Aeon New Sporty 125 Service Manual Download

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AEON MOTOR CO.,LTD

Summary of Contents for New Sporty 125

Page 2: ...ALLATION 16 4 ENGINE LUBRICATION AND COOLING SYSTEM 17 5 CYLINDER HEAD VALVES 26 6 CYLINDER PISTON 37 7 TRANSMISSION SYSTEM 46 8 FRONT WHEEL SUSPENSION AND STEERING 57 9 REAR WHEEL SYSTEM 68 10 FENDER...

Page 3: ...ct with the electrolyte flush the area thoroughly with water If you get the electrolyte in your eyes flush with water and contact a doctor immediately HOT PARTS Engine and exhaust pipe become very hot...

Page 4: ...ont Rear BRAKES Front Rear TIRES Front Rear Specifications subject to change without notice Air Cooled 4 syroke with Oil Cooler 125 cc 169 cc 52 4 57 8mm 61 57 8mm 9 1 1 6 21 Nm 4017 rpm 10 24 Nm 4403...

Page 5: ...4 1 4 SERIAL NUMBER The frame serial number is stamped on the front frame And stick a bar code paper to cover it The engine number is stamped under the crankcase...

Page 6: ...le nut Rear wheel bolt Exhaust muffler mounting bolt Engine hanger bolt Rear axle holder bolt Swingarm pivot nut Rear shock absorber mounting nut 5 N m 3 5 lbs ft 10 N m 7 2 lbs ft 22 N m 16 lbs ft 35...

Page 7: ...4 Gear oil 2 1 MAINTENANCE DATA SPECIFICATION SPARK PLUG Spark plug cap Recommended spark plugs Throttle lever free play Idle speed Brake lever free play Drive chain slack Front rear tire size Front r...

Page 8: ...t 30 hours Every 100 hours Every 200 hours Every 300 hours ENGINE OIL R R GEAR OIL R R FUEL FILTER R AIR VLEAN FILTER R ENGINE OIL FILTER C CARBURETOR I SPARK PLUG C VALVE GAP A IGNITION TIMING A CHAI...

Page 9: ...and automatic full closing in steering positions Inspect for deterioration damage cuts and nicks or kink in the throttle cable replace it if necessary Check the throttle lever free play should be not...

Page 10: ...ng the adjuster on the throttle housing Inspect the free play of the throttle lever 2 6 AIR CLEANER MAINTENANCE 1 Loosen the screw and remove the air cleaner from carburetor 2 Disassemble the air clea...

Page 11: ...arefully bending the side electrode SPARK PLUG GAP 0 6 0 7 mm RECOMMENDED REPLACEMENT PLUG NGK CR7HSA 6 Check the sealing washer and replace with a new one if damaged 7 With the sealing washer attache...

Page 12: ...g nut Tighten the axle holder lock nut Torque 90N m 65 Ft lbs When the drive chain becomes very dirty it should be removed cleaned and lubricated with the specified lubricant Clean the drive chain wit...

Page 13: ...ver assembly Inspect the rear brake lever and cable for excessive play or other damage Replace or repair if necessary Measure the free play of the brake lever at the end of the lever The standard is 1...

Page 14: ...turned straight ahead When there is excessive play inspect the tie rod kingpin bushing and ball joint Steering shaft holder bushing Remove the front fender Remove the steering shaft holder and check t...

Page 15: ...ck let the wheels turn 180 so the marks on the tires are aligned with the axle center height Measure the distance between the marks Calculate the difference in the front and rear measurements Toe in 5...

Page 16: ...STEP1 Unscrew this drain hole bolt and let the dirty oil flow out catching the oil in a proper container for later disposal STEP2 Reinstall the drain hole bolt an tightness STEP3 Fill with new gear oi...

Page 17: ...nect the carburetor cable by unscrew two screws on top of the carburetor Disconnect the wire connectors There are three connectors for carburetor auto choke starter motor and generator respectively Re...

Page 18: ...ATION GENERAL This section describes inspection and replacement of the engine oil oil filter screen and assembly of the oil pump Fill the oil pump with clean oil when reassembling the pump SPECIFICATI...

Page 19: ...oil consumption Normal oil consumption External oil leaks Oil not changed often enough Worn piston rings Faulty heat gasket Oil contamination Worn piston rings Faulty heat gasket Oil or filter not cha...

Page 20: ...the oil drain bolt NOTE drain the oil while the engine is warm to ensure complete draining Remove the oil filter cap spring and oil filter screen Check the O ring for damage or fatigue Install a new o...

Page 21: ...il level gauge Start the engine and let it idling for 2 or 3 minutes Stop the engine and check that the oil level at the upper line on the gauge Make sure there are no oil leaks 4 5 OIL PUMP REMOVAL R...

Page 22: ...21 Remove the left crankcase cover Remove the starting clutch outer and gear ass y Remove the flange bolts and oil separator Remove the oil pump chain and oil pump driven...

Page 23: ...22 sprocket Remove the oil pump ass y Disassemble the oil pump INSPECTION Measure the oil pump rotor to body clearance SERVICE LIMIT 0 12 mm Install the oil pump shaft and measure the pump...

Page 24: ...re the pump and clearance SERVICE LIMMIT 0 2 mm 4 5 OIL PUMPASS Y INSTALLATION Install the outer rotor inner rotor and oil pump shaft onto the body NOTE Pour a drop of clean engine oil inside the oil...

Page 25: ...24 chain Install the oil separator Install the starting clutch outer and gear ass y Install the new gasket dowel pins and right crankcase cover...

Page 26: ...25 Install the A C G generator ass y Install cooling fan composition Install fan cover 5 CYLINDER HEAD VALVES...

Page 27: ...e gasket O ring and dowel pins are in place SPECIFICATIONS ITEM STANDARD SERVICE LIMIT Cylinder compression 12 0 5 kg cm2 Cam lobe height IN EX 25 965 27 195 25 810 27 20 25 57 26 7 25 40 26 80 Rocker...

Page 28: ...urned or bent valve Incorrect valve timing Weak valve spring Cylinder head Leaking or damaged head gasket Warped or cracked cylinder head Faulty cylinder or piston Excessive noise Incorrect valve adju...

Page 29: ...gas waste recovery Remove the cylinder head cover Remove the air cleaner and carburetor Remove the inlet pipe ass y Remove the shroud compositions Relax the cam chain adjuster screw Remove the screw a...

Page 30: ...lder and dowel pins Relax the camshaft gear from cam chain and remove the camshaft INSPECTION Inspect the cam lobes surface and height of cam lobes for wear or damage SERVICE LIMIT IN 25 57 26 18 mm E...

Page 31: ...hafts and rocker arms Inspect the camshaft holder rocker arms and rocker arm shafts for wear or damage Measure the I D of each rocker arm SERVICE LIMIT 10 10 mm Measure the O D of each rocker arm shaf...

Page 32: ...the cam chain guide CYLINDER HEAD DISASSEMBLY Remove the valve cotters spring retainers and valve springs with a valve spring compressor INSPECTION Clean off all carbon deposits from the com bustion...

Page 33: ...he inner and outer valve springs SERVICE LIMITS Inner 31 2 mm Outer 34 1 mm Inspect each valve for turning burning scratches or abnormal stems wear Check the valve movement in the guide Measure and re...

Page 34: ...olerance If so replace guides as necessary and ream to fit If the valve guide is replaced the valve seat must be refaced CYLINDER HEAD ASS Y Lubricate each valve stem with oil Insert the valves into t...

Page 35: ...arm shafts into the camshaft holder Align the T mark on the flywheel with the index mark on the alternator cover by turning the flywheel counter clockwise Position the camshaft gear with cam chain so...

Page 36: ...20 N m 14 8 lbs ft Adjust the clearance between the rocker arm and valve stem by applying a feeler gauge STANDARD VALVE 0 08 mm Relax the cam chain adjusting bolt with coun terclockwise direction and...

Page 37: ...36 6 CYLINDER AND PISTON 6 1 SERVICE INFORMATION 6 2 TROUBLESHOOTING 6 3 CYLINDER REMOVAL 6 4 PISTON REMOVAL 6 5 CYLINDER INSTALLATION 6 1 SERVICE INFORMATION...

Page 38: ...iston pin bore 15 002 15 008 15 04 Piston rings Piston pin O D 14 994 15 000 14 960 Piston to pin clearance 0 002 0 014 0 02 Piston ring TOP 0 015 0 050 0 12 SECOND 0 015 0 050 0 12 Groove Clearance T...

Page 39: ...r Excessive carbon build up Excessive smoke Worn cylinder piston or piston rings Improper installation of piston rings Scored or scratched piston or cylinder wall Damaged valve stem seal 6 3 CYLINDER...

Page 40: ...cylinder surface NOTE Be carefully not to damage the gasket surface 6 4 PISTON REMOVAL Stuff a shop towel into the crankcase Remove the piston pin clip with needle nose pliers NOTE Do not allow the c...

Page 41: ...r walls for scratches or wear Measure and record the cylinder I D at three levels in both an X and Y axis Take the maximum reading to the cylinder wear SERVICE LIMITS 0 10 mm Calculate cylinder taper...

Page 42: ...ring to groove clearance SERVICE LIMITS TOP 0 12 mm SECOND 0 12 mm Inspect the piston for wear or damage Insert each piston ring into the cylinder and measure the ring end gap NOTE Push the rings into...

Page 43: ...the piston pin O D SERVICE LIMIT 14 960 mm Measure the piston pin O D SERVICE LIMIT 15 04 mm Calculate the piston to piston pin clearance SERVICE LIMITS 0 02 mm Measure the connecting rod small end I...

Page 44: ...rings Avoid piston and piston ring damage during installation Space the piston ring end gaps 120 degrees apart PISTON INSTALLATION Install the piston with it s IN mark on the intake valve Install the...

Page 45: ...mage the gasket surface Install the dowel pins a new gasket Coat the cylinder bore and piston rings with engine oil and install the cylinder NOTE Avoid piston rings damage cylinder bore during install...

Page 46: ...1 SERVICE INFORMATION If the drain tube ass y fills with water the tube should be drained SPECIFICATIONS ITEM STANDARD mm SERVICE LIMIT mm Driven the width 19 8 20 2 19 0 Weight roller O D 15 0 15 02...

Page 47: ...164 0 TORQUE VALUES Clutch outer nut 55 N m 40 6 lbs ft Drive face nut 55 N m 40 6 lbs ft 7 2 TROUBLE SHOOTING Engine starts but can t travel Worn driven belt Worn clutch lining Damaged driven face sp...

Page 48: ...47 7 3 C V T DISASSEMBLY LH CRANKCASE COVER REMOVAL Relax the band screw and remove the C V T inlet duct Remove the air cleaner case C V T INLET DUCT AIR CLEANER CASE...

Page 49: ...Clean off any gasket material from L crankcase surface C V T REMOVAL Relax the flange nut and remove the drive face Relax the flange nut Remove the drive pulley ass y and driven belt LH CRANKCASE COV...

Page 50: ...late and weight roller set Relax the special nut and remove the driven plate composition and driven face spring Inspect the driven belt for wear tears or damage Measure the width of driven belt SERVIC...

Page 51: ...movable driven face SERVICE LIMIT 28 03mm Inspect the drive face collar for wear or damage Measure the I D of drive face collar SERVICE LIMIT 24 098 mm Inspect the drive face boss for wear or damage...

Page 52: ...lutch weight lining SERVICE LIMIT 1 5mm Measure the length of driven face spring SERVICE LIMIT 164 0 mm Inspect the driven face ass y and replace them if necessary 7 4 KICK STARTER DISASSEMBLY Remove...

Page 53: ...ter idle gear ass y Remove the kick spindle bush INSPECTION Inspect the kick starter spindle composition for wear or damage Inspect the kick starter return spring for fatigue or damage Inspect the kic...

Page 54: ...damage 7 5 KICK STARTER ASSEMBLY Install the kick driven gear and spring Install the kick spindle bush return spring and spindle ass y Install the kick starter 7 6 C V T ASSEMBLY Assemble the driven...

Page 55: ...late Assemble the movable drive face weight roller set and drive face Install the movable drive face ass y and boss Install the drive face and kick starter ratchet DRIVE FACE BOSS MOVABLE DRIVEN FACE...

Page 56: ...belt and driven pulley ass y Install the dowel pins and gasket Install the LH crankcase cover Install the air cleaner case and C V T ducts DRIVE FACE FLANGE NUT DRIVE PULLEY DRIVEN BELT DOWEL PIN GASK...

Page 57: ...8 FRONT WHEEL SUPENSION AND STEERING 8 1 PARTS DRAWING 8 2 TROUBLESHOOTING 8 3 HANDLEBAR 8 4 THROTTLE HOUSING 8 5 FRONT WHEEL 8 6 FRONT BRAKES 8 7 STEERING SYSTEM 8 8 FRONT SUSPENSION 8 1 PARTS DRAWI...

Page 58: ...57...

Page 59: ...tened properly BRAKE DRAG Incorrect brake adjustment Sticking brake cable STEERS TO ONE SIDE Bent tie rods Wheel installed incorrectly Unequal tire pressure Bent frame Worn swing arm pivot bushing Inc...

Page 60: ...ber springs Worn or damage front swing arm bushing 8 3 HANDLEBAR SYSTEM Removal Remove the handlebar cover by unscrew two fix screws Remove the throttle lever housing on the right handlebar Remove bra...

Page 61: ...move the bolts attaching the handlebar upper holder Remove the handlebar Installation Install the switch housing Tighten two screws securely Install the throttle lever housing and brake lever bracket...

Page 62: ...Assembly is in the reverse order of disassembly 8 5 FRONT WHEEL Remove Raise the front wheels off the ground by placing a jack or other support under the frame Remove the front wheel nuts washer and w...

Page 63: ...re the brake drum inner diameter The maximum limit 111 mm Turn the inner race of each bearing with fingers The bearings should turn smoothly and quietly If the race does not turn smoothly or quietly r...

Page 64: ...rease to the brake cam and anchor pin and install the cam in the brake panel Soak the felt seal in the engine oil and install the seal on the brake cam Install the brake arm on the cam by aligning the...

Page 65: ...eel Install the castle nut and cotter pin 8 7 STEERING SYSTEM Remove the kingpin and Tie rod Remove the front wheels and brakes plates Remove the four self lock nuts from the tie rod ball joints and t...

Page 66: ...bar lower holder Unscrew steering shaft holder bolt remove steering shaft holder Take off the cotter pin below steering shaft Unscrew the steering shaft fix out below shaft Pull steering shaft careful...

Page 67: ...and oil seal tighten with the nuts Torque 33 N m 24 lbs ft 8 7 STEERING SYSTEM Installation of steering shaft Install the steering shaft nut and tighten it This nut is under this steering shaft Torque...

Page 68: ...9 REAR WHEEL SYSTEM 9 1 PARTS DRAWING 9 2 TROUBLESHOOTING 9 3 REMOVE REAR WHEELAND REAR BRAKE 9 4 DRIVE MECHNISM 9 5 REAR BRAKE AND WHEEL INSTALLATION 9 6 SHOCK ABSORBER 9 4 SWING ARM 9 1 Parts Drawin...

Page 69: ...xle bearing holder is faulty Brake Drag Incorrect brake adjustment Sticking brake cam Sticking brake cable Hard Suspension Bent damper rod Faulty swing arm pivot bushing Soft Suspension Wear shock abs...

Page 70: ...69 Hydraulic Cylinder Driving Rod The rear brake cable fixing set The cable connects to wire connector for front brake function Brake Pump The cable connectsto the left side brake lever...

Page 71: ...70 Left Side Brake Lever Right Side Brake Lever Wire Connector The cable connects to front brake drum Brake Oil Tube Brake Oil Tank...

Page 72: ...71 The Brake Adjustment Pan Phillips Bolts 93100 05016 K Plain Washer 94101 0514010 K Nylon Lock Nut 90350 05000 K 10 sets Rear Brake Caliper...

Page 73: ...72 Hex Flange Bolt 96000 08012 K 4 STEP 1 Take off the right side footwell for adjustment STEP 2 Take off the rear brake fixing set and the bolt of brake pump Rear Brake Cable Fixing Set...

Page 74: ...t changes the distance between the brake pump and the hydraulic cylinder driving rod Make the nut touch the surface of the rod and revolve 1 circle 360 then confirm the nut location and spin the rod t...

Page 75: ...tically please try this for couple times for confirmation If it doesn t work please be back to STEP 3 and decrease the distance until the oil could run out normally 2 Press on the brake pedal or the b...

Page 76: ...eft lever till the shortest position 2 Adjust the adjusting screw and keep the gap being 2 3 mm STEP 6 Wire Connector Adjustment 1 The distribution of front rear brake force on left lever 2 The balanc...

Page 77: ...76 STEP 7 The brake balance adjuster on right lever 9 4 DRIVE MECHNISM Left Right Front Brake Balance Adjuster...

Page 78: ...lips and mas ter link Remove the chain Disassemble the driven sprocket axle and sprocket collar Check the driven sprocket for damage or wear Replace if necessary Let the rear axle lie in V blocks and...

Page 79: ...the dust seal lips and install dust seals Assemble the rear axle and the driven sprocket Assemble the drive chains on the driven sprock et Assemble the master link and retaining clip NOTE The retainin...

Page 80: ...seat Unscrew the four bolts which connect the front fender and rear fender Unscrew the four screws which connect the rear fender and frame Unscrew the six screws which connect with footrest plate Pull...

Page 81: ...exhaust pipe Unscrew the two exhaust pipe bolts that fixed with engine NOTE Do not service the exhaust pipe while they are hot Remove the exhaust pipe bolts mounting on the frame below the rear fende...

Page 82: ...LEFT OR RIGHT POSITION GEARSHIFT BAR IS NOT AT NEUTRAL POSITION FAULTY IGNITION COIL FAULTY GENERATOR FAULTY CDI UNIT POORLY CONNECTED Between CDI and ignition coil Between alternator and CDI unit Be...

Page 83: ...YSTEM FAULTY ENGINE STOP SWITCH ENGINE PROBLEMS HEAD LIGHT DO NOT WORK THE SWITCH DO NOT PUSH TO THE ON POSITION THE LIGHT BULB IS BURN OUT NEED BE REPLACED 11 2 IGNITION COIL Remove the spark plug ca...

Page 84: ...ontains sulfuric acid electrolyte Contact with skin or eyes may cause severe burns Wear protective clothing and a face shield Electrolyte is poisonous Drink large quantities of water or milk and call...

Page 85: ...ing is preferred 11 8 ELECTRIC STARTER Information A weak battery may be unable run the starter motor quickly enough If the battery voltage is enough while the engine is not cranking the starter motor...

Page 86: ...ENT Remove five bolts on both sides of the head light cover Remove the headlight bulb and position light Remove the position light bulb Change the new one and install to the headlight seat Press and t...

Page 87: ...new bulb and reinstall Install the bulb seat to headlight seat Tighten five bolts Torque 5 N m 3 5 lbt ft TAIL LIGHT Remove taillight lens by removing the two nuts Replace taillight lens and secure wi...

Page 88: ...87 11 10 WIRING DIAGRAMS...

Page 89: ...fuel tank cap breather hole Faulty Spark Plug Fouled spark Plug Faulty CDI unit Faulty Alternator Faulty engine stop switch Poor connection Broken or shorted wires Broken or shorted ignition coil Wor...

Page 90: ...ent Check for intake pipe leak Deteriorated insulator O Ring Preform Spark Plug Test Loose or disconnected ignition system wires Faulty spark plug carbon fouled or wet Faulty alternator Faulty CDI uni...

Page 91: ...ause Faulty CDI unit or Pulse generator Check Fuel Flow to Carburetor Lack of fuel in tank Clogged fuel line Clogged fuel valve Clogged fuel filter Clogged fuel tank breather hose Remove Carburetor ch...

Page 92: ...on Leaking head gasket Worn Cylinder and or piston rings Check Carburetor Clean fuel jets Clean float valve Check Spark Plug Clean Re gap spark plug Faulty spark plug Spark plug is incorrect heat rang...

Page 93: ...aring Damaged steering shaft bushing Bent steering shaft Bent rim Improperly installed wheel hub Excessive wheel bearing play Bent swing arm Bent frame Excessive wear of swing arm bushing Bent Axle Be...

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Summary of Contents for New Sporty 125

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Aeon New Sporty 125, Service Manual

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Summary of Contents for New Sporty 125

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