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ROADWIN VJ125
DAELIM ROADWIN VJ125 User Manual
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SM48-0401-01E
HEAD OFFICE (F
ACT
OR
Y)
#58, SUNG SAN-DONG,
CHANGWON,
KYUNGNAM, K
OREA
TEL : (82-55) 239-7000 / F
AX :
(82-55) 239-7524
O
VERSEAS SALES OFFICE
#13-5, SUNG SOO 1DONG 1GA,
SUNG DONG GU,
SEOUL, K
OREA
TEL : (82-2) 498-6465 / F
AX :
(82-2) 467-9997
2
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
Engine Lacks Power
244
Poor Performance (at Low and Idle Speed)
245
Poor Performance (at High Speed)
246
Poor Handling
246
Poor Front/Rear Suspension Performance
247
Fuel Gauge Reading Inaccurate (Ignition Switch On)
247
Gauge Needle Shakes or Vertically Wobbles (Ignition Switch On)
248
4
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DAELIM ROADWIN VJ125 Specifications
General
Brand
DAELIM
Model
ROADWIN VJ125
Category
Motorcycle
Language
English
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