Chapter 2 Fuel system and lubrication
Refer to Chapter 7 for information relating to the
on Brazilian models
Contents
f
f
General description
Petrol tank : removal and replacement
Petrol feed pipe : examination
Petrol tap : removal, repair and replacement
Carburettor: removal - pre (T)PFC type
Carburettor: overhaul - pre (T)PFC type
Carburettor: adjustment - pre (T)PFC type .
Carburettor settings
1 Carburettor: (T)PFC type 9
2 Air cleaner: removal, cleaning and replacement of the
3 elements 10
4 Exhaust system: general
5 Oil pump: removal, examination and renovation 12
6 Oil filters: location and cleaning 13
7 Fault diagnosis 14
Specifications
Fuel tank capacity
Overall
litres (2.2 Imp gal)
Including reserve of 2 litres (0.4 Imp gal)
Fuel grade and type Either leaded
four-star (minimum octane rating of 91) or
unleaded premium
Carburettor
number - by machine serial (engine) number:
CG125 up to 1020010 077A-A
to 1104204 PD88E-A/B
on,
K1, CG125-B up to
1422468 PD88E-C
CG125-B 1422469 on PD88E-E
CG125-C up to 1608462
1608463 on, CG125-E PD45C-C*
(T)PFC type carburettor - see Chapter 7 for details
077A-A PD88E-A/B/C/E PD45C-A/C
Main jet 92 100 95(-A), 85(-C)
Pilot (slow) jet 38 40(-E
38(-A), 40(-C)
Needle clip position — grooves from top 3rd 3rd N/Av
Pilot screw - turns out from fully closed
N/Av
Float height 24.0 mm (0.95 in)
mm (0.73 in) N/Av
speed
1200
* Pilot jet not removable on PD88E-A/B/C carburettors
Engine/gearbox lubrication
Capacity - approx 1.0 litre (1.76 Imp pint)
Recommended oil Good quality SAE 10W/40 engine oil, API class SE or SF
1 General description
The fuel system comprises a petrol tank from which petrol
is fed by gravity to the float chamber. It is controlled by a petrol
tap with a built-in filter. The tap has three positions: 'Off', 'On',
'Reserve', the latter providing a reserve supply of petrol when
the main supply has run out. For cold starting the carburettor
has a manually operated choke. The machine should run on
'Choke' for the least amount of time.
The lubrication system is of the pressure fed type, supplying
oil to almost every part of the engine. There is a centrifugal filter
mounted directly on the end of the crankshaft. Centrifugal force
caused by the rotation of the engine throws the heavier
impurities outwards where they stick to the walls, allowing only
the clean, lighter oil through. Oil is picked up by the oil pump
and pressure fed through the right-hand crankcase where it is
diverted into two routes. In one direction it goes through a
passage in the right-hand crankcase cover and then through the
oil filter to the crankshaft. The other direction takes the oil
through a passage via a cylinder head stud to the rocker arms.
The transmission also receives oil under pressure, relying upon
this simple yet very efficient system.
2 Petrol tank: removal and replacement
1 The fuel tank is not bolted to the machine in any way. It is
held in place by three rubbers; two at the inner front and one at
the rear under the seat, which it is necessary to remove.
2 Unfasten the bolt on each side of the rear of the seat. Lift up
the back a little and pull back until the seat disengages with its
location bracket and lifts clear.
3 Turn the fuel to
position and ease off the rubber fuel
feed pipe clip and pipe. Lift the rear of the tank, pull to the rear,
then lift away.
4 If difficulty is found in replacing the tank, apply a small
amount of lubricant to the tank front rubbers before reassembly.
3 Petrol feed pipe: examination
The petrol feed pipe is made from thin walled synthetic
rubber and is of the push-on type. It is only necessary to replace
the pipe if it becomes hard or splits. It is unlikely that the retain-
ing clips should need replacing due to fatigue as the main seal
between the pipe and union is effected by an 'interference' fit.
