IMPORTANT NOTICE OPERATOR AND PASSENGER This vehicle is designed to carry the operator and one passenger. ON-ROAD USE This vehicle is designed to be used only on the road. READ THIS OWNER'S MANUAL CAREFULLY Pay special attention to statements preceded by the following words: WARNING Indicates a strong possibility of severe personal injury or death if instructions are not followed. CAUTION Indicates a possibility of personal injury or equipment damage if instructions are not followed.
CONTENTS SPECIFICATION OPERATION INSTRUCTION SAFETY PRECAUTIONS 3 4 HORN BUTTON EQUIPMENT USAGE 15 16 4 STEERING WHEEL LOCK 16 PRIOR TO STARTING VEHICLE 5 REAR CUSHION ADJUSTMENT 16 CORRECT ATTIRE 5 SELF INSPECTIONS BEFORE OPERATION 17 OPERATION 6 BRAKES CARGO 7 FUEL 20 MODIFICATION 8 TIRES 21 ATTACHMENT 8 ENGINE OIL LEVEL CHECK 22 MUFFLER 8 LIGHTS AND WINKER 22 9 BACK MIRROR 23 LICENSE PLATE 23 PARTS LOCATION METER READING AND USAGE 12 OPERATION 17 METER 12 FUE
MAINTENANCE SAFE DRIVING 48 29 PREPARATION BEFORE DRIVING 48 TOOL KIT 31 DRIVING METHOD 49 FRAME AND ENGINE NUMBERS 31 DRIVING POSITION 49 MAINTENANCE PRECAUTIONS 32 PRECAUTION WHEN DRIVING 50 THROTTLE GRIP 32 STARTING 51 MAINTENANCE SCHEDULE 2 28 33 TURNING METHOD 52 34 PRINCIPLE OF TURN 52 SPARK PLUG 35 EFFECT OF SPEED 52 IDLE SPEED ADJUSTMENT AIR CLEANER ELEMENT CHANGINE ENGINE OIL 36 3 POSITIONS OF TURNING 53 CLUTCH ADJUSTMENT 36 TURNING METHOD 54 DRIVE CHAIN
SPECIFICATION ITEM DATA LENGTH×WIDTH×HEIGHT(mm) 1,910×700×1,080 WHEEL BASE(mm) 1,220 GROUND CLEARANCE(mm) 125 SEAT HEIGHT(mm) 765 DRY WEIGHT(kgf) 96 ITEM TIRE SIZE SUSPENSION BRAKE DATA FR. 2.75-16-4PR RR. 3.00-16-4PR FR. TELESCOPIC RR. SWING ARM FR. HYDRAULIC DISK RR. DRUM BRAKE PASSENGER 2 ENGINE TYPE AIR COOLED 4 STROKE SPARK PLUG C7HSA(NGK) PISTON DISPLACEMENT(cc) 108.9 FUSE(A) 7 BORE AND STROKE(mm) 50×55.
OPERATION INSTRUCTION SAFETY PRECAUTIONS This manual describes matters pertaining to correct operation, safe operation and simple maintenance of the vehicle you purchased. To ensure more comfortable and safer operation, make sure to read this manual carefully prior to operation. ●The photographs and drawings shown in this manual may differ from those of actual vehicles due to changes in vehicle specifications and modifications made. ●This vehicle is designed for 2 riders including the operator.
PRIOR TO STARTING VEHICLE ●Read user's manual carefully. ●Conduct maintenance checks prior to operation. ●Always maintain vehicle in clean status and carry out specified maintenance checks. ●Make sure to stop engine and stay away from fire when fueling. ●Exhaust gas contains harmful substance such as carbon monoxide. Start engine in well-ventilated places. CORRECT ATTIRE ●Always make sure to wear helmet for safety. Wear gloves and safety goggles. ●Do not wear uniforms which might hinder operation.
OPERATION A helmet should always be worn and the helmet chin strap should be securely fastened. Correct shirts or jackets with tight-fitting sleeves should be worn, Always put on gloves. Shoes should fit properly, and shoes having little or no heel should be worn. 6 ●Operators should naturally fix bodies to keep smooth driving. ●Please check whether or not you are unnaturally strained and strung up. ●Driving pose has a great influence on safe operation.
CARGO ●When carrying cargo, you must keep in mind that operating the motorcycle, especially when turning, will be different. ●Make sure not to overload the vehicle with goods as this can make the vehicle unstable during operation. WARNING ●Overloading or improper loading can cause a crash and you can be seriously hurt or killed. ●Follow all load limits in this manual.
MODIFICATION ●Modification of vehicle structure of function deteriorates manipulatability or causes exhaust noise to become louder shortening the vehicle life. These modifications are not only prohibited by law but also are the acts harmful to other people. Modifications are not covered by warranty. MUFFLER ●Pay particular attention to fellow passenger so that he/she can prevent getting burnt by the hot muffler during travel. ATTACHMENT ●Except designated attachment by DAELIM MOTOR CO., LTD.
PARTS LOCATION SPEEDOMETER BACK MIRROR GEAR POSITION INDICATOR FUEL GAUGE BACK MIRROR HEADLIGHT SWITCH HIGH/LOW BEAM SWITCH FR.
PARTS LOCATION HEADLIGHT FUEL TANK LID (BENEATH THE SEAT) BATTERY/FUSE (INSIDE COVER) RR. CUSHION FR. TIRE RR.
PARTS LOCATION SEAT TOOL BOX AIR CLEANER ELEMENT (INNER PART) RR.
METER READING AND USAGE METER INDICATOR LAMPS Indicates speed in km/h during travel. Maintain legal speed limits to ensure safe operation. WINKER SPEEDOMETER Indicates total operating distance in km. FUEL GAUGE ODOMETER GEAR POSITION INDICATOR FUEL GAUGE HEADLIGHT HIGH-BEAM INDICATOR Indicates amount of gasoline in fuel tank. (The fuel gauge needle always indicates gasoline level regardless of whether main switch is in "OFF" position or in "ON" position.
SWITCH OPERATION MAIN SWITCH Main switch is used to turn on or turn off engine. Key position ON ON KEY LOCK MAIN SWITCH Key Key Starts engine. Power cannot be is supplied to removed electrical circuits. Stops engine. Cuts Key off all electrical can be circuits. removed Locks steering Key wheel. Cuts off all can be LOCK electrical circuits and steering wheel removed is locked. OFF OFF Function WARNING ●Do not manipulate main switch key during operation.
STARTER BUTTON If you press this button, starter motor runs and engine is started. HEADLIGHT (EUROPE ONLY) Put main switch key in "ON" position and manipulate headlight switch. HEADLIGHT SWITCH Switch position STARTER BUTTON CAUTION ●Do not press starter button repeatedly because it consumes great amount of power causing battery to be exhausted sooner.
WINKER SWITCH Use winker switch when you change course of travel to left or right. If this switch is turned on when the main switch is in "ON" status, winker is brinking. To release winker operation, return winker switch its original position. HORN BUTTON CAUTION ●The winker switch does not automatically turn back to its original position after completing the turn. Please set the switch back to its center position after turning.
EQUIPMENT USAGE STEERING WHEEL LOCK To prevent theft, lock steering wheel when parking the vehicle. REAR CUSHION ADJUSTMENT Take steps in opposite order of locking. WARNING ●Do not turn the key to LOCK while riding the vehicle; loss of vehicle control will result. CAUTION MAIN SWITCH KEY 1. Turn the steering wheel to left completely. 2. Insert main switch key. 3. Press the key and turn steering wheel to "Lock" position. 4. Remove the key.
SELF INSPECTIONS BEFORE OPERATION Self inspect the vehicle and have regular maintenance inspections for increased safety and the prevention of accidents. Self inspections before operation should be performed on a daily basis prior to operating the vehicle. BRAKE LEVER FREE PLAY : 10~20mm 10~20mm BRAKES The front brake is the hydraulic disk type, and the rear brake is the drum brake type. As the brake pad wear, the brake fluid level drops.
●Check that the fluid level is above the LOWER level mark with the vehicle in an upright position. ●Check through access cover which is observable through inspection groove located between the front handle cover and the right end section of headlight. (Use of a flash is recommended.) ●Brake fluid must be added to the reservoir whenever the fluid level begins to reach the LOWER level mark.
[REAR BRAKE] Push the brake pedal with hands for resistance and check if the pedal movement appropriate. If brake pedal movements is inappropriate, adjust the pedal free play using the rear wheel brake adjuster nut. After adjusting the brake, check the wear of the brake shoe. While tightly squeezing the rear brake pedal, if the “ ” mark of the brake shoe is worn. Please take the motorcycle to a service center for repair.
FUEL Check gasoline to see if there is a sufficient amount of gasoline to reach your destination. SEAT ●If the fuel gauge needle indicates E mark (red portion), fill fuel tank with gasoline as soon as possible. FUEL TANK CAP Reserve fuel capacity : Approximately 1.2 liter The fuel cock lever arrow indicates operating position. ●ON --- Gasoline is supplied. Set fuel cock to this position when starting engine. ●OFF -- Fuel is not supplied.
TIRES Check for an appropriate level of air pressure by examining how the tire sits on the ground. If you notice any abnormalities in the shape of the tire with regard to the area contacting the ground, use a tire gauge to check tire pressure and adjust the tire pressure to the appropriate level. Check tire tread and sides for cracks and damage. CRACKS Check tire tread and sides for nails, rocks, etc. That might have become wedged in the tire.
ENGINE OIL LEVEL CHECK CAUTION ●If air pressure is inadequate or if there are cracks, damage or abnormal wear on tires, it may cause trembling steering wheel and flat tire. ●Insufficient air pressure may cause the heavy steering wheel marking handling difficult, fuel over consumption and the excessive wear of tire outer area and excessive air pressure may cause easier wheel handling and lower fuel consumption. But it may also cause the excessive wear of tire center area.
OPERATION BACK MIRROR Sit squarely on the seat and check to see if you have a good view behind the vehicle by looking at the back mirrors. Also check for dirt and damage on the back mirrors. LICENSE PLATE Check to see if there is any dirt or damage to the license plate. Also check to see if the license plate is firmly secured to the vehicle. PRE-RIDE INSPECTION WARNING ●If the pre-ride inspection is not performed, severe personal injury or vehicle damage may result.
STARTING THE ENGINE Always follow the proper starting procedure described below. ●This vehicle is equipped with a side stand ignition cut-off system. The engine cannot be started if the side stand is down. WARNING ●Never run the engine in an enclosed area. The exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness and lead to death.
IF ENGINE CANNOT BE STARTED ●It is possible that starting will be more difficult if the vehicle has not been used for a long period of time or if the fuel hole is plugged up (starting problems even when there is sufficient fuel in the fuel tank may be an indication of a plugged fuel hole). When this happens, do not rotate the throttle grip and try the starter button a few times. NOTE ●Do not run engine idle unreasonably. This not only wastes fuel but also adversely affects engine.
RIDING NOTE ●Make sure you understand the function of the side stand mechanism. (see explanation for SIDE STAND on page 39) 1. After the engine has been warmed up, the vehicle is ready for riding. 2. While the engine is idling, depress the gearshift pedal to shift into 1st (low) gear. 3. Gradually increase engine speed by opening the throttle. 4. When the vehicle attains a mode-rate speed, close the throttle and shift to 2nd gear by depressing the gearshift pedal.
BRAKING PARKING 1. For normal braking, gradually apply both the front and rear brakes while down shifting to suit your road speed. 2. For maximum deceleration, close the throttle and apply the front and rear brakes firmly. WARNING ●If you apply brakes only on front wheel or rear wheel, vehicle may slide off sideway and fall. ●If you apply brakes abruptly during travel in rain or on wet road, tires slide off and may cause accidents. Reduce speed and apply brake cautiously.
MAINTENANCE ●The Required Maintenance Schedule specifies how often you should have your vehicle served, and what things need attention. It is essential that your vehicle be served as scheduled to retain its high level of safety, dependability, and emission control performance. ●These instructions are based on the assumption that the motorcycle will be used exclusively for its designed purpose.
MAINTENANCE SCHEDULE Perform the Self Inspections Before Operation at each scheduled maintenance period.
ODOMETER READING(NOTE 1) FREQUENCY ITEM ×1,000Km 1 4 8 12 16 MONTH 1 6 12 18 24 ★ BRAKE FLUID I I I I R ★ BRAKE SHOE / PAD WEAR I I I I I BRAKE SYSTEM I I I I I ★ BRAKE STOP SWITCH I I I I I ★ HEADLIGHT ADJUSTMENT I I I I I ★ SUSPENSION I I I I I I I I I I I I CLUTCH I SIDE STAND ★ BOLTS, NUTS, FASTENERS I I I I I ★★ WHEELS / TIRES I I I I I ★★ STEERING HANDLE BEARING I I I I I REMARK NOTE( 3) ★ If you do not have the appr
TOOL KIT FRAME AND ENGINE NUMBERS The tool kit is in the storage compartment inside the left sub side cover. Some roadside repairs, minor adjustments and parts replacement can be performed with the tools contained in the kit. ●No.2 screwdriver ●Screwdriver grip ●16mm Box wrench ●10x12mm Spanner ●Tool bag ●The frame and engine numbers are needed when registering your vehicle. ●They may also be required by your dealer when ordering replacement parts. ●Record the numbers here for your reference.
MAINTENANCE PRECAUTIONS The following is an explanation of correct inspection methods, cleaning and parts replacing. Please always refer to this section when wanting to inspect or repair your vehicle. WARNING ●If your vehicle is overturned or involved in a collision, inspect control levers, cables, brake hoses, calipers, accessories, and other vital parts for damage. Do not ride the vehicle if damage impairs safe operation.
AIR CLEANER ELEMENT If the air cleaner element is clogged with dust, there will be greater intake resistance, resulting in decreased power output and increased fuel consumption. 3. Take off the air cleaner element. CAUTION ●Do not operate the engine without the air cleaner element in place or severe engine damage may result.
CHANGING ENGINE OIL If engine oil is polluted, it seriously affects the engine life span. Maintain appropriate level of oil, use correct type of oil and observe oil exchange period. ●Stand vehicle on the main stand on level ground and run engine idle (warm up) for approximately 2-3 minutes. ●Stop engine and place a container under the engine. Remove oil level gauge and drain plug bolt, and drain engine oil. ●Tighten the drain plug bolt.
SPARK PLUG If electrode is stained or clearance is not right, satisfactory spark is not produced. Clean and make adjustment. ●If new plug is installed, turn 1/2 and tighten using a plug wrench. If plug is reused, turn 1/3-1/4 and tighten. PLUG GAP CAUTION SPARK PLUG SPARK PLUG CAP ●Remove spark plug cap. ●Clean around the plug. ●Using a plug wrench, remove plug. ●Clean plug with plug cleaner. ●Check electrode for wear and corrosion. If the center of electrode became round, replace the electrode.
IDLE SPEED ADJUSTMENT 1. Put vehicle in upright position on a flat ground. 2. Start engine and let in run idle for a few minutes. 3. Using the throttle stop screw, adjust idling to prescribed level. IDLE REVOLUTION: 1,600 100rpm 4. Tighten up pilot screw and loose backward 3/4. 5. Operate throttle lever lightly and verify there is no change in the number of idle running. If there is a change, repeat the process described in paragraph 3 and 4.
DRIVE CHAIN ●The service life of drive chain is dependent upon proper lubrication and adjustment. Poor maintenance can cause premature wear or damage to the drive chain and sprocket. ●The drive chain should be checked and lubricated as part of the Pre-ride Inspection. ●Under severe usage, or when the vehicle is ridden in unusually dusty or muddy areas, more frequent maintenance will be necessary.
●Drive chain slack should be checked and adjusted, if necessary, every 1,000km. ●When operated at sustained high speeds or under conditions of frequent rapid acceleration, the chain may requir more frequent adjustment. 1. Place the vehicle on its main stand with the transmission in neutral and the ignition switch off. 2. Loose the axle nut. 3. Loose the lock nuts on both sides of the swingarm. 4. Turn both adjusting nuts an equal number of turns until the correct drive chain slack is obtained.
WHEEL REMOVAL [FRONT WHEEL REMOVAL] 1. Raise the front wheel off the ground by placing a support block under the engine. 2. Loose the oval screw and remove the speedometer cable. 3. Remove the front caliper assembly from the fork by removing the fixing bolts. 4. Loosen the axle nut. 5. Withdraw the front wheel axle and remove the front wheel.
SIDE STAND [REAR WHEEL REMOVAL] 1. Set vehicle on main stand in upright position on level ground. 2. Loosen the rear brake adjuster nut and remove the brake rod from the brake arm. 3. Loosen the drive chain adjusting lock nuts and adjusting nuts. LOCK NUT ADJUSTER NUT 6. Install in the reverse order of removal. REAR AXLE NUT TORQUE : 4.0~5.0kgf.m ●After installing the wheel, apply the brake several times and then check if the wheel rotates freely.
BATTERY It is not necessary to check the battery electrolyte level or add distilled water as the battery is a maintenance-free (sealed) type. If your battery seems weak and/or is leaking electrolyte (causing hard starting or other electrical troubles), contact your authorized Daelim dealer. CAUTION ●Removing the battery cap strip can damage the cap strip and result in leaks and eventual battery damage.
FUSE REPLACEMENT Turn off the main switch to see if the fuse is severed. If the fuse is severed, exchange the fuse into 7A fuse. ●Fuse is installed inside fuse holder located near battery. ●To separate fuse, open fuse holder, hold both ends of fuse cord and pull up, and pull out the fuse connector crosswise. ●If the fuse immediately becomes severed after being changed with the new one, check another problem of the electric system.
BULB REPLACEMENT ●Be sure to turn the ignition switch OFF when replacing the bulb. ●Do not use bulbs other than that specified. ●After installing a new bulb, check that the light operates properly. WARNING ●The light bulb becomes very hot while the light is ON, and remain hot for a while after it is turned OFF. Be sure to let it cool down before servicing. CAUTION ●Do not put finger prints on the headlight bulb, as they may create hot spots on the bulb and cause it to break.
[TAIL/STOPLIGHT BULB] 1. Loosen the 2 screws and remove the taillight lens. 2. Slightly press down on the bulb and turn it counterclockwise. 3. Install a new bulb in the reverse order of removal. TAIL/STOPLIGHT BULB : 21V 21/5W TAILLIGHT LENS [WINKER BULB] (EUROPE ONLY) 1. Press the winker lens groove and open the winker lens using plain screwdriver. 2. Slightly press down on the bulb and turn it counterclockwise. 3. Install a new bulb in the reverse order of removal.
[WINKER BULB] 1. Remove the back mirrors. 2. Loosen the 4 screws and remove the front handle cover. 3. Slihgtly press down on the winker bulb holder and turn it counterclockwise. 4. Pull off the bulb without turning. 5. Install al new bulb in the reverse order of removal. 1. Loosen the 2 screws and remove the taillight lens. 2. Pull off the bulb without turning. 3. Install a new bulb in the reverse order of removal.
CABLE RUBBER PART CLEANING A rubber part is assembled on the cable to protect the inner cable. Make sure that this part is placed firmly around the correct part of the cable. When washing the car, do not directly spray water on to the rubber part is dirty, use a dry cloth to clean this area. INSPECTION PART RUBBER INSPECTION PART CAUTION ●Infiltration of the foreign materials or water caused by damage of lever (disengagement, tearing, etc.
STORAGE GUIDE Extended storage, such as for winter, requires that you take certain steps to reduce the effects of deterioration from non-use of the motorcycle. In addition, necessary repairs should be made BEFORE storing the motorcycle; otherwise, these repairs may be forgotten by the time the vehicle is removed from storage. ●Change the engine oil and filter. ●Empty the fuel tank into an approved gasoline container using a commercially available hand siphon or an equivalent method.
SAFE DRIVING PREPARATION BEFORE DRIVING ● Performing daily inspection ● Putting on the protective gears (Helmet, glove, goggles, etc.
DRIVING METHOD DRIVING POSITION The appropriate driving position is most important thing to driving safely. ① Eyes : Look at the front direction widely. ② Shoulders : Relieve the tension. ③ Arms : Relieve the tension and bend arms to inside and let them act as the spring. ④ Hands : Grip the handle the position away from the inside end of the handle with distance of one finger to facilitate the operation of the switch and lever.
PRECAUTION WHEN DRIVING ● ● ● ● ● ● ● ● 50 Secure the safe distance. Drive protectively. Do not obstruct the traffic. Do not drive on the pedestrian way or walkway. Drive on the left driveway when passing away. Make sure that you can apply the brake anytime. Always apply the brake when stopping temporarily. Do not drive excessively long distance and take enough break. ● If any abnormality is found, stop driving and contact service center to inspect the vehicle.
STARTING Prior to starting always look around to avoid accident. ① Get on the vehicle after pulling back the stand. ② Start driving slowly after turning on the winker and releasing the brake while ensuring the safety around the vehicle. CAUTION ●Return the side stand to its original position. Keep driving without doing this may cause turnover accident. ●Drive the vehicle only on the driveway. Driving on the walkway can cause accident.
TURNING METHOD PRINCIPLE OF TURN EFFECT OF SPEED CENTRIFUGAL FORCE GRAVITY The basic principle of turn is balancing using the centrifugal force which makes motorcycle go outside and the gravity which makes vehicle fall inside. 52 The centrifugal force increases in inverse portion to the radius of a curve and in portion to the square speed. Decelerate prior to entering the curved way to reduce the centrifugal force.
3 POSITIONS OF TURNING The basic principle of turn is balancing using combined force of the centrifugal force and the gravity. All 3 positions require straightening the head and keeping the eyes horizontally. < LEAN-WITH > This is a turning position with motorcycle and driver in a line. This position is the most natural and exact, so driver must learn it thoroughly. < LEAN-IN > This is a turning position with driver leaned inside more than motorcycle.
TURNING METHOD < LEAN-OUT > This is a turning position with motorcycle leaned inside more than driver, which is opposite to the lean-in position. With this position, quick turn is well performed and driver can obtain wide front visual field adequate to drive on the rained or slippy road because it has best road holding. However, special attention is required because there is danger of slipping on the bad holding road.
PRECAUTION WHEN TURNING Do not drive inside of large truck's turn circle. < DEAD ANGLE ZONE > Dead angle zone is the sight range which cannot be identified by driver and increases in proportion to the width of the vehicle. < DISTANCE BETWEEN THE FRONT AND REAR WHEEL TURN > It is distance between path of the front and rear wheel and increases in proportion to the length of the vehicle.
BRAKING METHOD BASIC PRINCIPLE OF BRAKE (FRICTION FORCE) RESTRAINT OF BRAKE EFFECT (INERTIA) ● Vehicle is braked using friction between road surface and tires. ● Braking distance increases 1.5 times on wet road and 3 times on icy road because friction force of road surface is decreased. NEW TIRE NEW TIRE IN A RAINY DAY EXISTING TIRE IN A RAINY DAY 56 Due to the inertia, vehicle does not stop immediately after applying the brake.
BRAKING METHOD IMPACT WHEN COLLISION ● Turn the throttle grip to its original position and decelerate Learn the proper braking method to prevent accident. using the engine brake. ● Erect the vehicle straight. ● Brake using both front and rear brakes. COMPARISION OF BRAKING DISTANCE ·Vehicle speed : 50 km/h When using both front and rear brakes When using only front brake Impact increases in proportion to the speed and weight.
MEMO : 58
WIRING DIAGRAM (EUROPE ONLY) 59
WIRING DIAGRAM 60
MEMO : 61
OWNER’S MANUAL 04. 2003 PRINTED 04.
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