DAELIM HISTORY 125 - User Manual

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Table of Contents2
How to Use this Manual2
General Safety3
Service Rules3
Caution When Wiring7
Serial Number Location11
Specifications12
Torque Values14
Symbols/Abbreviations16
Wiring Connections Diagram17
Lubrication19
Engine Oil19
Transmission Oil19
Service Information19
- Low or no Oil Pressure20
- Lubrication System Troubleshooting20
- Oil Contamination20
- Oil Level Low20
- Engine Oil Change21
- Engine Oil Level Inspection21
- Oil Filter Element Change22
- Oil Pump Removal22
- Oil Pump Disassembly23
- Oil Pump Inspection23
- Oil Pump Assembly24
- Oil Pump Installation24
- Radiator Inspection25
- Radiator Removal25
- Radiator Installation26
- Transmission Oil Inspection26
- Control Cable Lubrication27
- Lubrication Points27
- Tires Specifications29
- Maintenance Schedule31
Inspections/Adjustments29
- Air Cleaner32
- Fuel Line (Fuel Tube)32
- Throttle Grip Operation32
- Spark Plug33
- Valve Clearance33
- Carburetor Idle Speed34
- Cylinder Compression Pressure34
- Brake Fluid35
- Brake Lever Free Play36
- Headlight Aim36
- Side Stand36
- Bolts, Nuts, Fasteners37
  - Front Wheel Check37
  - Rear Wheel Check37
- Suspension37
- Steering Head Bearing38
- Wheels/Tires Checks38
External Parts39
- Names of Frame Covers40
- Front Cover41
- Front Fender41
- Front under Cover42
- Luggage Box42
- Center Cover43
- Rear Center Cover43
- Rear Carrier/Back Rest44
- Body Cover/Upper Body Cover44
- Rear Combination Light45
- Floor Side Cover45
- Floor Panel46
- Under Cover46
- Inner Box/Inner Box Lid47
- Rear Fender47
- Wind Screen/Front Handle Cover48
- Rear Handle Cover48
- Rear Wheel Mud Guard49
- Muffler Removal50
- Exhaust Pipe Removal and Installation50
- Fuel System Diagram52
- Fuel System Specifications53
- Carburetor Data53
- Fuel System Troubleshooting54
- Fuel Tank Installation55
- Fuel Tank Removal55
- Air Cleaner Removal56
- Carburetor Removal56
- Carburetor Disassembly57
- Carburetor Inspection57
- Float Chamber/Float/Jet Disassembly58
- Carburetor Cleaning59
- Float Chamber/Float/Jet Assembly59
- Float Level Inspection60
- Carburetor Installation61
- Carburetor Insulator Removal61
- Carburetor Insulator Inspection61
- Pilot Screw Adjustment62
Engine Removal63
- Engine Installation65
- LH. Crankcase Cover/Kick Starter/Continuously Variable Transmission66
Lh. Crankcase Cover/Kick Starter /Continuously Variable Transmission67
- LH. Crankcase Cover Removal68
- LH. Crankcase Cover Installation68
- Kick Starter Removal69
- Kick Starter Inspection70
- Kick Starter Installation71
- Drive Belt Removal72
- Drive Belt Inspection73
- Drive Belt Installation73
- Movable Drive Face Removal74
- Movable Drive Face Inspection75
- Movable Drive Face Installation75
- Clutch/Driven Pulley Removal77
- Clutch/Driven Pulley Disassembly77
- Clutch/Driven Pulley Inspection79
- Driven Face Bearing Inspection79
- Movable Driven Face Spring Inspection79
- Clutch Shoe Inspection79
- Driven Face Bearing Replacement80
- Clutch/Driven Pulley Assembly81
- Clutch/Driven Pulley Installation82
- AC Generator/Starter Clutch Diagram84
- AC Generator/Starter Clutch Specifications85
A.C.generator / Starter Clutch85
- AC Generator Removal86
- Shroud Removal86
- AC Generator Installation88
- RH Crankcase Cover Removal88
- Starter Reduction Gear Inspection89
- Starter Reduction Gear Removal89
- Starter Clutch Removal90
- Starter Reduction Gear Installation90
- Starter Clutch Inspection91
- Starter Clutch Installation92
- Cylinder Head/Valves Diagram94
- Cylinder Head/Valves Specifications95
- Cylinder Head/Valves Troubleshooting96
- Camshaft Removal97
- Camshaft Inspection98
- Cylinder Head Disassembly99
- Cylinder Head Removal99
- Cylinder Head Inspection100
- Valve Springs100
- Valves100
- Valve Guides Inspection101
- Valve Guides Replacement101
- Valve Seats Inspection102
- Valve Seat Refacing103
- Cylinder Head Assembly105
- Camshaft Assembly107
- Cylinder/Piston Diagram110
- Cylinder/Piston Specifications111
- Cylinder Removal112
- Cylinder Wear Inspection112
- Cylinder Warpage Inspection113
- Piston/Piston Ring Inspection113
- Piston/Piston Ring Removal113
- Piston Pin Inspection114
- Small End Bearing Surface Inspection114
- Piston Installation115
- Piston/Piston Ring Installation115
- Cylinder Installation116
- Transmission/Crankshaft/Crank Case Diagram118
- Transmission/Crankshaft/Crank Case Specifications119
- Transmission/Crankshaft/Crank Case Troubleshooting120
- Transmission Disassembly121
- Transmission Inspection122
- Transmission Assembly123
- Transmission Bearing Inspection123
- Crank Case Removal124
- Crankshaft Removal125
- Crankshaft Inspection126
- Transmission Bearing126
- Crankshaft Installation127
- Transmission Bearing Replacement127
- Crankcase Installation128
  - Front Wheel/Front Fork/Steering Diagram130
  - Front Wheel/Front Fork/Steering Specifications131
  - Front Wheel/Front Fork/Steering Troubleshooting132
  - Steering Handle Installation133
  - Steering Handle Removal133
  - Front Wheel Removal135
  - Front Wheel Inspection136
  - Front Wheel Bearing Replacement137
  - Front Wheel Assembly138
  - Speedometer Gear Replacement138
  - Front Wheel Installation139
  - Front Fork Disassembly140
  - Front Fork Removal140
  - Front Fork Assembly142
  - Front Fork Inspection142
  - Front Fork Installation144
  - Steering Stem Removal145
  - Steering Stem Installation147
  - Rear Wheel/Brake/Suspension/Rear Swing Arm Specifications149
  - Rear Wheel/Brake/Suspension/Rear Swing Arm Troubleshooting150
  - Rear Wheel Removal151
  - Rear Wheel Inspection152
  - Rear Wheel Installation152
  - Parking Brake Inspection153
  - Parking Brake Removal153
  - Brake Cam Disassembly154
  - Brake Shoe Disassembly154
  - Parking Brake Assembly/Installation154
  - Rear Cushion Disassembly155
  - Rear Cushion Inspection155
  - Rear Cushion Removal155
  - Rear Cushion Installation156
  - Rear Swing Arm Disassembly156
  - Rear Swing Arm Removal156
  - Brake System Diagram158
  - Brake System Troubleshooting159
  - Air Bleeding160
  - Brake Fluid Change160
  - Front Brake Pad Replacement162
  - Rear Brake Pad Replacement163
  - Brake Caliper Disassembly164
  - Brake Caliper Removal164
  - Brake Caliper Assembly165
  - Brake Caliper Inspection165
  - Brake Caliper Installation166
  - Master Cylinder Disassembly166
  - Master Cylinder Removal166
  - Master Cylinder Assembly167
  - Master Cylinder Inspection167
  - Master Cylinder Installation168
  - Brake Disk Inspection169
  - Battery/Charging System Serice Information171
  - Battery/Charging System Specifications171
  - Charging Device Location172
  - Triple Phase Full Wave Rectification Method172
  - Charging System Troubleshooting173
  - Battery (Open-Circuit Voltage) Inspection174
  - Battery Removal174
  - Charging System Inspection175
  - Charging Voltage Inspection175
  - Leak Test175
  - Harness Side Circuit Inspection176
  - Headlight Voltage Inspection176
  - Regulator/Rectifier Inspection176
  - AC Generator Charging Coil Inspection177
  - Regulator Rectifier Unit Inspection177
  - Regulator Rectifier Unit Replacement177
  - Ignition System Service Information179
  - Ignition System Specifications179
  - Ignition Devices Location180
  - Ignition System Troubleshooting181
  - CDI Ignition Circuit Inspection182
  - CDI Unit Inspection182
  - Pulse Generator Inspection182
  - PVA Measurement182
  - Ignition Coil Inspection183
  - Ignition Coil Replacement183
  - Primary Coil Inspection183
  - Secondary Coil Inspection183
  - Ignition Timing Inspection184
  - Side Stand Ignition Cut-Off Switch Inspection184
  - Side Stand Ignition Cut-Off Switch Installation185
  - Side Stand Ignition Cut-Off Switch Removal185
  - Starter System Specification187
  - Starter Devices Location188
  - Starter System Circuit Diagram188
  - Starter System Troubleshooting189
  - Starter Motor Disassembly190
  - Starter Motor Inspection190
  - Starter Motor Removal190
  - Starter Motor Assembly192
  - Starter Magnetic Switch Ground Line193
  - Starter Magnetic Switch Inspection193
  - Starter Magnetic Switch Removal193
  - Starter Magnetic Switch Voltage193
  - Starter Magnetic Switch Operation Check194
  - Lights/Meter/Switches Service Information195
  - Lights/Meter/Switches Troubleshooting195
  - Front/Rear Winker Bulbs Replacement196
  - Headlight Bulb Replacement196
  - Headlight Removal196
- Rear Combination Light197
- Speedometer Removal197
- Horn Inspection198
- Meter Bulb Replacement197
- Main Switch Removal198
- Main Switch Inspection198
- Handle Bar Switch Inspection198
- Trunk Lamp Switch Inspection199
- Front/Rear Stop Switch Inspection199
- Fuel Unit Inspection200
- Fuel Unit Removal200
- Parking Brake Switch Inspection200
Wiring Diagram201
Engine Won't Start or Hard to Start202
Troubleshooting202
- Engine Stalls, Hard to Start, Rough Idling203
- Poor Performance at Low Speed and Idling204
- Clutch Drive/Driven Pulley Poor Operation205
- Handle/Wheel Poor Operation205
- Poor Front/Rear Suspension Performance206

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DAELIM HISTORY 125 Specifications

General

Fuel System	Carburetor
Ignition	CDI
Transmission	Automatic
Front Suspension	Telescopic fork
Rear Suspension	Unit swing
Front Brake	Disc
Rear Brake	Drum
Front Tire	120/70-12
Rear Tire	130/70-12
Seat Height	780 mm
Fuel Capacity	6.5 Liters
Weight	115 kg
Cooling System	Air cooled
Engine Type	4-stroke