Daelim S-Five 50 & E-Five Manual Set, 2000s (P/N SM40-0103-01E)

The owner's manual covers everyday operation and routine care; the service manual provides workshop repair procedures. Use each publication for its named scooter rather than treating their specifications as interchangeable.

Check the configuration: The E-Five owner's manual describes a different wheel configuration from the S-Five service manual. Match the model, tire sizes, and applicable S-Five serial numbers in the specifications box before selecting repair data.

Searchable PDFs and Wiring Diagram Detail

Text search and diagram labels: Both manuals support text search in their main text and have no embedded PDF bookmarks. Small wiring-diagram labels require zooming.

ZIP download containing two printable, English-language PDFs with 250 pages total. The counts include the covers, four memo pages in the owner's manual, and the service manual's publication page and seven memo pages.

Owner Care, Engine Repair, and Scooter Electrical Systems

The following highlights are a selection of the contents, rather than a complete table of contents. Other topics include cable routing and the side-stand ignition cut-off system.

• Owner operation: Controls, pre-ride inspections, scheduled maintenance, starting, parking, loading, and safe-riding guidance for the E-Five.

• Engine and lubrication: Engine removal, oil-pump adjustment and bleeding, cylinder and piston service, crankcase separation, and crankshaft and transmission bearing work.

• Fuel system: PB11P carburetor teardown, auto bystarter testing, vacuum-operated fuel-cock checks, throttle-valve service, and inlet-pipe and reed-valve inspection.

• CVT and kick starter: Drive-belt replacement, variator and weight-roller inspection, clutch/driven-pulley disassembly, clutch-shoe replacement, and spring, seal, and bearing service.

• Chassis and brakes: Body-panel removal, wheels and tubeless tires, steering stem, front fork, rear cushion, rear drum brake, and front hydraulic-disc brake repair.

• Electrical diagnosis: MF battery, charging system, A.C. generator, regulator/rectifier, CDI ignition, pulse generator, starter motor and relay, senders, switches, meter, lamps, and horn.

• Service reference: Maintenance schedules, torque tables, fluid data, wear limits, inspection clearances, electrical test specifications, specialized-tool listings, troubleshooting charts, assembly drawings, and wiring diagrams.

The owner's manual supports routine checks; the deeper service procedures are suited to experienced mechanics equipped for electrical testing, bearing work, and spring-compression procedures.

E-Five Controls and Routine Maintenance

The owner's manual explains the instrument panel, warning lights, switches, electric and kick starting, seat and stand locks, trunk, brake-lock lever, parking, and loading. Its separate safe-riding section discusses riding posture, starts, turns, braking, and passenger or cargo stability.

Maintenance instructions cover brake-fluid and friction-part checks, rear brake-lever adjustment, engine and transmission oil, wheels and tires, spark plug, battery, fuse, bulbs, and the air-cleaner element. Side-stand inspection, washing, and storage guidance complete the routine-care material.

S-Five Engine and Fuel-System Repair

The service manual covers the carbureted SJ50E two-stroke engine with separate oil injection. Internal engine work extends through the cylinder head, cylinder, piston and rings, final transmission, crankshaft, crankcase bearings, oil seals, and engine-hanger link.

The engine-removal section distinguishes work possible with the engine installed from crankshaft and crankcase-bearing work requiring engine removal. That distinction helps plan access and shop equipment before disassembly.

Auto bystarter checks include resistance and enrichment-circuit airflow tests. The fuel tank, air cleaner, vacuum-operated fuel cock, throttle valve, inlet pipe, and reed valve have their own removal or inspection instructions.

CVT, Suspension, and Brake Service

Step-by-step procedures cover drive-belt replacement and clutch/driven-pulley service. The clutch-shoe section notes an alternate hardware arrangement using one retainer plate instead of three washers; driven-face bearing replacement includes hydraulic-press installation of the needle bearing.

Front-fork work extends through disassembly, inspection, seal replacement, and reassembly. Steering-stem procedures cover the bearing races and steel balls, while rear-cushion service includes spring removal and inspection.

Brake coverage distinguishes fluid replacement and bleeding from pad replacement, disc inspection, caliper overhaul, and master-cylinder overhaul. Rear drum-brake instructions cover shoes, springs, the brake cam, and assembly.

Electrical Tests, Troubleshooting, and Workshop Tools

Charging and starting: Harness checks include leakage, charging-current and voltage tests, regulator/rectifier diagnosis, A.C. generator service, and starter-motor overhaul.

Ignition: Peak-voltage and resistance tests use the Daelim PVA multi tester. The manual also covers CDI circuit checks and ignition-timing inspection; timing is inspected rather than adjusted.

Section 18 supplies fault-isolation charts for hard starting, low engine output, poor low- or high-speed performance, clutch/CVT operation, fuel-gauge faults, and starter faults.

Visual references include the oil-system drawing, CVT/clutch exploded view, crankshaft/crankcase assembly view, and front-fork and steering-stem views. Charging, ignition, and starting device-location layouts accompany the full wiring diagram.

The specialized-tool list identifies clutch spring compressor 07960-KM10000, crankcase puller 0751-00003, shock absorber compressor 07GM-0010000, and A.C. generator rotor puller 0750-00006.

CVT and Fuel-System Repair Cautions

The CVT chapter warns that using the rear wheel or rear brake to counterhold the clutch locknut can damage the final-reduction system. Fuel-system cautions address carburetor-body damage from wire probes and fuel-cock diaphragm damage from compressed air.

Fuel, brake-fluid, spring, and ignition work should be performed with the safeguards and equipment specified by Daelim.

Selected Belt-Wear and Spark-Plug Specifications

For the S-Five drive belt, the service manual lists a standard width of 17.5 mm and a service limit of 16.5 mm. These figures accompany the belt inspection and replacement instructions.

The B8HSA spark-plug inspection specifies an electrode gap of 0.6–0.7 mm. The same gap range appears in the E-Five owner's manual.