MZ 125 SM Repair Manual Download

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Summary of Contents for 125 SM

Page 1: ...Repair Manual MZ 125 SXJSM Reproduced for l MOTORRAO UNO ZWEIRAOWERK GMBH 8080116ENG ...

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Page 3: ...airs can endanger life and health or damage the vehicle Please also note that the hazard warnings important information and tips are not exhaustive It would be impossible to warn against all possible hazards and consequences which could result from failure to follow these instructions We are constantly working on the further development of our vehicles For this reason we reserve the rightto make c...

Page 4: ...05 02 MZ 125 SXlSM Repair Manual ...

Page 5: ...rques 18 Chassis 18 Engine 20 Chassis 23 Seat 23 Locking Hoop 24 Side Panelling 24 Fuel Tank 25 Filter Valve 26 Tank Cap 27 Fuel Filter 27 Lighting Signal System 28 Headlight 28 Tum Indicator Lights 30 Headlight Casing 31 Adjusting the Headlight 32 Tail Ligh 32 Ignition Steering Lock 33 Instruments 34 Speedometer and Lighting 34 Indication Lights 34 Reset Button 35 Instrument Mount 35 Ignition Loc...

Page 6: ... Telescopic Fork 60 Fork Spars 61 Dismantling the Telescopic Fork 62 Fork Bridges 65 Steering Bearing 66 Swing Fork 69 Brakes and Wheels 71 Brakes Front 71 Front Wheel Brake Adjustment 72 Brake Fluid 73 Bleeding the Brake System 75 Main Brake Cyiinder to Inspection Window 7 7 Replacing the Seal SeL 77 Entire Brake Caliper 78 Brake Pads 79 Brake Caliper Components 80 Brake Hose 81 Front Wheel 82 Re...

Page 7: ...ng the Electrolyte Level 114 Replacing the Battery 115 Charging the Battery 116 Ignition 117 Block Circuit Diagrams 117 Spark Plug 118 Spark Plug Connector with Ignition Cable 119 Ignition Coil 120 Ignition Box 122 Ignition Box Inspection 123 Conversion to the 80 km h Varian 124 Regulator Rectifier 125 Alternator 127 Stator 127 Rotor 128 Flasher Relay 130 Starter Relay 130 Shut off Relay 131 Therm...

Page 8: ...Cylinder Head 155 Removal 155 Valve Train 158 Timing Chain Tension and Guide Rails 158 Chain M1eel Camshaft 160 Installation 161 Valves 163 Valve Seat 165 Adjusting Valve Clearance 169 Cylinders 171 Removal 171 Cylinder Dimensions 172 Piston 172 Piston Rings 174 Installation 175 Intake Manifold 176 Transmission 177 Removal 177 Inspection 179 Crankshaft and Balance Shaft 181 Installation 182 Engine...

Page 9: ...vironment Possible dangers for the environment and information on how to prevent them ItiZl Tightening torque ft Special tightening torques to be observed Every safety item explains which danger exists what can happen what you can do to prevent injuries Warning of hazards when handling batteries Warning against corrosive liquids A Warning against hazardous voltage c Warning about flammable materia...

Page 10: ...l removed parts as necessary in the order in which they were moved This helps ensure that the parts are returned to their original locations When working on the vehicle protect painted surfaces and seats with a clean cloth or other suitable cover Carefully inspect all parts before removal to determine the purpose of the repair Use special tools when specified When removing multiple screws or nuts ...

Page 11: ...1 5 Identification Fig 1 Location of the engine number 1 MZ 125 SXlSM Repair Manual 05 02 Safety Regulations and Information Fig 2 Location of the vehicle identification number 2 7 ...

Page 12: ...8 05 02 Notes MZ 125 SXlSM Repair Manual ...

Page 13: ...tal weight permitted 320 kg 320 kg _ ii i iiiic ii i iii iimiiii iiimiiiiii ii i m i i i i ii iii iii iii i iii ii ii iiiii iii Engine type MZ 125 Method of operation control 4 stroke ignition engine DOHC 4 valves operated with bucket tappets Number of cylinders 1 vertical inclined 100 forward Cylinder capacity 124 cm3 Piston stroke 44 0 mm Hole 60 0 mm Output at rpm 11 kW 9000 rpm Cooling method ...

Page 14: ...buretor casing Exhaust gas setting max 4 5Vol CO iiii i i i i i iiiii i liiiiii iiii ii iii i ii ii iiiiii i i i g i iiii ii iii i i ii iiji i iiii iii iiii 0 Number of gears 6 Idling speed indicator pilot lamp tiN Lubrication wet sump drip lubrication Type of transmission spur pinion change wheel gear with dog type lock shift Operating system left foot centrols Primary step down gear system spur ...

Page 15: ...6 psi 230 260 kPal2 3 2 6 bar 33 66 psi Rim size 2 50 x 18 3 50 x 17 Rim wobble limit vertical 0 5mm 0 5mm side 0 5mm 0 5mm Front wheel brake Design hydraulic single disc brake with a two piston floating caliper I and manually operated cylinder Outside diameter x plate thickness 280x4mm Thickness of the brake pad 5 Omm Wear limit 2 Omm Main brake cylinder inside diameter 11 mm Brake caliper cylind...

Page 16: ...Riding speed more than 2 km h and less rpm limitation above 10 500 rpm than 80 kmlh Riding speed more than 80 km h ignition events to reduce performance Spark plug air gap NGK CR8E 0 7 mm Alternator alternating current generator 180 Wat 5000 rpm Battery 12V 9 Ah High and low beam bulb H4 12V 60 55W Parking light 12V 5W Direction indicators 12V 10W Taillight 12V 21 5W Speedometer illumination 12V 2...

Page 17: ...ttor 192 Check the carburettor settings Measure the exhaust fume values annually Check the brake fluid level Change the brake fluid Check the thickness of the brake linings Grease the ball joint between the shock absorber and the swingarm Check and service the telescopic fork Change the fork oil Check the air pressure and condition of the tires Check the wheel rim eccentricity Check the clearance ...

Page 18: ...ing on riding condi tions 1 x year or more often depending on riding conditions 1 x year or more often depending on riding conditions 1 x year or more often depending on riding conditions Clean and lubricate all sliding surfaces and bearings Check the side stand switch Check the lighting and signaling systems before every ride Check the headlight adjustment 32 also after every adjustment of the sp...

Page 19: ...ay for a ring chains 6 VVheel Bearing roller bearing grease 7 Ball joint on the shock absorbing leg bottom Grease or spray MoS2 8 Brake pedal roller bearing grease 9 Throttle twist grip roller bearing grease 10 Hand brake lever roller bearing grease I oil 11 Speedometer drive Oil 12 Speedometer drive in the front wheel roller bearing grease 13 Brake caliper sliding pin grease MoS2 MZ 125 SXlSM Rep...

Page 20: ...ecial Tools 2 3 4 5 6 8999200000 8999201000 8999202000 8999203000 8999204000 8999205000 Locking bolt Crankshaft Sleeve for Valve shaft seal Piston installation plate Pick up adjusting tool Locking tool Clutch Alternator rotor removal tool E 16 05 02 MZ 125 SXlSM Repair Manual ...

Page 21: ...parator tool 9 8999208000 Brace for index lever 10 8999209000 Installation sleeve for left crankshaft y 11 8999210000 Adapter for valve spring lifter 12 13 8999212000 3937001000 Installation sleeve for right crankshaft Spark plug spanner b_ _ Q MZ 125 SXlSM Repair Manual 05102 17 ...

Page 22: ... brake caliper M8 25 5 Rear axle M16 100 10 Rear brake caliper screw M8 25 5 Loctite 290 Rear brake caliper screw plug locking bolt M10x1 4 1 Brake pad locking bolt M10x1 6 5 Brake caliper sliding pin 15 5 Swing bearing pin M16 100 10 Side stand bearing bracket M6 5 2 Nm then turn 90 back Top handlebar locking screw M8 25 5 Front axle M14x1 5 60 5 Front axle locking ring M6 10 2 Brake hose banjo b...

Page 23: ...mount M6 4 1 Switch lever M6 10 2 Front wheel mud guard M6 6 1 Tank rear M8 20 s Fuel cock on tank SIS S 1 5 0 5 Spoiiericooier ivi6 6 1 Splash guard on intake muffler M5 0 5 0 5 Splash guard on frame M6 6 1 Side and rear panelling M6 6 1 Front mounting shackle M8 20 5 Rear mounting shackle M8 20 5 Intake muffler on frame M6 5 1 Pinion cover M6 6 2 Seat mounting at the tank M6 6 1 Collar screw for...

Page 24: ...ming chain shaft DIN 912 M6x90 8 8 10 2 Nm Bearing cap piece nut DIN 6923 M6 8 10 2 Nm Camshaft bolt DIN 931 M8x2S 10 9 30 2 Nm Loctite 243 Screw sliding rail M6 screw 10 2 Nm Loctite 243 Bolt index lever M6 bolt 8 2 Nm Loctite243 Oil pump screw DIN 912 M6x2S 8 8 mk 10 2 Nm micro encapsulated water pump screw DIN 912 M6x20 8 8 mk 10 2 Nm micro encapsulated Primary gear nut DIN 936 M16x1 S 22H left...

Page 25: ...l screen screw cap DIN 910 M18x1 5 MK 30 5 Nm Chain adjuster locking screw DIN 908 M18x1 5 15 5 Nm Crankshaft DIN 912 M8x20 8 8 MK 10 2 Nm locking screw Spark plug NGKCR8E 10 2 Nm Clutch cable counter bearing screw ISO 7380 M6x10 10 9 ps si 10 2 Nm Clutch activation DIN 6912 M5x20 8 8 ps si 5 2 Nm Loctite 243 and shaft locking screw colour markings Clutch activation ISO 7380 M6x1 0 1 0 9 ps si 8 2...

Page 26: ...22 05 02 Notes MZ 125 SXlSM Repair Manual ...

Page 27: ...it up and off Inspection Inspect the support elements 3 4 for wear and porosity Replace defective parts Installation 1 Snap in the opening beyond the seat under the screw on the fuel tank and slide it forward 2 Pressing lightly on the seat screw the peg 1 in the collar brushing 2 MZ 125 SXlSM Repair Manual 05 02 23 ...

Page 28: ...quipped with a top case carrier Installation Install in reverse order Also install the cable holder during mounting the right hand support bracket 3 3 Side Panelling 1 Remove seat 2 Remove the right and left hand spoiler 3 Dismount the support bracket or the top case carrier 4 Unscrew both oval flange head screws 2 5 Remove the side panel Installation Install in reverse order To do this insert the...

Page 29: ...ed Leaked or drained flammable liquids must be collected immediately removed from the working area and stored in an appropriate location until final disposal The fuel tank is made of plastic polyethylene PE Marlex Defective fuel tanks cannot be repaired They must be replaced The tank volume is approx 12 5 I Removal 1 Close the filter valve 2 Remove seat 3 Unscrew four oval flange head screws 1 on ...

Page 30: ...el drain into a suitable container 2 Unscrew two hexagon sheet metal screws St 5 5 3 Pull out the filter valve Screen Attention Possible eye injury Always wear protective goggles when working with compressed air m n I 11I l1 2 1 Separate the screen 1 from the filter valve by turning it to the left 2 Rinse out with engine cleaner and dry with compressed air 3 Insert the screen into the filter valve...

Page 31: ...g the tank cap the vent on the top of the tank cap is dirty The fuel can no longer flow out the engine performance is reduced When the vehicle tipped over the ball 2 shall prevent the fuel to flow out through the vent in the cap CD inspection Examine seals 3 and 4 for damage and porosity Clear vent hole in the cap 1 Installation Install in reverse order 3 4 3 Fuel Filter The external fuel filter w...

Page 32: ...ge base bulb 5 W 4x12 d 12V 5W 5 Headlight with bulb socket 6 Cable harness Removal 1 Remove the oval flange head screws 2 with shim plates 2 Remove the headlight reflector 5 3 Disconnect the connection cable 6 from the bulb 4 Pull off the rubber cap 6 from the headlight reflector 5 Remove the bulb 3 6 Check the terminals and clean if necessary The ends of the cable must be clean and tightly clamp...

Page 33: ...e solvent e g alcohol 2 Fit the rubber cap 3 Connect the connection cable and mount the reflector 4 Perform a function test 5 Adjust the headlight if necessary Replace the wedge base bulb parking light Type Wedge base bulb W2 1x9 5 d 12V 5W Note The terminals may tear off when removing the bulb from the cable Always hold the bulb by the socket Individual wires of the flexible cable must not be spl...

Page 34: ...crew the screw on the rear side 2 Remove the light emission lens 3 Turn the bulb slightly to remove it 4 Check the terminals and clean if necessary The ends of the cable must be clean and tightly clamped in 5 Insert the new bulb turning slightly and check that it sits tightly 6 Install the light emission lens Turn indicator light housing Removal 1 Unscrew the cable from the negative pole on the ba...

Page 35: ...ll off the connecting cable from the bulb 2 Dismount the turn indicators 2 on both sides Make certain that the tapping nut do not fall out of the bracket of the rubber holders 3 Pull the headlight housing from the front mud guard Installation Install in reverse order Inspect the rubber holders of the headlight mask and replace if necessary 1 Insert the headlight housing with the nose into the mud ...

Page 36: ... person weighing approx 75 kg Do not use the installation stand 2 Measure the distance from the centre of the headlight to the ground 3 Loosen the mounting screws of the headlight by about two turns 4 Switch on the night time light 5 Adjust the headlight by tilting and turning the headlight housing When the headlight is correctly adjusted the light dark border of the night time light cone must be ...

Page 37: ...clean if necessary The ends of the cable must be clean and tightly clamped in 4 Connect the cable 5 Insert a bulb 6 Screw on the light emission lens 7 Perform a function test 3 5 6 Ignition Steering Lock Every lock has a code number used by MZ to manufacture new keys If this code number is no longer available providing the VIN Vehicle Identification Number located on the right side of the steering...

Page 38: ...oil 1 Inspect the wedge base bulb and replace if necessary 2 Coat the socket with silicon spray and insert it 3 Mount the speedometer and screw in the speedometer shaft 4 Fit the front panelling the headlight and the turn indicator lights 5 Adjust the headlight 3 6 2 Indication Lights 1 Turn indicator light 2 Headlight control 3 Idler control 4 Warning light for cooling system 5 Warning light Oil ...

Page 39: ...plate and the housing 3 Insert the screw driver blade into slot of the axle bearing the reset button see expanded scope 4 Turn the reset button in clockwise direction left handed threading To do this hold the screw driver still 5 Pull the reset button out Installation Install in reverse order 3 6 4 Instrument Mount 1 Remove the headlight and speedometer 2 Loosen both M6 screws 3 Remove the instrum...

Page 40: ...ock is firmly in place Then the work must be performed again 2 Clean the threads 3 Apply the screw locking agent at medium tightness to the new break off screws screw on the lock 4 Screw on the lock Screw in the break off screws until the screw head breaks off 5 Place the switch on the ignition lock and screw it on The locking pins must fit exactly into the lock 6 Fit the upper fork bridge with th...

Page 41: ...f the noses 1 of the front panelling and remove it from the sliding pipes Installation 1 Slide the front wheel mud guard between the sliding pipes and press it onto the noses 1 with plastic caps 2 2 Insert the collar brushing into the front wheel mud guard from below and screw on the front wheel mud guard to the lower fork bridge 3 Insert the guide eyelet MZ 125 SXlSM Repair Manual 05 02 37 ...

Page 42: ...y to remove the end piece when replacing the rear reflector 1 Remove the end piece 2 Lift up both spring nuts from the plastic pins on the rear reflector using a screw driver 3 Pull out the rear reflector Installation After inspection the spring nuts can be reused 1 Insert the rear reflector into the end piece 2 Place the end piece flat on the scratch protected base 3 Press on the spring nuts with...

Page 43: ...e installed on the handlebar Throttle cable 1 1 850 3 mm x y 140 1 mm Startei cable 2 1 910 2 mm x y 100 2 mm Clutch cable 3 I 850 3 mm x y 120 2 mm Note Bowden cables must have freedom of motion in every position They must not be cramped or kinked Bowden cable must not be pre tensioned that is they must not apply force when not in use e g grinding clutch etc Maintenance The bowden cables must not...

Page 44: ...the bowden cable is too short 3 Lubricate the steering pipe slide on the throttle grip Do not use grease it reduces the twisting freedom 3 10 4 Rubber Grips Right rubber grip throttle twist grip 1 Cut through the rubber grip and remove it 2 Slide on a new rubber piece with a suitable rubber adhe sive Left rubber grip Attention Always wear protective goggles when working with compressed air 4 Treat...

Page 45: ...e binder 4 Remove the main brake cylinder switch and throttle twist grip 5 Unscrew the four screws on the top handlebar mount 6 Remove the handlebar Installation Install in reverse order Install the handlebar centred When posi tioning the handlebar mount make certain that the gaps between the handlebar mount and the front and back of the fork yoke are equal Tightening torque M8 handlebar mount scr...

Page 46: ...ndlebar and bend using a rubber or polyamide hammer The hammering forces out the swingarm Installation 1 Insert the swingarm into the handlebar The distance between the handlebar end and the swingarm end must be 25 mm 2 Mount the handlebar 3 10 7 Hand Brake Lever Removal 1 Unscrew the locking nut 1 and screw the slotted screw 2 off upward 2 Loosen the locking nut 3 and unscrew the adjusting screw ...

Page 47: ... switch open no connection signal Installation Install in reverse order 3 10 9 Clutch Lever Removal 1 Slide back the protective cover from the adjusting screw 2 Screw in the adjusting screw maximum play 3 Remove the screw and lock nut 4 Push the lever forward 5 Disconnect the bovlJden cable Note The cable pulley is slotted and may fall down during removal Inspection Inspect the bushing replace if ...

Page 48: ...ere are two options for replacing the starting carburettor lever 1st option 1 Remove the left rubber grip 1 see 3 10 4 Rubber Grips 2 Pull off the starting carburettor lever 2 to the left 3 Remove the starter bowden cable 3 2nd option 1 Remove all mounts from the handlebar except for the left rubber grip 2 Remove the handlebar 3 Pull off the starting carburettor lever to the right Installation Ins...

Page 49: ...air filter e g filter paper torn leads to a leaner less fuel fuel air mixture The engine performance is reduced and damage may be caused due to overheating Removal 1 Remove the seat 2 Lift up and remove the intake pipe 3 Remove the tension from the body bound rivet 1 by pulling out the middle part 4 Then pull body bound rivet upward and completely out 5 Pull the air filter 2 out upward Cleaning At...

Page 50: ...take muffler see arrow left in the figure 4 Install the seat 3 12 Shock Absorber Production models of the motorcycle are delivered with a spring length of 184 5 2 mm This is the proper setting for a load of approx 75 kg If a pillion rider is along the spring preload must be increased to a length of 177 mm The damping of the shock absorber cannot be adjusted Guidelines Single rider 75 kg spring len...

Page 51: ...ut 4 Adjust the headlight see 3 5 4 Adjusting the Headlight Removal 1 Remove the seat and side panel 2 Unscrew the upper M10 pan head screw holding the nut still 3 Pull off the screw 4 Unscrew the lower M10 pan head screw holding the nut still 5 Pull out the pan head screw 6 Pull out the shock absorber down and to the rear Installation Install in reverse order The lower screw must be inserted from...

Page 52: ...the special washer when the foot rest is folded up 3 Slide the clevis pin through from above 4 Position the washer and secure with a new splint 3 13 2 Front Foot Rest Removal 1 Pull off the foot rest rubber piece 1 2 Bend up the splint 2 remove the splint and washer 3 Puii out the pins 3 4 Pull the foot rest 4 and spring 5 out of the mount Installation 1 Slide the foot rest with spring onto the mo...

Page 53: ...sconnect cable from the cable harness 2 Hold the self tightening nut on the switch and turn only the screw 3 Remove the nut washer and side stand switch Installation 1 Adjust the side stand switch with the nose of the switching part in the hole of the side stand fork 2 Slide the side stand switch onto the mounting pins on the pivot bracket 3 Position the washer and self tightening nut hold it stil...

Page 54: ... the side stand to the springs and with the stand in folded position lift it onto the pivot bracket with the fork using some force 2 Grease the sleeve well insert the sleeve and screw 3 Adjust the side stand switch with the nose of the switching part in the hole of the side stand fork 4 Install the side stand switch T A hi i h h h 1 J1 O A C Alith l 1I In l Tho tt r fho IV IV LI HI v VVILI I 1 scr...

Page 55: ...r 4 8 Removing the air intake fitting of the carburetor 9 Empty the condensate collector 4 and clean if necessary 10 Remove the shock absorber 11 Remove the reserve brake fluid tank remove the main brake cylinder run the hose outward and attach it to the frame 12 Unscrew the four M6 screws 2 and remove the washers 13 Rotate the intake muffler downward around the pivot of the upper mount and pull i...

Page 56: ...the muffler 1 onto the manifold 3 2 Attach the muffler cable to the frame 3 Tighten the locking screw 2 on the manifold muffler connection The exhaust must not be under mechanical stress Note Exhaust jointing compound can be used to seal the muffler mani fold connection Any leak in the connection between exhaust silencer and exhaust manifold may cause muffler back firing The muffler must be treate...

Page 57: ...ffler 2 Remove the screw 1 and washers 3 Remove the mount plate 2 Installation 1 Inspect the spacer sleeve 3 and cable sleeve 4 replace if necessary 2 Install all parts loosely 3 Fit the mount plate 2 to the muffler 4 Tighten the screw 1 Tightening torque Hexagon head screw n i O 53 ...

Page 58: ...the manifold and slide it onto the stud bolts 4 Insert the manifold into the cylinder head and place the flange on the stud bolts 5 Position the washers and push the manifold against the seal with the nuts screw on a few turns It must still be possible to move the manifold 6 insiaii the muffler 7 Screw the manifold on tight Note Avoid poor seals Any leak in the connection between exhaust silencer ...

Page 59: ...e coolant manufacturer Fill the radiator system with a coolant All hose connections must be connected and leak proof Use an approx 30 cm hose with an inner diameter of 10 mm to fill the cooling system 1 Place the vehicle on the side stand 2 Let the engine cool 3 Remove the radiator cap by turning it to the left 4 Screw out the air bleeding screw 5 Connect the hose with funnel to the filler connect...

Page 60: ... connection 5 and increase the pressure slowly At 1 4 bar the valve of the radiator cap must open Air escapes from the radiator cap and flows through the hose into the container Air bubbles can be seen in the container Ifan opening pressure of over 1 4 bar is required the radiator cap must be replaced 3 17 3 Radiator Hoses J Inspect the radiator hoses for damage e g cracks and examine their condit...

Page 61: ...re fully to release the pressure 1 Let the engine cool 2 Remove the tank 3 Disconnect the fan cable from the power supply 4 Open the radiator cap carefully and let the pressure escape 5 Position a suitable container under the radiator to be emptied and drain the radiator one after the other 6 Loosen the lower clamp and pull off the radiator hose Drain the coolant into a suitable container 7 Loosen...

Page 62: ...ful with the a ring The thermostat cannot be separated from the thermostat housing only the top part can be removed Inspection If the opening temperature range does not match the ones speci fied the thermostat must be replaced A Position of the thermostat with coolant water temperatures 71 C closed B Position of the thermostat 1 with cold water temperatures 0 81 C open The difference between A and...

Page 63: ...e tool e g pliers and repeat the above measurement 7 The front edge of the thermostat must have moved 5 mm toward the inside in comparison with the recorded value 8 If the difference of 5 mm is not reached at 81 C the ther mostat must be replaced Installation Attention Risk of engine damage due to overheating The thermostat has bypass holes to ensure a minimum of water flow These bypass holes must...

Page 64: ...ndition of the road thereby improving safety A damping fluid level 140 2 5 mm B length without spring the upright pipe completely inserted I I I I i I I I t I I Volume per fork spar Recommendation 445 cm3 Gabel61 SAE 7 5 10 W Note Fork oil absorbs air humidity altering its function For this reason it must be replaced no later than every two yeais Fork oil attacks the paint Avoid drops and splashes...

Page 65: ...against tipping with belts 2 Remove the front wheel 3 Remove the speedometer shaft and brake hose from the guide open the rubber holders 4 Remove the mud guard see 3 8 Front Wheel Mud Guard 5 Remove the brake caliper 6 Remove the locking screws for the telescopic fork from the upper and lower fork bridges 7 Pull the spar down and out inspect the surface Installation 1 Insert the fork spar The join...

Page 66: ...acer sleeve pull the spring far enough out of the spar that oil can drip from the spring 5 Compress the fork spar let the fork oil flow into a suitable container Note Lack of care in working with the screw driver can lead to nicking and scratching of the upright pipe surfacel 6 Carefully remove the wiper The upright pipe must not be damaged Note Possible paint damage and destruction of the wiper s...

Page 67: ...that it does not fall down 11 Remove the support pipe with a stop spring 12 Lift the seal ring from the seat on the sliding pipe with turning motions of the screw driver blade Protect the sliding pipe against damage 13 Ram the slide tube cautiously against a support wood until the piston ring falls out 14 Clean all parts carefully MZ 125 SXlSM Reoair Manual 05 02 63 ...

Page 68: ... 16 two turns Then the support pipe 7 must protrude from the upright pipe 6 Place end stop cone 12 on the support pipe 14 Assemble the sliding pipe with the upright pipe 1 Place the sliding pipe 6 with brush onto the upright pipe 10 2 Centre the end stop To do this hold the upright pipe 10 and turn the sliding pipe approximately twice 3 Screw the sliding pipe with upright pipe using screw 9 and se...

Page 69: ...upright pipe with light pressure and screw together Torques 20Nm 21 Install the fork spar 3 18 3 Fork Bridges Removal 1 Remove the seat the fuel tank and the front wheel mud guard 2 Completely remove the handlebar disconnect the righl left plug connector switch and ignition lock careful of barbs under the fuel tank container 3 Place the handlebar onto the rear part of the frame Do not kink brake h...

Page 70: ...es 3 Disconnect the electrical system six plug connectors rightl left switch ignition switch headlight instruments 4 Remove the handlebar 5 Remove the upper fork bridge 6 Completely pull the telescopic fork down and out 7 Remove the cover and fitting washer from the top bearing 8 CarefUlly pound out the lower bearing from above using a hammer and spike Attention Damage to bearing Do not jam the be...

Page 71: ...ece material Steel C15 Threading pin material Steel 50CrV4 Attention Only use original spacer sleeves Do not flatten Oi bend the spacer sleeve vvhile pressing in the bearing p O _ I 4 D 1 Insert the new greased ball bearings 3 and spacer sleeves 4 into the steering head 5 2 Press the ball bearings and spacer sleeve into the steering head using the pressing tool described above 1 Hexagon nut 2 Pres...

Page 72: ...t the top fork bridge 12 position the washer 8 and tighten with the M24x1 nut 11 7 Mount the handlebar 8 Connect the cable to the cable harness and lay properly 9 Connect the three bowden cables Make certain they do not kink 10 Install the front wheel 11 Install the fuel tank and seat 12 Perform a function test on the front brake rl j 13 14 Tightening torque Top locking screws Bottom locking screw...

Page 73: ...1 em into the frame 2 Insert the swing fork into the frame and slide the swing bearing pins up to the stop 3 Position the locking washer Nord Lock 16x25 4 1 on the left and screw the nut 2 on a few turns Do not tighten it yet Note Possible damage to the swing bearing First screw on the shock absorberwith the swingarm then tighten the swing bearing bolts 4 Screw the shock absorber to the swing fork...

Page 74: ...70 05 02 Notes MZ 125 SXlSM Repair Manual ...

Page 75: ... in traffic Perform all work attentively and responsibly based on this repair manual The front brake is designed as a hydraulic disc brake with a two piston floating caliper 1 Sliding pin 2 Seal collar 3 Air bleeding screw 4 Banjo bolt M4x10 5 Piston 6 Brake disc 0 280 mm 7 Tension bracket 8 Brake pad 9 Piston with compression spring 10 Hermetic bellows 11 Main brake cylinder 12 Front brake light ...

Page 76: ... the seal ring 4 and the centre of the equalisation hole 3 is not larger than 1 5 to 2 mm see also the position of the brake piston 5 2 Open the storage tank 3 Turn the adjusting screw 1 to the right until brake fluid no longer escapes from the equalisation hole 3 when the brake lever is operated no motion can be detected on the surface of the liquid 4 Turn the adjusting screw 1 approximately one ...

Page 77: ... brake lever Position the vehicle such that the main brake cylinder sits horizontally When the main brake cylinder is horizontal the brake fluid level may not fall below the marking on the round inspection window 2 Adding fluid 1 Position the vehicle such that the main brake cylinder sits horizontally 2 Unscrew the two screws from the main brake cylinder cap 3 Remove the cap 1 bolster plate 2 and ...

Page 78: ...such that the main brake cylinder sits horizontally 2 Remove the dust cap from the air bleeding screw 3 Place a ring spanner and transparent hose on the air blee ding screw 4 Place the other end of the hose in a suitable container 5 Screw off the main brake cylinder cap 6 Open the air bieeding screw 7 Pump all of the brake fluid into the container by operating the brake lever While doing so consta...

Page 79: ...ner filled with brake fluid 6 Open the air bleeding screw work the brake lever once and stop 7 Close the air bleeding screw 8 Let go of the brake lever pump several times 1 Ox hold the lever down 9 Open the air bleeding screw Old brake fluid and air escape 10 Close the air bleeding screw 11 Repeat the process until the escaping brake fluid has no bubbles 12 Remove the ring spanner and hose return ...

Page 80: ...ke lever two or three times to empty the piston chamber 8 Place cleaning paper under the main brake cylinder 9 Unscrew the banjo bolt remove the brake hose and the two seals The brake hose remains attached to the clamp head 10 Unscrew the two screws of the mounting clamp 11 Remove the main brake cylinder Installation Note Always use new seal rings for the brake hose Grease and install the brake le...

Page 81: ... Perform function test 4 1 6 Replacing the Seal Set Rubber components must be replaced by new parts in case of damage or cracking or in general every 4 years 1 Drain the main brake cylinder 2 Remove the seal collar 1 3 Remove the piston 4 4 Replace the seal rings 2 and 3 5 Clean all parts with brake cleaner 6 Moisten new parts with brake fluid and insert them into the main brake cylinder Do not us...

Page 82: ... 5 Wrap cleaning paper around the brake hose 6 Elevate the opening of the brake hose fasten it to the frame if necessary This prevents the brake hose from draining It simplifies the bleeding process 7 Unscrew the two cylinder screws 5 with Nordlock washers 6 from the sliding pipe 8 Remove the adapter plate 7 with the brake caliper Installation 1 Place the brake caliper onto the brake disc 2 Screw ...

Page 83: ...laced Always replace the brake pads in pairs Removal 1 Unscrew the mounting pins 1 2 Remove both brake pads 2 3 Pull out the tension bracket 3 Installation Note The brake pad lining seats can be treated with copper paste or brake protector This prevents the brake pads from squeaking The tension bracket must be positioned under the mount pins 1 Insert the tension bracket 3 The wide sliding side mus...

Page 84: ...ake fluid Installation Inspect the pistons and sliding pins for damage corrosion etc Inspect the seal collars Rubber components must be replaced by new parts in case of damage or cracking or in general every 4 years 1 Insert pistons 2 Lightly grease the sliding pins install them into the brake caliper along with the adapter plate 3 Pull the large and small seal collars exactly over the sliding pin...

Page 85: ...ke fluid from the brake hose into a suitable container 4 Unscrew the banjo bolt from the brake caliper 5 Remove seals 6 Remove brake hose Inspection Inspect the brake hose for damage poor seal kinks crimps Installation Note Always use new seal rings Install in reverse order Add brake fluid Bleed brakes see 4 1 3 Bleeding the Brake System Perform function test MZ 125 SXlSM Reoair Manual Tightening ...

Page 86: ...ter drive 2 Spee 3 Seal nng 4 Dog DIN 625 6204 2RS 5 Ball beanng 21 6 Rim strap 25x 7 Rim 8 Spokes 9 heel hub 1 0 Spacer sleev IN625 6204 2RS 11 Ball beanng 12 Tyres 13 Air tube 14 Brake disc Washer 15 M14x1 5 nut 16 82 05 02 MZ 125 SXlSM Repair Manual ...

Page 87: ... tension belts be careful not to damage the paint The front wheel must be free of load 1 Screw off the axle nut 2 Loosen both locking screws 3 Open the left locking screw 4 Pull out the axle to the right side holding the wheel in its installed position 5 Remove the speedometer drive 6 Remove the brake disc from the brake caliper 7 Remove the wheel MZ 125 SX SM Repair Manual 05 02 83 ...

Page 88: ... the greased axle 15 far enough from the right fork spar that it is flush against the left bearing 4 Insert the spacer sleeves 1 5 Lift on the front wheel 6 Slide the axle through the left fork spar 7 Tighten the right locking screws 8 Screw on the axle nut and tighten 9 Loosen right locking screw 10 lMlen the parking brake is pulled push the telescopic fork the whole way through several times 11 ...

Page 89: ...y mounted on hub with new bearings installed in the swingarm measured on outside diameter Maximum deviation 0 25 mm Note With an eccentricity of 0 1 mm it is permissible to unscrew the brake disc from the hub to achieve a reduction in the measure ment value by twisting the brake disc and reinstalling it If this does not have the desired result the brake disc must be replaced Installation 1 Place t...

Page 90: ...heel bearing have too much play the wheel bear ings must be replaced If the spacer sleeve 2 length is less than 65 5 mm it must be replaced Otherwise the wheel bearings may be damaged Attention Possible burns Never touch the air outlet of the hot air pistol This becomes very hot during operation Do not direct the hot air pistol at flammable or heat sensitive materials Installation 1 Heat both whee...

Page 91: ...edometer shaft 1 2 Remove the front wheel see 4 2 1 Replacing the Front Wheel 3 Remove the seal ring and dog from the wheel hub Inspection Check the teeth for completeness and wear Check the seal ring for wear Check the dog for wear Replace defective components Installation 1 Insert the dog and seal ring into the wheel hub 2 Lubricate the speedometer drive 3 Install the front wheel and speedometer...

Page 92: ... this repair manual The rear brake is designed as a hydraulic disc brake with a two piston floating caliper 1 Storage Tank 2 Brake light switch 3 Main brake cylinder diameter 13 mm 4 Eccentric disc 5 Pressure rod L 55 mm 6 Brake lever 7 Reset spring for brake lever 8 Cap screw 9 Retaining bolt 10 Air bleeding screw 11 Seal collar 12 Sliding pin 13 Tension bracket 14 Banjo bolt M4x10 15 Piston 16 B...

Page 93: ...ust be between the MAX and MIN markings never lower Adding fluid Attention Brake fluid is aggressive and poisonous Avoid contact with skin Do not pour onto paint plastic or rubber surfaces Immediately wipe up spilled brake fluid Always cover sensitive components with a rag while working on the brake system Only use new DOT4 brake fluid Do not mix different kinds Brake fluid absorbs water from the ...

Page 94: ... Place the other end of the hose in a suitable container 5 Screw off the storage tank cap 6 Remove the hermetic bellows 7 Open the air bleeding screw 8 Pump all of the brake fluid into the container by operating the brake lever While doing so constantly add new brake fluid Note New brake fluid is lighter in colour than used Watch the brake fluid being pumped out When it becomes light the old brake...

Page 95: ...ake fluid 6 Open the air bleeding screw work the brake lever once and stop 7 Close the air bleeding screw 8 Let go of the brake lever pump several times 10x hold the lever down 9 Open the air bleeding screw Old brake fluid and air escape 10 Close the air bleeding screw 11 Repeat the process until the escaping brake fluid has no bubbles 12 Remove the ring spanner and hose return the dust cap 13 Che...

Page 96: ...orage tank 4 Screw off the storage tank cap c 0 _ ho hor t holl A c J vIIIVV II Ilv II v OV v 6 Completely drain the brake fluid out of the storage tank and hose into a suitable container 7 Open the hose clamps 2 remove the hose 3 Installation Inspect the components for damage particularly the hose 1 Connect the hose to the main brake cylinder and storage tank close clamps Undamaged clamps can be ...

Page 97: ...ose must always point upward 5 Remove the banjo bolt 4 and seals from the brake caliper 6 Let the hose drain into a suitable container 7 Press the brake hose out of the adhesive pads 2 Inspection Inspect all parts for damage poor seal kinks crushed points etc and replace if necessary Installation 1 Screw the brake hose 3 tightly to the rear brake caliper with the banjo bolt and new seal rings 2 Pr...

Page 98: ... the figure Observe the dimensions 4 Press on the adhesive pads a 4 3 7 Brake Caliper Removal 1 Screw off the banjo bolt remove the two seal rings 2 Wrap cleaning paper around the brake hose and banjo bolt 3 Elevate the opening of the brake hose fasten it to the frame if necessary This prevents the brake hose from draining Doing so simplifies the bleeding process 4 Unscrew the two screws 5 Remove ...

Page 99: ...Inspect the pistons and sliding pins for damage corrosion etc Inspect the seal collars Rubber components must be replaced by new parts in case of damage or cracking or in general every 4 years 1 Insert pistons 2 Lightly grease the sliding pins install them into the brake caliper along with the adapter plate 3 Pull the large and small seal collars exactly over the sliding pins The slide covers must...

Page 100: ...the cap screws 1 2 Unscrew the mounting pins 2 3 Pull the defective brake pads 4 out off the brake caliper 3 4 Remove the tension bracket 5 Installation Note The brake pad lining seats can be treated with copper paste or brake protector This prevents the brake pads from squeaking The tension bracket must be positioned under the mount pins 1 Insert the tension bracket 5 The wide sliding side must f...

Page 101: ... rings 7 on the bearing pins 2 of the brake lever 6 replace if necessary 2 Grease the bearing pins 3 Latch the spring 3 in the brake lever and slide it onto the pin 4 Slide the cylinder screw 1 through the bearing pins 5 Insert the bearing pins into the frame In doing so insert the spring into the corresponding hole in the frame and use force to lift it onto the spring hanger 6 Insert the washer 4...

Page 102: ...adjust a clearance of A 1 1 5 mm using the adjusting nut 8 at the pressure rod This results in a clearance of B approx 1 1 5 mm between the end of the pressure rod 12 and the face of the piston 11 If this adjustment is not made there is a risk that the equalisation hole 10 may remain blocked The brake fiuid can no longer fiow back The brake pressure is maintained the brake system overheats and the...

Page 103: ... Use a voltmeter set to the 20V range for measuring 1 Switch on the ignition The 12V vehicle power supply is on the red black cable against the ground 2 Operate the foot brake lever 3 Test the voltage on the black cable 12 V Switch OK 0 V Voltage Switch defective replace Installation Always use new seal rings Inspect the seal surfaces on the hose main brake cylinder and switch Rubber components mu...

Page 104: ...fluid 4 Close the clamp Undamaged clamps can be reused 5 Bleed the system see 4 1 3 Bleeding the Brake System 6 Perform function test Tightening torque M6 screws 4 3 13 Seal Set 10 2 Nm Replacing Rubber components must be replaced by new parts in case of damage or cracking or in general every 4 years 1 Drain the main brake cylinder 2 Remove the seal collar 1 3 Remove the locking ring 2 underneath ...

Page 105: ...8 Rim 9 Spokes 10 Balancing piece 11 Wheel hub complete 12 Spacer sleeve 13 Ball bearing dog side DIN 625 6204 2RS 14 Dog rubber piece 15 Inner reducing bush 16 Tyres 17 M8 hexagon nuts 18 Dog 19 Chain plate SX 52 teeth SM 49 teeth 20 M8x45 cylinder screws 21 Spacer sleeve 22 Outer reducing bush 23 Hexagon nut M16x1 5 MZ 125 XlSM Repair Manual 05 02 101 ...

Page 106: ...o damage the paint when using tension belts 1 Unload the rear wheel Note Do not operate the foot brake lever 2 Screw off the left axle nut 3 Pull the axle out halfway to the right 4 Remove the chain 5 Pull the axle out completely 6 Remove the adapter plate with the brake caliper for the counter bearing 7 Carefully pull out the wheel to the rear 102 05 02 MZ 125 SXlSM Repair Manual ...

Page 107: ...chain and chain plate Turn the wheel a Y to turn so that the cover plate of the chain adjuster sits tight against the swingarms Important Do not apply force Otherwise the chain chain plate may get damaged 7 Tighten the axle nut observe the specified torque 8 Inspect the wheel tracking 9 Expand the brake pads 10 Install the brake caliper over the brake disc 11 Observe the specified torque and use s...

Page 108: ...nd dog rubber piece The rubber piece must not be porous damaged or cracked Replace a defective rubber piece 5 Remove the screws and self tightening nuts Installation 1 Install a new chain plate with new nuts to the dog 2 Insert the dog rubber piece into the wheel Spray the dog with silicon spray to ease the installation 3 Insert the dog with the chain plate 4 I ount the whee see 4 4 1 Replacing th...

Page 109: ...refully pound out the left and right bearing and spacer sleeve using a spike Installation 1 Measure the spacer sleeve minimum 110 mm replace if necessary Note If it is shorter than 110 mm the spacer sleeve must be replaced Otherwise the wheel bearings may be damaged Attention Possible burns Never touch the air outlet of the hot air pistol This becomes very hot during operation Do not direct the ho...

Page 110: ...earings installed in the swingarm measured on outside0 Maximum deviation 0 25 mm Note With an eccentricity of more than 0 1 mm it is permissible to unscrew the brake disc from the hub to achieve a reduction in the measurement value by twisting the brake disc and reinstalling it If this does not have the desired result the brake disc must be replaced Installation 1 Position the brake disc The arrow...

Page 111: ...n freely Hazard Risk of injury Make certain that your fingers do not come between the chain and the chain wheel 1 00000000 Turn the rear wheel several times Measure the chain slack 0 at various points to find the tightest point The valid measurement must be taken at the tightest point of the chain To do this move the chain up and down If the chain is too tight slack O less than 60 mm or too loose ...

Page 112: ...e two screws of the pinion cover 2 Remove the pinion cover 3 Carefully open the chain lock with a pliers 4 Remove the chain lock 5 Remove the chain 6 Loosen the axle nuts by approx 1 turn 7 Mount the new chain 8 Loosen the chain adjuster on both sides until the chain lock can be inserted 9 Insert the chain lock and close it The closed end of the chain lock must point in the direction that the chai...

Page 113: ...for threaded drive shaft 9 7 mm long Tightening torque Pinion hexagon nut Inspection Inspect the following components Drive shaft Threading Shaft seal Teeth of the pinion and chain plate 1 and 2 worn 3 Ok When replacing the pinion or chain wheel a new chain should also be used Replace defective components 4 5 4 Replacing the Chain Slider 1 Unscrew the two nuts from the threaded pins on the swingar...

Page 114: ...onsult the operating manual of the machine manufacturer The use of other tools and equipment may lead to damage or unbalanced wheels The static unbalanced mass of a wheel in the direction of travel should ideally be 0 g A maximum of 50 g is permissible The directional markings must be observed when installing the tires These specify the direction of travel of the vehicle Tire pressure 1 or 2 perso...

Page 115: ... for SX y MZ 125 SXJSM Repair Manual Two different spoke types are used on the SX front wheel 1 Short spoke 235 mm 141 18 pes brake disc side 2 Long spoke 277 mm 144 18 pes Spoke nipple DIN 74371 M3 5 6 4x18 c 2 0 0 5Nm Rim 1 85x21 Front wheel hub Bassano Grimeca company X 25 5 mm Y 47 5 mm Position of eccentricity measurement A lateral eccentricity at the rim edge 0 5 mm B vertical eccentricity a...

Page 116: ...sc side Two different spoke types are used on the SM front wheel 1 Long spoke 178 mm 143 18 pcs 2 Short spoke 171 mm 147 18 pcs brake disc side Spoke nipple DIN 74371 M3 S 6 4x18 c 2 S 0 s Nm Rim 3 00x17 Front wheel hub Bassano Grimeca company x 76 S mm y 9 mm Spoke nipple DIN 74371 M3 S 6x16 c 2 S 0 s Nm Rim 3 S0x17 Rear wheel hub Bassano Grimeca company X 33 3mm y 63 S mm Position of eccentricit...

Page 117: ...dividual wires Replace the connection if wires are broken Note Only operate the vehicle with an intact connected battery 5 2 Fuses Attention Fire hazard and risk of serious damage to electrical components Never use fuses with a higher current rating than the one specified Never bypass the fuses or mend the fuses Specified fuses Main fuse light blue Fuse cartridge FKS 15 A Fan fuse brown Fuse cartr...

Page 118: ...els lead batteries are used The battery connections must be kept clean and preserved with battery grease 5 3 1 Checking the Electrolyte Level The electrolyte level must be above the lead contacts in each cell by a few millimetres Observe the markings The level may not fall below the MIN mark Only demineralised or distilled water may be used to refill the battery 1 Remove seat 2 Remove the left sid...

Page 119: ...ctions must be clean with secure contacts Clean the connections with a brass brush and apply battery grease Make certain that the battery rests securely Install the degassing hose such that no acid can splash onto parts of the vehicle Replace a defective degassing hose 1 During battery change position the bonding sheet on the front side leave the level markings visible 2 Position the battery and f...

Page 120: ...tery manufacturer Remove the battery for recharging see 5 3 2 Replacing the Battery 1 Connect the charging cable with correct polarity 2 Unscrew the plastic plug 3 Check the electrolyte level refill if necessary see 5 3 1 Checking the Electrolyte Level 4 Switch on the charger The charging current should be 0 9 A 10 of the nominal capacity for normal charging Observe the charging technology specifi...

Page 121: ...AET starting from vehicle identification number SNZ1 SXSM01 H501 04 8 Battery 9 Fuse tJID l RPM 9 Version B 80 km h variant 1 Spark plug with connection nut ISO terminal 2 Spark plug connector 3 Ignition coil 4 Ignition box version A 1version B 80 km h 5 Sensor coil 6 Alternator 7 Controller dash lined connection not available for AET starting from vehicle identification number SNZ1 SXSM01 H50104 ...

Page 122: ...o switch off the engine Replacing 1 Switch off ignition 2 Remove the spark plug connector 1 3 Puncture the dirty spark plug cavity discharge hole 2 with a wire Any water in the spark plug cavity flows out 4 Unscrew the spark plug using the spark plug spanner with rubber insert and a reversible screw driver 5 Replace the spark plug 6 Clean the gasket and unscrew the connection nut before installing...

Page 123: ... fuel mixture too lean oily wet Spark plug misfiring or poor seal on the piston rings 5 4 3 Spark Plug Connector with Ignition Cable The spark plug connector and ignition cable form a unit Correct functioning of the spark plug connector is only guaran teed when it is securely connected to the spark plug with the connection nut screwed onto the connection screw The ignition cable must be clean dry ...

Page 124: ...Position the earth cable on the lock nut of the upper bolt position the washer screw on the nut 2 Connect the plug contact to the ignition coil 3 Connect the ignition coil position the washer screw on self locking nut Observe the correct tightening torque otherwise the welded bolt may tear 4 Connect the spark plug connector 1 Frame 2 Hexagon nut 3 Washer 4 Earth cable lug 5 Ignition coil naked sid...

Page 125: ...ction Measure th 1 prima COlli resistance COl resistance _0 79 Q 15 t supply earth _ 10 a 20 C 2 Secondary c _7 6 kQ O I resistance s ar _ 20 Yo at 20 0C P k plug connect or earth MZ 125 SXJ8M RepairManual 05 02 121 ...

Page 126: ...at a later date or an elimination of the reduction Removal 1 Remove seat 2 Unscrew the two oval flange head screws 3 Remove connector at end of cable turned away from the ignition box connector 1 2 pin wires bk wh to pick up connector 2 3 pin wires br wires br chassis earth gn rd to tachometer rslwh to shut off relay connector 3 2 pin wires br ignition coil earth bl ignition coil 80 km h variant o...

Page 127: ...ite brown a or near a 0 defective Ignition box and 80 km h variant sensor In addition to the general inspection procedure please observe the following instructions to check the ignition box of the 80 km h variant Faults The ignition box limits the speed to approx 6500 rpm in each gear Possible causes too much acceleration when starting only in the 1st gear dirty sensor with ferruginous residue too...

Page 128: ...at the lowest position using the EJOT PT screws 6 non magnetic with the cable end toward the outside 9 Run the cable upward to the brake line 10 Attach the cable at the end of the brake line using the RAP cable binder 2 11 Run the cable on the wheel side alongside the brake line 12 Run the cable 3 and brake line 11 through together 13 Attach the cable behind the front shell with the RAP cable bind...

Page 129: ...fication number SNZ1 SXSM01 H501040 IP67 less than 1 mA 2 6 V Inspection Test the correct functioning of the battery before testing the component 1 Properly secure the vehicle on the installation stand 2 Ensure sufficient ventilation 3 Remove the left side panel 4 Ensure free access to the connections 1 of the battery 2 5 Securely connect the measurement device measurement range 20 V DC 6 Switch t...

Page 130: ...ed instead the SH626 12 Please also note Cut off the tubular terminal 7 on the cable harness Kink the red black 0 75 cable isolate it with a shrinkage hose and attach with a cable binder to the cable hamess 5 Run the cable upward between the frame and the intake muffler and connect the plug 6 to the jack on the battery cable insert the plug from the alternator cable into the jack 5 making certain ...

Page 131: ... identification number SNZ1SXSM01H501041 6 Battery 7 Consumer 8 Fuse 5 5 1 Stator Removal 1 Unscrew the 5 alternator cover screws remove the cover 2 Remove the screw and support plate 3 Unscrew the two stator locking screws micro encapsulated move the stator 4 Remove the plug Winding resistance 0 40 0 04 0 at 23 2 C Measurement is only possible with special methods Inspection For rating the rotor ...

Page 132: ...1 for the locking screw and ring seal 4 Screw in the locking screw 2 and screw it into the bulge in the cam shaft 5 Remove the screw 2 washer and sensor pick up 1 6 Screw the rotor removal tool tightly onto the rotor and pull the rotor away from the crankshaft by pulling on the pres sure screw The process can be assisted with a light blow to the clam ping bolt of the removal tool 7 Remove rotor Th...

Page 133: ...nsor adjustment tool 1 Temporarily fasten the sensor 2 with two screws 2 Insert the sensor adjustment tool 3 between the sensor and the break away plate 1 of the rotor 3 Lightly place the sensor on the sensor adjustment tool and screw it light This sets the distance between the sensor and the rotor to 0 5 0 1 mm 4 Remove the sensor adjustment tool 5 Install the alternator cover with stator 6 Remov...

Page 134: ... black 1blue 0 75 49 red 1white 0 75 5 7 Starter Relay The starter relay is located in a relay pocket This relay pocket is attached to two brackets on the frame Removal 1 Remove the seat 2 Pull out the relay pocket toward the middle of the vehicle 3 Remove the cable Note Slide on the relay pocket on the frame bracket so that the connec tion cable are placed on the bottom Installation Install in re...

Page 135: ...ed while the vehicle is in gear and the side stand is extended or if the engine continues to run then the shut off relay or the diode 31 see circuit diagram or the side stand switch or the neutral gear switch are defective Removal 1 Note the slot allocation 2 Remove the seat 3 Unscrew the screw 4 Remove the four cables Installation Install in reverse order MZ 125 XlSM Repair Manual 5 I I I 2 4 1 S...

Page 136: ...le lugs on one side Before heating the thermal switch 2 in the liquid connect the cable to the contacts top view 1 1 Heat coolant anti freeze preferably undiluted in a container and stir continuously Check the temperature with a thermometer 2 Hang the thermal switch 2 in the liquid with the brass probe 3 Use an appropriate tool such as an angle iron 3 to do this 4 The following switch states must ...

Page 137: ...s attached to the front part of the frame It is designed as an electromagnetic striking horn Removal 1 Carefully remove the plug contact using a pliers 2 Unscrew the hexagon nuts and remove the horn Installation Install in reverse order Note The horn must not be in contact with the fuel tank It is attached to the right side of the steering head pipe on the bottom of the clamp shell 05 02 133 ...

Page 138: ... down the starter has a short circuit fault or is blocked The starter must be replaced in both cases Removal 1 Remove the left side panel disconnect the negative pole on the battery 2 Remove the cable 1 from the oil pressure switch 3 Unscrew the 2 screws 2 remove the earth cable 3 4 Pull the starter straight out from the crankcase Do not lilt 5 Push back the rubber protector 6 Hold the lower nut s...

Page 139: ...f the fan motor is corroded The engine overheats the fuse burns out 1 Connect the vehicle power supply to the fan contacts 2 The fan must turn easily 3 Replace defective fans Attention Possible engine damage Ifwater enters the fan motor it may become corroded The fan breaks and the forced cooling is no longer guaranteed Overheating the engine leads to severe engine damage Install the fan with the ...

Page 140: ...n Diode in idle Diode circuit Diode in short circuit condition Continuity tester diagram D1 30 The speedometer illumination The parking light the tail lights when the parking light is on light and the instrument Z Ifthe light switch is in parking light illumination light when the 5 C ai c 0 g c or full light position the electrical ignition and the parking 0 8 installation is in operation without ...

Page 141: ...vice If the tolerance values are exceeded the components must be replaced 6 2 Inspection 6 2 1 Compression Pressure The compression pressure is measured with a compression testing device 1 Start the engine and let it warm up for a few minutes 2 Switch off the ignition disconnect the ignition cable Attention Risk of short circuit in open ignition circuit Possible damage to the ignition system Alway...

Page 142: ...ts in an inaccurate reading Unscrew the oil cap with oil dipstick from the oil filler neck and wipe off the dipstick Re insert then unscrew the cap again and check the oil level on the dipstick The oil level must be between the MIN and MAX markings Add oil if necessary but never more than the maximum 1 2 3 MAX MIN 4 Note If the oil level is at MIN up to 200 cm3 0 2 I of oil may be added 6 2 3 Oil ...

Page 143: ...l filler plug 2 6 Unscrew the oil drain plug 3 7 Unscrew the screw plug together with the oil screen 4 handling the seal carefully 8 Let the oil drain out completely 9 Unscrew the 2 screws of the oil filter cap 10 Remove the oil filter 11 Soak the new filter and O ring in oil then insert it renew the seal and screw the cap on tightly 12 Clean the coarse screen of the screw plugs and the magnet of ...

Page 144: ... has a bypass opening in the centre of the filter This bypass opening guarantees an emergency oil supply to the engine even when the oil filter is dirty The opening pressure of the bypass opening is 1 4 0 2 bar Installation 1 Spread oil on the seat for the seal ring on the inside of the filter 2 Soak the filter paper lightly in oil Improvement in the oil flow after the oil filter change 3 Place th...

Page 145: ...g into the nut of the oil return plug 4 Fasten the cap with two cylinder screws 6 2 6 Oil Pressure Sensor Type Switch pressure Bosch 03441 01090 0 5 0 8 bar inspection The oil pressure sensor monitors the oil pressure If there is no oil pressure e g insufficient motor oil damage to the oil circuit engine not in operation the indicator lamp lights If it is determined that no fault exists in the oil...

Page 146: ...e container 4 Drain the motor oil into a suitable container see 6 2 3 Oil Change 5 Disconnect the clutch bowden cable 6 Remove the spark plug connector 7 Completely remove the exhaust system see 3 16 Muffler 8 Remove the cable from the thermal switch 9 Open the carburettor hose clamp of the air intake fitting remove the air intake fitting from the intake manifold 10 Remove the radiator hose from t...

Page 147: ...engine support plate while holding the nuts still 21 Pull out the cylinder screws 22 Unscrew and pull out the screws of the rear engine suspen sion 23 Tilt the engine upward near the cylinders and pull it out toward the front right MZ 125 Sxt M Repair Manual 05 02 143 ...

Page 148: ...m 12 Pressure rod with ball 13 Clutch activation lever 14 Clutch cable counter bearing 15 Sliding bearing 6 4 1 Adjustment The bowden cable play is adjusted at the clutch lever It is measured at the end of the clutch lever and should be 3 5mm 1 Push back the rubber cap 2 Loosen the lock nut 3 Screw the adjusting screw inward or outward as required 4 Hold the adjusting screw tighten lock nut 5 Push...

Page 149: ... and needle bush and replace if necessary The shaft seal ring is destroyed by removing it Note The sliding bearing for the shaft of the clutch activation lever can only be replaced on a dismantled engine Installation 1 Insert needle bush and seal ring 2 Insert the clutch activation lever with spring at an angle of is 3 Screw in the screw for the clutch activation shaft with screw locking agent at ...

Page 150: ... spring for the oil pressure regulator 1 is supported by the surface under the oil filter cavity Changing the position of this surface results in changes to the engine oil pressure Engine damage is possible 6 The selector shaft is supported axially by the surface 2 on the rear of the clutch cover If the seal for the crankcase cover is forgotten the selector shaft may get jammed against the surface...

Page 151: ...locking washer and the first washer for the clutch also remove the dog and second washer for the clutch Note The nut that holds the pump drive gear against the crankshaft has left handed threading 17 Unscrew the nut for the pump drive gear Left handed threadingl 18 Remove the shock absorber 1 and clutch basket 2 at the same time Note The spacer and thrust washers behind the clutch basket may stick...

Page 152: ...Place them on a flat surface and check with a thickness gauge Unstressed Wear limit New Wear limit Replace worn or bumt out clutch plates Always replace clutch plates as a set Thickness Wear limit 11 Jays replace the inner plates as a set Clutch basket 38 5 mm 37 7 mm 3 0 05 mm 2 7mm 1 5 0 05 mm 1 3mm Attention Always replace the clutch basket completely together with the drive gear primary drive ...

Page 153: ... shock absorber at the same time 2 Slide the clutch locking tool ST 5 onto the dog 3 Insert the washer and locking plate 4 Screw the M12 nut on tightly turn the locking plate 5 Insert one pressure rod then insert the ball and the second pressure rod 6 Insert the disc spring The inner circumference lies on the dog the outer circumfe rence points to the plate packet If the disc spring and plates are...

Page 154: ...e housing 4 Remove pinion cover 5 Check the selector shaft for deformation To do this place a steel ruler or angle iron on the part that juts outward 6 Pull out the selector shaft Inspection 1 Check the curvature of the selector shaft 1 To do this roll the selector shaft over a flat surface 2 Check the pull back spring and retaining ring 2 for frac tures 3 Test the ease of action of the lever 3 In...

Page 155: ...ernating between clock wise and counter clockwise If the locking function does not work in the counter clock wise direction the free wheel is defective and must be replaced If pronounced chatter marks are found on the free wheel the free wheel must be replaced Removal of the free wheel is only useful for determining the extent of wear The free wheel is destroyed by removing it Installation Install...

Page 156: ...move the crankcase cover see 6 4 3 Removing the Clutch 2 Remove the locking washer from the pump shaft remove the 3 thrust washers 3 Pull off the oil pump gear Note Be careful the straight pin can fall out of the hole into the oil pump Loss possible 4 Remove the pump drive wheel 5 Unscrew the 3 cylinder screws remove the oil pump 6 Unscrew the Phillips screw take apart the oil pump 152 05 02 MZ 12...

Page 157: ... 5 Cylinder screws 6 Water pump 7 a ring 7x56 HBR 8 a ring 8x53 HBR Removal 1 Drain oil from the engine remove the crankcase cover see 6 4 3 Removing the Clutch 2 Remove the locking washer from the oil pump shaft remove the 3 washers 3 Unscrew the nut for the pump drive gear Left handed threading Remove the drive gear from the crankshaft 4 The following step is not necessary in every case because ...

Page 158: ...t through the housing Clean the hole if necessary using a suitable tool figure Inspection Inspect the following components for wear cracks damage replace the water pump if necessary Housing Gear water pump a rings Impeller a rings can be replaced separately The water pump is replaced as a unit Installation Install in reverse order Note CarefUlly place the water pump in the housing The impeller mus...

Page 159: ...uel tank 2 Remove the spark plug connector 3 Remove the spark piug 4 Unscrew the 4 decoupling elements from the valve cap Torx E10 5 Remove valve cap check seal 6 Bring the engine to the top dead centre position The piston 5 is located at the top dead point when the holes in the camshaft 1 2 point to the left 7 Unscrew the cylinder screw and screw in the crankshaft locking bolt 5 This inserts the ...

Page 160: ...e timing chain adjuster from above using a screw driver Insert the pressure pin 11 Remove the guide rail and bearing covers 1 4 12 Remove the timing chain and pull out the camshafts 13 Unscrew the 2 M6 cylinder screws near the timing chain shaft 14 Loosen the 4 M8 nuts for the cylinder head mount in a crosswise manner turning them approx 90 each until the counter pressure from the cylinder is elim...

Page 161: ...s Note Only replace the cylinder head seal together with the cylinder base seal Inspection Use an oil stone to clean combustion residue from the sealing surfaces Inspect the cylinder head for cracks Check that the sealing surface is level by placing a straight edge over both diagonals Wear limits 0 02 mm MZ 125 SXJSM Repair Manual 05 02 157 ...

Page 162: ...ke camshaft 9 Chain adjuster 2 Run the timing chain 1 downward 3 Unscrew the screw 2 pull out the tension rail 3 upwards 6 7 3 Timing Chain Tension and Guide Rails Removal 1 Remove the guide rail Left Guide rail with O rings RT 125 up to cylinder no 37 42 050 sand casting Right Guide rail with O rings RTlSXlSM 125 starting with cylinder no 37 42 053 gravity die casting MZ 125 SXlSM Repair Manual 0...

Page 163: ...T Inspection Timing chain A B Parts of the timing chain A 1 Bolt 2 Chain link 3 Guide In the event of significant wear on the lower edge of the inside of the guide B alignment faults occur Timing chain jams or has cracks Replace the timing chain and chain wheels as a set Guide rail Inspect for wear 1 Guide rail 2 Tension rail 3 Top guide rail MZ 1 ZS SXlSM Repair Manual 05 02 159 ...

Page 164: ...e camshaft and cover 0 020 0 046 mm maximum permissible eccentricity at the bearing 0 03 mm Chain Wheel Camshaft hen the components are adjusted correctly light markings can be seen centred on the edges of the timing chain 1 and the edges of the chain wheels 2 If there is too little tension in the timing chain the chain links do not grip the teeth of the chain wheels correctly These are worn out m...

Page 165: ... seal Always use a new head seal and a new base seal 4 Carefully position the complete cylinder head Do not damage the tension and guide rails 5 Screw on the screws and nuts as follows Lubricate the threads of the M8 tie rod numbers 1 4 and the two M6 hexagon recessed cap screws numbers 3a and 1a and the support surfaces with MoS2 Screw on the M6 screws and M8 nuts and tighten by hand Screw on the...

Page 166: ...w on the bearing covers and guide rails 10 Inspect the bearing clearance Attention A new head seal and a new base seal must be used after every removal of the cylinder head 11 Screw on the chain adjuster The 0 mark on the toothed rack must point upward 12 Tension the timing chain 13 Check and adjuslvalve clearance if necessary 162 Tightening torque Bearing cover screws M8 collar nuts M6x90 cylinde...

Page 167: ...T 1 to press the spring plate and spring together 3 Remove the valve collets 2 2 per valve 4 Remove the spring plate and valve spring 5 Remove the valve stem seal from the valve stem with the ST2 6 Remove the valve spring support 7 Pull the valve down and out The valve stem guide and valve seat rings are not intended to be replaced Attention Engine damage The cylinder head seal surface may not be ...

Page 168: ...max 4 05 max 4 05 Valve stem valve stem 0 008 0 034 0 018 0 044 guide clearance max 0 07 max 0 09 Tappet clearance while cold 20 5 C ON 0 09 0 11 mm OFF 0 11 0 14 mm Valve stem eccentricity maximum permissible valve stem eccentricity more than 0 01 mm Bucket tappet Outer diameter Clearance 24 967 24 980 mm 0 020 0 054 mm Valve springs A A max perm inclination ON 1 1 mm 1S OFF 1 1 mm 1S B B Length ...

Page 169: ...em guide to receive an accurate result 4 Measure the valve seat width The paint is worn off at all points where the valve plate and valve seat surface come into contact If the valve seat is too wide too narrow or not centred properly the valve seat must be reworked Fault correction A The valve seat is centred but too wide Valve or valve seat ring worn out Replace the cylinder head A 8 The valve se...

Page 170: ...50 with the specified valve seat grinder Always use the appropriate valve seat grinder 1 Position the valve seat grinder 1 and centre it in the valve guide 2 Turn the valve seat grinder downward onto the valve seat with even pressure approx 4 5 kg Avoid uneven grinding d Intake maximum diameter of 23 75 mm Exhaust maximum diameter of 20 25 mm 166 d Grind the valve seats as follows Section 1 05 02 ...

Page 171: ... seat after completing the lapping process Inspection 1 Apply touch up paint to the valve plate 2 Insert the valve into the cylinder head 3 Press the valve against the valve seat with the valve stem guide to receive an accurate valve seat measurement 4 Measure the valve seat width again If the valve seat width does not correspond to the specified value regrind and lap the valve seat Installation N...

Page 172: ...camshaft 1 Left exhaust camshaft 2 Right intake camshaft 3 Left intake camshaft 4 4 Tension the timing chain using the timing chain adjuster 5 djust the camshafts see 6 7 5 nsta ation 6 If necessary screw in the oil drain plug and screw plug screw in dipstick 7 Carefully pour 1 2 I of oil over the camshafts bucket tappets and timing chain wheels with timing chain SAE 15W 50 API SG SH or SAE 1OW 40...

Page 173: ... adjuster plates are available in thicknesses from 2 000 mm to 3 300 mm in 0 025 mm steps The following basic needs of adjuster plates results from the stati stical evaluation of the MZ 125 engine assembly operations Thickness Item number Thickness Item number inmms inmms 2 100 3742102100 2 450 3742102450 2 125 3742102 125 2 500 3742102500 2 150 3742102150 2 550 3742102550 2 175 3742102175 2 600 3...

Page 174: ...g chain shaft 4 Remove the timing chain from the chain wheels 5 Remove the camshafts 6 Lift out the adjuster plates using a tweezers or screw driver 7 Insert an appropriate adjuster plate into the cleaned bucket tappet 8 Lubricate the camshaft bearings insert camshaft 9 Install the bearing caps and gUide ails on top and screw on 10 Inspect the bearing clearance 11 Screw on the valve caps 170 Tight...

Page 175: ...he cylinder head seal 1 2 Remove the 2 fitting sleeves 2 for locking the cylinder head from the cylinder 3 Remove the cable 3 from the oil pressure sensor 4 Pull the timing chain upward and remove the cylinder Protect the pistons against damage 5 Remove the cylinder base seal 05 02 171 ...

Page 176: ...removed wire retaining rings must not be reused Always install new rings 3 Debur the retaining ring groove and pin hole if necessary The retaining ring groove must have sharp edges other wise secure seating of the wire retaining ring is not guaran teed 4 Slide out the piston pin from the piston Do not drive out the piston pin with a hammer 5 Pull out piston 6 Remove piston rings Carefully remove p...

Page 177: ...1 190 mm tapered compres sion ring Oil wiping ring 0 020 0 055 mm 2 470 2 490 mm D Piston pin hole Check the inside diameter 0 of the piston pin hole Wear limit 15 005 mm Piston dimension group The piston dimension group is placed on the piston base Usage in series up to engine no MZ125 001994 Piston dimension Piston 9015189000 group Dimensions in mms A 59 960 59 963 B 59 964 59 969 C 59 970 59 97...

Page 178: ...gher oil consumption local over heating and early wear The running surfaces must be clean Annular gap 1 Slide every piston ring 1 approx 20 mm into the cylinder 2 at a ilght angle to the cylinder hole 2 Measure the annular gap L with a thickness gauge Ring 1 rectangular ring 0 15 0 35 mm Ring 2 tapered compo ring 0 20 0 40 mm Ring 3 oil wiping ring 0 20 0 45 mm If the gap size of one piston ring i...

Page 179: ...e Cylinder dim I Piston dim group I Piston dim group I i 1 Slide the sleeves onto the left stud bolts 2 Position the new cylinder base seal Always use a new cylinder base seal 3 Cover the crankshaft well with cleaning paper 4 Lubricate the piston pin slide it through the piston and connecting rod eye 5 Snap the wire retaining ring for the piston pin into the ring groove with the opening facing dow...

Page 180: ...on 1 Inspect the seal 1 replace if necessary 2 Inspect the intake manifold 2 replace if necessary 3 Clean the seal surface 4 on the intake manifold and cylinder head with an oil stone 4 Position the seal and intake manifold screw in the cylinder screws 3 176 Tightening torque Cylinder screws 05 02 8 2 Nm MZ 125 SXlSM Repair Manual ...

Page 181: ...e housing half 2 Press back the index lever with the pin 2 of the ST 9 and affix it tightly to the housing ledge next to the star wheel If the index lever counter lock ST is not used 1 Unscrew the M6 pin 3 remove the index lever 4 and torsion spring 5 2 Remove pinion and sleeve 3 Completely remove the alternator cover 4 Remove the sensor and stator 5 Remove the curved washer 6 Turn the crankshaft ...

Page 182: ...r cover The tool must be positioned parallel to the housing If necessary loosen a screw somewhat to align the tool 11 Turn the M10 screw of the housing separation tool ST 8 and press off the right housing half The balance washers of the crankshaft the balance shaft and the driven shaft may remain attached to the housing half Loss possible 12 Pull out the selector fork shaft 1 2 with the 5th and 6t...

Page 183: ... replaced To do this heat the housing halves evenly to 1OO C for instance with a heating plate Note The needle bearing of the clutch shaft must be removed to dismantle the sliding bearing of the clutch activation shaft 6 10 2 Inspection Selector forks Inspect every selector fork for pit formation on the control gear and dog pins Measure 1 Control gear guide width 5 mm minimum 4 85 mm 2 Dog pin dia...

Page 184: ...elector fork shafts Gear wheels Inspect every gear wheel for wear and damage look for indica tions of heat damage blue discoloration Every control gear must slide easily along its shaft Check the grip of each gear into its opposite gear Inspect the teeth of the transmission gear wheels for pit formation and wear replace if necessary Inspect the shifting claws and apertures for rounded edges cracks...

Page 185: ...mum clearance 0 050 mm 2 Inspect the grooves for the curved washers 3 Inspect the cone surface for wear and damage 4 Inspect true run Maximum clearance 0 03 mm 5 Measure the axial clearance of the connecting rod eye Maximum clearance 0 5 mm Balance shaft Inspect the bearing 1 and shaft for wear and proper true run Shock absorber 1 Inspect the teeth for wear and damage 2 Check the roundness and the...

Page 186: ...haft without transmission 2 Slide the shafts to one side tum multiple times and measure the clearance between the crankshaft and housing 2nd option 1 Measure the housing clearance near the crankshaft bearing using a depth indicator 2 Measure the width of the crankshaft cheeks e g with a micrometer 3 Housing clearance minus crankshaft cheek width clea rance There must be a distance of at least a 0 ...

Page 187: ...when replacing the seal ring 6 Clean oil channels 7 Install the idling switch 8 Install the transmission 9 The transmission shaft must rest against the inner bearing rings Tap down using a plastic hammer if necessary 10 Clean oil away from the holes of the selector fork shafts in the housing 11 Insert the selector fork into the guide path of the control gears selector fork 2 4 1 in drive shaft des...

Page 188: ... balance shaft such that the gear wheels interlock at the markings Attention The protective sleeve protects the crankshaft sliding bearing If it is not used the sliding bearing may be destroyed 17 Slide the protective sleeve 2 onto the right tail shaft 18 Apply the Loctite 518 sealant thinly and evenly to the seal surfaces 1 of the left half of the housing Also spread the sealant around the holes ...

Page 189: ...in install the guide rail and tension rail Apply screw locking agent LOCTITE 243 to the threading 31 Connect the inspected and or new starter free wheel to the balance shaft 32 Apply screw locking agent LOCTITE 243 fasten the free wheel with washer and bolt Observe the specified torque 33 Install the water pump with new O rings Use new microencapsulated screws or screws with screw locking agent 34...

Page 190: ...tch 58 4 Nm turn the locking plate 52 Insert one clutch pressure rod into the clutch shaft then the ball and the second pressure rod 53 Remove the Clutch ST 5 test the easy turning of the clutch dog 54 Insert the disc spring The inner circumference lies on the dog the outer circumfe rence points to the plate packet 55 Starting with an inner plate insert 6 inner and 6 lining plates in alternation 5...

Page 191: ...pter and spring Attention The seal must not change the cross section of the supply and drainage openings for the oil filter and engine ventilation 63 Position the new crankcase cover seal 64 Position the crankcase cover screw on with 14 cylinder screws 65 Installing the oil filter see 6 2 4 Oil Filter 66 Install the cylinder with new base seal 67 Screw in the chain adjuster tension the timing chai...

Page 192: ...n the carburettor and the fuel system must be removed before adjustments are made to the carburettor 6 12 1 Settings Fuel level Proper functioning of the carburettor is only guaranteed when the specified fuel level is maintained The fuel level depends on how the float is set 1 Position the vehicle upright on the installation stand The carburettor must be positioned vertically 2 Attach a fuel gauge...

Page 193: ...rew it 1 5 2 turns 3 Turn the slide valve stop screw until 1800 100 rpm is reached 4 Repeat this alternating procedure until the engine runs properly Vllith exhaust measurement 1 Run the engine until it reaches operating temperature 2 Connect the exhaust measurement device according to the manufacturer If the depth of the measurement probe is insufficient connect an adapter to the exhaust silencer...

Page 194: ...e 4 Open the screw let the carburettor drain 5 Remove the fuel hose from the carburettor 6 Unscrew the starting carburettor 7 Unscrew seal cap 1 8 Pull out the throttle slide valve 2 9 Open the shell on the intake pipe rear and the shell on the carburettor connection piece front 10 Pull the carburettor away from the intake manifold and intake pipe pull it out on the front right 11 If the carburett...

Page 195: ... 4 Screws 5 Screw 6 Float 7 Pin 8 Screw with seal ring 9 Slide valve stop screw 10 Idling mixture screw 11 Idling jet 12 Main jet mount with needle jet 13 Main jet 14 Carburettor needle valve 15 Screw with plate 16 Plate 17 Starting carburettor complete 18 Throttle slide valve complete 19 Needle jet 05 02 Carburettor l I I I I J 191 ...

Page 196: ... the float is still in the float chamber 1 Float 2 Main jet with mount 3 Carburettor needle valve 4 Pin 1 Pull out pin 2 Remove the float and carburettor needle valve 3 Inspect parts Always replace the carburettor needle valve and the valve seat as a set 4 Attach the needle valve to the bracket on the float mounting plate 1 5 Install the float slide in the pin The float mounting plate should touch...

Page 197: ... for wear and contamination Clean if necessary Carburettor needle valve Inspect for wear and contamination Check the O ring 6 12 4 Installation Always use new seals 1 Insert the plate 7 and screw on with the screw 6 2 Scre v v in all jets 1 Idling mixture screw 2 Idling jet 3 Needle jet 4 Main jet with jet mount 5 Carburettor needle valve 6 Plate screw 7 Plate 8 Slide valve stop screw 3 Screw the ...

Page 198: ... throttle bowden cable out as far as possible 11 Press the spring back toward the sealing cap and hold it there 12 Attach the end of the throttle bowden cable to the throttle slide valve 13 Insert the throttle slide valve into the carburettor screw on the sealing cap 14 Inspect the a ring under the starting carburettor housing replace if necessary 15 Compress the spring of the starting carburettor...

Page 199: ...the engine Overflow hose The overflow hose must be run as shown in the sketch It may not be pinched the end must not extend past the under side of the engine 1 Carburetlor overflow hose 2 The top of the hose should not be above the lower edge of the carburetlor parting joint near the hose clamp 3 Overflow hose clamped between the frame pipe and intake muffler MZ 125 SXlSM Repair Manual 05 02 195 ...

Page 200: ...I L LC 196 05 02 Notes MZ 125 SXI M Repair Manual ...

Page 201: ...e screen 26 O i 1 li oa Adjustment 144 Fine grinding 167 UCl lI IUL 11 g Ju u 11 lJ11 w Battery 114 Inspection 148 Flasher relay 130 charge 116 Removal 146 Float 192 replace 115 Clutch activation lever 145 Float mounting plate 192 Battery output data 114 Clutch basket 148 Foot rest rubber piece 48 Bleed the brake system 75 Clutch bowden cable 39 Foot rests 48 Bolster plate 73 Coil resistance 121 f...

Page 202: ...elector fork shafts 180 Ignition box 122 Oil volumes 139 Selector forks 179 Ignition cable 119 Oil wiping ring 174 Selector shaft 150 Ignition coil Opening temperature range 58 Sensor 124 120 Overflow hose 195 Sensor adjustment 129 Ignition lock break off screws 36 Shock 38 Index lever counter lock 177 Shock absorber 46 149 181 Indication 34 P Adjustment 47 Injector needle 194 Shut off relay 131 I...

Page 203: ...age tank 72 92 Thermal switch operating tempera Valve seat 165 166 Hose 92 ture limits 132 Valve train 158 Swing bearing 69 Thermostat 58 Valves 163 Swing bearing pin 69 Inspection 58 Ventilation hose 195 Swing fork 69 Throttle 39 Swingarm 42 Throttle slide valve 190 Switch 44 Throttle twist grip 40 W Switch mount 44 Tightening torques 18 Timing chain 158 159 Warning light Oil pressure too low Top...

Page 204: ...200 05 02 Index MZ 125 SXI M Repair Manual ...

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