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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CHAPTER 1
GENERAL INFORMATION

2
GENERAL INFORMATION
Motorcycle identification
Frame identification
The number is stamped on the front tube of frame.
The frame number is make up of 3 parts, the first part
3 ones is the code of manufacturer(WMI); The
second part (6 ones) is the direction code of motor-
cycle (VDS) the third part (8 ones) is the inspecting
position. (VIS).
Engine Ser. No
The No.s of engines stamped on the crankcase.
There will be no further notice if the design or rule is
changed.
Note
Engine No.
JS154FMI/JYM154FMI 00000001

GENERAL INFORMATION
3
ImportantInformation
Importantinformationtoensuresafeandhigh
active work
(1)Motorcycle wash
Clear out the frame and engine to prevent the entry of
dust
(2)No smoking
Keep out fire from replacement position .
(3)Choose right tools
Use only the appropriate special tools will help pre-
vent damage caused by the use of inappropriate tools
or improvised techniques.
Use appropriate tools and metro logic instrument
for replacement.
Use double offset ring spanner and socket key in-
stead of non-adjustable wrench.
(4)Use authentic replacement parts
Use only genuine Jianshe Group parts for all re
placements. Use oil and grease recommended by
Jianshe Group for all lubrication jobs. Do not use Other
Brands' re-placement parts.
(5)Wearing parts must usually replaced (marked with
)
Replace all gaskets, oil seals , cotter pin ,circlip and
O-rings.

4
GENERAL INFORMATION
(6)Safe operation
Be careful in operation to avoid accident or get a
burn by the engine, exhaust pipe and silencer..
Always think of the right tools, right ways, right
fixture and the right position to ensure body's steady.
(7)The operation should be broken down in order and
the taken apart parts should be sort out in time.
Unscrew: from offside to inside on a cross by 2 or
3 times.
Check and measure the important parts while
breaking down, and keep the records for reference
The disassemble parts should be put in order to
prevent mix and loss.
The parts of the engine transmission must be
cleaned by oil and dried by compressed air after
knocked down.
(8)Defer to each part to confirm while assembling.
Screw down: from inside to offside on a cross by 2 or
3 times.
Defer to each part's correct results and the data
before broken down during the operation.
Do not let dust sticks on various components in
assembly
Smear motor oil on rotary and sliding parts (smear
grease on oil seal and O-rings). Make sure to follow
the screw moment method.
Two persons should cooperation perfectly when
work in with each other.
(9)Maintenance manual and parts catalog is necessary
Maintenance manual and parts catalog is necessary.
For efficiently, reliable and safe operation.

GENERAL INFORMATION
5
Gaskets Oil seal and O-rings
1. Replace all gaskets, oil seals and O-rings when
overhauling the engine. All gasket surfaces, oil seal
lips and o-rings surface must be cleaned.
2. Properly oil all mating parts and bearings during
reassembly. Apply grease to the oil seal lips.
Caution
Lock washer/plates and cotter pins
1.Replace all lock washer/plates and cutler pins after
removal. Bend lock tabs along the bolt or nut flats
after the bolt or nut has been tightened to specification.
Bearings and oil seals
Install bearings and oil seals so that the manufactures
marks of numbers are visible. When in-stalling oil
seals, apply a light coating of lightweight lithium base
grease to the seal lips. Oil bearings liberally when
installing, if appropriate.
Circlips
Check all circlips carefully before reassembly. Al-
ways replace piston pinclips after one use.
Replace distorted circlips, when installing a circlip
make sure that the sharp edged corner is positioned
opposite the thrust it receives view. Shafe.
Do not use compressed air to spin the bearings dry.
This will damage the bearing surfaces.

6
GENERAL INFORMATION
Special tools
The proper special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriates
special tools will help prevent damage caused by the use of inappropriate tools or improvised techniques.
Slide hammer bolt
Weight
DrawingSpecial tools name
Crankcase separating tool
Crankshaft installer set
Crankshaft installer bolt
Joint of different diameter tide
Spacer
Crankshaft installer tool
Shock absorber lever yoke
Handle
Antic kid tool
Valveadjusting tools
Liquid meter
Fuel level gauge
Rotor strip down tools
Front fork gasket press tool
Front fork gasket press tool attachment
Strip down rotor tools
Front fork gasket press tool

GENERAL INFORMATION
7
Turning and exhaust pipe wrench
Turning wrench
Magneto rotor holder
Clearance ruler
Cylinder compression gauge
Pocket tester
Inductive techometer
Valve spring compressor
Universal clutch holder
Ignition checker
DrawingSpecial tools name

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CHAPTER 2
SPECIFICATIONS

10
SPECIFICATIONS
General specifications
SAE 20W-40
SAE 10W-30