DAELIM Roadwin R Manuals

Manuals and User Guides for DAELIM Roadwin R. We have 1 DAELIM Roadwin R manual available for free PDF download: Service Manual

DAELIM Roadwin R Service Manual

DAELIM Roadwin R Service Manual (296 pages)

Brand: DAELIM | Category: Motorcycle | Size: 47.73 MB

Table of Contents

Table of Contents
3
General Information
5
- Service Information
  5
- Service Rules
  5
- Caution When Wiring
  9
- Model Identification
  13
- Engine Serial Number Location
  13
- Frame Serial Number Location
  13
- Specifications
  14
- Torque Values
  16
- Symbols / Abbreviations
  18
- Tools
  19
- Wiring Diagram
  20
- Detail of View (B)
  22
- Detail of View (A)
  22
- Detail of Fuse Box Part
  23
- Detail of Batter Part
  23
- Detail of Regrectifier Part
  23
- Detail of Throttle Body Part
  23
- Inspections / Adjustments
  25
- Tires
  25
- Maintenance Schedule
  27
- Fuel Line (Fuel Tube)
  28
- Throttle Grip Operation
  28
- Air Cleaner
  29
- Spark Plug
  29
- Valve Clearance
  30
- Shim Adjustment
  30
- Cylinder Compression Pressure
  31
- Drive Chain Slack Adjustment
  32
- Drive Chain Removal
  32
- Drive Chain Inspection
  33
- Drive Chain Installation
  33
- Drive Chain Slider
  34
- Rear Brake
  34
- Front Brake Pads
  34
- Brake Fluid
  34
- Brake Pad Wear
  34
- Rear Brake Pedal Free Play
  35
- Front Brake Lever Free Play
  35
- Rear Brake Pads
  35
- Brake System
  35
- Brake Stop Switch
  36
- Headlight Aim
  36
- Clutch System
  36
- Brake Pedal Height Adjustment
  36
- Side Stand
  37
- Bolts, Nuts, Fasteners
  38
- Front Suspension
  38
- Rear Suspension
  38
- Wheel/Tire
  39
- Standard Pressure
  39
- Steering Stem
  39
- Coolant Replacement
  40
- Coolant Level Inspection
  40
Lubrication
41
- Lubrication Troubleshooting
  42
- Engine Oil Level too Low
  42
- Oil Contamination
  42
- Low or no Oil Pressure
  42
- Engine Oil Level Inspection
  43
- Engine Oil Change
  43
- Recommended Engine Oil
  43
- Oil Filter Element Change
  44
- Oil Pump Removal
  44
- Oil Pump Disassembly
  44
- Oil Pump Installation
  45
- Oil Pump Assembly
  45
- Oil Pump Inspection
  45
- Lubrication Points
  46
- Fuel System Service Information
  49
- Fuel System Standard of Maintenance
  49
- Fuel System Troubleshooting
  49
- Engine Cranks but Won’t Start
  49
- Fuel Tank Removal
  50
- Fuel Tank Installation
  50
- Air Cleaner Case Removal
  51
- Air Cleaner Case Installation
  51
Ems(Engine Management System)
53
- Caution When Repairing the Ems Parts
  54
- Ignition System
  55
- Intake System
  55
- Fuel System
  55
- The Component Parts of the Ems
  55
- Terminal Arrangement of the Ecu
  56
- Wiring Diagram of the Ecu
  56
- SELF-DIAGNOSTIC FUNCTION by MIL (Malfunction Indicator Lamp)
  57
- Self-Diagnostic Function
  57
- Fail-Safe Function
  58
- How to Check the Fault Code
  59
- The Wireharness to Check the ECU
  59
- How to Show the Fault Code
  60
- How to Read the Fault Code
  60
- Fault Codes Table
  61
- Inspection before Diagnosis
  62
- Ems Trouble Shooting
  62
- How to Remove the Fault Code
  62
- Injector Removal
  63
- Checking Methods by Fault Codes
  64
- Checking of the Injector Circuit
  64
- Checking Procedure
  65
- Mapat(Manifold Air Pressure Sensor, Temperature Sensor)
  66
- Checking of the Intake Pressure Sensor
  68
- Checking of the Intake Temperature Sensor
  68
- Checking of Intake Temperature Sensor
  69
- Tps(Throttle Position Sensor)
  70
- Checking the Tps(Throttle Position Sensor) Circuit Diagram
  71
- Ets(Engine Temperature Sensor)
  73
- Checking the Circuit Diagram of ETS
  74
- Characters of ETS
  75
- Isa(Idle Speed Actuator)
  76
- Check the ISA(Idel Speed Actuator) Circuit
  77
- O2(Oxygen) SENSOR
  79
- Checking of Oxygen(O2) Sensor Circuit
  80
- Checking for a Fault Code by Oxygen(O2)Sensor Heater
  80
- Checking of Engine Speed Signal(Ess)Circuit
  82
- Checking of Mil(Malfunction Indicator Lamp)Circuit
  83
- Ecu(Electronic Control Unit)
  84
- Cps(Crank Position Sensor)
  85
- Fuel Pump
  86
- Checking of the Fuel Level Gauge
  88
- Throttle Body
  89
- Disconnect the Throttle Body
  89
- Assembly of the Throttle Body
  90
- Disassembly the Throttle Body Insulator
  90
- Adjustment of Throttle Cable
  91
- Inspection of Sensor and Actuator
  91
- Adjustment of Throttle Adjust Screw
  92
- How to Use Scan
  93
- When the ‘Isa Pwm’ Adjusting
  95
- When the Ignition Timing Is Check
  96
- When the Engine Rpm Is Check
  97
- Cooling System Service Information
  99
- Cooling System Specifications
  99
- Cooling System Torque Value
  99
- Radiator Installation
  99
- Coolant Leaks
  100
- Cooling System Troubleshooting
  100
- Engine Temperature too Low or Unstable
  100
- Engine Temperature too High
  100
- Coolant Inspection
  101
- Cooling System Inspection
  101
- Coolant Gravity Chart
  101
- Radiator Coolant Mixture Chart
  101
- Cooling System Test
  102
- Radiator Inspection
  102
- Radiator Removal
  102
- Radiator Disassembly
  103
- Check Thermostatic Switch
  104
- Water Pump / Impeller Removal
  105
- Mechanical Seal (Water Seal) Inspection
  105
- Water Pump
  105
- Water Pump Body Removal
  106
- Mechanical Seal Replacement
  107
- Water Pump Shaft/ Water Pump /Impeller Installation
  107
- Thermosensor Removal
  108
- Thermosensor Inspection
  108
- Thermosensor Installation
  108
- Thermostat Removal
  108
- Thermostat Inspection
  109
- Thermostat Installation
  109
- Engine Removal/Installation
  110
Engine Removal
112
Engine Installation
113
Clutch/Gearshift
114
- Clutch / Gearshift Service Information
  115
- Clutch / Gearshift General Safety
  115
- Clutch / Gearshift Specifications
  115
- Clutch / Gearshift Torque Values
  115
- Clutch / Gearshift Troubleshooting
  116
- Clutch Leverworking Is too Hard
  116
- When Gripping the Clutch Tightly, the Vehicle Moves
  116
- Clutch Slippage
  116
- Crankcase Cover Removal
  117
- Clutch Lever/Lifter Rod Remove
  117
- Clutch Removal
  118
- Clutch Inspection
  119
- Gear Shift Spindle Removal
  121
- Gear Shift Spindle Inspection
  121
- Gear Shift Spindle Installation
  122
- Clutch Installation
  123
- Primary Drive Gear Removal
  124
- Primary Drive Gear Installation
  125
- Crankcase Cover Installation
  125
- A.C Generator / Starter Clutch
  128
- A.C Generator / Starter Clutch Service Information
  129
- A.C Generator / Starter Clutch Specifications
  129
- A.C Generator / Starter Clutch Torque Values
  129
- A.C Generator / Starter Clutch Tools
  129
- A.C Generator Removal
  130
- Stator Removal/Installation
  132
- Starter Idle Gear Inspection
  133
- Reduction Gear Inspection
  133
- Starter Clutch Inspection
  135
- Starter Clutch Disassembly
  135
- Starter Clutch Installation
  136
- Cylinder Head / Valves
  138
- Cylinder Head / Valves Service Information
  139
- Cylinder Head / Valves Specifications
  139
- Cylinder Head / Valves Torque Values
  139
- Valve Guides
  139
- Valve Springs
  139
- Excessive White Smoke
  140
- Low Comperssion
  140
- Cylinder Head / Valves Tools
  140
- Cylinder Head / Valves Troubleshooting
  140
- Camshaft Removal
  141
- Cylinder Head Removal
  142
- Cylinder Head Disassembly
  143
- Cylinder Head Inspection
  143
- Valve Spring
  143
- Interval between Valve Stem and Valve Guide
  144
- Valve Guides Replacement
  144
- Valve Seats Inspection / Reface
  145
- Valve Seat Refacing
  146
- Cylinder Head Assembly
  148
- Cylinder Head Installation
  149
- Cylinder / Piston
  152
- Cylinder / Piston Service Information
  153
- Compression too Low
  153
- Cylinder / Piston Specifications
  153
- Cylinder / Piston Troubleshooting
  153
- Warpage Inspection
  155
- Piston Removal
  155
- Piston Pin Inspection
  156
- Small End Bearing Surface Inspection
  156
- Piston / Cylinder Assembly
  157
- Piston Ring Assembly
  157
- Piston / Cylinder Installation
  157
- Cylinder Installation
  158
- Crankcase/Transmission/Crankshaft
  160
- Crankcase/Transmission/Crankshaft Specifications
  161
- Crankcase/Transmission/Crankshaft Service Information
  161
- Crankcase/Transmission/Crankshaft Torque Values
  162
- Crankcase/Transmission/Crankshaft Tools
  162
- Crankcase/Transmission/Crankshaft Troubleshooting
  162
- Hard to Shift
  162
- Crankcase Disassembly
  163
- Transmission Disassembly
  164
- Crankshaft Removal
  166
- Crankshaft Inspection
  166
- Crankcase Bearing Inspection
  167
- Crankcase Bearing Replacement
  167
- Crankshaft Installation
  168
- Transmission Assembly
  169
- Crankcase Assembly
  170
- Excessive Exhaust Noise
  175
- Poor Performance
  175
External Parts
175
- Side Cover / Seat
  176
- Side Cover Removal
  176
- Seat Removal
  176
- Rear Seat(Pillion Seat)
  176
- Rear Cowl
  177
- Rear Fender
  177
- Rear Wheel Mudguard
  177
- Muffler/Exhaust Pipe Removal
  178
- Muffler/Exhaust Pipe Installation
  179
- Front Fender
  179
- Front Wheel/Front Fork/Steering
  180
- Front Wheel/Front Fork/Steering Service Information
  181
- Front Wheel/Front Fork/Steering Specifications
  181
- Front Wheel/Front Fork/Steering Torque Values
  181
- Front Wheel/Front Fork/Steering Tools
  182
- Front Wheel/Front Fork/Steering Troubleshooting
  182
- Hard Steering
  182
- Steers to One Side
  182
- Handle Bars Removal
  183
- Handle Bars Installation
  185
- Axle
  187
- Wheel Rim Runout
  187
- Front Wheel Inspection
  187
- Front Wheel Removal
  187
- Front Wheel Bearing Inspection
  188
- Front Wheel Disassembly
  188
- Wheel Bearing Replacement
  189
- Speedometer Gear Replacement
  189
- Front Wheel Assembly
  190
- Front Wheel Installation
  191
- Front Fork Removal
  192
- Front Fork Disassembly
  193
- Front Fork Inspection
  194
- Front Fork Assembly
  196
- Front Fork Installation
  199
- Steering Stem Removal
  200
- Steering Stem Race Replacement
  201
- Rear Wheel/Rear Suspension
  205
- Rear Wheel/Rear Suspension Service Information
  206
- Rear Wheel/Rear Suspension Specifications
  206
- Rear Wheel/Rear Suspension Torque Values
  206
- Rear Wheel/Rear Suspension Tools
  206
- Rear Wheel/Rear Suspension Troubleshooting
  207
- Wobble or Vibration in Motorcycle
  207
- Soft Suspension
  207
- Hard Suspension
  207
- Rear Wheel Removal
  208
- Rear Wheel Inspection
  208
- Driven Sprocket
  209
- Wheel Bearing
  209
- Rear Wheel Disassembly
  209
- Wheel Bearing Removal
  210
- Wheel Bearing Installation
  210
- Rear Wheel Installation
  211
- Rear Cushion Removal
  212
- Rear Cushion Inspection
  212
- Rear Cushion Bushing Replacement
  213
- Rear Cushion Disposal Procedure
  213
- Rear Cushion Installation
  214
- Swingarm Removal
  214
- Swingarm Disassembly/Inspection
  215
- Swingarm Assembly
  216
- Swingarm Installation
  217
- Hydraulic Brake
  219
- Hydraulic Brake Service Information
  220
- Hydraulic Brake General Safety
  220
- Hydraulic Brake Specifications
  220
- Hydraulic Brake Troubleshooting
  221
- Hydraulic Brake Torque Values
  221
- Hydraulic Brake Tool
  221
- Brake Lever/Pedal Soft or Spongy
  221
- Brake Fluid Replacement/Air Bleeding
  222
- Brake Fluid Draining
  222
- Brake Fluid Filling
  223
- Brake Bleeding
  224
- Brake Pad/Disk
  225
- Front Brake Pad Replacement
  225
- Rear Brake Pad Replacement
  226
- Brake Disk Inspection
  228
- Front Master Cylinder Removal
  228
- Front Master Cylinder Disassembly
  229
- Front Master Cylinder Inspection
  230
- Front Master Cylinder Assembly
  230
- Front Master Cylinder Installation
  232
- Rear Master Cylinder Removal
  232
- Rear Master Cylinder Disassembly
  233
- Rear Master Cylinder Inspection
  234
- Rear Master Cylinder Assembly
  235
- Rear Master Cylinder Installation
  236
- Front Brake Caliper Removal
  237
- Front Brake Caliper Disassembly
  237
- Front Brake Caliper Inspection
  238
- Front Brake Caliper Assembly
  238
- Rear Brake Caliper Removal
  239
- Front Brake Caliper Installation
  239
- Rear Brake Caliper Disassembly
  240
- Rear Brake Caliper Inspection
  241
- Rear Brake Caliper Assembly
  241
- Rear Brake Caliper Installation
  242
- Brake Pedal Removal
  242
- Brake Pedal Installation
  243
- Battery/Charging System
  245
- Battery/Charging System Service Information
  246
- Battery/Charging System Specifications
  246
- Battery/Charging System Tools
  246
- Charging System Faulty
  247
- No Power (Key Turned On)
  247
- Low Power (Key Turned On)
  247
- Battery/Charging System Troubleshooting
  247
- Battery Removal/Installation
  248
- Battery Voltage Inspection
  248
- Battery Charging
  248
- Charging System Inspection
  249
- Current Leakage Inspection
  249
- Charging Voltage Inspection
  249
- Regulator/Rectifier
  250
- Harness Side Circuit Inspection
  250
- Regulator / Rectifier Unit Inspection
  250
- Regulator/Rectifier Removal/Installation
  251
- A.C. Generator Charging Coil Inspection
  251
- Ignition System Specifications
  254
- Ignition System Service Information
  254
- Ignition System Troubleshooting
  255
- No Spark at Plug
  255
- Crank Position Sensor Inspection
  256
- Resistance Measurement
  256
- Pva Measurement
  256
- Inspection Items
  256
- Ignition Coil Inspection
  257
- Side Stand Switch Removal
  258
- Side Stand Switch Inspection
  258
- Electric Starter
  259
- Electric Starter Tools
  260
- Electric Starter Service Information
  260
- Electric Starter General Safety
  260
- Starter Motor will Not Turn
  261
- Starter Motor Turns Engine Slowly
  261
- Starter Motor Turns, but Engine Does Not Turn
  261
- Electric Starter Troubleshooting
  261
- Starter Motor Removal
  262
- Starter Motor Disassembly
  262
- Starter Motor Inspection
  263
- Starter Motor Assembly
  265
- Ground Line Inspection
  268
- Starter Magnetic Switch Voltage Inspection
  268
- Starter Magnetic Switch Operation Inspection
  268
- Starter Magnetic Switch Removal
  268
- Starter Magnetic Switch Continuity Inspection
  269
- Starter Magnetic Switch Installation
  269
- Lights/Meter/Switches
  271
- Lights/Meter/Switches Service Information
  272
- Lights/Meter/Switches Troubleshooting
  272
- Light Not Turned on When the Main Switch Is on
  272
- DIM Headlight
  272
- Headlight Bulb Replacement
  273
- Headlight Case Removal/Installation
  273
- Front/Rear Winker Bulb Replacement
  274
- Stop/Tail Light Inspection
  274
- Stop/Tail Light Bulb Replacement
  274
- Combination Meter Installation
  275
- Combination Meter Removal
  275
- Main Switch Inspection
  276
- Main Switch Removal/Installation
  276
- Handlebar Switches
  277
- Starter Switch
  277
- Lighting Switch
  277
- Winker Switch
  277
- Hazard Switch
  277
- Horn Switch
  277
- Front/Rear Stop Switch
  278
- Gear Change Switch
  279
- Horn
  279
- Winker Relay
  279
- Fuel Unit Inspection
  280
- Fuel Unit Installation
  280
- Engine Won’t Start or Is Hard to Start
  282
Troubleshooting
282
- Engine Lacks Power
  283
- Poor Performance (at Low and Idle Speed)
  284
- Poor Performance(at High Speed)
  285
- Poor Handling
  285
- Poor Front/Rear Suspension Performance
  286
- Fuel Gauge
  286
- Gauge Reading Inaccurate (Ignition Swtich On)
  286
- Gauge Needle Shakes or Vertically Wobbles. (Ignition Swtich On)
  287
Wiring Diagram
292

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