Baotian BT125T-2 User manual

BT125T-2
SERVICE MANUAL
JIANGMEN SINO-HONGKONG BAOTIAN MOTORCYCLE INDUSTRIAL CO., LTD

CONTENTS
CHAPTER ONE MAINTENANCE OF THE MOTORCYCLE
Ⅰ. ITEMSOFMAINTENANCE 1
Ⅱ. PERIODIC MAINTENANCE SCHEDULEAND MAINTENANCE LOCATIONS 1
Ⅲ. MAINTENANCE SPECIFICATIONS 4
Ⅳ. THROTTLE ACTUATION INSPECTION 5
Ⅴ. AIRFILTERINSPECTIONANDCLEANING 6
Ⅵ. BRAKE SYSTEM INSPECTION, ADJUSTMENTAND REPLACEMENT 6
Ⅶ. FRONTAND REAR SHOCK ABSORBER INSPECTION 9
Ⅷ. FRONTWHEELANDREARWHEELINSPECTION 9
Ⅸ. STEERING STEM INSPECTION 10
CHAPTER TWO MAINTENANCE INFORMATION
Ⅰ. FRAMENUMBERANDENGINENUMBERLOCATION 11
Ⅱ. PRECAUTIONSINOPERATION 11
Ⅲ. SPECIFIEDTORQUES 12
CHAPTER THREE BODY TROUBLESHOOTING
SECTION ONE BODY COMMON TROUBLES AND TROUBLE DETECTION 14
SECTION TWO DETAILED DESCRIPTIONS OF BODY PARTS TROUBLES
Ⅰ. FRONTWHEELSERVICE 17
Ⅱ. FRONTBRAKESERVICE(DISKBRAKE) 19
Ⅲ. FRONTSHOCKABSORBERSERVICE 21
Ⅳ. FRONTFORKSERVICE 22
Ⅴ. HANDLEBARSERVICE 24
Ⅵ. REARWHEELSERVICE 25
Ⅶ. REARBRAKESERVICE(DISKBRAKE) 27
Ⅷ. REARSHOCKABSORBERSERVICE 27
CHAPTER FOUR ELECTRIC PART TROUBLESHOOTING
SECTION ONE ELECTRIC PARTCOMMON TROUBLESAND TROUBLE DETECTION 28
SECTION TWO DETAILED DESCRIPTIONS OF ELECTRICASSEMBLIESAND PARTS SERVICE
Ⅰ. PRECAUTIONSINELECTRICCIRCUITSERVICE 31
Ⅱ. POWERCHARGINGSYSTEMSERVICE 31
Ⅲ. IGNITIONSYSTEMSERVICE 37
Ⅳ. ELECTRICSTARTINGSYSTEMSERVICE 43
Ⅴ. LIGHTINGANDSIGNALSYSTEMSERVICE 44

CHAPTER ONE MAINTENANCE OF THE MOTORCYCLE
Ⅰ. ITEMS OF MAINTENANCE
When the motorcycle is used, loosening of parts and mechanical wear inevitably occur to
varied extents. Neglect of timely maintenance not only reduces its mechanical function,
economic performance, stability and durability, but also threatens the safety of the motorcycle
and the rider. Correct and timely maintenance of the motorcycle is a must. Items of maintenance
refer to the parts and positions for maintenance. Different items of maintenance are effected at
different intervals and in different manners.
1. Running-in Maintenance
This is the maintenance at the end of the first 1000km and is an all-round inspection of the
motorcycle. A newly-bought motorcycle or a motorcycle fresh from an overhaul might be
severely overheated as a result of severe friction between the moving parts which might be
imperfect in finishing or fitting. Neglect in use might lead to damage of the friction surfaces and
might threaten the performance, and the service life, of the motorcycle. Please observe the
following points:
zRestrict the speed in speed range specified in the instruction manual.
zRestrict the load to 2/3 of the maximum load and ride in fairly good road conditions.
zRestrict the length of riding time to avoid long-time running of the engine.
zReplace engine oil at short intervals so that metal chips caused in the running-in period
can be discharged. It is recommended to replace engine oil for 3 times during the
running-in period.
2. Routine Maintenance
Routine maintenance is the basis of all kinds of maintenances. It refers to the daily
maintenance, including cleaning, inspection and common troubleshooting.
3. Periodic Maintenance
This maintenance is to restore normal performance of the motorcycle. The maintenance is
classified into first-grade periodic technical maintenance and second-grade periodic technical
maintenance (also known as items of maintenance) according to different mileages. Generally
speaking, a first-grade maintenance is effected after the initial 4000km and a second-grade
maintenance is effected every 8000km. As the service time extends, maintenance intervals
should be shortened accordingly.
Ⅱ. PERIODIC MAINTENANCE SCHEDULE AND MAINTENANCE LOCATIONS
After a period of use (one day, one month or half a year, for example) or a certain mileage
(1000km, 4000km, 8000km, for example), an all-round maintenance operation should be
effected, including comprehensive inspection, adjustment, tightening, lubrication, cleaning or
replacement. The specific regulation made according to time intervals or mileages is known as
maintenance interval. The motorcycle maintenance schedule is as follows.
1

1. Maintenance Schedule
Maintenance Schedule
time
item Mileage 1000km
1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000
New R
Engine oil R R R R R R R R R R R
300km
Engine oil
strainer C C
Gasoline
strainer R
New R
Gear oil Note 4 R R
300km
Throttle play A A A A
Carburetor I I C
Note 3,
4
Air filter I R R
Spark plug Clean every 3000km, replace when necessary
Brake system I I I I I I I I I I I I
Drive belt I
Suspension I I I
Tire I I I
Steering rod
bearing I I I
Screws and
bolts of parts I I
Notes:
1. I: Inspect and when necessary, clean, lubricate, supplement, modify or replace;
A: adjust; C: clean; R: replace; T: tighten.
2. Effect periodic maintenance according to the instructions in the user’s manual.
3. When the mileage exceeds the range specified in the schedule, repeat the maintenance.
4. In dusty or rainy conditions, inspection and replacement should be effected earlier.
5. In heavy load, long distance or rainy conditions, replacement should be effected earlier.
2

2. Maintenance locations
Throttle grip
actuation,play
£¨£©
Oiltank
brakeoillevel
£¨£©
Frontshock absorber
damage,loosening
£¨£
©
Frontrim
damage,oscillation
£¨£©
Fronttire
wear,damage,tirepressure
£¨£
©
Headlight
beam adjustment
£¨£©
Rearshockabsorber
damage,loosening
£¨£©
Airfilter
contamination
£¨£©
Rearbrakedisc
damage,wear
£¨£©
Rear brakecaliper
wearofbrakeblock
£¨£©
Gearcase
engineoilquantity,
oilreplacement
£¨ £©
Sparkplug
damage,contamination
£¨£©
Frontbrakedisc
damage,wear
£¨£©
Frontbrakecaliper
wearofbrakeblock
£¨£©
Rear rim
damage,oscillation
£¨£©
Reartire
wear,damage,tirepressure
£¨£©
Oiltank
brakeoillevel
£¨£©
3

Ⅲ. MAINTENANCE SPECIFICATIONS
The basic methods of motorcycle maintenance include inspection, adjustment, tightening,
lubrication, cleaning, supplementing and replacement, which constitute the main elements of
maintenance.
1. Inspection
Inspection refers to basic inspecting operations in accordance with items and
requirements specified in the user’s manual, including inspection with instruments or
with eyes for abnormalities in machine parts, directly comparing related data and
aligning with tools and gauges.
2. Adjustment
Adjustment refers to inspection-based adjustment and rectification of some specified
machine parts, including adjustment of machine part plays and rectification of
misfittings and deformations so as to restore correct positions, forms and plays.
3. Tightening
Tightening refers tightening of bolts, screws and nuts of machine parts with tools so as
to avoid loosening of machine parts and to obtain specified tightening torques.
4. Cleaning
Cleaning is needed by machine parts and positions which call for cleanliness and
tidiness. Cleaning operations include all the means and measures taken to remove dust,
contamination, metal chips, oily stains and carbon deposits that might lead to pipe
clogging or reduction in motorcycle performance. Cleaning measures are washing,
carbon deposit removing, rubbing, cleaning and clearing.
5. Lubrication
In order to facilitate smooth and easy running of moving machine parts, including
swinging parts, reciprocating parts, sliding parts and vibrating parts, to reduce scuffing,
abrasion, deformation and to reduce friction, it is necessary to coat or spray these parts
with a lubricant. Different lubricants and lubricating methods are required for different
machine parts with different functions. Application of lubricants to machine parts is
known as lubrication.
6. Replenishing, supplement and replacement
These operations refer to addition of oil, lubricants, cooling water, electrolyte, fuel and
replacement of damaged parts with new ones and replacement of denatured oils with
new oils.
4

IV. THROTTLE ACTUATION INSPECTION
Inspect throttle grip for easy and smooth
movement.
Inspect throttle free travel.
Free travel: 2-6mm
The main adjusting position is beside the
carburetor.
Remove rear store case cover.
Adjust by loosening the fastening nut and
turning the adjusting nut.
Fine adjustment is effected on the side of
the throttle grip.
Effected adjustment is by removing the dust
cover, loosening the tightening nut and turning
the adjusting nut.
adjusting nut
dust cover
tightening nut
free travel:2-6mm
adjusting nut
tightening nut
5

Ⅴ. AIR FILTER INSPECTION AND CLEANING
After a certain mileage, dust and impurities will gather in air filter case and strainer, which
will clog strainer pores and reduce inlet of air and thus lead to excessive concentration of mixed
gas and reduce the performance of engine. That’s why the strainer must be replaced every
20000km and in dusty or rainy conditions strainer must be replaced earlier.
Air Filter Strainer Inspection and Replacement:
Remove 7 screws of air filter.
Remove air filter strainer cover.
Remove 2 tightening screws of air filter
strainer.
Take out air filter strainer.
Inspect the strainer if there is any dust and
damage in it.
Replace it in case of dirty or damage.
zDon’t use water or any oil cleanser to
clean it.
zThe papery air filter strainer cannot be
cleaned by air because it is oil based.
Mount strainer.
Mount strainer cover.
Ⅵ. BRAKE SYSTEM INSPECTION, ADJUSTMENTAND REPLACEMENT
1. Front Brake (disk brake)
Remove the bolts linking brake caliper and
front shock absorber.
Remove brake caliper.
brake caliper
bolt
front shock
bolt
absorber
air filter strainer screws
strainer cover
screws
6

* Do not pull brake lever when brake caliper is
removed so as to prevent jamming of brake
block.
If brake block is jammed, pry it with screwdriver
and push piston back into caliper.
Brake Block Replacement:
Brake block must be replaced when it is worn
to the limit of use.
* It is not necessary to remove brake oil pipe
when replacing brake block.
* Brake block must be replaced as a set.
Remove two pieces of brake block pins by
means of a hexagon wrench.
brake block
brake caliper
Effect mounting in an order reversed to that of
dismounting.
*After effecting, first tighten the brake caliper
and put its hole right to the hole of brake caliper
and then put the brake block pin in and tighten it.
Brake Disc Inspection:
Inspect brake disc thickness.
Limit of use: 3.0mm
Inspect brake disc angularity.
Limit of use: 0.3mm
brake block pin
brake block pin
press brake block
7

2. Rear Brake (disk brake)
Remove the bolts linking brake caliper and
rear brake mounting board.
Remove brake caliper.
* Do not pull brake lever when brake caliper is
removed so as to prevent jamming of brake
block.
If brake block is jammed, pry it with screwdriver
and push piston back into caliper.
Brake Block Replacement:
Brake block must be replaced when it is worn
to the limit of use.
* It is not necessary to remove brake oil pipe
when replacing brake block.
* Brake block must be replaced as a set.
The method of replace the rear brake block is
the same as the front brake block'.
Brake Disc Inspection:
Inspect brake disc thickness.
Limit of use: 3.0mm
Inspect brake disc angularity.
Limit of use: 0.3mm
rear brake
caliper
brake disc
mounting bolts
mounting board
rear brake
8

Ⅶ. FRONTAND REAR SHOCK ABSORBER INSPECTION
1. Front ShockAbsorber
Tighten front brake lever, press front shock
absorber up and down and inspect actuation.
Inspect front shock absorber to see if there is
leakage of oil and if there is damage or loosening.
2. Rear ShockAbsorber
Press rear shock absorber to inspect
actuation. Inspect rear shock absorber to see if
there is oil leakage and if there is damage or
loosening in machine parts.
Lift rear wheel, press rear wheel right and
left to inspect if engine suspension lug buffer
bush is loose.
Ⅷ. FRONT WHEELAND REAR WHEEL INSPECTION
Wheel Rim Inspection:
Inspect wheel rim, remove rust stains and rubber chips.
Deformation and fissures are causes of air leakage. Do not use wheel rims in the following
cases:
Bruise of wheel rim face contacting tire bead ring exceeds 0.5mm in depth and 1.0mm in
width.
Tire Inspection:
Inspect if there is fissure or iron nail in the tire.
In one of the following conditions, tires must be replaced instead of repair.
zPuncture of tire by a foreigner matter 6mm in diameter or tire fissure.
zLayered tire.
front brake lever
zChunking of tread
zDamaged tire bead
zBroken tire bead or other tire bead damages
zBroken tire cord
9

zDamage due to forced dismounting
zFissure extending to frame
zAbnormal inner lining
zTire groove wear: front wheel <0.8mm, rear wheel < 0.8mm.
zPunctured or otherwise damaged tire flank
Inspect tire pressure by means of a tire pressure gauge
* Tire pressure should be inspected when the motorcycle is in a cold state.
Specified pressure Unit: kPa
Front wheel 250
Rear wheel 250
Tire Specifications:
Front wheel 120/70-12 56J
Rear wheel 110/90-12 64J
Inspect if front wheel nut is loose.
Inspect if rear wheel nut is loose.
If loose, tighten them to specified torques.
Torques: front wheel nut 60N·m
rear wheel nut 120N·m
Ⅸ. STEERING STEM INSPECTION
Swing handlebar right and left to see if there
is interference such as wire or other things.
Turn front wheel to see that handlebar is easy
in operation.
In case of any difficulty in operation, inspect
steering stem bearing assembly.
front axle nut
rear axle nut
10

CHAPTER TWO MAINTENANCE INFORMATION
I. FRAME NUMBER AND ENGINE NUMBER LOCATION
II. PRECAUTIONS IN OPERATION
zRemoved washers, 0-rings, elastic retaining rings and split pins must be replaced with
new ones.
zWhen mounting bolts, nuts and screws, proceed from trial tightening, from larger
diameters to smaller diameters and inner ones to outer ones in a diagonally order. Tighten
them to specific torques.
zParts and greases must be those made by our factory or recommended by our factory.
zSpecial operations must be effected with special tools or specified universal tools.
zRemoved parts must be rubbed or cleaned before they are inspected or measured. They
must be coated on the sliding faces before mounting.
zThey must be greased at the specified positions with designated or equivalent greases.
zParts must be tightened and their performances inspected at their positions when
mounted.
zThe battery’s negative terminal must be disconnected before operation.
Make sure that tools such as wrenches are not in contact with the frame.
zAt the completion of operations, reconfirm correct connections and fastenings.
The positive terminal must be connected first in case of a removed battery.
Connected terminals must be coated with lubricant.
The terminals must be completely covered with caps.
zWhen a fuse is burnt, inspect the cause and replace the fuse with a fuse of equivalent
capacity.
zAt the completion of operation, completely cover terminals with caps.
zWhen removing connectors with locks, they must be unlocked before operation.
zWhen removing connectors, the connectors proper must be held instead of pulling their
wires.
engine number
Frame
Number
11

zBefore connecting connectors, confirm that they are free from breakage, bending, over
length or loosening.
zConnectors must be inserted home.
When connecting connectors with locks, confirm that their locks are fastened.
Confirm that the wires are not loose.
zConfirm that connectors’ plastic sleeves completely cover the connectors without fail.
zBefore connecting the connectors, confirm that their sleeves are free from breakage and
their terminals are not oversized.
zConnector plugs must be fully inserted.
Confirm that plastic sleeves completely cover the terminals.
Plastic sleeves should not be placed with the open side up.
zWire bunch bands should be fixed at the specified position of motorcycle frame.
zWire clamps must correctly keep wires in place.
Avoid welding stains of welded clamps when clamping wires.
zWire bunches must be fixed away from turning or moving parts.
zDo not damage the covering of wire bunches.
In case of wire bunch defects, remedy it with insulating bands.
zWire bunches must not be covered with mounted parts.
zDo not twist or bend cables by force. Deformed or damaged cables would result in poor
rotation or damage.
III. SPECIFIED TORQUES
Torques at important positions and standard torques of other positions are as follows:
12

SPECIFIED TORQUES
Frame:
Designations of tightening positions Number Thread specification Torques: N·m
Engine suspension lug mounting nut 1 M10 45
Engine mounting nut 1 M10 45
Front axle nut 1 M12 60
Rear axle nut 1 M16 120
Rear shock absorber upper mounting bolt 1 M10 40
Rear shock absorber lower mounting bolt 1 M10 25
Front shock absorber upper lock bolt 4 M8 35
Steering stem lock nut 1 M25 70
Handlebar mounting nut 1 M10 45
Upper bearing top 1 M25 2.5
Exhaust muffler connector nut 2 M6 12
Exhaust muffler mounting bolt 2 M8 35
Standard Torques:
Designations Torques: N·m
Bolt, nut M5 5
Bolt, nut M6 10
Bolt, nutM8 21.5
Bolt, nut M10 35
Bolt, nut M12 55
Screw M5 4
Screw M6 9
Flange bolt, nut M6 12
Flange bolt, nut M8 27
Flange bolt, nut M10 40
13

CHAPTER THREE BODY TROUBLESHOOTING
SECTION ONE BODY COMMON TROUBLES AND TROUBLE DETECTION
Body part common troubles and possible causes are as follows:
Troubles Causes Details (reference)
Over tightening of handlebar adjusting nut
Handlebar rotation not
easy (strenuous turning
or unstable tightness)
Refer to “Front Fork
Service”
Steering stem over worn
Incorrect mounting of brake cable or
tachometer cable Refer to “Handlebar
Service”, “Front Fork
Service”
Remarkable deformation of steering stem
due to outside impact
Over tightening of steering stem top ball
bearing retainer
Heavy steering stem
turning Refer to “Front Fork
Service”
Damaged or broken ball bearing
Refer to “Front Wheel
Service”, “Rear Wheel
Service”
Reduced tire air
Refer to “Front Shock
Absorber Service”
Imbalance of right and left shock absorbers
Refer to “Front Fork
Service”
Bent front fork
Deflected steering stem
Refer to “Front Wheel
Service”
Bent front tire, deflected tire
Bent brake lever
Air in hydraulic device
Leakage in hydraulic
device
Clogged hydraulic
passage
Inadequate liquid
Contaminated brake
block and brake disc
Refer to “Brake System
Inspection, Adjustment
and Replacement”,
“Front Brake Service”
Feeble brake
lever
Disk brake failure
Bent or deformed brake
disc
Contaminated brake
caliper
14

Chart continued
Troubles Causes Details (reference)
Worn seal ring of brake
caliper piston
Viscous or worn brake
caliper piston
Inability of brake
caliper normal sliding
Worn main cylinder
piston seal ring
Feeble brake
lever
Viscous or worn main
cylinder piston
Contaminated main
cylinder
Clogged narrow brake
system
Clogged narrow liquid
passage
Viscous worn brake
caliper
Refer to “Brake System
Inspection, Adjustment
and Replacement”,
“Front Brake Service”
Disk brake failure
Inability of brake
caliper normal sliding
Stiff brake lever
Worn seal ring of brake
caliper piston
Viscous or worn main
cylinder piston
Contaminated brake
block and brake disc
Bent or deformed brake
disc
Inability of brake
caliper normal sliding
Resisted
braking
Wheel not adjusted
straight Refer to “Front Fork
Service”
Steering stem rotation not easy
Bent shock absorber
Deviation of
motorcycle direction
(inclining to roadside) Refer to “Front Shock
Absorber Service”
Shock absorber oil leakage
15

Chart continued
Troubles Causes Details (reference)
Bent front axle, incorrect wheel
mounting
Roundness error of wheel rim
Deformation of wheel rim
Deviation of motorcycle
direction (inclining to
roadside)
Refer to “Front Wheel
Service”
Inadequate tire pressure
Deformed wheel rim
Loose front wheel bearing
Poor tire Refer to “Front Wheel
Service”
Front wheel oscillation
Poor axle locking
Refer to “Front Shock
Absorber Service”
Soft front shock absorber Spring fatigue
Deformed wheel rim Refer to “Rear Wheel
Service”
Rear wheel oscillation Poor wheel
Refer to “Rear Shock
Absorber Service”
Soft rear shock absorber Spring fatigue
16

SECTION TWO DETAILED DESCRIPTION OF BODY PARTS TROUBLES
Precautions in Operation:
zForced mounting or dismounting of body cover parts will cause damage to claws and slots
of corresponding hoods.
zWhen mounting body cover parts, be sure to align the corresponding parts of hoods.
zWhen mounting body cover parts, avoid pressing wires, cables or pipes.
-
I. FRONT WHEEL SERVICE
Front Wheel Dismounting:
Support the body bottom to lift front wheel.
Remove front axle nut, brake calipers, front
absorbers connecting bolt and remove brake
calipers, front shock absorber, transmission gear
box, front axle bush and the small bush, remove
front axle.
Remove front wheel.
Remove brake disc mounting bolts.
Remove brake disc.
front shock
transmissiongearbox
front axle nut
front axle
absorber
brake disc brake caliper
bolt
front axle
mounting bolt
front wheel
front shock
absorber
front axlebush
small front axle bush
17

Axle Bending Inspection
Place axle on a V-seat and measure with a dial
gauge.
The dial gauge indicates a 1/2 bending value.
Limit of use: Replace if >0.2mm.
Wheel Rim Oscillation Inspection
Measure oscillation value on a correcting bench.
Limit of use: Replace if >2.0mm.
Traverse direction: Replace if >2.0mm.
Front Wheel Bearing Inspection
Remove front wheel bearing and dust cover.
Turn bearing inner race to inspect sliding.
Replace it with a new one in case of no sliding or
damage or loosening of outer race.
Front Wheel Bearing Replacement
dust cover front axle bush
Dismounting: Remove front wheel bearing by
means of a bearing remover, take out spacer.
Mounting: Apply grease to the bearing.
Drive in left bearings.
18