DAELIM BESBI SC125 - User manual

HOW TO USE THIS MANUAL
This manual describes effective maintenance procedure
for the SC125 manufactured by DAELI otor Co., Ltd.
To ensure safety and optimal operating conditions of the
vehicle, carry out regular inspections according to the
maintenance schedule (Section 3).
Sections 1 through 3 provide information on overall
vehicle; section 4, assembly and disassembly procedures
for external components, and section 5 describes
maintenance procedure for the engine, frame and electrical
systems.
To facilitate use of this manual, each page starts with
disassembly and system diagrams, service information,
and troubleshooting guide. If you cannot find the cause of
trouble, refer to Section 20: Troubleshooting.
Contents of this manual and specifications are
subject to change without prior notice for
improvement of vehicle quality.
No part of this publication may be reproduced
without written permission of DAELI otor Co.,
Ltd.,
CONTENTS
SERVICE INFORMATION
LUBRICATION
INSPECTIONS / ADJUSTMENTS
EXTERNAL PARTS
FUEL SYSTEM
ENGINE REMOVAL
LH.CRANK CASE COVER / KICK STARTER /
CONTINUOUSLY VARIABLE TRANSMISSION
A.C.GENERATOR / STARTER CLUTCH
CYLINDER HEAD / VALVE
CYLINDER / PISTON
TRANSMISSION/CRANK SHAFT/CRANK CASE
FRONT WHEEL / FRONT FORK / STEERING
REAR WHEEL / BRAKE / SUSPENSION /
REAR SWING ARM
BRAKE SYSTEM
GENERAL
ENGINE
FRAME
ELECTRICAL SYSTEM
CHARGING SYSTEM / BATTERY
STARTER SYSTEM
LIGHTS/METER/SWITCHES
IGNITION SYSTEM
TROUBLESHOOTING
WIRING DIAGRAM

1-1
1. SERVICE INFORMATION
GENERAL SAFETY 1-1
SERVICE RULES 1-1
CAUTION WHEN WIRING 1-5
SERIAL NUMBER LOCATION 1-9
SPECIFICATIONS 1-1
TORQUE VALUES 1-12
SYMBOLS / ABBREVIATIONS 1-14
WIRING DIAGRAM 1-15
GENERAL SAFETY
WARNING
1. Do not run the engine for a long time in closed or not well-ventilated area because the exhaust gas contains toxic
substances such as carbon monoxide, hydrocarbon, nitric oxide.
2. The battery fluid(lean sulfuric acid) is extremely toxic. It is dangerous if skin is exposed to it or if it enters into the eye.
Be careful in handling. When exposed to the battery fluid, wash it with water and get a medical check up.(store the
battery fluid in a safe place to avoid touching by the children)
3. Pay attention not to be burned and always put on the protection gears because the engine or the muffler is hot right after
engine stops.
4. Gasoline is extremely flammable. aintenance must performed in the place free of the open fire or electric spark.
5. When more than two person are working, always pay attention to other worker’s action and alway have safety in mind.
6. The skin exposed to used engine oil can be a major reason of the skin cancer. Pay attention not to exposed and wash
carefully with soap and water after handling.
7. If compressed air is used to clean the brake, dust scattered in the air can be breathed in by workers. Please take action not
to scatter dust in the brake cleaner, etc.
8. Flammable nitrogen gas is generated during charging the battery so charging must be performed in well-ventilated area
and free of the open fire and spark.
SERVICE RULES
1. Parts and lubrication oil must be DAELI genuine or
recommended parts.
2. Before maintenance, remove deposit or dust from the
chasis.

1-2
SERVICE INFORMATION
9. Check to see if the rubber part is worn out when
removing it and replace it if necessary. Some rubber part
is weak to gasoline and kerosene, so pay attention not to
soak with gasoline or oils.
10. Recommended grease must be applied to or filled in
the specified place.
7. Align the bolts to uniform the tightening points before
tightening them when you don’t know the bolt length.
8. Bolts, nuts and pieces must be tightened from the bigger
diameter to the smaller one, from inside to outside and
diagonally with the specified torque.
5. Clean the parts after the overhaul and before the test and
remove the cleaning oil with compressed air. Apply oil
to seal face during installation.
6. Check necessary place and measure necessary data
during installation. When installing, return to the state
before removing.
3. Store the parts of each system discriminatively to install
each part in the right place.
4. After removing gasket, O-ring, piston pin clip and cotter
pin, always replace them with the new one. When
removing the snap ring, it can be easily missed after
transformation or installation.

1-3
SERVICE INFORMATION
11. aintenance needed to use the specialized tools must
performed with the right tool.
12. Never reuse the ball bearing removed with the ball
applied pressure when removing press-fitted the
bearing.
13. Check the smooth rotation of inner or outer race of the
ball bearing by rotating it manually.
Replace the ball bearing having excessive axial/
longitudinal hanging.
Wipe the ball bearing likely to have hanging with
cleaning oil.(except double-sided sealed type ball
bearing)
Replace the ball bearing of which press-fitted part is
slacked at the case or shaft.
14. Pay attention to installation direction in case of the
single-sided sealed ball bearing. Install the open-
direction or double-sided sealed bearing in the way
that the face marked with manufacturer and size
should direct to the outer axle.
15. When blowing the ball bearing with compressed air
after cleaning, keep the race from rotating. High speed
rotation of the race may damage the bearing. Prior to
installation, apply oil or grease to the bearing.
16. Install the snap ring so that chamfered side directs to
the load-applied side. After installation, check the
proper installation by rotating the snap ring.
17. Check each part for proper tightening and operation
after installation.
18. The brake fluid and coolant can damage the painted
plastic or rubber parts. Keep these parts from
contacting with them and wash these parts with water
in case of contact.
’

1-4
SERVICE INFORMATION
21. Keep the pneumatic system interior or the engine
interior from the infiltration of dust.
22. Install the gasket mounted in the contact surface of
each case of the engine while removing gasket
material completely. Remove damaged contact surface
by wiping with the oil stone equally.
19. Install the oil seal so that the manufacturer marked
surface directs outer surface.(direction not covered
with oil)
Pay attention not to bend or damage the lip
Apply the grease to the lip
20. Connect the tube until the tube fully inserted in the
joint. Install the clip if it is supplied. Replace the tube
having slacked end.
23. Pay attention not to bend the cable excessively.
Transformed or damaged cable may cause malfunction
or damage.
24. Install the boots with the installing groove by inserting
the boots into the groove.
’

1-5
SERVICE INFORMATION
Each cord must be connected depending on its color.
When connecting different cord, attach color tube
around the connector. Connect the coupler to the
connector with same color and same pin number.
Identify the two-colored cord by main color first and
then spriped color .
When measuring voltage or resistance of the cord
terminal using tester, contact the tester plug behind of
the coupler. Pay attention not to open the cord terminal
and contact the tester plug from the front of the coupler
in case of water-proof coupler.
Recheck the condition of contact, securing and
continuity of each part after maintenance.
When connecting the battery, the plus terminal must be
connected first.
After connecting the terminal, apply the grease to the
terminal.
When disconnecting the battery, the minus terminal
must be disconnected first.
ake sure that the tool such as spanner do not contact
with the frame.
Connect covers to the terminal after maintenance.
If the fuse is short-circuited, find out the cause and
repair. Replace with the fuse having the specified
capacity.
If there is rust in the terminal, remove the rust with sand
paper prior to connecting.
CAUTION WHEN WIRING
VALIDATION
OF CAPACITY! REMOVE
THE
RUST!

1-6
SERVICE INFORMATION
Insert the lock of the coupler until the lock is fully
secured.
Turn off the main switch before connecting/dis-
connecting.
Release the lock to disconnect the lock of the coupler.
The lock of the coupler has two types according to
releasing method(press type and pull type) so release it
properly according to the shape.
- Typical releasing method of the coupler is illustrated in
the following.
When disconnecting the coupler, disconnect it while
holding the coupler body. Pull while holding the wire
harness cord and do not remove the coupler connection.
Release the lock by inserting the coupler slightly and
then narrowing connection to remove the coupler.
Pay attention not to damage the vinyl cover of the
coupler.
Check to see if there is bended terminal and secure it to
avoid disconnecting.
If the wire harness coating is damaged, repair by
winding vinyl tape or replace it.
Prior to connecting the connector, make sure that the
cover is not damaged and the mess terminal is not
opened.

1-7
SERVICE INFORMATION
Wire band must be secured firmly in the specified
location of the frame. In case of aluminium band,
secure the wire harness to the coated part.
Secure the wire harness firmly using the clamp.
Insert the connector until the vinyl cover is fully
inserted into the terminal.
The opening of the vinyl cover must face at the ground
direction but in case of the plain connector, the draining
opening must face at the sky direction.
When removing T-start, broaden the groove of T-start
using the wiring driver and release the torque.
Connect the harness and the hose to T-start and then
insert until the groove is locked.
When removing T-start from the frame, replace it with
the new one.
In case of the weld clamp, do not clamp in the welded
part.
When clamping the wire harness, make sure that the
harness is not contacted with the shaft or rotating part.
When clamping the wire, pay attention not to contact
with hot part.
The wire harness must be routed without contacting
with the end of the lamp or any sharp edge.
The wire harness must be routed without contacting
with the end of the bolt or the piece.

1-8
SERVICE INFORMATION
If necessary, lock the wire harness properly. When mounting parts, make sure that the wire harness
is not pressed by the parts.
In case that the wire harness is contacted with the end or
the sharp edge, protect both parts with tube or tape.
The wire must not hang down or be pulled excessively.
Do not twist the wire harness. Wire the wire harness not to be pulled or expanded
when the handle is turned to the right or the left
completely. Avoid excessive bending or chewing and
interference with the engine.
Prior to using the tester, please read the manual care-
fully and understand the contents.
When testing the resistance of the tester, the zero
adjustment must be performed before testing.
Do not drop or throw the parts especially
semiconductor contained parts because these parts may
be damaged by the impact of the drop.
NOT TO
PULL!
Is this
measurement ran e or
confi uration in accord
with the manual?

1-9
SERVICE INFORMATION
SERIAL NUMBER LOCATION
ENGINE SERIAL NUMBER LOCATION FRAME SERIAL NUMBER LOCATION

1-1
SERVICE INFORMATION
ITEM SPECIFICATIONS
1,820 mm
685 mm
1,060 mm
1,300 mm
755 mm
110 mm
105 kg
235 kg
Underbone
Bottom link
Swing arm / 66mm
3.50 - 10 51J
3.50 - 10 51J
1.75 Kgf /
2.00 Kgf /
2.00 Kgf /
2.25 Kgf /
Hydraulic disk
Drum brake
5.0
1.0
26
Air cooled / 4stroke
1(Single cylinder), front angle 15
52.4 57.8 mm
124.6
9.2 : 1
SOHC 2valve
0.9 After disassembly
0.75 After Oil change
0.11 After disassembly
0.09 After Oil change
Forced pressure splash type
Dry process
13.0 kgf / (570 rpm)
0BTDC
25 ABDC
33 BBDC
0BTDC
0.05 mm
0.05 mm
OVERALL LENGTH
OVERALL WIDTH
OVERALL HEIGHT
WHEEL BASE
SEAT HEIGHT
GROUND CLEARANCE
DRY WEIGHT
GROSS WEIGHT
TYPE
FRONT SUSPENSION / STROKE
REAR SUSPENSION / STROKE
FRONT TIRE SIZE / TYPE
REAR TIRE SIZE / TYPE
TIRE PRESSURE 1 PERSON FRONT
REAR
2 PERSON FRONT
REAR
FRONT / REAR BRAKE
PARKING BRAKE
FUEL TANK CAPACITY FULL CAPACITY
RESERVE CAPACITY
CASTER ANGLE
TYPE
CYLINDERS / ARRANGE ENT
BORE AND STROKE
DISPLACE ENT
CO PRESSION RATIO
VALVE TRAIN
OIL CAPACITY
TRENS ISSION OIL CAPACITY
LUBRICATION SYSTE
AIR CLEANER TYPE
CYLINDER CO PRESSION PRESSURE
INTAKE VALVE OPEN
CLOSED
EXHAUST VALVE CLOSED
OPEN
VALVE CLEARANCE (COOLING-OFF PERIOD)
INTAKE
EXHAUST
DIMENSIONS
FRAME
ENGINE
SPECIFICATIONS

1-11
SERVICE INFORMATION
ITEM SPECIFICATIONS
CV type ( vacuum ) 23 mm
PD24J
Auto-bystarter
# 110
2 and trust out
11 mm
1.600 100 ( rpm )
Automatic Transmission(V-belt)
2.800
3.077
AC-C.D.I Ignition
13
12V 8AH
P-Z9HC(CHA PION)
0.6 - 0.7 mm
15A
Kick / starter motor
12V 35 / 35W
12V 10W 4
12V LED
12V1.7W 1
12V1.7W 2
12V 3.4W 2
12V 5W
TYPE / VENTURI BORE
ODEL ARK
CHOKE TYPE
AIN JET
PILOT SCREW INITIAL SETTING
FLOAT LEVEL
IDLE SPEED
CLUTCH TYPE
PRI ARY REDUCTION
SECONDARY REDUCTION
IGNITION SYSTE
IGNITION TI ING F ARK
BATTERY TYPE / CAPACITY
SPARK PLUG
SPARK PLUG GAP
FUSE CAPACITY
STARTING SYSTE
HEADLIGHT ( HIGH / LOW )
WINKER LIGHTS ( FR / RR )
TAIL / STOP LIGHT
HIGH-BEA PILOT
WINKER PILOT LA P
SPEEDO ETER LA P
LICENSE LA P
CARBURETOR
DRIVE TRAIN
ELECTRICAL
SYSTEM

1-12
SERVICE INFORMATION
ITEM REFERENCETORQUE VALUE
THREAD DIA
(mm)
Q’TY
1.5 kgf m
2.5 kgf m
1.1 kgf m
1.1 kgf m
5.5 kgf m
7.5 kgf m
5.5 kgf m
1.0 kgf m
1.2 kgf m
5.5 kgf m
2.9 kgf m
1.0 kgf m
0.4 kgf m
0.9 kgf m
1.2 kgf m
1.0 kgf m
0.9 kgf m
1.0 kgf m
5.5 kgf m
0.9 kgf m
APPLY ENGINE OIL
APPLY ENGINE OIL
30
12
5
6
12
12
12
8
12
30
8
6
6
6
6
8
8
6
22
6
1
1
4
2
1
1
1
1
1
1
4
2
1
4
8
1
1
3
1
2
OIL FILTER CAP
OIL DRAIN PLUG BOLT
VALVE ADJUST SCREW LOCK NUT
CYLINDER HEAD BOLT
FLYWHEEL BOLT
DRIVE FACE NUT
CLUTCH OUTER BOLT
CA CHAIN TENSIONER PIVOT BOLT
SPARK PLUG
DRIVE PLATE
CA SHAFT HOLDER NUT
CA CHAIN TENSIONER FLANGE BOLT
CA CHAIN TENSIONER PAN SCREW
CYLINDER HEAD COVER BOLT
ISSION COVER BOLT
ISSION COVER DRAIN BOLT
ISSION COVER CHECK BOLT
COOLING FAN BOLT
STARTING CLUTCH NUT
STARTER OTOR FLANGE BOLT
TORQUE VALUES
ENGINE
ITEM REFERENCETORQUE VALUE
THREAD DIA
(mm)
Q’TY
7.0 kgf m
0.25 kgf m
6.0 kgf m
6.0 kgf m
3.1 kgf m
1.2kgf m
4.25 kgf m
12.5 kgf m
0.4 3kgf m
2.25kgf m
4.0 kgf m
4.0 kgf m
3.5kgf m
5.25 kgf m
4.5 kgf m
4.0 kgf m
1.5 kgf m
4.5 kgf m
26
26
10
12
8
6
8
16
5
22
10
10
10
12
10
10
10
10
1
1
2
1
1
2
3
1
1
2
2
2
2
2
1
2
1
1
STEERING STE NUT
STEERING TOP THREAD NUT
HANDLE POST
FRONT AXLE NUT
FRONT CALIPER BRACKET BOLT
FRONT ASTER CYLINDER HOLD BOLT
FRONT DISK PLATE BOLT
REAR AXLE NUT
SPEEDO ETER GEAR BOX SCREW
FRONT FORK BOLT
REAR CUSHION UPPER BOLT
REAR CUSHION UNDER BOLT
REAR CUSHION ROD LOCK NUT
ENGINE HANGER UPPER BOLT
ENGINE HANGER LAWER BOLT
AIN STAND BOLT
SIDE STAND PIVOT SCREW
SIDE STAND PIVOT NUT
FRAME
Torque values listed above are for specific tightening points. Torque values for other items are listed in the following table.

1-13
SERVICE INFORMATION
ITEM ITEMTORQUE VALUE TORQUE VALUE
0.5 kgf m
1.0 kgf m
2.2 kgf m
3.5 kgf m
5.5 kgf m
0.4 kgf m
0.9 kgf m
1.2 kgf m
2.7 kgf m
4.0 kgf m
5mm BOLT, NUT
6mm BOLT, NUT
8mm BOLT, NUT
10mm BOLT, NUT
12mm BOLT, NUT
5mm SCREW
6mm SCREW
6mm FLANGE BOLT, NUT
8mm FLANGE BOLT, NUT
10mm FLANGE BOLT, NUT
SH (Small Head) : Indicates 6mm bolt of 8mm flange head.

SYMBOL
CAUTION
NOTE
SYMBOL
1-14
SERVICE INFORMATION
SYMBOLS / ABBREVIATIONS
The following symbols are used in this manual to represent job-related warnings or cautions.
MEANING
Indicates dangerous area. Serious
accident may result if instructions are not
followed.
The following symbols indicate oil adding, oil change, or parts.
MEANING
Add oil. If there is no specific oil indicated, use the designated or recommended engine oil.
Apply grease
Indicates reference page. (example : Refer to page 3-1)
MEANING
Indicates important work. inor injury or
vehicle part damage may result if instruction
are not followed.
Indicates general safety matters. Provides
safety and appropriate handling procedures.
(3-1)
ASS’Y
The following abbreviations are used in this manual.
ASSEMBLY
Left
Right
LH.
RH.
SYMBOL
WARNING
OIL
GREASE

1-15
SERVICE INFORMATION
WIRING DIAGRAM
FR.WINKER
FUEL TANK
FUEL STRAINER COMP.
FUEL TANK
SAI PIPE C.D.I UNIT
MUFFLER
FUEL PUMP
AIR CLEANER
ENGINE
KICK
KEY SET
IGNITION COIL COMP.

1-16
SERVICE INFORMATION
SPEEDOMETER CABLE
FR. BRAKE HOSE
CARBURETOR
INSULATOR
START
MAGNETIC SWITCH
C.D.I UNIT COMP.
IGNITION COIL COMP.
SAI PIPE COMP.
GAS
RATIO CONTROLLER
WINKER RELAY
HEADLIGHT
CONTROLLER
KEY SET
REG.
RECTIFIER

2-1
2. LUBRICATION
SERVICE INFORMATION
GENERAL SAFETY
WARNING
The exhaust gas contains poisonous substance. Do not keep engine idling in a closed or poorly ventilated place for a
long period of time.
Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. It is desirable
not to handle used oil frequently; however wash your hands thoroughly with soap and water immediately after
handling the used oil.
The oil pump can be serviced without removing the engine from the frame.
ENGINE OIL
TRANSMISSION OIL
TORQUE VALUES
OIL FILTER SCREEN CAP 1.5 f m
OIL PUMP BOLT 1.1 f m
OIL DRAIN PLUG BOLT 2.5 f m
SERVICE INFORMATION 2-1
TROUBLE SHOOTING 2-2
ENGINE OIL LEVEL INSPECTION 2-3
ENGINE OIL CHANGE 2-3
OIL FILTER ELEMENT CHANGE 2-3
OIL PUMP 2-4
TRANSMISSION OIL INSPECTION 2-7
LUBRICATION POINTS 2-8
OIL CAPACITY
RECOMMENDED
OIL
0.9 (After disassembly)
0.75 (After Oil change)
API service classification : L grade
Viscosity : AE10W-40
(Use appropriate type of oil with viscosity satisfying
the atmospheric temperature
In your riding area based on the table shown on the
right side.)
OIL CAPACITY
RECOMMENDED OIL
0.11 (Full capacity)
0.09 (After oil change)
DMC Genuine mission oil or AE 80W/90
-10 0 10 20 30 40

2-2
LUBRICATION
TROUBLE SHOOTING
Oil level low
Oil consumption naturally.
External oil leaks.
Worn piston ring or incorrect piston ring installation.
Worn valve guide or seal.
Oil contamination
Oil or filter not changed often enough.
Faulty head gasket.
Worn piston rings.
Low or no oil pressure
Clogged oil orifice.
Incorrect oil being used.