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Worx Generic QJ125-26A, Инструкция по эксплуатации и техническому обслуживанию, Страница: 42 / 166

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Symptom:  Electric horn mutes.     Diagnosis procedures

 

 

 

Electric horn mutes. 

Turn on ignition switch; slide turn signal 

lamp switch and check.   

Turn signal lamp is not lit or dim. 

Turn signal lamp shines brightly. 

Battery is low or the wire from battery 

to ignition switch is broken or shorted. 

Power supply from battery is normal. 

Pull out power line from power terminal of electric horn; touch 

the power line quickly with ground wire to check spark.   

Spark at touch 

No spark at touch

 

Connect power line of horn, use a screwdriver to 

connect non-power terminal (terminal to button) 

of horn with ground wire.

Power line between ignition switch 

and electric horn is broken. 

Electric horn sounds after connection. 

Inner contact of horn is poorly 

contacted or the wire from 

horn to button is broken. 

Adjust volume and tune of horn. 

Horn does not work after adjustment. 

Horn works normally after adjustment. 

Horn is damaged. 

Horn is improperly adjusted 

Electric horn does not sound after connection. 

Содержание Generic QJ125-26A

Страница 1: ...Service Manual Holtvej 8 10 H ruphav 6470 Sydals Telefon 45 73 15 11 00 Fax 45 73 15 11 01 E mail info scanmi dk www scanmi dk CVR 27 73 31 07 April 2013 Worx 125...

Страница 2: ...Two wheel Motorcycle QJ125 26A Instruction and Maintenance Manual ZHEJIANG QIANJIANG MOTORCYCLE CO LTD...

Страница 3: ...DI Assembly 70 2 5 Ignition Coil 71 2 6 Trigger 72 III Starting System 74 3 1 Preparatory Data 74 3 2 Fault Diagnosis 75 3 3 Starting Motor 75 3 4 Starting Relay 77 IV Bulbs Switches Instruments 79 4...

Страница 4: ...ting System 120 10 1 Preparatory Data 120 10 2 Fault Diagnosis 120 10 3 Oil Pump 121 XI Carburetor 125 11 1 Preparatory Data 125 11 2 Fault Diagnosis 125 11 3 Removal of Carburetor 126 11 4 Installati...

Страница 5: ...eparatory Data 156 16 2 Fault Diagnosis 156 16 3 Crankcase 157 16 4 Crankshaft Connecting Rod Assembly 160 Exhaust System Inspection and Maintenance 161 XVII Emission Control System 162 17 1 Emission...

Страница 6: ...ch component This shall be started from the time of periodical inspection The parts following Chapter One demonstrate the main point of disassembly installation and check of electrics parts finished v...

Страница 7: ...No fire or smoking is allowed in operation site and gasoline storage place Storage Battery Battery shall be away from spark fire and smoking places since it may emit explosive gases Keep it in well ve...

Страница 8: ...e clean the components and blow them with compressed air Plastic parts may age and deteriorate which are apt to be damaged by solvent or oil Check before re installation and replace if necessary To lo...

Страница 9: ...damage to it Installation of rubber hose fuel vacuum or coolant insert its end into bottom of connector so that there is enough room for the hose clamp to grip the connector Install the rubber or plas...

Страница 10: ...the cable from being pulled too tightly or slacking too much when the cable is wired along the handle pipe The cable shall not be affected by any neighbored components at any turning position The cab...

Страница 11: ...steners 3 While re assembling new washers O rings cotter pins and locking plates shall be renewed 4 While tightening bolt or nut please first fasten bolts of large diameter or internal bolts and then...

Страница 12: ...e Remarks Special socket wrench Clutch holder Flywheel extractor Feeler gauge Bearing puller Bearing installer Oil seal remover Puller handle Piston pin puller Piston ring pliers Spark plug socket wre...

Страница 13: ...Figure 1 5 Figure 1 6 Figure 1 7 Figure 1 8 Figure 1 9 Figure 1 10 Handle Figure 1 11 Figure 1 12 Pliers Piston...

Страница 14: ...Figure 1 13 Figure 1 14 Figure 1 15 Figure 1 16 Figure 1 17 Figure 1 18 Figure 1 19 Figure 1 20 Figure 1 21 Figure 1 22...

Страница 15: ...Socket wrench Micrometer Magnetic stand V block Dial gauge Vernier caliper Spring clamp ring pliers Hammer screwdriver Front fork oil seal installer Front fork seal driver Steering nut wrench Figure 1...

Страница 16: ...Figure 1 31 Figure 1 32 Figure 1 33 Figure 1 34 Figure 1 35 Figure 1 36 2 Special tools for chassis overhaul Front fork seal driver Figure 1 37 3 Steering nut wrench Figure 1 38...

Страница 17: ...ents Special tools and their pictures for electrical component measurement are listed in Table 1 39 and Table 1 40 Table 1 39 Name Remarks Multimeter Ignition tester Figure 1 41 Figure 1 42 Continued...

Страница 18: ...ification Front tubeless tyre 90 90 17 Air cleaner Dry Rear tubeless tyre 110 80 17 Drive Train Clutch type Wet multi plate friction type Fuel tank capacity 16 0 5L Gear shift pattern Five speed left...

Страница 19: ...if magneto flywheel or trigger coil looses Loosen drain screw of carburetor and check if there is oil flowing out from overflow pipe Refuel gasoline Check compression pressure in the cylinder Check oi...

Страница 20: ...ine can continue to run when it is started Carburetor is clogged inside or float is too high Carburetor starter i e cranking enrichment system fails 1 Check leakage at external connection parts of eng...

Страница 21: ...low or the gasoline has been stored for a too long time 2 Check if engine runs at a high speed for a very long time or overloaded Check cooling system Air cooling the engine Check if radiator plates a...

Страница 22: ...Carburetor starter i e cranking enrichment system works normally 3 Check if float of carburetor is too low Mixture ratio of air fuel is normal Check if exhaust of cylinder and exhaust muffler is clog...

Страница 23: ...nical surface of driven wheel and mobile driven wheel are excessively worn or worn to groove 6 Check if raceway on the inner end face of friction wheel is excessively worn or pitted due to crush 1 Che...

Страница 24: ...ine has idle speed after adjustment Engine has no idle speed after adjustment Air adjusting screw of carburetor or throttle adjusting screw is improperly adjusted Check if carburetor idle jet idle oil...

Страница 25: ...Air pressure too low Air pressure normal Gas up as specified Check if fuel tank fuel switch delivery pipe or carburetor leaks oil Exclude as practical situations Check mixture ratio Mixture ratio of...

Страница 26: ...ce Check if contact area between braking shoe and friction disc is worn terribly Repair or replace clutch shoe Refill engine oil Check if viscosity of engine oil in the crankcase is too low or the oil...

Страница 27: ...aft separation push rod and other components of clutch control mechanism are excessively worn No No No No Yes Yes Yes Yes 4 stroke engine exhaust muffler gives off blue white smoke Check if engine oil...

Страница 28: ...shift fork hole is excessively worn 3 Check if shift fork is deformed 4 Check if fork shaft is distorted or over worn Drum type brake fails Check if clearance of brake handle bar is within 10mm 20mm...

Страница 29: ...case and check if meshing depth of each gear meets requirement Enough meshing depth Insufficient meshing depth Hydraulic disc brake fails Check brake liquid level in the liquid tank of main brake pump...

Страница 30: ...ot charge Resistance is less than standard Charging coil is shorted Resistance is infinitely great Resistance meets the standard Charging coil or its output wires are shorted Disconnect connectors of...

Страница 31: ...the negative wire to check current leakage Leaking current is smaller than specified Leaking current is bigger than specified usually It shall be no more than 1mA Check if charging coil of magneto is...

Страница 32: ...er button and the click sound from starter relay cannot be heard Push starter button and a click sound from starter relay can be heard Disassemble the connector of starter relay from cables of the who...

Страница 33: ...4 Check if armature coil is broken or shorted 1 Check if contact inside clutch switch is poorly contacted 2 Check if starter button contact is poorly contacted 3 Check if rectifier diode is damaged 4...

Страница 34: ...ck if it is on state Check if starter button contact is poorly contacted Disassemble starter motor and make the following inspections 1 Check if the carbon brush is over worn 2 Check if carbon brush s...

Страница 35: ...of rectification regulator from cables of the whole vehicle Lights are lit Lights are not lit Short circuit inside rectifier Disassemble headlamp assembly and check if the bulb is burnt Electric horn...

Страница 36: ...of wire to short circuit power line and output line of lighting switch Wiring from magneto or ignition switch to lighting switch is broken or shorted Lamp is lit after short circuit Lamp is still not...

Страница 37: ...f density of electrolyte in the battery is too low check if pole plates inside the battery are vulcanized or broken Separate conductors of rectification regulator from cables of the whole vehicle Meas...

Страница 38: ...from the cables of the whole vehicle Check brightness of light Light recovers after separation Headlamp is still dim after separation Stable voltage of rectification regulator is too low Check if char...

Страница 39: ...r of bulb in the lighting system is up to the requirement Replace the bulb 1 Check if contacts in headlamp switch and side lamp switch are poorly contacted 2 Check if connectors and earth wire are poo...

Страница 40: ...d with a voltmeter No voltage display No voltage display Grounding wire of lamp holder is of poor contact or bulb of turn signal lamp is badly contacted with lamp holder Power line to the lamp holder...

Страница 41: ...contact of turn signal lamp is poor contacted Check if there is power output from power input line of turn signal lamp switch by lamp test Test lamp is on Test lamp is off Power line of turn signal l...

Страница 42: ...power line quickly with ground wire to check spark Spark at touch No spark at touch Connect power line of horn use a screwdriver to connect non power terminal terminal to button of horn with ground w...

Страница 43: ...p is not lit after short circuit Brake lamp is lit after short circuit Use a screwdriver or a piece of wire to touch quickly power line of brake lamp switch and grounding wire and check sparks Brake l...

Страница 44: ...n system Carburetor Bolt nut fastening part Ignition timing Tyre specification Wheel rim tyre Preparatory Standard General Warning Before running the engine please make sure the area you are working i...

Страница 45: ...l type Ignition time BTDC15 1 1400 100rpm Frame Clearance of front brake handle 10 20mm Clearance of rear brake pedal 20 30mm Pneumatic pressure unit of tyre Kpa Specification Tyre pressure QJ125 26A...

Страница 46: ...on of looseness of bolts at all positions I I I I I I Torque wrench Check if gearbox leaks oil I I I I I I Common tool Spark plug inspection and replacement I I R R I Common tool Gearbox oil replaceme...

Страница 47: ...be performed according to the specifications on the user s manual unauthorized repair and adjustment are forbidden We will not be responsible for the results 2 You shall clean more frequently the air...

Страница 48: ...ied clearance Rotate inward to increase clearance rotate outward to reduce clearance Tighten locknut When the clearance is adjusted rotate handle leftward and rightward to make sure idle of engine doe...

Страница 49: ...cap Remove spark plug with a spark plug wrench or other applicable tools Inspection If the insulator is cracked or damaged If electrodes are worn Combustion condition and color Light grey color means...

Страница 50: ...ct the battery which may result in interior component damage of the whole vehicle Battery charging circuit voltage inspection Open the seat cushion and take down the right protecting plate Disassemble...

Страница 51: ...arm up the engine and then adjust idle speed Run the engine and connect engine tachometer Adjust the throttle cable lock screw to specified RPM Idle speed RPM 1400 100rpm min If idle speed RPM is unst...

Страница 52: ...oil level inspection please do not tighten engine oil ruler Oil level inspection Stop the motorcycle on the flat ground with its middle stand and support the vehicle vertically When engine oil is cons...

Страница 53: ...back onto the engine Attention Oil should be changed when the engine is warm Place the engine on the side stand Make sure all the engine oil is completely and quickly drained When the drain plug is r...

Страница 54: ...edal clearance Measure brake pedal clearance Clearance 20 30mm If the clearance measured does not meet the specified value adjust it Adjust clearance of brake pedal Screw in or screw off adjuster If t...

Страница 55: ...cy service life and luminous flux of bulb If oil is adhered to the bulb clean it with a cloth moistened with alcohol or highly volatile rubber solution Install headlamp assembly Clutch Check clearance...

Страница 56: ...oosened Rear Suspension Compress upward and downward the rear shock absorber to check its actuator Check if components on the rear shock absorber are loosened or injured Lift and support the rear whee...

Страница 57: ...ont shaft is loosened Check if lock nut of rear shaft is loosened If loosened tighten it to specified torque Tightening torque Front shaft lock nut 40 60 N m Rear shaft lock nut 85 98 N m Steering Ste...

Страница 58: ...ing parts used in electric system Fastening position and fastening part name Tightening torque N m Starting motor clutch cover bolt Starting motor clutch locknut Rectifier bolt High voltage coil mount...

Страница 59: ...Charging System 1 Starting relay 2 Scintillator 3 Battery 4 Electric igniter 5 High voltage ignition coil 6 Power lock assembly...

Страница 60: ...oo high voltage on the battery the life span of the battery will be shortened 3 When the battery is not be used for a long period it will self discharge and its capacitance will drop The battery shoul...

Страница 61: ...er High voltage coil mounting bolt 9 0 N m Flywheel remover Flywheel locknut 5 0 N m Testing device Vehicle block protecting plate bolt 9 0 N m Multimeter 1 2 Fault Diagnosis No power Unstable power B...

Страница 62: ...ad wire Battery charging circuit voltage inspection Open the battery cover and remove battery pressure plate assembly Disconnect lead wire of the battery connector Measure voltage between terminals of...

Страница 63: ...ition switch and main wiring 1 4 2 Charging state inspection While inspection battery shall be fully charged and a multimeter be used for the test Warm up the engine and then install fully charged bat...

Страница 64: ...self Attention Do not touch the metal part of multimeter probe with your finger Check with a multimeter If impedance values measured by different multimeters are not the same it perhaps the inspection...

Страница 65: ...d 1 7 2 Removal Remove vehicle block protecting plate Remove protecting plate of engine on the left side Remove flywheel locknut Use a flywheel remover to take down the flywheel Remove the fixation ke...

Страница 66: ...agnetism on the inner surface of flywheel ensure there is no bolt on it Fix the flywheel using a universal non adjustable spanner and then tighten the locknut Torque value 9 0 N m Install protecting p...

Страница 67: ...Ignition System 1 Relay 2 Scintillator 3 Battery 4 Igniter 5 High voltage ignition coil 6 Power lock assembly 7 Voltage regulator Ignition System...

Страница 68: ...ignition system problem due to poor contact of sockets Please check first if parts of the connector are well contacted 6 Check if heat value of spark plug is proper Improper spark plug may result in...

Страница 69: ...high voltage wire is not good Inferior CDI assembly after items are tested and proved abnormal or spark plug no sparking High voltage power is normal spark plug no sparking Inferior spark plug or seco...

Страница 70: ...ith spark plug installed on the cylinder head Connect lead wire of ignition coil a shunt is connected between the terminal black white of primary coil and the grounding vehicle block Press starting mo...

Страница 71: ...o terminal is normal it indicates that the connector is of poor contact or wiring is broken When measured results at both sides are abnormal the trigger is damaged Please refer to items listed in Diag...

Страница 72: ...etween terminals of primary coil Standard value 0 4 10 20 Impedance value within the range is good Impedance value indicates broken wire inside the coil The coil shall be replaced 2 5 3 Secondary coil...

Страница 73: ...emove protecting plate of vehicle block Remove lead wire connector of trigger Measure the impedance between blue white terminal of lead wire at engine side and grounding vehicle block Standard value 1...

Страница 74: ...Starting System 1 Starting relay 2 Scintillator 3 Battery 4 Electronic igniter 5 high voltage ignition coil 6 Power lock assembly 7 Rectifier 8 Electric horn Starting Diagram...

Страница 75: ...n be performed on the engine Starting clutch removal refers to removal instruction Basic data Item Standard Service Limit Length of starting brush 12 5mm 8 5mm Starting idler shaft bushing 8 3mm Start...

Страница 76: ...er supply to check if starting motor runs to confirm your operation is safe First remove the lead wire clip of starting engine Remove starting motor mounting bolt and take down the starting motor Roll...

Страница 77: ...both ends of brush shaft Press brush into its holder and install front cover of electrodes Attention There should be no hurt on the contact surface of brush and armature Take care Installation shaft o...

Страница 78: ...ry voltage shall meet the specified When there is no voltage at wire terminal of starting relay inspect braking switch continuity and lead wire 3 4 3 Starting relay ground loop inspection Remove start...

Страница 79: ...Bulbs Switches Instruments 1 Headlamp 2 Instruments 3 Electric horn 4 Left rear turn signal lamp...

Страница 80: ...and perform continuity test All the plastic connectors have pawls on them Release clamping of the pawl before removal Align pawl to its hole when it is reinstalled While trouble shooting electric fau...

Страница 81: ...p rear cover Tighten the new bulb into the socket Avoid touching bulb glass with your bare hands during installation and staining it with oil which may affect transparency service life and luminous fl...

Страница 82: ...he tail lamp hood is in good condition and correct position 4 5 3 Tail lamp bulb replacement 4 5 3 1 Removal Screw off mounting bolts on the tail lamp hood Remove tail lamp hood 3 so that tail lamp bu...

Страница 83: ...ey to position and you will be able to pull out the key and the tail lamp Stop Lamp will be kept on 4 7 2 Ignition switch replacement Remove the headlamp Screw off the mounting bolts and remove the ig...

Страница 84: ...the draw bar bracket for the rear brake lever Remove throttle handle and bolts Take down throttle handle from the handle and remove the throttle cable Remove locknut on the handle and take down the h...

Страница 85: ...mounting bolt Rear shaft locknut Upper bracket assembly mounting bolt Front shaft locknut Front shock absorber mounting bolt Rear shaft locknut Rear shock absorber top nut Rear shock absorber bottom...

Страница 86: ...t 3mm D Mounting torque for Bolt 7 in the diagram 22 29 N m 1 Oil pump block assembly 2 Hydraulic brake handle 3 Handle mounting bolt 4 Nut M6 5 Fixed cover 6 Bolt M6 23 7 Front hydraulic brake mounti...

Страница 87: ...ting bolt 6 Bolt M6 30 7 Washer 6 8 Rear brake rocker arm 9 Nut M6 10 Washer 11 Cam shaft O sealing ring 12 Rear braking cam shaft 13 Rear wheel right bush 14 Rolling bearing 6302 2RS 15 Braking shoe...

Страница 88: ...m ID 130 131 Rear brake shoe thickness 4 0 3 0 5 1 2 Tightening Torque Value Front wheel shaft locknut 55 62 N m Front brake cylinder assembly mounting bolt 22 29 N m Rear wheel shaft locknut 85 98 N...

Страница 89: ...Front brake 1 Hydraulic brake handle 7 2 Oil pump block assembly 5 3 Braking hose assembly 4 4 Braking cylinder assembly 6 5 Hydraulic brake disc 2 Note Detailed breakdown drawing refers to P85 Attent...

Страница 90: ...mbly Please do not contaminate braking shoe and brake disc with oil Attention A contaminated braking shoe will reduce braking performance and result in brake failure Tighten bolt and nut to their spec...

Страница 91: ...etailed exploded view refers to P86 5 4 2 Inspection Check if braking shoe assembly and brake drum are worn Replace them if necessary Measure braking shoe thickness and brake drum ID and record the ma...

Страница 92: ...failure Tighten bolt and nut to their specified torque value Torque value Rear wheel locknut 85 98 N m Do not contaminate braking shoe with oil If a braking shoe is polluted by oil clean it with brake...

Страница 93: ...ly install pawl of each part during combination Do not damage the fittings during exterior part installation 1 Right cowling installation plate 2 Cowling installation plate 3 Right decorative panel II...

Страница 94: ...el Front mudguard Rear mudguard assembly Rear rail Rear tail cover connectiong board Tail lamp Tail lamp support Attention Do not damage exterior parts during assembly and disassembly Do not damage th...

Страница 95: ...aft 2 Gear seat assembly 3 Gear seat oil seal 4 Drive plate 5 Bearing 6 Front wheel middle sleeve 7 Front brake disc 8 Front brake disc mounting bolt 9 Front wheel oil seal assembly 10 Front wheel lef...

Страница 96: ...ng handle jacket 10 Left handle assembly 11 Left handle 12 Slotted Nut 13 Handle mounting bolt 14 Bolt M6 25 15 Fixed cover 16 Adjusting screw tube 17 Slotted nut 18 Left and right rear mirror holders...

Страница 97: ...6 12 21 Upper bracket assembly 22 Nut M6 23 Side reflector assembly 24 Washer 10 25 Dust cover 26 27 Combination screw M6 16 28 Location pin 29 Upper steel bowl of upper bearing 30 Steel ball 3 16 inc...

Страница 98: ...ion Please do not let oil contaminate braking shoe braking shoe assembly and brake disc Basic data of the motorcycle as a whole Measuring position Item Standard value mm Service Limit mm Front wheel s...

Страница 99: ...e shock absorber 7 3 Front Wheel 7 3 1 Disassembly Attention Stand the motorcycle reliably Screw off speedometer mounting bolts and remove speedometer cable Screw off front shaft locknuts Remove front...

Страница 100: ...eve 11 of front wheel Remove oil seal assembly 10 Remove bearing 5 Inspect rolling of bearing If bearing does not roll roll smoothly or steadily or bearing is worn or loosened replace it with a new on...

Страница 101: ...d assembly diagram Front wheel locknut tightening torque 55 62 N m 7 4 Steering Handle 7 4 1 Removal Remove left and right rear mirror assemblies 1 and 2 Open the fixed cover Remove left handle assemb...

Страница 102: ...off upper bracket mounting bolt and lower bracket pinch bolt Remove headlamp bracket Remove the front fork Tools Steering handle welded assembly mounting bolt wrench Locknut wrench Special remover for...

Страница 103: ...grease on the top holder race Turn steering handle left and right to have steel balls closely fit Tools Locknut wrench Rotate the front fork left and right to be sure of its smoothness and there shall...

Страница 104: ...teeth 7 Oil seal 8 Rolling bearing 6204 2RS 9 Chain drive sleeve 10 Sprocket hub 11 Sprocket mounting bolt 12 Rear wheel left sleeve assembly 13 Rear wheel buffer 14 Bearing spacer 15 Tubeless tyre 1...

Страница 105: ...Rear Shock Absorber 1 Cap nut M10 1 25 2 Rear shock absorber mounting gasket 3 Rear shock absorber assembly 4 Washer 12 Bolt M10 1 25 40...

Страница 106: ...1 Locking nut M14X1 5 2 Dust ring assembly 3 Bush 4 Oil seal 5 Middle sleeve 6 Rubber gasket for protecting plate 7 Rear swing arm welding assembly 8 Washer 12 9 Chain adjuster spacer 10 Connecting r...

Страница 107: ...hub 3 Chain drive sleeve 4 Rolling bearing 6204 2RS 5 Oil seal 6 Sprocket 43 teeth 7 Sprocket stopper 8 Nut M8 9 Chain 428H 1 126 10 Chain guard 11 Boss bolt A Tightening torque of Bolt 1 in the diag...

Страница 108: ...th oil Basic preparatory data Item Standard Value mm Service Limit mm Rear wheel Shimmy Longitudinal 2 0 Transversal 2 0 Tightening torque Rear shat locknut 85 98 N m Rear shock absorber top nut 37 44...

Страница 109: ...orn braking shoe Worn brake drum Contaminated braking shoe Contaminated brake drum 8 3 Rear Wheel 8 3 1 Removal Stand the motorcycle steadily and rear wheel is off the ground Remove rear brake pedal a...

Страница 110: ...eeds 2 0mm Transversal Replace it when the measured value exceeds 2 0mm When rear wheel shimmy exceeds service limit rear wheel bearing is loosened which results in wobbly rear wheel Check and replace...

Страница 111: ...ing If it is replace rear shock absorber assembly 8 4 Install Rear Shock Absorber Install the rear shock absorber in the reverse order of removal Install upper locknut and lower mounting bolt on the r...

Страница 112: ...sembly 15 and intermediate sleeve 14 Install rear swing arm assembly 6 Install rear swing arm onto the frame and insert rear swingarm shaft Install and tighten rear swing arm shaft nut to specified to...

Страница 113: ...an Take the cleaned chain from kerosene and dry it in the air Inspect roller and its side plate If it is damaged or worn replace the drive chain Lubricate drive chain Drive chain lubricant can be purc...

Страница 114: ...h a new one 8 5 4 Installation Install it in the reverse order of removal Install drive chain chain cover rear left shock absorber rear wheel and drive sprocket cover Adjust slackness of drive chain a...

Страница 115: ...Seat Cushion 1 Seat cushion assembly 2 Rear rail 3 Rear luggage carrier screw II 4 Rear luggage carrier screw I...

Страница 116: ...Left fuel tank protecting plate 6 Fuel tank installation gasket 7 Fuel sensor assembly 8 Sensor rubber gasket 9 Nut M6 10 Fuel switch assembly 11 Wire clamp 8 12 Oil hose 4 5 2 140 13 Wire clamp 9 14...

Страница 117: ...set at OFF position while removing fuel tank While installation tighten bolt and nut to their specified torque After installation check if all the components are correctly fixed and work normally Bas...

Страница 118: ...Remove connector from lead wire of oil level sensor Fuel switch shall be set at OFF position Disconnect fuel hose and carbon canister connecting hose Remove bolt washer damper and fuel tank Remove the...

Страница 119: ...ew Closing bolt Right side cover bolt Front left cover bolt Coil screw Clutch separating disc bolt Clutch locknut Filter screen cover bolt Tensioner pinch bolt Drive gear locknut Drive sprocket bolt E...

Страница 120: ...untershaft assembly 7 Filter screen 8 Engine oil pump 9 Filter element assembly Note When the engine oil pump is removed clean carefully all the components and purge them with high pressure gas During...

Страница 121: ...riction between plasmids of lubricating oil It is used to reduce wear of component cool components of higher heat absorb impact from bearing and other parts weaken noise increase tightness between pis...

Страница 122: ...crew Take down oil pump block drive gear and pump shaft Screw off the screw Take down pump seat Remove the screw and take down pump cover Disassemble oil pump Check radial clearance between inner roto...

Страница 123: ...Check clearance between external rotor and oil pump seat Allowable limit 0 2mm Check clearance between rotor end faces Allowable limit 0 15mm Testing gauge Testing gauge Flat board...

Страница 124: ...gine Oil Pump As shown in the following figure Attention After assembly inner and external rotors shall rotate smoothly and be out of nimbleness 10 3 2 Installation Install the oil pump in the reverse...

Страница 125: ...ore 11 Idle jet 12 Main jet 13 Main nozzle 14 Main foam pipe 15 Mixture screw 16 Mixture screw spring 17 Fixture screw washer 18 Mixture screw seal ring 19 Plunger adjusting screw spring 20 Plunger ad...

Страница 126: ...de the float may deteriorate which will clog idle nozzle and idle may become dangerous Function of carburetor Carburetor is one of the key parts for oil supply system of the engine Its working perform...

Страница 127: ...ark while acceleration Improper work of enrich valve Too low mixed gas concentration Improper work of needle valve Too high oil level Oil outflow from carburetor Clogged airway Dirty air cleaner 11 3...

Страница 128: ...e it if necessary Check carburetor itself and fuel pipe If they are dirty clean it according to the user s manual 11 4 Installation Assembly Install idle jet main jet main nozzle and main foam pipe In...

Страница 129: ...ting screw 23 Valve collet 24 Valve spring upper retainer 25 Valve spring 26 Valve rod sealing assembly 27 Valve guide 28 Valve spring lower retainer 29 O ring 30 Rubber air intake assembly 31 Stud 32...

Страница 130: ...d high temperature and high pressure fuel gas It accomplishes air intake and exhausting operation with valve mechanism Basic Data Unit mm Item Standard Service Limit Cylinder cover flatness 0 03 0 05...

Страница 131: ...ression pressure Air leakage at cylinder head Too much carbon deposited in the combustion chamber Improperly installed spark plug 12 3 Cylinder Head 12 3 1 Removal Screw off the ten locknuts and remov...

Страница 132: ...05mm Clearance between rocker arm and rocker arm shaft Allowable limit 0 08mm Screw off the two locknuts and remove the lock washer cam shaft and C type gasket Screw off the three cap nuts and hexagon...

Страница 133: ...ness of junction surface of cylinder cover Allowable limit 0 05mm If flatness of junction surface of cylinder cover exceeds the service limit put a piece of fine sandpaper on the flat plate and fit th...

Страница 134: ...eposition in the valve guide with a reamer before inspection Attention Rotate the reamer in clockwise Please do not rotate he reamer in counterclockwise Measure valve guide ID Allowable limit Intake E...

Страница 135: ...a special valve guide remover Install a new O ring onto the new valve guide Install the valve guide from the top of cylinder head Attention Please do not hurt cylinder head while installing valve gui...

Страница 136: ...clearly Remove 1 4 of external edge of valve race with a 32 angle milling cutter Remove 1 4 of bottom of valve race with a 60 angle milling cutter Remove the milling cutter and check the places proces...

Страница 137: ...and cutting please apply some polishing agent on the surface of valve Polish the valve gently 12 7 Cylinder Head Installation Install the cylinder head in the reverse order of removal Attention While...

Страница 138: ...7 Location pin 8 Washer 9 Cylinder cover connecting bent pipe assembly 10 Bolt 11 Cylinder cover connecting bent pipe washer assembly 12 Cylinder block 13 Washer 14 Tensioner assembly 15 Bolt 16 Bolt...

Страница 139: ...shaft to rotate It forms a combustion chamber with cylinder head It works as a slide valve to compress regularly fresh mixed gas from crankcase into cylinder and exhaust combustion gas from the cylind...

Страница 140: ...ure Noisy piston Too much carbon deposited in the combustion chamber Damaged cylinder piston and piston ring Worn piston pin hole and piston pin 13 3 Cylinder Block 13 3 1 Cylinder Block Removal Screw...

Страница 141: ...eposited carbon inside the piston ring Install the piston ring Measure the clearance between piston ring and piston ring groove Allowable limit Top ring 0 09mm Second ring 0 09mm Remove piston ring an...

Страница 142: ...0 angle with piston pin about 11mm below piston skirt Allowable limit 56 93mm Inspect wear and scratch on inner wall of cylinder Attention Measure cylinder ID at three positions i e upper intermediate...

Страница 143: ...m Check flatness of cylinder surface Allowable limi 0 05mm Measure Connecting rod small end ID Allowable limit 14 06mm 13 4 2 Installation of piston Install location pin Apply engine oil evenly on eac...

Страница 144: ...ttention Install with the Point mark at the bottom of piston facing the exhaust valve 13 5 Install Cylinder Install washer and location pin onto the crankcase Apply evenly engine oil on inner wall of...

Страница 145: ...assembly 12 Driven friction plate 13 Center bracket 14 Sleeve 15 Thrust washer 16 Housing assembly Attention You don t have to remove the engine from frame while overhauling clutch Viscosity and level...

Страница 146: ...ly variable transmission Basic data Unit mm Clutch Braking shoe thickness 2 9 3 2 6 Length of pressure spring 31 29 7 14 2 Fault Diagnosis Tight clutch release lever Clutch slips at acceleration Trans...

Страница 147: ...ever sleeve bearing separating plate and clutch spring Removed components refer to exploded view Use a special tool to screw off clutch locknut Remove locknut and washer Remove clutch center bracket R...

Страница 148: ...roove of clutch If there are fix and adjust with a file If there is a lot for fix and adjustment replace it Check if teeth of pressure plate and center bracket are injured If they are replace them Mea...

Страница 149: ...m 14 4 Disassemble Main Shaft and Countershaft Inspection Check respectively wear of tooth surface and drive pawls If they are seriously worn or damaged replace them Remove bearing and oil seal on lef...

Страница 150: ...e if necessary Attention Hammered out bearing cannot be reused Replace it with a new one Remove bearing and oil seal with special tools Main shaft and countershaft combination Attention Apply each gea...

Страница 151: ...Reduction Gear 1 Gearshift drum 2 Shift fork 3 Shift fork shaft 4 Main shaft assembly 5 Countershaft assembly Function Transfer torque and determinate the final output torque and rotary speed...

Страница 152: ...b OD 39 8 40 39 75 Gearshift hub lock groove width 6 1 6 2 6 35 15 2 Fault Diagnosis Hard to engage gear Difficult gearshift Worn or distorted gearshift fork Clutch is not completely separated Broken...

Страница 153: ...view 15 3 2 Exploded View 15 3 3 Inspection Before disassembly gearshift plate shall work flexibly and smoothly Check if gearshift plate and gearshift shaft assembly are worn If they are seriously wor...

Страница 154: ...shift drum Remove gearshift fork Measure shift fork OD Allowable limit 9 96mm Measure shift fork hole ID Allowable limit 10 05mm Measure shift fork thickness Allowable limit 4 6mm Shift fork shaft Gea...

Страница 155: ...drum Allowable limit 39 75mm Measure the width of gearshift drum lock groove Allowable limit 6 35mm Remove balance shaft gear 15 4 Installation Install it in the reverse order of removal Lock groove w...

Страница 156: ...Bolt 6 Piston Attention Crankcase is a thin wall casting part Avoid impact on it during operation in case it may be distorted or broken Clean carefully all the components before inspection and test an...

Страница 157: ...ad It bears impact from combustion and inertia force from movement of crankshaft connecting rod and forms a partial enclosed space for air and oil Suspension hole is set on the crankcase which can be...

Страница 158: ...move gear chamber cover Remove starting motor gear needle bearing and washer Screw off bolts on left front cover and left rear cover of crankcase Remove left front cover and left rear cover Remove sta...

Страница 159: ...plate and take down cam assembly Remove bearing locating device 16 3 2 Exploded View of Cam Assembly Measure cam bush ID Allowable limit 14 10mm Measure cam height Allowable limit 32 5mm Cam shaft sp...

Страница 160: ...roller cover and its cover washer Remove washer and location pin Use an electric or pneumatic tool to screw off locknut Remove oil filter roller and take down the drive gear Screw off engine oil pump...

Страница 161: ...earance Allowable limit 0 55mm Measure connecting rod big end clearance along X Y direction Allowable limit 0 05mm Crankshaft shimmy measurement Allowable limit 0 01mm Check if there is abnormal noise...

Страница 162: ...lysts are added into the muffler welding assembly in the diagram C Tightening torque of combined screw 6 for muffler protecting plate in the diagram 5 9 N m 1 Exhaust pipe gasket assembly 2 Bolt M8 30...

Страница 163: ...for the customers at a reasonable price 1 Without performing regular maintenance according to the time and traveled distance specified by the company 2 Users not performing regular inspection adjustme...

Страница 164: ...service life of the engine when your motorcycle is often used on sand gravel roads or in severely polluted environment More frequent servicing may be required when the motorcycle is often driven at h...

Страница 165: ...mber clean For Delivery Qualified Qualified Qualified Qualified Qualified Qualified Classification Equipment Constituted Part Desired Function Emission control system Catalytic device Catalytic conver...

Страница 166: ...QJ125 26A Schematic Circuit Diagram...

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