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DAELIM B-BONE Service Manual

DAELIM B-BONE Manual Online:

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DAELIM B-BONE User Manual
DAELIM B-BONE User Guide
DAELIM B-BONE Online Manual

Text of DAELIM B-BONE User Guide:

  • DAELIM B-BONE, 8-8 LH.CRANK CASE COVER/CONTINUOUSLY VARIABLE TRANSMISSION DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY DRIVEN PULLEY LOCK NUT WRENCH LOCK NUT CLUTCH SPRING COMPRESSOR DRIVEN FACE SPRING DRIVEN FACE SPRING DRIVEN FACE SPRING DRIVEN FACE SPRING DRIVEN FACE SPRING DRIVEN FACE SPRING DRIVEN FACE SPRING DRIVEN FACE SPRING DRIVEN FACE SPRING DRIVEN FACE SPRING DRIVEN FACE SPRING DRIVEN FACE SPRIN

  • DAELIM B-BONE, 6-12 FUEL SYSTEM FUEL PUMP FUEL PUMP FUEL PUMP FUEL PUMP FUEL PUMP FUEL PUMP FUEL PUMP FUEL PUMP FUEL PUMP FUEL PUMP FUEL PUMP FUEL PUMP FUEL PUMP FUEL PUMP FUEL PUMP FUEL PUMP FUEL PUMP FUEL PUMP FUEL PUMP FUEL PUMP FUEL PUMP FUEL PUMP After install the fuel pump, check the blowing quantity of fuel in the outlet tube. ! NOTE ● Check the gaskets. ● Check the suction valve, outlet valve and relief valve for damage and crack. ● Install in the reverse order of removal.

  • DAELIM B-BONE, 1-10 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 substances 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 bec

  • DAELIM B-BONE, 1-15 SERVICE INFORMATION •Insert the lock of the coupler until the lock is fully secured. •Turn off the main switch before connecting/dis- connecting. •Release the lock to disconnect the lock of the coupler. •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. •When disconnecting the coupler, disconnect it while holding the coupler body. Pull while holding the wire harness cord and do not remove

  • 9-7 A.C GENERATOR / STARTER CLUTCH THRUST WASHER THRUST WASHER THRUST WASHER THRUST WASHER THRUST WASHER THRUST WASHER THRUST WASHER THRUST WASHER THRUST WASHER THRUST WASHER THRUST WASHER THRUST WASHER THRUST WASHER THRUST WASHER THRUST WASHER THRUST WASHER THRUST WASHER THRUST WASHER THRUST WASHER THRUST WASHER THRUST WASHER THRUST WASHER LOCK NUT LOCK NUT LOCK NU

  • DAELIM B-BONE, 11-6 CYLINDER / PISTON CYLINDER GASKET CYLINDER GASKET CYLINDER GASKET CYLINDER GASKET CYLINDER GASKET CYLINDER GASKET CYLINDER GASKET CYLINDER GASKET CYLINDER GASKET CYLINDER GASKET CYLINDER GASKET CYLINDER GASKET CYLINDER GASKET CYLINDER GASKET CYLINDER GASKET CYLINDER GASKET CYLINDER GASKET CYLINDER GASKET CYLINDER GASKET CYLINDER GASKET CYLINDER GASKET CYLINDER GASKET PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON PISTON DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOWEL PIN DOW

  • DAELIM B-BONE, 14-6 REAR WHEEL/SUSPENSION/REAR SWING ARM REAR SWING ARM REMOVAL ● Remove the EX. Muffler. ● Remove the rear brake caliper. ● Loosen the rear axle U-nut. ● Remove the rear swing arm. ● Install the rear cushion. ● Tighten the top and bottom of the cushion with bolts. TORQUE VALVE : UPPER SIDE : 3.5~4.5kgf m LOWER SIDE : 3.5~4.5kgf m INSTALLATION ● Install the spring, stopper rubber to the damper comp. ● Apply thread locking agent to the hex nut, and install the rear cushion compressor attachment on the damper rod. ● Fix the upper metal, and tighten

  • DAELIM B-BONE, 6-7 FUEL SYSTEM ASSEMBLY ● Install the needle jet, needle jet holder, main jet and slow jet. ● Tighten the pilot jet until it seat lightly, then turn it out as much as number recorded during removal. ● Install the pilot jet rubber. ● Install the float valve set, float comp, float pin. ● Measure the float level with the float valve gauge. FLOAT LEVEL : 13 mm TOOL : FLOAT COMP LEVEL GAUGE ● Install the float chamber set. ● Install the stay plate set and 4 pan screws. ● Install the valve plate set, compression spring in the vacuum pis

  • 5-36 EMS(Engine Management System) MEASUREMENT PVA ● Disconnect the ACG (L/G) connector. ● Connect the (+)cord of PVA tester to the green terminal or ground wire. ● Connect the (-)cord of PVA tester to the blue terminal. ● Crank the engine with the starter motor and measure the peak voltage of crank position sensor coil. ● HIGHEST VOLTAGE : 1.5V Over. ●

  • DAELIM B-BONE, 9-2 A.C GENERATOR / STARTER CLUTCH SHROUD REMOVAL ● Remove the following parts. - RR. Inner - SAI Tube - RH. / LH. Pillion step holder - Muffler comp A.C GENERATOR REMOVAL ● Loosen the rear cushion under cover. ● Loosen the 3 bolts securing RH. shroud. ● Remove the SAI. ● Remove the shroud. ● Loosen the 3 cooling fan bolts. ● Remove the A.C.G. wiring from the A.C.G. wiring setting clamp securing the engine and frame. ● Loosen the RH. shroud 4 flange bolts and 4 tapping screws. ● Remove the RH. shroud. ● Loosen the LH. shroud setting screw. ● Remove the LH. shroud. ● Install in the reverse or

  • LH. CRANKCASE COVER DISASSEMBLY ● Remove the air cleaner and flange bolt securing B stay. ● Remove the flange bolts securing LH. crankcase. ● Remove the LH. crankcase cover. ● Remove the gasket and dowel pin. INSTALLATION ● Install the new gasket and dowel pin after removing the gasket of the crankcase surface. ● Install the LH. crankcase cover. ● Install the air cleaner an

  • DAELIM B-BONE, 15-11 BRAKE SYSTEM MASTER CYLINDER SET MASTER CYLINDER SET MASTER CYLINDER SET MASTER CYLINDER SET MASTER CYLINDER SET MASTER CYLINDER SET MASTER CYLINDER SET MASTER CYLINDER SET MASTER CYLINDER SET MASTER CYLINDER SET MASTER CYLINDER SET MASTER CYLINDER SET MASTER CYLINDER SET MASTER CYLINDER SET MASTER CYLINDER SET MASTER CYLINDER SET MASTER CYLINDER SET MASTER CYLINDER SET MASTER CYLINDER SET MASTER CYLINDER SET MASTER CYLINDER SET MASTER CYLINDER SET LEVER LEVER LEVER LEVER LEVER LEVER LEVER LEVER LEVER LEVER LEVER LEVER LEVER LEVER LEVER LEVER LEVER LEVER LEVER LEVER LEVER LEVER MASTER CYLINDER BODY MASTER CYLINDER BODY MASTER CYLINDER BODY MASTER CYLI

  • DAELIM B-BONE, 7-1 ENGINE REMOVAL/INSTALLATION 7. ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION ····· 7-1 ENGINE REMOVAL/INSTALLATION · 7-2 SERVICE INFORMATION GENERAL SAFETY NOTE •Use a jack to remove or install the engine. Support the motorcycle with a jack firmly, taking precautions not to damage the frame, engine, cable or harness. •Attach tape to the frame to protect it during the engine removal or installation. ● The following works can be carried out without removing the engine from the vehicle body. -TRANSMISSION (⇨SECTION 12) -STARTING CLUTCH (⇨SECTION 9) -OIL PUMP (⇨SECTION 4) -A.C. GENERATOR (⇨SECTION 9) -

  • DAELIM B-BONE, 15-8 BRAKE SYSTEM LH CALIPER BODY LH CALIPER BODY LH CALIPER BODY LH CALIPER BODY LH CALIPER BODY LH CALIPER BODY LH CALIPER BODY LH CALIPER BODY LH CALIPER BODY LH CALIPER BODY LH CALIPER BODY LH CALIPER BODY LH CALIPER BODY LH CALIPER BODY LH CALIPER BODY LH CALIPER BODY LH CALIPER BODY LH CALIPER BODY LH CALIPER BODY LH CALIPER BODY LH CALIPER BODY LH CALIPER BODY PISTON A PISTON A PISTON A PISTON A PISTON A PISTON A PISTON A PISTON A PISTON A PISTON A PISTON A PISTON A PISTON A PISTON A PISTON A PISTON A PISTON A PISTON A PISTON A PISTON A PISTON A PISTON A PISTON A PISTON A PISTON A PISTON A PISTON A PISTON A PISTO

  • DAELIM B-BONE, 13-2 FRONT WHEEL/FRONT FORK/STEERING TROUBLESHOOTING Hard steering ● Steering top cornice too tight. ● Damaged steering stem steel ball. ● Faulty steering ball race, cone race. ● Insufficient tire pressure. ● Tire is worn. Steers to one side or does not track straight ● Bent front fork. ● Bent front axle. ● Bent frame. ● Tire is worn or modification. ● Worn wheel bearing. Front wheel wobbling ● Bent rim. ● Faulty wheel bearing. Hard to rotate the wheel. ● Faulty wheel bearing. Soft suspensio

  • DAELIM B-BONE, 18-3 STARTER SYSTEM STARTER MOTOR REMOVAL ● Remove the starter motor cable from the starter magnetic switch. ● Loosen the 2 flange bolts securing the engine case, remove the battery earth cable and starter motor. ● Install in the reverse order of removal. DISASSEMBLY ● Remove the starter motor cable. ● Before disassembling the starter motor mark the position of the case and cover so the starter can be assembled correctly later. ● Loosen the starter motor case bolts and remove the motor cover. INSPECTION ● Check for continuity of the starter motor case. -Between cord terminal“⊕” and bracket“⊖”: normal if no continuity. -Between cord terminal and bru

  • DAELIM B-BONE, 5-35 EMS(Engine Management System) ● Remove the RH. shroud. ● Remove the cooling fan. ● Remove the fly wheel. ● Remove the 3 screws securing ACG stator. ● Remove the 2 screws securing CKP. REMOVE ● Remove the center cover. ● Remove the ACG coupler. ● Remove the CKP coupler. ● CKP is located inside the RH. crank case cover. ! CAUTION △ 15. CKP(Crank Position Sensor) ● Before disassembly, the key is off. ● Check the ACG stator and position sensor. ● Take precaution not to use the stator comp (18 termi

  • DAELIM B-BONE, 11-5 CYLINDER / PISTON TOP RING SECOND RING MARK R TOP RING SECOND RING SIDE RAIL SIDE RAIL OIL RING PISTON 20mm SPACER CRANK SHAFT CONNECTING ROD CRANK SHAFT CONNECTING ROD CRANK SHAFT CONNECTING ROD CRANK SHAFT CONNECTING ROD CRANK SHAFT CONNECTING ROD CRANK SHAFT CONNECTING ROD CRANK SHAFT CONNECTING ROD CRANK SHAFT CONNECTING ROD CRANK SHAFT CONNECTING ROD CRANK SHAFT CONNECTING ROD CRANK SHAFT CONNECTING ROD CRANK SHAFT CONNECTING ROD CRANK SHAFT CONNECTING ROD CRANK SHAFT CONNECTING ROD CRANK SHAFT CONNECTING ROD CRANK SHAFT CONNECTING ROD CRANK SHAFT CONNECTING ROD CRANK SHAFT CONNECTING ROD CRANK SHAFT CONNECTING ROD CRANK SHAFT CONNECTING ROD CRANK SHAFT CONN

  • DAELIM B-BONE, 2-11 INSPECTIONS/ADJUSTMENTS LUBRICATION POINTS Use general grease unless specified here. Apply oil or grease to the other sliding surfaces not shown here. CONTROL CABLE LUBRICATION Periodically disconnect the upper end of the throttle cable and that of clutch cable, then apply oil after cleaning. Change it when the cable lengthened. RR. BRAKE LEVER PIVOT THROTTLE GRIP STEERING HEAD BEARING WHEEL BEARING MAIN / SIDE STAND PIVOT WHEEL BEARING / SPEDOMETER GEAR

  • ● Apply engine oil to the camshaft, and install it on the cylinder head with the cam thread facing downward. ● Assemble the cam chain and cam sprocket after matching the cam sprocket timing mark in parallel with the top of the cylinder head. ● Install the dowl pins on the cylinder head. ● Install the cam shaft holder. ● Install the cam cover plate. �

  • 5-7 EMS(Engine Management System) HOW TO CHECK THE FAULT CODE There are two methods of checking the fault codes. 1) Use the MIL in the speedometer. 2) The diagnostic tool. First) Use the MIL in the speedometer(refer to how to read the fault codes and fault codes table and diagnostic methods for each part) Second) The diagnostic tool (refer to scan user’s manual.) ● Turn off the ignition key �

  • DAELIM B-BONE, 19-3 LIGHTS/SWITCHES/HORN TAIL & STOP BULB TAIL & STOP BULB TAIL & STOP BULB TAIL & STOP BULB TAIL & STOP BULB TAIL & STOP BULB TAIL & STOP BULB TAIL & STOP BULB TAIL & STOP BULB TAIL & STOP BULB TAIL & STOP BULB TAIL & STOP BULB TAIL & STOP BULB TAIL & STOP BULB TAIL & STOP BULB TAIL & STOP BULB TAIL & STOP BULB TAIL & STOP BULB TAIL & STOP BULB TAIL & STOP BULB TAIL & STOP BULB TAIL & STOP BULB REAR WINKER REAR WINKER REAR WINKER REAR WINKER REAR WINKER REAR WINKER REAR WINKER REAR WINKER R

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