SYM XS125 K Scooter Full Service & Repair Manual

SERVICE MANUAL 中华战马修护手册

PREFACE PREFACE l This shop manual describes the technical feature and servicing procedures for the SANYANG XS125-K. l All information, illustrations, directions and specifications included in this publication are base on SANYANG XS125-K. l SANYANG reserves the right to make changes at any time without notice and without incurring any obligation whatever. SANYANG INDUSTRY CO.,LTD. SERVICE DIVISION

CONTENTS CONTENTS GENERAL INFORMATION............................................................................. 1 INSPECTION/ADJUSTMENT ........................................................................ 2 LUBRICATION SYSTEM ................................................................................ 3 ENGINE REMOVAL/INSTALLATION ........................................................... 4 CYLINDER HEAD/VALVE .............................................................................. 5 CYLINDER/PISTON ........................................................................................ 6 CLUTCH/OIL PUMP/GEAR SHIFT ................................................................ 7 A.C. GENERATOR .......................................................................................... 8 CRANK SHAFT/CRANK CASE/TRANSMISSION ........................................ 9 CARBURETOR ................................................................................................ 10 HEADLIGHT/STEERING/FRONT WHEEL/FRONT FORK ......................... 11 REAR WHEEL/REAR SUSPENSION............................................................. 12 BATTERY/CHARGING SYSTEM .................................................................. 13 IGNITION SYSTEM ......................................................................................... 14 SWITCHES/HORN ........................................................................................... 15 WIRING DIAGRAM .......................................................................................... 16

1.GENERAL INFORMATION 1-1 SERVICE RULES ................................... 1-1 SPECIFICATIONS .................................. 1-2 TORQUE VALUES ................................. 1-3 TROUBLE SHOOTING ........................... 1-4 SERVICE RULES: (1)Use new packings, gaskets,O-rings and cotter pins space and clipes whenever reassembling. (5)Clean all removed parts in or with solvent, and lubricate their sliding surfaces upon disassembly. (2)When tightening bolts or nuts, begin on center or larger diameter bolts and tighten them in criss- cross pattern in two or more steps if necessary. (6)Coat or fill parts with specified grease where specified. (3)Use genuine SANYANG parts and lubricants or those equivalent. When parts are to be reused, they must be inspected carefully to make sure they are not damaged or deteriorated and in good usable condition. (7)Upon assembling, check every possible part for proper installation and movement or operation. (4)Use special tool when use of such a tool is specified. (8)Work safely and give your work your undivided attention. Exchange signals as frequently as possible when a work involves two or more workers. Do not run the engine unless the shop or working area is well ventilated. Symbol Marks: :Apply engine oil. NOTE: Things must be noticed. CAUTION: Things that could cause damage to the engine parts. :Apply grease. WARNING: Things that could cause damage to the person or partner.

1.GENERAL INFORMATION 1-2 SPECIFICATIONS ITEM XS125-K Overall length 2040mm Overall width 750mm Overall height 1100mm Wheel base 1280mm Ground clearance 150mm DIMENSIONS Dry weight 130kg Type Single pipe Front suspension and travel Telescope 165mm Rear suspension and travel Swing arm 63mm Front tire size and tire pressure 2.75-18 2.25Kg/C ㎡ Rear tire size and tire pressure 90/90-18 2.50Kg/C ㎡ Front brake Disk type Rear brake Drum type Fuel capacity 14.5 liter Fuel reserve capacity 2.0 liter Caster angle 26 ° FRAME Front fork oil capacity 160c.c Type Air cooled 4 stroke engine Cylinder arrangement Single cylinder 15~ inclinde from vertical Bore & stroke 56.5 x49.5mm Displacement 124.1c.c. Compression ratio 9.0:1 Oil capacity 0.80 ~0.95liter (0.9 liter for change) opens 5°BTDC Intake valve closes 35 °ABDC opens 30°BBDC Exhaust valve closes 5 °ATDC IN. 0.10mm Valve clearance EX. 0.15mm ENGINE Idle speed 1400±100 rpm Clutch Wet muti-plate type Transmission 5-speed internationl Primary reduction ratio 4.05 I 2.769 II 1.722 III 1.318 IV 1.1250 Gear ratio V 0.962 Final reduction ratio 2.53 DRIVE TRAIN Gearshift pattern 1→N→2→3→4→5 Ignition system C.D.I. unit "F" mark BTDC 15° ±20°/1500rpm Ignition timing Full advance BTDC 29.5° ±2°/4000rpm Starting system Electrical motor and kickstarter Alternator A.C. generator Battery capacity 12N7A-3A(8AH) Fuse 15A Spark plug D7RC ELECTRICAL Spark plug gap 0.6~0.7mm

1.GENERAL INFORMATION 1-3 ENGINE TIGHTEN LOCATION Q'TY THREAD DIA(mm) TORQUE(kgf ·cm) Starting clutch outer bolt socket Cylinder stud bolt Shift drum stopper hex bolt Gear shift cam hex bolt Cylinder stud bolt Cylinder head cap nut Driven gear hex bolt Chain adjuster Oil filter screen cover Starter moror bolt Oil pump HEX bolt Primary drive gear nut Cylinder head bolt Cylinder head nut Fly wheel bolt Cylinder head cover Reduction gear cover bolt L. Crank case cover bolt R. Crank case cover A.C.G.pluse bolt A.C.G.flange bolt 3 10 1 1 4 4 2 2 1 2 2 1 1 4 1 4 3 8 11 2 3 8 6 6 6 8 8 6 6 10 6 6 16 8 8 10 6 6 6 6 4 5 100~150 80~120 80~120 80~120 180~220 280~300 100~150 80~120 150-300 80~120 70~110 400~500 280~320 280~320 400~500 80~120 80~120 80~120 80~120 40~50 40~70 FRAME TIGHTEN LOCATION Q'TY THREAD DIA(mm) TORQUE(kgf ·cm) Front wheel axle nut Rear wheel axle nut Rear fork pivot nut Engine upper hanger nut Engine front hanger nut Handle pipe upper holder bolt Steering stem nut Front fork nut Rear shock absorber Rear brake torque link Front fork top bridge Front fork bottom bridge Final drive sprocket Seat bolt Drive sprocket bolt 1 1 1 3 4 4 1 1 4 1 2 2 4 2 2 14 14 14 10 10 8 22 22 10 8 8 12 8 8 6 600~800 1000~1200 800~1000 400~550 450~550 180~ 250 600~900 400~500 300~400 150~200 400~550 400~500 270~330 200~250 100~140 STANDARD TORQUE TYPE TORQUE(kgf·cm) TYPE TORQUE(kgf·cm) 5 mm bolt, nut 6 mm bolt, nut 8 mm bolt, nut 10 mm bolt, nut 12 mm bolt, nut 45~60 80~120 180~250 300~400 500~600 5 mm bolt 6 mm bolt 6 mm flange bolt, nut 8 mm flange bolt, nut 10 mm flange bolt, nut 35~50 70~110 100~140 240~300 350~450

1.GENERAL INFORMATION 1-4 Torque specifications listed below for respective locations. TROUBLE SHOOTING A. HARD START OR CANNOT START start engine with choke closed engine knocks, but no starting follow the starter keypoints to re-start inspection adjustment cause loosen carburetor drain screw, check inner side for gasoline enough gasoline supplied for carbuertor remove spark plug,insert it into plug cap, check the spark by touching engine grid test cylinder compression spark plug jump spark weak or no spark normal compression pressure too low or no pressure engine dose not fire spark plug dry no gasoline in the tank fuel tube between gasoline tank and carburetor clogged. float chamber fuel tube clogged gasoline cover air hole clogged fuel filter clogged fuel filter screen clogged gasoline auto fuel cup faulty spark plug faulty fouled spark plug CDI unit fualty pulse coil faulty high voltage coil cable open or short high voltage coil open or short main switch faulty A.C.G. faulty Battery faulty valve too tight, no gap valve seat faulty cylinder, piston, piston ring faulty cylinder gasket leak valve burnt out valve timing faulty crankcase leak when wmpress Fuel tube clogged muffler clogged auto air cut poor action inlet duct has air in ignition timing incorrect carburetor fuel adjusting screw set faulty air cleaner clogged symptom no gasoline supplied for carburetor remove and check the spark plug again spark plug wet carburetor fuel level too high auto air cut poor action throttle excessively

1.GENERAL INFORMATION 1-5 B. ROTATION ROUGH (LACKS POWER) symptom inspection adjustment cause start engine and slightly apply fuel engine speed up engine speed can't up adjust ignition timing use timing tester valve adjuster poor ignition timing correct ignition timing incorrect valve clearance correct valve coearance incorrect compression pressure check compression normal pressure to low carburetor block check remove spark plug no clogged block air cleaner clogged fuel tube clogged air hole on the fuel tank cap blocked exhaust tube clogged auto air cut faulty carburetor vacuum diaphragm worn auto fuel cup faulty faulty CDI unit faulty A.C.Generator fualty valve seat cylinder, piston worn gasket leak valve timing incorrect piston ring worn remove and clean remove dirt spark plug improper heat range spark plug clearance misadjustment no fouled discolored dirt and color change valve clearance misadjustment valve seat worn check crankcase oil level for too much or dirt oil lever normal oil too much too much oil too little oil oil no replacement check cylinder head lubrication normal abnormal oil tube clogged lean projection from oil pump engine too hot no overheating overheated piston, cylinder worn lean mixture poor gasoline carbon in burning chamber too much ignition timing too early (C.D.I. faulty) clutch slip high speed continue working no knock shock knocks carbon in burning chamber too much poor gasoline clutch slip lean mixture ignition timing too early(C.D.I.faulty)

1.GENERAL INFORMATION 1-6 C. ROTATION ROUGH (ESPECIALLY IN THE LOW SPEED AND IDLE SPEED) symptom inspection adjustment cause ignition timing adjustment faulty CDI unit faulty A.C.Generator valve gap adjust faulty normal abnormal adjust carburetor fuel adjusting screw adjust OK adjust faulty lean mixture(loosen screw) rich mixture(tighten screw) no air inlet has air inlet carburetor gasket has air inlet insulator plate gasket poor carburetor locking nut loose insulator plate gasket torn vacuum tube crack Remove spark plug,insert to the plugcap, check spark by toucning engine irongrid. sparking well poor sparking poor or dirty spark plug faulty CDI unit faulty A.C.Genertor poor ignition coil spark plug cable open or short poor main switch good no good vacuum tube damaged air inlet duct clogged, damaged

1.GENERAL INFORMATION 1-7 D. ROTATION ROUGH (HIGH SPEED) symptom inspection adjustment cause ignition timing adjustment faulty CDI unit faulty pulse generator normal abnormal valve clearance adjustment normal abnormal poor adjustment valve seat faulty normal abnormal check auto fuel cup for fuel supplied. too little fuel in the fuel tank fuel tube, fuel filter clogged air hole on the fuel tank colgs auto fuel cup faulty no blocked blocked valve timing adjusting inspection timing correct timing incorrect cam sprocket aligning marks incorrect carburetor blocked check valve spring clean good spring broken loose elasticity faulty spring

SYM XS125 K Scooter Full Service & Repair Manual

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