Generic TR 125 User manual

Service Manual

Holtvej 8-10, Høruphav, 6470 Sydals

Telefon: +45 73 15 11 00

Fax: +45 73 15 11 01

E-mail: [email protected] · www.scanmi.dk

CVR: 27 73 31 07

Maj 2013

TR 125

Two-wheel Motorcycle QJ125GY-16A

Instruction and Maintenance Manual

ZHEJIANG QIANJIANG MOTORCYCLE CO., LTD.

Contents

Preface ·································································································· - 1 -

Preparatory Data ······················································································· - 2 -

Inspection/Adjustment ··············································································· - 15 -

Check and Maintenance of Body ··································································· - 32 -

I Braking System ···················································································· - 34 -

1.1 Maintenance Instruction········································································· - 34 -

1.2 Fault diagnosis···················································································· - 35 -

1.3 Front Hydraulic Brake··········································································· - 36 -

1.4 Back liquid brake················································································· - 38 -

II Vehicle Housing ··················································································· - 42 -

III Front Wheel/Front Suspension ······························································· - 45 -

3.1 Preparatory Data ················································································· - 45 -

3.2 Fault diagnosis···················································································· - 45 -

3.3 Front wheel ······················································································· - 47 -

3.4 Direction handle·················································································· - 49 -

3.5 Front fork··························································································- 49 -

IV Rear Wheel/Rear Suspension ································································· - 54 -

4.1 Preparatory Data ················································································· - 54 -

4.2 Fault Diagnosis ··················································································· - 55 -

4.3 Rear wheel ························································································ - 56 -

4.4 Rear Shock Absorber ············································································ - 57 -

4.5 Rear Swing Arm·················································································· - 58 -

4.6 Drive Chain ······················································································· - 59 -

V Storage Battery/Charging System ····························································· - 62 -

5.1 Preparatory Data ················································································· - 62 -

5.2 Fault Diagnosis ··················································································· - 63 -

5.3 Storage Battery ··················································································· - 64 -

5.4 Charging System ················································································· - 65 -

5.5 Voltage-current Regulator······································································· - 66 -

5.6 Alternator Charging Coil ········································································ - 67 -

5.7 alternator light coil ··············································································· - 67 -

5.8 disassembly of alternator········································································ - 68 -

VI Ignition System··················································································· - 71 -

6.1 Preparatory Data ················································································· - 71 -

6.2 Fault Diagnosis ··················································································· - 72 -

6.3 Ignition System Inspection······································································ - 73 -

6.4 CDI Assembly ···················································································· - 75 -

6.5 Ignition Coil ······················································································ - 75 -

6.6 Trigger ····························································································· - 76 -

VII Starting System ················································································· - 78 -

7.1 Preparatory Data ················································································· - 78 -

7.2 Fault Diagnosis ··················································································· - 79 -

7.3 Starting Motor ···················································································· - 79 -

7.4 Starting Relay····················································································· - 81 -

VIII Bulbs/Switches/Instruments································································· - 82 -

8.1 Preparatory Data ················································································· - 82 -

8.2 Fault Diagnosis ··················································································· - 82 -

8.3 Headlamp Bulb Replacement··································································· - 83 -

8.4 Front Turn Signal Lamp Bulb Replacement ·················································· - 84 -

8.5 Taillight/license plate lamp/rear turn-lamp bulb replacement ······························ - 84 -

8.6 Instrument························································································· - 85 -

8.7 Main Switch ······················································································ - 85 -

8.8 Horn································································································ - 86 -

8.9 Handle switch····················································································· - 86 -

Engine Inspection and Maintenance ······························································· - 87 -

IX Lubricating System ············································································· - 89 -

9.1 Preparatory Data ················································································· - 89 -

9.2 Fault Diagnosis ··················································································· - 89 -

9.3 Oil Pump ·························································································· - 90 -

X Cooling system ···················································································· - 93 -

10.1 Preparatory data················································································· - 93 -

10.2 Fault diagnosis ·················································································· - 93 -

10.3 Water pump······················································································ - 94 -

XI Cylinder Head···················································································· - 97 -

11.1 Preparatory Data ················································································ - 97 -

11.2 Fault Diagnosis·················································································· - 98 -

11.3 Cylinder Head ··················································································· - 98 -

XII Cylinder Block and Piston·································································· - 107 -

12.1 Preparatory Data ·············································································· - 107 -

12.2 Fault Diagnosis ··············································································· - 108 -

12.3 Cylinder Head················································································· - 108 -

XIII Crankcase······················································································- 113 -

13.1 Preparatory Data ···············································································- 113 -

13.2 Fault Diagnosis ················································································- 114 -

13.3 Crankcase ·······················································································- 115 -

13.4 Clutch ···························································································- 116 -

13.5 Gearshift mechanism········································································· - 121 -

13.6 Crankcase connecting rod combination···················································· - 122 -

13.7 Variable speed chamber······································································ - 125 -

Exhaust System Inspection and Maintenance·················································· - 128 -

XV Emission Control System ··································································· - 129 -

15.1 Emission Control System Guarantee······················································· - 129 -

15.2 Regular maintenance guidelines ···························································· - 129 -

15.3 Emission Control System Mechanical Functions········································· - 130 -

15.4 Catalyst conversion system·································································· - 131 -

15.5 Solutions to Idle Exhaust Exceeding Specified Value ··································· - 132 -

Inspection and Maintenance of EFI System ···················································· - 133 -

XVI EFI System Description ···································································· - 134 -

16.1 Introduction to EFI System of finished enginecycle ····································· - 134 -

16.2 EFI system parts ·············································································· - 134 -

16.3 Troubleshooting diagnosis··································································· - 146 -

16.4 Common troubleshooting···································································· - 153 -

16.4.3 Concise troubleshooting ··································································· - 154 -

QJ125GY-16A circuit diagram ············································································i

- 1 -

Preface

The Instruction and Maintenance Manual contains an introductory description of

maintenance on QJ125GY-16A motorcycle.

Preparatory data include attentions that shall be paid on all the maintenance

operations in the Instruction and Maintenance Manual. Please read the manual

carefully before operation.

Check and adjustment contains main aspects for inspection and adjustment, safety

of the vehicle, performance and maintenance of each 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 vehicle, engine and other

components.

System diagrams, breakdown drawings, fault diagnosis, maintenance and other

explanatory contents are presented before each part.

Note:

The parts which are not explained separately in the manual apply to both of the

motorcycles.

For any pattern and structure change of the motorcycle, or any difference between

the product and pictures, drawings and instructions in the manual, the product shall

prevail. The product is subject to changes without prior personal notice.

- 2 -

ZHEJIANG QIANJIANG MOTORCYCLE CO., LTD.

Finished Automobile Institute

Preparatory Data

General Safety Maintenance Rules

Specification Table Fault Diagnosis

General Safety

Carbon monoxide (CO)

When it is necessary to start the engine, please make sure the operation area is well ventilated. Never run the

engine in an enclosed place.

Attention

Gas exhausted from the motorcycle contains harmful carbon monoxide, which may lead to loss of

consciousness and death.

It is necessary to run the engine in an open area. To run the engine in an enclosed site, ventilation system shall

be used.

Gasoline

Operate in well-ventilated site. No fire or smoking is allowed in operation site and gasoline storage place.

Storage Battery

Electrolyte in the storage battery has sulfuric acid, so leave eyes、skin and clothes away from it. Once got

electrolyte on our skin or clothes, you will have to wash them by fresh water thoroughly; once into our eyes, to

see a doctor immediately is necessary.

Special Tool

- 3 -

When disassembly and installation is in process, general tools and special tools should be selected correctly.

When it is time to use the special, the general can not be substitution. Besides, appropriate power is welcomed

to avoid the damage of components.

High Temperature Burn

Tips: Do not be burned by engine, exhaust pipe,silencer and other components with high temperature. When

operating together with others, you’d better look after each other and keep a way for safety.

- 4 -

Maintenance Rules

While repairing and servicing, use tools of metric system as possible. Incorrect tools may damage the

motorcycle.

Before taking down or opening protecting plate for repair work, please clean the dirt on the external surfaces

of components or combination parts and prevent the dirt from falling into engine, chassis or braking system

After disassembly and before measuring friction, please clean the

components and blow them with compressed air.

—Bending or Warping are forbidden in operation, otherwise tough

operation or advanced damage will be caused.

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 loose component with many assembling units, it shall start from

external to internal and loosen smaller assemblies first.

The complicated assemblies such as transmission case shall be put

in proper assembling order for easy assembly in the future.

Incorrect Incorrect

Incorrect

- 5 -

Pay special attention to the key fitting position before disassembly. The components that are not used any more

shall be replaced on time before disassembly.

Length of bolts and screws are different for assembly

components and protecting plates. They shall be installed at correct positions. If confused, just put the bolt in

the hole and see if it matches.

Fill lubricating grease into the groove during oil seal installation. Check

if the oil seal is smooth and if there is any 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 plastic dust cover back to its

originally designed position

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