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CBF 125 AIR COOLING ENGINE SERVICE MANUAL

RENEGADE SPORT & SCRAMBLER X 125 EFI

84

8.2.

Technical specifications

unit: mm

Item

Standard

Service Limit

Crankshaft,
Connecting

Rods

Connecting Rod

Large End:

Radial Clearance

0~0.008

0.03

Side Clearance

0.1~0.35

0.5

Crankshaft Runout

0.03

0.08

Fork

Fork Outer diameter

Φ9.966~φ9.984

Φ9.93

Fork Inner diameter

Φ10.000~φ10.018

φ10.05

Shift Fork Ear Thickness

4.93~5.00

4.5

Drive train

Gear tooth inner

hole diameter

M4

Φ20.000~φ20.021

Φ20.04

M5

Φ20.000~φ20.021

Φ20.04

C1

Φ20.500~φ20.521

Φ20.55

C2

Φ23.000~φ23.021

Φ23.04

C3

Φ23.025~φ23.046

Φ23.06

Bushing diameter

M4

Φ19.959~φ19.980

Φ19.93

M5

Φ19.959~φ19.980

Φ19.93

C1

Φ20.459~φ20.480

Φ20.41

C2

Φ22.984~φ23.005

Φ22.95

Bushing inside

diameter

M4

Φ17.000~φ17.018

φ17.04

C1

Φ17.000~φ17.018

φ17.04

C2

Φ20.000~φ20.021

Φ20.04

The shaft diameter

M4

φ16.966~φ16.984

φ16.93

C1

φ16.966~φ16.984

φ16.93

C2

φ19.974~φ19.987

φ19.94

C3

φ19.979~φ20.000

φ19.95

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Содержание CBF 125

Страница 1: ...CBF 125 ENGINE AIR COOLING SERVICE MANUAL AND DELPHI EFI DIAGNOSTIC...

Страница 2: ...1 MAIN TECHNICAL PARAMETERS 2 GENERAL MAINTENANCE 3 LUBRICATION SYSTEM 4 CYLINDER HEAD PARTS MAINTENANCE 5 CYLINDER BLOCK AND PISTON 6 RIGHT COVER CLUTCH BALNACE GEAR GEARSHIFT 7 LEFT COVER STARTING M...

Страница 3: ...6 C C Compression ratio 9 2 1 Valve Timing In Open 5 BTDC Close 37 ABDC Out Open 50 BBDC Close 3 ATDC Max power 7 2 1 5 kW 7500 1 5 rpm Max torque 9 2 1 5 N m 6000 1 5 rpm Idle speed 1400 100 r min Tr...

Страница 4: ...100rpm 1 5 Cylinder Head and Valves unit mm Item Standard Service Limit Valve Clearance Inlet 0 04 0 06 Exhaust 0 04 0 06 Valve Stem Diameter Inlet 4 975 4 990 4 92 Exhaust 4 955 4 970 4 90 Valve Guid...

Страница 5: ...38 52 39 52 3 Inner diameter of piston pin hole 14 002 14 008 14 04 Closure clearance of piston ring Top 0 1 0 25 0 35 Second 0 15 0 30 0 4 Oil 0 2 0 7 0 85 Piston Ring Groove Clearance Top 0 02 0 06...

Страница 6: ...nnecting Rod Big End Radial Clearance 0 0 008 0 03 Side Clearance 0 1 0 35 0 5 Crankshaft Run out 0 03 0 08 Fork Outer diameter of fork shaft 9 966 9 984 9 93 Inner diameter of fork 10 000 10 018 10 0...

Страница 7: ...ADE SPORT SCRAMBLER X 125 EFI 7 GENERAL MAINTENANCE 2 1 ENGINE MAINTENANCE CYCLE 8 2 2 ENGINE MAINTENANCE STANDARDS 8 2 3 TORQUE STANDARS 8 2 4 SPARK PLUG MAINTENANCE 9 2 5 VALVE CLEARANCE ADJUSTMEN 1...

Страница 8: ...ion system the fuel filter must be changed every 3000 Km as is specified in the table and the fuel pump filter changed every 10000 km 2 2 Engine Maintenance Standards Item Standard Service Limit Engin...

Страница 9: ...age the engine If the lateral and center electrode have erosion or covered with accumulation of carbon the spark plug shall be cleaned or replaced The clearance of spark plugs shall be 0 8 1 0 mm Asse...

Страница 10: ...on Mark line T on rotor of magneto is aligned with center of view hole Remove upper cover of cylinder head refer to 4 2 section Check Valve Clearance Note The inspection and adjustment of the valve cl...

Страница 11: ...125 AIR COOLING ENGINE SERVICE MANUAL RENEGADE SPORT SCRAMBLER X 125 EFI 11 Tighten caps of large and small view holes respectively Install upper cover of cylinder head and check the engine for leaka...

Страница 12: ...or 3 5minutes 2 6 4 2 3minutes after stopping the engine support the vehicle using the main stand on firm level ground remove oil level gauge wipe it up and reinsert it Then put it out again to check...

Страница 13: ...r hands with soap and water as soon as possible after handling used oil Changing the oil filter requires a torque wrench If you do not have it or the necessary skill to do the task we recommend you vi...

Страница 14: ...o inspection The oil screen shall not be cleaned with gasoline or other solvents that may damage rubber Reinstall the right cover refer to 6 5 section 2 7 11 Check if bolt and sealing washer are in go...

Страница 15: ...VICE MANUAL RENEGADE SPORT SCRAMBLER X 125 EFI 15 LUBRICATION SYSTEM 3 1 Lubrication system schematic diagram 16 3 2 Lubrication system technical specifications 17 3 3 Troubleshooting 17 3 4 Oil pump...

Страница 16: ...CBF 125 AIR COOLING ENGINE SERVICE MANUAL RENEGADE SPORT SCRAMBLER X 125 EFI 16 3 1 Lubrication system schematic diagram...

Страница 17: ...tween rotor and pump body 0 15 Requirements of tightening torque Fastening bolt of oil pump 10N m Screw on cover plate of oil pump 3N m 3 3 Troubleshooting Name of component Type of damage Symptom of...

Страница 18: ...ion 3 4 1 Oil pump dismantle 3 4 1 1 Dismantle right cover refer to 6 5 section then remove circlip and take out gears of oil pump 3 4 1 2 Take out the pin and remove fastening bolt of oil pump Take o...

Страница 19: ...embled thoroughly 3 4 3 Check of oil pump Note When checking oil pump turn the rotor to measure it at multiple points so as judge it if its wear is beyond service limit If wear measured at any point i...

Страница 20: ...ck fit clearance between outer and inner rotors of oil pump Service limit 0 20mm 3 4 3 3 Take out the shaft and pin from the oil pump Use knife straight edge and feeler gauge to measure axial clearanc...

Страница 21: ...umference of outer rotor and install the rotor into oil pump casing 3 4 4 2 Apply lube oil on the circumference of inner rotor pin shaft and pin and install them into oil pump casing 3 4 4 3 Install c...

Страница 22: ...125 EFI 22 3 4 4 5 Assemble oil pump and tighten the bolt Assemble the pin 3 4 4 6 Install oil pump gears onto pin shaft and install circlip Apply an appropriate amount of lube oil on the gears 3 4 4...

Страница 23: ...RAMBLER X 125 EFI 23 CYLINDER HEAD PARTS MAINTENANCE 4 1 CYLINDER HEAD EXPLODED VIEW 24 4 2 UPPER COVER OF CYLINDER HEAD MAINTENANCE 25 4 3 ROCKER ARM SET MAINTENANCE 27 4 4 CYLINDER HEAD SET MAINTENA...

Страница 24: ...CBF 125 AIR COOLING ENGINE SERVICE MANUAL RENEGADE SPORT SCRAMBLER X 125 EFI 24 4 1 Cylinder Head exploded view...

Страница 25: ...pper cover of cylinder head maintenance 4 2 1 Remove two bolts form upper cover of cylinder head 4 2 2 Take out upper cover and corresponding seal gasket 4 2 3 Positioning pin and O ring for removing...

Страница 26: ...e and clean it using air gun 4 2 6 Assemble bolts and washers after the head cover is checked Need to be replaced old washer by a new one 4 2 7 Assembly location pin and a new O ring 4 2 8 Clean the s...

Страница 27: ...ed at right place install rubber gasket of bolt of cylinder head with mark UP upwards 4 2 10 Assembling head cap upper cover bolts and tighten Tightening torque 10N m 4 3 Rocker arm set maintenance 4...

Страница 28: ...AL RENEGADE SPORT SCRAMBLER X 125 EFI 28 4 3 1 3 Remove the fastening bolts from timing sprocket chain 4 3 1 4 Remove the timing sprocket chain Care shall be taken when using a tool to fix the chain t...

Страница 29: ...MBLER X 125 EFI 29 4 3 1 5 Remove AB Nut to take out the ROCKER ARM set 4 3 1 6 Loosen fastening bolt on stop plate and remove the stop plate Then remove camshaft 4 3 1 7 Remove fastening bolt of rock...

Страница 30: ...t both ends of camshaft for free rotation 4 3 1 10 Inspect the cam for abrasion Service limit Inlet 31 8 mm Exhaust 31 5mm 4 3 1 11 And check rocker arm shaft for wear Service limit 9 91mm 4 3 1 12 Ch...

Страница 31: ...Assemble rocker arm and rocker shaft in accordance with sequence shown in the illustration 4 3 2 3 Use flat screwdriver to turn rocker arm shaft so verify that screw hole on rocker arm shaft is aligne...

Страница 32: ...riate amount of SO2 grease into cams 4 3 2 6 Mounting the camshaft into the rocker bracket take special attention to the projected point on flange shall be upward as shown in the figure 4 3 2 7 Mounti...

Страница 33: ...h sides of gasket and external surface of nut then install them into rocker arm bracket 4 3 2 10 Tighten AB bolt nut in turns Fastening torque 35N m 4 3 2 11 Follow the preceding steps to adjust the e...

Страница 34: ...olts Fastening torque 9N m 4 3 2 14 Loosen tensioner device to check if chain is tensioned 4 3 2 15 Replace O ring with a new one and assemble the tensioning screw 4 4 Cylinder head set maintenance 4...

Страница 35: ...35 4 4 1 2 move the cylinder head assembly 4 4 1 3 Remove the cylinder head seal gasket and the two position pins 4 4 1 4 Use special tooling to dismantle valve collet seat ring valve valve steam sea...

Страница 36: ...eck of cylinder head assembly 4 4 2 1 Check the cylinder Head combustion chamber clean the carbon deposit 4 4 2 2 ck valve spring for free length In 37 8 mm Outer 40 8 mm 4 4 2 3 Inspection flatness o...

Страница 37: ...CBF 125 AIR COOLING ENGINE SERVICE MANUAL RENEGADE SPORT SCRAMBLER X 125 EFI 37...

Страница 38: ...X 125 EFI 38 4 4 3 Assembly of Cylinder head set Cylinder head exploded view 4 4 3 1 Assemble the components according to the order of exploded view 4 4 3 2 When installing valve spring care shall be...

Страница 39: ...r head assembly shall be subject to air tightness test Next operation shall not be done unless the cylinder head assembly is confirmed air tight 4 4 3 4 Assembly positioning pins and a new cylinder he...

Страница 40: ...ERVICE MANUAL RENEGADE SPORT SCRAMBLER X 125 EFI 40 4 5 Tensioner device extraction and installation 4 5 1 Remove the screw of the tensioning device 4 5 2 Use the right tools to adjust the tensioning...

Страница 41: ...CBF 125 AIR COOLING ENGINE SERVICE MANUAL RENEGADE SPORT SCRAMBLER X 125 EFI 41 4 5 3 Assembly of Tensioner device 4 5 4 Replace O ring with a new one 4 5 5 Tighten the screw...

Страница 42: ...SERVICE MANUAL RENEGADE SPORT SCRAMBLER X 125 EFI 42 CYLINDER BLOCK AND PISTON 5 1 CYLINDER BLOCK PISTON EXPLODED VIEW 43 5 2 LIMITS FOR SERVICE 44 5 3 TROUBLESHOOTING 44 5 4 CYLINDER BLOCK PISTON DIS...

Страница 43: ...CBF 125 AIR COOLING ENGINE SERVICE MANUAL RENEGADE SPORT SCRAMBLER X 125 EFI 43 5 1 Cylinder block piston exploded view...

Страница 44: ...4 14 13 96 Clearance between piston pin and piston pin hole 0 002 0 014 0 04 Small End of Connecting Rod Inner diameter 14 015 14 028 14 06 Clearance between small end of connecting rod and piston pin...

Страница 45: ...plate 5 4 1 2 Knock cylinder block slightly with rubber hammer to separate cylinder block from crankcase Take out cylinder block upwards Care shall be taken to not damage piston when dismantling cyli...

Страница 46: ...all be taken at two directions mutually perpendicular at every layer Limit value 52 5mm 5 4 2 2 Calculate cylindricity of cylinder bore in accordance with the maximum value measured at the positions L...

Страница 47: ...Use long nose pliers to remove circlip of piston pin 5 4 3 3 Remove Piston pin 5 4 3 4 Turn piston rings manually to check if the piston rings can rotate freely on the piston without seizure Use thum...

Страница 48: ...er bore and piston skirt calculate their fit clearance Limit value 0 09mm 5 4 4 3 Diameter inspection of piston pin hole Limit value 14 04mm 5 4 4 4 Detection of piston pin diameter Limit value 13 96m...

Страница 49: ...into cylinder block and press them down with piston Check gap of each piston ring with feeler gauge Limit value Top ring 0 40mm Second ring 0 40mm Oil ring 0 85mm 5 4 4 9 heck for clearance between p...

Страница 50: ...CBF 125 AIR COOLING ENGINE SERVICE MANUAL RENEGADE SPORT SCRAMBLER X 125 EFI 50...

Страница 51: ...ston rings must be placed away from each to other by 120 Incorrect assembly of piston rings will directly cause oil burning abnormal wear and tear of piston 5 4 5 piston cylinder block installation Wh...

Страница 52: ...n to reuse circlip otherwise the engine may be damaged Piston pin circlip must be installed to its place Split of circlip shall be alternated away from the installing position on the piston Split of c...

Страница 53: ...PORT SCRAMBLER X 125 EFI 53 Install guide plate of chain into cylinder block Note Guide plate shall be installed to its place as shown in the figure otherwise the plate may be damaged abnormally Assem...

Страница 54: ...RIGHT COVER CLUTCH BALANCED GEAR GEARSHIFT 55 6 2 CLUTCH TECHNICAL SPECIFICATIONS 56 6 3 TIGHTENING TORQUE REQUIREMENTS 56 6 4 TROUBLESHOOTING 56 6 5 RIGHT COVER EXTRACTION AND INSTALLATION 57 6 6 CLU...

Страница 55: ...CBF 125 AIR COOLING ENGINE SERVICE MANUAL RENEGADE SPORT SCRAMBLER X 125 EFI 55 6 1 Exploded view of right cover clutch balancing gear gearshift...

Страница 56: ...ear locking nut 45N m Five star plate fastening bolts 12N M Positioning plate fastening Bolts 12N M Clutch lid fastening Bolts 12N m 6 4 Troubleshooting 6 4 1 Clutch does not release or not fully rele...

Страница 57: ...extraction and installation First drain off oil from engine remove bolts from right cover Remove the paper gasket and positioning pin Check the crankshaft oil seal is intact Removal of right cover Tak...

Страница 58: ...for deformation check iif pushing rod and spring are damaged if they are replace them with new ones Partial assembly of right cover Replace oil seal of control arm with new one Apply appropriate amoun...

Страница 59: ...in figure Then install pushing rod of clutch Assembly location pins and new paper gasket Removal clutch gasket and engine oil from crankcase before assembling Assemble right cover bracket bolts First...

Страница 60: ...stallation 6 6 1 Clutch extraction Dismantle 4 bolts from end cover of clutch then take out end cover of clutch bearing declutch spring Dismantle locknut and washer of clutch Take out upper and lower...

Страница 61: ...R X 125 EFI 61 Take out declutch shaft sleeve 6 6 2 Checking of clutch Check bearing of clutch for free rotation Check declutch spring of clutch for damage Measure free length of spring Service limit...

Страница 62: ...mit 2 6mm Check driven friction plates flatness Service limit 0 20mm Check outer case of clutch and shaft sleeve for abnormal geometry Measure inner hole diameter of driven gear on outer case Service...

Страница 63: ...ve onto main shaft Apply appropriate amount of lube oil onto gears Assemble outer case and declutch washer New friction plates shall be immersed in engine oil before assembly When assemble central sle...

Страница 64: ...tools to fix pressure plate and tighten locknut of clutch Tightening torque shall meet specified requirement Tightening torque 45N m Assemble spring and clutch end cover and tighten bolts on the end...

Страница 65: ...arts in order 6 6 3 1 Pin 6 6 3 2 Locating plate 6 6 3 3 Locating plate bolt 6 6 3 4 Locating plate spring 6 6 3 5 Washer 6 6 4 Check of gearshift arm Check if lever of arm bends deforms or wears abno...

Страница 66: ...e pin and star shaped plate Pin holes on the star shaped plate shall be aligned with two cylindrical pins 6 6 7 Tighten bolt on star shaped plate Tightening torque 12 N m 6 6 8 Apply lube oil to gears...

Страница 67: ...alancing gear Note Do not damage woodruff and circumference of crankshaft when removing drive gear and balancing gear 6 6 2 Drive gear and balancing drive gear Assembly 6 6 2 1 Check woodruff key for...

Страница 68: ...ve gear with woodruff key on crankshaft and assemble them Apply appropriate amount of engine oil on gears 6 6 2 5 Assemble oil filter washer locknut 6 6 2 6 Tighten nut to specified torque Tightening...

Страница 69: ...shaft sleeve and woodruff key 6 6 3 3 Balancing driven Gear Disassembly and assembly Dismantle circlip washer disc washer flat washer in turn Take out balancing driven gear two springs two buffer rub...

Страница 70: ...g face between gear and hub Install buffer rubber bushing on right position on the hub Install driven gear onto the rub Install buffer spring into gear Install washer disc washer washer circlip in tur...

Страница 71: ...alancing shaft and keyway 6 8 1 2 Align keyway of balancing driven gear with woodruff key on balancing shaft Meanwhile rotate balanced driven gear to align the keyway with timing mark on balancing dri...

Страница 72: ...5 EFI 72 7 LEFT COVER STARTING MOTOR SYSTEM MAGNETO 7 1 EXPLODED VIEW OF LEFT COVER STARTING MOTOR SYSTEM MAGNETO 73 7 2 LEFT COVER EXTRACTION AND INSTALLATION 74 7 3 STARTING MOTOR SYSTEM EXTRACTION...

Страница 73: ...CBF 125 AIR COOLING ENGINE SERVICE MANUAL RENEGADE SPORT SCRAMBLER X 125 EFI 73 7 1 Exploded view of left cover starting motor system magneto...

Страница 74: ...stallation 7 2 1 Take out gearshift switch harness from harness groove 7 2 2 Loosen fastening bolt on left cover and remove left cover 7 2 3 Take out locating pin and paper gasket Assemble locating pi...

Страница 75: ...5 7 2 5 Insert gearshift switch harness into harness groove on left cover 7 3 Starting motor system extraction and installation 7 3 1 Dismantle left cover and take out shaft sleeve dual gear shaft and...

Страница 76: ...n magneto Use special tools to dismantle magneto rotor 7 3 5 Check needle bearing woodruff key on crankshaft for damage 7 3 6 Clean off engine oil from tapered face of crankshaft Install magneto rotor...

Страница 77: ...que Tightening torque 65 N m 7 3 9 Replace O ring with a new one Apply appropriate amount of lube oil onto O ring before assembling 7 3 10 Assemble starting motor 7 3 11 Apply appropriate amount of lu...

Страница 78: ...k Assemble large starting gear onto magneto rotor then check if the gear can rotate normally making it rotate counterclockwise 7 3 13 Magneto rotor disassembly 7 3 13 1 Use special tools to fix rotor...

Страница 79: ...ENGINE SERVICE MANUAL RENEGADE SPORT SCRAMBLER X 125 EFI 79 7 3 13 4 Check teeth of large starting gear for damage Measure outer diameter of large starting gear Service limit 45 60mm 7 3 13 5 Magneto...

Страница 80: ...with threaded hole 7 3 13 8 Apply appropriate amount of fastening adhesive onto threads of bolts then use tools to locate and tighten the bolt Tightening torque 16 N m 7 3 13 9 Install large starting...

Страница 81: ...ake out magneto 7 4 3 Install a magneto onto left cover then tighten bolts 7 4 4 Install sensor and tighten bolts Press cable clip of magneto into corresponding position on left cover and tighten bolt...

Страница 82: ...RACTION AND INSTALLATION 8 1 CRANKSHAFT EXPLODED VIEW 83 8 2 TECHNICAL SPECIFICATIONS 84 8 3 CRANKSHAFT EXTRACTION 85 8 4 DRIVE TRAIN EXTRACTION AND CHECK 87 8 5 BEARINGS EXTRACTION 90 8 6 BEARINGS IN...

Страница 83: ...CBF 125 AIR COOLING ENGINE SERVICE MANUAL RENEGADE SPORT SCRAMBLER X 125 EFI 83 8 1 Crankcase exploded view...

Страница 84: ...iameter 10 000 10 018 10 05 Shift Fork Ear Thickness 4 93 5 00 4 5 Drive train Gear tooth inner hole diameter M4 20 000 20 021 20 04 M5 20 000 20 021 20 04 C1 20 500 20 521 20 55 C2 23 000 23 021 23 0...

Страница 85: ...block right cover left cover in accordance with steps described above 8 3 2 Loosen and dismantle fastening bolt on chain guard then take out chain guard tension plate guide plate and chain 8 3 3 Disma...

Страница 86: ...n right crankshaft 8 3 7 Dismantle fastening bolts on crankshaft 8 3 8 Place crankcase properly with right half downwards Knock counter shaft and crankshaft with rubber hammer to loosen adhesive on ha...

Страница 87: ...heck chain tension plate for severe wear or damage If there is replace the tension plate with a new one 8 4 Drive train extraction and check 8 4 1 Take out fork shaft of main and counter shafts 8 4 2...

Страница 88: ...er diameter of the gears Service limit M4 20 04mm M5 20 04mm C1 20 55mm C2 23 07mm C3 23 07mm 8 4 4 3 Check shaft sleeve for severe wear and damage Measure inner and outer diameters of shaft sleeve Bu...

Страница 89: ...r of main and counter shafts M4 16 93mm C1 16 93mm C2 19 94mm C3 19 95mm Calculate fit clearance between gears and shaft sleeve Service limit 0 10mm 8 4 5 Check of gearshift drum 8 4 5 1 Check both en...

Страница 90: ...al wear and damage 8 4 6 Replacement of bearings 8 4 6 1 Turn inner race of bearing to check if it can rotate freely 8 4 6 2 Check bearing cage and balls looking for severe wear and damage 8 5 Bearing...

Страница 91: ...OOLING ENGINE SERVICE MANUAL RENEGADE SPORT SCRAMBLER X 125 EFI 91 8 5 3 Dismantle counter shaft and gearshift arm oil seals located on left half 8 5 4 Dismantle bearings from left half using a bearin...

Страница 92: ...sponding holes with special tools Note 1 Bearing shall be installed using special tools 2 When pressing bearing force shall be applied on outer race of bearing otherwise the bearing may be damaged 8 6...

Страница 93: ...rease onto inner and outer races of bushing to guarantee initial lubrication 8 7 4 Install the components and parts onto their original positions Note All gears assembled shall be able to rotate and m...

Страница 94: ...CBF 125 AIR COOLING ENGINE SERVICE MANUAL RENEGADE SPORT SCRAMBLER X 125 EFI 94 8 7 5 Main shaft Exploded view 8 7 6 Counter shaft exploded view...

Страница 95: ...aken to not miss washers at both ends of the shafts 8 7 9 Marks on forks C Main shaft fork R L Counter shaft fork 8 7 10 Install forks of counter and main shafts into corresponding positions Face of f...

Страница 96: ...ft to check if all components and parts are installed in the right positions and main and counter shafts can rotate freely 8 8 Crankshaft check 8 8 1 Dismantle balanced shaft 8 8 2 Dismantle crankshaf...

Страница 97: ...Check timing drive sprocket on crankshaft for abnormal wear and damage If there is check correspondingly timing driven sprocket chain tensioner etc for abnormal condition When it is necessary to repl...

Страница 98: ...8 9 Crankcase installation 8 9 1 Install crankshaft into right half of crankcase 8 9 2 Install balanced shaft 8 9 3 Clean matching faces on left and right halves of crankcase Apply sealing adhesive o...

Страница 99: ...nstalled onto their positions and if there are foreign elements in the crankcase 8 9 6 Install and approximate the bolts then tighten them with torque spanner to specified torque Tightening torque 12N...

Страница 100: ...Apply adhesive to thread on 2 3 of length then install pressing pin body guard and bolts onto crankshaft case Tighten the bolts to specified value Tightening torque 10N m 8 9 11 Install chain tension...

Страница 101: ...DE SPORT SCRAMBLER X 125 EFI 101 9 EFI DIAGNOSTIC SYSTEM RENEGADE SPORT SCRAMBLER X 125 EFI 9 1 GENERAL INFORMATION 102 9 2 PRECAUTIONS 102 9 3 TOOLS 103 9 4 MALFUNCTION CODES AND MAINTENANCE 103 9 3...

Страница 102: ...ion off before connect or disconnect the connectors Make sure the ECU temperature is below 80 Please do not disassemble the fuel pipe arbitrariliy If have to please first release the pressure and make...

Страница 103: ...ly Do not ignore engine maintenance situations like cylinder pressure and the mechanical ignition timing If a malfcode continue after rechecking change another ECU to do the test If the malfcode disap...

Страница 104: ...are short battery J2 8 J2 10 of theECU and pin C D of the connector Yes Change the harness No Next 6 Crank the engine and stay idle Check whether the intake air temperature goes up whenthe engine tem...

Страница 105: ...the engine to stay idle Check whether the intake air temperature goes up when the engine temperature goes up Yes Help No Change the sensor Malfcode P0117 Information Coolant Oil Temperature Sensor Ci...

Страница 106: ...14 of the ECU and pin C and D of the sensor Yes Harness issue No Next 6 crank the engine and stay idle Check whether the engine temperture goes high whenengine get warm Yes Help No Change the sensor...

Страница 107: ...and C of the sensor Yes Harness issue No Next 6 Use multimeter to check whether the voltage between pin A and B is about 5V Yes Help No Step 5 Malfcode P0131 P0132 Information O2S 1 Circuit Low High...

Страница 108: ...tance between pin A andB of the injecotr is about 10 14 20 No Change the injector Yes next 5 Use the multimeter to check whether the voltage of Pin B is about 12V Yes Help No Next 6 Check whether the...

Страница 109: ...check whether the voltage of pin B is about 12V Yes Help No Next 6 Check whether the connection of pin 2 of the coil and J2 01 of ECU is open or shor to battery ground Yes Harness issue No Help Malfco...

Страница 110: ...the maintenance situation cylinder pressure mechanical timing and fuel quality Change the ECU and repeat the test if the issue is gone then the root cause is the ECU Or change the old one back to che...

Страница 111: ...rd to starting STEP OPERATION SOLVED FOLLOWING STEP 1 Check wether the fuel pump pressure is about 250kPa at idle Yes Next No Check the pump 2 Pull out the spark plug check whether the sparkover is no...

Страница 112: ...e body and bypass channel Yes Clean the TB No Next 3 Check whether the IACV works well Yes Next No Check the IACV 4 Check whethe the fuel pressure is about 250kPa Yes Next No Check the pump 5 Check wh...

Страница 113: ...emperature sensor and check whether the engine works well Yes Help No Change the sensor Acceleration gets worse STEP OPERATION SOLVED FOLLOWING STEP 1 Check whether the air filter is blocked and wheth...

Страница 114: ...cked or not No help Yes maintenance Backfire STEP OPERATION SOLVED FOLLOWING STEP 1 Pull out the spark plug check whether the sparkover is normal Yes Next No Check the ignition system 2 Check whether...

Страница 115: ...rk STEP OPERATION SOLVED FOLLOWING STEP 1 Pull out the spark plug check whether the sparkover is normal Yes Next No Check the ignition system 2 Check whether the timing is right Yes Next No Adjust the...

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