DAELIM ROADWIN VJ125 - SERVICE Manuals

Manuals and User Guides for DAELIM ROADWIN VJ125 - SERVICE. We have 1 DAELIM ROADWIN VJ125 - SERVICE manual available for free PDF download: Service Manual

DAELIM ROADWIN VJ125 - SERVICE Service Manual

DAELIM ROADWIN VJ125 - SERVICE Service Manual (252 pages)

Brand: DAELIM | Category: Motorcycle | Size: 83.36 MB

Table of Contents

Table of Contents
2
General Information
4
- Service Information
  4
- Service Rules
  4
- Caution When Wiring
  8
- Model Identification
  12
- Engine Serial Number Location
  12
- Frame Serial Number Location
  12
- Specifications
  13
- Torque Values
  15
- Symbols/Abbreviations
  17
- Tools
  18
- Vehicle Wiring Diagram
  19
- Specifications Table
  24
- Tires Specifications
  24
Inspections/Adjustments
24
- Maintenance Schedule
  26
- Fuel Line (Fuel Tube)
  27
- Throttle Grip Operation
  27
- Carburetor Choke
  28
- Air Cleaner
  28
- Spark Plug
  29
- Valve Clearance
  29
- Carburetor Idle Speed
  30
- Cylinder Compression Pressure
  30
- Drive Chain Slack Adjustment
  31
- Drive Chain Removal
  31
- Drive Chain Inspection
  32
- Drive Chain Installation
  32
- Drive Chain Slider
  33
- Brake Fluid
  33
- Front Brake Pads
  33
- Rear Brake Pedal Free Play
  34
- Brake System Inspection
  34
- Front Brake Lever Free Play
  34
- Rear Brake Pads
  34
- Brake Stop Switch
  35
- Headlight Aim
  35
- Clutch System
  35
- Brake Pedal Height Adjustment
  35
- Side Stand
  36
- Bolts, Nuts, Fasteners
  37
- Rear Suspension Inspection
  37
- Front Suspension Inspection
  37
- Wheels/Tires
  38
- Steering Head Bearings
  38
- Standard Pressure (Tires)
  38
- Engine Oil
  40
- Oil Pump
  40
- Torque Values (Lubrication System)
  40
Lubrication
40
- Troubleshooting (Lubrication)
  41
- Engine Oil Change
  42
- Engine Oil Level Inspection
  42
- Oil Filter Element Change
  43
- Oil Pump Removal
  43
- Oil Pump Disassembly
  43
- Oil Pump Inspection
  44
- Oil Pump Assembly
  44
- Oil Pump Installation
  45
- Lubrication Points
  46
- Control Cable Lubrication
  46
- Fuel System Diagram
  47
- Fuel System Specifications
  48
- Fuel System Torque Value
  48
- Carburetor Data
  48
- Fuel System Service Information
  48
- Fuel System Troubleshooting
  49
- Fuel Tank Removal
  50
- Fuel Tank Installation
  50
- Air Cleaner Case Removal
  51
- Air Cleaner Case Installation
  51
- Throttle Valve Removal
  52
- Carburetor Removal
  53
- Throttle Valve Installation
  53
- Carburetor Disassembly
  54
- Accelerator Pump
  54
- Float, Float Valve
  55
- Jet
  56
- Carburetor Assembly
  56
- Float Level Adjustment
  57
- Accelerator Adjustment
  58
- Carburetor Installation
  58
- Pilot Screw Adjustment
  59
- Cooling System Diagram
  61
- Cooling System Torque Value
  62
- Cooling System Service Information
  62
- Radiator Removal
  63
- Radiator Hose Inspection
  63
- Radiator Installation
  63
- Engine Removal/Installation - Diagram
  65
- Engine Removal/Installation - Service Information
  66
- Engine Removal/Installation - Specification
  66
- Engine Removal/Installation - Torque Values
  66
Engine Removal
67
- Engine Installation
  68
- Clutch/Gearshift Diagram
  69
- Clutch/Gearshift Service Information
  70
- Clutch/Gearshift Specifications
  70
- Clutch/Gearshift Torque Values
  70
- Clutch/Gearshift Troubleshooting
  71
- R. Crankcase Cover Removal
  72
- Clutch Lever/Lifter Rod
  72
- Clutch Removal
  73
- Clutch Inspection
  74
- Gear Shift Spindle Removal
  76
- Gear Shift Spindle Inspection
  76
- Gear Shift Spindle Installation
  77
- Clutch Installation
  78
- Primary Drive Gear Removal
  79
- Primary Drive Gear Installation
  80
- R. Crankcase Cover Installation
  80
- A.C Generator/Starter Clutch Diagram
  83
- A.C Generator/Starter Clutch Service Information
  84
- A.C Generator/Starter Specifications
  84
- A.C Generator/Starter Torque Values
  84
- A.C Generator/Starter Troubleshooting
  84
- A.C Generator/Starter Removal
  85
- Stator Removal/Installation
  87
- Starter Idle Gear Inspection
  88
- Reduction Gear Inspection
  88
- Starter Clutch Inspection
  88
- Starter Clutch Disassembly
  88
- Starter Clutch Installation
  89
- A.C Generator Installation
  90
- Cylinder Head/Valves Diagram
  93
- Cylinder Head/Valves Service Information
  94
- Cylinder Head/Valves Specifications
  94
- Cylinder Head/Valves Torque Values
  94
- Cylinder Head/Valves - Tools Needed
  95
- Cylinder Head/Valves Troubleshooting
  95
- Camshaft Removal
  96
- Camshaft Holder Disassembly
  97
- Camshaft Inspection
  97
- Cylinder Head Removal
  98
- Cylinder Head Disassembly
  99
- Cylinder Head Inspection
  99
- Valve Springs
  99
- Valves
  100
- Valve Guides Inspection
  100
- Valve Guides Replacement
  100
- Valve Seats Inspection
  101
- Valve Seat Refacing
  102
- Cylinder Head Assembly
  104
- Camshaft Assembly
  106
- Cylinder/Piston Diagram
  109
- Cylinder/Piston Service Information
  110
- Cylinder/Piston Specifications
  110
- Cylinder/Piston Troubleshooting
  110
- Cylinder Removal
  111
- Cylinder Wear Inspection
  111
- Piston Inspection
  112
- Piston/Piston Ring Removal
  112
- Warpage Inspection
  112
- Piston Disassembly
  112
- Piston Pin Inspection
  113
- Small End Bearing Surface Inspection
  113
- Piston Assembly
  114
- Piston Installation
  114
- Cylinder Installation
  115
- Crankcase/Transmission/Crankshaft Diagram
  117
- Crankcase/Transmission/Crankshaft Service Information
  118
- Crankcase/Transmission/Crankshaft Specifications
  118
- Crankcase/Transmission/Crankshaft Troubleshooting
  119
- Crankcase/Transmission/Crankshaft Torque Values
  119
- Crankcase/Transmission/Crankshaft - Tools Needed
  119
- Crankcase Disassembly
  120
- Transmission Disassembly
  121
- Transmission Inspection
  121
- Crankcase Removal
  123
- Crankcase Inspection
  123
- Crankcase Bearing Inspection
  124
- Crankcase Bearing Replacement
  124
- Crankchaft Installation
  125
- Transmission Assembly
  126
- Crankcase Assembly
  127
- External Parts Service Information
  132
- External Parts Troubleshooting
  132
- Seat Removal
  133
- Side Cover Removal
  133
- Rear Seat (Pillion Seat)
  133
- Rear Cowl
  134
- Rear Fender
  134
- Rear Wheel Mudguard
  134
- Muffler/Exhaust Pipe Removal
  135
- Muffler/Exhaust Pipe Installation
  136
- Front Fender
  136
- Front Wheel/Front Fork/Steering Diagram
  137
- Front Wheel/Front Fork/Steering Service Information
  138
- Front Wheel/Front Fork/Steering Specifications
  138
- Front Wheel/Front Fork/Steering Torque Values
  138
- Front Wheel/Front Fork/Steering - Tools Needed
  139
- Front Wheel/Front Fork/Steering Troubleshooting
  139
- Handlebars Removal
  140
- Handlebars Installation
  142
- Front Wheel Removal
  144
- Front Wheel Inspection
  144
- Front Wheel Disassembly
  145
- Wheel Bearing Replacement
  146
- Speedometer Gear Replacement
  146
- Front Wheel Assembly
  147
- Front Wheel Installation
  148
- Front Fork Removal
  149
- Front Fork Disassembly
  150
- Front Fork Inspection
  151
- Front Fork Assembly
  153
- Front Wheel/Front Fork/Steering Installation
  156
- Steering Stem Removal
  157
- Race Replacement
  158
- Steering Stem Installation
  159
- Rear Wheel/Rear Suspension Diagram
  161
- Rear Wheel/Rear Suspension Service Information
  162
- Rear Wheel/Rear Suspension Specifications
  162
- Rear Wheel/Rear Suspension Torque Values
  162
- Rear Wheel/Rear Suspension - Tools Needed
  162
- Rear Wheel/Rear Suspension Troubleshooting
  163
- Rear Wheel Inspection
  164
- Rear Wheel Removal
  164
- Rear Wheel Disassembly
  165
- Rear Wheel Bearing Removal
  166
- Rear Wheel Assembly
  166
- Rear Wheel Bearing Installation
  167
- Rear Wheel Installation
  168
- Rear Cushion Removal
  168
- Rear Cushion Inspection
  169
- Rear Cushion Installation
  170
- Swingarm Removal
  170
- Swingarm Disassembly/Inspection
  171
- Swingarm Assembly
  172
- Swingarm Installation
  173
- Hydraulic Brake Diagrams
  175
- Hydraulic Brake Service Information
  176
- Hydraulic Brake Specifications
  176
- Hydraulic Brake Torque Values
  177
- Hydraulic Brake Troubleshooting
  177
- Brake Fluid Replacement/Air Bleeding
  178
- Brake Fluid Draining
  178
- Brake Fluid Filling
  179
- Brake Bleeding
  180
- Brake Pad/Disk
  181
- Front Brake Pad Replacement
  181
- Rear Brake Pad Replacement
  182
- Front Master Cylinder Removal
  184
- Brake Disk Inspection
  184
- Front Master Cylinder Disassembly
  185
- Front Master Cylinder Inspection
  186
- Front Master Cylinder Assembly
  186
- Front Master Cylinder Installation
  188
- Rear Master Cylinder Removal
  188
- Rear Master Cylinder Disassembly
  189
- Rear Master Cylinder Inspection
  190
- Rear Master Cylinder Assembly
  191
- Rear Master Cylinder Installation
  192
- Front Brake Caliper Removal
  193
- Front Brake Caliper Disassembly
  193
- Front Brake Caliper Inspection
  194
- Front Brake Caliper Assembly
  194
- Front Brake Caliper Installation
  195
- Rear Brake Caliper Removal
  195
- Rear Brake Caliper Disassembly
  196
- Rear Brake Caliper Inspection
  197
- Rear Brake Caliper Assembly
  197
- Rear Brake Caliper Installation
  198
- Brake Pedal Removal
  198
- Brake Pedal Installation
  199
- Battery/Charging System Diagram
  201
- Battery/Charging System Service Information
  202
- Battery/Charging System Specifications
  202
- Battery/Charging System Troubleshooting
  203
- Charging System Faulty - Chart
  203
- Battery Charging
  204
- Voltage Inspection
  204
- Battery Removal/Installation
  204
- Charging System Inspection
  205
- Current Leakage Inspection
  205
- Charging Voltage Inspection
  205
- Regulator/Rectifier Unit Inspection
  206
- Harness Side Circuit Inspection
  206
- Regulator/Rectifier Removal/Installation
  207
- A.C. Generator Charging Coil Inspection
  207
- Ignition System Diagram
  209
- Ignition System Specifications
  210
- Ignition System Service Information
  210
- Ignition System Troubleshooting
  211
- CDI Unit Circuit Inspection
  212
- CDI Unit Performance Test
  212
- Pulse Generator Inspection
  212
- Resistance Measurement
  212
- PVA Measurement
  213
- Ignition Coil Inspection
  213
- Primary Coil Inspection
  213
- Secondary Coil Inspection
  213
- Side Stand Switch Operating Principle
  214
- Ignition Replacement
  214
- Ignition Timing
  214
- Side Stand Switch Inspection
  215
- Side Stand Switch Replacement
  215
- Electric Starter Diagram
  217
- Electric Starter Service Information
  218
- Electric Starter Specification
  218
- Electric Starter Troubleshooting
  219
- Starter Motor Removal
  220
- Starter Motor Disassembly
  220
- Starter Motor Inspection
  221
- Starter Motor Assembly
  223
- Starter Motor Installation
  225
- Starter Magnetic Switch Removal
  226
- Starter Magnetic Switch Operation Inspection
  226
- Ground Line Inspection
  226
- Starter Magnetic Switch Voltage Inspection
  226
- Continuity Inspection
  227
- Starter Magnetic Switch Installation
  227
- Lights/Meter/Switches Diagram
  229
- Lights/Meter/Switches Specifications
  230
- Lights/Meter/Switches Service Information
  230
- Lights/Meter/Switches Troubleshooting
  231
- Headlight Bulb Replacement
  232
- Headlight Case Removal/Installation
  232
- Position Light Bulb Replacement
  233
- Front/Rear Winker Bulb Replacement
  233
- Stop/Tail Light Inspection
  233
- Stop/Tail Light Bulb Replacement
  234
- Combination Meter Removal
  234
- Combination Meter Disassembly
  234
- Combination Meter Installation
  235
- Combination Meter Assembly
  235
- Main Switch Inspection
  236
- Main Switch Removal/Installation
  236
- Handlebar Switches
  237
- Front/Rear Stop Switch
  238
- Neutral Switch
  238
- Horn
  238
- Winker Relay
  239
- Fuel Unit Removal
  239
- Fuel Unit Installation
  240
- Fuel Unit Inspection
  240
Wiring Diagram
242
Engine Won't Start or Is Hard to Start
243
Troubleshooting
243

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