Daelim Roadwin VJ 125 Factory Service Manual, 2004–2007 (P/N SM48-0401-01E)

This Daelim factory service manual covers the Roadwin VJ125 (2004–2007). Daelim published this edition in January 2004 under P/N SM48-0401-01E.

Text Search and Diagram Readability

Search and viewing: The service chapters have searchable text. The PDF has a contents page and no embedded bookmarks. Zoom in on the main wiring diagram to read the small connector labels and wire color codes.

The ZIP download contains one printable PDF with 251 pages and 21 chapters. The page count includes the original cover spread, the publication page, 15 memo pages, and one blank page.

Engine, Chassis, and Electrical Service

These selected topics show the range of work covered. The manual also includes headlight aiming and replacement of the seat, body panels, fenders, rear mudguard, and exhaust components.

• Maintenance and lubrication: Follow the factory service schedule for valve clearance, spark plug, compression, and drive chain checks. The lubrication chapter covers oil changes, filter replacement, and oil pump inspection.

• Fuel and oil cooling: Find fuel tank and air cleaner removal, carburetor overhaul and adjustment, and service for the oil radiator and its hoses.

• Engine and drivetrain: Covers engine removal and installation, clutch and gearshift service, AC generator and starter clutch work, and overhaul of the cylinder head, cylinder, piston, transmission, and crankshaft.

• Wheels, suspension, and brakes: Covers wheel bearings and speedometer drive service, fork and steering stem overhaul, rear shock and swingarm work, and hydraulic brake bleeding and repair.

• Electrical diagnosis: Covers charging, DC-CDI ignition, electric starting, lighting, meters, switches, and fuel sender tests. Circuit diagrams and fault charts support the checks.

• Workshop references: Component torque tables, clearances, fluid capacities, wear limits, and electrical test specifications accompany exploded views, harness routing drawings, and a special-tool index.

The manual suits technicians who already use measuring tools and circuit testers. Experienced owners can use the maintenance chapter for scheduled checks and adjustments.

Carburetor and Oil Radiator

The fuel chapter identifies the PD24 carburetor by its VJ125 C setting-series mark. It covers jet and passage cleaning, float and float valve inspection, accelerator pump checks, and pilot screw adjustment. Forcing the pilot screw against its seat can damage the seat.

The cooling chapter covers the air-cooled engine’s oil radiator. It shows radiator removal and installation, identifies the oil-through bolts, and covers inspection of the core, hoses, and clamps.

In-Frame Service and Engine Removal

The oil pump, carburetor, oil radiator, clutch, gearshift spindle, AC generator, and starter clutch can be serviced with the engine in the frame. The camshaft and rocker arms can also be serviced in place. Cylinder head removal, cylinder and piston work, and internal transmission and crankshaft service require engine removal. The manual calls for secure support of the motorcycle and engine during removal.

Cylinder head procedures cover valve guides, seat reconditioning, cam timing, and cam chain tensioner installation. Turning a valve too quickly during assembly can damage its stem seal. The cylinder and crankcase chapters include piston ring and small-end checks, crankcase separation, shift fork and shaft inspection, crankshaft measurement, bearing replacement, and reassembly. The wet multiplate clutch section covers the discs, plates, springs, lifter, primary drive gear, and right crankcase cover.

Wheels, Suspension, and Hydraulic Brakes

Chassis procedures cover handlebar controls, fork bushings and seals, steering bearing races, the rear driven flange and damper rubbers, and swingarm bushings. The brake chapter covers fluid replacement and bleeding, pad and disc inspection, front and rear master cylinder and caliper overhaul, piston and seal checks, and brake pedal service.

Ignition, Charging, and Starting Faults

The hard-start chart separates fuel delivery, spark, and cylinder compression checks so you can narrow down the fault before disassembly. Electrical procedures cover battery current leakage, regulator/rectifier checks, pulse generator and ignition coil measurements, ignition timing, side stand interlock tests, and starter motor and magnetic switch service. The lighting and meter chapter includes switch continuity and fuel sender resistance tests. Separate fault charts cover loss of power, poor low- or high-speed operation, handling and suspension complaints, and erratic fuel gauge readings.

Carburetor Setting and Clutch Wear Examples

The PD24 float level is specified at 12.5 mm with the carburetor tilted so the float arm contacts the float valve.

The clutch inspection table gives a standard friction disc thickness of 2.9–3.0 mm and a service limit of 2.6 mm for evaluating disc wear.