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14-4

BRAKE SYSTEM

LOCK PLATE

FRONT CALIPER

SETTING

BOLTS

HANGER PIN

LOCK PLATE

BRAKE PAD

REPLACEMENT

FRONT BRAKE PAD

NOTE

·When replacing brake pads, replace whole set.

·Do not remove the brake hose when replacing brake

pads.

● Open the lock plate tangs, and loosen the hanger pin.

● Loosen the 2 front brake caliper setting bolts from the

front fork.

● Remove the front caliper from the RH. front fork.

● To install a new brake pad into the brake, press the

piston to return to the original position.

● Remove the hanger pin, lock plate, and brake pad.

● Verify that the pad spring is installed in specific

position.

Table of Contents2
How to Use this Manual2
General Safety3
Service Rules3
Caution When Wiring7
Serial Number Location11
Specifications12
Torque Values14
Symbols/Abbreviations16
Wiring Connections Diagram17
Lubrication19
Engine Oil19
Transmission Oil19
Service Information19
- Low or no Oil Pressure20
- Lubrication System Troubleshooting20
- Oil Contamination20
- Oil Level Low20
- Engine Oil Change21
- Engine Oil Level Inspection21
- Oil Filter Element Change22
- Oil Pump Removal22
- Oil Pump Disassembly23
- Oil Pump Inspection23
- Oil Pump Assembly24
- Oil Pump Installation24
- Radiator Inspection25
- Radiator Removal25
- Radiator Installation26
- Transmission Oil Inspection26
- Control Cable Lubrication27
- Lubrication Points27
- Tires Specifications29
- Maintenance Schedule31
Inspections/Adjustments29
- Air Cleaner32
- Fuel Line (Fuel Tube)32
- Throttle Grip Operation32
- Spark Plug33
- Valve Clearance33
- Carburetor Idle Speed34
- Cylinder Compression Pressure34
- Brake Fluid35
- Brake Lever Free Play36
- Headlight Aim36
- Side Stand36
- Bolts, Nuts, Fasteners37
  - Front Wheel Check37
  - Rear Wheel Check37
- Suspension37
- Steering Head Bearing38
- Wheels/Tires Checks38
External Parts39
- Names of Frame Covers40
- Front Cover41
- Front Fender41
- Front under Cover42
- Luggage Box42
- Center Cover43
- Rear Center Cover43
- Rear Carrier/Back Rest44
- Body Cover/Upper Body Cover44
- Rear Combination Light45
- Floor Side Cover45
- Floor Panel46
- Under Cover46
- Inner Box/Inner Box Lid47
- Rear Fender47
- Wind Screen/Front Handle Cover48
- Rear Handle Cover48
- Rear Wheel Mud Guard49
- Muffler Removal50
- Exhaust Pipe Removal and Installation50
- Fuel System Diagram52
- Fuel System Specifications53
- Carburetor Data53
- Fuel System Troubleshooting54
- Fuel Tank Installation55
- Fuel Tank Removal55
- Air Cleaner Removal56
- Carburetor Removal56
- Carburetor Disassembly57
- Carburetor Inspection57
- Float Chamber/Float/Jet Disassembly58
- Carburetor Cleaning59
- Float Chamber/Float/Jet Assembly59
- Float Level Inspection60
- Carburetor Installation61
- Carburetor Insulator Removal61
- Carburetor Insulator Inspection61
- Pilot Screw Adjustment62
Engine Removal63
- Engine Installation65
- LH. Crankcase Cover/Kick Starter/Continuously Variable Transmission66
Lh. Crankcase Cover/Kick Starter /Continuously Variable Transmission67
- LH. Crankcase Cover Removal68
- LH. Crankcase Cover Installation68
- Kick Starter Removal69
- Kick Starter Inspection70
- Kick Starter Installation71
- Drive Belt Removal72
- Drive Belt Inspection73
- Drive Belt Installation73
- Movable Drive Face Removal74
- Movable Drive Face Inspection75
- Movable Drive Face Installation75
- Clutch/Driven Pulley Removal77
- Clutch/Driven Pulley Disassembly77
- Clutch/Driven Pulley Inspection79
- Driven Face Bearing Inspection79
- Movable Driven Face Spring Inspection79
- Clutch Shoe Inspection79
- Driven Face Bearing Replacement80
- Clutch/Driven Pulley Assembly81
- Clutch/Driven Pulley Installation82
- AC Generator/Starter Clutch Diagram84
- AC Generator/Starter Clutch Specifications85
A.C.generator / Starter Clutch85
- AC Generator Removal86
- Shroud Removal86
- AC Generator Installation88
- RH Crankcase Cover Removal88
- Starter Reduction Gear Inspection89
- Starter Reduction Gear Removal89
- Starter Clutch Removal90
- Starter Reduction Gear Installation90
- Starter Clutch Inspection91
- Starter Clutch Installation92
- Cylinder Head/Valves Diagram94
- Cylinder Head/Valves Specifications95
- Cylinder Head/Valves Troubleshooting96
- Camshaft Removal97
- Camshaft Inspection98
- Cylinder Head Disassembly99
- Cylinder Head Removal99
- Cylinder Head Inspection100
- Valve Springs100
- Valves100
- Valve Guides Inspection101
- Valve Guides Replacement101
- Valve Seats Inspection102
- Valve Seat Refacing103
- Cylinder Head Assembly105
- Camshaft Assembly107
- Cylinder/Piston Diagram110
- Cylinder/Piston Specifications111
- Cylinder Removal112
- Cylinder Wear Inspection112
- Cylinder Warpage Inspection113
- Piston/Piston Ring Inspection113
- Piston/Piston Ring Removal113
- Piston Pin Inspection114
- Small End Bearing Surface Inspection114
- Piston Installation115
- Piston/Piston Ring Installation115
- Cylinder Installation116
- Transmission/Crankshaft/Crank Case Diagram118
- Transmission/Crankshaft/Crank Case Specifications119
- Transmission/Crankshaft/Crank Case Troubleshooting120
- Transmission Disassembly121
- Transmission Inspection122
- Transmission Assembly123
- Transmission Bearing Inspection123
- Crank Case Removal124
- Crankshaft Removal125
- Crankshaft Inspection126
- Transmission Bearing126
- Crankshaft Installation127
- Transmission Bearing Replacement127
- Crankcase Installation128
  - Front Wheel/Front Fork/Steering Diagram130
  - Front Wheel/Front Fork/Steering Specifications131
  - Front Wheel/Front Fork/Steering Troubleshooting132
  - Steering Handle Installation133
  - Steering Handle Removal133
  - Front Wheel Removal135
  - Front Wheel Inspection136
  - Front Wheel Bearing Replacement137
  - Front Wheel Assembly138
  - Speedometer Gear Replacement138
  - Front Wheel Installation139
  - Front Fork Disassembly140
  - Front Fork Removal140
  - Front Fork Assembly142
  - Front Fork Inspection142
  - Front Fork Installation144
  - Steering Stem Removal145
  - Steering Stem Installation147
  - Rear Wheel/Brake/Suspension/Rear Swing Arm Specifications149
  - Rear Wheel/Brake/Suspension/Rear Swing Arm Troubleshooting150
  - Rear Wheel Removal151
  - Rear Wheel Inspection152
  - Rear Wheel Installation152
  - Parking Brake Inspection153
  - Parking Brake Removal153
  - Brake Cam Disassembly154
  - Brake Shoe Disassembly154
  - Parking Brake Assembly/Installation154
  - Rear Cushion Disassembly155
  - Rear Cushion Inspection155
  - Rear Cushion Removal155
  - Rear Cushion Installation156
  - Rear Swing Arm Disassembly156
  - Rear Swing Arm Removal156
  - Brake System Diagram158
  - Brake System Troubleshooting159
  - Air Bleeding160
  - Brake Fluid Change160
  - Front Brake Pad Replacement162
  - Rear Brake Pad Replacement163
  - Brake Caliper Disassembly164
  - Brake Caliper Removal164
  - Brake Caliper Assembly165
  - Brake Caliper Inspection165
  - Brake Caliper Installation166
  - Master Cylinder Disassembly166
  - Master Cylinder Removal166
  - Master Cylinder Assembly167
  - Master Cylinder Inspection167
  - Master Cylinder Installation168
  - Brake Disk Inspection169
  - Battery/Charging System Serice Information171
  - Battery/Charging System Specifications171
  - Charging Device Location172
  - Triple Phase Full Wave Rectification Method172
  - Charging System Troubleshooting173
  - Battery (Open-Circuit Voltage) Inspection174
  - Battery Removal174
  - Charging System Inspection175
  - Charging Voltage Inspection175
  - Leak Test175
  - Harness Side Circuit Inspection176
  - Headlight Voltage Inspection176
  - Regulator/Rectifier Inspection176
  - AC Generator Charging Coil Inspection177
  - Regulator Rectifier Unit Inspection177
  - Regulator Rectifier Unit Replacement177
  - Ignition System Service Information179
  - Ignition System Specifications179
  - Ignition Devices Location180
  - Ignition System Troubleshooting181
  - CDI Ignition Circuit Inspection182
  - CDI Unit Inspection182
  - Pulse Generator Inspection182
  - PVA Measurement182
  - Ignition Coil Inspection183
  - Ignition Coil Replacement183
  - Primary Coil Inspection183
  - Secondary Coil Inspection183
  - Ignition Timing Inspection184
  - Side Stand Ignition Cut-Off Switch Inspection184
  - Side Stand Ignition Cut-Off Switch Installation185
  - Side Stand Ignition Cut-Off Switch Removal185
  - Starter System Specification187
  - Starter Devices Location188
  - Starter System Circuit Diagram188
  - Starter System Troubleshooting189
  - Starter Motor Disassembly190
  - Starter Motor Inspection190
  - Starter Motor Removal190
  - Starter Motor Assembly192
  - Starter Magnetic Switch Ground Line193
  - Starter Magnetic Switch Inspection193
  - Starter Magnetic Switch Removal193
  - Starter Magnetic Switch Voltage193
  - Starter Magnetic Switch Operation Check194
  - Lights/Meter/Switches Service Information195
  - Lights/Meter/Switches Troubleshooting195
  - Front/Rear Winker Bulbs Replacement196
  - Headlight Bulb Replacement196
  - Headlight Removal196
- Rear Combination Light197
- Speedometer Removal197
- Horn Inspection198
- Meter Bulb Replacement197
- Main Switch Removal198
- Main Switch Inspection198
- Handle Bar Switch Inspection198
- Trunk Lamp Switch Inspection199
- Front/Rear Stop Switch Inspection199
- Fuel Unit Inspection200
- Fuel Unit Removal200
- Parking Brake Switch Inspection200
Wiring Diagram201
Engine Won't Start or Hard to Start202
Troubleshooting202
- Engine Stalls, Hard to Start, Rough Idling203
- Poor Performance at Low Speed and Idling204
- Clutch Drive/Driven Pulley Poor Operation205
- Handle/Wheel Poor Operation205
- Poor Front/Rear Suspension Performance206

Brand	DAELIM
Model	HISTORY 125
Category	Scooter
Language	English

DAELIM HISTORY 125 User Manual

Table of Contents

Questions and Answers:

DAELIM HISTORY 125 Specifications

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