Royal Alloy GP125S User manual

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Dear users:
Thank you for choosing your Royal Alloy GP125S/GP200Sscooter. In order to make you drive more safe and
comfortable, please read carefully and fully understand the contents of this manual.
This manual explains the main information, such as the structure, characteristic, basic inspection and maintenance, and
the structure and maintenance of EFI etc for your scooter, so that you can carry out regular maintenance operations on
your vehicle. As it is not possible to include complete mechanical notions in this manual, users should have basic
mechanical knowledge. Without this knowledge, repairing or checking the vehicle may be inefficient or even dangerous.
So you should be extremely cautious so as not to damage components or injure individuals. If you can't complete the
repair and maintenance independently, please contact the local dealer.
Company reserves the right to make any changes due to the renewal of the product. If there is any change, no notice will
be made, please refer to the real scooters. The main technical modifications and changes in repair procedures are
communicated to all Sales Outlets and its International Subsidiaries. These changes will be introduced in the subsequent
editions of the manual.
The important information below will appear in this manual:
CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.
WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.

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Contents
CHARACTERISTICS.............................................................................................................................................................4
TOOLING..............................................................................................................................................................................18
ELECTRICAL SYSTEM...................................................................................................................................................... 54
REMOVE ENGINE FROM VEHICLE................................................................................................................................61
ENGINE DISASSEMBLY....................................................................................................................................................83
EFI SYSTEM.......................................................................................................................................................................122
BRAKING SYSTEM.......................................................................................................................................................... 145
COOLING SYSTEM.......................................................................................................................................................... 160
FINAL INSPECTION......................................................................................................................................................... 165

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CHARACTERISTICS
Maintenance rules
Vehicle identification
Specifications
Transmission system description
Lubrication system description
Fuel system description
Cooling system description
Chassis and suspensions system
Front and Rear wheel description
Braking system description
Electrical system description
Tightening torque

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Maintenance rules
1. Use the spare parts and lubricants of our company or recommended by our company, the spare parts and lubricants
that are not in conformity with the design specifications of our company may damage the motorcycle.
Recommended brand model: MOTOREX scooter semi synthetic 4 stroke SAE 10W/40.
2. Replace spring washers, washers, O-rings (OR), cotter pins and circlips with new parts when reassembling
components.
3. When tightening nuts and screws, start either from the components with the largest diameter or from the innermost
components, proceeding diagonally. Tighten nuts and screws in successive steps to the specified torque.
4. After decomposition, clean parts in clean solvents. Lubricate any smooth surface before assembly.
5. After reassembling, check all parts to install and operate correctly.
6. Dredge all cables and harnesses.
7. Please go to our authorized dealership for repair, unless the owner has special tools and maintenance data and is a
qualified mechanist.

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Vehicle identification
Chassis number is stamped on the frame right side frame rail.
Engine number is stamped on the rear of the crankcase assembly.

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CAUTION These numbers are necessary for vehicle registration identification, and changing the identification
number may be severely punished by the law, especially if the revision of the chassis number will be invalid even if
the warranty is invalid
Specifications
Vehicle data
Engine data
Model
GP125S
GP200S
Engine model
1P58MI(125CC)
1P63ML-4(200CC)
Overall size (mm)
1845×670×1115
Engine idle speed
1900±100rpm
1800 ±100 rpm
Wheel base (mm)
1390
Engine type
1 cylinder, S, horizontal,
Liquid cooling, double
overhead camshaft,
4 Valve

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Saddle height (mm)
780
Bore × stroke (mm)
58*47(125CC)
63*58(200CC)
Minimum ground
clearance (mm)
145
Total displacement
(mL)
124.2(125CC)
181(200CC)
Net weight (kg)
142
Compression ration
12±0.5:1(125CC)
11.6±0.5:1(200CC)
Max loading weight (kg)
210
Max net power, rate
(kW/r/min)
10/8000(125CC)
13/8250(200CC)
Fuel tank capacity (L)
10.5
Max net torque, rate
(Nm/r/min)
12/7500(125CC)
16.4/7500(200CC)
Front tyre size/ Inflating
pressure
110/70-12 /32 PSI
Start mode
Electric
Rear tyre size/ Inflating
pressure
120/70-12 /34 PSI
Ignition mode
EFI (Magneti Marelli)
Front brake
Disc brake
Valve clearance(mm)
Intake: 0.10～0.15

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Exhaust:0.20～0.25
Rear brake
Disc brake
Lubrication type
Pressure/splash
Battery capacity
12V 9Ah
Spark plug
NGK PMR9B
Horn
90-100dB(A)
Clutch
Automatic centrifugal dry
clutch
Variator
Continuous, automatic
Transmission system description
Item
Standard
Transmission
CVT with V belt + final reduction unit
CVT ratio
2.9～0.89:1(125)
2.4～0.86:1(200)
Gear ratio
66/14*58/23=11.89(125)
66/14*54/27=9.43(200)
Engine wheel total ratio
10.6～34.5(125)
8.1～22.5(200)

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Lubrication system description
Item
Standard
Engine oil 1000ml
Brand name: APL SJ
SAE10W-40
Change Engine oil
900ml
Change Engine oil and
engine oil filter
950ml
Dismantle engine, inject oil
1000ml
Transmission oil 200ml
Brand name: 75W-80
Change transmission oil
180ml
Dismantle engine, inject oil
200ml
Fuel system description
Item
description
Fuel number
Unleaded fuel 95 or higher
Fuel tank capacity
10.5L

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Cooling system description
Item
description
Coolant liquid
capacity
When change
1.15L
When dismantle
1.20L
Recommended antifreeze
The coolant or the same quality ethylene glycol antifreeze
is mixed with distilled water according to 1:1. The freezing
point reaches -40℃and boiling point to 108℃.
Chassis and suspensions system
Item
Standard
Chassis type
High-strength steel tubular chassis, single spar at the front,
superimposed double cradle at the rear
Steering rake angle
26.30°
Front suspension
Adjustable preloading, hydraulic action telescopic fork

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Front suspension travel
104mm
Rear suspension
Hydraulic double-acting shock absorber and adjustable
preloading
Rear suspension travel
80mm
Front and Rear wheel description
Item
Standard
Wheel Rims material
Aluminium alloy
Front tyre
Tubeless 110/70-12
Rear tyre
Tubeless 120/70-12
Front tyre inflation pressure
32/220(Psi/kPa)
Rear tyre inflation pressure
34/234(Psi/kPa)

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Braking system description
Item
Standard
Braking system
ABS
Front brake
Ø220mm disc brake with hydraulic transmission
Rear brake
Ø220mm disc brake with hydraulic transmission
Brake fluid
FMVSS DOT4+
Electrical system description
Item
Standard
Battery capacity
12V-9Ah
Fuses
20-15-15-15A
(Permanent-magnet) Alternator
12 V - 330W at 8000 rpm
Spark plug
NGK PMR9B

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Bulbs/
warning
lights
High-/low-beam bulb
Square lamp:12V 35/35W
Round lamp:LED
Front position lamp
LED
Tail light bulb
LED
License plate light bulb
LED
Brake lamp
LED
Front and rear turn indicator bulbs
LED
Speedometer
Instrument panel lighting bulb
LED
Turn indicator warning light
LED
High-beam warning light
LED
Engine oil pressure warning light
LED
Low fuel warning light
LED
EFI check warning light
LED

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Tightening torque
Vehicle part:
Fastening parts
Number
Thread specification
Torque Nm
Nut fixing engine hanger
1
M10
45
Nut fixing engine
1
M10
45
Front wheel axle nut
1
M12
60
Rear wheel axle nut
1
M14
100
Upper screw fixing rear shock
absorber
2
M10
40
Lower screw fixing rear shock
absorber
2
M8
25
Upper screw fixing front shock
absorber
2
M6
12
Lower screw fixing front shock
absorber
2
M12
60

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Locking nut fixing direction column
1
M25
70
Nut fixing handlebar
1
M10
45
Screw fixing front brake disc
3
M8
25
Fastening bolt fixing rear wheel
5
M12
60
Screw fixing rear brake disc
5
M8
25
Reference bolts for other specifications: GB1231-2006 bolt torque standard
Engine part:
Fastening parts
Number
Thread specification
Torque Nm
Cylinder head screw A
4
M8
24～26
Cylinder head screw B
2
M6
10～12
Camshaft cover fixing screw
8
M6
10～12
Timing sprocket screw
2
M8
25～30
Exhaust pipe joint fixing screw
2
M6
9～12
Oil filter cover
2
M6
9～12

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Combined box screw
3
M6
9～12
Intake manifold fixing screw
3
M6
9～12
Crankcase oil releasing screw
1
M18
33～38
Gear box oil releasing screw
1
M12
23～27
Pressure regulating valve screw
1
M18
33～38
Front clutch nut
1
M12
70～80
Rear clutch nut
1
M12
55～65
Generator rotor fixing screw
1
M8
23～27
Water temperature sensor
1
M12
20～24
Spark plug
1
M10
9～11
Oil pressure switch
1
M10
9～11
Reference bolts for other specifications: GB1231-2006 bolt torque standard

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TOOLING
1. Special tools(The following tools are restricted to professional technicians only,consumers must not operate
without authorization):
No.
Name
Tool number
Picture
1
Valve spring
compressor
Z01
2
Threaded bolt for
locking crankshaft at
TDC
Z02

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3
Clutch driving
wheel locator
Z03
4
Shaft bearing punch
Z06.1---Z06
.8
5
Oil seal punch
Z07.1--Z07.
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