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BT125T-2

SERVICE MANUAL

JIANGMEN SINO-HONGKONG BAOTIAN MOTORCYCLE INDUSTRIAL CO., LTD

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Содержание BT125T-2

Страница 1: ...BT125T 2 SERVICE MANUAL JIANGMEN SINO HONGKONG BAOTIAN MOTORCYCLE INDUSTRIAL CO LTD ...

Страница 2: ...TER THREE BODY TROUBLESHOOTING SECTION ONE BODY COMMON TROUBLES AND TROUBLE DETECTION 14 SECTION TWO DETAILED DESCRIPTIONS OF BODY PARTS TROUBLES Ⅰ FRONT WHEEL SERVICE 17 Ⅱ FRONT BRAKE SERVICE DISK BRAKE 19 Ⅲ FRONT SHOCK ABSORBER SERVICE 21 Ⅳ FRONT FORK SERVICE 22 Ⅴ HANDLEBAR SERVICE 24 Ⅵ REAR WHEEL SERVICE 25 Ⅶ REAR BRAKE SERVICE DISK BRAKE 27 Ⅷ REAR SHOCK ABSORBER SERVICE 27 CHAPTER FOUR ELECTRI...

Страница 3: ... Restrict the length of riding time to avoid long time running of the engine z Replace engine oil at short intervals so that metal chips caused in the running in period can be discharged It is recommended to replace engine oil for 3 times during the running in period 2 Routine Maintenance Routine maintenance is the basis of all kinds of maintenances It refers to the daily maintenance including cle...

Страница 4: ... I I I I I I I I I I I I Drive belt I Suspension I I I Tire I I I Steering rod bearing I I I Screws and bolts of parts I I Notes 1 I Inspect and when necessary clean lubricate supplement modify or replace A adjust C clean R replace T tighten 2 Effect periodic maintenance according to the instructions in the user s manual 3 When the mileage exceeds the range specified in the schedule repeat the mai...

Страница 5: ...light beam adjustment Rear shock absorber damage loosening Air filter contamination Rear brake disc damage wear Rear brake caliper wear of brake block Gear case engine oil quantity oil replacement Spark plug damage contamination Front brake disc damage wear Front brake caliper wear of brake block Rear rim damage oscillation Rear tire wear damage tire pressure Oil tank brake oil level 3 ...

Страница 6: ... specified tightening torques 4 Cleaning Cleaning is needed by machine parts and positions which call for cleanliness and tidiness Cleaning operations include all the means and measures taken to remove dust contamination metal chips oily stains and carbon deposits that might lead to pipe clogging or reduction in motorcycle performance Cleaning measures are washing carbon deposit removing rubbing c...

Страница 7: ...the carburetor Remove rear store case cover Adjust by loosening the fastening nut and turning the adjusting nut Fine adjustment is effected on the side of the throttle grip Effected adjustment is by removing the dust cover loosening the tightening nut and turning the adjusting nut adjusting nut dust cover tightening nut free travel 2 6mm adjusting nut tightening nut 5 ...

Страница 8: ...ews of air filter Remove air filter strainer cover Remove 2 tightening screws of air filter strainer Take out air filter strainer Inspect the strainer if there is any dust and damage in it Replace it in case of dirty or damage z Don t use water or any oil cleanser to clean it z The papery air filter strainer cannot be cleaned by air because it is oil based Mount strainer Mount strainer cover Ⅵ BRA...

Страница 9: ...g brake block Brake block must be replaced as a set Remove two pieces of brake block pins by means of a hexagon wrench brake block brake caliper Effect mounting in an order reversed to that of dismounting After effecting first tighten the brake caliper and put its hole right to the hole of brake caliper and then put the brake block pin in and tighten it Brake Disc Inspection Inspect brake disc thi...

Страница 10: ...to caliper Brake Block Replacement Brake block must be replaced when it is worn to the limit of use It is not necessary to remove brake oil pipe when replacing brake block Brake block must be replaced as a set The method of replace the rear brake block is the same as the front brake block Brake Disc Inspection Inspect brake disc thickness Limit of use 3 0mm Inspect brake disc angularity Limit of u...

Страница 11: ...ine suspension lug buffer bush is loose Ⅷ FRONT WHEELAND REAR WHEEL INSPECTION Wheel Rim Inspection Inspect wheel rim remove rust stains and rubber chips Deformation and fissures are causes of air leakage Do not use wheel rims in the following cases Bruise of wheel rim face contacting tire bead ring exceeds 0 5mm in depth and 1 0mm in width Tire Inspection Inspect if there is fissure or iron nail ...

Страница 12: ...wheel 250 Rear wheel 250 Tire Specifications Front wheel 120 70 12 56J Rear wheel 110 90 12 64J Inspect if front wheel nut is loose Inspect if rear wheel nut is loose If loose tighten them to specified torques Torques front wheel nut 60N m rear wheel nut 120N m Ⅸ STEERING STEM INSPECTION Swing handlebar right and left to see if there is interference such as wire or other things Turn front wheel to...

Страница 13: ...sed at the specified positions with designated or equivalent greases z Parts must be tightened and their performances inspected at their positions when mounted z The battery s negative terminal must be disconnected before operation Make sure that tools such as wrenches are not in contact with the frame z At the completion of operations reconfirm correct connections and fastenings The positive term...

Страница 14: ...sleeves completely cover the terminals Plastic sleeves should not be placed with the open side up z Wire bunch bands should be fixed at the specified position of motorcycle frame z Wire clamps must correctly keep wires in place Avoid welding stains of welded clamps when clamping wires z Wire bunches must be fixed away from turning or moving parts z Do not damage the covering of wire bunches In cas...

Страница 15: ...Rear shock absorber lower mounting bolt 1 M10 25 Front shock absorber upper lock bolt 4 M8 35 Steering stem lock nut 1 M25 70 Handlebar mounting nut 1 M10 45 Upper bearing top 1 M25 2 5 Exhaust muffler connector nut 2 M6 12 Exhaust muffler mounting bolt 2 M8 35 Standard Torques Designations Torques N m Bolt nut M5 5 Bolt nut M6 10 Bolt nutM8 21 5 Bolt nut M10 35 Bolt nut M12 55 Screw M5 4 Screw M6...

Страница 16: ...steering stem top ball bearing retainer Heavy steering stem turning Refer to Front Fork Service Damaged or broken ball bearing Refer to Front Wheel Service Rear Wheel Service Reduced tire air Refer to Front Shock Absorber Service Imbalance of right and left shock absorbers Refer to Front Fork Service Bent front fork Deflected steering stem Refer to Front Wheel Service Bent front tire deflected tir...

Страница 17: ...rake System Inspection Adjustment and Replacement Front Brake Service Disk brake failure Inability of brake caliper normal sliding Stiff brake lever Worn seal ring of brake caliper piston Viscous or worn main cylinder piston Contaminated brake block and brake disc Bent or deformed brake disc Inability of brake caliper normal sliding Resisted braking Wheel not adjusted straight Refer to Front Fork ...

Страница 18: ... Front Wheel Service Inadequate tire pressure Deformed wheel rim Loose front wheel bearing Poor tire Refer to Front Wheel Service Front wheel oscillation Poor axle locking Refer to Front Shock Absorber Service Soft front shock absorber Spring fatigue Deformed wheel rim Refer to Rear Wheel Service Rear wheel oscillation Poor wheel Refer to Rear Shock Absorber Service Soft rear shock absorber Spring...

Страница 19: ...I FRONT WHEEL SERVICE Front Wheel Dismounting Support the body bottom to lift front wheel Remove front axle nut brake calipers front absorbers connecting bolt and remove brake calipers front shock absorber transmission gear box front axle bush and the small bush remove front axle Remove front wheel Remove brake disc mounting bolts Remove brake disc front shock transmission gear box front axle nut ...

Страница 20: ...e if 2 0mm Traverse direction Replace if 2 0mm Front Wheel Bearing Inspection Remove front wheel bearing and dust cover Turn bearing inner race to inspect sliding Replace it with a new one in case of no sliding or damage or loosening of outer race Front Wheel Bearing Replacement dust cover front axle bush Dismounting Remove front wheel bearing by means of a bearing remover take out spacer Mounting...

Страница 21: ...Mount brake caliper as specified II FRONT BRAKE SERVICE DISK BRAKE Brake Oil Replacing z Prevent dust or water from entering brake system z Do not use brake oils of different specifications or impure brake oils z Prevent brake oil from dripping onto rubber plastic or painted parts Brake Oil Exhausting Place main cylinder at a level place remove oil reservoir cover and diaphragm Connect a hose to o...

Страница 22: ...hragm set and oil reservoir cover Tighten oil reservoir cover bolt Main Brake Oil Tank Dismounting and Mounting Dismounting Remove each 2 bolts and screws of front part and rear part of head cover Remove front part and rear part of head cover Exhaust brake oil from front brake system Pull out brake switch plug from main cable Remove bracket bolts from handlebar Remove main cylinder Remove brake oi...

Страница 23: ...inder bore Measure outside diameter of piston at the end of auxiliary cup Mounting Apply pure brake oil to piston main cup and auxiliary cup Mount spring piston retaining ring and piston cap z Piston cup cannot be used inside out Apply grease to brake lever axis pin Mount brake lever and brake switch Mount main cylinder main cylinder bracket and lock them Mount brake oil pipe oil pipe bolt brake o...

Страница 24: ...ounting Mount front shock absorber on front fork and mount 4 bolts Torque upper bolt 35N m Mount front wheel IV FRONT FORK SERVICE Dismounting Remove motorcycle body covering parts Remove nut and blot from handlebar Remove handlebar Remove steering stem setting nut Remove upper bearing cup upper bearing top and bearing set upper bearing cup bearing top and ball set handlebar set nut bolt nut head ...

Страница 25: ...nt Inspect for completeness of bearing balls and if there is effect replacement with new ones Inspect for proper tightness of steering stem and if not effect adjustment and fasten it Inspect for correct position of bearing cup and bearing top and if not effect correct mounting Bearing Cup and Bearing Top Replacement Remove bearing cup and bearing top with special bearing cup and bearing top remove...

Страница 26: ...ANDLEBAR SERVICE Dismounting Remove covering parts of front part and rear part Remove rear brake main cylinder Remove connectors of left handlebar switch Remove 2 screws of left handlebar switch Remove left handlebar switch Remove left grip from handlebar Remove front brake main cylinder Remove connectors of right handlebar switch Remove 2 screws of right handlebar switch Remove right handlebar sw...

Страница 27: ...ase to throttle cable Mount throttle grip and connect throttle cable Mount left grip Mount covering parts of front head cover and rear head cover z Confirm easy rotation of throttle grip z When mounting handlebar rubber apply a thin film of adhesive to contacting face and then mount grip in a turning manner VI REAR WHEEL SERVICE Dismounting Remove 2 connecting nuts and 2 mounting bolts of exhaust ...

Страница 28: ...ount rear wheel with brake disc Mount rear wheel bush rear brake mounting board and fasten rear axle nut Torque 120N m z The hole on the rear brake mounting board must be matching with the hole on the engine Mount exhaust muffler Fasten exhaust muffler connecting nuts Fasten mounting bolts of the exhaust muffler engine and rear brake mounting board Exhaust muffler connecting nut 12N m Exhaust muff...

Страница 29: ...torcycle frame bolt connecting rear shock absorber and engine Remove rear shock absorber Inspection Inspect rear shock absorber oil seal for oil leakage inspect buffer bar and spring for deformation and other parts for damage and loosening Mounting Mount rear shock absorber Torque upper mounting bolt 40N m bottom mounting bolt 25N m Mount motorcycle body covering parts bolt absorber rear shock fra...

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