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HARTFORD CG-125, Руководство по обслуживанию

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Hartford Industrial Co., Ltd.

NO

CG

4.Cylinder,cylinder

head,valves and piston

Page

4-2

4.2Specifications

Part

Item

Specification

Service limit

Rocker arms

Inner diameter

12.000~12.018mm

12.1mm

Rocker spindle

Outer diameter

11.984~11.966mm

12.0mm

Pushrod

Cup radius and length

6.5mm/141.5mm

 ----------

Outer valve spring

Free length

40.9mm

39.7mm

Inner valve spring

Free length

33.5mm

32.5mm

Outer valve spring

Pressure @ length

15.6kg/35.4mm

-----------

Inner valve spring

Pressure @ length

7.1kg/30.7mm

-----------

Inlet valve stem

Diameter

5.450~5.465mm

5.42mm

Exhaust valve stem

Diameter

5.430~5.445mm

5.40mm

Inlet valve guide

Inside diameter

5.484~5.488mm

5.50mm

Exhaust valve guide

Inside diameter

5.484~5.488mm

5.50mm

Inlet valve to guide

Clearance

0.010~0.035mm

0.08mm

Exhaust valve to guide

Clearance

0.030~0.035mm

0.10mm

Cylinder(125cc)

Bore

56.500~56.513mm

56.6mm

Out of round

-------------------

0.05mm

Obliqueness

-------------------

0.05mm

Cylinder (150cc)

Bore

62.000~62.013mm

62.1mm

Out of round

--------------------

0.05mm

Obliqueness

--------------------

0.05mm

Piston(125cc)

Diameter

56.460~56.480mm

56.360mm

Piston pin hole

Diameter

15.002~15.008mm

15.05mm

Piston pin

Outer diameter

14.993~15.00mm

14.85mm

Piston / bore

0.020~0.050mm

0.11mm

Piston(150cc)

Diameter

61.990~61.970mm

61.890mm

Piston pin hole

Diameter

15.002~15.008mm

15.05mm

Piston pin

Outer diameter

14.993~15.00mm

14.85mm

Piston / bore

0.020~0.050mm

0.11mm

Piston ring to Clearance 1

st

 

0.025~0.055mm

0.13mm

2

nd

0.015~0.045mm

0.12mm

Installed end gap

1

st

0.15~0.35mm

0.5mm

2

nd

0.15~0.30mm

0.5mm

Oil ring

0.20~0.50mm

-----------

Piston Thickness

1

st

1.160~1.185mm

1.15mm

2

nd

1.175~1.190mm

1.16mm

Содержание CG-125

Страница 1: ...Service manual part engine For CG 125 150 Issued date April 1999 HARTFORD INDUSTRIAL CO LTD ...

Страница 2: ...Foreword Chapter 2 General specifications Chapter 3 Reason a breakdown Chapter 4 Cylinder cylinderhead valves and piston Chapter 5 Generator Start motor Chapter 6 Clutch and gear box Chapter 7 Carburetor Chapter 8 Removing and Installing the engine Chapter 9 Maintenance Chapter10Electrical system ...

Страница 3: ...Service manual part Engine for CG 125 150 HARTFORD INDUSTRIAL CO LTD Chapter 1 Foreword ...

Страница 4: ...S The FMS is planned and designed by Hartford is engineering staff and is composed of a series of Hartford machining centers Our engine production capabilities do not end with engineering and production Our commitment to quality is as modern and comprehensive as our facility The most up to date testing and measurement devices are used to assure that the engines we ship will meet your most exacting...

Страница 5: ... part name 2 1 2 1 1 Profile diagram 2 1 2 1 2 Main part name 2 2 2 2 Engine specifications 2 3 2 3 Lubrication system 2 4 2 4 Transmission 2 5 2 4 1 Clutch 2 5 2 4 2 Gear 2 5 2 5 Other 2 6 2 5 1 Ignition system 2 6 2 5 2 Generator 2 6 2 5 3 Base 2 6 2 5 4 Torque settings 2 7 2 5 5 Points for attention 2 8 2 5 6 Special tools 2 9 ...

Страница 6: ...Hartford Industrial Co Ltd NO CG 2 General Specifications Page 2 1 2 1 Profile diagram and Main part name 2 1 1 Profile diagram 432 315 2 347 6 15 15 5 162 124 32 238 5 267 140 ...

Страница 7: ... Main part name 11 2 5 4 13 1 6 3 15 10 9 8 12 14 7 6 Main part 1 Cylinder 2 Cylinder head 3 Carburetor 4 Holder comp pkr 5 Valve 6 Oil pump 7 Piston 8 Clutch 9 Right crank case 10 Left crank case 11 Generator 12 Leak bolt 13 Drive sprocket 14 Engine number 15 Starter Gear ...

Страница 8: ...ooled single cylinder OHV four stroke Single cylinder canted 15 degrees 90 octane or higher 56 5 x 49 5mm 124cc 9 1 33kg 5 degrees BTDC 35 degrees ABDC 30 degrees BBDC 5 degrees ATDC 0 06 0 08mm 0 06 0 08mm 1400 100 rpm Hemispherical Single camshaft OHV 9 5 8200 0 95 8200 45 more or less depends on road conditions Air cooled single cylinder OHV four stroke Single cylinder canted 15 degrees 90 octa...

Страница 9: ...l filter type Oil flow rate Oil grade Oil capacity Oil delivery Crankcase Cylinder head Transmission Gerotor Centrifugal and screen 4 4l min 8500rpm SAE 10W 30 0 8 1 2L 2 44l min 8500rpm 1 27l min 8500rpm 1 63l min 8500rpm Gerotor Centrifugal and screen 4 4l min 8500rpm SAE 10W 30 0 8 1 2L 2 44l min 8500rpm 1 27l min 8500rpm 1 63l min 8500rpm ...

Страница 10: ...ox International Left foot 1 4 Gearbox International 2 4 Gearbox Circulate 3 5 Gearbox International Left foot 4 speed 5 speed 4 speed 5 speed Gearbox type Operation Gear ratios Primary reduction 1st gear 2nd gear 3rd gear 4th gear 5th gear Final education 4 055 73 18 2 769 13 36 1 722 18 31 1 272 22 28 1 000 25 25 2 773 15 41 4 055 73 18 2 4 15 36 1 882 17 32 1 400 20 28 1 130 23 26 0 960 25 24 2...

Страница 11: ...on 15deg BTDC 1400rpm 32 35deg 3500rpm Cyclic AS41 NGK D7 or DR 8EA 12 x 19 0 6 0 7mm CDI electronic ignition 15deg BTDC 1400rpm 32 35deg 3500rpm Cyclic AS41 NGK D7 or DR 8EA 12 x 19 0 6 0 7mm Item 125C C 4 5 speed 150C C 4 5 speed Type Voltage regulator rectifier Maximum output ACG flywheel Solid state 0 12kw 5000rpm ACG flywheel Solid state 0 12kw 5000rpm Item 125C C 4 5 speed 150C C 4 5 speed S...

Страница 12: ...ue settings Reference settings Torque kg m 5mm UNT BOLT 6mm UNT BOLT 8mm UNT BOLT 10mm UNT BOLT 12mm UNT BOLT 5mm SCREW 6mm SCREW 6mm RAISED EDGE SCREW 8mm RAISED EDGE SCREW 10mm RAISED EDGE SCREW 0 45 0 6 0 8 1 2 1 8 2 5 3 0 4 0 5 0 6 0 0 35 0 5 0 7 1 1 1 0 1 4 2 4 3 0 3 0 4 0 ...

Страница 13: ...nuts by the diagonal way 3 Use the specified parts and lubricating oil 4 Use the tools by the rules 5 Use organic solvent to clean all the parts and smear with lubricating oil on their surface before assembling 6 Add suitable grease by the rule 7 Check the relative position of mechanism after assembling 8 Pay attention to safety when you repair and maintain this machine ...

Страница 14: ...ress down assembly tool for 150c c Rod push screw assembly tool for 125 150c c Cap 30 mm assembly tool for 125 150c c Mixing ratio adjust tool for 125 150c c Fltwheel comp nut assembly tool for 125 150c c Oir pump nut assembly tool for 125 150c c Piston ring 1st assembly tool for 125c c Piston ring 2nd assembly tool for 125c c Piston ring 1st assembly tool for 150c c Diamomd fix tool for air door ...

Страница 15: ...Hartford Industrial Co Ltd NO CG 2 General Specifications Page 2 10 VALVE IN OUT TOOL VALVE IN OUT TOOL CRANKCASE ASSEMBLY FRAMF PART NO 60000340 PART NO 60000310 ...

Страница 16: ...ason a breakdown 3 1 Engine is difficult or impossible to start 3 1 3 2 Engine output poor 3 2 3 3 Idle or show running poor 3 3 3 4 Poor high speed running 3 4 3 5 Starter motor inoperable 3 5 3 6 Start motor turns constantly 3 6 3 7 Engine noisy 3 7 3 8 High noxious emissions 3 8 ...

Страница 17: ...on rings or valves stuck 2 Valve clearance incorrect 3 Cylinder or piston rings excessively worn 4 Cylinder head gasket leaking or damaged 5 Decompressor leaking or cracked 6 Poor starter motor performance 7 Transmission faulty 1 Clutch slipping 2 Clutch face damaged or faulty 3 Clutch plates damaged or faulty Compression pressure low Remove carburetor screws check if there is fuel Insufficient fu...

Страница 18: ...d or faulty 1 CDI unit faulty 2 AC generator faulty 1 Cylinder or piston rings excessively worn 2 Gasket leaking or damaged 3 Decompressor leaking or cracked 4 Piston rings scored or damaged 1 Jet blocked 2 Carburetor incorrectly installed 3 Carburetor incorrectly adjusted 1 Piston or cylinder worn or damaged 2 Fuel mixture too weak 3 Fuel line faulty 4 Combustion chamber carbon deposits excessive...

Страница 19: ... leaking 2 Carburetor mounting nuts loose 3 Intake manifold gaskets damaged or leaking 4 Carburetor flange seal damaged or leaking 1 Spark plug fouled or worn 2 CDI faulty 3 AC generator faulty 4 Ignition coil open circuit or faulty 5 HT lead or spark plug cap short circuit or faulty Check ignition timing Check carburetor adjustment Check for air leak at intake manifold Remove spark plug ground bo...

Страница 20: ... carburetor Normal Incorrect Insufficient flow Check rotation of camshaft Normal Slack present Start engine 1 CDI faulty 2 AC generator faulty 3 Spark plug fouled or fuel mixture incorrect 1 Not enough fuel in tank 2 Fuel line or filter blocked 3 Fuel cap vent blocked 1 Chain adjustment incorrect 2 Slack present 3 Shaft or bearings damaged or faulty 4 Insufficient engine oil ...

Страница 21: ...rns Starter motor turns No flash or no light Starter motor does not turn Connect starter lead directly to battery Starter motor Starter motor does not turn Fault in main wiring harness 1 Fuse broken 1 Starter switch contact poor 2 Voltage regulator short circuit 3 Loose battery terminals 1 Carbon brushes worn 2 Rotor coils short or open circuit 3 Stator coils short or open circuit 4 Connections lo...

Страница 22: ...Co Ltd NO CG 3 Reason a breakdown Page 3 6 3 6 Starter turns constantly Possible cause Check Possible reason Switch off ignition Motor still turns Starter solenoid short circuit Motor stops Starter drive gear return faulty ...

Страница 23: ...ively loose 2 Valve rocker arms worn Piston slap 1 Cylinder or piston worn 2 Combustion chamber carbon deposits excessive 3 Piston pin or connecting rod worn or damaged Clutch noisy 1 Clutch drum drive tabs excessively worn Starter or transmission noisy 1 Rear wheel cut drive worn or disintegrated 2 Primary gears worn 3 Transmission gears worn ...

Страница 24: ...ltage regulator faulty d Ignition coil faulty e Alternator plate or spark plug cap shorted 2 Exhaust valve worn 3 Cylinder worn Low High 1 Fuel mixture weak or ignition system faulty 2 Vacuum leak a pressure pipe b inlet manifold c caps High High 1 Air filter blocked 2 Carburetor faulty a Idle mixture too rich b Float chamber incorrectly assembled c Choke operation faulty d Main jet loose e Idle s...

Страница 25: ...ylinder 4 4 4 4 Inspection and overhaul 4 5 4 4 1 Check the holder comp pkr 4 5 4 4 2 Check the pushrod 4 5 4 4 3 Check the Guide pushrod 4 5 4 4 4 Check the cylinder 4 5 4 4 5 Check the piston 4 6 4 4 6 Check the spring valves 4 7 4 4 7 Check the cylinder head 4 7 4 4 8 Inspect the valves and valve guides 4 8 4 4 9Inspect overhaul the valve seats 4 9 4 5 Installing the cylinder 4 10 4 5 1Installi...

Страница 26: ...worn or Valve spring broken damaged Pushrods and rocker spindles loose Piston rings installed incorrectly Push rods worn or bent Cylinder or piston scored Cam lobes worn Camshaft worn Cylinder or piston worn Excessive carbon deposits Note The rockers rocker support and pushrods can be serviced with the engine installed in the chassis Oil to the valve train passes through the cylinder block into th...

Страница 27: ...4 5 488mm 5 50mm Inlet valve to guide Clearance 0 010 0 035mm 0 08mm Exhaust valve to guide Clearance 0 030 0 035mm 0 10mm Cylinder 125cc Bore 56 500 56 513mm 56 6mm Out of round 0 05mm Obliqueness 0 05mm Cylinder 150cc Bore 62 000 62 013mm 62 1mm Out of round 0 05mm Obliqueness 0 05mm Piston 125cc Diameter 56 460 56 480mm 56 360mm Piston pin hole Diameter 15 002 15 008mm 15 05mm Piston pin Outer ...

Страница 28: ...DC on the compression stroke Remove the three rocker support bolts Remove the rocker support Remove the pushrods Remove the four cylinder head bolts Remove the pushrod guide plate Remove the cylinder head and gasket Remove the valve retaining collets Remove the three 10 x 20mm cylinder locating dowels Note to preserve seal and prevent oil and or air leaks do not damage the cylinder head or valve c...

Страница 29: ... Remove and discard the cylinder head gasket Remove and discard the cylinder base gasket Remove the traces of gasket sealant from the cylinder and head Piston pin Piston Note to prevent distortion or damage to the cylinder or piston avoid the use of excessive force disassembling Remove the piston do not allow the piston pin or clips fall into the crankcase Pin dowel Note to preserve seal and preve...

Страница 30: ... pushrod Check the pushrod ends for wear or damage Check the pushrods for bending or distortion If unserviceable replace 4 4 3Check the guide pushrod Check the plate damage or rusting If the pushrods do not move freely replace the plate 4 4 4Check the cylinder Check the cylinder bore for scoring or burning Measure the cylinder bore Service limits Out of round 0 050mm Obliqueness 0 050mm Bore diame...

Страница 31: ...ole diameter and ovality Service limit 15 05mm Measure the diameter of the piston Service limit 125cc 56 36mm 150cc 61 89mm Measure the 1st piston ring thickness Service limit 1 15mm Measure the 2nd piston ring thickness Service limit 1 16mm Insert the piston rings into the bore and measure the ring gap Piston ring gap service limit 0 5mm Measure the piston pin outer diameter Service limit 14 85mm...

Страница 32: ...gs Inspect the piston rings for scoring or damage Measure the piston pin hole diameter and ovality Outer spring service limit 39 7mm Inner spring service limit 32 5mm 4 4 7Check the cylinder head Check the cylinder head for scoring or damage With a straight edge and feeler gauges check the head gasket surface for warping or distortion Service limit 0 10mm ...

Страница 33: ...service limit Inlet valve service limit 5 42mm Inlet valve service limit 5 40mm Valve guide inside diameter service limit Inlet valve 5 50mm Exhaust valve 5 40mm Subtract the stem diameter from the valve guide inside diameter and obtain the clearance Inlet valve 0 08mm Exhaust valve 0 10mm If the clearance exceeds the service limit replace the valve and or the valve guide Before measuring the valv...

Страница 34: ...il First use a 45 degree cutter to face the valve seat then a 32 degree cutter to face the next of the total seat width The 60 degree cutter is used to face the next of the total seat width Finally the 45 degree cutter is used again to finish the lower part of the seat If the valve seat edge is too high use a 37 5 degree angle cutter to remove material and a 45 degree cutter to correct the angle I...

Страница 35: ...llets are correctly install or serious engine damage is likely Reinstalling the cylinder Fit a new cylinder base gasket Reinstall the locating dowels and the four cylinder studs Tighten the studs into the crankcase with1 0 1 4 kg m of torque Always install new valve stem seals when replacing the valves Do not over compress the valve springs with the valve spring compressor Take care not to drop an...

Страница 36: ... Use long nose pliers to reinstall the locating Avoid damaging the piston or rings during installation The mark on the piston ring indicates the upper side The rings should move freely in their grooves New circlips should used The ends of the circlip should not touch when reinstalled Take care not to drop a circlip into the crankcase Be sure that the piston is at TDC on the compression stroke Clid...

Страница 37: ... 20mm cylinder head locating dowels Replace the cylinder head with a new gasket Replace the rocker arms and support assembly Replace the four cylinder head nuts Tighten to 2 8 3 0kgm torque Install the pushrods Install the three bolts Tighten to 1 0 1 4kgm Nut cylinder head Guide pushrod Bolt FR brake stopper arm Holder comp PKR Pushrod ...

Страница 38: ...th pointer in the alternator case Adjust by loosening the locking screws and rotating the adjusting screw Re tighten and check clearance again Valve clearance should be 0 06 0 08mm inlet and exhaust Reinstall the valve cover with a new rubber O ring and oil lightly Replace the three 6 x 28mm cylinder head screws Tighten to 2 8 3 0kg m torque Replace the 6 x 12mm screws and tighten to 1 0 1 4kg m t...

Страница 39: ...5 1 Generator 5 1 5 1 1Removing the lift crank case 5 1 5 1 2Removing the generator rotor 5 1 5 1 3Installing the generator rotor 5 1 5 1 4Installing the lift crank case 5 1 5 2 Start motor 5 2 5 2 1Removing the start motor 5 2 5 2 2Removnig the start drive gears 5 2 5 2 3Installing the start motor 5 2 ...

Страница 40: ...he rotor Inspect the coils for signs of short circuit or broken wires Replace the coil with a new part if necessary Replace the coil taking care to avoid the coil or its leads touching the rotor Replace the rotor and tighten the retaining bolt to 2 6 3 2kgm torque 5 1 4Installing the lift crank case Replace the alternator cover with the stator coil installed Refit the electrical connector block Re...

Страница 41: ...r motor retaining screws Remove the starter motor 5 2 2 Removing the starter drive gears Remove the starter motor drive gear shaft Remove the starter reduction gear and shaft Reassemble is the reverse of disassembly 5 2 3Installing the starter motor Reassemble is the reverse of disassembly Replace the starter motor and tighten the retaining bolts to 0 8 1 2kg m Bolt flange ...

Страница 42: ...ter 6 Clutch Transmission 6 1Reason a breakdown 6 1 6 1 1Removing the right crank case cover 6 2 6 2Clutch 6 3 6 2 1Removing the clutch 6 3 6 2 2Check the clutch 6 4 6 3Transmission 6 5 6 3 1Removing the gearshift mechanism 6 5 6 3 2Installing the right crank case cover 6 7 ...

Страница 43: ...h fails to release vehicle creeps in gear 1 Too much slack in clutch cable 2 Distorted clutch parts C Clutch lever loose 1 Clutch cable 2 Clutch operating mechanism worn or damaged D Difficulty changing gear 1 Gearshift plate distorted 2 Clutch cable adjustment incorrect E Gearshift pedal detent poor 1 Gearshift return spring broken or displaced 2 Gearshift shaft distorted F Transmission jumps out...

Страница 44: ...emove the exhaust Remove the footrests Remove the clutch cable Remove the kickstarter Remove the right crank case cover Item New specification Service limit Clutch operating arm free slack 10 20mm Clutch spring free length 35 5mm 32 4mm Clutch friction plate thickness 3 0mm 2 5mm Clutch plate distortion 0 2mm Oil pump inner rotor clearance 0 30mm 0 35mm Outer rotor to body clearance 0 30 0 36mm 0 ...

Страница 45: ...ve the16 mm retaining nut Remove the oil filter body Remove the oil seal and clutch pushrod Remove the clutch center 20mm C clip Remove the clutch spring pressure plate screws Remove the clutch spring pressure plate and springs Remove the clutch center Remove the clutch friction plates Remove the clutch plates and pressure plate Remove the 20mm retaining ring washer Remove the clutch basket Rod cl...

Страница 46: ...asket Check the faces of the drive slots for indentation lInspecting the clutch springs Measure the free length of the four clutch springs Service limit 32 4mm l Inspecting the clutch plates Measure the distortion of the plates with a feeler gauge and a flat surface Service limit 0 2mm l Replacing the clutch Reassembly is the reverse of disassembly When replacing the clutch springs tighten the fou...

Страница 47: ...anism Remove the gearshift mechanism Remove the clutch Remove the gearshift pedal Remove the gearshift shaft Note when removing the gearshift shaft note the gearshift shaft return spring hooked on the lug located on the crankcase Spindle comp gear shift Stopper comp gear shift drum Cam gear Gear shift spindle comp ...

Страница 48: ...the gearshift detent arm Remove the gearshift cam Check all parts for wear or damage Reassembling the gearshift mechanism Locate the rollers and install the gearshift cam Reinstall the gearshift shaft and plate Spindle comp gear shift Stopper comp gear shift drum Cam gear ...

Страница 49: ... Install the clutch cable Install the kickstarter and exhaust pipe Refill the engine with fresh oil Adjust the clutch cable free slack Note the gearshift shaft return spring should locate against the lug in the crankcase Install the gearshift pedal and check the smooth operation of the gearshift mechanism Cam gear shift Stopper comp gear shift drum Right crankcase Lever comp clutch Spindle comp ge...

Страница 50: ...7 2Carburetor 7 2 7 2 1 Names of carburetor parts 7 2 7 2 2 Removing the carburetor 7 2 7 2 3 Throttle valve 7 3 7 2 4 Removing the float and float needle 7 3 7 2 5 Installing the float and float needle 7 4 7 2 6 Replace the throttle slide 7 4 7 2 7 Inspecting the float needle 7 5 7 2 8 Adjusting the float height 7 5 ...

Страница 51: ...ulty Low cylinder compression Fuel air mixture excessively rich Fuel air mixture excessively lean Air filter blocked Fuel dirty or contaminated Fuel air mixture excessively lean Carburetor jets blocked Carburetor body air passages blocked Fuel pipe blocked Float level too low Fuel filter blocked Float needle faulty or damaged Fuel air mixture excessively rich Choke valve seized Float level too hig...

Страница 52: ...urn the fuel valve to the OFF position Remove the fuel line Drain the fuel from the carburetor Remove the air filter hose clamp Remove the throttle cable Remove the carburetor mounting nut Remove the carburetor Air control lever Spring Needle Throttle valve Oil cup Float Float bowl screws Carburetor top Note Fuel is flammable and should be washed off the vehicle if spilled Mounting nut Air filter ...

Страница 53: ...edle and throttle valve for wear or damage 7 2 4Removing the float and float needle Remove the three M4 x 16mm screws Remove the float bowl Remove the support pin with long nose pliers Remove the float and Float needle Screws Float bowl Float Support pin Return the fuel inside to fuel tank Needle lock spring Needle Throttle valve Needle lock clip ...

Страница 54: ...mixture screws Replace the float bowl 7 2 6Replace the throttle slide Replace the needle Needle lock clip and needle lock spring Replace throttle cable Note Take care during reassemble not to damage any of the parts Note Do not damage the jets Note Before removing the idle mixture screw Screw the adjuster screw in Fully counting the turns Main needl Float needle Idle mixture screw Replace the miss...

Страница 55: ...float needle Examine the float and float needle for wear or damage 7 2 8Adjusting the float height The float height is set by bending the float tang Use the special gauge to measure the float height Correct float height 125C C 14 5mm Model PD026A 150C C 14mm Model PD19D Abrade ...

Страница 56: ... manual part Engine for CG 125 150 HARTFORD INDUSTRIAL CO LTD Chapter 8 Removing and installing the engine 8 1Removing and installing the engine 8 1 8 1 1Removing the engine 8 1 8 1 2Installing the engine 8 3 ...

Страница 57: ... the OFF position Remove the cover left rear crank case and pedal gear change Remove the generator wires Remove the control cables and retaining nuts Remove the tachometer cable Loosen the rear wheel axle Loosen the chain adjusters and slide the rear wheel forward Remove the master link and release the drive chain Pedal gear change Cover left rear crank case Rear wheel axle Nut Chain ...

Страница 58: ...e spark plug cap Removing the spank plug Removing the carburetor mounting nuts and dismount the carburetor Remove the crankcase exhaust hose Removing the clutch cable Removing the kick starter Spank plug Spank plug cap Mounting nut Carburetor Crankcase exhaust hose Clutch cable Kick starter ...

Страница 59: ...Remove the tachometer 8 1 2Installing the engine Installation is reverse of disassembly Note l Take care to correctly reinstall the control cables and electrical wires l Adjust the throttle cable slack l Adjust the clutch cable slack l Refill the engine with the approved oil SAE10W 30 Exhaust pipe Exhaust pipe nut Front engine mounting plate Rear engine mounting bolts Note Before removal support t...

Страница 60: ...L CO LTD Chapter 9 Maintenance 9 1Engine oil Oil filter 9 1 9 1 1Check the engine oil 9 1 9 1 2Change the engine oil 9 1 9 1 3Clean the oil filter room 9 3 9 1 4Clean the oil filter screen 9 3 9 1 5Check the spark plug 9 3 9 2 Periodic maintenance and check 9 4 ...

Страница 61: ...l as necessary to replenish to the mark 6 Do not over fill as this may damage the engine 7 Check the level again after filling 9 1 2Change the Engine oil Remove the oil filter screen Remove the drain plug and release the engine oil Refill with 0 8 1 0 liters of oil Recommended oil SAE10W 30 Engine Oil Ruler Insfficient Just To Much Note Before changing the oil run the engine for 5 minutes to bring...

Страница 62: ...ecommended oil viscosity 1 In normal climates use SAE 10W 30 or premium grade 2 In colder weather use SAE 5W 30 3 The engine oil should be changed after covering the first 300km 4 The engine oil should then be changed every 1000km 15W 40 10W 30 20 29 C F 5W 30 18 0 4 7 20 40 16 60 38 27 80 100 20W 50 Engine oil to suit thermometer ...

Страница 63: ... as necessary Clean the oil filter screen 9 1 4Clean the oil filter screen Remove the oil filter cover and screen Clean with compressed air 9 1 5Chenk the spark plug 1 Fouling or excessive gap A will cause incomplete combustion 2 Use a wire brush to clean deposits from the electrodes 3 Replace spark plugs at 3000 5000km intervals l SPARK PLUG TYPE NGK Oil filter room Electrode A TYPE D 7EA D 8EA D...

Страница 64: ...1000km Every month 1000 1500km Every 3000km Every 6000km Engine oil R R transmission oil R R Clutch I A I A Valve clearances A A Ignition timing A A Carburetor A C Clean oil filter C C Main screw I T I T Spark plug R COVERAGE PROVIDED BY THE WARRANTY BEFORE 1000km OF NEW MOTORCYCLE HAVE RIDED PLASE KEEP SPEED LOWER THAN 60km hr IF SPEED IS HIGHER THAN LIMIT THE ENGINE BREAKS WOULD NOT PROVIDED BY ...

Страница 65: ... manual part Engine for CG 125 150 HARTFORD INDUSTRIAL CO LTD Chapter 10 Electrical system 10 1 CDI 10 1 10 2 Starter switch assy 10 2 10 3 Regulator 10 3 10 4 Coil comp 10 4 10 5 Electrical assembly draw 10 5 ...

Страница 66: ... CDI to calculate when the action PU pickup coil produces a signal to capacitor 2 2u 400v Figure 1 Ext Source Coil provides energy by therefore the gas is ignited second side high Voltage to let Pulg onto ignite source coil In fact the ignition Coil occurs the to own the ideal operaion The main job of CDI match the angle ignition that can make engine The design of engine on per RPM needs to CDI Ca...

Страница 67: ...s VOLTAGE DROPAT CONTACT POINT INSULATION RESISTANCE more or equal 1M RESISTANCE VALUE 3 4 10 in 20 c RETURN VOLTAGE equal or below 3V OPERATING VOLTAGE equal or below 7 5V ENERGIZATION CURRENT equal or below 3V 2 1 0 5 5 0 O 3 4 TERMINAL 25 0 2 17 0 0 0 2 2 4 150 10 L 50 mm OPERATION DURABILITY NOMINAL CURRENT 150A NOMINAL VOLTAGE DC12V SPECIFICATION Ω Ω ...

Страница 68: ...amine R red line which looks battery and load is to find out how much energy charge and the usage of load to provide adeguate Voltage for the battery The main job of regulator is to regulate and needs to send power for Battery Charge by coutrolling circuit to know whether it should be signal To examine the Voltage of Battery must pass through regulator to change DC generates Voltage to AC signal T...

Страница 69: ...TERFERENCE SYSTEM NOTE HIGH TEMP TEST DIELECTRIC RESISTANCE CONTINUOUS IGNITION RPM RANGE LOWEST RPM FOR CONTINUOUS IGNITION STATICAL RESISTANCE R1 0 31 0 03 100C C DOWN 5 Ω 125C C UP 10 Ω 80 Constant Temperature over1hour NO change over1000M equal or below 300 1000rpm 6mm equal or below 300rpm 6mm Ω R2 4 0 0 4 Ω Ω ...

Страница 70: ...L REGULATOR CURRENT ORANGE SKY BULE BROWN PINK GRAY YELLOW BLUE GREEN BLACK RED WHITE CONTRAST LIST RE W H BL GN YE BK GR P OR BR LG SB INDICTOR FUSE BOX RELAY STARTER 12V BATTERY 12V 6AH 紅 START NEUTRAL INDICTOR IN FRONT BRAKE ASSY IN NEUTRAL SWITCH IN PASSING IN HORN IN 15A SWITCH OUT W INKER RELAY IN REAR BRAKE ASSY IN IGNITION START IN FOR START GENERATOR ...

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