DAELIM VJF125, Roadwin 250R FI VJF125 Service Manual

HOW TO USE THIS MANUAL

This manual describes effective maintenance procedure for the VJF125 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.

• 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.

CONTENTS

GENERAL INFORMA TION INSPECTIONS / ADJUSTMENTS LUBRICA TION FUEL SYSTEM

ENGINE

1

2

3

4

COOLING SYSTEM

6

EMS (

Engine Management System

)

5

ENGINE REMOV AL CLUTCH / GEARSHIFT A.C.GENERA TOR / ST ARTER CLUTCH CYLINDER HEAD / V ALVES CYLINDER / PISTON

CRANKCASE / TRANSMISSION / CRANKSHAFT

EXTERNAL P ARTS

REAR WHEEL /REAR SUSPENSION

FRONT WHEEL/FRONT FORK/STEERING

HYDRAULIC BRAKE

FRAME

ELECTRICAL SYSTEM

BATTER Y / CHARGING SYSTEM

ELECTRIC ST ARTER LIGHTS/METER/SWITCHES

IGNITION SYSTEM

7

8

9

10

11

12

13

14

15

16

17

18

WIRING DIAGRAM

19

TROUBLESHOOTING

20

22

21

1-1

1. GENERAL INFORMATION

SERVICE INFORMA TION

··············

1-1

SERVICE RULES

····················

1-1

CAUTION WHEN WIRING

··········

1-5

MODEL IDENTIFICATION

··········

1-9

SPECIFICATIONS

··················

1-10

TORQUE VALUES

··················

1-12

SYMBOLS / ABBREVIATIONS

······

1-14

TOOLS

····························

1-15

WIRING DIAGRAM

················

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 must be DAELIM genuine or

recommended parts.

2. Before maintenance, remove deposit or dust from the chasis.

1

1-2

GENERAL INFORMA TION

9. Check to see if the rubber part is worn out when removing it and replace it if necessary . Some rubber part is weak to gasoline and kerosene, so pay attention not to soak with gasoline or oils.

10. Recommended grease must be applied to or filled in the specified place.

7. Align the bolts to uniform the tightening points before tightening them when you don’t know the bolt length.

8. Bolts, nuts and pieces must be tightened from the bigger diameter to the smaller one, from inside to outside and diagonally with the specified torque.

5. Clean the parts after the overhaul and before the test and remove the cleaning oil with compressed air. Apply oil to seal face during installation.

6. Check necessary place and measure necessary data during installation. When installing, return to the state before removing.

3. Store the parts of each system discriminatively to install each part in the right place.

4. After removing gasket, O-ring, piston pin clip and cotter pin, always replace them with the new one. When removing the snap ring, it can be easily missed after transformation or installation.

1-3

GENERAL INFORMA TION

11. Maintenance needed to use the specialized tools must be performed with the right tool.

12. Never reuse the ball bearing removed with the ball applied pressure when removing press-fitted the bearing.

13. Check the smooth rotation of inner or outer race of the ball bearing by rotating it manually .

• Replace the ball bearing having excessive axial/ longitudinal hanging.

•Wipe the ball bearing likely to have hanging with

cleaning oil.(except double-sided sealed type ball bearing)

• Replace the ball bearing of which press-fitted part is slacked at the case or shaft.

14. Pay attention to installation direction in case of the single-sided sealed ball bearing. Install the opendirection or double-sided sealed bearing in the way that the face marked with manufacturer and size should direct to the outer axle.

15. When blowing the ball bearing with compressed air after cleaning, keep the race from rotating. High speed rotation of the race may damage the bearing. Prior to installation, apply oil or grease to the bearing.

16. Install the snap ring so that chamfered side directs to the load-applied side. After installation, check the proper installation by rotating the snap ring.

17. Check each part for proper tightening and operation after installation.

18. The brake fluid and coolant can damage the painted plastic or rubber parts. Keep these parts from contacting with them and wash these parts with water in case of contact.

SINGLE-SEALED TYPE

DOUBLE-SEALED TYPE

OPEN TYPE

SNAP RING

CHAMFERED EDGE

MANUFACTURER’S NAME, BEARING No.

1-4

GENERAL INFORMA TION

21. Keep the pneumatic system interior or the engine interior from the infiltration of dust.

22. Install the gasket mounted in the contact surface of each case of the engine while removing gasket material completely. Remove damaged contact surface by wiping with the oil stone equally .

19. Install the oil seal so that the manufacturer marked surface directs outer surface.(direction not covered with oil)

• Pay attention not to bend or damage the lip.

• Apply the grease to the lip.

20. Connect the tube until the tube fully inserted in the joint. Install the clip if it is supplied. Replace the tube having slacked end.

23. Pay attention not to bend the cable excessively. Transformed or damaged cable may cause malfunction or damage.

24. Install the boots with the installing groove by inserting the boots into the groove.

MANUFACTURER’S NAME

CAVITY

CLIP

FITTING

BOOTS

1-5

GENERAL INFORMA TION

•Each cord must be connected depending on its color. When connecting different cord, attach color tube around the connector. Connect the coupler to the connector with same color and same pin number .

•Identify the two-colored cord by main color first and then spriped color .

•When measuring voltage or resistance of the cord terminal using tester, contact the tester plug behind of the coupler. Pay attention not to open the cord terminal and contact the tester plug from the front of the coupler in case of water-proof coupler .

•Recheck the condition of contact, securing and continuity of each part after maintenance.

•When connecting the battery, the plus terminal must be connected first.

•After connecting the terminal, apply the grease to the terminal.

•When disconnecting the battery, the minus terminal must be disconnected first.

•Make sure that the tool such as spanner do not contact with the frame.

•Connect covers to the terminal after maintenance.

•If the fuse is short-circuited, find out the cause and

repair. Replace with the fuse having the specified capacity .

•If there is rust in the terminal, remove the rust with sand paper prior to connecting.

CAUTION WHEN WIRING

BLACK CORD

WHITE COUPLER.

WHITE

RED STRIPE

WHITE / RED CORD

TESTER PLUG

WHITE TUBE

BLACK TUBE

VALIDATION OF CAPACITY!

REMOVE THE RUST!

1-6

GENERAL INFORMA TION

•Insert the lock of the coupler until the lock is fully secured.

•Turn off the main switch before connecting/disconnecting.

•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 the coupler connection.

•Release the lock by inserting the coupler slightly and then narrowing connection to remove the coupler .

•Pay attention not to damage the vinyl cover of the coupler.

•Check to see if there is bended terminal and secure it to avoid disconnecting.

•If the wire harness coating is damaged, repair by winding vinyl tape or replace it.

•Prior to connecting the connector, make sure that the cover is not damaged and the mess terminal is not opened.

1-7

GENERAL INFORMA TION

•Wire band must be secured firmly in the specified location of the frame. In case of aluminium band, secure the wire harness to the coated part.

•Secure the wire harness firmly using the clamp.

•Insert the connector until the vinyl cover is fully

inserted into the terminal.

•The opening of the vinyl cover must face at the ground direction but in case of the plain connector, the draining opening must face at the sky direction.

•When removing T-start, broaden the groove of T-start using the wiring driver and release the torque.

•Connect the harness and the hose to T-start and then insert until the groove is locked.

•When removing T-start from the frame, replace it with the new one.

•In case of the weld clamp, do not clamp in the welded part.

•When clamping the wire harness, make sure that the harness is not contacted with the shaft or rotating part.

•When clamping the wire, pay attention not to contact with hot part.

•The wire harness must be routed without contacting with the end of the lamp or any sharp edge.

•The wire harness must be routed without contacting with the end of the bolt or the piece.

WIRING DRIVER

DRAINING HOLE

GROOVE SIDE

1-8

GENERAL INFORMA TION

•If necessary, lock the wire harness properly. •When mounting parts, make sure that the wire harness is not pressed by the parts.

•In case that the wire harness is contacted with the end or

the sharp edge, protect both parts with tube or tape.

•The wire must not hang down or be pulled excessively.

•Do not twist the wire harness. •Wire the wire harness not to be pulled or expanded

when the handle is turned to the right or the left completely. Avoid excessive bending or chewing and interference with the engine.

•Prior to using the tester, please read the manual care-

fully and understand the contents.

•When testing the resistance of the tester, the zero

adjustment must be performed before testing.

•Do not drop or throw the parts especially semiconductor contained parts because these parts may be damaged by the impact of the drop.

NOT TO PULL!

Is this measurement range or configuration in accord

with the manual?

1-9

GENERAL INFORMA TION

MODEL IDENTIFICATION

ENGINE SERIAL NUMBER LOCA TION

•The engine serial number is stamped on left crankcase.

FRAME SERIAL NUMBER LOCA TION

•The frame serial number is stamped on the left side of steering head.

FRAME SERIAL NUMBER

ENGINE SERIAL NUMBER

RADIA TOR

CALIPER

BRAKE DISK

GEAR SHIFT PEDAL

MAIN ST AND

SIDE ST AND

MAIN STEP BAR

PILLION STEP BAR

REAR CUSHION

HELMET HOLDER

TOOL BOX

1-10

GENERAL INFORMA TION

SPECIFICATIONS

ITEM SPECIFICATIONS

OVERALL LENGTH 2,025mm OVERALL WIDTH 778mm OVERALL HEIGHT 1,180mm

DIMENSIONS

WHEEL BASE 1,380mm SEAT HEIGHT 780mm GROUND CLEARANCE 139mm DRY WEIGHT 173kgf CURB WEIGHT 292kgf

TYPE Double Cradle FRONT SUSPENSION / STROKE Telescopic / 130mm REAR SUSPENSION / STROKE Swingarm / 28mm FRONT TIRE SIZE (TYPE) 110/70-17 54P (Tubeless) REAR TIRE SIZE (TYPE) 140/60-17 69P (Tubeless) TIRE PRESSURE 1 PERSON FRONT

2.00kgf/cm2(200kPa)

REAR 2.00kgf/cm

2

(200kPa)

FRAME 2 PERSON FRONT

2.00kgf/cm2(200kPa)

REAR 2.25kgf/cm

2

(225kPa) FRONT BRAKE Hydraulic Disk REAR BRAKE Hydraulic Disk FUEL CAPACITY 14.85ℓ FUEL RESERVE CAPACITY 4.0ℓ CASTER ANGLE 25.2° TRAIL 93.5mm FRONT FORK OIL CAPACITY 265±2.5cc

TYPE Liquid 4-stroke DOHC(4 Valve) CYLINDER NUMBER, ARRANGEMENT

1 Cylinder, 20°Inclined from vertical BORE AND STROKE 56.5 X 49.5mm DISPLACEMENT 124.1cm

3

COMPRESSION RATIO 11.8:1 VALVE TRAIN DOHC Chain Drive OIL CAPACITY 1.5 ℓAfter Disassembly

1.35ℓAfter Draining and Oil Filter Change

ENGINE

1.3 ℓAfter Draining LUBRICATION SYSTEM Wet Pressing and Spray AIR FILTRATION TYPE Paper Filter CYLINDER COMPRESSION 13.0kgf/cm

2

(600rpm)

INTAKE VALVE OPEN 23°BTDC

CLOSED 55°ABDC (1.12mm Lift)

EXHAUST VALVE OPEN 66.3°BBDC

CLOSED 23.6°ATDC (1.12mm Lift) VALVE CLEARANCE INTAKE 0.15±0.02mm (A COOLING-OFF PERIOD)

EXHAUST 0.20±0.02mm

ENGINE DRY WEIGHT 32.0kgf

1-11

GENERAL INFORMA TION

ITEM SPECIFICATIONS

CLUTCH TYPE Multiplate Wet Clutch / 5 TRANSMISSION TYPE Constant Mesh GEAR RATIO 1st 3.200(37/12 T)

DRIVE TRAIN

GEAR RATIO 2nd 2.143(32/17 T) GEAR RATIO 3rd 1.438(29/21 T) GEAR RATIO 4th 1.095(23/21 T) GEAR RATIO 5th 0.923(24/26 T)

GEARSHIFT PATTERN Left foot operated return system

Down 1-N-2-3-4-5 Up

IGNITION TYPE Full Transisterized IGNITION TIMING “F” MARK 18°BTDC / 1,600(rpm)

FULL ADVANCE 30°BTDC / 8,500(rpm) AC GENERATOR 12V-17A/5,000(rpm) BATTERY CAPACITY 12V 10AH SPARK PLUG CR9EH- 9 SPARK PLUG GAP 0.8 -0.9mm FUSE CAPACITY 30A STARTING SYSTEM Starter Motor

ELECTRICAL

HEADLIGHT (HIGH/LOW BEAM) 55W/55W POSITION LAMP 5W TURN SIGNAL LAMP 10W×4 STOP/TAIL LIGHTS 21W/5W SPEEDOMETER LAMP 3W NEUTRAL INDICATOR LAMP LED×1 HIGH BEAM INDICATOR LAMP LED WINKER INDICATOR LAMP LED LICENCE PLATE LAMP 5W TACHOMETER LAMP LED×1 MALFUNCTION INDICATOR LAMP LED

1-12

GENERAL INFORMA TION

TORQUE VALUES

ENGINE

FRAME

kgf.m,(N.m)

TORQUE

kgf.m,(N.m)

REFERENCE

THREAD DIA

(mm)

Q’TY

ITEM

REFERENCE

THREAD DIA

(mm)

Q’TY

ITEM

8 4 4 1 2 1 1 1 1 3 2 3 1 2

12

1 7 1 1

10

1 1 1 1

M6×1.0

M10×1.25

M6×1.0 M6×1.0 M6×1.0

M6×1.0 M16×1.0 M16×1.0

M12×1.25

M8×1.25

M6×1.0

M10×1.25

M6×1.0

M6×1.0 M14×1.5 M30×1.5

M6×1.0

M10×1.25

M6×1.0 M36×1.5

M12×1.25

Apply Engine Oil Apply Engine Oil

Apply Engine Oil Remove negative screw Remove negative screw

1.0~1.2

3.5~4.5

0.8~1.2

1.0~1.4

0.35~0.5

6.0~7.0

5.0~6.0

3.0~3.4

1.0~1.4

1.0~1.2

0.4~0.8

1.0~2.0

1.0~1.2

1.0~1.4

1.0~2.0

CAM HOLDER BOLT(SHBOLT) CYLINDER HEAD SPECIAL SOCKET NUT CYLINDER HEAD COVER BOLT CAM CHAIN TENSIONER PIVOT BOLT CAM CHAIN TENSIONER LIFTER BOLT CAM CHAIN TENSIONER LIFTER SCREW PRIMARY DRIVE GEAR NUT CLUCH LOCK NUT FLYWHEEL BOLT STARTER CLUTCH SOCKET BOLT BEARING SET PLATE BOLT OIL FILTER COVER SOCKET BOLT SHIFT DRUM STOPPER ARM BOLT DRIVE SPROCKET BOLT R.CRANKCASE COVER BOLT OIL FILTER COVER BOLT L.CRANKCASE COVER BOLT A.C GENERATOR CAP CRANKSHAFT HOLE CAP CRANKCASE BOLT SPARK PLUG START MOTOR NUT TAPPET ADJUST HOLE CAP ENGIN TEMPERATURE SENSOR

1 1 2 4 2 1 1 1 1 4 2

M10×1.25 M10×1.25 M10×1.25

M8×1.25

M8×1.25 M10×1.25 M10×1.25

M 5×0.8

M14×1.5 M10×1.25 M10×1.25

HEX NUT

U- NUT U- NUT

4.5~5.5

5.0~6.0

4.5~5.5

2.4~3.0

1.0~2.0

4.0~5.0

0.35~0.5

8.0~10.0

5.5~6.5

3.4~4.0

REAR ENGIN HANGER BOL T(UPPER) REAR ENGIN HANGER BOL T(UNDER) FRONT ENGIN HANGER BOL T(UPPER/UNDER) FRONT ENGIN HANGER PLA TE BOL T STEERING HANDLE PIPE BOL T SIDE ST AND PIVOT SCREW SIDE ST AND PIVOT NUT SPEEDOMETER GEAR BOX SCREW REAR AXLE NUT DRIVE SPROKET NUT REAR BRAKE OIL BOL T

TORQUE

1-13

GENERAL INFORMA TION

REFERENCE

THREAD DIA

(mm)

Q’TY

ITEM

*Torque specifications listed above are for important fastener. Other should be tighten to the standard torque values below.

*SH(Small Head) : It describe 6mm bolt of 8mm flange bolt.

TYPE

TORQUE

TYPE

TORQUE

kgf·mN

·

m kgf·mN

·

m

15mm BOLT, NUT 4.0~6.0 0.45~0.6 5mm SCREW 3.4~5.0 0.35~0.5 16mm BOLT, NUT 8~12 0.8~1.2

6mm SCREW, FLANGE BOLT

7~11 0.7~1.1

18mm BOLT, NUT 18~25 1.8~2.5

6mm FLANGE BOLT, NUT

9.8~14 1.0~1.4

10mm BOLT, NUT 29~39 3.0~4.0

8mm FLANGE BOLT, NUT

24~29 2.4~3.0

12mm BOLT, NUT 49~59 5.0~6.0

10mm FLANGE BOLT, NUT

34~44 3.5~4.5

(Include SH type)

kgf.m,(N,m)

FRAME

2 2 1 6 4 4 2 1 1 2 2 2 1 2 2 4 2 5

M8×1.25

M6×1.0 M14×1.5 M8×1.25

M10×1.25

M8×1.25

M6×1.0 M22×1.0 M22×1.0 M8×1.25 M8×1.25 M8×1.25

M14×1.25 M10×1.25

6mm T apping

M8×1.25 M8×1.25 M8×1.25

U- NUT

2.8~3.4

1.0~1.4

5.5~6.5

4.0~4.5

3.0~4.0

2.8~3.4

1.0~1.4

6.0~9.0

0.25~0.35

2.4~3.0

3.0~4.0

2.4~3.0

8.0~10.0

3.5~4.5

0.5~0.7

4.0~4.5

1.8~2.5

4.0~4.5

REAR CALIPER BRACKET BOLT REAR MASTER CYLINDER HOLDER SOCKET BOL T FRONT AXLE NUT FRONT BRAKE DISK BOLT BRAKE OIL BOLT (FRONT/REAR) CALIPER BRACKET BOLT (FRONT/REAR) FRONT MASTER CYLINDER HOLDER BOLT STEERING STEM NUT STEERING TOP THREAD FORK TOP BRIDGE PINCH BOLT BOTTOM BRIDGE PINCH BOLT FORK HANDLE PIPE MOUNTING BOLT SWINGARM PIVOT NUT REAR CUSHION UPPER/UNDER BOLT CHAIN SLIDER SCREW L. DOWNTUBE COMP ‘B’ HANDLE WEIGHT SOCKET BOLT REAR BRAKE DISK SOCKET BOLT

SYMBOL

1-14

GENERAL INFORMA TION

SYMBOLS / ABBREVIATIONS

The following symbols are used in this manual to represent job-related warnings or cautions.

MEANING

Indicates dangerous area. Serious accident may result if instructions are not followed.

MEANING

Indicates important work. Minor injury or vehicle part damage may result if instruction are not followed. Indicates general safety matters. Provides safety and appropriate handling procedures.

SYMBOL

The following symbols indicate needed lubrication steps, the changing of parts, and required specialized tools, etc. when performing maintenance.

CAUTION

Use option tool. These tools are obtained as you order parts.

Indicates reference page. (Example : Refer to page 3-1)

Use recommended engine oil, unless otherwise specified.

Use molybdenum oil solution (mixture of the engine oil and molybdenum grease with the ratio 1:1)

Use multi-purpose grease (Lithium based multi-purpose grease NLG #2 or equivalent)

Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or equivalent)

Use molybdenum disulfide paste containing more than 40% molybdenum disulfide, NLGI #2 or equivalent)

Use silicone grease

Apply a locking agent. Use the agent of the middle strength, unless otherwise specified

Apply sealant

Replace the parts with new ones before assembly

Use brake fluid, DOT3 or DOT4. Use the recommended brake fluid, unless otherwise specified

Use Fork or Suspension Fluid

Use special tool

Special grease, etc. that do not correspond to the above are indicated without using symbols.

(󱐇3-1)

1-15

GENERAL INFORMA TION

TOOLS

SPECIAL COMMON

DESCRIPTION REF. SEC. DESCRIPTION REF. SEC.

TESTER, GAUGE

COMPRESSION GAUGE DIGITAL MULTI TESTER PVA TESTER BATTERY TESTER TESTER RECORDER

2 17, 18 17, 18

18

5

DESCRIPTION REFERENCE SECTION REMARK

VALVE SEAT CUTTER

VALVE SEAT CUTTER 45° VALVE SEAT CUTTER 35° VALVE SEAT CUTTER 35° VALVE SEAT CUTTER 60° CUTTER HOLDER 5mm

10 10 10 10 10

24.5mm IN, EX 23mm IN

20mm EX

22mm IN, EX

Use with Valve Seat

DESCRIPTION REFERENCE SECTION REMARK

CLUTCH CENTER HOLDER 8 ACG ROTOR PULLER 9 VALVE GUIDE DRIVER 10 VALVE GUIDE REAMER 10 UNIVERSAL BEARING PULLER 12 BEARING REMOVER SET 12 THREAD ADAPTER 12 ASSEMBLY SHAFT 12 CRANK CASE ASSEMBLY COLOR 12 BALL RACE DRIVER 14 STEERING STEM DRIVER 14 FORK SEAL DRIVER 14 STEERING STEM SOCKET 14 SNAP RING PLIERS 16

WRENCH, 8×9mm 2 ADJUSTING WRENCH, B 2 LOCK NUT WRENCH, 20×24mm 6 EXTENSION BAR 8, 14 FLY WHEEL HOLDER 8, 9 VALVE SPRING COMPRESSOR 10 DRIVER 12, 14, 15 ATTACHMENT 12, 14, 15 PILOT 12, 14, 15 FORK SEAL DRIVER BODY 14 BEARING REMOVER HEAD 15 BEARING REMOVER SHAFT 15 LOCK NUT(M8) 10

1-16

GENERAL INFORMA TION

WIRING DIAGRAM

1-17

GENERAL INFORMA TION

1-18

GENERAL INFORMA TION

1-19

GENERAL INFORMA TION

MEMO

2-1

2. INSPECTIONS/ADJUSTMENTS

SERVICE INFORMATION

•The exhaust gas contains poisonous substance. Do not keep engine idling in a closed or poorly ventilated place for a long period of time.

SPECIFICA TIONS

TIRES

2

SERVICE INFORMATION

······

2-1

MAINTENANCE SCHEDULE

···

2-3

FUEL LINE (FUEL TUBE)

······

2-4

THROTTLE GRIP OPERATION

····

2-4

AIR CLEANER

·· ·· ·· ·· ·· ·· ··

2-5

SPARK PLUG

·· ·· ·· ·· ·· ·· ··

2-5

VALVE CLEARANCE

·· ·· ·· ··

2-6 CYLINDER COMPRESSION PRESSURE··2-7 DRIVE CHAIN

················

2-8 DRIVE CHAIN SLIDER

·· ·· ·· ··

2-9 BRAKE FLUID

········ ······

2-9

BRAKE PAD WEAR

·· ·· ·· ·· ··

2-9

BRAKE SYSTEM

·· ·· ···· ·· ··

2-10

BRAKE STOP SWITCH

········

2-11

HEADLIGHT AIM

·· ·· ·· ·· ·· ··

2-11

CLUTCH SYSTEM

············

2-11

SIDE STAND

·· ·· ·· ·· ·· ·· ·· ··

2-12

SUSPENSION

·· ·· ·· ·· ·· ·· ··

2-13

BOLTS, NUTS, FASTENERS

······

2-13

WHEEL/TIRE

················

2-14

STEERING STEM

·········· ··

2-14

COOLANT LEVEL INSPECTION

····

2-15

COOLANT REPLACEMENT

····

2-15

THROTTLE GRIP PLA Y 2~6mm SP ARK PLUG CR9EH-9 SP ARK PLUG GAP 0.8~0.9mm

IN. 0.15mm EX. 0.20mm

CARBURETOR IDLE SPEED 1,600rpm

±100rpm CYLINDER COMPRESSION 13.0kgf/㎠ ( 600rpm ) DRIVE CHAIN SLACK 10~20mm REAR BRAKE PEDAL FREE PLA Y 10~20mm CLUTCH LEVER FREE PLA Y 10~20mm

•For information on engine oil and oil filter, refer to sections 3-3 and 3-4.

•Stand the main stand prior to beginning work.

V ALVE CLEARANCE

COLD TIRE PRESSURE

TIRE SIZE

DRIVER ONL Y

DRIVER AND A

P ASSENGER

FRONT

REAR

FRONT

REAR

FRONT

REAR

FRONT

REAR

2.00kgf/㎠ (200kPa, 29psi )

2.25kgf/㎠ (225kPa, 32psi ) 1 10/70-17 54S 140/60-17 69S

5.5mm

7.0mm

TIRE PART MINIMUM-DEPTH

2-2

TORQUE VALUES

SPARK PLUG 1.0~1.2kgf-m CYLINDER HEAD COVER BOLT 0.8~1.2kgf-m AC GENERATOR CAP 0.4~0.8kgf-m HOLE CAP 30mm 0.6~1.0kgf-m AIR CLEANER CASE COVER SCREW 0.4~0.8kgf-m REAR AXLE NUT 8.0~10.0kgf-m DRIVE SPROCKET BOLT 1.0~1.4kgf-m DRIVEN SPROCKET NUT 5.6~6.5kgf-m

TOOLS

WRENCH, 8×9mm COMPRESSION GAUGE

INSPECTIONS / ADJUSTMENTS

2-3

INSPECTIONS / ADJUSTMENTS

MAINTENANCE SCHEDULE

• Perform the Self Inspections Before Operation at each scheduled maintenance period.

I : INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY. R : REPLACE L : LUBRICATE C : CLEAN A : ADJUST

＊ If you do not have the appropriate tools or information to conduct maintenance, or if you feel you are not capable to

perform maintenance on this vehicle, contact authorized dealers or repair shops for maintenance and repairs.

 To ensure safety , inspections and maintenance of these parts must be carried out by dealers, or repair centers.

NOTES :

(1) After the odometer reading exceeds 1,200Km, repeat maintenance service at intervals indicated in the table. (2) Service more frequently when riding in unusually wet or dusty areas. (3) Replace every 2 years, or at indicated odometer interval, whichever comes first. Replacement requires

mechanical skill.

＊



＊



FUEL LINE FUEL FIL TER THROTTLE GRIP OPERA TION AIR CLEANER ELEMENT SP ARK PLUG VAL VE CLEARANCE ENGINE OIL ENGINE OIL FIL TER ELEMENT OIL FIL TER SCREEN DRIVE CHAIN BRAKE FLUID BRAKE /P AD WEAR BRAKE SYSTEM BRAKE STOP SWITCH HEADLIGHT AIM CLUTCH SYSTEM SIDE ST AND SUSPENSION BOL TS, NUTS, FASTENERS WHEELS/TIRES STEERING HEAD BEARING RADIA T OR COOLANT RADIA T OR CORE RADIA T OR CAP

I

I R R C

I

R

I

R

I

I R R C

I

R

I R R

I R R C

I

I R

I

R

I

R

I

I R R C

I

NOTE (2)

NOTE (3)

Every 1,000㎞ : I and L

FREQUENCY

ODOMETER READING(NOTE 1)

61218

1/2 4 8 12 REMARK

ITEM

x 1000Km

MONTH

2-4

INSPECTIONS / ADJUSTMENTS

FUEL LINE (FUEL TUBE)

• Check the connection between injector and fuel tube.

• Check the fuel tube for deterioration, damage or

leakage. Replace it if necessary .

THROTTLE GRIP OPERATION

• Check if the throttle grip operates smoothly in all steering positions.

• If not operating smoothly, check the deterioration, damage and kink of the throttle cable.

• Measure the free play at the throttle grip.

FREE PLAY : 2~6mm

•For simple adjustment, use the adjuster under the

throttle grip.

•Adjust the free play by loosening the lock nut and

turning the adjuster .

•After adjusting, tighten the lock nut.

•Major adjustments are made with the lower adjuster.

•Adjust the free play by loosening the lock nut and

turning the adjuster.

•After adjustment, tighten the lock nut securely.

•Recheck the throttle operation.

•Replace any damaged parts, if necessary.

FUEL TUBE

INJECTOR

LOCK NUT

ADJUSTER

THROTTLE CABLE

THROTTLE

CABLE

THROTTLE CABLE

FREEPLAY

THROTTLE GRIP

2-5

INSPECTIONS / ADJUSTMENTS

AIR CLEANER

• Remove the seat. (⇨13-2)

• Loosen the 4 screws, remove the air cleaner cover.

• Remove the air cleaner element.

• Also replace the filter any time it is excessively dirty or

damage.

• Install in the reverse order of removal.

•Do not reuse the filter element to clean by

compressed air.

SPARK PLUG

• Remove the spark plug cap.

• Check the plug for damage, contamination or deposits.

• If the spark plug is severely contaminated or damaged,

raplace with a new one. If the plug can be reused after removing only the carbon, use plug cleaner and wire brush to clean the plug.

• Always use a feeler gauge to check the gap.

GENUINE PLUG : CR9EH-9 SPARK PLUG GAP : 0.8~0.9mm TORQUE : 1.1kgf·m

• Assemble the spark plug.

•Make sure there is no dirt or debris on the seat of the

spark plug hole before inserting the spark plug.

•To prevent damage to the cylinder head, handtighten the spark plug before using a wrench to tighten to the specified torque.

•Do not overtighten the spark plug.

0.8~0.9mm

CHECK GAP,

DEPOSITS

CHECK FOR

CRACKS

CHECK WASHER FOR DAMAGE

AIR CLEANER

HOUSING COVER

AIR CLEANER

HOUSING COVER

AIR CLEANER

HOUSING COVER

AIR CLEANER

HOUSING COVER

AIR CLEANER

HOUSING COVER

AIR CLEANER

HOUSING COVER

AIR CLEANER

HOUSING COVER

AIR CLEANER

HOUSING COVER

AIR CLEANER

HOUSING COVER

AIR CLEANER

HOUSING COVER

AIR CLEANER

HOUSING COVER

AIR CLEANER

HOUSING COVER

AIR CLEANER

HOUSING COVER

AIR CLEANER

HOUSING COVER

AIR CLEANER

HOUSING COVER

AIR CLEANER

HOUSING COVER

AIR CLEANER

ELEMENT

AIR CLEANER

ELEMENT

AIR CLEANER

ELEMENT

AIR CLEANER

ELEMENT

AIR CLEANER

ELEMENT

AIR CLEANER

ELEMENT

AIR CLEANER

ELEMENT

AIR CLEANER

ELEMENT

AIR CLEANER

ELEMENT

AIR CLEANER

ELEMENT

AIR CLEANER

ELEMENT

AIR CLEANER

ELEMENT

AIR CLEANER

ELEMENT

AIR CLEANER

ELEMENT

AIR CLEANER

ELEMENT

AIR CLEANER

ELEMENT

AIR CLEANER

ELEMENT

AIR CLEANER

ELEMENT

SPARK PLUG WRENCH

SCREWS

2-6

INSPECTIONS / ADJUSTMENTS

VALVE CLEARANCE

• Remove the cylinder head cover.

• Remove the A.C generator cap and crankcase hole cap.

• Rotate the flywheel counterclockwise to align the "T"

mark with the index mark on the left crankcase cover .

• Make sure the piston is at TDC(Top Dead Center) on the compression stroke.

SHIM ADJUSTMENT

• If the valve clearance is out of standard, adjust the shim as below .

- Remove the camshaft.

- Remove the valve lifter and shim.

• Remove the valve lifter and clean by compressed air.

• Mop the oil from the attached area of shim, and

measure and record the thinkness with a micrometer .

•Inspect and adjust valve clearance while the engine

is cold. (below 35°C/95°F)

•If the valve lifter is to be removed, use the special tool.

•Be careful not to drop the shim into the cylinder when remove the shim with valve lifter .

•If it is too difficult to remove the shim, use a tweezer or magnet.

•Valve lifter, and shim should be preserved on the assembly position distinguishably .

• Measure the valve clearance with a feeler gauge.

VALVE CLEARANCE : INTAKE : 0.15mm

EXHAUST : 0.20mm

“T” MARK

FEELER GAUGE

VALVE LIFTER

SHIM

CAM SHAFT

SHIM

2-7

INSPECTIONS / ADJUSTMENTS

•The type of shim is 33

•The clearance of shim is 1,500mm to 2,300mm with

0.025mm clearance.

•The maximum reading is usually reached within 4~7seconds

•

compression 13.0kg f/㎠

•Meaure the thickness of new shim and removed shim, using a micrometer accurately .

•If the demanded thickness of shim is over 2,300mm, check the valve seat and remove the carbon deposit and modify the valve seat.

• Demanded thickness of shim :A

• Recorded clearance of the valve lifter : B

• Specified clearance of the valve lifter : C

(In :0.15mm / Ex : 0.20mm)

• Removed thickness of the shim : D

• how to calculate : A = (B-C)+D

Example) B : 0.06mm D : 1.875mm C :

0.15mm(IN) A = (0.06-0.15)+1.875mm New thickness of the shim : 1.775mm

• Install the chosen shim into the valve spring retainer.

• Apply the molybdenum to wet side of valve lifter and

install the lifter.

• Install the cam shaft and rotate the crank shaft for many timed and recheck the valve clearance after setting the shim.

• Apply the engine oil to O-ring of pulse generator cover

cap and install the cap.

TORQUE : 0.6kgf-m

CYLINDER COMPRESSION PRESSURE

• Warm up the engine to normal operating temperature.

• Stop the engine, disconnect the spark plug caps and

spark plug. install the compression gauge. open the throttle completely and crank the engine with the starter motor until the gauge reading stops rising.

Tool:compression gauge.

If compression is low , check the following

-Incorrect valve clearance adjustment.

-Valve leakage.

-Leak the gasket from the cylinder head.

-Worn piston/cylinder.

If compression is high, check the following

-Carbon deposits on the piston head, cylinder head.

118800

118800 118822

118822

118822 118855

118855

118855 118888

118888

1.800mm

1.800mm 1.825mm

1.825mm

1.825mm 1.850mm

1.850mm

1.850mm 1.875mm

1.875mm

SHIM

COMPRESSION PRESSURE GAUGE

DAELIM VJF125, Roadwin 250R FI VJF125 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual