A-EON New Sporty 125 User manual

AEON MOTOR CO.,LTD

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  

1
CONTENTS
1. INFORMATION………………………………………...
2
2. MAINTENANCE…………………….…………………
6
3. ENGINE REMOVAL AND INSTALLATION…………
16
4. ENGINE LUBRICATION AND COOLING SYSTEM..
17
5. CYLINDER HEAD & VALVES………………………..
26
6. CYLINDER & PISTON………………………………...
37
7. TRANSMISSION SYSTEM……………………………
46
8. FRONT WHEEL, SUSPENSION AND STEERING…..
57
9. REAR WHEEL SYSTEM………………………………
68
10.
FENDERS AND EXHAUST PIPE……………………..
79
11.
ELECTRICAL SYSTEM……………………………….
81
12.
TROUBLE SHOOTING………………………………..
88

2
1. INFORMATION
1.1 Safety
1.2 Notes
1.3 Specifications
1.4 Serial number
 Torque valve

1.1 Safety
GASOLINE
Gasoline is extremely flammable and is explosive under certain condition. Do not smoke or
allow sparks or flames in your work area.
CARBON MONOXIDE
Never run the engine in a closed area. The exhaust contains poisonous carbon monoxide gas that
may cause loss of consciousness and lead to death.
BATTERY ELECTROLYTE
The battery electrolyte contains sulfuric acid. Protect your eyes, skin and clothing. If you come
into contact with the electrolyte, flush the area thoroughly with water. If you get the electrolyte
in your eyes, flush with water and contact a doctor immediately.
HOT PARTS
Engine and exhaust pipe become very hot and remain hot for one hour after the engine is run.
Wear insulated gloves before handling these parts.
USED ENGINE /GEAR OIL
Used engine oil and gear oil may cause skin disease after repeated contact with the skin for long
periods. Keep out of reach of children.
1.2 NOTES
All information, illustrations, directions and specifications included in this publication are base
on the latest product information available at the time of approval for printing.
No part of this publication may be reproduced without written permission.

3
1.3 SPECIFICATION
ENGINE 125 / 180
Type
Displacement
Bore and Stroke
Compression
Maximum Torque
Carburetor
Ignition
Starting
Lubrication
Air Cleaner
Transmission
CHASSIS
Overall Length
Overall Width
Overall Height
Seat Height
Wheel Base
Ground Clearance
Dry Weight
Fuel Tank Capacity
SUSPENSION
Front
Rear
BRAKES
Front
Rear
TIRES
Front
Rear




Specifications subject to change without notice.
Air-Cooled 4-syroke
with Oil Cooler
125 cc/169 cc
52.4×57.8mm/61×57.8mm
9.1:1
6.21 Nm@4017 rpm/10.24 Nm@4403 rpm
MIKUNI 125/180
Capacitor Discharge
Electrical & Kick-Start
Forced pressure
and wet sump
AE-9
Automatic(C.V.T. V-belt)
71.7 inches (1820mm)
38.4 inches (975mm)
41.7 inches (1060mm)
30.7 inches (675mm)
41.9 inches (1065mm)
6.5 inches (165mm)
166kg (365lb)
8.0 liter
Swing Axle
Swing Arm
Drum
Disc
21” × 7” - 10”
21” × 10” - 8”


4
1.4 SERIAL NUMBER
The frame serial number is stamped on the front frame.
And stick a bar code paper to cover it.
The engine number is stamped under the crankcase.


5
1.5 TORQUE VALUES
STANDARD
5mm bolt and nut
6mm bolt and nut
8mm bolt and nut
10mm bolt and nut
12mm bolt and nut
ENGINE
Cylinder head nut
Spark plug
Cylinder head bolt
Alternator bolt
FRAME
Handlebar upper holder bolt
Throttle housing cover screw
Steering shaft nut
Steering shaft holder bolt
Wheel rim bolt
Tie rod lock nut
King pin nut
Handlebar lower holder nut
Front wheel bolt
Front axle nut
Front brake arm nut
Rear brake arm nut
Rear axle nut
Rear wheel bolt
Exhaust muffler mounting bolt
Engine hanger bolt
Rear axle holder bolt
Swingarm pivot nut
Rear shock absorber mounting nut
5 N.m (3.5 lbs.ft)
10 N.m (7.2 lbs.ft)
22 N.m (16 lbs.ft)
35 N.m (25 lbs.ft)
55 N.m (40 lbs.ft)
28 N.m (20.7 lbs.ft)
12 N.m (8.9 lbs.ft)
20 N.m (14.8 lbs.ft)
8 N.m (5.9 lbs.ft)
24 N.m (17.7 lbs.ft)
4 N.m (2.9 lbs.ft)
50 N.m (36.9 lbs.ft)
33 N.m (24 lbs.ft)
18 N.m (13.3 lbs.ft)
35 N.m (25.8 lbs.ft)
40 N.m (29 lbs.ft)
40 N.m (29.5 lbs.ft)
24 N.m (17.7 lbs.ft)
60 N.m (44 lbs.ft)
4 N.m (3.0 lbs.ft)
7 N.m (5.2 lbs.ft)
60 N.m (44.3 lbs.ft)
24 N.m (17.7 lbs.ft)
30 N.m (22.1 lbs.ft)
30 N.m (22 lbs.ft)
90 N.m (65 lbs.ft)
90 N.m (65 lbs.ft)
45 N.m (33 lbs.ft)

6
2. Maintenance
2.1 Maintenance data
2.2 Maintenance schedule
2.3 Fuel tube
2.4 Throttle operation
2.5 Throttle cable adjustment
2.6 Air cleaner
2.7 Spark plug
2.8 Idle speed
2.9 Drive chain
2.10 Brake system
2.11 Wheels and tires
2.12 Steering system
2.13 Toe-in
2.14 Gear oil
2.1 MAINTENANCE DATA
SPECIFICATION
SPARK PLUG
Spark plug cap
Recommended spark plugs
Throttle lever free play:
Idle speed
Brake lever free play:
Drive chain slack
Front/rear tire size
Front/rear tire pressure
Toe-in
TORQUE VALUES
SPARK PLUG
TIE-ROD LOCK NUT
ENGINE OIL
Viscosity:
GEAR LUBRICATION OIL
Viscosity:
0.6-0.7mm
NGK C7HSA or CR7HSA
5-10mm
1800rpm
10~20mm
15-25mm
21×7-10 / 22×10-8
3±0.3psi (0.15 kgf/cm2)
5±10mm
12-19 N.m
35-43 N.m
SAE 15W-40
SAE 85W-140

7
2.2 MAINTENANCE SCHEDULE
The maintenance intervals in the follow table is based upon average riding, condition. Riding
in usually dusty areas, require more frequent servicing.
Service Item Initial Service
(First 30 hours)
Every 100 hours Every 200 hours Every 300 hours
ENGINE OIL R R
GEAR OIL R R
FUEL FILTER R
AIR VLEAN
FILTER R
ENGINE OIL
FILTER
C
CARBURETOR
I
SPARK PLUG C
VALVE GAP A
IGNITION
TIMING A
CHAIN A
BATTERY I
DRIVE
BATTERY I
CLUTCH I
THROTTLE
OPERATE I
TIRE
PRESSURE Check before riding each time
BRAKE
SYSTEM Check before riding each time
NUTS/BOLTS T
A: Adjust C: Clean I: Inspection R: Replace T: Tighten

8
2.3 FUEL TUBE


Inspect the fuel lines for deterioration,
damage or leakage and replace if necessary.
2.4 THROTTLE OPERATION

Inspect for smooth lever operation, full opening
and automatic full closing in steering positions.
Inspect for deterioration, damage, cuts and
nicks, or kink in the throttle cable, replace it if
necessary.
Check the throttle lever, free play should be
not more than 5-10 mm at the tip of the
throttle lever.

Disconnect the throttle cable at the upper end.
Lubricate the cable with commercially lubricant
to prevent premature wear.

9
2.5 THROTTLE CABLE ADJUSTMENT

Slide the rubber cap of the adjuster off the
throttle housing, loosen the lock nut and adjust
the free play of the throttle lever by turning the
adjuster on the throttle housing. Inspect the free
play of the throttle lever.
2.6 AIR CLEANER MAINTENANCE

(1) Loosen the screw and remove the air
cleaner from carburetor.
(2) Disassemble the air cleaner cover and body.
(3) Remove the air cleaner element and screen..
(4) Install the new one.
(5) Assemble the air cleaner body and cover and
re-attach to the carburetor with screw.

10
2.7 SPARK PLUG
The spark plug is located at the front of the
engine.
(1) Disconnect the spark plug cap and remove
the spark plug
(2) Visually inspect the spark plug electrode
for wear or cranks in insulator. Replace if
needed.
(3) The center electrode should have square
edges and the side electrode should have a
constant thickness.
(4) Discard the spark plug if there is apparent
wear or if the insulator is cracked or
chipped.
(5) Measure the gap with a wire-type feeler
gauge and adjust if necessary by carefully
bending the side electrode.
SPARK PLUG GAP: 0.6~0.7 mm
RECOMMENDED REPLACEMENT PLUG:
NGK CR7HSA
(6) Check the sealing washer and replace with a
new one if damaged.
(7) With the sealing washer attached thread the
spark plug in by hand to prevent cross
threading. Tighten the spark plug. TORQUE:
12-19 N-m
2.8 IDLE SPEED SETTING
(1) Inspect and adjust the idle speed after all
other engine maintenance items have been
performed and are within specifications. The
engine must be warm for accurate idle speed
inspection and adjustment.
(2) Warm up the engine for about ten minutes
and connect a tachometer.
(3) Turn the throttle stop screw as required to
obtain the specified idle speed.
IDLE SPEED: 1700 ± 100 rpm

11
2.9 DRIVE CHAIN ADJUSTMENT
Stop ATV and shift transmission into neutral.
Inspect the chain slack midway between the
sprockets. The standard is 10-25 mm (5/8-1
inch).
If needed remove the chain protective cover and
adjust the chain slack.
Loosen the axle holder lock nut then adjust the
drive chain slack by turning the adjusting nut.
Tighten the axle holder lock nut.
Torque = 90N.m (65 Ft. lbs)
When the drive chain becomes very dirty, it
should be removed, cleaned and lubricated with
the specified lubricant.
Clean the drive chain with kerosene and wipe it
dry.
Inspect the drive chain for possible wear or
damage.
Replace the chain, if it is worn excessively or
damaged.
Inspect the sprocket teeth, if it has excessive
wear or damage, replace if needed.
Use a commercial chain lubricant to lubricate
the drive chain, replace and adjust the slack as
described above.

12
2.10 BRAKE SYSTEM ADJUSTMENT
Inspect the front brake lever and cable for
excessive play or other damage.
Replace or repair if necessary.
Measure the free play of the brake lever at the
end of the lever. The standard is 10~20 mm.
Adjust the free play of the front brake lever by
turning the adjuster on the brake lever assembly.
Inspect the rear brake lever and cable for
excessive play or other damage.
Replace or repair if necessary.
Measure the free play of the brake lever at the
end of the lever. The standard is 10-20 mm.
Adjust the free play of the rear brake lever by
turning the adjuster on the rear axle.
BRAKE SHOE WEAR
Front Brake
Release the front wheel and inspect the brake
lining thickness. Service Limit: 2.0mm (0.08
inch), if either lining is worn beyond the service
limit, replace both brakes shoes.
2.11 WHEELS AND TIRES

13
Inspect the tire surface for cuts, nails or other
sharp objects.
Check the tire pressure at cold tire conditions.
The standard tire pressure is 3psi.
(0.15kgf/cm2 )
2.12 STEERING SYSTEM
Check the free play of the steering shaft with the
front wheels, turned straight ahead. When there
is excessive play, inspect the tie-rod, kingpin
bushing and ball joint.
Steering shaft holder bushing
Remove the front fender.
Remove the steering shaft holder and check the
steering shaft bushing for wears or damage.
If the bushing is worn or damaged, change a
new one.
Grease the steering shaft bushing and install the
parts in the reverse order of removal.
Torque: steering shaft holder bolt: 33N.m ( 24
Ft. lbs)
2.13 TOE-IN

14
Park the vehicle on level ground with the front
wheels facing straight ahead.
Mark the centers of the tires to indicate the axle
center height.
Measure the distance between the marks.
Carefully move the vehicle back, let the wheels
turn 180° so the marks on the tires are aligned
with the axle center height.
Measure the distance between the marks.
Calculate the difference in the front and rear
measurements.
Toe-in: 5±10 mm
If the toe-in is out of standard, adjust it by
changing the length of the tie-rods equally by
turning the tie-rod while holding the ball joint.
Tighten the lock nuts.
Torque: 35-43 N.m
2.14 GEAR OIL MAINTENANCE

15
Gear oil needs to be changed every 200 hours.
There is a gear oil drain hole bolt at the rear of
the engine.
(STEP1)
Unscrew this drain hole bolt and let the dirty oil
flow out, catching the oil in a proper container
for later disposal.
(STEP2)
Reinstall the drain hole bolt an tightness.
(STEP3)
Fill with new gear oil through the oil fill hole
located on the engine case beside the gear box.
3.1 ENGINE REMOVALAND INSTALLATION

16
ENGINE SHOULD ONLY BE REMOVED IN THE CONDITIONS OF NECESSARY
REPAIRS OR ADJUSTMENT TO THE TRANSMISSION AND COMBUSTION SYSTEM
ONLY!
3.2 ENGINE REMOVAL
Remove the front, rear rack, and handle bar.
Remove the footrest.
Remove the spark plug cap from the spark plug.
Remove the exhaust muffler.
Disconnect the carburetor cable by unscrew two
screws on top of the carburetor.
Disconnect the wire connectors. There are three
connectors for carburetor auto-choke, starter
motor and generator respectively.
Remove the engine hanger bolts over the engine.
Remove the engine and air cleaner together.
3.2 ENGINE REPLACEMENT
Engine installation is essentially the reverse order
of removal.
The torque of engine hanger bolt is 30 Nm
Route the wires and cable properly in reverse
order of removal.
4. LUBRICATION

17
4.1 Service Information
4.2 Trouble Shooting
4.3 Engine Oil Level
4.4 Engine Oil & Filter Change
4.5 Oil Pump Removal /Installation
4.1 SERVICE INFORMATION
GENERAL
This section describes inspection and replacement of the engine oil, oil filter screen and
assembly of the oil pump.
Fill the oil pump with clean oil when reassembling the pump.
SPECIFICATIONS
Engine Oil Capacity 0.8-1.0 Liters /
Engine Oil Recommendations Viscosity: (SAE 15W-40)
API Service classification: SF-SG
OIL PUMP STANDARD SERVIC LIMIT

18
Cover-to-rotor clearance --------- 0.12
Rotor tip clearance -------- 0.12
End clearance 0.01-0.10 0.2
TORQUE VALUE
Oil Drain Bolt 20~30 N.m (14.8~22.1 lbs.ft)
4.2 THROTTLE SHOOTING
Oil level too low / high oil consumption
Normal oil consumption.
External oil leaks.
Oil not changed often enough.
Worn piston rings.
Faulty heat gasket.
Oil contamination
Worn piston rings.
Faulty heat gasket.
Oil or filter not changed often enough.
4.3 ENGINE OIL LEVEL
Place the engine on the level plane.
Check the oil level with the oil level gauge,
but do not screw it in when making this
check.
4.3 ENGINE OIL LEVEL

19
Add the recommended oil up to the upper
level if the oil level is below or near lower
level line on the gauge.
4.4 ENGINE OIL & FILTER CHANGE
Remove the oil filter cap and the oil drain bolt.
NOTE: drain the oil while the engine is warm to
ensure complete draining.
Remove the oil filter cap, spring and oil filter
screen.
Check the O-ring for damage or fatigue.
Install a new oil filter screen and spring then
install the cap.
Install the oil drain bolt with sealing washer.
UPPER LEVEL
OIL DRAIN
SPRING
O-RING
OIL FILTER
OIL FILTER SCREEN
LOWER LEVEL