DAELIM HISTORY 125 - SERVICE Manuals

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DAELIM HISTORY 125 - SERVICE Service Manual

DAELIM HISTORY 125 - SERVICE Service Manual (209 pages)

Brand: DAELIM | Category: Scooter | Size: 89.75 MB

Table of Contents

Table of Contents
2
How to Use this Manual
2
General Safety
3
Service Rules
3
Caution When Wiring
7
Serial Number Location
11
Specifications
12
Torque Values
14
Symbols/Abbreviations
16
Wiring Connections Diagram
17
Lubrication
19
Engine Oil
19
Transmission Oil
19
Service Information
19
- Low or no Oil Pressure
  20
- Lubrication System Troubleshooting
  20
- Oil Contamination
  20
- Oil Level Low
  20
- Engine Oil Change
  21
- Engine Oil Level Inspection
  21
- Oil Filter Element Change
  22
- Oil Pump Removal
  22
- Oil Pump Disassembly
  23
- Oil Pump Inspection
  23
- Oil Pump Assembly
  24
- Oil Pump Installation
  24
- Radiator Inspection
  25
- Radiator Removal
  25
- Radiator Installation
  26
- Transmission Oil Inspection
  26
- Control Cable Lubrication
  27
- Lubrication Points
  27
- Tires Specifications
  29
- Maintenance Schedule
  31
Inspections/Adjustments
29
- Air Cleaner
  32
- Fuel Line (Fuel Tube)
  32
- Throttle Grip Operation
  32
- Spark Plug
  33
- Valve Clearance
  33
- Carburetor Idle Speed
  34
- Cylinder Compression Pressure
  34
- Brake Fluid
  35
  - Brake Pad Replacement
    35
  - Brake System Checks
    35
  - Parking Brake Shoe Replacement
    35
- Brake Lever Free Play
  36
- Headlight Aim
  36
- Side Stand
  36
- Bolts, Nuts, Fasteners
  37
  - Front Wheel Check
    37
  - Rear Wheel Check
    37
- Suspension
  37
- Steering Head Bearing
  38
- Wheels/Tires Checks
  38
External Parts
39
- Names of Frame Covers
  40
- Front Cover
  41
- Front Fender
  41
- Front under Cover
  42
- Luggage Box
  42
- Center Cover
  43
- Rear Center Cover
  43
- Rear Carrier/Back Rest
  44
- Body Cover/Upper Body Cover
  44
- Rear Combination Light
  45
- Floor Side Cover
  45
- Floor Panel
  46
- Under Cover
  46
- Inner Box/Inner Box Lid
  47
- Rear Fender
  47
- Wind Screen/Front Handle Cover
  48
- Rear Handle Cover
  48
- Rear Wheel Mud Guard
  49
- Muffler Removal
  50
- Exhaust Pipe Removal and Installation
  50
- Fuel System Diagram
  52
- Fuel System Specifications
  53
- Carburetor Data
  53
- Fuel System Troubleshooting
  54
- Fuel Tank Installation
  55
- Fuel Tank Removal
  55
- Air Cleaner Removal
  56
- Carburetor Removal
  56
- Carburetor Disassembly
  57
- Carburetor Inspection
  57
- Float Chamber/Float/Jet Disassembly
  58
- Carburetor Cleaning
  59
- Float Chamber/Float/Jet Assembly
  59
- Float Level Inspection
  60
- Carburetor Installation
  61
- Carburetor Insulator Removal
  61
- Carburetor Insulator Inspection
  61
- Pilot Screw Adjustment
  62
Engine Removal
63
- Engine Installation
  65
- LH. Crankcase Cover/Kick Starter/Continuously Variable Transmission
  66
Lh. Crankcase Cover/Kick Starter /Continuously Variable Transmission
67
A.C.generator / Starter Clutch
85
- AC Generator Removal
  86
- Shroud Removal
  86
- AC Generator Installation
  88
- RH Crankcase Cover Removal
  88
- Starter Reduction Gear Inspection
  89
- Starter Reduction Gear Removal
  89
- Starter Clutch Removal
  90
- Starter Reduction Gear Installation
  90
- Starter Clutch Inspection
  91
- Starter Clutch Installation
  92
- Cylinder Head/Valves Diagram
  94
- Cylinder Head/Valves Specifications
  95
- Cylinder Head/Valves Troubleshooting
  96
- Camshaft Removal
  97
- Camshaft Inspection
  98
- Cylinder Head Disassembly
  99
- Cylinder Head Removal
  99
- Cylinder Head Inspection
  100
- Valve Springs
  100
- Valves
  100
- Valve Guides Inspection
  101
- Valve Guides Replacement
  101
- Valve Seats Inspection
  102
- Valve Seat Refacing
  103
- Cylinder Head Assembly
  105
- Camshaft Assembly
  107
- Cylinder/Piston Diagram
  110
- Cylinder/Piston Specifications
  111
- Cylinder Removal
  112
- Cylinder Wear Inspection
  112
- Cylinder Warpage Inspection
  113
- Piston/Piston Ring Inspection
  113
- Piston/Piston Ring Removal
  113
- Piston Pin Inspection
  114
- Small End Bearing Surface Inspection
  114
- Piston Installation
  115
- Piston/Piston Ring Installation
  115
- Cylinder Installation
  116
- Transmission/Crankshaft/Crank Case Diagram
  118
- Transmission/Crankshaft/Crank Case Specifications
  119
- Transmission/Crankshaft/Crank Case Troubleshooting
  120
- Transmission Disassembly
  121
- Transmission Inspection
  122
- Transmission Assembly
  123
- Transmission Bearing Inspection
  123
- Crank Case Removal
  124
- Crankshaft Removal
  125
- Crankshaft Inspection
  126
- Transmission Bearing
  126
- Crankshaft Installation
  127
- Transmission Bearing Replacement
  127
- Crankcase Installation
  128
  - Front Wheel/Front Fork/Steering Diagram
    130
  - Front Wheel/Front Fork/Steering Specifications
    131
  - Front Wheel/Front Fork/Steering Troubleshooting
    132
  - Steering Handle Installation
    133
  - Steering Handle Removal
    133
  - Front Wheel Removal
    135
  - Front Wheel Inspection
    136
  - Front Wheel Bearing Replacement
    137
  - Front Wheel Assembly
    138
  - Speedometer Gear Replacement
    138
  - Front Wheel Installation
    139
  - Front Fork Disassembly
    140
  - Front Fork Removal
    140
  - Front Fork Assembly
    142
  - Front Fork Inspection
    142
  - Front Fork Installation
    144
  - Steering Stem Removal
    145
  - Steering Stem Installation
    147
  - Rear Wheel/Brake/Suspension/Rear Swing Arm Specifications
    149
  - Rear Wheel/Brake/Suspension/Rear Swing Arm Troubleshooting
    150
  - Rear Wheel Removal
    151
  - Rear Wheel Inspection
    152
  - Rear Wheel Installation
    152
  - Parking Brake Inspection
    153
  - Parking Brake Removal
    153
  - Brake Cam Disassembly
    154
  - Brake Shoe Disassembly
    154
  - Parking Brake Assembly/Installation
    154
  - Rear Cushion Disassembly
    155
  - Rear Cushion Inspection
    155
  - Rear Cushion Removal
    155
  - Rear Cushion Installation
    156
  - Rear Swing Arm Disassembly
    156
  - Rear Swing Arm Removal
    156
  - Brake System Diagram
    158
  - Brake System Troubleshooting
    159
  - Air Bleeding
    160
  - Brake Fluid Change
    160
  - Front Brake Pad Replacement
    162
  - Rear Brake Pad Replacement
    163
  - Brake Caliper Disassembly
    164
  - Brake Caliper Removal
    164
  - Brake Caliper Assembly
    165
  - Brake Caliper Inspection
    165
  - Brake Caliper Installation
    166
  - Master Cylinder Disassembly
    166
  - Master Cylinder Removal
    166
  - Master Cylinder Assembly
    167
  - Master Cylinder Inspection
    167
  - Master Cylinder Installation
    168
  - Brake Disk Inspection
    169
  - Battery/Charging System Serice Information
    171
  - Battery/Charging System Specifications
    171
  - Charging Device Location
    172
  - Triple Phase Full Wave Rectification Method
    172
  - Charging System Troubleshooting
    173
  - Battery (Open-Circuit Voltage) Inspection
    174
  - Battery Removal
    174
  - Charging System Inspection
    175
  - Charging Voltage Inspection
    175
  - Leak Test
    175
  - Harness Side Circuit Inspection
    176
  - Headlight Voltage Inspection
    176
  - Regulator/Rectifier Inspection
    176
  - AC Generator Charging Coil Inspection
    177
  - Regulator Rectifier Unit Inspection
    177
  - Regulator Rectifier Unit Replacement
    177
  - Ignition System Service Information
    179
  - Ignition System Specifications
    179
  - Ignition Devices Location
    180
  - Ignition System Troubleshooting
    181
  - CDI Ignition Circuit Inspection
    182
  - CDI Unit Inspection
    182
  - Pulse Generator Inspection
    182
  - PVA Measurement
    182
  - Ignition Coil Inspection
    183
  - Ignition Coil Replacement
    183
  - Primary Coil Inspection
    183
  - Secondary Coil Inspection
    183
  - Ignition Timing Inspection
    184
  - Side Stand Ignition Cut-Off Switch Inspection
    184
  - Side Stand Ignition Cut-Off Switch Installation
    185
  - Side Stand Ignition Cut-Off Switch Removal
    185
  - Starter System Specification
    187
  - Starter Devices Location
    188
  - Starter System Circuit Diagram
    188
  - Starter System Troubleshooting
    189
  - Starter Motor Disassembly
    190
  - Starter Motor Inspection
    190
  - Starter Motor Removal
    190
  - Starter Motor Assembly
    192
  - Starter Magnetic Switch Ground Line
    193
  - Starter Magnetic Switch Inspection
    193
  - Starter Magnetic Switch Removal
    193
  - Starter Magnetic Switch Voltage
    193
  - Starter Magnetic Switch Operation Check
    194
  - Lights/Meter/Switches Service Information
    195
  - Lights/Meter/Switches Troubleshooting
    195
  - Front/Rear Winker Bulbs Replacement
    196
  - Headlight Bulb Replacement
    196
  - Headlight Removal
    196
- Rear Combination Light
  197
- Speedometer Removal
  197
- Horn Inspection
  198
- Meter Bulb Replacement
  197
- Main Switch Removal
  198
- Main Switch Inspection
  198
- Handle Bar Switch Inspection
  198
- Trunk Lamp Switch Inspection
  199
- Front/Rear Stop Switch Inspection
  199
- Fuel Unit Inspection
  200
- Fuel Unit Removal
  200
- Parking Brake Switch Inspection
  200
Wiring Diagram
201
Engine Won't Start or Hard to Start
202
Troubleshooting
202

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