPARK PLUG CR8EH - 9
SPARK PLUG GAP 0.8 - 0.9mm
FUSE CAPACITY 30A(main), 15AX 4
STARTING SYSTEM
CELL STARTING(STARTER MOTOR)
ELECTRICAL HEADLIGHT(HIGH / LOW)
60/55W
POSITION LAMP
5W
SYSTEM WINKERS
16W 2, 10W 2
TAIL/STOP LAMP
COMBI METER LAMP LED (8EA)
(SPEEDOMETER/TACHOMETER) LED
NEUTRAL INDICATOR LAMP LED x 1
HIGH BEAM INDICATOR LAMP LED
TURN SIGNALINDICATOR LAMP LED x 1
NUMBER PLATE POSITION LAMP LED
TACHOMETER LAMP LED x 1
SERVICE INFORMATION

TORQUES

STEERING STEM NUT

M26 1.0 6~8
STEERING TOPTHREAD
M26 1.0 0.2 ~ 0.3
BOTTOM BRIDGE(FORK PIPE) BOLT
M10 1.25 7.0 ~ 8.0
HANDLE POST NUT
M10 1.25 5.5 ~ 6.5 U-NUT
FRONT WHEELAXLE NUT
M12 1.25 5.0 ~ 7.0 U-NUT
REAR WHEELAXLE NUT
M16 1.5 12 ~ 13 U-NUT
BRAKE OIL BOLT(FRONT/REAR)
M10 1.25 3.0 ~ 4.0
CALIPER BRACKET BOLT(FRONT/REAR)
M8 1.25 2.8 ~ 3.4
MASTER CYLINDER HOLDER
M6 1.0 1.0 ~ 1.4
BOLT(FRONT/REAR)
M8 1.25 4.0 ~ 4.5
DISK PLATE BOLT(FRONT/REAR)
M5 0.8 0.35 ~ 0.5
SPEEDOMETER GEAR BOX SCREW
M8 1.25 1.5 ~ 2.5
FRONT FORK BOTTOM BOLT
M22 1.0 1.5 ~ 3.0
FORK BOLT
M10 1.25 3.5 ~ 4.5
REAR CUSHION UPPER BOLT
M10 1.25 3.5 ~ 4.5
REAR CUSHION UNDER BOLT
M10 1.25 3.0 ~ 4.0
REAR CUSHION ROAD LOCK NUT
M12 1.25 5.0 ~ 5.5
ENGINE HANGER UPPER BOLT
M10 1.25 4.0 ~ 5.0 U-NUT
ENGINE HANGER LOW NUT
M10 1.25 3.5 ~ 4.5
MAIN STAND BOLT
M10 1.25 1.0 ~ 2.0
SIDE STAND PIVOT SCREW
M10 1.25 4.0 ~ 5.0
SIDE STAND PIVOT NUT
 SERVICE INFORMATION

CYLINDER HEAD COVER BOLT M6 1.0 1.0 ~ 1.2

CAP HOLER BOLT M6 1.0 1.0 ~ 1.2
CAM CHAIN GUIDE BOLT M6 1.0 1.0 ~ 1.2
CYLINDER HEAD SOCKET M10 1.25 3.5 ~ 4.5 Engine oil applied
CYLINDER BOLT M6 1.0 1.0 ~ 1.2
SPARK PLUG M10 1.0 1.5 ~ 1.7
ENGINE TEMPERATURE SENSOR M12 1.25 1.6 ~ 2.0
TENSIONER PIVOT BOLT M6 1.0 0.8 ~ 1.2
TENSIONER LIFT BOLT M6 1.0 1.0 ~ 1.4
TENSIONER LIFT SCREW M6 1.0 0.35 ~ 0.5
ACG FLYWHEEL NUT M16 1.0 6.0 ~ 6.7
STARTER CLUTCH OUTER SOCKET M8 1.25 3.0 ~ 3.4
OIL PUMPASS BOLT M6 1.0 1.0 ~ 1.2
OIL SEPERATOR M6 1.0 1.0 ~ 1.2
ACG STATOR COMPSCREW M5 0.35 ~ 0.5
TAPPETADJUST HOLE CAP M30 1.5 1.0 ~ 1.2
WATER PUMP IMPELLER M7 1.0 1.0 ~ 1.4
DRIVE FACE NUT M12 1.25 5.0 ~ 6.0
DRIVE PLATE NUT M28 5.0 ~ 6.0
CLUTCH OUTER NUT M12 1.25 5.0 ~ 6.0
MISSION COVER BOLT M8 1.25 3.0 ~ 4.0
MISSION CASE BOLT M8 1.25 3.0 ~ 4.0
MISSION COVER BOLT M8 1.25 1.6 ~ 2.0
MISSION COVER CHECK BOLT M8 1.25 1.6 ~ 2.0
STARTER MOTOR BOLT M6 1.0 1.0 ~ 1.4

Torque values listed above ate for specific tightening points. Torque values for other items are listed in the following tables.

4 BOLT, NUT 0.15 ~ 0.4 4 SCREW 0.15 ~ 0.3

5 BOLT, NUT 0.45 ~ 0.6 5 SCREW 0.35 ~ 0.5
6 BOLT, NUT 0.8 ~ 1.2 6 SCREW 0.7 ~ 1.1
(SH Flange bolt included) (SH TYPE included)
8 BOLT, NUT 1.8 ~ 2.5 6 FLANGE BOLT,NUT 1.0 ~ 1.4
10 BOLT, NUT 3.0 ~ 4.0 8 FLANGE BOLT,NUT 2.4 ~ 3.0
12 BOLT, NUT 5.0 ~ 6.0 10 FLANGE BOLT,NUT 3.5 ~ 4.5

SH(Small Head) : presents 6mm bolt of 8mm flange head

SERVICE INFORMATION

TOOL

ACG ROTOR PULLER Used for disassembly ACG Rotor from Crank shaft 9
VALVE GUIDE DRIVER Used at the time of replacing valve guide
10
VALVE GUIDE RIMMER
BEARING REMOVER SET Used at the time of disassembling bearings of crank case
THREAD ADAPTER Used at thetime of assembling crank shaft to crank case
12
ASSEMBLY SHAFT
CRANK ASSEMBLY COLLAR
BALL RACE DRIVER Used at the time of disassembling top blace and bottom ball race
STEERING STEM DRIVER Used at the time of pressing bottom cone race to steering stem
13
FORK SEALDRIVER Used at the time of inputting the oil seal of front fork
STEERING STEM SOCKET Used at the time of disassembling steering head top thread
SNAP RING PLIER Used at the time of disassembling the cir clip of master cylinder 15

COMPRESSION GAUGE Used at the time of measuring the compression power of cylinder 2
MULTI TESTER Used at measuring electrical parts 5,16,17,18,19
PVATESTER 5,16,17,18,19
SCANNER Used at diagnosis of ECU and sensors 5
 SERVICE INFORMATION

SYMBOLS / ABBREVIATIONS
The following symbols are used in this manual to represent job-related warnings or cautions
SYMBOL MEANING SYMBOL MEANING
Indicates important work. Minor injury or vehicle part damage
Indicates dangerous areas. WARNING
mayresultifinstructionarenotfollowed
WARNING Serious accidents may result if instructions are not
Indicates general cautions. Provides safety and
followed. WARNING
appropriate handling procedures.

The following abbreviations are used in this manual.

ASS Y
LH.
RH.

Indicates oil applying. If there is no specific oil indicated, use the designated or recommended engine oil

Indicates molybdenum solution applying. Molybdenum solution is made by mixing engine oil and molybdenum
grease as 1:1 mixing ratio.

Indicates to apply grease(NLG 1#2)

Indicates to apply molybdenum grease(Containing more than 30% molydenum disulfide, NLG 1#2 or equivalent)

Indicates to apply molybdenum best(Containing more than 40% molydenum disulfide, NLG 1#2 or equivalent)

Indicates to apply silicone grease.

Indicates to apply ointment onto screw lock.

If not designated, use medium strength one.

Indicates to seal

Indicates the replacement part as new one whenever disassembly

Indicates to apply brake fluid. Use the recommended one(DOT3 or DOT4)

Indicates to apply the recommended oil

Indicates to use special tools

Indicates to use optional tools. Because this kind of tool is dealt as spare part, refer to the parts list to check the correct
tool number.

Indicates the reference. For left example, indicates the reference 3-1.

In case of special greases not written on above, they have not any specific symbols.
SERVICE INFORMATION

PARTS COMPOSITION MAP

TOP

STRAIGHT

RH. FRONT SIDE RH. CENTER SIDE RH. REAR SIDE

LH. FRONT SIDE LH. CENTER SIDE LH. REAR SIDE

TOTAL AREA DETAIL COMPOSITON MAP

 SERVICE INFORMATION

COMBINATION METER ASS Y CODE

WINKER RELAY
DESS RECEIVER
FR. BRAKE HOSE

HAZARD / START SWITCH CODE

WATER PATH TUBE

HEAD LIGHT ASS Y CODE

COMBINATION SWITCH TUBE

DESS CORD COMP

FUEL PUMP RELAY
FUEL LEAD LOCK CABLE
LIGHT RELAY
SEAT OPEN SWITCH CODE STARTER CONTROL RELAY
SEAT OPEN RELAY
FRONT BRAKE HOSE

REAR BRAKE CODE

WIRE HARNESS

RH. FRONT SIDE

REAR BRAKE HOSE

WINKER SWITCH COUPLER

HAZARD / START SWITCH COUPLER

DESS COMBINATION / LOCK SWITCH

FRONT BRAKE HOSE

FUEL LID LOCK CABLE

COMBINATION METER ASS Y

SEAT LOCK CABLE

FUEL BREATHER TUBE

DESS RECEIVER CHARGING SOCKET COUPLER
SEAT OPEN RELAY

FUEL SPLY TUBE

VINYL TUBE
HEADLIGHT ASS Y COUPLER

FRONT BRAKE HOSE

RADIATOR HOSE

HORN CONNECTOR

LH. FRONT SIDE

SERVICE INFORMATION

BATTERY(12V 10AH)

FUEL BREATHER TUBE

FUEL SPLY TUBE
SEAT LOCK CABLE FUEL HOSE
CHARGING SOCKET WIRE
METER SOCKET WIRE INJECTOR
EMI ASS Y
INJECTOR CODE

HIGH TENSION CODE

EMI CODE

LF ANTENNA TRUNK LAMP CODE

STARTER MOTOR CABLE
LF ANTENNA CODE STARTER MOTOR CABLE

OXYGEN SENSOR COUPLER

FUEL PUMP CODE

SEAT LOCK CABLE

FUEL BREATHER TUBE

LH. CENTER SIDE

EMI ASS Y
REAR BRAKE HOSE

STARTER MAGNETIC(+) CABLE

BATTERY(-) CABLE EMI CODE

STARTER MOTOR CABLE REAR BRAKE PIPE

BATTERY(-) CODE LF ANTENNA
OXYGEN SENSOR CODE THROTTLE CABLE
START MAGNETIC(+) CABLE
STARTER MOTOR CABLE OXYGEN SENSOR CODE WATER PATH TUBE
FAN MOTOR CODE
START MAGNETIC SWITCH ASS Y
FUEL PUMP CODE
START MAGNETIC SWITCH CODE

FUEL HOSE RADIATOR HOSE B

RADIATOR HOSE A
OXYGEN SENSOR CODE
THROTTLE CABLE
WATER PATH TUBE
REAR BRAKE HOSE PIPE TUBE CLIP

REAR BRAKE HOSE PIPE

WATER PIPE HOSE

RH. CENTER SIDE

 SERVICE INFORMATION

SEAT LOCK CABLE

WIRE HARNESS

SEAT OPEN SOLENOID

ECU COMP

SEAT OPEN SOLENOID CODE

ECU GROUND CONNECTION CODE

TOTAL SENSOR WIRE

WIRE HARNESS ENGINE BREATHE TUBE

SEAT LOCK CABLE

ENGINE BREATHER TUBE

BREATHER TUBE GUIDE

LH. REAR SIDE

WIRE CLIP

ACG CODE COMP

REGULATOR RECTIFIER

REGULATOR RECTIFIER CODE

FUEL HOSE

INJECTOR CODE

REAR BRAKE CODE

WATER HOSE B

WATER HOSE C
WATER HOSE A

RH. REAR SIDE

SERVICE INFORMATION

REAR BRAKE HOSE PIPE

WATER PATH TUBE HIGH TENSION CODE
ACG CODE THERMO SENSOR REGULATOR RECTIFIER CODE

START MAGNETIC(+) CABLE ACG CODE COMP

BATTERY(-) CABLE REAR BRAKE HOSE

FUEL HOSE CLIP ACG CODE COMP
THERMO SENSOR CODE

SCANNER COUPLER
INJECTOR COUPLER
TPS CODE
ISA CODE
BATTERY(+) CABLE
STARTER MOTOR CABLE
BATTERY(-) CABLE
IGNITION COIL PULLER
IGNITION COIL GROUND CONNECTION CODE

WIRE CLIP

MAPAT COUPLER SEAT OPEN SOLENOID

WIRE HARNESS HIGH TENSION CODE COMP WIRE HARNESS
SEAT OPEN SOLENOID CODE

TOP

SPEEDOMETER CABLE

DESS RECEIVER

FUEL BREATHER TUBE

FUEL SPLY TUBE

SPEEDOMETER CABLE

CABLE GUIDE

HORN COMP
BRAKE HOSE CLAMP
WATER PATH TUBE
RADIATOR HOSE FRONT BRAKE HOSE

STRAIGHT
 SERVICE INFORMATION

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 sub-
stances 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 2. Before maintenance, remove deposit or dust from the
recommended parts. chasis.

3. Store the parts of each system discriminatively to 4. After removing gasket, O-ring, piston pin clip and cot-
install each part in the right place. ter pin, always replace them with the new one. When
removing the snap ring, it can be easily missed after
transformation or installation.
SERVICE INFORMATION

5. Clean the parts after the overhaul and before the test and 6. Check necessary place and measure necessary data dur-
remove the cleaning oil with compressed air. Apply oil ing installation. When installing, return to the state
to seal face during installation. before removing.

7. Align the bolts to uniform the tightening points before 8. Bolts, nuts and pieces must be tightened from the bigger
tightening them when you don’t know the bolt length. diameter to the smaller one, from inside to outside and
diagonally with the specified torque.

9. Check to see if the rubber part is worn out when 10. Recommended grease must be applied to or filled in
removing it and replace it if necessary. Some rubber part the specified place.
is weak to gasoline and kerosene, so pay attention not to
soak with gasoline or oils.

11. Maintenance needed to use the specialized tools must 12. Never reuse the ball bearing removed with the ball
performed with the right tool. applied pressure when removing press-fitted the bear-
ing.
 SERVICE INFORMATION

13. Check the smooth rotation of inner or outer race of the 14. Pay attention to installation direction in case of the
ball bearing by rotating it manually. single-sided sealed ball bearing. Install the open-
• Replace the ball bearing having excessive axial/ direction or double-sided sealed bearing in the way
longitudinal hanging. that the face marked with manufacturer and size
•Wipe the ball bearing likely to have hanging with should direct to the outer axle.
cleaning oil.(except double-sided sealed type ball bear- DOUBLE-SEALED TYPE
SINGLE-SEALED TYPE
ing)
• Replace the ball bearing of which press-fitted part is
slacked at the case or shaft.

OPEN TYPE MANUFACTURER’S NAME, BEARING No.

15. When blowing the ball bearing with compressed air 16. Install the snap ring so that chamfered side directs to
after cleaning, keep the race from rotating. High speed the load-applied side. After installation, check the
rotation of the race may damage the bearing. Prior to proper installation by rotating the snap ring.
installation, apply oil or grease to the bearing.
SNAP RING

CHAMFERED EDGE

17. Check each part for proper tightening and operation 18. The brake fluid and coolant can damage the painted
after installation. plastic or rubber parts. Keep these parts from contact-
ing with them and wash these parts with water in case
of contact.

19. Install the oil seal so that the manufacturer marked 20. Connect the tube until the tube fully inserted in the
surface directs outer surface.(direction not covered joint. Install the clip if it is supplied. Replace the tube
with oil) having slacked end.
• Pay attention not to bend or damage the lip
• Apply the grease to the lip

CAVI-
MANUFACTURER’S NAME

CLIP

FITTING
SERVICE INFORMATION

21. Keep the pneumatic system interior or the engine 22. Install the gasket mounted in the contact surface of
interior from the infiltration of dust. each case of the engine while removing gasket materi-
al completely. Remove damaged contact surface by
wiping with the oil stone equally.

23. Pay attention not to bend the cable excessively. 24. Install the boots with the installing groove by inserting
Transformed or damaged cable may cause malfunction the boots into the groove.
or damage.

BOOTS
 SERVICE INFORMATION

CAUTION WHEN WIRING

•Each cord must be connected depending on its color. •When measuring voltage or resistance of the cord ter-
When connecting different cord, attach color tube minal using tester, contact the tester plug behind of the
around the connector. Connect the coupler to the con- coupler. Pay attention not to open the cord terminal
nector with same color and same pin number. and contact the tester plug from the front of the cou-
•Identify the two-colored cord by main color first and pler in case of water-proof coupler.
then striped color . TESTER PLUG RED STRIPE

WHITE WHITE
TUBE COUPLER.
BLACK TUBE
WHITE
•Recheck the condition of contact, securing and conti-
nuity of each part after maintenance.
BLACK CORD RED STRIPE •When connecting the battery, the plus terminal must
be connected first.
•After connecting the terminal, apply the grease to the
terminal.

WHITE / RED CORD

•When disconnecting the battery, the minus terminal •Connect covers to the terminal after maintenance.
must be disconnected first.
•Make sure that the tool such as spanner do not contact
with the frame.

•If the fuse is short-circuited, find out the cause and •If there is rust in the terminal, remove the rust with
repair. Replace with the fuse having the specified sand paper prior to connecting.
capacity.

VALIDATION REMOVE
OF CAPACITY! THE
RUST!
SERVICE INFORMATION

•Turn off the main switch before connecting/dis-con- •When disconnecting the coupler, disconnect it while
necting. holding the coupler body. Pull while holding the wire
•Release the lock to disconnect the lock of the coupler. harness cord and do not remove the coupler connection.
•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.

•Insert the lock of the coupler until the lock is fully

secured.

•Release the lock by inserting the coupler slightly and •Pay attention not to damage the vinyl cover of the cou-
then narrowing connection to remove the coupler. pler.

•Check to see if there is bended terminal and secure it to •If the wire harness coating is damaged, repair by wind-
avoid disconnecting. ing 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.