Motive Power Industry PA125 User manual

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PREFACE
This manual offers all service specialists with the technological
procedures of maintenance, repairing for PA125 detailedly show
those whom may concern how to maintain, repair, change parts,
troubleshoot and reassemble, etc.
At every important section we illustrate by assembly, explosion
diagrams and photographs, if necessary, please check the diagrams
already shown.
Though we have tried our best, please kindly instruct us any
faults found in this manual.
MOTIVE POWER INDUSTRY CO., LTD.

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CONTENTS
1. The specification 4
2. Service information 5
(1)The operation notice 6
(2)Looking torque value 7
(3)Lubrication instruction 9
(4)Wiring diagram 12
(5)Troubleshooting 13
3. Checking and adjustment 19
(1)Checking table 20
(2)Battery 24
(3)Clean the air cleaner 25
(4)Oil screen 26
(5)The final reduction mechanism oil 26
(6)Spark plug 27
(7)Compression pressure measurement 27
(8)Valve clearance 28
(9)Ignition timing 28
(10)Idle Adjustment 29
(11)Front brake adjustment 29
(12)Rear brake adjustment 30
(13)Tire 30
(14)Throttle cables adjustment 31
4. Dismantling, maintaining, repairing and assembling operation 32
(1)Lubrication system 33
(2)Plastic parts of chassis 37
(3)Engine dismantling 42
(4)Drive pulley, starter, clutch,driven pulley 44
(5)Cylinder head and valve 53
(6)Cylinder and piston 58
(7)AC generator flywheel 63
(8)Final transmission mechanism 66
(9)Crankcase, crank shaft 70
(10)Carburetor 74
(11)Steering stem, front wheel, front brake comp., front fork 78
(12)Rear wheel, rear brake, rear damper 87
(13)Fuel tank, oil tank 92

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5. Electric equipment 95
(1)Troubleshooting 96
(2)Battery 97
(3)Recharge system 99
(4)Ignition system 101
(5)Starting system 103
(6)Starting clutch 105
(7)Handle bar switch 107

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1. Specification ŸChassis steelpipe
ŸSuspension
ŸName PA-125 front: telescopic
ŸModel PA-125 rear: 4-bar linkage,
ŸDimension uni-absorber
Overall length:1710mm ŸTransmission
Overall width: 645mm primary reduction :direct drive
Overall height:1060mm second reduction:42/15*42/13
Overall base: 1210mm clutch type: centrifugaldry type
ŸWeight selector : V belt ,C.V.T.
Total net weight:101kg ŸWheel
front: 35kg front: 3.5-10
rear: 64kg rear: 3.5-10
Carrying capacity: ŸTire
2 passengers:150kg
Total weight:211kg front 1.50kg/cm2
Front: 62kg rear 1.75kg/cm2
Rear: 149kg ŸBrake
ŸPerformance front: 190mm hydraulic
Fuelconsumption: 42km/L disk brake
rear: drum brake
ŸGradient ability:22 ŸSpeedometer 130km/hr
ŸEngine ŸLamp
Model: C2front: 12V-35W/30W*1
Fuel: unleaded or leaded
Cooling system: forced air cooling
by fan license plate: 12V-5WX1
brake lamp: 12v-21W/5W X 1
Cylinder signal lamp : 12V-10W X 4
bore: 51.5mm ŸHorn AC12V
stroke: 60.0mm ŸSilencer: diffusible absorption
number 1 closed type
Arrangement: horizontal
Displacement: 124.9cc Trail: 71mm
Compression ration 9.2:1 Front wheel travel: 55.5 mm
Ignition: CDI Rear wheel travel: 61 mm
Start: kick or electric start
Lubrication: pressuring and spraying

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2. Service information:
(1)The notice for operation--------------------------------------------------------------------6
(2)Locking torque value-----------------------------------------------------------------------7
a. For engine
b. For chassis
c. Others
(3)Lubrication instruction---------------------------------------------------------------------9
a. For engine
b. For chassis
c. Wheel bearing -------------------------------------------------------------------------12
(4)Wiring diagram----------------------------------------------------------------------------13
(5)Troubleshooting
1. Hard starting or no starting
2. Not smooth rotation(weak acceleration; inefficient horse)
3. Engine running not smoothly(low speed)
4. Engine running not smoothly(high speed)
5. Charging abnormal(battery over charging or over discharging)
6. No Sparking, spark plug

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(1) The operation notice:
1. Always replace gasket, Oring, cotter, pins and clip whenever reassembled.
2. When tighten screws or nuts, lock tightly as per specified locking torque, and in the sequence
of
cross direction.
3. Use PGO,or PGO Recommended parts.
4. After dismantling please wash all parts necessary for checking and grease all
contact surface when reassembling.
5. Use grease recommended by P.G.O.
6.When removing battery, please dismantle the negative pole (-) first, when
assembling please connect positive pole (+) first.
6. Before installing a new fuse, confirmthe specification is correct or not.
7.After reassembling, please re-check that all connecting point, locking parts,
circuits, polar characteristics are good, before selling out.

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(2) TORQUE VALUE
1. Engine:
NO Locking location Q’TY Thread dia. (mm) Locking torque (kg-m) Remark
1Cylinder head bolt A (intake)260.9~1.1
2Cylinder head bolt B (Exhaust) 282.2
3Cap, oil filter graze 130 1.5~2.0
4Flange nut, cam shaft base 482.2
5Fixing nut, air valve adjustment 250.7 Greasing on thread
6Guiding pin bolt, inner chain adjustment 160.9~1.1
7Oil bolt 181.7~2.0
8Fixing nut, clutch outer 112 5.0~6.0
9Nut, driven plate 112 5.0~6.0
10 Nut, driving plate 112 5.0~6.0
11 Spark plug 110 1.2~1.3
12 Nut, drive clutch 122 9.0~10.0 Left thread
13 Screw, inner chain adjuster 160.4~0.6
2. Chassis:
NO Locking location Q’TY Thread dia. (mm) Locking torque (kg-m) Remark
1Locking nut, steering stem 110 4.5
2Front axle nut 112 4.5 ~5.5 U type nut
3Rear axle nut 116 11~ 13 U type nut
4Rear shock absorber bolt(upper) 110 4.0
5Rear shock absorber bolt(lower) 182.4 ~3.0
6Front brake caliper bolt 282.0 ~3.0
7Chassis bolt, engine hanger bracket 210 3.5 ~4.5
8Engine bolt, engine hangerbracket 110 3.0 ~4.0
9Brake hose bolt 210 3.0 ~ 3.5
10 Air release valve 160.6
11 Front drum brake arm bolt 161.0
12 Rear drum brake arm bolt 161.0

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3.Other parts please refer the following table:
Standard torque values:
NO Item Torque (kgf-m)
1 5mm bolt and nut 0.45-0.6
2 6mm bolt and nut 0.8-1.2
3 8mm bolt and nut 1.8-2.5
4 10mm bolt and nut 3.4-4.0
5 12mm bolt and nut 5.0-6.0
6 5mm screw 0.35-0.5
7 6mm screw 0.7-1.1
8 6mm flange bolt and screw 1.0-1.4
9 7mm flange bolt and screw 1.0-1.4
10 8mm flange bolt and screw 2.0-3.0
11 10mm flange bolt and screw 3.0-4.0

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(3)Lubrication instruction:
A. Engine
NO Lubrication location Oil type Remarks
1 crankcase:rotating part,
sliding part premium 4 stroke
Auto-separated
Lubrication
2 cylinder:rotating part,
sliding part.
motorcycle oil
or SAE15W40
Total 900 c.c.
Replacement 800c.c
3 drive gear box SAE85-140 Total 110 c.c.
Replacement 90c.c
4 gasket of starter shaft clean grease (#3)
5 start idle gear sliding
parts
clean grease (#3)

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B.CHASSIS
Steel ball, steering
Front brake fluid
Front brake cam