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 PRINTED 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. To facilitate use of this manual, each page starts with disassembly and system diagrams, service information, and troubleshooting guide. If you cannot find the cause of trouble, refer to Section 21: Troubleshooting. CONTENTS GENERAL INFORMATION INSPECTIONS / ADJUSTMENTS LUBRICATION FUEL SYSTEM EMS (Engine Management System) COOLING SYSTEM ENGINE FRAME ELECTRICAL SYSTEM ENGINE REMOVAL CLUTCH / GEARSHIFT A.C.GENERATOR / STARTER CLUTCH CYLINDER HEAD / VALVES CYLINDER / PISTON CRANKCASE / TRANSMISSION / CRANKSHAFT Contents of this manual and specifications are subject to change without prior notice for improvement of vehicle quality. No part of this publication may be reproduced without written permission of DAELIM MOTOR. EXTERNAL PARTS FRONT WHEEL/FRONT FORK/STEERING REAR WHEEL /REAR SUSPENSION HYDRAULIC BRAKE BATTERY / CHARGING SYSTEM IGNITION SYSTEM ELECTRIC STARTER LIGHTS/METER/SWITCHES TROUBLESHOOTING WIRING DIAGRAM 1. GENERAL INFORMATION SERVICE INFORMATION SERVICE RULES CAUTION WHEN WIRING MODEL IDENTIFICATION SPECIFICATIONS 1-1 1-1 1-5 1-9 1-10 TORQUE VALUES SYMBOLS / ABBREVIATIONS TOOLS WIRING DIAGRAM 1-12 1-14 1-15 1-16 SERVICE INFORMATION 1. Do not run the engine for a long time in closed or not well-ventilated area because the exhaust gas contains toxic substances such as carbon monoxide, hydrocarbon, nitric oxide. 2. The battery fluid(lean sulfuric acid) is extremely toxic. It is dangerous if skin is exposed to it or if it enters into the eye. Be careful in handling. When exposed to the battery fluid, wash it with water and get a medical check up.(store the battery fluid in a safe place to avoid touching by the children) 3. Pay attention not to be burned and always put on the protection gears because the engine or the muffler is hot right after engine stops. 4. Gasoline is extremely flammable. Maintenance must be performed in the place free of the open fire or electric spark. 5. When more than two person are working, always pay attention to other worker's action and always have safety in mind. 6. The skin exposed to used engine oil can be a major reason of the skin cancer. Pay attention not to be exposed and wash carefully with soap and water after handling. 7. If compressed air is used to clean the brake, dust scattered in the air can be breathed in by workers. Please take action not to scatter dust in the brake cleaner, etc. 8. Flammable nitrogen gas is generated during charging the battery so charging must be performed in well-ventilated area and free of the open fire and spark. SERVICE RULES 1. Parts and lubrication oil must be DAELIM genuine or recommended parts. 2. Before maintenance, remove deposit or dust from the chasis. 1-1 GENERAL INFORMATION 3. Store the parts of each system discriminatively to install each part in the right place. 4. After removing gasket, O-ring, piston pin clip and cotter pin, always replace them with the new one. When removing the snap ring, it can be easily missed after transformation or installation. 5. Clean the parts after the overhaul and before the test and remove the cleaning oil with compressed air. Apply oil to seal face during installation. 6. Check necessary place and measure necessary data during installation. When installing, return to the state before removing. 7. Align the bolts to uniform the tightening points before tightening them when you don't know the bolt length. 8. Bolts, nuts and pieces must be tightened from the bigger diameter to the smaller one, from inside to outside and diagonally with the specified torque. 9. Check to see if the rubber part is worn out when removing it and replace it if necessary. Some rubber part is weak to gasoline and kerosene, so pay attention not to soak with gasoline or oils. 10. Recommended grease must be applied to or filled in the specified place. 1-2 GENERAL INFORMATION 11. Maintenance needed to use the specialized tools must be performed with the right tool. 12. Never reuse the ball bearing removed with the ball applied pressure when removing press-fitted the bearing. 13. Check the smooth rotation of inner or outer race of the ball bearing by rotating it manually. Replace the ball bearing having excessive axial/ longitudinal hanging. Wipe the ball bearing likely to have hanging with cleaning oil.(except double-sided sealed type ball bearing) Replace the ball bearing of which press-fitted part is slacked at the case or shaft. 14. Pay attention to installation direction in case of the single-sided sealed ball bearing. Install the opendirection or double-sided sealed bearing in the way that the face marked with manufacturer and size should direct to the outer axle. ' 15. When blowing the ball bearing with compressed air after cleaning, keep the race from rotating. High speed rotation of the race may damage the bearing. Prior to installation, apply oil or grease to the bearing. 16. Install the snap ring so that chamfered side directs to the load-applied side. After installation, check the proper installation by rotating the snap ring. 17. Check each part for proper tightening and operation after installation. 18. The brake fluid and coolant can damage the painted plastic or rubber parts. Keep these parts from contacting with them and wash these parts with water in case of contact. 1-3 GENERAL INFORMATION 19. Install the oil seal so that the manufacturer marked surface directs outer surface.(direction not covered with oil) Pay attention not to bend or damage the lip. Apply the grease to the lip. 20. Connect the tube until the tube fully inserted in the joint. Install the clip if it is supplied. Replace the tube having slacked end. ' 21. Keep the pneumatic system interior or the engine interior from the infiltration of dust. 22. Install the gasket mounted in the contact surface of each case of the engine while removing gasket material completely. Remove damaged contact surface by wiping with the oil stone equally. 23. Pay attention not to bend the cable excessively. Transformed or damaged cable may cause malfunction or damage. 24. Install the boots with the installing groove by inserting the boots into the groove. 1-4 GENERAL INFORMATION CAUTION WHEN WIRING Each cord must be connected depending on its color. When connecting different cord, attach color tube around the connector. Connect the coupler to the connector with same color and same pin number. Identify the two-colored cord by main color first and then spriped color . When measuring voltage or resistance of the cord terminal using tester, contact the tester plug behind of the coupler. Pay attention not to open the cord terminal and contact the tester plug from the front of the coupler in case of water-proof coupler. Recheck the condition of contact, securing and continuity of each part after maintenance. When connecting the battery, the plus terminal must be connected first. After connecting the terminal, apply the grease to the terminal. When disconnecting the battery, the minus terminal must be disconnected first. Make sure that the tool such as spanner do not contact with the frame. Connect covers to the terminal after maintenance. If the fuse is short-circuited, find out the cause and repair. Replace with the fuse having the specified capacity. If there is rust in the terminal, remove the rust with sand paper prior to connecting. VALIDATION OF CAPACITY! REMOVE THE RUST! 1-5 GENERAL INFORMATION Turn off the main switch before connecting/disconnecting. Release the lock to disconnect the lock of the coupler. The lock of the coupler has two types according to releasing method(press type and pull type) so release it properly according to the shape. - Typical releasing method of the coupler is illustrated in the following. When disconnecting the coupler, disconnect it while holding the coupler body. Pull while holding the wire harness cord and do not remove the coupler connection. Insert the lock of the coupler until the lock is fully secured. Release the lock by inserting the coupler slightly and then narrowing connection to remove the coupler. Pay attention not to damage the vinyl cover of the coupler. Check to see if there is bended terminal and secure it to avoid disconnecting. If the wire harness coating is damaged, repair by winding vinyl tape or replace it. Prior to connecting the connector, make sure that the cover is not damaged and the mess terminal is not opened. 1-6 GENERAL INFORMATION Insert the connector until the vinyl cover is fully inserted into the terminal. The opening of the vinyl cover must face at the ground direction but in case of the plain connector, the draining opening must face at the sky direction. When removing T-start, broaden the groove of T-start using the wiring driver and release the torque. Connect the harness and the hose to T-start and then insert until the groove is locked. When removing T-start from the frame, replace it with the new one. Wire band must be secured firmly in the specified location of the frame. In case of aluminium band, secure the wire harness to the coated part. Secure the wire harness firmly using the clamp. In case of the weld clamp, do not clamp in the welded part. When clamping the wire harness, make sure that the harness is not contacted with the shaft or rotating part. When clamping the wire, pay attention not to contact with hot part. The wire harness must be routed without contacting with the end of the lamp or any sharp edge. The wire harness must be routed without contacting with the end of the bolt or the piece. 1-7 GENERAL INFORMATION In case that the wire harness is contacted with the end or the sharp edge, protect both parts with tube or tape. The wire must not hang down or be pulled excessively. NOT TO PULL! If necessary, lock the wire harness properly. When mounting parts, make sure that the wire harness is not pressed by the parts. Do not twist the wire harness. Wire the wire harness not to be pulled or expanded when the handle is turned to the right or the left completely. Avoid excessive bending or chewing and interference with the engine. Prior to using the tester, please read the manual carefully and understand the contents. When testing the resistance of the tester, the zero adjustment must be performed before testing. Is this measurement range or configuration in accord with the manual? Do not drop or throw the parts especially semiconductor contained parts because these parts may be damaged by the impact of the drop. 1-8 GENERAL INFORMATION MODEL IDENTIFICATION ENGINE SERIAL NUMBER ENGINE SERIAL NUMBER ENGINE SERIAL NUMBER FRAME SERIAL NUMBER FRAME SERIAL NUMBER FRAME SERIAL NUMBER ENGINE SERIAL NUMBER LOCATION The engine serial number is stamped on left crankcase. FRAME SERIAL NUMBER LOCATION The frame serial number is stamped on the left side of steering head. 1-9 GENERAL INFORMATION SPECIFICATIONS ITEM SPECIFICATIONS DIMENSIONS OVERALL LENGTH OVERALL WIDTH OVERALL HEIGHT WHEEL BASE SEAT HEIGHT GROUND CLEARANCE DRY WEIGHT CURB WEIGHT TYPE FRONT SUSPENSION / STROKE REAR SUSPENSION / STROKE FRONT TIRE SIZE (TYPE) REAR TIRE SIZE (TYPE) TIRE PRESSURE 1 PERSON FRONT REAR 2 PERSON FRONT REAR FRONT BRAKE REAR BRAKE FUEL CAPACITY FUEL RESERVE CAPACITY CASTER ANGLE TRAIL FRONT FORK OIL CAPACITY TYPE CYLINDER NUMBER, ARRANGEMENT BORE AND STROKE DISPLACEMENT COMPRESSION RATIO VALVE TRAIN OIL CAPACITY 2,025mm 764mm 1,180mm 1,380mm 780mm 139mm 162kgf 292kgf Double Cradle Telescopic / 130mm Swingarm / 28mm 110/70-17 54P (Tubeless) 140/60-17 69P (Tubeless) 2.00kgf/cm2(200kPa) 2.00kgf/cm2(200kPa) 2.00kgf/cm2(200kPa) 2.25kgf/cm2(225kPa) Hydraulic Disk Hydraulic Disk 14.85 4.0 25.2 93.5mm 265 2.5cc Liquid 4-stroke DOHC(4 Valve) 1 Cylinder, 20 Inclined from vertical 56.5 X 49.5mm 124.1cm3 11.8:1 DOHC Chain Drive 1.5 After Disassembly 1.35 After Draining and Oil Filter Change 1.3 After Draining Wet Pressing and Spray Paper Filter 13.0kgf/cm2 (600rpm) 23 BTDC 55 ABDC (1.12mm Lift) 66.3 BBDC 23.6 ATDC (1.12mm Lift) 0.15 0.02mm 0.20 0.02mm 32.0kgf FRAME ENGINE LUBRICATION SYSTEM AIR FILTRATION TYPE CYLINDER COMPRESSION INTAKE VALVE OPEN CLOSED EXHAUST VALVE OPEN CLOSED VALVE CLEARANCE INTAKE (A COOLING-OFF PERIOD) EXHAUST ENGINE DRY WE ...