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. [. . . ] 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). side cover mounting bolts, then remove the R/L. 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. Remove the two flange bolts and two special bolts. Remove the rear fender mounting body cover clips. 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). Remove the CDI, light relay and winker relay from the rear fender. Disconnect the taillight connector and winker connector. SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW Remove the R/L special screws. Remove the rear fender mounting bolts, then remove the rear fender. 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. [. . . ] Check the ignition timing and valve clearance. Incorrect. CAUSE OF TROUBLE Faulty valve clearance adjustment. Fuel flows freely. Fuel flows restricted. No fuel to fuel tank. Remove the carburetor and check for clogged jets. [. . . ]