DAELIM DAYSTAR Service Manual

10-2
Crank Case / Transmission / Crankshaft / Kick Starter
Torque Values
Main shaft bearing setting plate 1.2kgf-m(12N.m)
Crank case bolt 1.1kgf-m(11N.m)
Tools
Special
Universal Bearing Puller
Bearing Remover Set, 15mm
Remover Ass'y 15mm
Remover Shaft
Remover Head
Sliding Weight
Thread Adapter
Assembly Shaft
Crank Case Assembly Collar
Trouble Shooting
Hard to shift
 Incorrect clutch system adjustment
(Free play is too big)
 Shift fork bent
 Shift fork shaft bent
 Gear shift spindle claw bent
 Shift drum guide grooves damaged
 Shift drum guide pin damaged.
Transmission jumps out of gear
 Gear dogs worn
 Shift fork shaft bent
 Shift drum stopper damaged
 Shift drum guide grooves worn
 Gear shift fork slot worn
Engine noise
 Connecting rod big end bearing worn
 Connecting rod bent
 Crank shaft main bearing worn
 Transmission gear worn
Poor kick starter operation
 Kick starter ratchet dogs worn, damaged
 Kick starter pinion gear damaged
 Ratchet guide plate worn, damaged
 Incorrect kick starter ratchet assembly
Item Standard Service Limit
M3 0.20-0.062(0.0008-0.0024) 0.10(0.004)
Transmissin Bush-to-shaft clearance C1 0.016-0.052(0.0006-0.0020) 0.09(0.004)
C2 0.013-0.047(0.0005-0.0019) 0.09(0.004)
Connecting rod big end side
0.05-0.3(0.002-0.012) 0.6(0.02)
clearance
Connecting rod bid end
Crankshaft
vertical direction clearance
0-0.008(0-0.0003) 0.05(0.002)
Right 0.1(0.004)
Crankshaft runout
Left 0.1(0.004)
Kick starter
Piston Gear I.D. 20.000-20.021(0.7847-0.7882) 20.05(0.789)
Spindle O.D. 19.959-19.980(0.7858-0.7866) 19.90(0.783)

DAELIM DAYSTAR Specifications

General

Fuel System	Carburetor
Front Suspension	Telescopic Fork
Front Brake	Disc
Rear Brake	Drum
Engine Type	4-Stroke, Air-cooled
Displacement	124 cc
Transmission	5-speed
Fuel Capacity	12.5 liters
Weight	125 kg
Rear Suspension	Dual shock absorbers