Daelim ROADWIN VJ125 SERVICE MANUAL

SM48-0401-01E

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

HOW TO USE THIS MANUAL

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.

󳥍 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.,

CONTENTS

GENERAL INFORMATION

INSPECTIONS / ADJUSTMENTS

LUBRICATION

FUEL SYSTEM

ENGINE

1

2

3

4

COOLING SYSTEM

5

ENGINE REMOVAL

CLUTCH / GEARSHIFT

A.C.GENERATOR / STARTER CLUTCH

CYLINDER HEAD / VALVES

CYLINDER / PISTON

CRANKCASE / TRANSMISSION / CRANKSHAFT

EXTERNAL PARTS

REAR WHEEL /REAR SUSPENSION

FRONT WHEEL/FRONT FORK/STEERING

HYDRAULIC BRAKE

FRAME

ELECTRICAL SYSTEM

BATTERY / CHARGING SYSTEM

ELECTRIC STARTER

LIGHTS/METER/SWITCHES

IGNITION SYSTEM

6

7

8

9

10

11

12

13

14

15

16

17

WIRING DIAGRAM

18

TROUBLESHOOTING

19

20

21

1-1

1. GENERAL INFORMATION

SERVICE INFORMATION

··············

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 INFORMATION

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 INFORMATION

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.

’

1-4

GENERAL INFORMATION

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.

’

1-5

GENERAL INFORMATION

󳢯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

VALIDATION OF CAPACITY!

REMOVE THE RUST!

1-6

GENERAL 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 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 INFORMATION

󳢯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.

1-8

GENERAL INFORMATION

󳢯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 INFORMATION

MODEL IDENTIFICATION

ENGINE SERIAL NUMBER LOCATION

󳢯The engine serial number is stamped on left crankcase.

FRAME SERIAL NUMBER LOCATION

󳢯The frame serial number is stamped on the left side of

steering head.

1-10

GENERAL INFORMATION

SPECIFICATIONS

ITEM SPECIFICATIONS

OVERALL LENGTH 2,010mm OVERALL WIDTH 740mm OVERALL HEIGHT 1,040mm

DIMENSIONS

WHEEL BASE 1,380mm SEAT HEIGHT 780mm GROUND CLEARANCE 150mm DRY WEIGHT 130kgf CURB WEIGHT 147kgf

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 16ℓ FUEL RESERVE CAPACITY 1.1ℓ CASTER ANGLE 25.2° TRAIL 93.5mm FRONT FORK OIL CAPACITY 265±2.5cc

TYPE Air Cooled 4-stroke SOHC CYLINDER NUMBER, ARRANGEMENT

1 Cylinder, 15°Inclined from vertical

BORE AND STROKE 56.5 X 49.5mm DISPLACEMENT 124.1cm

3

COMPRESSION RATIO 10.7:1 VALVE TRAIN SOHC Chain Drive OIL CAPACITY 1.1 ℓAfter Disassembly

1.05ℓAfter Draining and Oil Filter Change

ENGINE

1.0 ℓAfter Draining

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

2

(600rpm)

INTAKE VALVE OPEN 6°BTDC

CLOSED 22°ABDC (1.12mm Lift)

EXHAUST VALVE OPEN 24°BBDC

CLOSED -4°ATDC (1.12mm Lift)

VALVE CLEARANCE INTAKE 0.12±0.02mm (A COOLING-OFF PERIOD)

EXHAUST 0.12±0.02mm

ENGINE DRY WEIGHT 32.3kgf

1-11

GENERAL INFORMATION

ITEM SPECIFICATIONS

TYPE PD 24 VENTURI BORE 24mm SETTING SERIES MARK VJ 125 C MAIN JET #100

CARBURETOR

SLOW JET #38 PILOT SCREW INITIAL SETTING 2 1/8 FLOAT LEVEL 12.5mm IDLE SPEED 1,600±100(rpm)

CLUTCH TYPE Multiplate Wet Clutch TRANSMISSION TYPE Constant Mesh Transmission GEAR RATIO 1st 3.083(37/12 T)

DRIVE TRAIN

GEAR RATIO 2nd 1.882(32/17 T) GEAR RATIO 3rd 1.380(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

1-N-2-3-4-5

IGNITION TYPE DC-CDI Ignition IGNITION TIMING “F” MARK 8°BTDC / 1,600(rpm)

FULL ADVANCE

28°BTDC / 4,000(rpm)

AC GENERATOR 12V-11A/5,000(rpm) BATTERY CAPACITY 12V 10AH SPARK PLUG CR8EH - 9 SPARK PLUG GAP 0.8 - 0.9mm FUSE CAPACITY 15A STARTING SYSTEM Starter Motor

ELECTRICAL

HEADLIGHT (HIGH/LOW BEAM) 35W/35W POSITION LAMP 3W WINKER LAMP 10W×4 STOP/TAIL LIGHTS 21W/5W SPEEDOMETER LAMP 3W FUEL RESERVE INDICATOR LAMP 2W NEUTRAL INDICATOR LAMP 3W HIGH BEAM INDICATOR LAMP 3W WINKER INDICATOR LAMP 3W×2 LICENCE PLATE LAMP 5W TACHOMETER LAMP 2W

1-12

GENERAL INFORMATION

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

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

11

3 7 1 1

10

1 2 1 2 2 4

M8×1.25

M6×1.0

M8×1.25

M6×1.0 M6×1.0

M36×1.5

M5×0.5 M16×1.0 M16×1.0

M10×1.25

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

M12×1.25 M12×1.25

M5×12

Apply Engine Oil

Apply Engine Oil Apply Engine Oil Apply Engine Oil

2.0 (20)

1.0 (10)

1.2 (12)

0.4 (4)

1.5 (15)

1.1 (11)

6.5 (65)

5.5 (55)

3.2 (32)

1.2 (12)

1.1 (11)

0.6 (6)

0.8 (8)

1.1 (11)

1.2 (12)

3.2(32)

0.4(4)

CAM SHAFT HOLDER NUT CYLINDER HEAD COVER BOLT CAM CHAIN TENSIONER PIVOT BOLT CAM CHAIN TENSIONER LIFTER BOLT CAM CHAIN TENSIONER LIFTER SCREW TAPPET VALVE ADJUST HOLE CAP TAPPET ADJUST NUT PRIMARY DRIVE GEAR NUT CLUTCH 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 OIL PUMP MOUNT BOLT START MOTOR NUT OIL THROUGH BOLT(CYLINDER) OIL THROUGH BOLT(RADIATOR) AIR CLEANER CASE COVER SCREW

2 1 2 1 1 1 1 4 2

M10×1.25 M10×1.25

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

4.9 (49)

2.6 (26)

1.5 (15)

4.5 (45)

0.42 (4.2)

8.8(88)

5.9(59)

3.4(34)

ENGINE HANGER BOLT (REAR) ENGINE HANGER BOLT (FRONT) STEERING HANDLE PIPE BOLT SIDE STAND PIVOT SCREW SIDE STAND PIVOT NUT SPEEDOMETER GEAR BOX SCREW REAR AXLE NUT DRIVE SPROCKET NUT REAR BRAKE OIL BOLT

TORQUE

1-13

GENERAL INFORMATION

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.

TYPE

TORQUE

TYPE

TORQUE

kgf··mN

··

m kgf··mN

··

m

15mm BOLT, NUT 0.5 5 5mm SCREW 0.4 4

16mm BOLT, NUT 1.0 10

6mm SCREW, FLANGE BOLT

0.9 9

18mm BOLT, NUT 2.1 21

6mm FLANGE BOLT, NUT

0.9 9

10mm BOLT, NUT 3.5 35

8mm FLANGE BOLT, NUT

2.7 27

12mm BOLT, NUT 5.5 55

10mm FLANGE BOLT, NUT

4.0 40

kgf.m,(N,m)

FRAME

2 2 1 6 4 4 2 1 1 2 2 2 1 2 2 4 2 3

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 Tapping

M8×1.25 M8×1.25 M8×1.25

U- NUT

SOCKET BOLT

3.0(30)

1.2(12)

5.9(59)

4.2(42)

3.4(34)

3.0(30)

1.2(12)

7.4(74)

0.3(3)

2.6(26)

3.4(34)

2.6(26)

8.8(88)

3.4(34)

0.6(6)

4.2(42)

2.0(20)

4.2(42)

REAR CALIPER BRACKET BOLT REAR MASTER CYLINDER HOLDER SOCKET BOLT 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 BOLT

SYMBOL

1-14

GENERAL INFORMATION

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 INFORMATION

TOOLS

SPECIAL COMMON

DESCRIPTION REF. SEC. DESCRIPTION REF. SEC.

TESTER, GAUGE

COMPRESSION GAUGE DIGITAL MULTI TESTER PVA TESTER BATTERY TESTER

2 16, 17 16, 17

17

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

9

24.5mm IN, EX 23mm IN

20mm EX

22mm IN, EX

Use with Valve Seat

DESCRIPTION REFERENCE SECTION REMARK

CLUTCH CENTER HOLDER 7 ACG ROTOR PULLER 8 VALVE GUIDE DRIVER 9 VALVE GUIDE REAMER 9 UNIVERSAL BEARING PULLER 11 BEARING REMOVER SET 11 THREAD ADAPTER 11 ASSEMBLY SHAFT 11 CRANK CASE ASSEMBLY COLOR 11 BALL RACE DRIVER 13 STEERING STEM DRIVER 13 FORK SEAL DRIVER 13 STEERING STEM SOCKET 13 SNAP RING PLIERS 15

WRENCH, 8

9mm 2 ADJUSTING WRENCH, B 2 FLOAT LEVEL GAUGE 4 LOCK NUT WRENCH, 20

24mm 7 EXTENSION BAR 7, 13 FLY WHEEL HOLDER 7, 8 VALVE SPRING COMPRESSOR 9 DRIVER 11, 13, 14 ATTACHMENT 11, 13, 14 PILOT 11, 13, 14 FORK SEAL DRIVER BODY 13 BEARING REMOVER HEAD 14 BEARING REMOVER SHAFT 14

1-16

GENERAL INFORMATION

WIRING DIAGRAM

FR. BRAKE HOSE

SPDMT. CABLE

THROTTLE CABLE

ST.-HAZ. SW. CORD FR. BRAKE HOSE

CABLE GUIDE

CLUTCH CABLE

CHOKE CABLE

NOISE SUPPRESSOR CAP

HORN COMP.

LH. RADIATOR HOSE

RH. RADIATOR HOSE

HIGH TENSION CORD

CLUTCH CABLE

RR. BRAKE HOSE

RR. BRAKE RESERVE TUBE

RR. BRAKE HOSE CLAMP

RR. BRAKE HOSE

RR. CALIPER ASS'Y.

BATTERY EARTH CABLE

ST.-MOTOR CABLE

SIDE STAND SW. CORD

RR. STOP SW. CORD

ST.-MAG SW. CORD

ST.-MAG. BATTERY CABLE(+)

BATTERY EARTH CABLE

HARNESS COVER

WIRE CLIP

ST.-MAG. BATTERY CABLE(+)

BATTERY EARTH CABLE

ST.-MAG. SW. WIRE

C

CLUTCH CABLE

WINKER SW. CORD

CHOKE CABLE

CABLE GUIDE

LH. FR. WINKER

HEAD LIGHT

CABLE GUIDE

SPEEDOMETER CABLE

FR.BRAKE HOSE

THROTTLE CABLE

WIRE HARNESS

WIRE CLIP

BREATHER TUBE

DRAIN TUBE

WIRE CLAMP (WIRE PIVOT)

WIRE CLIP

FUEL UNIT CORD

REG. RECTIFIER WIRE

EARTH WIRE

FUEL UNIT WIRE

ACG. WIRE

FUSE WIRE

ST.-MAG. SW. WIRE

WIRE CLIP CABLE CLAMP

SEAT LOCK CABLE

WIRE HARNESS

HELMET HOLDER & SEAT LOCK ASS'Y.

HORN COMP.

HORN CORD

WIRE GROMMET

BRAKE HOSE CLAMPER

SPDMT. CABLE CLAMP

ST.-MOTOR CABLE

ACG. CORD

HARNESS COVER(ACG. CORD SETT.)

E

A

G

1-17

GENERAL INFORMATION

WIRE HARNESS

IGN. COIL

WIRE CLIP

THROTTLE CABLE JUNCTION CLAMP

FUEL COCK

WIRE CLAMP(WIRE PIVOT)

FUEL COCK(RES)

FUEL COCK(ON)

FUEL STRAINER COMP.

WIRE HARNESS

AIR VENT TUBE

CHOKE CABLE

CLUTCH CABLE

LH. RADIATOR HOSE

RH. RADIATOR HOSE

THROTTLE JUNCTION

CABLE GUIDE

IGN. COIL CORD

CHOKE CABLE

THROTTLE CABLE (TO. ACCELERATION PUMP)

THROTTLE CABLE(TO. CARB.)

ST.-MAG. SW. WIRE

FUSE CODE

ST.-MAG. BATTERY CABLE(+)

FUSE BOX

BATTERY EARTH CABLE

BATTERY BAND

AIR VENT TUBE

CDI COMP.

HEAD LIGHT RELAY

SEAT LOCK CABLE

LH. RR. WINKER CORD

RH. RR. WINKER CORD

TAIL LIGHT SOCKET COMP.

HEAD LIGHT RELAY WIRE

CDI COMP. WIRE

WINKER RELAY WIRE

WINKER RELAY

TAIL LIGHT WIRE

WIRE CLIP

TAIL LIGHT CORD

TAIL LIGHT ASS'Y.

1-18

GENERAL INFORMATION

ST.-MAG. BATTERY CABLE(+)

ST.-MAG. SW. WIRE

BATTERY EARTH CABLE

WIRE CLIP

HARNESS COVER

ST.-MAG. BATTERY CABLE(+)

ST.-MAG. SW. ASS'Y.

ST.-MOTOR CABLE

BATTERY EARTH CABLE

SIDE STAND SW. CORD

RR. STOP SW. CORD

RESERVE TANK

RR. BRAKE HOSE

RR. BRAKE HOSE GUIDE

RR. BRAKE RESERVE TUBE

RR. BRAKE HOSE

RR. CALIPER

RR. BRAKE HOSE

RESERVE TANK

RR. BRAKE RESERVE TUBE

RR. BRAKE HOSE CLAMP

RR. BRAKE HOSE GUIDE

TUBE CLIP

RR. BRAKE HOSE GUIDE

DETAIL OF VIEW C

DETAIL OF VIEW B

1-19

GENERAL INFORMATION

BRAKE HOSE CLAMP

BRAKE HOSE

RH. RADIATOR HOSE

BRAKE HOSE CLAMPER

SPDMT. CABLE

HORN COMP.

SPDMT. CABLE GUIDE

DETAIL OF VIEW A

FUEL DRAIN TUBE

DRAIN TUBE

TUBE GUIDE

DRAIN TUBE

ENG. DREATHER TUBE

CLUTCH CABLE

DETAIL OF VIEW D

RH. CABLE GUIDE

COMBI. METER CORD

WINKER SW. CORD

RH. WINKER CORD

LH. WINKER CORD

WIRE CLIP

COMB. SW. CORD

COMB. SW. WIRE

HAZARD SW. CORD

DETAIL OF HEAD LIGHT CASE PART

WINKER SW. WIRE

WINKER WIRE

WIRE CLIP

WIRE HARNESS

HEAD LIGHT WIRE

RH. WINKER CORD

FR. BRAKE HOSE

THROTTLE CABLE

ST. HAZARD SW. CORD

CHOKE CABLE

CLUTCH CABLE

WIRE HARNESS

HEAD LIGHT CASE

THROTTLE CABLE

WINKER SW. CORD

CHOKE CABLE

CLUTCH CABLE

LH. WINKER CORD

LH. CABLE GUIDE

DETAIL OF VIEW G

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.

SPECIFICATIONS

TIRES

2

SERVICE INFORMATION

······

2-1

MAINTENANCE SCHEDULE

····

2-3

FUEL LINE (FUEL TUBE)

······

2-4

THROTTLE GRIP OPERATION

····

2-4

CARBURETOR CHOKE

········

2-5

AIR CLEANER

··············

2-5

SPARK PLUG

··············

2-6

VALVE CLEARANCE

········

2-6

CYLINDER COMPRESSION PRESSURE

··

2-7

CARBURETOR IDLE SPEED

····

2-7

DRIVE CHAIN

················

2-8

DRIVE CHAIN SLIDER

········

2-10

BRAKE FLUID

················

2-10

BRAKE PAD WEAR

··········

2-10

BRAKE SYSTEM

············

2-11

BRAKE STOP SWITCH

········

2-12

HEADLIGHT AIM

············

2-12

CLUTCH SYSTEM

············

2-12

SIDE STAND

················

2-13

SUSPENSION

··············

2-14

BOLTS, NUTS, FASTENERS

····

2-14

WHEELS/TIRES

··············

2-15

STEERING HEAD BEARINGS··2-15

THROTTLE GRIP PLAY 2~6mm SPARK PLUG CR8EH-9 SPARK PLUG GAP 0.8~0.9mm

IN. 0.12±0.02mm

EX. 0.12±0.02mm CARBURETOR IDLE SPEED 1,600±100rpm CYLINDER COMPRESSION 13.0kgf/㎠ ( 600rpm ) DRIVE CHAIN SLACK 10~20mm REAR BRAKE PEDAL FREE PLAY 10~20mm CLUTCH LEVER FREE PLAY 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.

VALVE CLEARANCE

COLD TIRE PRESSURE

TIRE SIZE

DRIVER ONLY

DRIVER AND A

PASSENGER

FRONT

REAR

FRONT

REAR

FRONT

REAR

FRONT

REAR

200kPa (2.00kgf/㎠ ) 200kPa (2.00kgf/㎠ ) 200kPa (2.00kgf/㎠ ) 225kPa (2.25kgf/㎠ )

110/70-17 54P

140/60-17 60P

5.5mm

7.0mm

TIRE 󳤆PART MINIMUM-DEPTH

2-2

TORQUE VALUES

SPARK PLUG 1.1 kgf-m( 11N.m) CYLINDER HEAD COVER BOLT 1.0 kgf-m( 10N.m) VALVE ADJUSTING NUT 1.1 kgf-m( 11N.m) AC GENERATOR CAP 0.6 kgf-m( 6N.m) CRANKSHAFT HOLE CAP 0.8 kgf-m( 8N.m) AIR CLEANER CASE COVER SCREW 0.43kgf-m(4.3N.m) REAR AXLE NUT 8.8kgf-m(88N.m) DRIVE SPROCKET BOLT 1.2kgf-m(12N.m) DRIVEN SPROCKET NUT 5.9kgf-m(59N.m)

TOOLS

WRENCH, 8×9 mm ADJUSTING WRENCH, B 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

● These instructions are based on the assumption that the motorcycle will be used exclusively for its designed purpose.

Sustained high speed operation, or operation in unusually wet or dusty conditions, will require more frequent service than specified in the following chart.

󳢤 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) At higher odometer readings, repeat at the frequency interval established here. (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 FILTER

THROTTLE GRIP OPERATION

CARBURETOR CHOKE

AIR CLEANER ELEMENT

SPARK PLUG

VALVE CLEARANCE

CARBURETOR IDLE

ENGINE OIL

ENGINE OIL FILTER

DRIVE CHAIN

DRIVE CHAIN SLIDER

BRAKE FLUID

BRAKE /PAD WEAR

BRAKE SYSTEM

BRAKE STOP SWITCH

HEADLIGHT AIM

CLUTCH SYSTEM

SIDE STAND

SUSPENSION

BOLTS, NUTS, FASTENERS

WHEELS/TIRES

STEERING HANDLE BEARING

I

R

I

R

I

R

I

R

I

R

I

R

I

R

I

R

I

R

I

R

I

2-4

2-5

2-6

2-7

3-3

3-4

2-8

2-10

2-11

2-12

2-13

2-14

2-15

NOTE (2)

NOTE (3)

Every 1,000㎞ : I and L

FREQUENCY

ODOMETER READING(NOTE 1)

61218

1 4 8 12 REMARK

ITEM

x 1000Km

MONTH

REFER TO

PAGE

2-4

INSPECTIONS / ADJUSTMENTS

FUEL LINE (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

●Throttle grip free play can be adjusted at either end of

the throttle cable.

●Minor adjustment are made with the upper adjuster.

●Adjust the free play by loosening the lock nut and

turning the adjuster.

FUEL TUBE

2~6mm

ADJUSTER

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.

2-5

INSPECTIONS / ADJUSTMENTS

CARBURETOR CHOKE

● Check the deterioration, damage and kink of the choke

cable. Check if the choke lever operates smoothly in any position.

● Pull the choke lever to the left, and close it perfectly.

AIR CLEANER

● Remove the seat. (⇨12-2)

● Loosen the 4 screws, remove the air cleaner housing

cover.

● Remove and discard the air cleaner element in

accordance with the maintenance schedule. (⇨2-3)

● Also replace the air cleaner element any time it is

excessively dirty or damage.

● Install the removed parts in the reverse order of

removal.

● Check if the choke valve is closed perfectly by moving

the carburetor choke arm.

● When adjustment is necessary, loosen the choke cable

clamp in order that choke valve can be opened, and then adjust by moving the choke cable cover.

󳢯The element is a viscous type which contains oil.

Therefore do not use compressed air to clean the air cleaner element.

CHOKE LEVER

SCREWS

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

CHOKE ARM

FEELER GAUGE

2-6

INSPECTIONS / ADJUSTMENTS

CHECK GAP, DEPOSITS

CHECK FOR CRACKS

CHECK WASHER FOR DAMAGE

0.8mm~0.9mm

SPARK PLUG

● Remove the spark plug cap and disassemble the plug.

● 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 : CR8EH-9 SPARK PLUG GAP : 0.8~0.9mm TORQUE : 1.1kgf··m (11N··m)

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.

󳢯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.

󳢯Inspect and adjust valve clearance while the engine

is cold. (below 35° C/95°F)

“T” MARK

0.8~0.9mm

CHECK GAP,

DEPOSITS

CHECK FOR

CRACKS

CHECK WASHER FOR DAMAGE

INDEX MARK

SPARK PLUG

● Measure the valve clearance with a feeler gauge.

VALVE CLEARANCE : INTAKE : 0.12±±0.02mm

EXHAUST : 0.12±±0.02mm

● Loosen the lock nut with a vlave wrench, and set valve

clearance to a prescribed level by turning the adjusting screw with a valve adjusting wrench.

● After setting clearance to the prescribed level, hold the

adjuster screw with a valve adjusting wrench, and tighten the lock nut.

TORQUE : 1.1kgf··m (11N··m) TOOLS : WRENCH 8x9mm

ADJUSTING WRENCH B FEELER GAUGE

2-7

INSPECTIONS / ADJUSTMENTS

● Measure the vlave clearance again.

● Install the cylinder head cover and tighten the bolts.

TORQUE : 1.0kgf··m (10N··m)

● Install the A.C generator cap and crankcase hole cap.

TORQUE : A.C GENERATOR CAP : 0.6kgf··m(6N··m) CRANK CASE HOLE CAP : 0.8kgf··m(8N··m)

CYLINDER COMPRESSION PRESSURE

● Warm up the engine.

● Stop the engine, and remove the spark plug cap 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

COMPRESSION PRESSURE : 13.0㎏㎏f/㎠㎠(600rpm)

● If compression is low, check the following:

- Incorrect valve clearance adjustment

- Valve leakage

- Leakage from the cylinder head gasket.

- Worn piston/cylinder

● If compression is high, check the following:

- Carbon deposits on the piston head, and cylinder head.

󳢯The maximum reading is usually reached within

4~7 seconds

ADJUSTING WRENCH B

SPARK PLUG WRENCH

COMPRESSION GAUGE

CARBURETOR IDLE SPEED

● Warm up the engine for about ten minutes.

● Turn the throttle stop screw as required to obtain the

specified idle speed.

IDLE SPEED : 1,600±±100rpm

THROTTLE STOP SCREW

󳢯Inspect all other engine adjustments are within

specifications and adjust idle speed.

󳢯The engine must be warm for accurate adjustment.

Support the motorcycle on a level surface and shift the transmission into neutral.

Daelim ROADWIN VJ125 SERVICE MANUAL

Specifications and Main Features

Frequently Asked Questions

User Manual