Daelim Roadwin 125 FI Service Manual

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HEAD OFFICE (FACTORY) #58, SUNG SAN-DONG, CHANGWON, KYUNGNAM, KOREA TEL : (82-55) 239-7000 / FAX : (82-55) 239-7524 OVERSEAS SALES OFFICE #13-5, SUNG SOO 1DONG 1GA, SUNG DONG GU, SEOUL, KOREA TEL : (82-2) 498-6465 / FAX : (82-2) 467-9997

SM48-0401-01E

CONTENTS

This manual describes effective maintenance procedure for the VJ125 manufactured by DAELIM Motor Co., Ltd. To ensure safety and optimal operating conditions of the vehicle, carry out regular inspections according to the maintenance schedule (Section 2). Sections 1 through 2 provide information on overall vehicle; and section 3 describes maintenance procedure for the engine, frame and electrical systems. To facilitate use of this manual, each page starts with disassembly and system diagrams, service information, and troubleshooting guide. If you cannot find the cause of trouble, refer to Section 21: Troubleshooting.

GENERAL INFORMATION

1

INSPECTIONS / ADJUSTMENTS

2

LUBRICATION

3

FUEL SYSTEM

4

COOLING SYSTEM

5

ENGINE REMOVAL

6

CLUTCH / GEARSHIFT

7

A.C.GENERATOR / STARTER CLUTCH

8

CYLINDER HEAD / VALVES

9

CYLINDER / PISTON

10

CRANKCASE / TRANSMISSION / CRANKSHAFT

11

EXTERNAL PARTS

12

FRONT WHEEL/FRONT FORK/STEERING

13

REAR WHEEL /REAR SUSPENSION

14

HYDRAULIC BRAKE

15

BATTERY / CHARGING SYSTEM

16

IGNITION SYSTEM

17

ELECTRIC STARTER

18

LIGHTS/METER/SWITCHES

19

WIRING DIAGRAM

20

TROUBLESHOOTING

21

FRAME ELECTRICAL SYSTEM

Contents of this manual and specifications are subject to change without prior notice for improvement of vehicle quality. No part of this publication may be reproduced without written permission of DAELIM Motor Co., Ltd.,

ENGINE

HOW TO USE THIS MANUAL

1. GENERAL INFORMATION 1 ······· SERVICE INFORMATION· ·········· SERVICE RULES· CAUTION WHEN WIRING ····· MODEL IDENTIFICATION ····· SPECIFICATIONS ·········

1-1 1-1 1-5 1-9 1-10

········· TORQUE VALUES· SYMBOLS / ABBREVIATIONS ··· ·············· TOOLS· WIRING DIAGRAM ········

1-12 1-14 1-15 1-16

SERVICE INFORMATION 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 because the engine or the muffler is hot right after engine stops. 4. Gasoline is extremely flammable. Maintenance must be 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 always 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 be 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 mu