Jianshe JS125-6B User manual

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MAINTENANCE MANUAL
NOTICE
This manual was produced by the chongqing Jianshe motorcycle co., Ltd primarily for use by Jianshe
Group dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic
in one manual, so if is assumed that anyone who uses this book to perform maintenance and repairs on
JS125-6B motorcycle has a basic understanding of the mechanical ideas and the procedures of machine
repair.Repairs attemped by anyone without this knowledge are likely to render the machine unsafe and
until for use.
Chongqing Jianshe Industries(Group)Co., Ltd is continually striving to improve all its models. Modi-
fications and significant changes in specifications or procedures will be forwarded to all authorized Jianshe
Group dealers and will appear in future editions of this manual where applicable.
IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following notations.
The Safety Alert Symbol means ATTENTION!BECOME ALERT!YOUR SAEFTY IS INVOLED!
Failure to follow WARNING instructions could result in severe injury or death to the machine operator,
a bystander or a person inspecting or repairing the machine.
A CAUTION indicates special precautions that must be taken to avoid damage to the machine.
A NOTE provides key information to make procedures easier or clearer.
Maintenance manual of four-wheeled cross-
country vehicle model JS125-6B
First edition July 2007
This manual is published by Jianshe Industries Co., Ltd (Group)
publishing factory. Jianshe Industries Co., Ltd (Group) maintains the
copyright of publishing. Without permitted, publishing is prohibited.

1 Special tool
2 Tighten
3 Filling electrolyte
4 Wear limit, clearance
5 Engine speed
6 Tester
7 Apply engine oil
8 Apply gear oil
9 Apply molybdenum disulfide oil
10 Apply wheel bearing grease
11 Apply lightweight lithium-soap base grease
12 Apply molybdenum disulfide grease
13 Apply fluid locking agent
14 Install a new part
ILLUSTRATED SYMBOLS
COLOR INDICATIONS
123
456
789
10 11 12
13 14

CONTENT
CHAPTER 1 GENERAL INFORMATION
Motorcycleidentification ............................................................................................................. 2
ImportantInformation.................................................................................................................. 3
Specialtools ............................................................................................................................... 6
CHAPTER 2 SPECIFICATIONS
Generalspecifications ................................................................................................................ 10
ChecktheSpecification ............................................................................................................. 13
Lock torque .............................................................................................................................. 18
Lubricationpointandtypeoflubricants ...................................................................................... 21
Enginelubricationflow............................................................................................................... 23
CHAPTER 3 PERIODIC INSPECTION AND ADJUSTMENT
Introduction .............................................................................................................................. 26
Periodicmaintenance/lubrication ................................................................................................ 26
Disassembleandinstallthe seat cushion, oil tank andcovertypes ............................................... 28
Checkand adjust valve clearance .............................................................................................. 30
Adjustidlespeed ...................................................................................................................... 32
Check/adjustthe free play ofthe throttle cable ........................................................................... 33
Check the spark plug ................................................................................................................ 34
Inspectcompression pressure .................................................................................................... 35
Checkengineoil........................................................................................................................ 36
Replaceengineoil ..................................................................................................................... 37

Adjustclutch ............................................................................................................................. 38
Cleantheair cleaner .................................................................................................................. 39
Adjustfrontbrake ..................................................................................................................... 40
Check front brake shoes ........................................................................................................... 41
Check front brake (disk) ........................................................................................................... 42
Checkbrakelining .................................................................................................................... 42
Checktheamountofbrakefluid ................................................................................................ 42
Exhaust ..................................................................................................................................... 43
Replacebrakefluid ................................................................................................................... 44
Check and adjust the rear brake ................................................................................................ 45
Check the rear brake shoes ....................................................................................................... 45
Check the rear brake switch ...................................................................................................... 45
Checkand adjust thedrive chain ............................................................................................... 46
Checkfrontfork ....................................................................................................................... 47
Adjust rear shock absorber ....................................................................................................... 47
CheckTire ................................................................................................................................48
Checksteeringdevice ............................................................................................................... 49
Check battery ........................................................................................................................... 50
CHAPTER 4 ENGINE
Disassemble the engine ................................................................................................ 54
Readytodisassembletheengine ............................................................................................ 54
Disassembletheengine .......................................................................................................... 55
Disconnect the engine .................................................................................................. 56
Cylinderhead,cylinderandpiston.......................................................................................... 56
Left crankcase cover and starter motor .................................................................................. 58
Clutchandoilpump............................................................................................................... 59

Oilpump ............................................................................................................................... 61
Startingshaftandidlegear ..................................................................................................... 61
Shiftshaft .............................................................................................................................. 62
Rotor .................................................................................................................................... 62
Crankcase............................................................................................................................. 63
Balancingdevice,transmissionandshiftingrod ....................................................................... 63
Crankshaftandcounterbalance .............................................................................................. 64
Rockerarmandcamshaft ...................................................................................................... 64
Valve ..................................................................................................................................... 65
Check and repair ........................................................................................................... 66
Cylinderhead ........................................................................................................................ 66
Valveseat.............................................................................................................................. 67
Valveandvalveguide ............................................................................................................ 69
Valve spring.......................................................................................................................... 70
Camshaft............................................................................................................................... 70
Rocker arm and rocker arm shaft........................................................................................... 71
Timingchain,sprocket,chainguideplateandchaintensioner .................................................. 72
Cylinderandpiston................................................................................................................ 73
Pistonpin .............................................................................................................................. 74
Pistonring ............................................................................................................................. 75
Crankshaft ............................................................................................................................ 76
Balancingdevice.................................................................................................................... 77
Cultch ................................................................................................................................... 77
Transmissionandshiftlever .................................................................................................... 79
Kick starter ........................................................................................................................... 80
Oilpumpandoilfilter ............................................................................................................ 81
Crankcase............................................................................................................................. 82

Bearingandoilseal................................................................................................................ 82
Circlipandwasher................................................................................................................. 82
Engine assembly and adjustment................................................................................... 83
Valve,rockerarmandcamshaft ............................................................................................ 83
Crankshaftand bala nce device.............................................................................................. 86
Transmission.......................................................................................................................... 88
Gearshiftcam and fork ......................................................................................................... 89
Crankcase............................................................................................................................. 92
Shift shaft,kick starter axleand kick starteridle gear .............................................................. 94
Clutch,oilpump .................................................................................................................... 97
Timingsystem ...................................................................................................................... 102
Cylinderandpiston.............................................................................................................. 106
Cylinderhead ...................................................................................................................... 107
Camshaftand dowel pin ..................................................................................................... 108
Intake and exhaust system ........................................................................................... 109
Carburetor .......................................................................................................................... 109
Intake,exhaustsystem ......................................................................................................... 114
CHAPTER 5 CHASSIS
Frontwheel............................................................................................................................. 116
Front brake............................................................................................................................. 117
Rearwheel.............................................................................................................................. 124
Rear brake.............................................................................................................................. 125
Divingchain ............................................................................................................................ 128
Frontfork ............................................................................................................................... 132
Steeringseatand handlebar ..................................................................................................... 139
Rear shock absorber and rear arm........................................................................................... 146

CHAPTER 6 CABLE AND ELECTRIC APPLIANCE SYSTEM
Cable/harnesswire/tubediagram ............................................................................................ 150
Electricdeviceprinciple ........................................................................................................... 158
Electricappliance .................................................................................................................... 159
Componentsofelectricappliance ............................................................................................ 161
Ignitionsystemdiagram ........................................................................................................... 165
Starting motor ........................................................................................................................ 174
Chargingsystem ...................................................................................................................... 178
Lighting system....................................................................................................................... 181
Signalsystem .......................................................................................................................... 186
CHAPTER 7 TROUBLESHOOTING
ElectricApplianceSystem ....................................................................................................... 196
CompressionSystem............................................................................................................... 197
Intake\ExhaustSystem ........................................................................................................... 198

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