User manual DAELIM ROADWINR VJF125 SERVICE MANUAL

[. . . ] HEAD OFFICE(FACTORY) #58, SUNG SAN-DONG, CHANG WON, KYUNGNAM, KOREA TEL: (82-55) 239-7000 / FAX: (82-55) 239-7520 OVERSEAS SALES OFFICE(FACTORY) 13-5, SEONGSU 1-GA, 2DONG, SEONGDONG-GU, SEOUL, KOREA TEL: (82-2) 3408-2634 / FAX: (82-2) 467-9997 SERVICE MANUAL 2007. 01 PUBLICATION COPY PROHIBIT HOW TO USE THIS MANUAL This manual describes effective maintenance procedure for the VJF125 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. [. . . ] Support the cylinder head and drive the old guides out of the combustion chamber side of the cylinder head. TOOL : VALVE GUIDE DRIVER Avoid damaging the head when driving the valve guide out. Apply oil to a new O-ring and install it onto a new valve guide. Drive the new guide in from the camshaft side of the cylinder head while the cylinder head is still heated. TOOL : VALVE GUIDE DRIVER When reaming new valve guides, insert the valve guide reamer from the combustion chamber side. TOOL : VALVE GUIDE REAMER Take care not to tilt or lean the reamer in the guide while reaming. Otherwise, the valve is installed slanted, that causes oil leaks from the stem seal and improper valve seat contact and results in the valve seat refacing not able to be performed. Use cutting oil on the reamer during this operation. Rotate the reamer clockwise, never counterclockwise when inserting and removing. Reface the valve seats and clean the cylinder head thoroughly to remove any metal particles. VALVE SEATS INSPECTION / REFACE Clean all intake and exhaust valves thoroughly to remove carbon deposits. Apply a light coating of Prussian Blue to each valve face. Tap the valve against the valve seat serveral times with the valve guide reamer, without rotating the valve, to check for proper valve seat contact. Remove the valve and inspect the valve seat face. The valve seat contact should be within the specified width and evenly all around the circumference. If the valve seat width is not within specification, reface the valve seat. 10-7 CYLINDER HEAD / VALVES Valve faces and stem tips cannot be ground. If a valve face or stem tip is rough, worn unevenly, or contacts the seat improperly, the valve must be replaced. Measure the valve seat width. STANDARD VALUE : 0. 7~0. 9 mm SERVICE LIMIT : 1. 3 mm VALVE SEAT VALVE SEAT VALVE SEAT VALVE SEAT VALVE SEAT REFACING 70 20 IN : 22mm EX : 22mm IN : 23mm Reface the worn valve seat by using valve seat cutters and grinders. Follow the refacer manufactuer's operating instructions. Be careful not to grind the seat more than necessary. IN : 24. 5mm EX : 24. 5mm EX : 20mm ROUGHNESS OR SCRATCH Using a 45 degree cutter, remove any roughness or irregularities from the seat. Reface the valve seat whenever the valve guide has been replace. VALVE SEAT 45 Using a cutter, remove material. of the existing valve seat SERVICE LIMIT : IN : 20 degrce cutter EX : 30 degrce cutter CUT THE SEAT PART 35 10-8 CYLINDER HEAD / VALVES Using a 70 degree cutter, remove the bottom old seat. OLD SEAT WIDTH of the 70 Using a 45 degree cutter, cut the seat to the proper width. VALVE SEAT WIDTH : 0. 9~1. 1mm SEAT WIDTH 45 CONTACT TOO HIGH OLD SEAT WIDTH Apply a light coating of Prussian Blue to each valve face. Tap the valve against the valve seat serveral times with the valve guide reamer, without rotating the valve, to check for proper valve seat contact. If the contact area is too high, grind the seat using cutter as like. IN : 20 degree , EX : 30 degree flat cutter 35 Refinish the seat to specifications, using a 45 degree finish cutter. If the contact area is too low on the valve, grind the seat using 70 degree cutter. . CONTACT TOO LOW Refinish the seat to specifications, using a 45 degree finish cutter. OLD SEAT WIDTH 60 10-9 CYLINDER HEAD / VALVES After cutting the valve seat, apply lapping compound to the valve face, and insert the valve with a valve guide reamer. Do not excessively press and turn the valve to set it as it may cause damage. The seat surface may become worn on one side if the valve is set in the same position. Turn the valve slightly when setting it. Take precautions not to allow compound to get into the clearance between the stem and guide while the valve is being set. CYLINDER HEAD ASSEMBLY Install new stem seals with valve spring seat. Lubricate each valve stem with molybdenum grease and insert the valve into the valve guide turning a valve too fast can damage the stem seals. Check to see if the valve move up and down smoothly. Install the valve springs with the narrow pitch forward to cylinder head. FOR CYLINDER HEAD FOR CYLINDER HEAD FOR CYLINDER HEAD Install the spring retainer. [. . . ] 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. Check valve timing Correct. Clogged. Damaged fuel strainer or screen. Incorrect. Cam sprocket not installed properly. 5. [. . . ]