SANYANG HD 125 Wartungshandbuch

SERVICE MANUAL 中华战马修护手册

1.GENERAL INFORMATION 1-7 D. ROTATION ROUGH (HIGH SPEED) symptom inspection adjustment cause ignition tim

12. REAR WHEEL/REAR SUSPENSION 12-1 TROUBLE SHOOTING...12-1 SERVICE INFORMATION...12-1 REAR WHEEL...

12. REAR WHEEL/REAR SUSPENSION 12-2 REAR WHEEL REAR WHEEL REMOVAL Raise the rear wheel off the ground on the main stand. Remove the exhaust muffler.

12. REAR WHEEL/REAR SUSPENSION 12-3 BEARING FREE PLAY INSPECTION Shake the bearing back and forth and spin it by hand, replace it with a new one if

12. REAR WHEEL/REAR SUSPENSION 12-4 FINAL DRIVEN SPROCKET ASSEMBLY Install the drive sprocket and new lock plates on the driven flange and tighten t

12. REAR WHEEL/REAR SUSPENSION 12-5 Measure the brake drum I.D. Service limit: ∮152mm REAR BRAKE PANEL NOTE: Grease the place as figure

12. REAR WHEEL/REAR SUSPENSION 12-6 Install the hold arm. Install the brake linkage. Adjust the drive chain tension (2-13). Drive chain

12. REAR WHEEL/REAR SUSPENSION 12-7 Remove the spring and rubber. SHOCK ABSORBER SPRING INSPECTION Measure the shock absorber spring f

12. REAR WHEEL/REAR SUSPENSION 12-8 REAR FORK REAR FORK REMOVAL Remove the muffler. Remove the rear wheel (12-3). Remove the rear shock absorber (12

12. REAR WHEEL/REAR SUSPENSION 12-9 REAR FORK INSTALLATION Install the rear fork. TORQUE: 800~1000 kgf・cm Install the rear shock absorber and rear

13. BATTERY/CHARGING SYSTEM 13-1 TROUBLE SHOOTING...13-1 SERVICE INFORMATION...13-2 BATTERY...

1.GENERAL INFORMATION 1-8 E. POOR CHARGE (BATTERY OVER DISCHARGE OR OVER CHARGE) symptom inspection ad

13. BATTERY/CHARGING SYSTEM 13-2 CHARGING SYSTEM FAILURE 1. Loose broken or shorted wire 2. Faulty voltage regulator 3. Faulty generator 4. Battery

13. BATTERY/CHARGING SYSTEM 13-3 BATTERY BATTERY REMOVAL AND INSTALLATION Remove the right side cover. Disconnect the battery negative cable first,

13. BATTERY/CHARGING SYSTEM 13-4 Connect the charger positive(+) cable to the battery positive (+) terminal, negative (-) cable to the battery negat

13. BATTERY/CHARGING SYSTEM 13-5 STATOR COILS TEST NOTE: This test can be made with the stator on the frame. Disconnect and measure the A.C. generat

14. IGNITION SYSTEM 14-1 TROUBLE SHOOTING...14-1 SERVICE INFORMATION...14-2 IGNITION COIL ...

14. IGNITION SYSTEM 14-2 SERVICE INFORMATION GENERAL INSTRUCTION This section contains the ignition system. Be sure that the battery is fully charge

14. IGNITION SYSTEM 14-3 IGNITION COIL IGNITION COIL REMOVAL Remove the seat. Remove the fuel tank. Remove the spark plug cap. Disconnect all wires t

15. SWITCHES/HORN 15-1 TROUBLE SHOOTING...15-1 SERVICE INFORMATION...15-2 MAIN/DIMMER SWITCH...

15. SWITCHES/HORN 15-2 SERVICE INFORMATION GENERAL INSTRUCTIONS All electrical wires are color-coded. Check

15. SWITCHES/HORN 15-3 MAIN SWITCH DIMMER SWITCH BLACK/WHITE B/W GREEN G RED R BLACK B BROWN/RED Br/R BROWN

1.GENERAL INFORMATION 1-9 F.SPARK PLUG NO SPARK symptom Inspection adjustment cause replace with new s

15. SWITCHES/HORN 15-4 FRONT BRAKELIGHT SWITCH Check that the front brakelight switch for conductivity betw

2.INSPECTION/ADJUSTMENT 2-1 ENGINE MAINTENANCE SCHEDULE ...2-2 SERVICE INFORMATION...2-3 ENGINE OIL/OIL FILTER.

2.INSPECTION/ADJUSTMENT 2-2 MAINTENANCE SCHEDULE Maintenance kilometer 300KM Every 1000KM Every 3000KM Every 6000KM Every 12000KM Item Che

2.INSPECTION/ADJUSTMENT 2-3 SERVICE INFORMATION SPECIFICATLON ENGINE Oil capacity 1.1～1.5 liter Spark plug gap A6RTC Spark plug gap 0.6-0.7mm

2.INSPECTION/ADJUSTMENT 2-4 OIL/OIL FILTER OIL LEVEL CHECK Start and warm up the engine for few minutes,then stop the engine. Check the oil level

2.INSPECTION/ADJUSTMENT 2-5 OIL FILTER SCREEN CLEANING Remove the oil filter cap, oil filter screen and drain the engine oil. Operate the kick start

2.INSPECTION/ADJUSTMENT 2-6 COMPRESSION TEST Warm up the engine. Stop the engine .Remove spark plug .Insert the compression gauge. Push in the ch

2.INSPECTION/ADJUSTMENT 2-7 VALVE CLEARANCE NOTE: Remove the timing inspection hole cap and crankshaft hole cap. Rotate the generator rotor coun

PREFACE PREFACE l This shop manual describes the technical feature and servicing procedures for the SANYANG XS125-K. l All information, illustrati

2.INSPECTION/ADJUSTMENT 2-8 Install the valve adjuster caps and generator cap. NOTE: IGNITION TIMING Use the standard tester to c

2.INSPECTION/ADJUSTMENT 2-9 Inspect the C.D.I unit with C.D.I tester. Replace the faulty C.D.I unit. SWITCH C.D.I. normal C.D.I faulty 1. OFF 2.

2.INSPECTION/ADJUSTMENT 2-10 CARBURETOR THROTTLE GRIP FREE PLAY Check throttle grip free play. Free play:2-6mm THROTTLE GRIP ADJUSTM

2.INSPECTION/ADJUSTMENT 2-11 IDLING SPEED ADJUSTMENT Warm up the engine. Turn the stop screw to obtain the idling speed of 1100rpm. Turn the air scr

2.INSPECTION/ADJUSTMENT 2-12 AIR CLEANER Remove the left side cover. Remove the air cleaner cover. Remove the air cleaner element. NOTE: Clean t

2.INSPECTION/ADJUSTMENT 2-13 FREE PLAY ADJUSTMENT Loosen the lock nut and turn the adjuster. Turn the adjuster ,clockwise for decreasing the free p

2.INSPECTION/ADJUSTMENT 2-14 REAR BRAKE PEDAL FREE PLAY Measure the brake pedal free play before the brake start to engage. Free play :20-30mm

2.INSPECTION/ADJUSTMENT 2-15 Loose the rear wheel axle nut for adjusting. Turn the adjusting nuts on both adjusters as necessary. CAUTION: Tighten

2.INSPECTION/ADJUSTMENT 2-16 SUSPENSION FRONT SUSPENSION Check the action of the front forks by compressing them several times with the front b

2.INSPECTION/ADJUSTMENT 2-17 STEERING Raise the front wheel off the ground and check that the handlebar rotates freely.If the handlebar moves uneven

CONTENTS CONTENTS GENERAL INFORMATION...1 INSPECTION/ADJUSTMENT ...

2.INSPECTION/ADJUSTMENT 2-18 HEADLIGHT AIM Adjust vertically by turning headlight up and down with the headlight bolts loosening. Fasten the bo

3.LUBRICATION SYSTEM 3-0 CAM SHAFT OIL LINE OF CAM SHAFT PISTON OIL FILTER OIL ORIFICE OF CRANKSHAFT OIL PUMP MAIN SHAFT COUNTER SHAFT

3.LUBRICATION SYSTEM 3-1 TROUBLE SHOOTING...3-1 SERVICE INFORMATION... 3-1 TROUBLE SHOOTING OIL LEVEL

4.ENGINE REMOVAL/INSTALLATION 4-1 SERVICE INFORMATION...4-1 ENGINE REMOVAL...4-2 ENGINE INSTALLATION

4.ENGINE REMOVAL/INSTALLATION 4-2 ENGINE REMOVAL Drain the engine oil. Turn the fuel cock to “OFF” and disconnect the fuel tubes and all connect

4.ENGINE REMOVAL/INSTALLATION 4-3 Remove the clutch cable. Remove the spark plug cap. Remove the muffler. Loosen carburetor clip. Separ

4.ENGINE REMOVAL/INSTALLATION 4-4 Remove the front engine hanger bolt. NOTE: Places jack or padded block under the engine before removing the fro

5. CYLINDER HEAD/ VALVE 5-1 TROUBLE SHOOTING...5-1 SERVICE INFORMATION...5-2 CAM SHAFT REMOVAL ...

5.INSPECTION/ADJUSTMENT 5-2 SERVICE INFORMATION GENERAL INSTRUCTIONS Camshaft, rocker arm shaft and rocker arm can be serviced with the engine ins

5. CYLINDER HEAD/ VALVE 5-3 CAMSHAFT REMOVAL NOTE: The camshaft, rocker arm and rocker arm shaft can be serviced with the engine installed on the fr

1.GENERAL INFORMATION 1-1 SERVICE RULES...1-1 SPECIFICATIONS ...1-2 TORQUE VALUES

5.INSPECTION/ADJUSTMENT 5-4 CYLINDER HEAD REMOVAL Remove the cam chain tensioner bolt. Remove the 8mm bolt. Remove the 4 cylinder head nuts. Remov

5. CYLINDER HEAD/ VALVE 5-5 CAMSHAFT INSPECTION Inspect the cams of the camshaft for wear. Service limit: Inlet: 31.25mm

5.INSPECTION/ADJUSTMENT 5-6 CYLINDER HEAD DISASSEMBIY Remove carbon deposits from the combustion chamber. Remove valve spring and valve spring and

5. CYLINDER HEAD/ VALVE 5-7 VALVE/VALVE GUIDE INSPECTION Inspect valves for scratches, burning or wear. Check the valve movement in the guide. Measu

5.INSPECTION/ADJUSTMENT 5-8 VALVE GUIDE REPLACEMENT Drive out the valve guide from the combustion chamber side with a 5mm valve guide remover. NOT

5. CYLINDER HEAD/ VALVE 5-9 VALVE SEAT INSPECTION/ REFACING Clean intake and exhaust valves to remove carbon deposits. Apply a light coating of prus

5.INSPECTION/ADJUSTMENT 5-10 VALVE SEAT GRINDING NOTE: Follow the instructions described in the cutter instruction manual. Remove any ro

5. CYLINDER HEAD/ VALVE 5-11 Using a 32 degree cutter, remove 1/4 of the existing valve seat material. Remove the bottom 1/4 of the ol

5.INSPECTION/ADJUSTMENT 5-12 If the contact area is too high on the valve,the seat must be lowered using a 37.5 degree cutter, then finish with a

5. CYLINDER HEAD/ VALVE 5-13 CYLINDER HEAD ASSEMBLY Compress the valve springs with a valve spring compressor and install the valve cotters into the

1.GENERAL INFORMATION 1-2 SPECIFICATIONS ITEM XS125-K Overall length 2040mm Overall width 750mm Overall height 1100mm Wheel base 1280mm Groun

5.INSPECTION/ADJUSTMENT 5-14 CYLINDER HEAD INSTALLATION CAMSHAFT AND CAMSPROCKET ASSEMBLY NOTE: Rocker arms must be installed at the right positio

5. CYLINDER HEAD/ VALVE 5-15 CAM SHAFT INSTALLATION Rotate the generator rotor and align the "T" mark with the index mark. Install the cam

6. CYLINDER/PISTON 6-1 TROUBLE SHOOTING...6-1 SERVICE INFORMATION...6-1 CYLINDER REMOVAL...

6.CYLINDER/PISTON 6-2 CYLINDER REMOVAL Remove the cylinder head. Remove the dowel pins and gasket. Remove the cylinder. NOTE: Avoid the dowel pins f

6. CYLINDER/PISTON 6-3 PISTON REMOVAL Remove the piston pin clip with pliers. Press the piston pin out of piston, remove the piston. NOTE: Avoid the

6.CYLINDER/PISTON 6-4 Measure the piston O.D. at the skirt. Service limit: 56.48mm NOTE: Measure the piston O.D. at a point from the bottom. Calcul

6. CYLINDER/PISTON 6-5 PISTON RING INSTALLATION Install the piston rings. NOTE: Space the piston ring end gaps 120 degree apart. Ÿ Avoi

6.CYLINDER/PISTON 6-6 PISTON INSTALLATION Install the piston, piston pin and piston pin clip. NOTE: Ÿ Position the "IN" mark on the piston

7.CLUTCH/OIL PUMP/GEAR SHIFT 7-1 TROUBLE SHOOTING...7-1 SERVICE INFORMATION...7-1 RIGHT CRANKCASE COVER

7.CLUTCH/OIL PUMP/GEAR SHIFT 7-2 RIGHT CRANKCASE COVER REMOVAL Drain oil from the engine. Disconnect the clutch cable. Remove the kick starter ar

1.GENERAL INFORMATION 1-3 ENGINE TIGHTEN LOCATION Q'TY THREAD DIA(mm) TORQUE(kgf・cm) Starting clutch outer bolt socket Cylinder stud bolt

7.CLUTCH/OIL PUMP/GEAR SHIFT 7-3 Remove the bearing, clutch bolt, clutch lifter plate and clutch spring. CLUTCH SPRING INSPECTION Mea

7.CLUTCH/OIL PUMP/GEAR SHIFT 7-4 CLUTCH FRICTION DISC INSPECTION Replace the clutch disks if they have any score or discolora

7.CLUTCH/OIL PUMP/GEAR SHIFT 7-5 Remove the 20 mm washer and clutch outer. CLUTCH OUTER INSPECTION Check the clutch outer for cracks

7.CLUTCH/OIL PUMP/GEAR SHIFT 7-6 Install and tighten the 20mm set ring. Install the clutch springs, lifter plate and tighten the bolt

7.CLUTCH/OIL PUMP/GEAR SHIFT 7-7 OIL PUMP OIL PUMP REMOVAL Remove the right crankcase cove. Remove the oil filter rotor. Remove the oil pump cover

7.CLUTCH/OIL PUMP/GEAR SHIFT 7-8 Measure the outer rotor-to-body clearance. Service limit: 0.40mm Measure the rotor-to-cover clearan

7.CLUTCH/OIL PUMP/GEAR SHIFT 7-9 OIL PUMP INSTALLATION Install new O-rings. Install the oil pump to the right crankcase.

7.CLUTCH/OIL PUMP/GEAR SHIFT 7-10 Remove the gearshift drum stopper arm. Remove the gearshift cam. Check each part for wear or damage.

7.CLUTCH/OIL PUMP/GEAR SHIFT 7-11 Install the gearshift spindle. NOTE : Align the gearshift return spring on the projection of the crankcase. Chec

8. A.C.GENERATOR 8-1 SERVIE INFORMATION...8-1 LEFT CRANKCASE COVER REMOVAL...8-2 FLYWHEEL REMOVAL...

1.GENERAL INFORMATION 1-4 Torque specifications listed below for respective locations. TROUBLE SHOOTING A. HARD START OR CANNOT START

8. A.C.GENERATOR 8-2 LEFT CRANKCASE COVER REMOVAL Remove the gearshift pedal. Remove the left crankcase rear cover. Disconnect the AC generator and

8. A.C.GENERATOR 8-3 STATOR COIL INSPECTION NOTE : This inspection can be made with the stator in the frame. Check the starter for continuity. Conti

8. A.C.GENERATOR 8-4 STARTER MOTOR REMOVAL Disconnect the starter motor wire from the motor.. Remove the starter motor by removing the bolts.

9.CAMSHAFT/CRANKSHAFT/CRANKCASE/TRANSMISSION/KICKSTARTER 9-1 TROUBLE SHOOTING...9-1 SERVICE INFORMATION...

9.CAMSHAFT/CRANKSHAFT/CRANKCASE/TRANSMISSION/KICKSTARTER 9-2 CRANKCASE SEPARATION Remove the right crankcover and interial parts. (7-3~ 7-13)

9.CAMSHAFT/CRANKSHAFT/CRANKCASE/TRANSMISSION/KICKSTARTER 9-3 Remove the left crankcover all 6mm attaching bolts. Separate the left crankcase from th

9.CAMSHAFT/CRANKSHAFT/CRANKCASE/TRANSMISSION/KICKSTARTER 9-4 Support the crankshaft bearings on a V-block and measure the runout using a gauge. NOTE

9.CAMSHAFT/CRANKSHAFT/CRANKCASE/TRANSMISSION/KICKSTARTER 9-5 TRANSMISSION DISASSEMBLY Remove the crankshaft. Remove the shift fork shaft. Remove the

9.CAMSHAFT/CRANKSHAFT/CRANKCASE/TRANSMISSION/KICKSTARTER 9-6 Measure the shift fork shaft O.D. Service limit: 11.976mm SHIFT DRUM INSPEC

9.CAMSHAFT/CRANKSHAFT/CRANKCASE/TRANSMISSION/KICKSTARTER 9-7 Check the crankcase bearings, replace them if they have excessive free play or noisy.

1.GENERAL INFORMATION 1-5 B. ROTATION ROUGH (LACKS POWER) symptom inspection adjustment cause start engine and sl

9.CAMSHAFT/CRANKSHAFT/CRANKCASE/TRANSMISSION/KICKSTARTER 9-8 TRANSMISSION ASSEMBLY NOTE: Before assembling,coat each gears with engine oil.

9.CAMSHAFT/CRANKSHAFT/CRANKCASE/TRANSMISSION/KICKSTARTER 9-9 Install the crankshaft assemblies in the right crankcase. Install the main

9.CAMSHAFT/CRANKSHAFT/CRANKCASE/TRANSMISSION/KICKSTARTER 9-10 KICK STARTER DISASSEMBLY Remove the kick starter spindle assembly. Remove

9.CAMSHAFT/CRANKSHAFT/CRANKCASE/TRANSMISSION/KICKSTARTER 9-11 KICK STARTER ASSEMBLY Reverse the operation of diassembly for assembing. C

10. CARBURETOR 10-1 TROUBLE SHOOTING...10-1 SERVICE INFORMATION...10-1 CARBURETOR REMOVAL...

10. CARBURETOR 10-2 CARBURETOR REMOVAL Disconnect the fuel line. Disconnect the all connect tubes. Drain fuel from the carburetor. WARNING: Keep awa

10. CARBURETOR 10-3 Remove the carburetor assembly. FLOAT/FLOAT VALVE/JETS DISASSEMBLE Remove the float chamber body. WARNING: Pour

10. CARBURETOR 10-4 Remove the main jet, needle jet and needle jet holder. NOTE: Avoid damage to the jets. Remove the air screw. NOTE: Be

10. CARBURETOR 10-5 FLOAT/FLOAT VALVE/ JETS ASSEMBLY Install the stop screw, air screw, main jet, needle jet and needle jet holder. NOTE: Do not dam

10. CARBURETOR 10-6 Connect the throttle cable. NOTE: Route the throttle cable end through the adjuster and the carburetor top. Make sure that the t

1.GENERAL INFORMATION 1-6 C. ROTATION ROUGH (ESPECIALLY IN THE LOW SPEED AND IDLE SPEED) symptom inspection

11. HEADLIGHT/STEERING FRONT WHEEL/FRONT FORK 11-1 TROUBLE SHOOTING...11-1 SERVICE INFORMATION...11-1 HE

11. HEADLIGHT/STEERING FRONT WHEEL/FRONT FORK 11-2 HEADLIGHT HEADLIGHT REMOVAL Remove the headlight screw. Remove the headlight case. Disconnect the

11. HEADLIGHT/STEERING FRONT WHEEL/FRONT FORK 11-3 METER METER REMOVAL Remove the headlight case . Disconnect each wire and connector. Disconnect

11. HEADLIGHT/STEERING FRONT WHEEL/FRONT FORK 11-4 NOTE: Coat the throttle grip hole with grease. Install the winker switch assembly. NOTE: Align th

11. HEADLIGHT/STEERING FRONT WHEEL/FRONT FORK 11-5 FRONT BRAKE FRONT BRAKE DISC INSPECTION (DISC BRAKE) Replace the brake pads if the wear indicato

11. HEADLIGHT/STEERING FRONT WHEEL/FRONT FORK 11-6 FRONT BRAKE PANEL INSPECTION Remove the brake shoes and springs. Remove the brake arm and brake c

11. HEADLIGHT/STEERING FRONT WHEEL/FRONT FORK 11-7 FRONT WHEEL INSTALLATION Install the front wheel. Install the axle shaft from the right side. Ti

11. HEADLIGHT/STEERING FRONT WHEEL/FRONT FORK 11-8 If the front fork is too soft or too hard, refill or drain the shock absorber fluid. Shock absorb

11. HEADLIGHT/STEERING FRONT WHEEL/FRONT FORK 11-9 STEERING STEM DISASSEMBLY Remove the front fork top bridge bolts. NOTE: Do not let the steel bal

11. HEADLIGHT/STEERING FRONT WHEEL/FRONT FORK 11-10 Grease the steel balls and cone races, install the steering stem. Install the steer