DAELIM NS125III - SERVICE User manual

SERVICE MANUAL
SERVICE MANUAL
SM37-0211-01E
HEAD OFFICE (FACTORY)
#58, SUNG SAN-DONG, CHANGWON, KYUNGNAM, KOREA
TEL : [phone] / FAX : [phone]
OVERSEAS SALES OFFICE
#13-5, SUNG SOO 1DONG 1GA, SUNG DONG GU, SEOUL, KOREA
TEL : [phone] / FAX : [phone]

How to use this manual
This manual describes effective maintenance
procedure for the NS125Ⅲmanufactured by
DAELIM Motor Co., Ltd.
To ensure safety and optimal operating conditions
of the vehicle, carry out regular inspections
according to the maintenance schedule(Section 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 DAELIM Motor Co., Ltd..
Service Information
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Lubrication
Inspections/Adjustments
External Parts
Fuel System
Engine Removal/Installation
L. Crank Case Cover / Kick Starter /
Continuously Variable Transmission
Generator/Starter Clutch
Cylinder Head/Valve
Cylinder/Piston
Transmission/Crankshaft/Crank Case
Front Wheel/Front Fork/Steering
Rear Wheel/Brake/Suspension
Brake System
Charging System/Battery
Ignition System
Starter System
Light/Switch/Horn
Wiring Diagram
Troubleshooting
Contents
Engine General
Frame
Electrical System

Service Information
1-1
General Safety 1-1
Service Rules 1-1
Caution when Wiring 1-5
Identification Numbers 1-9
Specifications 1-10
Torque Values 1-12
Symbols/Abbreviations 1-14
Wiring Diagram 1-15
1. Service Information
1
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. Maintenance 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 DAELIM 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. Maintenance 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.
󳢯Make sure that the tool such as spanner do not contact
with the frame.
󳢯Connect covers to the terminal after maintenance.
󳢯If the fuse is short-circuited, find out the cause and
repair. Replace with the fuse having the specified
capacity.
󳢯If there is rust in the terminal, remove the rust with sand
paper prior to connecting.
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 range or
configuration in accord
with the manual?

Service Information
1-9
Identification Numbers
Frame serial number
Engine serial number
FARME SERIAL NUMBER LOCATION
󳢯The frame serial number is stamped on the front
central part of the frame.
ENGINE SERIAL NUMBER LOCATION
󳢯The engine serial number is stamped on the central
part of the left crankcase.

Service Information
1-10
Item Specifications
Overall length 1,970mm
Overall width 700mm
Overall height 1,110mm
Dimensions Wheel base 1,350mm
Seat height 765mm
Ground clearance 130mm
Dry weight 110kg
Curb weight 240kg
Type Underbone
Front suspension/stroke Telescopic/97mm
Rear suspension/stroke Swing arm/74mm
Front tire size/type 120/70-13/Tubeless
Rear tire size/type 130/60-13/Tubeless
Tire Pressure 1 person Front 1.75kg/㎠(175kPa)
Rear 2.00kg/㎠(200kPa)
Frame 2 person Front 2.25kg/㎠(225kPa)
Rear 2.25kg/㎠(225kPa)
Front brake Hydraulic disk
Rear brake Drum brake
Fuel tank capacity Full capacity 7.5ℓ
Reserve capacity 1.2ℓ
Caster angle 25○
Trail 84.7㎜
Front fork oil capacity 80㎤
Type Oil cooled/air cooled 4 cycle SOHC engine
Cylinders/Arrangement 1(Single cylinder), front angle 80○
Bore and stroke 56 ×50.7 mm
Displacement 124.9㎤
Compression ratio 10.8 : 1
Valve train SOHC chain drive
Oil capacity 1.1ℓAfter disassembly
0.75ℓAfter Oil filter change
Engine 0.8ℓAfter Oil change
0.9ℓ
After Oil change with Oil in the Oil hose removed
Lubrication system Forced pressure splash type
Air cleaner type Wet sump
Cylinder compression 13.8kg/㎠
Intake valve: Open 5○BTDC
Closed 14○ABDC
Exhaust valve: Closed 18○BBDC
Closed 1○ATDC
Valve clearance(cooling-off period)
intake 0.12 ±0.02 ㎜
Exhaust 0.12 ±0.02 ㎜
Specifications

Service Information
1-11
Item Specifications
Type/Venturi bore CV type(vacuum)24.2mm
Model mark BDS 26 -112
Choke type Autoby-starter
Carburetor Main jet #95
Pilot screw initial setting 1 and 1/2 trust out
Float level 13 mm
Idle speed 1,800±100(rpm)
Clutch type Automatic Transmission
Drive Train Primary reduction 3.231(42/14)
Secondary reduction 2.786(39/14)
Ignition system C.D.I. lgnition
Ignition timing F mark 15○BTDC/1,800(rpm)
Full advance 19○
AC generator capacity 125W/5,000(rpm)
Battery type/capacity Closed type (MF)12V 8AH
Spark plug CR8EH-9
Spark plug gap 0.8-0.9mm(0.031-0.035in)
Electrical Fuse capacity 15A
Systems starting system Kick/starter motor
Headlight(high/low) 12V 35/35W
Position light 12V 3.4W
Turn signal light(Fr/Rr) 12V 10W×4
Tail/stop light 12V 21 / 5W
High-beam indicator 12V 3.4W
Turn signal indicator 12V 3.4W×2
Speedometer lamp 1.7W×2
Trunk lamp 1.4W×1

Service Information
1-12
Item Q’ty Thread dia(mm) Torque value Remarks
kg.m(N.m,ft-lb)
Oil filter cap 1 20 1.5(15, 11)
Valve adjust screw lock nut 4 5 1.1(11, 8)
Kick starter pedal bolt 1 6 1.2(12, 8)
Flywheel bolt 1 12 5.5(55, 40) Apply engine oil
Drive face bolt 1 12 5.5(55, 40)
Clutch outer bolt 1 12 5.5(55, 40)
Cam chain tensioner pivot bolt 1 8 1.0(10, 7)
Spark plug 1 12 1.2(12, 9)
Cam sprocket bolt 2 6 1.2(12, 9) Apply engine oil
Camshaft holder nut 4 8 2.0(20, 14) Apply engine oil
Cam chain tensioner mounting bolt 2 6 1.2(12, 9)
Cam chain tensioner sealing screw 1 6 0.4(4, 2.9)
Cylinder head cover bolt 4 6 1.0(10, 7)
Transmission cover bolt 8 6 1.2(12, 8)
Transmission cover drain bolt 1 8 1.0(10, 7)
Transmission cover check bolt 1 8 0.9(9, 6)
Cooling fan bolt 3 6 1.0(10, 7)
Starting clutch nut 1 22 9.5(95, 67)
Starter motor terminal nut 2 6 0.9(9, 6)
Radiator hose eye joint bolt 4 12 3.2(32, 23)
Radiator hose nut 2 14 3.2(32, 23)
Torque Values
Engine
Item Q’ty Thread dia(mm) Torque value Remarks
kg.m(N.m,ft-lb)
Steering stem lock nut 1 26 7.5(75, 55)
Steering top thread nut 1 26 0.3(3, 2) Initial torque
Handle post nut 1 10 6.0(60, 44)
Front fork bottom bridge bolt 4 10 7.5(75, 55)
Front fork socket bolt 2 8 2.0(20, 14)
Apply locking agent
Front axle nut 1 12 5.5~6.5(55~65, 40~47)
Front brake disk bolt 3 8 3.9(39, 28)
Apply locking agent
Ignition coil bolt 1 5 0.5(5, 4)
Rear axle nut 1 14 6.0-8.0(60-80, 43-58)
Engine hanger nut 2 10 7.3(73, 53)
Engine hanger plate bolt 6 10 2.7(27, 20)
Frame

Service Information
1-13
Item Q’ty Thread dia(mm) Torque value Remarks
kg.m(N.m,ft-lb)
Brake caliper bracket bolt 2 8 2.7(27, 20)
Brake caliper bleeder valve 1 8 0.6(6, 4.3)
Brake caliper slide pin (socket bolt) 1 8 2.3(23, 17)
Brake caliper pin bolt 1 8 1.8(18, 13)
Apply locking agent
Brake pad pin bolt 2 8 1.8(18, 13)
Master cylinder reservoir cap 4 4 0.13(1.3, 0.94)
Brake hose bolt 2 10 3.5(35, 25)
Brake lever pivot bolt 1 6 1.0(10, 7)
Brake lever pivot lock nut 1 6 1.0(10, 7)
Rear shock-absorber upper bolt 1 10 2.7(27, 20)
Rear shock-absorber lower bolt 1 10 4.0(40, 29)
Rear shock-absorber damper rod lock nut 2 10 3.8(38, 27) Apply locking agent
Torque values listed above are for specific tightening points. Torque values for other items are listed in the
following table.
SH(Small Head): Indicates 6mm bolt of 8mm flange head.
Item Torque Value Item Torque Value
N.m Kg-m ft-lb N-.m Kg-m ft-lb
5mm bolt, nut 5 0.5 4 5mm screw 4 0.4 3
6mm bolt, nut 10 1.0 7 6mm screw 9 0.9 7
8mm bolt, nut 22 2.2 16 6mm flange bolt, nut 9 0.9 7
10mm bolt, nut 35 3.5 25 6mm flange bolt, nut 12 1.2 9
12mm bolt, nut 55 5.5 40 8mm flange bolt, nut 27 2.7 20
10mm flange bolt, nut 40 4.0 29

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

Wiring Diagram
Service Information
1-15
Rear brake cable
Winker relay
Stop switch connector
Front winker connector
Front brake hose
Horn
Radiator
Packing lever
Front brake hose
Speedometer cable
Rear brake cable
Radiator hose
Throttle cable
Main switch
Resister(excepted
some countries)
Front winker connector
Speedometer Cable
Front brake master
cylinder