Daelim Roadwin 125 Fi

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IMPORTANT NOTICE

●OPERATOR AND PASSENGER


This motorcycle is designed to carry the operator and one passenger.

●ON-ROAD USE
This motorcycle is designed to be used only on the road.

●READ THIS OWNER'S MANUAL CAREFULLY


Pay special attention to statements preceded by the following words:

WARNING
Indicates a strong possibility of severe personal injury or death if instructions are not followed.

CAUTION
Indicates a possibility of personal injury or equipment damage if instructions are not followed.

NOTE
Gives helpful information.

This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when resold or otherwise
transferred to a new owner or operator.

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CONTENTS
SPECIFICATION ······································· 3 EQUIPMENT USAGE ···································17
OPERATION INSTRUCTION ···························· 4 STEERING LOCK ······································17
SAFETY PRECAUTIONS ································ 4 SEAT ···············································17
PRIOR TO STARTING VEHICLE ··························· 5 HELMET HOLDER ······································18
CORRECT ATTIRE ····································· 5 STORAGE COMPARTMENT ·······························18
OPERATION ·········································· 6 SELF INSPECTIONS BEFORE OPERATION ···············19
CARGO ············································· 7 BRAKES·············································19
MODIFICATION········································ 8 TIRES ··············································21
ATTACHMENT ········································ 8 CLUTCH·············································23
MUFFLER············································ 8 FUEL ···············································24
PARTS LOCATION ···································· 9 ENGINE OIL ··········································25
METER READING AND USAGE ··························12 LIGHTS AND WINKER ···································25
METER ·············································12 BACK MIRROR ········································26
TACHOMETER ········································12 LICENSE PLATE ·······································26
FUEL GAUGE ·········································13 OPERATION ··········································26
INDICATOR LAMPS ·····································13 PRE-RIDE INSPECTION··································26
SWITCH OPERATION ··································14 STARTING THE ENGINE ·································27
MAIN SWITCH ········································14 IF ENGINE CANNOT BE STARTED ··························28
KEYS ··············································15 RUNNING-IN··········································28
HEADLIGHT ··········································15 RIDING ·············································29
STARTER BUTTON ·····································16 BRAKING ············································30
WINKER SWITCH ······································16 PARKING ············································30
HORN BUTTON········································16

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MAINTENANCE ········································31 SAFE DRIVING ········································51
MAINTENANCE SCHEDULE ·······························32 PREPARATION BEFORE DRIVING ·····················51
TOOL KIT ············································34 DRIVING METHOD ··································52
FRAME AND ENGINE NUMBERS ····························34 DRIVING POSITION ···································52
MAINTENANCE PRECAUTIONS ····························35 PRECAUTION WHEN DRIVING ···························53
THROTTLE OPERATION ·································35 STARTING ·········································54
AIR CLEANER ·········································36 TURNING METHOD ··································55
ENGINE OIL ··········································37 PRINCIPLE OF TURN ··································55

SPARK PLUG ·········································38 EFFECT OF SPEED ···································55


DRIVE CHAIN ·········································39 3 POSITIONS OF TURNING ·····························56
WHEEL REMOVAL ······································41 TURNING METHOD ···································57

BRAKE PAD WEAR ·····································43 PRECAUTION WHEN TURNING ··························58


IDLE SPEED ··········································44 BRAKING METHOD··································59
SIDE STAND ··········································44 BASIC PRINCIPLE OF BRAKE(FRICTION FORCE)··············59

BATTERY ············································45 RESTRAINT OF BRAKING EFFECT (INERTIA)·················59

FUSE REPLACEMENT ···································46 BRAKING METHOD ···································60

BULB REPLACEMENT ···································47 COMPARISION OF BRAKING DISTANCE ····················60

CABLE RUBBER PART ··································49 IMPACT WHEN COLLISION······························60

CLEANING ···········································49 WIRING DIAGRAM ·····································61


STORAGE GUIDE ······································50

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SPECIFICATION

ITEM DATA ITEM DATA

LENGTH×WIDTH×HEIGHT 2,010×740×1,040mm FUEL TANK CAPACITY 16.0ℓ


WHEEL BASE 1,380mm ENGINE OIL CAPACITY 1.1ℓ

GROUND CLEARANCE 150mm FR. 110/70-17 54P


TIRE SIZE
SEAT HEIGHT 780mm RR. 140/60-17 69P
DRY WEIGHT 130kgf FR. TELESCOPIC
SUSPENSION
PASSENGER OPERATOR AND ONE PASSENGER RR. SINGLE ARM

AIR & OIL COOLED FR. HYDRAULIC DISK


ENGINE TYPE BRAKE
4 CYCLE, SOHC RR. HYDRAULIC DISK
PISTON DISPLACEMENT 124.1cc SPARK PLUG CR8EH-9
BORE AND STROKE 56.5×49.5mm FUSE 15A
STARTING SYSTEM START MOTOR HEADLIGHT BULB 12V 35W/35W
TRANSMISSION TYPE 5 STEPS RETURN STOP/TAIL LIGHT BULB 12V 21/5W
IGNITION SYSTEM DC-C.D.I WINKER BULB 12V 10W×4
BATTERY CAPACITY 12V 10Ah(MF TYPE) POSITION LIGHT BULB 12V 5W

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OPERATION INSTRUCTION SAFETY PRECAUTIONS
This manual describes matters pertaining to correct operation, ●Careful driving and the wearing of proper attire and safety
safe operation and simple maintenance of the vehicle you equipment are the most important factors in the safe operation
purchased. of the vehicle. Please obey traffic regulations and do not be
To ensure more comfortable and safer operation, make sure to hurried and careless.
read this manual carefully prior to operation. ●Many new vehicle owners operate their newly purchased
●The photographs and drawings shown in this manual may vehicles with great care and attention to safety factors.
differ from those of actual vehicles due to changes in vehicle However, after becoming accustomed to the operations are
specifications and modifications made. often discarded, which can lead to accidents. Please don't let
●This motorcycle is designed for 2 riders including the this happen to you and always approach the operation of your
operator. vehicle with the safety considerations needed.
When operating the motorcycle, always keep in mind and
obey the notes of precaution printed on the“ Safety
Precaution Label” ”attached to the motorcyle.
CAUTION
●Do not use polluted gasoline. ●Always wear helmet.
Using polluted gasoline will cause rust inside the ●Always put on gloves.
fuel tank, and will close the supply of fuel to the ●Observe posted speed limits.
carburetor, leading to an improper engine starting ●Park the motorcycle away from people (especially
or may cause serious damage to an engine. children) as the muffler can get very hot.
●Do not use polluted or low-grade oil.
●For safety, do not illegally modify the vehicle.
Always use genuine oil to protect and extend
motorcycle performance and its life span. ●Regularly conduct specified maintenance
●If any failure occurs due to the use of polluted inspections.
gasoline or oil, such failure will be excluded from <Maintenance Inspection Points>
being eligible for repairs under the warranty. Brakes, Tires, Oil, Lights, Horn, Instruments

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PRIOR TO STARTING VEHICLE CORRECT ATTIRE
●Read user's manual carefully. ●Always make sure to wear helmet for safety. Wear gloves and
●Conduct maintenance checks prior to operation. safety goggles.
●Always maintain motorcycle in clean status and carry out ●Do not wear uniforms which might hinder operation. It is
specified maintenance checks. dangerous if the uniform is caught by brake lever or by the
●Make sure to stop engine and stay away from fire when rotating part of drive chain.
fueling. ●Do not wear slippers which might obstruct brake operation or
●Exhaust gas contains harmful substance such as carbon transmission gear operation.
monoxide. Start engine in well-ventilated places. ●Many automobile/motorcycle accidents happen because the
automobile driver does not “see” the motorcyclist.
Make yourself conspicuous to help avoid the accident that
wasn’t your fault :
- Wear bright or reflective clothing.
- Don’t ride in another motorist’s “blind spot”.

WARNING
●Not wearing a helmet increases the chance of serious
injury or death in a crash.
●Be sure you and your passenger always wear a helmet,
eye protection and other protective apparel when you
ride.

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OPERATION
A helmet should always be ●Operators should naturally fix bodies to keep smooth driving.
worn and the helmet chin
strap should be securely ●Please check whether or not you are unnaturally strained and
fastened.
strung up.
Correct shirts or jackets with ●Driving pose has a great influence on safe operation.
tight-fitting sleeves should be
worn,
Please always maintain the center of your body in the middle of
seat. Especially do not sit at the rear seat because it may lessen
the weight of front wheel and cause trembling steering wheel.
●A passenger should hold on to the vehicle or the operator with
both hands and keep both feet on the pillion step bar.
●When wanting to turn, slightly lean to body toward the
direction of the turn. It is unsafe if the body is not moved in
union with the vehicle.
Always put on gloves.
●Curvy roads and poor, unpaved roads constantly change in
surface quality. Driving on these roads can be unsafe if certain
safety precautions are not followed.
●In order to safely drive through these driving conditions,
anticipate coming road conditions, slow down to at least half
the normal speed, and relax your shoulders and wrists while
securely holding the handles.
●Driving with one or both hands not holding the handles or the
front wheel lifted can cause severe injury or death of the driver
Shoes should fit properly, and shoes having little or
no heel should be worn. resulted from the turnover of the vehicle.

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CARGO
●When carrying cargo, you must keep in mind that operating the WARNING
motorcycle, especially when turning, will be different.
●Overloading or improper loading can cause a crash and
●Make sure not to overload the motorcycle with goods as this
you can be seriously hurt or killed.
can make the motorcycle unstable during operation.
●Follow all load limits in this manual.

CAUTION
●Only load cargo in or on designated areas as
placing or fastening cargo to other areas can cause
MAXIMUM LOAD : 30kg
damage to the vehicle.
●Do not place articles between the frame body
cover and engine as this can burn the goods.
●Do not attach large or heavy items (such as a
sleeping bag or tent) to the handle bars or fork.
Unstable handling or slow steering response may
result.

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MODIFICATION MUFFLER
●Modification of vehicle structure of function deteriorates ●Pay particular attention to fellow passenger so that he/she can
manipulatability or causes exhaust noise to become louder prevent getting burnt by the hot muffler during travel.
shortening the vehicle life. These modifications are not only
prohibited by law but also are the acts harmful to other people.
Modifications are not covered by warranty.

ATTACHMENT
●Except designated attachment by DAELIM MOTOR CO.,
LTD., don't attach any extra lighting device, because it may
cause an early discharging of battery.
●Carefully inspect the accessory to make sure it does not
obscure any lights, reduce ground clearance and banking angle,
or limit suspension travel, steering travel or control operation.
●Do not add electrical equipment that will exceed the CAUTION
motorcycle’s electrical system capacity. A blown fuse could
cause a dangerous loss of lights or engine power. ●Do not park in the place where many pedestrians
●This vehicle was not designed to pull a sidecar or trailer. are passing through. Pedestrians or children can be
Handling may be seriously impaired of so equipped. burned by contacting with the muffler.
●Fellow passenger care must pay enough attention
not to be burn by contacting with the muffler.
●If haystack or vinyl is stuck to the muffler, fire can
be occurred.

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PARTS LOCATION

SPEEDOMETER TACHOMETER

BACK MIRROR FUEL GAUGE BACK MIRROR


FRONT BRAKE FLUID
RESERVOIR

80
60 100 5 6
4 7
40 3 x1000rpm 8
120
2
9

CHOKE LEVER 20

0 160
mph
140
F
0 10

11
FRONT BRAKE LEVER
km/h E
N

PASSING SWITCH
THROTTLE GRIP
CLUTCH LEVER

HEADLIGHT SWITCH
HEADLIGHT
DIMMER SWITCH
STARTER BUTTON

WINKER SWITCH
HORN BUTTON FUEL FILLER CAP MAIN SWITCH

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PARTS LOCATION

REAR BRAKE FLUID RESERVOIR

BATTERY

HEADLIGHT

REAR TIRE
FRONT TIRE

CALIPER

BRAKE DISK

MUFFLER PILLION STEP BAR MAIN STEP BAR REAR BRAKE PEDAL OIL FILLER CAP/DIPSTICK

10

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PARTS LOCATION

TOOL BOX

HELMET HOLDER

REAR CUSHION

RADIATOR

CALIPER

PILLION STEP BAR

BRAKE DISK

GEAR SHIFT PEDAL MAIN STAND SIDE STAND MAIN STEP BAR

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METER READING AND USAGE

TACHOMETER
SPEEDOMETER TACHOMETER <SPEEDOMETER> Shows engine revolutions per minute.
ODOMETER Shows riding speed.
<TACHOMETER RED ZONE>
<ODOMETER> Never allow the tachometer needle to
Shows accumulated mileage. enter the red zone, even after the engine
has been broken in.
x1000rpm

F
<TRIPMETER>
E
N
Shows mileage per trip.
CAUTION
To reset the tripmeter, turn the tripmeter
knob to the direction of arrow. ●Running the engine beyond
recommended maximum engine
speed (the beginning of the
TRIP METER INDICATOR LAMPS FUEL GAUGE tachometer red zone) can damage the
engine.
METER
TACHOMETER
SPEEDOMETER ODOMETER

x1000rpm

TRIPMETER RESET KNOB E


N

TRIPMETER
TACHOMETER RED ZONE

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FUEL GAUGE INDICATOR LAMPS
Indicates amount of gasoline in fuel tank. <HIGH BEAM INDICATOR>
(The fuel gauge needle always indicates Lights when the headlight is on high
gasoline level regardless of whether main beam. (blue) NEUTRAL INDICATOR HIGH BEAM INDICATOR
switch is in "OFF" position or in "ON"
<NEUTRAL INDICATOR>
position.) If needle is within E mark,
Lights when the transmission is in neutral.
immediately fill gasoline. Balance at this
(green)
time is approximately 1.2 litres.
<LEFT WINKER INDICATOR> x1000rpm

Flashes when the left turn signal operates.


TACHOMETER F

(green) E
N

<RIGHT WINKER INDICATOR>


Flashes when the right turn signal
x1000rpm
operates. (green)
F

E
LEFT WINKER RIGHT WINKER
INDICATOR INDICATOR

FUEL GAUGE

WARNING
●To avoid running out of fuel that
may result in a sudden stop.

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SWITCH OPERATION

MAIN SWITCH
The main switch is used to turn on or turn
WARNING
off engine.
The main switch is below the indicator ●Do not manipulate main switch key
panel. during operation. If the main switch
key is placed on "Off" or "Lock"
position, all electrical system will not
Key Key function. Never operate the main
Function
position Removal
switch key during travel as it might
Starts engine. Power Key cause unexpected accidents, If it is
ON is supplied to cannot be necessary to remove the main switch
electrical circuits. removed
key, stop the vehicle first prior to
Stops engine. Cuts Key removing.
OFF off all electrical can be
circuits. removed
CAUTION
OFF ON Locks steering
wheel. Cuts off all Key ●Prior to dismounting from the
LOCK electrical circuits can be motorcycle, make sure to lock the
ON and steering wheel removed steering wheel and remove key.
FF
O is locked. ●If the key is left in "ON" position
PUSH

KEY MAIN
IO N

SWITCH without starting engine, battery is


IT

LO
C K I GN discharged.
●Do not use a number of keys together
with a metal key holder. The keys
LOCK
and the key holder may cause
scratches or other damage to the
cover while operating the motorcycle.
(Recommend cloth or leather key
holders)

14

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KEYS HEADLIGHT
This motorcycle has two keys and a key <HEADLIGHT SWITCH> <HEADLIGHT DIMMER SWITCH>
number plate. The headlight switch has three positions; Push the dimmer switch to D (HI) to
You will need the key number if you ever , and OFF marked by a dot to the select high beam or to D (LO) to select
have to replace a lost key. Store the plate below of . low beam.
in a safe place.
: Headlight, taillight, position <PASSING LIGHT CONTROL SWITCH>
light and meter lights on. When this switch is pressed, the headlight
flashes on to signal approaching cars or
: Position light, taillight and when passing.
meter lights on. PASSING LIGHT CONTROL
SWITCH
OFF (dot) : Headlight, taillight, position
light and meter lights off.

KEY NUMBER PLATE


HEADLIGHT SWITCH

NOTE
●Do not drop the keys or set heavy
objects on them. HEADLIGHT DIMMER SWITCH
●Do not grind, drill or in any way alter
the original shape of the keys.
CAUTION
●Keep the keys away from magnetic ●Use the high beam only in the
objects. suburban road or when the usage of
the high beam not hinder the safe
driving of the car ahead.

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STARTER BUTTON WINKER SWITCH HORN BUTTON
The starter button is next to the throttle Move to ⇦(L) to signal a left turn, ⇨(R) Press the button to sound the horn.
grip. to signal a righ turn. Press to turn signal
When the starter button is pressed, the off.
starter motor cranks the engine. See page
24 for the starting procedure.

WINKER SWITCH

HORN BUTTON
STARTER BUTTON
CAUTION
CAUTION ●The winker switch does not auto-
matically turn back to its original
●Do not press starter button repeatedly position after completing the turn.
because it consumes great amount of Please set the switch back to its
power causing battery to be center position after turning.
exhausted sooner.

16

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EQUIPMENT USAGE

STEERING LOCK SEAT


To lock the steering, turn the handlebars <FRONT SEAT> <REAR SEAT>
all the way to the left or right, turn the key To remove the front seat, insert the To remove the rear seat, remove both
to LOCK while pushing in. ignition key into the seat lock. front seat and center cover, remove the
Remove the key. Turn the ignition key counterclockwise, seat mounting bolt, and then pull the seat
To unlock the steering, turn the key to and then pull the seat back and up. front and up.
OFF while pushing in. To install the front seat, insert the tab into To install the seat, insert the tab into the
the recess under the frame and push down recess under the frame and tighten the
KEY on the rear of the seat. mount bolt scurely.
Push in

FRONT SEAT
FRONT SEAT CENTER COVER REAR SEAT
TAB

Turn to LOCK

WARNING
●Do not turn the key to LOCK while
riding the vehicle; loss of vehicle
control will result. KEY MOUNTING BOLT

17

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HELMET HOLDER STORAGE COMPARTMENT
The helmet holder is on the left side below The storage compatment is under the seat.
NOTE
the seat. Insert the ignition key and turn it This owner’s manual and the tool kit
clockwise to unlock. should be stored in the compartment. ●When washing your motorcycle, be
Hang your helmet on the holder pin. Turn Remove the front seat (page 17). careful not to flood this area with
the key counterclockwise to lock the Pull out the center cover while turning the water.
holder and then remove the key. lever to the left. ●This compartment is for light weignt
Reinstall the center cover by aligning its items.
tabs and turning the lever to the right.
HELMET HOLDER

CENTER COVER

KEY
TOOL KIT
HOLDER PIN

WARNING
●The helmet holder is designed for
helmet security while parked. Do not
ride with a helmet attached to the
holder; the helmet may interfere with
safe operation and result in loss of
control.

18

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SELF INSPECTIONS BEFORE OPERATION

Self inspect the motorcycle and have [FRONT BRAKE]


regular maintenance inspections for <BRAKE LEVER FREE PLAY> <FRONT BRAKE FLUID LEVEL>
increased safety and the prevention of Lightly squeeze the brake lever until
accidents. tension is felt to check for an appropriate WARNING
Self inspections before operation should amount of free play. No free play in the
●Brake fluid may cause irritation.
be performed on a daily basis prior to brake lever or overly loose brake lever is
Avoid contact with skin or eyes. In
operating the motorcycle. indication of a problem in the brake
case of contact, flush thoroughly with
system.
water and call a doctor if your eyes
BRAKES were exposed.
BRAKE LEVER FREE PLAY : 10~20mm ●KEEP OUT OF REACH OF CHIL-
Both the front and rear brake are the
DREN
hydraulic disk type.
As the brake pad wear, the brake fluid
level drops. CAUTION
There are no adjustments to perform, but ●When adding brake fluid, be very
fluid level and pad wear must be inspected 10~20mm
careful not to allow foreign materials
periodically. The system must be to enter the reserve tank.
inspected frequently to ensure there are no ●Do not fill past upper level.
fluid leaks. This can cause brake fluid to leak out
If the control lever or pedal free travel of the reserve tank.
becomes excessive and the brake pads are ●Do not let brake fluid contact vehicle
not worn beyond the recommended limit, parts as this damages painted areas.
there is probably air in the brake system If oil contacts parts, quickly clean the
and it must be bled. See your authorized fluid off using a dry cloth.
Daelim dealer for this service. ●Use recommended brake fluid as
other types can undergo chemical
changes.

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Check that the fluid level is above the SCREWS [REAR BRAKE]
LOWER level mark with the motercycle <REAR BRAKE FLUID LEVEL>
in an upright position.
Brake fluid must be added to the reservoir WARNING
MASTER
whenever the fluid level begins to reach CYLINDER ●Brake fluid may cause irritation.
the LOWER level mark. CAP
Avoid contact with skin or eyes. In
DIAPHRAGM case of contact, flush thoroughly with
1. Remove the screws and master cylinder PLATE water and call a doctor if your eyes
cap, diaphragm plate, and diaphragm. were exposed.
2. Fill the reservoir with recommended ●KEEP OUT OF REACH OF CHIL-
brake fluid from a sealed container up UPPER DIAPHRAGM DREN
to the UPPER level mark. LEVEL

RECOMMENDED BRAKE FLUID CAUTION


is DOT3 LOWER ●When adding brake fluid, be very
LEVEL
3. Reinstall the diaphragm, diaphragm careful not to allow foreign materials
plate, and master cylinder cap. to enter the reserve tank.
4. Tighten the screws securely. ●Do not fill past upper level.
This can cause brake fluid to leak out
Other checks : of the reserve tank.
●Make sure there are no fluid leaks. ●Do not let brake fluid contact vehicle
●Check for deterioration or cracks in the parts as this damages painted areas.
hose and fitting. If oil contacts parts, quickly clean the
●Check the brake pad for wear when fluid off using a dry cloth.
refilling with brake fluid. ●Use recommended brake fluid as
other types can undergo chemical
changes.

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TIRES
Check the brake fluid level with the <TIRE PRESSURE CHECK>
motorcycle in an upright position. Check for an appropriate level of air
Brake fluid must be added to the reservoir pressure by examining how the tire sits on
whenever the fluid level begins to reach the ground. If you notice any abnormali-
the LOWER level mark. UPPER LEVEL MARK ties in the shape of the tire with regard to
1. Remove the reservoir cap, reservoir cap the area contacting the ground, use a tire
plate, and diaphragm. UPPER
gauge to check tire pressure and adjust the
2. Fill the reservoir with recommended
LOWER
tire pressure to the appropriate level.
brake fluid from a sealed container up
to the UPPER level mark. <TIRE PRESSURE>

RECOMMENDED BRAKE FLUID is LOWER LEVEL MARK FRONT 110/70-17 54P


SIZE
DOT3 REAR 140/60-17 69P
3. Reinstall the diaphragm, reservoir cap WITH ONE FRONT 2.00
RESERVOIR CAP
TIRE PERSON REAR 2.00
plate and cap securely.
PRESSURE
(kgf/㎠) WITH TWO FRONT 2.00
Other checks : RESERVOIR CAP
PLATE PERSON REAR 2.25
●Make sure there are no fluid leaks.
●Check for deterioration or cracks in the
hose and fitting. DIAPHRAGM
●Check the brake pad for wear when
refilling with brake fluid.
UPPER
LOWER

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<CRACKS/DAMAGE> <FOREIGN MATERIALS>
CAUTION
Check tire tread and sides for cracks and Check tire tread and sides for nails, rocks,
damage. etc. That might have become wedged in ●If air pressure is inadequate or if
the tire. there are cracks, damage or abnormal
CRACKS
wear on tires, it may cause trembling
NAIL
steering wheel and flat tire.
●Insufficient air pressure may cause
the heavy steering wheel marking
handling difficult, fuel over cons-
ROCK umption and the excessive wear of
tire outer area and excessive air
DAMAGE pressure may cause easier wheel
<TREAD DEPTH> handling and lower fuel cons-
●Check the wear indicator (wear limit umption. But it may also cause the
<ABNORMAL WEAR>
marking) to see if there is an excessive wear of tire center area.
Check tire tread for signs of abnormal
insufficient amount of tread remaining. ●This motorcycle is equipped with
wear.
●If the indicators are visible, replace tire tubeless tires. If you have flat tires,
with a new one. please contact authorised main-
tenance shops for inspection.
WEAR INDICATOR
WEAR INDICATOR LOCATION MARKING
ABNORMAL (WEAR LIMIT MARKING)
WEAR

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CLUTCH
Clutch adjustment may be reguired if the <CLUTCH LEVER ADJUSTMENT>
motorcycle stalls when shifting into gear 1. Loosen the lock nut and turn the 4. Start the engine, pull in the clutch lever
or tends to creep; or if the clutch slips, adjuster. Tighten the lock nut and check and shift into gear. Make sure the
causing acceleration to lag behind engine the adjustment. engine does not stall and the motorcycle
speed. 2. If the adjuster is threaded out near its does not creep. Gradually release the
Minor adjustments can be made with the limit or if the correct free play cannot clutch lever and open the throttle.
clutch cable adjuster at the lever. The motorcycle should begin to move
be obtained, loosen the lock nut and
CLUTCH LEVER FREE PLAY:10~20mm turn in the cable adjuster completely. smoothly and accelerate gradually.
Tighten the lock nut.

LOCK NUT ADJUSTER LOCK NUT

Decrease Increase
free play free play

Decrease
free play

Increase
free play

CLUTCH CABLE
ADJUSTER

3. Loosen the lock nut at the lower end of NOTE


the cable. Turn the adjusting nut to ●If proper adjustment cannot be
obtain the specified free play. Tighten obtained or the clutch does not work
the lock nut and check the adjustment. correctly, see your Daelim dealer.

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FUEL
<FUEL COCK> NOTE FILLER NECK

●ON: With the fuel cock in the ON ●Remember to check that the fuel
position, fuel with flow from the main cock is in the ON position each time KEY
fuel supply to the carburetor. you refuel. If the cock is left in the
●OFF: With the fuel cock in the OFF RES position, you may run out of
position, fuel cannot flow from the tank fuel with no reserve.
to the carburetor.
Turn the fuel cock OFF whenever the ON OFF RES
FUEL FILLER CAP
motorcycle is not in use.
RES RES RES

●RES: With the fuel cock in the RES


OFF

OFF

OFF

position, fuel with flow from the ON ON ON

reserve fuel supply to the carburetor. WARNING


Use the reserve fuel only when the
●Gasoline is extremely flammable and
main supply in gone. Refill the tank as <FUEL TANK>
is explosive under certain conditions.
soon as posible after switching to RES.
The fuel tank capacity including the Refuel in a well-ventilated area with
The reserve fuel supply is : 1.1ℓ reserve supply is : 16.0ℓ the engine stopped. Do not smoke or
To open the fuel fill cap; allow flames or sparks in the area
1. Insert the ignition key and turn it where gasoline is stored or where the
WARNING
clockwise. fuel tank is refueled.
●To avoid running out of fuel that may 2. The cap is hinged and will lift up. ●Do not overfill the tank. After
result in a sudden stop, learn how to 3. Do not overfill the tank. There should refueling, make sure the fuel fill cap
operate the fuel cock when riding the be no fuel in the filler neck. is closed securely.
motorcycle. 4. After refueling, to close the fuel fill ●Avoid repeated or prolonged contact
cap, push the cap into the filler neck
with skin or breathing of vapor.
until it snaps closed and locks.
KEEP OUT OF REACH OF CHILDREN.
5. Remove the key.

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ENGINE OIL LIGHTS AND WINKER
<ENGINE OIL LEVEL CHECK> CAUTION <HEADLIGHT, TAILLIGHT>
Start the engine and make sure the lights
Check the engine oil level each day before ●Running the engine with insufficient turn on. Also check to see if the lights are
riding the motorcycle. oil pressure may cause serious engine damaged or if there is dirt on them.
The level must be maintained between the damage.
upper and lower level marks on the oil <BRAKE LIGHT CHECK>
level gauge. Turn the main switch to ON.
1. Start the engine and let it idle for a few OIL LEVEL GAUGE While separately operating the front and
minutes. rear brakes, check to see if the brake light
2. Stop the engine and put the motorcycle turns on. Also check to see if there is any
on its main stand on level ground. damage to the lens or if there is dirt on the
3. After a few minutes, remove the oil brake light.
level gauge, wipe it clean, and reinsert
<WINKER CHECK>
the gauge without screwing it in.
UPPER
UPPER Turn the main switch to ON.
Remove the gauge. The oil level should LEVEL
LEVEL Check to see if all the winker in the front
be between the upper and lower marks
and rear of the vehicle (including left and
on the oil level gauge. LOWER
LOWER right sides) are flashing properly. At the
4. If required, add the specified oil up to LEVEL
LEVEL same time, check to make sure that the
the upper level mark. automatic sound signal of the winker is
Do not overfill. working. Check also to see if any of the
5. Reinstall the oil level gauge. lens are damaged or dirty.
Check for oil leaks.

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OPERATION

BACK MIRROR PRE-RIDE INSPECTION


Sit squarely on the seat and check to see if ●Throttle - check for smooth opening
WARNING
you have a good view behind the vehicle and full closing in all steering positions.
by looking at the back mirrors. Also check ●If the pre-ride inspection is not ●Lights and horn - check that headlight,
for dirt and damage on the back mirrors. performed, severe personal injury or tail/brake light, turn signals, indicators
motorcycle damage may result. and horn function properly.
●Side stand switch ignition cut-off
LICENSE PLATE Inspect your motorcycle every day before system - check for proper function
you ride it. The items listed here will only (page 44).
Check to see if there is any dirt or damage
take a few minutes to inspect, and in the ●Angle rear view mirror.
to the license plate.
Also check to see if the license plate is long run they can save time, expense, and
firmly secured to the vehicle. possibly your life. CAUTION
●Check for signs of abnormality which
●Observe safety rules when conduc-
might have occurred on the previous
ting inspections.
day. ●Conduct inspections on a flat, solid
●Engine oil level - add engine oil if ground with the main stand erected.
required (page 25). Check for leaks.
●Fuel level - fill fuel tank when necessary
(page 24). Check for leaks. If you are unable to correct trouble even
●Front and rear brakes - check operation; after you make adjustment or correction,
make sure that is no brake fluid leakage contact authorized maintenance shops,
(page 19~21). dealers or designated repair shops for
●Tires - check condition and pressure necessary inspection and repairs.
(page 21~22).
●Drive chain - check condition and slack
(page 39~40). Adjust and lubricate if
necessary.

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STARTING THE ENGINE
Always follow the proper starting <PREPARATION> 3. Once engine is started, pull and release
procedure described below. Before starting, insert the key, turn the throttle grip repeatedly to run engine
ignition switch ON and confirm the idle until engine is heated, and close
●This motorcycle is equipped with a side
following: choke lever completely. If engine
stand ignition cut-off system. The
engine cannot be started if the side ●The transmission is in NEUTRAL warming up takes time, run engine idle
stand is down, unless the transmission (neutral indicator light ON) with the choke lever slightly closed.
is in neutral. If the side stand is up, the ●The fuel cock is ON.
engine can be started in neutral or in <WHEN ENGINE IS HOT (SUMMER)>
<WHEN ENGINE IS COLD (WINTER)>
gear with the clutch lever pulled in. 1. Close throttle grip and press starter
1. Pull the chock lever back all the way to
After starting with the side stand down, button. (If engine is not started with 1-2
Fully ON.
the engine will shut off if the times trial, verify fuel cock lever is in
Fully OFF
transmission is put in gear before "ON" position)
raising the side stand. 2. If engine is not started with throttle grip
closed, open throttle grip approximately
WARNING 1/8 to 1/4 and press starter button.
●Never run the engine in an enclosed
area. The exhaust contains poisonous
carbon monoxide gas that can cause
Fully ON
loss of consciousness and lead to
death.
CHOKE LEVER
CAUTION
●Do not keep the starter button
2. Close throttle grip, and press starter
pressed for more than 5 seconds at a
button.
time. Release the starter button for
approximately 10 seconds before
pressing it again.

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IF ENGINE CANNOT BE STARTED RUNNING-IN
●It is possible that starting will be more If engine cannot be started or vehicle does During initial running-in newly machined
difficult if the vehicle has not been used not move, check the followings. surfaces will be in contact with each other
for a long period of time or if the fuel ●Is there fuel in fuel tank? and these surfaces will wear in quickly.
hole is plugged up (starting problems ●Are you operating in accordance with Running-in maintenance at 1,000km is
even when there is sufficient fuel in the the instructions given in user's manual? designed to compensate for this initial
fuel tank may be an indication of a ●Is fuse not cut? minor wear.
plugged fuel hole). ●Is starter motor running? Timely performance of the running-in
When this happens, do not rotate the ●If starter motor is not running due to maintenance will ensure optimum service
throttle grip and try the starter button a battery consumption, try starting motor life and performance from the engine.
few times. by using kick start technique. The general rules as follows:
1. Never labour the engine with full
NOTE
throttle at low engine speeds. This rule
●Do not run engine idle unreasonably. is applicable not only during running-in
This not only wastes fuel but also but at all times.
adversely affects engine. 2. Maximum continuous engine speed
●If starter button is pressed in gear during the first 1,000km must not
position, vehicle may bring out to exceed 5,000 rpm.
fall. Make sure gear is in neutral
position prior to starting engine. CAUTION
●Running the engine beyond recom-
mended maximum engine speed (the
beginning of the tachometer red
zone) can damage the engine.

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RIDING
1. After the engine has been warmed up, <GEAR DOWN OPERATION>
NOTE
the motorcycle is ready for riding. If you gear down when you need to
2. While the engine is idling, pull in the drastically accelerate speed such as when ●Make sure side stand is in original
clutch lever and depress the gearshift you are passing another motorcycle, speed position prior to starting motorcycle.
pedal to shift into 1st (low) gear. can be accelerated. If you ride too fast, it If side stand moves unsatisfactorily,
3. Slowly release the clutch lever and at adversely affects engine because engine check lubrication state on side stand
the same time gradually increase engine revolution is excessive. joint.
speed by opening the throttle. Coor- ●Shift gear adequately according to
dination of the throttle and clutch lever vehicle speed.
will assure a smooth positive start. ●To save fuel and maintain optimum
4. When the motorcycle attains a mode- vehicle life, do not accelerate or
rate speed, close the throttle, pull in the decelerate speed abruptly.
23
clutch lever and shift to 2nd gear by 45 ●Always start in the 1" gear, and start
raising the gearshift pedal. carefully as slow as possible.
This sequence is repeated to progre- ●If you hear abnormal noise during
ssively shift to 3rd, 4th, 5th (top) gear. travel, contact authorized main-
5. Coordinate the throttle and brakes for GEAR CHANGE PEDAL tenance shop immediately for
1 inspection and necessary action.
smooth deceleration.
●Maintain legal speed limits.
6. Both front and rear brakes should be
used at the same time and should not be CAUTION
applied strongly enough to lock the
wheel, or braking effectiveness will be ●Touch pedal lightly with foot and
reduced and control of the motorcycle shift gear perfectly until you hear
be difficult. "Click" at the pedal. If you apply
excessive force when shifting gear,
transmission may be damaged.

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BRAKING PARKING
1. For normal braking, gradually apply <ENGINE BRAKE> 1. After stopping the vehicle, shift the
both the front and rear brakes while If you turn throttle grip in reverse, engine transmission into neutral, turn the fuel
down shifting to suit your road speed. brake functions and, if you need stronger cock OFF, turn the ignition switch OFF
2. For maximum deceleration, close the braking, shift gear down from 4th to 3rd and remove the key.
throttle and apply the front and rear and so forth. When you travel on a long 2. Put the vehicle on main stand and park
brakes firmly. descent or on a sharp descent, use on level ground in places free of traffic.
intermittent braking technique and engine 3. Use the side stand to support the
WARNING brake simultaneously. vehicle while parked.
●If you apply brakes only on front 4. Turn the handlebar fully to the left and
wheel or rear wheel, vehicle may CAUTION lock the steering to help prevent theft.
slide off sideway and fall. ●Do not shift to lower gear while
●If you apply brakes abruptly during traveling at an excessive speed as it CAUTION
travel in rain or on wet road, tires may suddenly increase the engine
slide off and may cause accidents. speed, adversely affect the engine ●Park the vehicle on firm, level ground
Reduce speed and apply brake and transmission, and cause the rear to prevent it from falling over.
cautiously. part of the vehicle to be shaken. ●Park in a safe area that will not block
●Avoid repeated brake operation as it traffic. When you parked the vehicle
may cause brake temperature to rise, after driving, make sure foot the
leading to braking effect deterio- vehicle beyond man's reach because
ration. engine and muffler are still hot.
●If you must park on a slight incline,
●When possible, reduce speed or
aim the front of the vehicle uphill to
brake before entering a turn; closing
reduce the possibility of rolling off the
the throttle or braking in mid-turn
side stand or overturning.
may cause wheel slip. Wheel slip
will reduce control of the motorcycle.

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MAINTENANCE
●The Required Maintenance Schedule specifies how often you should have your motorcycle served, and what things need attention.
It is essential that your motorcycle be served as scheduled to retain its high level of safety, dependability, and emission control
performance.
●These instructions are based on the assumption that the motorcycle will be used exclusively for its designed purpose. Sustained high
speed operation, or operation in unusually wet or dusty conditions, will require more frequent service than specified in the
MAINTENANCE SCHEDULE.
Consult your authorized Daelim dealer for recommendations applicable to your individual needs and use.

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MAINTENANCE SCHEDULE
Perform the Self Inspections Before Operation at each scheduled maintenance period.
I: INSPECT AND, CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY
R: REPLACE L: LUBRICATE C: CLEAN

FREQUENCY ODOMETER READING(NOTE1)


×1,000Km 1 4 8 12 16 REMARK
ITEM
MONTH 1 6 12 18 24
★ FUEL LINE I I I I
★ FUEL FILTER R R R R
★ THROTTLE OPERATION I I I I I
★ CARBURETOR CHOKE I I I I I
AIR CLEANER ELEMENT R R R R NOTE( 2)
SPARK PLUG I R I R
★ VALVE CLEARANCE I I I I
★ CARBURETOR IDLE I I I I I
★ ENGINE OIL R R R R R
★★ ENGINE OIL FILTER R R R R R
DRIVE CHAIN Every 1,000Km : I and L

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FREQUENCY ODOMETER READING(NOTE 1)
×1,000Km 1 4 8 12 16 REMARK
ITEM
MONTH 1 6 12 18 24
★ BRAKE FLUID I I I I R NOTE( 3)
★ BRAKE SHOE / PAD WEAR I I I I I
BRAKE SYSTEM I I I I I
★ BRAKE STOP SWITCH I I I I I
★ HEADLIGHT ADJUSTMENT I I I I I
★ SUSPENSION I I I I
CLUTCH I I I I I
SIDE STAND I I I I
★ BOLTS, NUTS, FASTENERS I I I I I
★★ WHEELS / TIRES I I I I I
★★ STEERING HANDLE BEARING I I I I I

★ If you do not have the appropriate tools or information to conduct maintenance, or if you feel you are not capable to perform
maintenance on this vehicle, contact authorized dealers or repair shops for maintenance and repairs.
★★To ensure safety, inspections and maintenance of these parts must be carried out by dealers, or repair centers.

NOTES : (1) At higher odometer readings, repeat at the frequency interval established here.
(2) Service more frequently when riding in unusually wet or dusty areas.
(3) Replace every 2 years, or at indicated odometer interval, whichever comes first. Replacement requires mechanical skill.

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TOOL KIT FRAME AND ENGINE NUMBERS
The tool kit is under the seat (page 17). ●The frame and engine numbers are ●The frame number is stamped on the
Some roadside repairs, minor adjustments needed when registering your left side of the steering head.
and parts replacement can be performed motorcycle. ●The engine number is stamped on under
with the tools contained in the kit. ●They may also be required by your of the left crankcase.
●No.2 screwdriver dealer when ordering replacement parts.
●Screwdriver grip ●Record the numbers here for your
●16mm Box wrench reference.
●10x12mm Spanner
FRAME NO. ENGINE NO.
●5mm Hex wrench
●Tool bag

TOOL KIT

VJ125E
KH

1000017
Y3A
4A0
000
000
0

ENGINE NUMBER
FRAME NUMBER

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MAINTENANCE PRECAUTIONS THROTTLE OPERATION
The following is an explanation of correct ●Check for smooth rotation of the
CAUTION
inspection methods, cleaning and parts throttle grip from the fully open to the
replacing. Please always refer to this ●Always observe safety rules when fully closed position at both full
section when wanting to inspect or repair performing maintenance on the steering positions.
your motorcycle. vehicle. ●Measure the throttle grip free play at
●Choose a flat surface and make sure the throttle grip flange. The standard
WARNING the main stand is in a secure down
free play should be approx : 2~6mm
position.
●If your motorcycle is overturned or ●To adjust the free play, loosen the lock
●Use correct tools.
involved in a collision, inspect control nut and turn the adjuster.
●Conduct engine maintenance with the
levers, cables, brake hoses, calipers,
engine key out of the ignition.
accessories, and other vital parts for
●Be careful around the engine and
damage. Do not ride the vehicle if
muffler when performing mainte-
damage impairs safe operation. Have
nance as these areas can become
your authorized Daelim dealer inspect
extremely hot.
the major components, including
●After self maintenance, the waste
frame, suspension and steering parts,
material must be packed in the
for misalignment and damage that you
specified container and entrusted
may not be able to detect.
disposal to the authorized disposal LOCK NUT ADJUSTER
●Use new, genuine Daelim parts or their
company.
equivalent for maintenance and repair.
●Exhaust gas contains harmful WARNING
Parts which are not of equivalent
substance such as carbon monoxide.
quality may impair the safety of your ●Operating the motorcycle with an
Do not carry out inspections on
motorcycle and the effective operation inadequate throttle grip free play can
vehicle in closed places, or in poorly
of the emission control systems. be hazardous. Inadequate throttle grip
ventilated places, with engine free play can cause engine speed to
running. rise suddenly when you turn the
handlebars.

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AIR CLEANER
When the element becomes dirty, there 1. Remove the front seat (page 17)
will be greater intake resistance, resulting 2. Remove the air cleaner case cover by
in decreased power output and increased removing the screws.
fuel consumption.
3. Remove the air cleaner inner pipe, and AIR CLEANER
The air cleaner should be serviced at
remove the air cleaner element. CASE COVER
regular intervals (page 32).
Service more frequently when riding in 4. Replace the air cleaner element if it is
dusty areas. excessively dirty, torn or damage. AIR CLEANER
INNER PIPE
5. Install the air cleaner.
CAUTION 6. Install the removed parts in reverse
order of removal.
●Do not operate the engine without the AIR CLEANER
ELEMENT
air cleaner element in place or severe
engine damage may result.
●If you usually ride in dusty areas or
regularly operate in vehicle in wet, CAUTION
muddy conditions, you must inspect
the air cleaner element more fre- ●If air cleaner element is inadequately
quently than shown in the main- assembled, dust and other waste
tenance schedule. materials are absorbed directly
●If, at any time, the air cleaner inducing cylinder wear and output
element is submerged in water, deterioration, and adversely affecting
immediately clean the element and engine durability. Assemble correctly.
the inside of the air cleaner cover.

AIR CLEANER
CASE COVER

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ENGINE OIL
If engine oil is polluted, it seriously <RECOMMENDED OIL>
WARNING
affects the engine life span. Maintain If oil sold on markets or privately-
appropriate level of oil, use correct type of ●Be sure to keep oil away from children manufactured oil (low-grade) is used,
oil and observe oil exchange period. and pets. Dispose of used oil properly engine life is adversely affected, and the
●Stand vehicle on the main stand on privilege of warranty repairs cannot be
level ground and run engine idle (warm OIL LEVEL GAUGE guaranteed.
up) for approximately 2-3 minutes. GRADE (SE, SF, SH)
●Stop engine and place a container under
the engine. Remove oil level gauge and CAUTION
oil drain bolt, and drain the oil.
●Tighten the oil drain bolt. ●If you change engine oil immediately
after engine is stopped, be careful of
·m
DRAIN BOLT TORQUE: 2.5kgf·
UPPER
UPPER burns because the engine, muffler
LEVEL
LEVEL
●Fill the crankcase with the recom- and engine oil are still hot.
mended grade oil. ●Exercise caution not to allow dust or
LOWER
LOWER
OIL CAPACITY : LEVEL
LEVEL other foreign matter to flow in when
-FULL : 1.1ℓ refilling engine oil.
-EXCHANGE: 1.0ℓ ●If oil level is lower or higher than
OIL FILTER SCREEN SPRING
-FILTER EXCHANGE: 1.05ℓ prescribed level, engine is adversely
affected.
●Start the engine and keep it idle for a
●Do not mix oil with those of different
few minutes.
●Stop the engine and check the oil level. manufacturers or grade, or do not use
If the oil level is low, add the recom-
VJ125E
1000017 low-quality oil as it may cause
mended engine oil. deterioration of oil, leading to
●Check on oil leaks. accidents.

OIL FILTER SCREEN OIL DRAIN BOLT

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SPARK PLUG
If electrode is stained or plug gap is not 4. Inspect the electrode and center 7. Tighten the spark plug 1/2 turn with a
right, satisfactory spark is not produced. porcelain for deposits, erosion or cabon spark plug wrench to compress the
fouling. If the erosion or deposit is washer.
Recommended plug :
heavy, replace the plug. Clean a carbon 8. Reinstall the spark plug cap and the
-Standard : CR8EH-9
or wet-fouled plug with a plug cleaner, spark plug cover.
-For cold climate : CR7EH-9
otherwise use a wire brush.
1. Remove the spark plug cover to remove 5. Check the spark plug gap using a wire-
CAUTION
the spark plug. type feeler gauge. If adjustment is
2. Disconnect the spark plug cap from the necessary, bend the side electrode ●If plug of different maker or different
spark plug. carefully. heat value is used, it causes
3. Clean any dirt from around the spark The gap should be : 0.8~0.9mm unsatisfactory engine starting,
plug base. inadequate engine revolution and
Remove the spark plug using the spark output deterioration.
plug wrench furnished in the tool kit. SIDE ELECTRODE
●The spark plug must be securely
SPARK PLUG GAP tightened. An improperly tightened
SPARK PLUG WRENCH
plug can become very hot and
possibly damage the engine.
●To install a spark plug, turn it in as
far as possible with your fingers, then
tighten it with a wrench.
Do not overtighten or cross thread
the spark plug or the aluminum
threads of the cylinder head will be
6. With the plug washer attached, thread damaged. Do not allow contaminants
the spark plug in by hand to prevent to enter the engine through the spark
cross-threading. plug hole when the plug is removed.

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DRIVE CHAIN
●The service life of drive chain is <INSPECTION>
dependent upon proper lubrication and 1. Turn the engine off, put motorcycle in 4. Rotate the rear wheel slowly and
adjustment. Poor maintenance can upright position on the main stand and inspect the drive chain and sprockets
cause premature wear or damage to the shift the transmission into neutral. for any of the following conditions:
drive chain and sprocket. 2. Check slack in the lower drive chain
■ DRIVE CHAIN
●The drive chain should be checked and run midway between the sprockets.
① Damaged rollers
lubricated as part of the Pre-ride Drive chain slack should be adjusted to
② Loose Pins
Inspection. allow the following vertical movement
③ Dry or Rusted Link
●Under severe usage, or when the by hand: 10~20mm
3. Roll the motorcycle forward. Stop ④ Kinked or Binding Link
vehicle is ridden in unusually dusty or ⑤ Excessive Wear
muddy areas, more frequent main- check drive chain slack. Repeat this
procedure several times. Drive chain ⑥ Improper Adjustment
tenance will be necessary. ⑦ Missing O-ring
slack should remain constant. If the
chain is slack only in certain sections, ■ SPROCKETS
WARNING some links are kinked and binding, ⑧ Excessively Worn Teeth
●For your safety, drive chain condition Binding and kinking can frequently be ⑨ Broken or Damaged Teeth
and adjustment should be checked eliminated by lubrication.
prior to each use of the vehicle. ●A drive chain with damaged rollers,
Always follow the manufacturer’s 10~20mm loose pins or missing O-ring must be
recommendations for proper lubri- replaced.
cation and replacement of the chain. ●A chain which appears dry or shows
signs of rust, requires supplementary
lubrication.

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<ADJUSTMENT> ADJUSTING NUT CAUTION
●Drive chain slack should be checked
and adjusted, if necessary, every ●Excessive chain slack could cause
1,000km. the chain to come off the sprockets,
●When operated at sustained high speeds resulting in loss of control or serious
or under conditions of frequent rapid engine damage.
acceleration, the chain may requir more ●Make sure the right and left chain
frequent adjustment. adjuster graduations are set in the
same position.
1. Place the motorcycle on its main stand
with the transmission in neutral and the
LOCK NUT AXLE NUT <LUBRICATION AND CLEANING>
ignition switch off.
Lubricate every 1,000km or sooner if
2. Loose the axle nut.
5. Tighten the axle nut to specified torque. chain appears dry.
3. Loose the lock nuts on both sides of the
The O-rings in this chain can be damaged
swingarm. AXLE NUT TORQUE : 6.0~8.0kgf.m by steam cleaning, high pressure washers,
4. Turn both adjusting nuts an equal
6. Tighten the adjusting nuts lightly, then and certain solvents. Clean the side
number of turns until the correct drive
tighten the lock nuts by holding the surfaces of the chain with a dry cloth. Do
chain slack is obtained. Turn the
adjusting nuts with a spanner. not brush the rubber O-rings. Brushing
adjusting nuts clockwise to tighten the
will damage them.
chain or counterclockwise to provide 7. Recheck drive chain slack.
Wipe dry and lubricate only with SAE 80
more slack. Adjust the chain slack at a
or 90 gear oil. Commercial chain
point midway between the drive WARNING lubricants may contain solvents which
sprocket and the rear wheel sprocket.
●If a torque wrench is not used for this could damage the rubber O-rings.
Rotate the rear wheel and recheck slack
installation, see your authorized dealer
at other section of the chain.
as soon as possible to verify proper
Chain slack should be : 10~20mm
assembly.

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WHEEL REMOVAL
[FRONT WHEEL REMOVAL] INSTALLATION NOTES:
NOTE
1. Raise the front wheel off the ground by ●Position the front wheel between the
placing a support block under the ●Do not depress the brake lever when fork legs and insert the axle from the
engine. the wheel is off the motorcycle. right side, through the left fork leg and
2. Loose the oval screw and remove the The caliper piston will be forced out wheel hub.
of the cylinder with subsequent loss
speedometer cable.
of brake fluid. If this occurs,
3. Remove the front caliper assembly CAUTION
servicing of the brake system will be
from the fork by removing the fixing
necussary. See your authorized ●When installing the wheel, carefully
bolts.
Daelim dealer for this service. fit the left brake disk between the
4. Loosen the axle nut.
brake pads to avoid damaging the
5. Withdraw the front wheel axle, side pads.
BRAKE CALIPER
collar and remove the front wheel.
AXLE NUT FIXING BOLTS ●Prior to assembling, align the projected
ASSEMBLY
FRONT WHEEL AXLE part( ) of the speedometer gear box
with the projected part of the left front
fork.

PROJECTED PART

OVAL SCREW SPEEDOMETER


CABLE

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●Tighten the front axle nut to the [REAR WHEEL REMOVAL] 5. Remove the axle shaft, side collars and
specified torque. 1. Place the motorcycle on its main stand rear wheel from the swing arm.
in upright position on level ground.
FRONT AXLE NUT TORQUE :
2. Loosen the drive chain adjusting nut
5.0~7.0kgf.m
lock nuts and adjusting nuts.
●Fit the caliper over the disk, taking care 3. Remove the rear axle nut.
not to damage the brake pads. Install 4. Remove the drive chain from the driven
the caliper fixing bolts, and tighten to a sprocket by pushing the rear wheel
torque of : 2.7kgf.m forward.
●Install the speedometer cable and
tighten the oval screw. ADJUSTING NUT

●After installing the wheel, apply the


brake several times and then check if DRIVE CHAIN AXLE SHAFT
the wheel rotates freely. Recheck the
wheel if the brake drags or if the wheel NOTE
does not rotate freely. ●Do not depress the brake pedal while
the wheel is off the motorcycle.
WARNING The caliper pistons will be forced out
of the cylinders with subsequent loss
●If torque wrench was not used for of brake fluid. If this occurs,
installation, see you authorized dealer LOCK NUT AXLE NUT servicing of the brake system will be
as soon as possible to verify proper nececcary. See your authorized
assembly. Improper assembly may lead Daelim dealer for this service.
to loss of braking capacity.

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BRAKE PAD WEAR
INSTALLATION NOTES: Brake pad wear depends upon the severity <FRONT BRAKE>
●To install the rear wheel, reverse the of usage, the type of riding, and road
removal procedure. conditions. (Generally, the pads will wear
faster on wet and dirty roads.)
●Tighten the axle nut to the specified
torque. Inspect the pads at each regular
maintenance interval. (page 33)
REAR AXLE NUT TORQUE : 6.0~8.0kgf.m
●Adjust the drive chain. (page 39) [FRONT/REAR BRAKE]
CAUTION ●Check the cutout in each pad.
●If either pad is worn to the cutout,
●When installing the wheel, carefully replace both pads as a set.
fit the left brake disk between the ●See your authorized Daelim dealer for CUTOUTS
brake pads to avoid damaging the this service.
pads. <REAR BRAKE>
●After installing the wheel, apply the
brake several times and then check if
the wheel rotates freely. Recheck the
wheel if the brake drags or if the wheel
does not rotate freely.

WARNING
●If torque wrench was not used for
installation, see you authorized dealer
as soon as possible to verify proper
assembly. Improper assembly may lead CUTOUTS
to loss of braking capacity.

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IDLE SPEED SIDE STAND
The engine must be at normal operating ●Erect main stand and place motorcycle
temperature for accurate idle speed in upright position on level ground.
adjustment. Ten minutes of stop-and-go ●Check the spring for damage or loss of
riding is sufficient. tension and the side stand assembly for
1. Warm up the engine, shift to neutral freedom of movement.
and place the motorcycle on its stand. ●Check the side stand ignition cut-off
2. Adjust idle speed with the throttle stop system;
screw. ① Put the side stand up.
② Start the engine.
IDLE SPEED (IN NEUTRAL) : ③ Lower the side stand. The engine
±100 min-1 (rpm)
1,600± should stop as you put the side stand
down.
●If the side stand system does not
THROTTLE STOP SCREW
CAUTION operate as described, inspect it in the
closest authorized repair center.
●Make sure that the engine is fully
warmed up before adjusting the idle
speed. Improper adjustment can
result in increased engine wear.

SIDE STAND SWITCH SIDE STAND SPRING

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BATTERY
It is not necessary to check the battery NEGATIVE(-) BATTERY
WARNING TERMINAL LEAD
electrolyte level or add distilled water as
the battery is a maintenance-free (sealed) ●Battery acid is poisonous and
type. If your battery seems weak and/or is corrosive. Avoid contact with eyes,
leaking electrolyte (causing hard starting skin, clothing, and painted surfaces.
or other electrical troubles), contact your If battery acid comes in contact with
authorized Daelim dealer. any of these, flush immediately with
large amounts of water.
CAUTION If acid contacts the eyes or skin, get
medical attention.
●Removing the battery cap strip can ●KEEP OUT OF REACH OF CHILDREN. BATTERY BAND POSITIVE(+)
damage the cap strip and result in leaks ●Even though the battery is sealed, it TERMINAL LEAD
and eventual battery damage. still vents explosive gases.
●When the vehicle is to be stored for an Do not allow open flames or sparks CAUTION
extended period of time, remove the near the battery.
●Make sure that terminals do not contact
battery from the vehicle and charge it
with other adjacent parts when handling
fully. Then store it in a cool, dry place. If
/ terminals.
the battery is to be left in the vehicle,
disconnect the negative cable from the <BATTERY REMOVAL>
battery terminal. 1. Turn the ignition switch OFF. <CLEANING BATTERY TERMINALS>
2. Remove the front seat (page 17). ●If the battery terminal is polluted, or in
3. Remove the battery band. rust, separate battery and clean it.
WARNING
4. Disconnect the negative terminal lead ●Battery terminal in rust with white
●The battery gives off explosive gases; from the battery first, then disconnect the powder should be cleaned with warm
keep sparks, flames, and cigarettes positive terminal lead. water. In case of serious rust of battery
away. Provide adequate ventilation 5. Pull out the battery from the battery box. terminal, disassemble the battery cord and
when charging or using the battery in grind it with wirebrush or sandpaper.
an enclosed space.

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FUSE REPLACEMENT
Turn off the main switch to see if the fuse is BATTERY
CAUTION
severed. If the fuse is severed, exchange the
fuse into 15A fuse. ●Turn the ignition switch OFF before
●Fuse is installed inside fuse holder located checking or replacing fuse to prevent
near battery. accidental short-circuiting.
●To separate fuse, open fuse holder, hold ●When disassemble fuse, make sure that
both ends of fuse cord and pull up, and fuse holder isn't separated.
pull out the fuse connector crosswise. ●After assembling fuse in the part of
●If the fuse immediately becomes severed connector, check if fuse moves easily
after being changed with the new one, FUSE HOLDER to a line. If fuse moves easily, it may
check another problem of the electric cause an accident at heating.
system. ●When replacing any of the electrical
<DISASSEMBLY> <ASSEMBLY> parts (lights and gauges), be sure to
WARNING replace them with the recommended
●Never use a fuse with a different rating parts. Using different parts can lead to
from that specified. Serious damage to the fuses burning out or damage to the
the electrical system or a fire may battery.
result, causing a dangerous loss of CORD
●When washing the vehicle take special
lights or engine power. card not to allow to be splashed in the
area of the fuse.
FUSE CONNECTOR

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BULB REPLACEMENT
●Be sure to turn the ignition switch OFF [HEADLIGHT BULB] [POSITION LIGHT BULB]
when replacing the bulb. ●Before replacing the bulb, be sure to 1. Pull the position light socket and
●Do not use bulbs other than that check the switches for loose connection remove it.
specified. of the connector. 2. Pull out the bulb without turning
●After installing a new bulb, check that 3. Install a new bulb in the reverse order
1. Loosen the washer screws and remove
the light operates properly. of removal.
the headlight.
2. Pull off the socket without turning. POSITION LIGHT BULB : 12V 5W
WARNING 3. Loosen the pin and remove the bulb.
●The light bulb becomes very hot while 4. Install a new bulb in the reverse order
the light is ON, and remain hot for a of removal.
while after it is turned OFF. Be sure to
HEADLIGHT BULB : 12V 35/35W
let it cool down before servicing.

SOCKET
CAUTION SCREW
BULB
●Do not put finger prints on the
headlight bulb, as they may create
hot spots on the bulb and cause it to
break. Wear clean gloves while BULB POSITION LIGHT SOCKET
replacing the bulb.
If you touch the bulb with your bare WIRE

hands, clean it with a cloth moistened


with alcohol to prevent its early
SCREW
failure.
HEADLIGHT UNIT

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[STOP/TAILLIGHT BULB] [WINKER BULB]
1. Loosen the screws and remove the <Front winker bulb> <Rear winker bulb>
taillight lens. 1. Loosen the screw and remove the 1. Loosen the screw and remove the
2. Slightly press down on the bulb and winker lens. winker lens.
turn it counterclockwise. 2. Slightly press down on the bulb and 2. Slightly press down on the bulb and
3. Install a new bulb in the reverse order turn it counterclockwise. turn it counterclockwise.
of removal. 3. Install a new bulb in the reverse order 3. Install a new bulb in the reverse order
of removal. of removal.
STOP/TAILLIGHT BULB : 12V 21/5W
FRONT WINKER BULB : 12V10Wx2 REAR WINKER BULB : 12V10Wx2
TAILLIGHT LENS

SCREWS

SCREW
SCREW BULB WINKER LENS
BULB
WINKER LENS

TAIL & STOP BULB

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CABLE RUBBER PART CLEANING
A rubber part is assembled on the cable to Clean your motorcycle regularly to protect
protect the inner cable. the surface finishes and inspect for
Make sure that this part is placed firmly damage, wear, and oil, coolant or brake
around the correct part of the cable. fluid leakage.
When washing the car, do not directly
spray water on to the rubber part is dirty,
use a dry cloth to clean this area. CAUTION
●Make sure to stop the engine prior to car
washing.
1. After cleaning, rinse the motorcycle
●High pressure water (or air) can damage
thoroughly with plenty of clean water.
certain parts of the motorcycle.
Strong detergent residue can corrode
●Be careful not to allow water to enter the alloy parts.
INSPECTION PART RUBBER INSPECTION PART muffler during the washing. Water inside 2. Dry the motorcycle, start the engine,
the muffler may cause an improper and let it run for several minutes.
engine starting or rust occurrence. 3. Test the brakes before riding the
●Do not let water get inside the braking motorcycle. Several applications may
system during the washing, as water be necessary to restore normal braking
inside the brake system may weaken the performance.
CAUTION braking power. Upon completion of 4. Lubricate the drive chain immediately
washing, select a safe place where there after washing and drying the
●Infiltration of the foreign materials or is no traffic obstruction, and start the motorcycle.
water caused by damage of lever
vehicle.
(disengagement, tearing, etc.) may WARNING
Lightly apply the brake while driving at a
cause freezing in winter season
slow speed and check the braking power. ●Braking efficiency may be temporarily
resulting in faulty operation, sudden
accelation and braking force decrease. If the braking power has been weakened, impaired immediately after washing
If any damage is found, replace with apply brake lightly while driving at a the vehicle. Anticipate longer stopping
the new on immediately. slow speed to dry up the brake system. distance to avoid a possible accident.

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STORAGE GUIDE
Extended storage, such as for winter, CAUTION <REMOVAL FROM STORAGE>
requires that you take certain steps to reduce 1. Uncover and clean the motorcycle.
the effects of deterioration from non-use of ●Gasoline is extremely flammable and 2. Change the engine oil if more than 4
the motorcycle. is explosive under certain conditions. months have passed since the start of
In addition, necessary repairs should be Perform this operation in a well- storage.
made BEFORE storing the motorcycle; ventilated area with the engine 3. Charge the battery as required. Install the
otherwise, these repairs may be forgotten by stopped. Do not smoke or allow battery.
the time the motorcycle is removed from flames or sparks in the area where 4. Perform all Self Inspections Before
storage. gasoline is drained or stored and Operation checks (page 19).
where the fuel tank is refueled. Test ride the motorcycle at low speeds in
<STORAGE> a safe riding area away from traffic.
1. Change the engine oil and filter. 4. Remove the battery. Store in an area
2. Empty the fuel tank into an approved protected from freezing temperatures and
gasoline container using a commercially direct sunlight. Slow charge the battery
available hand siphon or an equivalent once a month.
method. 5. Wash and dry the motorcycle. Wax all
3. If storage will last more than one month, painted surfaces.
carburetor draining is very important, to 6. Inflate the tires to their recommended
assure proper performance after storage. pressures. Place the motorcycle on
blocks to raise both tires off the ground.
7. Cover the motorcycle (don't use plastic
or other coated materials) and store in an
unheated area, free of dampness with a
minimum of daily temperature variation.
Do not store the motorcycle in direct
sunlight.

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SAFE DRIVING
PREPARATION BEFORE DRIVING
● Performing daily inspection
● Putting on the protective gears (Helmet, glove, goggles, etc.)
● Bringing the driver's licence
● Determinating the path to the desired destination

ING
FO RM PR FU
Y OT EL
PER DAIL ION GE ECT ,
EC T
P AR IV
INS S E
R'S
IVE
DR ENCE
LIC

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DRIVING METHOD
DRIVING POSITION
The appropriate driving position is most important thing to
driving safely.
① Eyes : Look at the front direction widely.
② Shoulders : Relieve the tension.
③ Arms : Relieve the tension and bend arms to inside and let
them act as the spring.
④ Hands : Grip the handle the position away from the inside
end of the handle with distance of one finger to
facilitate the operation of the switch and lever.
⑤ Wrist : Keep the state to act freely without applying excessive
force to the shoulder and arms.
⑥ Knees : Press the fuel tank slightly.
⑦ Feet : Place the feet to face the front parallel and make the
step bar be placed in the center of feet.

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PRECAUTION WHEN DRIVING
● Secure the safe distance. ● If any abnormality is found, stop driving and contact service
● Drive protectively. center to inspect the vehicle.
● Do not obstruct the traffic. ● Restart the vehicle after 2~3 min when it is turned over.
● Do not drive on the pedestrian way or walkway. ● Always turn on the headlight at night.
● Drive on the left driveway when passing away.
● Make sure that you can apply the brake anytime.
● Always apply the brake when stopping temporarily.
● Do not drive excessively long distance and take enough
break.

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STARTING
Prior to starting always look around to avoid accident.
① Get on the vehicle after pulling back the stand.
② Start driving slowly after turning on the winker and
releasing the brake while ensuring the safety around the
vehicle.

CAUTION
●Return the side stand to its original position. Keep
driving without doing this may cause turnover accident.
●Drive the vehicle only on the driveway. Driving on the
walkway can cause accident. Also, if the wheel is
transformed when advancing directly to the walkway, the
vehicle can be overturned resulting in injury of the driver
due to the driving unstability.
●Overspeed driving on the unpaved road can cause the
vehicle to be overturned resulting in injury of the driver
due to the driving unstability.
●Do not drive in the gravel road. If any gravel enters the
wheel or engine case, the vehicle can be overturned
resulting in injury of the driver.
●If possible, do not drive close to the sea or on the road
where calcium chloride is treated.
The muffler, external parts and welded parts can be
corroded rapidly, and also in case of damage of the frame,
the vehicle can be overturned resulting in injury of the
driver.

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TURNING METHOD
PRINCIPLE OF TURN EFFECT OF SPEED

CENTRIFUGAL
FORCE
GRAVITY

The basic principle of turn is balancing using the centrifugal The centrifugal force increases in inverse portion to the radius
force which makes vehicle go outside and the gravity which of a curve and in portion to the square speed. Decelerate prior
makes vehicle fall inside. to entering the curved way to reduce the centrifugal force.

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3 POSITIONS OF TURNING
The basic principle of turn is balancing using combined force of < LEAN-IN >
the centrifugal force and the gravity. This is a turning position with driver leaned inside more than
All 3 positions require straightening the head and keeping the motorcycle. This position is adequate to drive on the rained or
eyes horizontally. slippy road because it has best road holding.
However, special attention is required because front visual field
< LEAN-WITH >
is poor when driver leans inside more than motorcycle.
This is a turning position with motorcycle and driver in a line.
This position is the most natural and exact, so driver must learn
it thoroughly.

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TURNING METHOD
< LEAN-OUT >
This is a turning position with motorcycle leaned inside
more than driver, which is opposite to the lean-in position.
With this position, quick turn is well performed and driver can
obtain wide front visual field adequate to drive on the rained or
slippy road because it has best road holding. However, special
attention is required because there is danger of slipping on the
bad holding road.

① Turn the throttle grip to its original position and decelerate


using both front and rear brakes.
② Lean the vehicle toward inside of turn circle while driving
slowly at constant speed.
③ Accelerate gradually.

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PRECAUTION WHEN TURNING
Do not drive inside of large truck's turn circle.

< DEAD ANGLE ZONE > < DISTANCE BETWEEN THE FRONT AND REAR WHEEL TURN >
Dead angle zone is the sight range which cannot be identified by It is distance between path of the front and rear wheel and
driver and increases in proportion to the width of the vehicle. increases in proportion to the length of the vehicle.

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BRAKING METHOD
BASIC PRINCIPLE OF BRAKE (FRICTION FORCE) RESTRAINT OF BRAKE EFFECT (INERTIA)
● Vehicle is braked using friction between road surface and
tires.
● Braking distance increases 1.5 times on wet road and 3
times on icy road because friction force of road surface is
decreased.

NEW TIRE

NEW TIRE IN A
RAINY DAY

Due to the inertia, vehicle does not stop immediately after


EXISTING applying the brake.
TIRE IN A
RAINY DAY

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BRAKING METHOD IMPACT WHEN COLLISION
● Turn the throttle grip to its original position and decelerate Learn the proper braking method to prevent accident.
using the engine brake.
● Erect the vehicle straight.
● Brake using both front and rear brakes.

COMPARISION OF BRAKING DISTANCE


·Vehicle speed : 50 km/h

When using both front and rear brakes

When using only front brake Impact increases in proportion to the speed and weight. The
impact when collision to concrete wall at 50 km/h is same
as one when falling from the height of 10m.

When using only rear brake

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WIRING DIAGRAM

LIGHT/START SW. FR.STOP SW. COMB. SW. FUEL UNIT WINKER RELAY HORN
RH. FR WINKER Sb Sb
12V 10W G
BATTERY
BAT3

BAT1
BAT2
ST.
HL

M 12V 10AH
TL START-MAG.S/W

R
G/Y
Y/R
Br/L

ILLUM, LAMP
FUEL METER

Y/R

Br

G
V

G/Y
Br/W RR STOP SW.
B
(ENGINE)

R
B
12V 1.7W L/W
L / Y/ G
W W
Y/W

R
G B Gr Lg G FUSE 15A
Br/L
Y/R

G/Y

B/W
Y/R
Br
V

B 2P
B

3P
MINI

B
(ENGINE)
B 6P
TACHOMETER

MINI 2P MINI

G L / Y/
R
B

W WG
G/Y
Br/L
Y/R

B/Y
B
Br

G/Y
B
V

R
ILLUM, LAMP G
Br/W B/W B/W

3P MINI
12V 1.7W G/W G/W IGNITION CONTROL UNIT
Lg/R Lg/R
HIGH BEAM
SPEEDOMETER

G G G
12V 3W L
Br/W Br
ILLUM, LAMP G L/W L/W
Br/W
G
12V 3.4W or 3W Y/W
9P
MINI
Y/W

B B B Sb Sb
NETURAL Lg/R
B/Y B/Y

12V 3W Sb Sb
RH. RR WINKER
12V 10W
TURN RH.
INDICATOR

L L
G
LAMP

Sb
12V 3W Lg/R Lg/R
2P MINI

G Br Br/W

3P MINI
TURN LH. O O O G/Y G/Y
G G
12V 3W
STOP & TAIL LIGHT
SIDE 12V 21/5W
STAND
SWITCH

G
G B/W G
G
O O

HEAD LIGHT L L 2P MINI

W W LH. RR WINKER
12V 35/35W G G
G B/W

12V 10W
B R V P

POSITION LIGHT G
Gr Gr
Br G B L W B L/Y
12V 5W / / / /
Y Y Y G
G/W

B G /
W/L

B B W W P Y L Y
LG LG
4P
2P MINI
SB 9P SB
MINI
O O
G/W

Y Y Y L/Y
W/L

Br/W Br/L LIGHT RELAY G

G DC CDI UNIT
G
L. FR WINKER G
L L

O O W W
12V 10W
G

Y Y Y G B R
B/Y
G

3
6P
W Br/W B L SB O Gr LG B

PULSE GEN.
A.C.G REG.RECTI.
LO
BAT3 BODY EARTH
HI R L W HO BAT2
BAT 2
IGN. COIL
WINKER,DIMMER,PASSING,HORN S/W. GEAR POSITION

B BLACK V VIOLET

COMB. SW. START HAZARD WINKER HORN DIMMER PASSING SIDE STAND SW. START LIGHTING Y YELLOW Br BROWN
BAT1 BAT2 ST BAT2 W R L W R L Ho BAT2 BAT 3 Hi Lo BAT 2 BAT2 Hi E CDI ST1 BAT2 BAT3 TL HL
L BLUE O ORANGE
G GREEN Sb SKY BLUE
ON FREE OFF R FREE Hi Hi FREE FREE OFF
R RED Lg LIGHT GREEN
OFF PUSH HAZ N PUSH (N) STAND PUSH P
W WHITE P PINK
LOCK COLOR Y/R B COLOR Gr Sb O L COLOR Lg B Lo COLOR Y/R B H
Gr GRAY
COLOR R B COLOR Gr Sb O COLOR B/W L W B COLOR B L COLOR G B/W COLOR V Br Br/L
COLOR COMB : GROUND/MARKING

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MEMO :

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MEMO :

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OWNER’S MANUAL

11. 2003 PRINTED NO COPY


11. 2003 PUBLICATION

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