User manual DAELIM ROADWIN VJ125 SERVICE MANUAL

[. . . ] 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. [. . . ] ( Section 6) GEAR CHANGE SWITCH GEAR CHANGE SWITCH GEAR CHANGE SWITCH 11-12 MEMO EXTERNAL PARTS 12-0 12. EXTERNAL PARTS SERVICE INFORMATION TROUBLESHOOTING SEAT/SIDE COVER REAR SEAT (PILLION SEAT) REAR COWL 12-1 12-1 12-2 12-2 12-3 REAR FENDER REAR WHEEL MUDGUARD MUFFLER/EXHAUST PIPE FRONT FENDER 12-3 12-3 12-4 12-5 SERVICE INFORMATION GENERAL SAFETY Because of the hat muffler, avoid the check immediately after the engine stop. This section covers removal and installation of the seat and exhaust muffler. Always replace the exhaust pipe gaskets after removing the exhaust pipe from the engine. Always inspect the exhaust muffler for leaks after installation. TROUBLESHOOTING Excessive exhaust noise Broken exhaust system Exhaust gas leak Poor performance Deformed exhaust system Exhaust gas leak Clogged muffler 12-1 EXTERNAL PARTS SEAT / SIDE COVER SEAT REMOVAL Insert the ignition key into the seat lock. Turn the ignition key counterclockwise, and then pull the seat back and up. Installation is in the reverse order of removal. SIDE COVER REMOVAL Remove the seat (see above). Installation is in the reverse order of removal. BOLT BOLT BOLT CENTER COVER CENTER COVER CENTER COVER SETTING GROMMET SETTING GROMMET SETTING GROMMET SETTING GROMMET REAR SEAT(PILLION SEAT) Remove the seat (see above). Remove the center cover setting grommet and center cover. CENTER COVER CENTER COVER CENTER COVER Remove the seat mounting bolt, and then pull the seat front and up. Installation is in the reverse order of removal. FLANGE BOLT FLANGE BOLT 12-2 EXTERNAL PARTS FLANGE BOLT FLANGE BOLT SPECIAL BOLTS SPECIAL BOLTS SPECIAL BOLTS REAR COWL Remove the seat. Carefully spread the bottom of both sides of the rear cowl, then remove it. Installation is in the reverse order of removal. BODY COVER CLIPS BODY COVER CLIPS BODY COVER CLIPS LIGHT RELAY LIGHT RELAY LIGHT RELAY DC-CDI DC-CDI DC-CDI WINKER RELAY WINKER RELAY WINKER RELAY REAR FENDER Remove the rear cowl (see above). Disconnect the taillight connector and winker connector. SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW Remove the R/L special screws. Installation is in the reverse order of removal. MOUNTING BOLTS MOUNTING BOLTS MOUNTING BOLTS REAR WHEEL MUDGUARD REAR WHEEL MUDGUARD REAR WHEEL MUDGUARD REAR WHEEL MUDGUARD Remove the rear wheel mudguard mounting bolts and rear wheel mudguard. Installation is in the reverse order of removal. FLANGE BOLTS FLANGE BOLTS FLANGE BOLTS 12-3 EXTERNAL PARTS BOLT/NUT BOLT/NUT BOLT/NUT MUFFLER/EXHAUST PIPE Do not service the exhaust system while it is hot. REMOVAL Remove the exhaust pipe to muffler mounting bolts. Remove the muffler mounting bolt/nut and washer, then remove the muffler. MUFFLER MUFFLER MUFFLER BOLTS BOLTS BOLTS BOLTS Remove the exhaust pipe flange gasket. GASKET GASKET GASKET Remove the exhaust pipe joint cap nuts. CAP NUTS CAP NUTS CAP NUTS Remove the following. - Exhaust pipe joint - Exhaust pipe joint collar - Exhaust pipe - Exhaust pipe gasket - Muffler damper stay MUFFLER DAMPER STAY MUFFLER DAMPER STAY 12-4 EXTERNAL PARTS INSTALLATION Install the removed parts in the reverse order of removal. Check the protrusion of the exhaust pipe stud bolt. Install the new exhaust pipe gasket onto the exhaust ports of the cylinder head. Install the new gasket onto the exhaust pipe. FRONT FENDER FRONT FENDER SPECIAL SCREWS SPECIAL SCREWS SPECIAL SCREWS FRONT FENDER Remove the wire grommat from the front fender. Installation is in the reverse order of removal. WIRE GROMMAT WIRE GROMMAT WIRE GROMMAT 12-5 FRONT WHEEL/FRONT FORK/STEERING 13-0 13. FRONT WHEEL/FRONT FORK/STEERING SERVICE INFORMATION TROUBLESHOOTING HANDLEBARS 13-1 13-2 13-3 FRONT WHEEL FRONT FORK STEERING STEM 13-7 13-12 13-20 SERVICE INFORMATION GENERAL SAFETY A contaminated brake disk and pad reduce stopping power. Discard contaminated pads and clean a contaminated disk with a brake degreasing agent. [. . . ] Poor carburetor maintenance. 21-2 TROUBLESHOOTING INSPECTION 9. Overheated Contaminated or discolored CAUSE OF TROUBLE Lean fuel mixture. Clogged oil passage. Level low or high Valve train lubricated improperly. Excessive carbon build-up in combustion chamber. Engine does not knocking. Engine knocking POOR PERFORMANCE (AT LOW AND IDLE SPEED) INSPECTION 1. [. . . ]