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Worx Generic QJ125-26A, Instruction And Maintenance Manual, Page: 99 / 166

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Worx Generic QJ125-26A Instruction And Maintenance Manual Download Page 99

7.2.2 Wobbly Direction Handle 

Damaged handle bearing. 
Not enough tyre pressure. 
Front fork bent, front wheel shaft bent. 
Distorted and crooked front wheel tyre. 

7.2.3 Wobbly Front Wheel 

Distorted wheel 
Worn front wheel bearing 
Defective front tyre 

7.2.4 Difficult Rotation of Wheel 

Shaft or bearing seat fault 
Braked 

7.2.5 Noisy Front Shock Absorber 

Friction sound of shock absorber protecting plate 
Loosened bolts on the shock absorber. 

7.3 Front Wheel 

7.3.1 Disassembly 

Attention: 

Stand the motorcycle reliably. 
Screw off speedometer mounting bolts and remove 
speedometer cable. 
Screw off front shaft locknuts. 
Remove front shaft (1), take down bearing seat assembly (2) and 
front wheel.                                         
Screw off bolts and remove front mudguard and lead wire of 
odometer.  
Remove front brake hose. 
Remove oil seal assembly (10) and bearing (5) with an oil seal 
remover and a bearing remover respectively. 
 

* Note: Refer to Page 95 of the manual for detailed QJ125 
Motorcycle front wheel disassembly and assembly diagram. 
 

7.3.2 Inspection 

7.3.2.1 Shaft Curvature Inspection 

Summary of Contents for Generic QJ125-26A

Page 1: ...Service Manual Holtvej 8 10 H ruphav 6470 Sydals Telefon 45 73 15 11 00 Fax 45 73 15 11 01 E mail info scanmi dk www scanmi dk CVR 27 73 31 07 April 2013 Worx 125...

Page 2: ...Two wheel Motorcycle QJ125 26A Instruction and Maintenance Manual ZHEJIANG QIANJIANG MOTORCYCLE CO LTD...

Page 3: ...DI Assembly 70 2 5 Ignition Coil 71 2 6 Trigger 72 III Starting System 74 3 1 Preparatory Data 74 3 2 Fault Diagnosis 75 3 3 Starting Motor 75 3 4 Starting Relay 77 IV Bulbs Switches Instruments 79 4...

Page 4: ...ting System 120 10 1 Preparatory Data 120 10 2 Fault Diagnosis 120 10 3 Oil Pump 121 XI Carburetor 125 11 1 Preparatory Data 125 11 2 Fault Diagnosis 125 11 3 Removal of Carburetor 126 11 4 Installati...

Page 5: ...eparatory Data 156 16 2 Fault Diagnosis 156 16 3 Crankcase 157 16 4 Crankshaft Connecting Rod Assembly 160 Exhaust System Inspection and Maintenance 161 XVII Emission Control System 162 17 1 Emission...

Page 6: ...ch component This shall be started from the time of periodical inspection The parts following Chapter One demonstrate the main point of disassembly installation and check of electrics parts finished v...

Page 7: ...No fire or smoking is allowed in operation site and gasoline storage place Storage Battery Battery shall be away from spark fire and smoking places since it may emit explosive gases Keep it in well ve...

Page 8: ...e clean the components and blow them with compressed air Plastic parts may age and deteriorate which are apt to be damaged by solvent or oil Check before re installation and replace if necessary To lo...

Page 9: ...damage to it Installation of rubber hose fuel vacuum or coolant insert its end into bottom of connector so that there is enough room for the hose clamp to grip the connector Install the rubber or plas...

Page 10: ...the cable from being pulled too tightly or slacking too much when the cable is wired along the handle pipe The cable shall not be affected by any neighbored components at any turning position The cab...

Page 11: ...steners 3 While re assembling new washers O rings cotter pins and locking plates shall be renewed 4 While tightening bolt or nut please first fasten bolts of large diameter or internal bolts and then...

Page 12: ...e Remarks Special socket wrench Clutch holder Flywheel extractor Feeler gauge Bearing puller Bearing installer Oil seal remover Puller handle Piston pin puller Piston ring pliers Spark plug socket wre...

Page 13: ...Figure 1 5 Figure 1 6 Figure 1 7 Figure 1 8 Figure 1 9 Figure 1 10 Handle Figure 1 11 Figure 1 12 Pliers Piston...

Page 14: ...Figure 1 13 Figure 1 14 Figure 1 15 Figure 1 16 Figure 1 17 Figure 1 18 Figure 1 19 Figure 1 20 Figure 1 21 Figure 1 22...

Page 15: ...Socket wrench Micrometer Magnetic stand V block Dial gauge Vernier caliper Spring clamp ring pliers Hammer screwdriver Front fork oil seal installer Front fork seal driver Steering nut wrench Figure 1...

Page 16: ...Figure 1 31 Figure 1 32 Figure 1 33 Figure 1 34 Figure 1 35 Figure 1 36 2 Special tools for chassis overhaul Front fork seal driver Figure 1 37 3 Steering nut wrench Figure 1 38...

Page 17: ...ents Special tools and their pictures for electrical component measurement are listed in Table 1 39 and Table 1 40 Table 1 39 Name Remarks Multimeter Ignition tester Figure 1 41 Figure 1 42 Continued...

Page 18: ...ification Front tubeless tyre 90 90 17 Air cleaner Dry Rear tubeless tyre 110 80 17 Drive Train Clutch type Wet multi plate friction type Fuel tank capacity 16 0 5L Gear shift pattern Five speed left...

Page 19: ...if magneto flywheel or trigger coil looses Loosen drain screw of carburetor and check if there is oil flowing out from overflow pipe Refuel gasoline Check compression pressure in the cylinder Check oi...

Page 20: ...ine can continue to run when it is started Carburetor is clogged inside or float is too high Carburetor starter i e cranking enrichment system fails 1 Check leakage at external connection parts of eng...

Page 21: ...low or the gasoline has been stored for a too long time 2 Check if engine runs at a high speed for a very long time or overloaded Check cooling system Air cooling the engine Check if radiator plates a...

Page 22: ...Carburetor starter i e cranking enrichment system works normally 3 Check if float of carburetor is too low Mixture ratio of air fuel is normal Check if exhaust of cylinder and exhaust muffler is clog...

Page 23: ...nical surface of driven wheel and mobile driven wheel are excessively worn or worn to groove 6 Check if raceway on the inner end face of friction wheel is excessively worn or pitted due to crush 1 Che...

Page 24: ...ine has idle speed after adjustment Engine has no idle speed after adjustment Air adjusting screw of carburetor or throttle adjusting screw is improperly adjusted Check if carburetor idle jet idle oil...

Page 25: ...Air pressure too low Air pressure normal Gas up as specified Check if fuel tank fuel switch delivery pipe or carburetor leaks oil Exclude as practical situations Check mixture ratio Mixture ratio of...

Page 26: ...ce Check if contact area between braking shoe and friction disc is worn terribly Repair or replace clutch shoe Refill engine oil Check if viscosity of engine oil in the crankcase is too low or the oil...

Page 27: ...aft separation push rod and other components of clutch control mechanism are excessively worn No No No No Yes Yes Yes Yes 4 stroke engine exhaust muffler gives off blue white smoke Check if engine oil...

Page 28: ...shift fork hole is excessively worn 3 Check if shift fork is deformed 4 Check if fork shaft is distorted or over worn Drum type brake fails Check if clearance of brake handle bar is within 10mm 20mm...

Page 29: ...case and check if meshing depth of each gear meets requirement Enough meshing depth Insufficient meshing depth Hydraulic disc brake fails Check brake liquid level in the liquid tank of main brake pump...

Page 30: ...ot charge Resistance is less than standard Charging coil is shorted Resistance is infinitely great Resistance meets the standard Charging coil or its output wires are shorted Disconnect connectors of...

Page 31: ...the negative wire to check current leakage Leaking current is smaller than specified Leaking current is bigger than specified usually It shall be no more than 1mA Check if charging coil of magneto is...

Page 32: ...er button and the click sound from starter relay cannot be heard Push starter button and a click sound from starter relay can be heard Disassemble the connector of starter relay from cables of the who...

Page 33: ...4 Check if armature coil is broken or shorted 1 Check if contact inside clutch switch is poorly contacted 2 Check if starter button contact is poorly contacted 3 Check if rectifier diode is damaged 4...

Page 34: ...ck if it is on state Check if starter button contact is poorly contacted Disassemble starter motor and make the following inspections 1 Check if the carbon brush is over worn 2 Check if carbon brush s...

Page 35: ...of rectification regulator from cables of the whole vehicle Lights are lit Lights are not lit Short circuit inside rectifier Disassemble headlamp assembly and check if the bulb is burnt Electric horn...

Page 36: ...of wire to short circuit power line and output line of lighting switch Wiring from magneto or ignition switch to lighting switch is broken or shorted Lamp is lit after short circuit Lamp is still not...

Page 37: ...f density of electrolyte in the battery is too low check if pole plates inside the battery are vulcanized or broken Separate conductors of rectification regulator from cables of the whole vehicle Meas...

Page 38: ...from the cables of the whole vehicle Check brightness of light Light recovers after separation Headlamp is still dim after separation Stable voltage of rectification regulator is too low Check if char...

Page 39: ...r of bulb in the lighting system is up to the requirement Replace the bulb 1 Check if contacts in headlamp switch and side lamp switch are poorly contacted 2 Check if connectors and earth wire are poo...

Page 40: ...d with a voltmeter No voltage display No voltage display Grounding wire of lamp holder is of poor contact or bulb of turn signal lamp is badly contacted with lamp holder Power line to the lamp holder...

Page 41: ...contact of turn signal lamp is poor contacted Check if there is power output from power input line of turn signal lamp switch by lamp test Test lamp is on Test lamp is off Power line of turn signal l...

Page 42: ...power line quickly with ground wire to check spark Spark at touch No spark at touch Connect power line of horn use a screwdriver to connect non power terminal terminal to button of horn with ground w...

Page 43: ...p is not lit after short circuit Brake lamp is lit after short circuit Use a screwdriver or a piece of wire to touch quickly power line of brake lamp switch and grounding wire and check sparks Brake l...

Page 44: ...n system Carburetor Bolt nut fastening part Ignition timing Tyre specification Wheel rim tyre Preparatory Standard General Warning Before running the engine please make sure the area you are working i...

Page 45: ...l type Ignition time BTDC15 1 1400 100rpm Frame Clearance of front brake handle 10 20mm Clearance of rear brake pedal 20 30mm Pneumatic pressure unit of tyre Kpa Specification Tyre pressure QJ125 26A...

Page 46: ...on of looseness of bolts at all positions I I I I I I Torque wrench Check if gearbox leaks oil I I I I I I Common tool Spark plug inspection and replacement I I R R I Common tool Gearbox oil replaceme...

Page 47: ...be performed according to the specifications on the user s manual unauthorized repair and adjustment are forbidden We will not be responsible for the results 2 You shall clean more frequently the air...

Page 48: ...ied clearance Rotate inward to increase clearance rotate outward to reduce clearance Tighten locknut When the clearance is adjusted rotate handle leftward and rightward to make sure idle of engine doe...

Page 49: ...cap Remove spark plug with a spark plug wrench or other applicable tools Inspection If the insulator is cracked or damaged If electrodes are worn Combustion condition and color Light grey color means...

Page 50: ...ct the battery which may result in interior component damage of the whole vehicle Battery charging circuit voltage inspection Open the seat cushion and take down the right protecting plate Disassemble...

Page 51: ...arm up the engine and then adjust idle speed Run the engine and connect engine tachometer Adjust the throttle cable lock screw to specified RPM Idle speed RPM 1400 100rpm min If idle speed RPM is unst...

Page 52: ...oil level inspection please do not tighten engine oil ruler Oil level inspection Stop the motorcycle on the flat ground with its middle stand and support the vehicle vertically When engine oil is cons...

Page 53: ...back onto the engine Attention Oil should be changed when the engine is warm Place the engine on the side stand Make sure all the engine oil is completely and quickly drained When the drain plug is r...

Page 54: ...edal clearance Measure brake pedal clearance Clearance 20 30mm If the clearance measured does not meet the specified value adjust it Adjust clearance of brake pedal Screw in or screw off adjuster If t...

Page 55: ...cy service life and luminous flux of bulb If oil is adhered to the bulb clean it with a cloth moistened with alcohol or highly volatile rubber solution Install headlamp assembly Clutch Check clearance...

Page 56: ...oosened Rear Suspension Compress upward and downward the rear shock absorber to check its actuator Check if components on the rear shock absorber are loosened or injured Lift and support the rear whee...

Page 57: ...ont shaft is loosened Check if lock nut of rear shaft is loosened If loosened tighten it to specified torque Tightening torque Front shaft lock nut 40 60 N m Rear shaft lock nut 85 98 N m Steering Ste...

Page 58: ...ing parts used in electric system Fastening position and fastening part name Tightening torque N m Starting motor clutch cover bolt Starting motor clutch locknut Rectifier bolt High voltage coil mount...

Page 59: ...Charging System 1 Starting relay 2 Scintillator 3 Battery 4 Electric igniter 5 High voltage ignition coil 6 Power lock assembly...

Page 60: ...oo high voltage on the battery the life span of the battery will be shortened 3 When the battery is not be used for a long period it will self discharge and its capacitance will drop The battery shoul...

Page 61: ...er High voltage coil mounting bolt 9 0 N m Flywheel remover Flywheel locknut 5 0 N m Testing device Vehicle block protecting plate bolt 9 0 N m Multimeter 1 2 Fault Diagnosis No power Unstable power B...

Page 62: ...ad wire Battery charging circuit voltage inspection Open the battery cover and remove battery pressure plate assembly Disconnect lead wire of the battery connector Measure voltage between terminals of...

Page 63: ...ition switch and main wiring 1 4 2 Charging state inspection While inspection battery shall be fully charged and a multimeter be used for the test Warm up the engine and then install fully charged bat...

Page 64: ...self Attention Do not touch the metal part of multimeter probe with your finger Check with a multimeter If impedance values measured by different multimeters are not the same it perhaps the inspection...

Page 65: ...d 1 7 2 Removal Remove vehicle block protecting plate Remove protecting plate of engine on the left side Remove flywheel locknut Use a flywheel remover to take down the flywheel Remove the fixation ke...

Page 66: ...agnetism on the inner surface of flywheel ensure there is no bolt on it Fix the flywheel using a universal non adjustable spanner and then tighten the locknut Torque value 9 0 N m Install protecting p...

Page 67: ...Ignition System 1 Relay 2 Scintillator 3 Battery 4 Igniter 5 High voltage ignition coil 6 Power lock assembly 7 Voltage regulator Ignition System...

Page 68: ...ignition system problem due to poor contact of sockets Please check first if parts of the connector are well contacted 6 Check if heat value of spark plug is proper Improper spark plug may result in...

Page 69: ...high voltage wire is not good Inferior CDI assembly after items are tested and proved abnormal or spark plug no sparking High voltage power is normal spark plug no sparking Inferior spark plug or seco...

Page 70: ...ith spark plug installed on the cylinder head Connect lead wire of ignition coil a shunt is connected between the terminal black white of primary coil and the grounding vehicle block Press starting mo...

Page 71: ...o terminal is normal it indicates that the connector is of poor contact or wiring is broken When measured results at both sides are abnormal the trigger is damaged Please refer to items listed in Diag...

Page 72: ...etween terminals of primary coil Standard value 0 4 10 20 Impedance value within the range is good Impedance value indicates broken wire inside the coil The coil shall be replaced 2 5 3 Secondary coil...

Page 73: ...emove protecting plate of vehicle block Remove lead wire connector of trigger Measure the impedance between blue white terminal of lead wire at engine side and grounding vehicle block Standard value 1...

Page 74: ...Starting System 1 Starting relay 2 Scintillator 3 Battery 4 Electronic igniter 5 high voltage ignition coil 6 Power lock assembly 7 Rectifier 8 Electric horn Starting Diagram...

Page 75: ...n be performed on the engine Starting clutch removal refers to removal instruction Basic data Item Standard Service Limit Length of starting brush 12 5mm 8 5mm Starting idler shaft bushing 8 3mm Start...

Page 76: ...er supply to check if starting motor runs to confirm your operation is safe First remove the lead wire clip of starting engine Remove starting motor mounting bolt and take down the starting motor Roll...

Page 77: ...both ends of brush shaft Press brush into its holder and install front cover of electrodes Attention There should be no hurt on the contact surface of brush and armature Take care Installation shaft o...

Page 78: ...ry voltage shall meet the specified When there is no voltage at wire terminal of starting relay inspect braking switch continuity and lead wire 3 4 3 Starting relay ground loop inspection Remove start...

Page 79: ...Bulbs Switches Instruments 1 Headlamp 2 Instruments 3 Electric horn 4 Left rear turn signal lamp...

Page 80: ...and perform continuity test All the plastic connectors have pawls on them Release clamping of the pawl before removal Align pawl to its hole when it is reinstalled While trouble shooting electric fau...

Page 81: ...p rear cover Tighten the new bulb into the socket Avoid touching bulb glass with your bare hands during installation and staining it with oil which may affect transparency service life and luminous fl...

Page 82: ...he tail lamp hood is in good condition and correct position 4 5 3 Tail lamp bulb replacement 4 5 3 1 Removal Screw off mounting bolts on the tail lamp hood Remove tail lamp hood 3 so that tail lamp bu...

Page 83: ...ey to position and you will be able to pull out the key and the tail lamp Stop Lamp will be kept on 4 7 2 Ignition switch replacement Remove the headlamp Screw off the mounting bolts and remove the ig...

Page 84: ...the draw bar bracket for the rear brake lever Remove throttle handle and bolts Take down throttle handle from the handle and remove the throttle cable Remove locknut on the handle and take down the h...

Page 85: ...mounting bolt Rear shaft locknut Upper bracket assembly mounting bolt Front shaft locknut Front shock absorber mounting bolt Rear shaft locknut Rear shock absorber top nut Rear shock absorber bottom...

Page 86: ...t 3mm D Mounting torque for Bolt 7 in the diagram 22 29 N m 1 Oil pump block assembly 2 Hydraulic brake handle 3 Handle mounting bolt 4 Nut M6 5 Fixed cover 6 Bolt M6 23 7 Front hydraulic brake mounti...

Page 87: ...ting bolt 6 Bolt M6 30 7 Washer 6 8 Rear brake rocker arm 9 Nut M6 10 Washer 11 Cam shaft O sealing ring 12 Rear braking cam shaft 13 Rear wheel right bush 14 Rolling bearing 6302 2RS 15 Braking shoe...

Page 88: ...m ID 130 131 Rear brake shoe thickness 4 0 3 0 5 1 2 Tightening Torque Value Front wheel shaft locknut 55 62 N m Front brake cylinder assembly mounting bolt 22 29 N m Rear wheel shaft locknut 85 98 N...

Page 89: ...Front brake 1 Hydraulic brake handle 7 2 Oil pump block assembly 5 3 Braking hose assembly 4 4 Braking cylinder assembly 6 5 Hydraulic brake disc 2 Note Detailed breakdown drawing refers to P85 Attent...

Page 90: ...mbly Please do not contaminate braking shoe and brake disc with oil Attention A contaminated braking shoe will reduce braking performance and result in brake failure Tighten bolt and nut to their spec...

Page 91: ...etailed exploded view refers to P86 5 4 2 Inspection Check if braking shoe assembly and brake drum are worn Replace them if necessary Measure braking shoe thickness and brake drum ID and record the ma...

Page 92: ...failure Tighten bolt and nut to their specified torque value Torque value Rear wheel locknut 85 98 N m Do not contaminate braking shoe with oil If a braking shoe is polluted by oil clean it with brake...

Page 93: ...ly install pawl of each part during combination Do not damage the fittings during exterior part installation 1 Right cowling installation plate 2 Cowling installation plate 3 Right decorative panel II...

Page 94: ...el Front mudguard Rear mudguard assembly Rear rail Rear tail cover connectiong board Tail lamp Tail lamp support Attention Do not damage exterior parts during assembly and disassembly Do not damage th...

Page 95: ...aft 2 Gear seat assembly 3 Gear seat oil seal 4 Drive plate 5 Bearing 6 Front wheel middle sleeve 7 Front brake disc 8 Front brake disc mounting bolt 9 Front wheel oil seal assembly 10 Front wheel lef...

Page 96: ...ng handle jacket 10 Left handle assembly 11 Left handle 12 Slotted Nut 13 Handle mounting bolt 14 Bolt M6 25 15 Fixed cover 16 Adjusting screw tube 17 Slotted nut 18 Left and right rear mirror holders...

Page 97: ...6 12 21 Upper bracket assembly 22 Nut M6 23 Side reflector assembly 24 Washer 10 25 Dust cover 26 27 Combination screw M6 16 28 Location pin 29 Upper steel bowl of upper bearing 30 Steel ball 3 16 inc...

Page 98: ...ion Please do not let oil contaminate braking shoe braking shoe assembly and brake disc Basic data of the motorcycle as a whole Measuring position Item Standard value mm Service Limit mm Front wheel s...

Page 99: ...e shock absorber 7 3 Front Wheel 7 3 1 Disassembly Attention Stand the motorcycle reliably Screw off speedometer mounting bolts and remove speedometer cable Screw off front shaft locknuts Remove front...

Page 100: ...eve 11 of front wheel Remove oil seal assembly 10 Remove bearing 5 Inspect rolling of bearing If bearing does not roll roll smoothly or steadily or bearing is worn or loosened replace it with a new on...

Page 101: ...d assembly diagram Front wheel locknut tightening torque 55 62 N m 7 4 Steering Handle 7 4 1 Removal Remove left and right rear mirror assemblies 1 and 2 Open the fixed cover Remove left handle assemb...

Page 102: ...off upper bracket mounting bolt and lower bracket pinch bolt Remove headlamp bracket Remove the front fork Tools Steering handle welded assembly mounting bolt wrench Locknut wrench Special remover for...

Page 103: ...grease on the top holder race Turn steering handle left and right to have steel balls closely fit Tools Locknut wrench Rotate the front fork left and right to be sure of its smoothness and there shall...

Page 104: ...teeth 7 Oil seal 8 Rolling bearing 6204 2RS 9 Chain drive sleeve 10 Sprocket hub 11 Sprocket mounting bolt 12 Rear wheel left sleeve assembly 13 Rear wheel buffer 14 Bearing spacer 15 Tubeless tyre 1...

Page 105: ...Rear Shock Absorber 1 Cap nut M10 1 25 2 Rear shock absorber mounting gasket 3 Rear shock absorber assembly 4 Washer 12 Bolt M10 1 25 40...

Page 106: ...1 Locking nut M14X1 5 2 Dust ring assembly 3 Bush 4 Oil seal 5 Middle sleeve 6 Rubber gasket for protecting plate 7 Rear swing arm welding assembly 8 Washer 12 9 Chain adjuster spacer 10 Connecting r...

Page 107: ...hub 3 Chain drive sleeve 4 Rolling bearing 6204 2RS 5 Oil seal 6 Sprocket 43 teeth 7 Sprocket stopper 8 Nut M8 9 Chain 428H 1 126 10 Chain guard 11 Boss bolt A Tightening torque of Bolt 1 in the diag...

Page 108: ...th oil Basic preparatory data Item Standard Value mm Service Limit mm Rear wheel Shimmy Longitudinal 2 0 Transversal 2 0 Tightening torque Rear shat locknut 85 98 N m Rear shock absorber top nut 37 44...

Page 109: ...orn braking shoe Worn brake drum Contaminated braking shoe Contaminated brake drum 8 3 Rear Wheel 8 3 1 Removal Stand the motorcycle steadily and rear wheel is off the ground Remove rear brake pedal a...

Page 110: ...eeds 2 0mm Transversal Replace it when the measured value exceeds 2 0mm When rear wheel shimmy exceeds service limit rear wheel bearing is loosened which results in wobbly rear wheel Check and replace...

Page 111: ...ing If it is replace rear shock absorber assembly 8 4 Install Rear Shock Absorber Install the rear shock absorber in the reverse order of removal Install upper locknut and lower mounting bolt on the r...

Page 112: ...sembly 15 and intermediate sleeve 14 Install rear swing arm assembly 6 Install rear swing arm onto the frame and insert rear swingarm shaft Install and tighten rear swing arm shaft nut to specified to...

Page 113: ...an Take the cleaned chain from kerosene and dry it in the air Inspect roller and its side plate If it is damaged or worn replace the drive chain Lubricate drive chain Drive chain lubricant can be purc...

Page 114: ...h a new one 8 5 4 Installation Install it in the reverse order of removal Install drive chain chain cover rear left shock absorber rear wheel and drive sprocket cover Adjust slackness of drive chain a...

Page 115: ...Seat Cushion 1 Seat cushion assembly 2 Rear rail 3 Rear luggage carrier screw II 4 Rear luggage carrier screw I...

Page 116: ...Left fuel tank protecting plate 6 Fuel tank installation gasket 7 Fuel sensor assembly 8 Sensor rubber gasket 9 Nut M6 10 Fuel switch assembly 11 Wire clamp 8 12 Oil hose 4 5 2 140 13 Wire clamp 9 14...

Page 117: ...set at OFF position while removing fuel tank While installation tighten bolt and nut to their specified torque After installation check if all the components are correctly fixed and work normally Bas...

Page 118: ...Remove connector from lead wire of oil level sensor Fuel switch shall be set at OFF position Disconnect fuel hose and carbon canister connecting hose Remove bolt washer damper and fuel tank Remove the...

Page 119: ...ew Closing bolt Right side cover bolt Front left cover bolt Coil screw Clutch separating disc bolt Clutch locknut Filter screen cover bolt Tensioner pinch bolt Drive gear locknut Drive sprocket bolt E...

Page 120: ...untershaft assembly 7 Filter screen 8 Engine oil pump 9 Filter element assembly Note When the engine oil pump is removed clean carefully all the components and purge them with high pressure gas During...

Page 121: ...riction between plasmids of lubricating oil It is used to reduce wear of component cool components of higher heat absorb impact from bearing and other parts weaken noise increase tightness between pis...

Page 122: ...crew Take down oil pump block drive gear and pump shaft Screw off the screw Take down pump seat Remove the screw and take down pump cover Disassemble oil pump Check radial clearance between inner roto...

Page 123: ...Check clearance between external rotor and oil pump seat Allowable limit 0 2mm Check clearance between rotor end faces Allowable limit 0 15mm Testing gauge Testing gauge Flat board...

Page 124: ...gine Oil Pump As shown in the following figure Attention After assembly inner and external rotors shall rotate smoothly and be out of nimbleness 10 3 2 Installation Install the oil pump in the reverse...

Page 125: ...ore 11 Idle jet 12 Main jet 13 Main nozzle 14 Main foam pipe 15 Mixture screw 16 Mixture screw spring 17 Fixture screw washer 18 Mixture screw seal ring 19 Plunger adjusting screw spring 20 Plunger ad...

Page 126: ...de the float may deteriorate which will clog idle nozzle and idle may become dangerous Function of carburetor Carburetor is one of the key parts for oil supply system of the engine Its working perform...

Page 127: ...ark while acceleration Improper work of enrich valve Too low mixed gas concentration Improper work of needle valve Too high oil level Oil outflow from carburetor Clogged airway Dirty air cleaner 11 3...

Page 128: ...e it if necessary Check carburetor itself and fuel pipe If they are dirty clean it according to the user s manual 11 4 Installation Assembly Install idle jet main jet main nozzle and main foam pipe In...

Page 129: ...ting screw 23 Valve collet 24 Valve spring upper retainer 25 Valve spring 26 Valve rod sealing assembly 27 Valve guide 28 Valve spring lower retainer 29 O ring 30 Rubber air intake assembly 31 Stud 32...

Page 130: ...d high temperature and high pressure fuel gas It accomplishes air intake and exhausting operation with valve mechanism Basic Data Unit mm Item Standard Service Limit Cylinder cover flatness 0 03 0 05...

Page 131: ...ression pressure Air leakage at cylinder head Too much carbon deposited in the combustion chamber Improperly installed spark plug 12 3 Cylinder Head 12 3 1 Removal Screw off the ten locknuts and remov...

Page 132: ...05mm Clearance between rocker arm and rocker arm shaft Allowable limit 0 08mm Screw off the two locknuts and remove the lock washer cam shaft and C type gasket Screw off the three cap nuts and hexagon...

Page 133: ...ness of junction surface of cylinder cover Allowable limit 0 05mm If flatness of junction surface of cylinder cover exceeds the service limit put a piece of fine sandpaper on the flat plate and fit th...

Page 134: ...eposition in the valve guide with a reamer before inspection Attention Rotate the reamer in clockwise Please do not rotate he reamer in counterclockwise Measure valve guide ID Allowable limit Intake E...

Page 135: ...a special valve guide remover Install a new O ring onto the new valve guide Install the valve guide from the top of cylinder head Attention Please do not hurt cylinder head while installing valve gui...

Page 136: ...clearly Remove 1 4 of external edge of valve race with a 32 angle milling cutter Remove 1 4 of bottom of valve race with a 60 angle milling cutter Remove the milling cutter and check the places proces...

Page 137: ...and cutting please apply some polishing agent on the surface of valve Polish the valve gently 12 7 Cylinder Head Installation Install the cylinder head in the reverse order of removal Attention While...

Page 138: ...7 Location pin 8 Washer 9 Cylinder cover connecting bent pipe assembly 10 Bolt 11 Cylinder cover connecting bent pipe washer assembly 12 Cylinder block 13 Washer 14 Tensioner assembly 15 Bolt 16 Bolt...

Page 139: ...shaft to rotate It forms a combustion chamber with cylinder head It works as a slide valve to compress regularly fresh mixed gas from crankcase into cylinder and exhaust combustion gas from the cylind...

Page 140: ...ure Noisy piston Too much carbon deposited in the combustion chamber Damaged cylinder piston and piston ring Worn piston pin hole and piston pin 13 3 Cylinder Block 13 3 1 Cylinder Block Removal Screw...

Page 141: ...eposited carbon inside the piston ring Install the piston ring Measure the clearance between piston ring and piston ring groove Allowable limit Top ring 0 09mm Second ring 0 09mm Remove piston ring an...

Page 142: ...0 angle with piston pin about 11mm below piston skirt Allowable limit 56 93mm Inspect wear and scratch on inner wall of cylinder Attention Measure cylinder ID at three positions i e upper intermediate...

Page 143: ...m Check flatness of cylinder surface Allowable limi 0 05mm Measure Connecting rod small end ID Allowable limit 14 06mm 13 4 2 Installation of piston Install location pin Apply engine oil evenly on eac...

Page 144: ...ttention Install with the Point mark at the bottom of piston facing the exhaust valve 13 5 Install Cylinder Install washer and location pin onto the crankcase Apply evenly engine oil on inner wall of...

Page 145: ...assembly 12 Driven friction plate 13 Center bracket 14 Sleeve 15 Thrust washer 16 Housing assembly Attention You don t have to remove the engine from frame while overhauling clutch Viscosity and level...

Page 146: ...ly variable transmission Basic data Unit mm Clutch Braking shoe thickness 2 9 3 2 6 Length of pressure spring 31 29 7 14 2 Fault Diagnosis Tight clutch release lever Clutch slips at acceleration Trans...

Page 147: ...ever sleeve bearing separating plate and clutch spring Removed components refer to exploded view Use a special tool to screw off clutch locknut Remove locknut and washer Remove clutch center bracket R...

Page 148: ...roove of clutch If there are fix and adjust with a file If there is a lot for fix and adjustment replace it Check if teeth of pressure plate and center bracket are injured If they are replace them Mea...

Page 149: ...m 14 4 Disassemble Main Shaft and Countershaft Inspection Check respectively wear of tooth surface and drive pawls If they are seriously worn or damaged replace them Remove bearing and oil seal on lef...

Page 150: ...e if necessary Attention Hammered out bearing cannot be reused Replace it with a new one Remove bearing and oil seal with special tools Main shaft and countershaft combination Attention Apply each gea...

Page 151: ...Reduction Gear 1 Gearshift drum 2 Shift fork 3 Shift fork shaft 4 Main shaft assembly 5 Countershaft assembly Function Transfer torque and determinate the final output torque and rotary speed...

Page 152: ...b OD 39 8 40 39 75 Gearshift hub lock groove width 6 1 6 2 6 35 15 2 Fault Diagnosis Hard to engage gear Difficult gearshift Worn or distorted gearshift fork Clutch is not completely separated Broken...

Page 153: ...view 15 3 2 Exploded View 15 3 3 Inspection Before disassembly gearshift plate shall work flexibly and smoothly Check if gearshift plate and gearshift shaft assembly are worn If they are seriously wor...

Page 154: ...shift drum Remove gearshift fork Measure shift fork OD Allowable limit 9 96mm Measure shift fork hole ID Allowable limit 10 05mm Measure shift fork thickness Allowable limit 4 6mm Shift fork shaft Gea...

Page 155: ...drum Allowable limit 39 75mm Measure the width of gearshift drum lock groove Allowable limit 6 35mm Remove balance shaft gear 15 4 Installation Install it in the reverse order of removal Lock groove w...

Page 156: ...Bolt 6 Piston Attention Crankcase is a thin wall casting part Avoid impact on it during operation in case it may be distorted or broken Clean carefully all the components before inspection and test an...

Page 157: ...ad It bears impact from combustion and inertia force from movement of crankshaft connecting rod and forms a partial enclosed space for air and oil Suspension hole is set on the crankcase which can be...

Page 158: ...move gear chamber cover Remove starting motor gear needle bearing and washer Screw off bolts on left front cover and left rear cover of crankcase Remove left front cover and left rear cover Remove sta...

Page 159: ...plate and take down cam assembly Remove bearing locating device 16 3 2 Exploded View of Cam Assembly Measure cam bush ID Allowable limit 14 10mm Measure cam height Allowable limit 32 5mm Cam shaft sp...

Page 160: ...roller cover and its cover washer Remove washer and location pin Use an electric or pneumatic tool to screw off locknut Remove oil filter roller and take down the drive gear Screw off engine oil pump...

Page 161: ...earance Allowable limit 0 55mm Measure connecting rod big end clearance along X Y direction Allowable limit 0 05mm Crankshaft shimmy measurement Allowable limit 0 01mm Check if there is abnormal noise...

Page 162: ...lysts are added into the muffler welding assembly in the diagram C Tightening torque of combined screw 6 for muffler protecting plate in the diagram 5 9 N m 1 Exhaust pipe gasket assembly 2 Bolt M8 30...

Page 163: ...for the customers at a reasonable price 1 Without performing regular maintenance according to the time and traveled distance specified by the company 2 Users not performing regular inspection adjustme...

Page 164: ...service life of the engine when your motorcycle is often used on sand gravel roads or in severely polluted environment More frequent servicing may be required when the motorcycle is often driven at h...

Page 165: ...mber clean For Delivery Qualified Qualified Qualified Qualified Qualified Qualified Classification Equipment Constituted Part Desired Function Emission control system Catalytic device Catalytic conver...

Page 166: ...QJ125 26A Schematic Circuit Diagram...

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