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SERVICE MANUAL - Sarner Trading AB

1. Installation flywheel x semi cycle key AC generator wire fix bracket AC generator wire coil 3 rubber seal aia hs Wp 14 4 BATTERY CHARGE AND IGNITION SYSTEM e Follow the reverse sequence to do the assembly operation e When install the flywheel be sure the semi cycle key is installed into crankshaft at correct position x Be sure inside of the flywheel do not have any nuts or screws which will damage the generator coil e Install the flywheel with spanner tool and tie up the fixed nut Locking torque 5 5 kg m IGNITION SYSTEM AD ile GR pusar coil sik mainswitch ignition coil me lt AC generator sparkplug HIGH TENSION COIL Remove e Remove the spark plug and connect with the cap Check e Make the spark plug contact with ground and press the start button e Check is there any spark on the gap of spark plug During the test do not touch any metal parts to avoid electrical shock good spark plug 14 5 BATTERY CHARGE AND IGNITION SYSTEM e Primary coil is measured 2 terminals behind ignition coil e Remove the spark plug cap and 2 wires behind the coil e Check the resistance of primary coil Standard 0 1 1 0 Q 20 C e If the resistance reads oo then replace new coil e Measure the resistance between the spark plug cap and one terminal Standard 7 12 KQ 20 C with cap e Remove the spark plug cap and measure again Stan
2. check the spark plug spark damage or stain sparking sa sh ee j C D I damage A C G damage sparking normal sparking abnormal coil damage spark plug cable damage odr short main switch damage em i i ee Ce A C G damage air hole damage or blocking pressure tube damage end l 7 INFORMATION FOR PREPARATION REVOLUTION NOT SMOOTH HIGH SPEED Diagnose Check and Adjust Reason of Trouble normal abnormal C D I damage ACG pulse coil damage i adjusting isn t correct normal abnormal valve set damage em i i i eC normal fule filter blocking air hole of fuel tank blocking fuel cup damage fuel of tank is too less cleaning check and adjust valve i timing valve timing is valve timing isn t camshaft gear mark position is not correct correct correct r emcee ie i ee Ce normal spring broken or spring damage elastic deformation pring g end 1 8 INFORMATION FOR PREPARATION CHARGE ABNORMAL Diagnose Check and Adjust Reason of Trouble q start engine and measure voltage of the two terminal for battery It f batt yolar of battery MOMAES OF DANGLY battery damage can t go up is normal measure the resistance of ACG coil coil damage measure value oo high YL wire damage em i i ee Ce battery have voltage R wire damage voltage l check socket of regulator loosen EIE EEEE EEE socket damage over charge SSS SS SSS SSS 7 SHG amaga check
3. e Remove cylinder head cover e Rotate the cooling fan and keep the gear mark of camshaft aim at the TDC position and the ACG flywheel T mark aim at the mark of crankcase When you adjusting the valve don t invert the crankshaft otherwise can not adjust the exhaust valve VALVE GAP CHECK amp ADJUST Valve gap IN 0 06 mm EX 0 10 mm e Loose the fixed nut and rotating the adjusting nut reach to the proper gap e Screw the fixing nut and check the gap again e Using the valve gap adjuster to adjust the valve gap ADJUSTING IDLE SPEED Engine idle speed adjustment have to do it when the engine is warm e Starting the engine and connect with the rpm meter e Adjust the idle speed adjust screw reach to the normal idle speed The idle speed is 1700 100 rpm If the idle speed is unstable or slightly pull the throttle the engine does not go smoothly then adjust the throttle valve Stopper screw 2 5 CHECK AND ADJUST IGNITION TIMING The ignition system of this vehicle is controlled by C D I unit thus don t need to adjust anything If the ignition timing isn t correct then checking the ignition system whether normally e Removing the L side cover e Removing the rubber bung e Using the timing light to check the ignition timing The mark of crankcase aim at the F mark of flywheel when the engine speed running at idle IGNITION PERIOD e Using the timing light to check the
4. STANDARD TORQUE 0 4 CHASSIS Locking Place Torque kg m Handle bar bottom flange nut 14 a ae a a eee ao ee Foot rest flange bolt 6 O A o o 9 Nylon insert type COo 2 a ee a a a Front rim nut 7 Rearrimnut_ O 2 O ee E ENGINE Dia mm ylinder Head Bolt A l 8 09 Stud bolt side Cylinder Head BoltB 1 o 09 o Oil Filter Cap C ie o Ld P j es 1 4 INFORMATION FOR PREPARATION The following drawing that shows the disassembling situation of the cover parts for GK 125R Go Gart 1 5 INFORMATION FOR PREPARATION REVOLUTION NOT SMOOTH LOST POWER Diagnose engine speed go up ignite timing is correct valve gap is correct compression pressure is normal engine speed can t go up fully ignite timing isn t correct valve gap isn t correct compression pressure no blocking is too low blocking spark plug normal spark plug stain oil quantity is normal normal oil quantity is too rich abnormal normal over heat Ls continue Check and Adjust ia ia _ i start engine and go up speed slight adjusting ignite timing l adjusting valve gap is not correct testing compression pressure loosen spark plug and check check the oil l quantiity of crankcase is too rich or dirty check cylinder head lubricating r7 7 increase engine speed or continue t
5. e O ring must be greased and tie up im ee Comechain Locking torque E fixed bolt f er S 1 0 kg m The O ring must fit into correction position ADLY MOTO FRONT WHEEL SUSPENSION BRAKE STEERING Attention of Operation Diagnosis of Trouble Heavy steering movement Air pressure too low inside of front tire Rim radial ball bearing broken Brake efficiency abnormal Brake lining wear out Brake pads adjust not correct or wear out Brake drum wear out Tire wear out 12 0 e Remove the body cover and support the frame body bottom before remove the front wheel don t invert the front wheel when front wheel depart ground Steering handle not straight Loose not correct adjustment or damaged right or left link Ass y Steering shaft bended Suspension arm knuckle damaged Rim damaged Front wheel shaking or deviation Front rim defected Loose or damaged of front rim bearings Tire defect Bad adjustment or defected of the right or left link Ass y Bad adjustment or defected of the right or left knuckle ADLY MOTO FRONT WHEEL SUSPENSION BRAKE STEERING Disassembly of Front Wheels Operation Parts name Q ty Disassembly front wheels L R Rubber cover Cotter pin Slotted nut Plain washer 12 40 4 5 A U Nhe NNN WN Disassembly front brake drum Spacer tube Hex washer face bolt 10 20 Front brake drum Rim 7 5 2 Tire 18 7 7 Oo OAT NN
6. 8 R R R SIGNAL 12V 5W DGR LL GR GR C1 mE a CE EE ee eed Ed GRAE TURN SWITH BR DBR TAIL LIGHT 12V 35W 35W 12V5W 21W HEAD LIGHT 4 af T DGR mS A m o GR F L DB TE a F as SIGNAL Cea S Le i i T amp R L SIGNAL WRANING LIGHT o R L FR a Oo Eo rr ml L Be 2 on ototo pe ltl i LHI gt or 1 SPEEDOMETER eee eee a ns HIGH TENSION COIL DAT BATTERY IG IGNITION FLUSHER E GROUND EARTH RELAY ST START SPARK PLUG AC A C GENERATOR EONTR C D I UNIT A BRAEK 1 r FR FLUSHER RELAY SWITCH A C GENERATOR COMP LEFT HANDLE SWITCH 5W5Q
7. Reverse cable a Reverse cable a pet p ee eee Ke OCOD Assembly e Assembly with sequence in reverse of reverse 121 disassembly 12 6 REAR WHEEL SUSPENSION BRAKE Diagnosis of Troubles Rear wheel shaking or deviation The shape of rear rim damaged Rear wheel axle damaged Swing arm sub Ass y damaged Rear rim bearing defected Rear suspension too soft Spring too soft or adjust not correct Brake efficiency abnormal Brake lining wear out Brake pads adjust not correct or wear out Brake drum wear out Tire wear out 13 0 REAR WHEEL SUSPENSION BRAKE Assembly Disassembly Rear Wheel Operation Parts name Disassembly L R Rubber cover Cotter pin 3 32 Scotch nutl2mm Plain washer 12 40 4 5 Front brake drum Hex washer face bolt Nylon nut 8mm Spring washer 8 5 13 2 Hex washer face bolt 8 20 10 Bearing holder 11 Radial ball bearing OMANI NNABWN NNNABADDHDDANWONNDN WLW 13 Tire 18 9 5 8 Assembly e Assembling with sequence in reverse 13 gt of disassembly 13 1 REAR WHEEL SUSPENSION BRAKE Disassembly Assembly of Rear Brake Operation Parts name Q ty Assembly with sequence in reverse of disassembly OMAN NB WN Disassembly Rear Brake Hex washer face bolt 8 12 Rear brake cylinder sub ass y Ladder bolt 6 14 2 5 Front brake disc cover Brake hose hex nut 10 22 Plain washer 10 14 5 5 Rear brake hose Hex washer face bolt
8. factory It does not need to adjust the fuel screw again Remember the setup before disassembly Use neutral gear to adjust the carburetor e Smoothly turn the fuel adjusting screw into the end then return back to the standard setup The normal setup is 3 1 8 3 4 turns Out e After engine warm up adjust the a throttle valve adjusting screw to setup clamp carburetor the standard idle speed Idle engine rev 1700 100 rpm e Slightly increase the engine speed for few times and the idle engine speed should keep the same e If the engine rev is not stable repeat above adjust procedure on fuel adjusting screw and throttle adjusting screw until the engine speed is normal 5 7 FUEL SYSTEM FUEL CUP Smoking prohibited e Remove the fuel tube and vacuum tube from carburetor Check If the fuel cup have no vacuum pressure and the fuel come out then the valve film inside the fuel cup is damaged e Install with the reverse procedure AIR CLEANER ASSEMBLY e Release the clamp screw which connect to the carburetor e Take off the air hose connect to the final transmission gear box e Loose 3 fixed bolts under the air cleaner assembly to dismount the air cleaner SN A SSA T lt tee M a _ 1 Aw i Ne p 7 5 8 FUEL SYSTEM Disassembly of Fuel Tank Disassembly of handle bar and front cover x WARNING e No fire e Shall be wiped off when fuel overflowed 28A
9. gears shafts and bearings When bearings has been damaged use special tool to pull out all bearings TLCT125 06 Bearing puller set Reverse idle gear shaft 10 2 idle gear shaft gt f shaft Final gear FINAL TRANSMISSION Bearing installation e Use the tool press the bearing outer ring when install into crankcase or mission cover Attention x The bearings have to be pressed on outer ring to avoid damage of bearings Final transmission installation e Install the main gear assembly and final gear shaft into crankcase e Install the final gear onto shaft e Install new gasket and dowel pins e Install the mission cover and bolts Locking torque 1 2 kg m e assembly the gear set and mission in reverse sequence e Fill in final transmission gear oil into gear box Recommend oil 85W 140 SAE 90 Exchange 300 c c Disassembly 350 c c 10 3 CRANKCASE CRANKSHAFT TROUBLE DIAGNOSE Engine noise e Loose of crankshaft bearings e Loose of bearings inside crankshaft connecting rod CRANKCASE CRANKSHAFT CRANKCASE DISASSEMBLY e Remove the cam chain tensioner by unscrew the fixed bolt e Use special tool to pull out the kick start driven gear TLCT 125 05 Kick start driven gear puller VA ick start drive gear rankcase fixed bolt a e Take off 2 bolts on R crankcase e Disassembly L R crankcase Do not damage the gasket area o
10. then install the pump shaft When install the pump shaft beware the angle position match with the Inner rotor dowel pin inner rotor Pump cover e Install the dowel pin e Siting the dowel pin and the pump cover e Locking the screw After installed turning the pump slightly a Anona and confirm the function is normal i 2 WWE Install e Install the pump back to crankcase Installing the pump the arrow mark have to be toward upper position x Add the standard oil in pump then 4 4 LUBRICANT SYSTEM e Install the pump then tie up the bolts y e The pump gear has to fit into the shaft then install the gear and chain e Install the nut and tie up Locking torque 1 0 kg m e Mounting the oil separator and tie up the bolts starter clutch ass y e Mounting the starting clutch gear and starter clutch e Mounting the gasket and dowel pins e Use special tool to fix the starter clutch lock nut TLCT125 04 e Mounting the R crankcase cover with 5 fixed bolts e Mounting the pulsar coil and ACG e Tie up 5 bolts on R crankcase cover Locking the bolt have to follow the cross wise direction FUEL SYSTEM TROUBLE DIAGNOSE Start up function abnormal e No spark of spark plug e Compression pressure too low e No fuel in carburetor e Air stock inside air cleaner e Stock of fuel pipe e Defect of rubber film in carburetor e Bad adjustment of fuel level Too much fuel i
11. 10 87 Rear brake caliper ass y Assembly Rear break 9 1 PFNrRNNRFNKR WY REAR WHEEL SUSPENSION BRAKE Disassembly Assembly of rear axle Disassembly rear axle Plastic spacer Hex washer face bolt 8 20 Rear sprocket hub Hex nut M33 14 Hex washer face bolt 8 20 Rear sprocket Rear sprocket hub Plastic spacer DDmWeoerrtanszWwne ee pd pd pd pb b NE NO ee a Assembly with sequence in reverse of disassembly 13 3 REAR WHEEL SUSPENSION BRAKE Disassembly Assembly of chain Disassembly chain removal Hex flange nut with serration Hex washer face bolt 6 30 Rear chain cover Idle sprocket spring Nylon nut 10mm Hex washer face bolt 10 32 Spacer tube Idle sprocket Radial ball bearing Plain washer 10 17 2 5 Nylon nut 8mm spring washer 8 2 18 0 8 idle sprocket shift Hex washer face bolt 10 155 Rear axle hex flange nut with serration 12mm Nylon nut 14mm Plain washer 15 29 3 Drive sprocket ass y Drive chain Assembly Assembly with sequence in reverse 231 of disassembly 13 4 l 2 l l l l l l l l l l l l l l l l 2 l l l l 1 REAR WHEEL SUSPENSION BRAKE Disassembly Assembly of chain chain roller 15 Ae Operation Parts name Hex flange nut with serration Hex washer face bolt 6 30 Rear chain cover External cir clip Plain washer 12 18 1 2 Chain roller Nylon nut 8mm Plain washer 8 14 2 Plain washer
12. NNN WO WN Assembly e Assembling with sequence in reverse of front brake drum 9 5 disassembly Assembly wheels 4 WARNING Change the R L bearing set if necessary 12 1 ADLY MOTO FRONT WHEEL SUSPENSION BRAKE STEERING Disassembly of Front Brake N lt SY e Poo ea Disassembly front brake drum L R Nylon nut 10mm Hex washer face bolt 10 175 Cotter pin 2 19 Scotch flange nut 10mm Plain washer 10 20 2 Upper a arm ass y Hex slotted nut 12mm Plain washer 12 22 2 Nylon nut 10mm Hex washer face bolt 10 175 Lower oscillation arm Strain spring Front brake shoe comp Right knuckle ass y left knuckle ass y front brake cable SOMAIDNAPWN 4 2 6 2 6 2 4 2 4 2 2 2 2 l l 2 NNN e Assembling with sequence in reverse front brake drum 161 of disassembly parking brake 20 17 WARNING Change the R L bearing set if necessary 12 2 ADLY MOTO FRONT WHEEL SUSPENSION BRAKE STEERING Disassembly of Suspension Arm Operation Parts name Q ty x Assembling with sequence in reverse of Hex washer face bolt 10 40 Nylon nut 10mm Front cushion A UNa Hex washer face bolt 10 179 Assembly 12 1 disassembly 12 3 ADLY MOTO FRONT WHEEL SUSPENSION BRAKE STEERING Disassembly of Steering Shaft Ass y Disassembly steering shaft Ass y Handle Wheel A ssy Hex flange nut with serration 8mm Steering shaft holder Steering shaft ass y 312
13. S and cover Locking torque 1 5 kg m e Adding the proper oil quantity engine disassembly 0 9L change 0 75L e Check the engine oil whether leaking If not then starting the engine at idle speed for few minutes and checking the oil level again 4 1 LUBRICANT SYSTEM OIL PUMP Remove e Remove the fan and ACG e Take off 5 bolts on R crankcase cover and remove it e Remove the gasket and the dowel pin e Remove the starting clutch gear and starter clutch TLCT125 04 Use special tool to loose the starter clutch lock nut Attention the lock nut is the thread The lock nut is the left thread type e Take off 2 bolts of the oil separator and remove it e Take off the nut on pump drive gear e Remove the pump drive gear and chain Pulsar coil dowel pin LUBRICANT SYSTEM e Take off the fixed bolts on oil pump and remove the oil pump ass y Disassembling e Take off the screw on oil pump and disassembling the oil pump Check e Check the gap between the pump body and outer rotor The gap limit is 0 10 mm e Check the gap between inner and outer rotor The gap limit is 0 06 mm oS oil pimp A outer rotor oil pump body 4 3 LUBRICANT SYSTEM install it e Check the gap between the top face of rotor and the pump body The gap limit is 0 2 mm os Pa git a y a vty OE Lie A i A r Assembling e Mounting the inner and outer rotor
14. ignition period e Keep the engine speed about 5000rpm if the flywheel mark aim at the enter angle mark of crankcase then the ignition period is correct CYLINDER PRESSURE e Remove the spark plug e Install the pressure gauge e Open the throttle and press the electric start button The normal cylinder pressure is about 128kg cm 570 rpm If the cylinder pressure is too low then check the following items Valve leakage Valve gap is too tie Cylinder head gasket is damage Piston ring wear out Piston cylinder wear out If the cylinder pressure is too high then check the combustion chamber and the top face of piston whether with too much carbon residue 2 6 CHECK AND ADJUST GEAR OIL Oil quantity check bolt washer AI _ x When you will check the quantity of gear oil the main stand have to rise at the ground flat level e Stop the engine and removing the quantity check bolt If the oil level is around the bottom of bolt hole then the gear oil quantity is enough Refill the gear oil if it too less The standard gear oil is SAE 85W 140 e Install the quantity check bolt x Confirm the washer of the bolt whether damage Chang the gear oil e Take off the quantity check bolt e Remove the oil release bolt and release the oil e Install the oil release bolt x Confirm the washer of the bolt whether damaged Gear oil quantity disassemble 350
15. should aim at the pressed mark of idle gear e Put the starter spring into the stop position Install the stopper plate Install the gasket and dowel pins Install the drive belt and drive face Install the L crankcase and kick starter arm i 7 SN m av A biii vig fi A e r D B lt y 1 f i A 7 i Yo Vii m 4 press line ig Press mark 9 8 FINAL TRANSMISSION GK 125R TROUBLE DIAGNOSE Engine starts but vehicle does not Gear oil leaking move e Too much gear oil filled e Transmission gears broken e Oil seal wear out or damage e Transmission gears burns out 10 0 FINAL TRANSMISSION DISASSEMBLY TRANSMISSION GEAR BOX e Remove drive chain and sprocket e Drain transmission gear oil e Remove the bolts and pull out mission cover e Remove the mission cover together with the gear set e Remove the gasket and dowel pins e Remove the hex flange bolt shift lever and contact plate x Check if the shift shaft is wear out or not check if then is any wear out of the sliding area of the shifter arm 10 1 FINAL TRANSMISSION DISASSEMBLY TRANSMISSION GEAR BOX e Remove the hex socket bolt then pull out the shaft e pull outer in remedial shaft and find drive gears e Take out the final gear and gear shaft e Take out the main gear shaft and main gear Check final transmission gearbox e Check the wear out or damage of
16. starter idle gear Replace if over 10 1 mm e Measure the outside diameter of idle gear shaft and check the movement between the gear and shaft Replace if below 9 9 mm 15 3 dri starter idle gear gear shaft needle bearing clutch cover STARTING SYSTEM guides semmi cycle key clutch body g KX OO drive gear needle bearing or o dowel pin clitch over roller spring Assembly and Installation e Install the springs and rollers into clutch body e The dowel pin must fit into correct position between the clutch body and cover The clutch cover or 3 bolts should use lock tie glue to ensure the tightness e Grease the needle bearing and install into the clutch body with starter drive gear e Install the starter clutch assembly aim at the semi cycle key of crankshaft clutch body e Install the starter idle gear gear shaft and R crankcase cover base on reversed sequence 15 4 MAIN SWITCH See O eee Tea ae ear sr lorF O7O on gt t to st_ O 0 0 BR BROWN GEAR CHANGE CONTROL BK BLACK GR GREEN R L DIRECTION R RED INDICATOR W WHITE HIGH LIGHT DRAK GREEN INDICATOR DBR DRAK BROWN DRIVE LIGHT INDICATOR BR NEUTRAL LIGHT B BERTI a W R INDICATOR e A S A E INDICATOR BR IGNI m GR BK REVERSE AL C SWITCH W R __ DRIVE A gt E SWITCH SIGNAL BK E ayy Jia e BK W
17. 8 2 18 0 8 idle sprocket shift idle sprocket spring idle sprocket bracket nylon nut 10mm bracket Hex washer face bolt 10 155 spacer hex flange nut with serration DA me me SS e e A Me NN le ee ee S aaae S aaa S aaa S aoaaa S aaae S WA nNKRWNRF DDL ENAMA UWUN e Plain washer 15 29 3 Drive sprocket ass y Drive chain Assembly Assembly with sequence in reverse 21 1 of disassembly 13 5 REAR WHEEL SUSPENSION BRAKE Assembly Disassembly of engine mounting bracket amp Rear Cushion Operation Parts name Disassembly engine mounting bracket Nylon nut 10mm Plain washer 10 22 2 Hex washer face bolt 10 55 Hex washer face bolt 8 40 Hex washer face bolt 8 20 R cross bar NMR WN Disassembly Rear cushion 7 Nylon nut 10mm Plain washer 10 17 1 5 9 Hex washer face bolt 10 40 10 Rear cushion Assembly e Assembly with sequence in reverse of engine mounting bracket 6 1 disassembly Rear cushion 7 10 13 6 REAR WHEEL SUSPENSION BRAKE Assembly Disassembly of engine rack ass y Operation Parts name Disassembly engine rack 1 Nylon nut 10mm 4 2 Plain washer 10 22 1 5 2 3 Hex washer face bolt 10 48 l 4 Rubber bush 2 X replace if necessary 5 Hex flange nut with serration 2 12mm 6 Hex washer face bolt 12 65 2 7 Engine bracket ass y l e Assembly with sequence in reverse of disassembly 13 7 BATTERY CHARGE AND IGNITION SYSTEM INFORMATION FOR PREPAR
18. ATION Battery electrolyte contains sulfuric acid which can cause severe burns Avoid contact of skin eyes or clothing When sulfuric acid water spill into clothing will stick to skin Take off the clothing and flush with water e Battery can be charged and discharged Without charging the battery will have less lifetime and damaged after discharged e If the battery have short circuit inside both terminal will not have voltage existed Besides the regulator rectifier lost the function and shorter lifetime e If the battery stay too long without use it will lost power and have less capacity The battery need to charge each 2 3 months e After fill up the electrolyte the new battery will generate voltage It s necessary to recharge if the voltage is low It s necessary to leave the battery for more than 20 minutes before sealing the cap It will increase the lifetime of new battery if recharged before installed e Do not unplug the electrical components from wire hardness when the current 1s working This will cause too high of voltage and damage other compounds such as rectifier light bulbs etc Turn off the main switch to OFF before the operation The Maintenance Free battery does not need to refill electrolyte or water All charge system needs to be load before check Do not use quick charge unless it s in urgent The battery needs to be taking out from vehicle when doing charge work When checking the voltage
19. CK sound is normal e Check the function if no CLICK Check e Remove the starter relay and connect with battery and test meter e Using full charged battery connect with the yellow red and green yellow wires of the relay e When the battery connect to starter relay the current should pass between 2 terminals STARTER CLUTCH Disassembly e Remove the R crankcase cover e Remove the L crankcase cover e Using the fixed spanner to hold the primary drive face then remove the nut e Remove the fixed nut of starter clutch e Take out the starter clutch assembly e Remove the starter idle gear shaft and of es map eT A 1 N d b rs g the gear fixed spanner 15 2 STARTING SYSTEM Check the starter clutch assembly e Put the starter clutch together with drive gear to check the movement e The starter drive gear can only rotate in clock wise direction Counter clock wise rotation will fixed to hold the clutch body Disassembly e Check the contact surface of drive gear and rollers Replace if damaged e Measure the inside diameter of starter drive gear Working limit Replace if over 32 1mm e Check the needle bearing and replace if damaged e Disassemble the starter clutch body e Check 3 springs and working surface of the clutch body with rollers Replace if abnormal e Measure the outside diameter of clutch cover Replace if below 27 9 mm e Measure the inside diameter of
20. ER PLAY e Check the throttle lever operating whether is smoothly e Check the throttle lever play whether is normal The main adjusting nut for throttle play is on the side of carburetor e Loose the fixed nut and adjust the play nut to proper position Play nut The micro adjusting nut for the throttle play is under the throttle grip e Removing the prevention dust cover of throttle cable loose the fixed nut and adjust the play nut to proper position Fixed nut 2 3 CHECK AND ADJUST AIR CLEANER Take off the tapping screws of air cleaner cover and remove the cover Take off two screws of air filter Check the filter whether is dirty or damaged If it s dirty or damaged then clean it or change a new one The material of filter is paper with sponge thus don t use compression air to clean the filter Check period If the vehicle often driving at the rainy or abominable surroundings please check the filter more frequently SPARK PLUG e Remove the spark plug cap e If the spark plug grimy or with carbon residue then using the copper brush to clean it Spark plug specification C7HSA without resistance CR7HSA with resistance Check the gap of spark plug Gap 0 6 0 7 mm e Using the standard plug socket spanner to install the spark plug 2 4 SCrew CHECK AND ADJUST VALVE ADJUSTING x When you check or adjust the valve do it at the low engine temperature about 35 C
21. ON FOR PREPARATION Attention on Operation Certified lubricants in cans shall be used on all the elements to be lubricated on ge After assembly performance of all elements shall be duly checked and the locking shall be duly verified Incase of an operation is performed by over 2 people the assignment shall be conducted in coordination and safety shall be the first priority Definition of signs The sign given in the Service Manual shall refer to the operation methods and observation OIL lubrication by designated lubricant GREASE Lubrication by grease Special Too Parts on which special tools shall be used General Too General tools shall be used New Replace by new items after dismounting Attention e ih if E Dangerous and important operations 1 2 INFORMATION FOR PREPARATION SPECIFICATION TYPE GK 125R LENGTH WIDTH HEIGHT WHEEL BASE NET WEIGHT ENGINE TYPE COOLING 4 STROKE Single Cylinder AIR COOLED BORExSTROKE 52 4x57 8 lt a X f YN lt Z z gt O N IGNITION STARTER ELECTRIC KICK Hydraulic Shock Absorber AUTOMATIC Front 18 7 7 Rear 18 9 5 8 Front Drum Rear Disc MY o nrte ONL m Saa E NO NI TNO le InN N Sy ees na OIII oo d js s 5 JE 5 5 DISPLACEMENT SUSPENSION TRANSMISSION 1 3 INFORMATION FOR PREPARATION LOCKING TORQUE The standard locking torque shall apply in case of no specification
22. SERVICE MANUAL GK 125R 92 61 July 04 High Power Engine HER CHEE INDUSTRIAL CO LTD Preface The Service Manual in reference is provided as the technical information for checking and preparation of ADLY GK 125R GO KART and the edit description is given in diagrams with Operation Sequence Highlights and Checking Arrangement for reference of the service staffs The information illustrations or contents included in this manual may be different with the actual scooter in case specifications are changed Your understanding will be appreciated HER CHEE INDUSTRIAL CO LTD INDEX Information for preparation ss L l Muffler Cover parts aaaaaaaaaaaaaaaaaaaaaaaaaaa 2 Check and Adjust Cl Oaaaaaa 2 Lubricant system e COaaaaaaaaaaaa 4 Fuelsystetm ss L 5 Remove O COINS T dele Oo hate dees 6 Cylinder head Valve ss 7 Cylinder Piston 2 2 2 ec aoeee te oats tenets eens sinless ts colt ete 8 Transmission Kick start Ck aL 9 Final transmission pies con ttc nahh atten inicet te aetna deere eacutuneee 10 Crankcase Crankshaft CC CCC O O aL 11 Front wheel Brake Suspension steering 12 Rear wheel Brake Suspension k 13 Battery Charge and Ignition system ss 14 Starting system C 15 Wiring diagram 16 ASSEMBLY INSTRUCTION For GK 125R Take out the battery and fill with acid liquid Pre charge the battery will extend its life The preparation and charge procedure is based on the
23. Split spring pin 6 24 Internal cir clip Washer 26 39 1 5 Steering drive gear Bush Hex flange nut with serration 8mm Hex washer face bolt 8 48 pd cee pad on pa p pa DRAKRDWDDBOMPAADUNSWNE ma me KD PO N BNO me m me KS WO RS KS N e Disassembly knuckles Cotter pin 2 19 Nylon nut 10mm Ball joint right thread Inner tie rod rack end NNNYN WY e Assembling with sequence in reverse knuckles 21 17 of disassembly steering shaft Ass y 16 gt WARNING Adjusting gap of throttle 12 4 ADLY MOTO FRONT WHEEL SUSPENSION BRAKE STEERING Disassembly of pedal system ra IA E Ce ih NE 15 bo 12 Disassembly reverse Hex washer face bolt 10 70 Brake arm Cotter pin 2 15 Brake pedal comp Hex washer face bolt 6 16 Cable bracket Hex nut 6mm Pedal fix bracket Brake arm pin Drive nut Rear brake fixture Brake elbow Stop switch spring Stop switch ass y Brake rod Accelerator pedal Hex washer face bolt 10 60 Hex nut 6mm Reset spring Throttle cable Accelerator pedal Assembly e Assembly with sequence in reverse of Brake pedal 161 disassembly Accelerator pedal 21 17 l 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 eet ee N9 m 12 5 ADLY MOTO FRONT WHEEL SUSPENSION BRAKE STEERING Assembly Disassembly of reverse Disassembly reverse Pan Phillips bolt 5 10 Outer cover Fix shift Hex flange nut with serration Smm Shift lever Shift plate Seat lock ass y
24. ach ring should be greased with oil top ring Do not scratch piston and do not band 4 Ry peroni ang piston rings x The mark on piston ring must face up x Be sure the rings rotate freely after install into piston AUA top ring ZZA second ring Piston installation e Clean the gasket stick on top of crankcase piston pin Do not drop off any material into crankcase e Install piston piston pin and rings The IN mark on top of cylinder must aim at the intake valve position Piston pin clip must not drop into crankcase Use cloth to seal the crankcase 8 3 CYLINDER PISTON Cylinder Installation e Put the dowel pins and gasket on top of crankcase gasket e Cylinder inside surface piston and piston rings must be greased with oil e Beware of the pressure from piston ring and install into cylinder Be careful not to damage or band the piston ring The opening section of piston rings should not be the same with piston pin and set into 120 to each other cylinder e Install 2 bolts of the cylinder e Install cam chain guide comp e Install cylinder head e Tie up the nuts and bolts on camshaft holder and cylinder head cover n gt Be cam chain guide comp 8 4 TRANMISSION KICK START 5 5kg m i MA a04 TROUBLE DIAGNOSE Vehicle does not move after engine Power insufficient start up e Drive belt wear out e Drive belt wear ou
25. alve to see 1f it s burned or banded Check the movement between valve and guide is smooth or not Valve outside diameter working limit Replace under 4 9 mm Cylinder head assembly e Install valve seal spring seat Install new valve seal after removed e Install valve into cylinder head with some grease on seal spring seat e Install springs spring holder cotter and use special tool to assembly x Must use the special tool Valve cotter sharp edge face toward cylinder head bottom l pe spring holder tool TLCT125 02 7 6 CYLINDER HEAD VALVE e Use rubber hammer hit the valve top for 2 3 times to have better contact between valve and cotter Beware not to damage the valve Cylinder head installation e Install dowel pins and new gasket e Install cam chain guide comp e Install cylinder head e Install camshaft Cylinder rock arm Assembly of camshaft holder On top of camshaft holder EX mark is for exhaust side e Assembly rock arm stopper plate rock arm shaft Cutting edge of inlet rock arm shaft Should match with camshaft holder bolt hole Te tia Camshaft holder i Cutting edge of outlet rock arm shaft Should match with camshaft holder bolt hole 1 1 CYLINDER HEAD VALVE camshaft sprocket cam chain Installation of camshaft holder e Rotate ACG flywheel let the T mark aim to crankcase Make the big hole on camshaft gear face
26. battery s instruction Install the rear wheels and parts in the following order A 16x40x5mm washer B 16mm hex bolt torque 750 950 kg cm 74 93 N m C Cotter pin open up the end after installed D Rubber cap Install the front wheels and parts in the following order A 12x40x4 5mm washer B 12mm hex bolt torque 300 350kg cm 29 5 34N m C Cotter pin open up the end after installed D Rubber cap Install the battery with the red wire to positive and black wire to the negative After the battery is connected put the plastic cover on it Place the steel bracket over the cover and tie up with 2 hex bolts Install the fuel tank on the rear rack and fuel valve on the frame Fill up with unleaded fuel and turn the fuel valve to ON position Install the seat from front Pull the lock lever under the seat and fit into the seat rail Push back to set into proper position and release the lock lever Install the L R roller cage tube started from the front of frame Push the clip on the frame and set tube onto the frame Install the rear tube to the frame Install the top roller cage cross tube The shorter tube is in the front and longer one for the rear Tie up 4 hex bolts to fix the top roller cage cross bar and 4 hex socket bolts to fix the L R tube on the frame Turn on the main switch and try to start the engine In order to use the electric starter you need to check the following A Step on
27. blocking e Muffler with dent Remove the muffler e Taking off the nuts that connect to the cylinder e Taking off the bolt that fix to the frame e Remove the muffler and gasket Note When you assembling the muffler don t forget to put gasket on muffler first Replace a new gasket after dismounting the muffler MEMO 3 2 LUBRICANT SYSTEM valeur ou filter oil pump TROUBLE DIAGNOSE Oil quantity reduced Engine burn e Normal consumption e No oil pressure or pressure too low e Oil leaking e Oil thoroughfare blocking e Piston ring wear out or installed Oil type isn t correct wrong e Rubber seal of valve wear out 4 0 LUBRICANT SYSTEM Information for Operation ENGINE OIL amp FILTER Oil quantity x When you check the oil quantity the vehicle have to stand on flat ground Starting the engine about 2 3 min then stop it After 2 3 min check the oil quantity e Remove the oil level gauge and check If the oil level under the lower limit then add the standard oil to upper limit of gauge oil level gauge Oil Exchange x The motor oil will flow more easily if the engine is warm e The oil release nut is under R crank case cover Take off the oil filter cover can have better release of the oil wma Oil filter cover p E e Check the O ring of oil filter cover Fe Replace new ring if it s damaged g e After cleaning the filter then 5 mounting the oil filter filter spring
28. c c change 300 c c e Check all parts whether leaking after assembly TRANSMISSION V BELT transmission belt e Remove the L crankcase cover e Check the belt whether wear out or chapping If the belt is damage then change it 2 7 CHECK AND ADJUST BRAKE SYSTEM Front brake e Check the brake pads If the brake pad has any dint or wearing very serious then change it e Check the quantity of brake oil Make the steering straightly check the brake fluid whether keep between the upper and lower level e Refill recommended DOT 3 brake oil when necessary Rear brake e Follow the front brake procedure to check the brake pads disk and oil Check the brake disk If the brake disk wear thickness less than 3mm or chap then change it Check the play of parking brake lever normal play 10 20 mm If the play of the rear brake over the normal value then adjust the adjusting nut of rear brake engine stopped then check the lining 2 8 parking brake leve CHECK AND ADJUST TIRE RIM e Check the tires whether have any nail broken etc e Check the tire pressure The normal tire pressure Front tire 1 68 kg cm 24psi Rear tire 1 68 kg cm 24psi e Checking the shaft and nut of front wheel whether loosen e Checking the nut of rear wheel whether loosen STEERING e Turning the steering from right side to left side check the steering operating e Be sure th
29. d contact of wire connectors e Starter clutch defect e Starting motor gear abnormally stock e Main switch defect l l e Break lever switch defect Starting Motor working engine does not working e Starter relay defect e Bad connection of wirin e Starter clutch defect e Rotation reversed of starting motor e Starting motor defect due to wrong connection e Low power of battery STARTING MOTOR d i ge Disassembly Before remove the starting motor turn off the main switch first To ensure the safety remove the ground green wire from battery and turn on the main switch to check the motor rotates or not e Remove the wire strip of starting motor e Take off 2 bolts and remove the motor e Remove the rubber cover and disconnect the wire e Check the movement of starting motor shaft e Check the motor rotation by connecting full charged battery direct to the starting motor When using the battery test motor be sure to hold the motor tightly to avoid damage Installation e Installation is based on reversed sequence e Check all wiring connectors rubber covers and O ring are installed correctly e Grease the O ring and install the starting motor with 2 bolts 15 1 STARTING SYSTEM STARTER RELAY Function check e Remove the R body cover e Turn on main switch and hold the brake lever then press the start bottom e The starter relay will make CLICK sound The CLI
30. dard 3 5 KQ 20 C without cap AC Generator pulsar coil e Remove the R side cover e Measure the resistance between pulsar wire green yellow and ground wire green Standard 40 300 Q 20 C 14 6 spark plug cap ELECTRICAL DEVICE Check Main Switch e Remove connector of main switch wire check conductivity between each terminal Remove main switch e Disconnect main switch wire Pull the main switch Bracket inside front cover e Push the stopper on main switch underneath front cover then push out the main switch 14 7 ELECTRICAL DEVICE e Check Left Switch HORN 14 8 ELECTRICAL DEVICE Head Light Witch Exchange of Bulbs Head light bulb Press down the bulb base and turn left to change head light bulb 14 9 ELECTRICAL DEVICE Rear light bulb Brake light bulb Rear direction light bulb e Remove 2 screws pull out the light cover then change bulb e Remove R L screw on direction light cover pull out the cover then replace the bulb SIGNAL Light Witch b singal cover bolt singal cover 14 10 ELECTRICAL DEVICE pilot lamp Press down the bulb base and turn left to change bulb SPEEDOMETER e Remove speedometer bracket FAA Va WTA 14 11 STARTING SYSTEM TR BLE DIAGNOSE eee Start enna Low Power of Starting Motor Pace broken e Low power of the battery e Low power of the battery e Ba
31. e wiring and cable does not affect the steering handle e Check the ball bearing on bottom of steering column whether is loose 2 9 CHECK AND ADJUST DRIVE CHAIN Check the drive chain condition e The drive chain should be check adjust and lubricate regularly e The free play of the drive chain should be between 20 30mm up and down e When install the chain clip beware the clip direction 2 10 ADLY MOTO STEERING WHEEL MUFFLER Information for preparation Don t enforce to remove the cover parts of the GK 125 otherwise will cause the connecting nail of cover parts broken Please according to the operating instruction when assembling the cables and wires Remove cover parts of the GK 125 Ne Steering Wheel Taking off 3 hex washer face bolt Disconnect main switch wire and lt gt neutral indicator wire Note When assembling the above parts that follow the opposite sequence of disassembling Attention x When assembling the above parts please confirm the connecting status of join section Note When you assembling the above parts that follow the opposite sequence of disassembling 3 1 ADLY MOTO STEERING WHEEL MUFFLER Muffler Locking Torque Muffler fixed bolt 3 5 kg m Muffler connect nut 1 2 kg m Trouble Diagnose Exhaust sound level is too high e Muffler broken e Muffler leakage Power isn t enough e Muffler leakage B e Muffler
32. erminal M White Yellow Red _ Green White 3 100k Yellow 5100k Pred o gt PS Green 5100 e 14 2 BATTERY CHARGE AND IGNITION SYSTEM Check the coils of AC Generator Charge coil e The check for charge coil of ACG can be done on engine assembly e Disconnect the 4P connector of ACG e Measure the resistance between ACG white wire and ground green wire Resistance 0 2 Q 20 C Lighting coil e The lighting for charge coil of ACG can be done on engine assembly e Measure the resistance between ACG yellow wire and ground green wire Resistance 0 1 1 0 Q 20 C Check resister e Measure the resistance between the resister and ground green wire Resistance 5W5 0 Q 4 0 6 0 Q Remove the AC Generator Disassembly e Remove the R body cover e Unscrew 2 fixed bolts and 2 tapping screws e Remove the cooling fan cover e Unscrew 4 fixed bolts on cooling fan r and remove the fan K di Fan cover 14 3 BATTERY CHARGE AND IGNITION SYSTEM e Use fixed spanner to hold the flywheel of generator e Unscrew the nut on flywheel e Use flywheel puller to remove the generator flywheel TLPT O1 e Remove the semi cycle key e Unplug the AC generator connecting wires e Remove the wire fix bracket e Take off the pulsar coil fixed bolts e Remove the rubber seal from crankcase and take off the generator flywheel puller e Remove the pulsar coil
33. f the crankcases This will avoid the oil leaking after assembly e Remove the gasket and dowel pins CRANKCASE CRANKSHAFT e Loose the cam chain and remove crankshaft from crankcase e Take out cam chain e Scratch off the gasket which between crankcases Do not damage the gasket area of the crankcases e Remove both oil seals from L R crankcases CRANKSHAFT e Check the tolerance between connecting rod and crankshaft Working limit Replace if over 0 55mm tolerance e Check the balance of crankshaft Working limit Replace if over 0 10mm CRANKCASE CRANKSHAFT e Rotate the bearings to check if any abnormal noise or loose e Use special tool if need to pull out the bearings TLCT 125 00 Bearing puller Replace complete crankshaft assembly if necessary Crankcase assembly e Press in the oil seal for L R crankcases and do not damage the inner part of the seals e Install the cam chain into L crankcase e Install the crankshaft into L crankcase Beware not to damage the oil seal by install the cam chain cam chain gasket e Install dowel pins and new gasket Setup the L crankcase on the bottom and install the R crankcase CRANKCASE CRANKSHAFT e Tie up 2 bolts on L crankcase Locking torque 0 9 kg m e Install the kick start driven gear e Install the cam chain adjuster guide e Install the new O ring on the fixed bolt for cam chain adjuster
34. fan cover clip a O 4 odin re Tesh G IN 4 iL lt Ki ewe ZOD AGT ae j ae mace x RESIS s i aes gy S i S Ve he a SS M VEAS bf VE a an 7 4 CYLINDER HEAD VALVE e Remove cylinder head Fixed bolts Cylinder head Dowel pin e Remove dowel pins gasket e Remove cam chain guide comp gt a Gr MT et E A be gt Cylinder head gasket mM ma ai z AA fh miiy 4 wat Cam chain guide comp eY e Clean the dirt on cylinder surface Attestation Be careful not to damage cylinder Valve spring holder tool contact surface Be careful do not drop anything into engine Valve spring holder tool TLCT125 02 Disassembly cylinder head Use valve spring holder tool to remove the spring holder cotter spring valve and seal Valve spring must use special tool to disassembly Parts removed have to place in certain order assembly in opposite order 7 5 CYLINDER HEAD VALVE e Clean carbon material inside combustion chamber e Clean gasket material stick on cylinder head surface Attention Beware not to damage the contact surface of cylinder head Check cylinder head Check the hole of spark plug and valve guide to see if it s damaged Check valve spring Working limit Outer spring Replace under 34 1mm Inner spring Replace under 31 2mm Check valve and valve guide Check v
35. if wear out or damaged e Check the inside diameter of cover Working limit Replace if over 125 5 mm e Check the clutch lining if wear out or damaged e Measure the thickness of the clutch lining Working limit Replace if under 1 5 mm The clutch lining and driven face can not have any oil attached e Inside the boss of driven face assembly should be greased Use 9 9 5 g to grease fairly 9 6 clutch cover grease TRANMISSION KICK START KICK STARTER Disassembly e Remove L crank case cover 9 1 e Remove gasket and dowel pins e Remove drive face and belt 9 2 e Remove the washer on starter spindle assembly e Remove the kick starter stop plate and the starter spring e Pull out the starter spindle assembly starter spring e Remove the starter idle gear assembly Disassembly e Disassembly starter spindle assembly e Check if the spindle wear out or er damaged peo e Assembly the starter spindle based on reversed procedure The starter spindle should be greased TRANMISSION KICK START e Disassembly the starter idle gear to check if there is any damage e Assembly the gear should base on reversed procedure Check e Check the contact surface of L crankcase and crank case cover if there is any damage or wear out Installation e The pin on starter idle gear shaft should aim at the correct position of L crankcase The pressed line on starter gear
36. must use the electrical meter TROUBLE DIAGNOSE No Electrical Power No Continues Current e Over discharged of the battery e Bad contact of battery with main wire e Wire hardness did not connected to hardness the battery e Bad connection of charge system e Fuse broken e Bad contact of the lighting system e Main switch defect cause short circuit Low Voltage Charge System no function e Battery charges insufficient e Bad connection of the wire hardness e Bad connection connectors e Charge system defect e Main wire hardness broken or short e Regulator rectifier defect circuit e Regulator rectifier defect e AC Generator defect 14 0 BATTERY CHARGE AND IGNITION SYSTEM BATTERY Remove the battery e Take off the battery fixed plate e Disconnect the wire GR than the wire RD Beware not to contact with frame body when disconnect the terminal It will damage the battery even the flaming will cause fire with gasoline e Check the voltage after disconnected e Measure the voltage from both terminals Fully charged 12 8V Charge insufficient 12 0V x Connect the wire RD than the wire GR to avoid short circuit e Installation based on reversed ce procedure battery CHARGE Connection Charger to battery Charger to battery Avoid any flaming material around the battery Turn off the charger before start or after finish the charge operation The spark may cause ex
37. nside combustion chamber Air stock inside air cleaner Too much fuel cause over flow By passed air sock into fuel system Degeneration of gasoline Starter plunger defect Stock of idle system or chock system Too thick of Fuel Air mixture Starter plunger defect Float needle valve abnormal Too much fuel cause over flow Stock of airflow inside carburetor Stock of air cleaner Fuel level too high Muffler make explore noise when deceleration e Too much air e Air stop valve abnormal e Too thin of F A mixture at idle speed Ignition not continuously when accelerate e Ignition system abnormal e Too thin of F A mixture Difficult to start Engine stops after start up Idle speed not stable Stock of fuel system Ignition system abnormal Fuel Air mixture too thin or thick Degeneration of gasoline By passed air sock into fuel system Bad adjustment of idle speed Bad adjustment of fuel quantity Fuel or airflow stock of idle speed Too much fuel cause over flow Stock of starter plunger system Bad adjustment of fuel level Too thin of Fuel Air mixture Stock of nozzles inside carburetor Stock of float valve Fuel level too low Stock of fuel system By passed air sock into fuel system Vacuum film abnormal Throttle valve abnormal FUEL SYSTEM CARBURETOR Removing e Remove the R L side body cover center cover rear carrier seat and helmet box e Remove the auto plunger wire from carburetor e Loose the fuel relea
38. on pin and piston wear out 8 0 CYLINDER PISTON REMOVE CYLINDER e Remove cylinder head e Remove the cam chain guide comp e Remove the cylinder e Remove the cylinder gasket and dowel pins e Clean the gasket stick on cylinder REMOVE THE PISTON e Take off piston pin clip x Beware not to drop off the clip into crankcase e Take out piston pin and remove the piston e Check the piston piston pin and piston rings x Beware not to break or damage the piston rings e Clean the residual carbon around the piston ring and ditch on piston 8 1 CYLINDER PISTON e Mounting the piston rings and measuring the gap between piston ring and piston ditch Working limit Top ring replace above 0 09mm 2 ring replace above 0 09mm e Take off piston rings and put into the bottom of cylinder Use piston to press the ring into cylinder e Measure the opening gap of the piston ring Working limit Replace if over 0 5mm e Measure the hole of the piston pin Working limit rer nen oe n Replace if inside diameter is over 15 04mm e Measure outside diameter of piston Z pin Working limit Replace if under 14 96mm e Measure outside diameter of piston x It s important to measure the outside diameter with vertical position The measure point is about 9mm away from the bottom Working limit Replace if under 52 3mm 8 2 CYLINDER PISTON Piston rings installation e E
39. oo low Compression Pressure too low Bad adjustment of valve tolerance Valves banded or burn Valve timing not correct Damage of valve spring Sealing of valves and seats abnormal Leaking of cylinder head gasket Bottom of cylinder head damaged Wrong installation of spark plug Valve gap adjustment 0 12 mm Compression Pressure too high e Too much carbon residue inside combustion chamber Emission with White Smoke e Valves or valve guide attrition e Oil seal on valve attrition Noise e Bad adjustment of valve gap e Valve burn or spring damaged e Camshaft or rock arm attrition e Attrition of cam chain guide comp CYLINDER HEAD VALVE ___ Cylinder head cover Remove the camshaft e Take off 4 bolts on cylinder head cover and remove the head cover e Removing the cam chain adjuster cover screw e Locking the inside small screw of the cam chain adjuster that the locking direction is clock wise Camshaft sprocket a m l Pii cam chain i ng Fix bolt 4 R Straight line e Let the T mark on ACG fly wheel aim at the crankcase sign The big hole on camshaft gear toward up then the camshaft position is on TDC 7 1 CYLINDER HEAD VALVE e Remove 2 fixed bolts on cylinder pa EAA A ENS VE SAE head e Remove hex nuts and washers on eo washer camshaft holder Unscrew the bolts cross wise for 2 3 times e Remove the camshaft holder and dowel pin
40. orking limit Replace if outside diameter is under 17 3 mm Check e Check inside diameter of the movable drive face Working limit Replace if over 24 10mm e Check the damage and wear out of movable drive face boss e Measure sliding outside diameter of the boss Working limit Replace if under 23 90 mm 9 3 cam plate weight roller TRANMISSION KICK START Assembly diagram e Put the weight rollers into movable drive face e Install the cam plate cam plate e Put the boss into drive face assembly boss movable drive face 9 4 TRANMISSION KICK START Installation e Put the movable drive face assembly into the crank shaft movable drive face Se a e Put the drive belt into rear driven face assembly e Put the drive belt on the boss of movable drive face assembly e Install the fixed drive face washer and nut e Use fixture to hold the drive face and nut tie up the nut Locking torque 5 5 kg m Drive belt and drive face can not have any oily material After tie up the nut move the drive belt to normal position f ae j i b N Fae 2 ae e drive face E 4 de hw 7 6 9 5 TRANMISSION KICK START CLUTCH DRIVEN FACE ASS Y e Remove the L crank case cover 9 1 e Remove the fixed drive face and drive belt 9 2 e Use fixture to hold the clutch cover and loose the nut e Remove the clutch cover Check e Check the cover
41. plosion during connecting Please follow the charge instruction on battery as the operation standard Don t use quick charge unless urgent x Measure the voltage after finish charge for 30 minutes Charge current standard 0 7A Charge time standard 5 10 Hr Battery voltage above 12 8V 14 1 BATTERY CHARGE AND IGNITION SYSTEM CHARGE SYSTEM Check the charge condition e The battery must be full charged in order to check the charge condition Use electrical meter for measuring e After engine warm up and use the full charged battery to check e Connect the voltage meter on both terminal of battery e After start up the engine disconnect the fuse and connect the current meter on both end of the wire terminals e Use RPM meter to measure the engine revolution Voltmeter e Slightly increase the engine revolution to measure the voltage and current Charge voltage and current 13 5 15 5V 1 0 A under 5000rpm im gt 4 i oN h YY A J T f sA Se terminal of 7 main fuse e If the value does not meet the requirement check the regulator rectifier main fuse Check the headlight charge condition e Remove the headlight cover Set the electrical meter on AC stage e Check from the headlight connector Voltage 12 14V AC 5000rpm e If the value does not meet the requirement check the regulator rectifier Regulator rectifier e Measure the resistance of each t
42. s eRemove the cam chain gear from cam chain then take out camshaft e Check the cam surface to see if it s wear out or damaged Working limit Replace if IN cam under 25 57 mm EX cam under 25 41 mm 7 2 CYLINDER HEAD VALVE e Check the camshaft bearing to see if it s wear out or loose If it s loose or damaged then change whole set of camshaft Disassembling the camshaft holder e Using 5 mm bolt to screw in and pull out the rock arm shaft e Remove the stopper plate and rock arms Rock arm Rock arm shaft 5mm bolt e Check the camshaft holder rock arms and rock arm shafts holder If the sliding face of rock arm wear out then check the cam surface of the cam shaft e Check the inside diameter of camshaft holder on rock arm activity part Replace above 10 10 mm e Check the inside diameter of rock arm Replace if above 10 10 mm e Check the outside diameter of rock arm shafts Replace if below 9 91 mm e Check the gap between the rock arm and the rock arm shaft Replace if above 0 10 mm 7 3 CYLINDER HEAD VALVE Check the stopper plate One way plate e Check the stopper plate and spring e Check the movement of the one way plate Disassembly the cylinder head e Remove camshaft e Remove carburetor e Remove exhaust muffler e Remove carburetor intake manifold stopper plate e Remove cooling fan cover e Remove bolts screws and engine cover e Open up
43. see sects SORES X Zi B lt Kx 2 SF oe lt 5 oe SRS Se RIS sea lt x 3 s KRY te see uS SKS cece aes SKS w IRS Disassembly Pan phillips bolt 6 15 Fuel tank net Hex bolt 6 16 Clip Fuel tube Hex washer face bolt 6 16 Fuel cap Remove the fuel tank together with fuel Fuel tank comp cock OANNNB WN Assembly Operating with sequence in reverse 8 of disassembly REMOVE OF ENGINE Attention of Operation e Operation after disassembling the engine Crank shaft case Crank shaft Exchange bearing of final transmission mechanisms Disassembly of Engine e Disassembly of external cover of body e Disassembly of throttle valve and cable 1 Air Cleaner Ass y l 2 Exhaust muffler l 6 1 Drive Sprocket Ass y Nylon nut of engine plain washer of engine Hex washer face bolt of engine Hex washer face bolt of engine Engine Assembly 81 6 2 x WARNING Actually for brace the frame avoid body turn inside out WARNING Carry out following adjusting after installation REMOVE OF ENGINE Disassembly of Muffler nA BW N Re e Assembling with sequence in reverse of disassembly Assembly 5 gt Disassembly Take off the engine Ass y 1 Nut cap 6mm 1 Hex washer face bolt 8 32 2 Exhaust bracket l Muffler l CYLINDER HEAD VALVE 1 2kg m TROUBLE DIAGNOSE Idle Speed not Stable e Compression pressure t
44. sing screw of the carburetor and release the fuel in float chamber e Remove the fuel tube and vacuum pressure tube e Loose the adjusting and fixed nut of throttle cable e Removing the throttle cable e Loose the clamp on intake manifold and remove the carburetor AUTO PLUNGER STARTER Check function e After the engine stop after 10 min then check resistance on both terminals If there is no resistance between terminals then change a new auto plunger 5 1 Auto plunger wire fuel tube i ba i t G Ts gt j n h js r a i 1 t vacuum tube vacuum tube FUEL SYSTEM Disassembling e Remove screw and mounting bracket e Remove the auto plunger starter form carburetor Check Check the auto plunger starter needle and valve whether wear out If it s damaged then change the plunger The YL wire on auto plunger starter connect with terminal and the GR wire connect with the terminal of battery After about 5 min the auto plunger starter warm up then the needle will go up Otherwise the auto plunger is damaged and need to change the plunger Installation Put the auto plunger starter into carburetor Put the fixed plate firmly on the dint and locking screw Auto plunger starter bracke Needle bracket FUEL SYSTEM AIR VALVE Disassembling e Remove the vacuum pressure tube e Take off 2 screws and remove the pres
45. sure film cover spring and film Assembling e Mounting the film into carburetor e Put the spring gt cover back then locking 2 screws Attention x When mounting the film the dint of the film have to aim at correct position of carburetor VACUUM PRESSURE CHAMBER Removing e Take off 2 screws and remove the cover e Remove the vacuum film with piston 5 3 vacuurn film piston SCrews Vacuum chamber cover FUEL SYSTEM e Push the fixed clamp and turn L side to take out the clamp e Remove the spring and needle Beware not to damage the vacuum film Check e Check the needle whether wears e Check the piston whether damaged e Check the film whether chapped or damaged Assembling e Put the vacuum film and piston into the carburetor body e Keep the piston of film at top Position throttle full open position e The upheaval of film aim at the dint of carburetor body e Mounting the cover and locking the screws Be careful not to damage the film Hold the piston at full open position when locking the screws of the cover FLOAT CHAMBER Disassembling e Loose 4 screws on the float chamber cover e Remove the float pin float and valve 5 4 bolt vacuum chamber cover float chamber FUEL SYSTEM Check e Check the float valve and valve set whether damage or blocking e Check the surface of float needle and valve seat whether grimy or wear o
46. t e Driven ass y spring defect e Drive face comp damage e Drive face dirty or oily e Clutch lining wear out e Weight roller wear out e Driven ass y spring defect TRANMISSION KICK START LEFT CRANKCASE COVER Disassembly e Remove the kick starter arm e Take off fixed bolts and remove the L crankcase cover e Remove the gasket and dowel pins Assembly e Install the gasket and dowel pins e Install the L crankcase cover Do not pull out kick starter spindle and press the spindle firmly when e All brackets for cables have to set into correct position and tie up to the cover e Be sure all cables go into the bracket 9 1 TRANMISSION KICK START Drive face disassembly e Remove L crankcase cover e Use fixture to hold the drive face and take off screw washer and drive face e Take off drive belt from movable drive face assembly Check e Check the drive belt to see if it s damaged rubber fiber came off or any other abnormal wear out e Check the width of drive belt Working limit Replace if under 19 0mm Use genuine parts to replace Movable drive face ass y movable face ass y Boss movable drive face ae mY Ed e Take off the movable drive face assembly TRANMISSION KICK START Disassembly e Remove the cam plate e Remove the weight roller Check e Check the wear out and damage of weight roller e Measure outside diameter of weight rollers W
47. the brake pedal for safety B Turn the main switch to right in order to start the engine C Do not continue to start up the engine for more then 10 seconds O OOOUOUOOU oO N e o Nl NHN aa A W P D I Pre Delivery Inspection For GK 125R Record the frame and engine number into the owner s manual Check that all tires have correct pressure specified on the tire or in the owner s manual Engine oil 4 stroke 10W 40 is enough Battery is installed properly All brake cables are adjusted properly Fuel tank has enough gasoline to operate Check the suspension and drive chain for proper setup Check that all electrical components and lights are working properly Make sure that the owner s manual and tool bag are installed properly INFORMATION FOR PREPARATION Attention on Operation All washers oil rings clamp rings opening pins shall be duly replaced by a new item when dismounted O Q Locking of all screws nuts cross screws shall be performed in the order of first the large screws and then the small ones and from inside to outside in opposite angles by tightening the torque locks All items must use original parts pure oil and greases 2 All service shall use special tools and general tools to repair All dismounted items requiring for checks shall be duly cleaned and for assembly all items shall be duly lubricated 1 1 INFORMATI
48. the voltage between regulator and frame main switch at ON main switch at ON L 3 the battery have the battery have no GR wire broken voltage voltage BUE 4 check the socket of regulator SSeS aS J regulator damage 1 9 INFORMATION FOR PREPARATION SPARK PLUG NO SPARKING Diagnose normal abnormal 5 normal abnormal L normal abnormal normal abnormal abnormal Check and Adjust change spark plug and check again check spark plug cap ignition coil loosen te e a a a a i M check C D I unit socket loosen te e a i i M check the terminal of C D I unit unimpeded measure resistance Gs ee ee check relate spare parts em i i eC SSS SS SS SS SS change CDI unit Ena eS Se ee J LESS SS SS Se 1 10 Reason of Trouble the previous spark plug damage spark plug cap loosen socket damage main switch damage pulser coil damage coil damage lighten coil damage main switch damage socket joint connect abnormal the previous C D I unit damage the previous coil damage CHECK AND ADJUST INFORMATION WARNNING Do not start the engine at a close zone because the exhaust gases from the engine including some noxious emission such as CO HC NOx etc that can result serious damage for ealth Strictly prohibit using any flammable thing in the working zone because that can rise fire easily ENGINE ITEM SPECIFICATION REMARK Throttle Free Pla
49. to the top E and two small holes on L R side Epo straight horizontally to the cylinder _ top edge camshaft cam direction meaty face down e Install chain onto camshaft gear TDC hole e Install dowel pins e Put the camshaft holder washers and bolts then tie up the bolts on cylinder head Locking torque for cylinder head nuts 2 0 kg m Grease on top of the stub bolt Unscrew the bolts cross wise for 2 3 times e Adjust gap between valve and valve screw e Counter Clock Wise rotates the small screw in cam chain tension adjuster will release the adjuster The tension adjuster will adjust cam chain automatically 7 8 CYLINDER HEAD VALVE New O ring should be greased before tie up the cover screw x ring must put into the correct position Replace new O ring on cylinder head cover before assembly the cover The O ring must fit into the cover with correct position e Tie up cylinder head cover fixed bolts cylinder head cover CYLINDER PISTON 1 0kg m Ase TT gt band prohibited TROUBLE DIAGNOSE Low compression pressure Exhaust with white smoke e Piston ring wear out burn or broken e Piston ring wear out burn or broken e Cylinder piston wear out or damaged Cylinder piston wear out or damaged Compression pressure too high Piston noise e Piston or combustion chamber stocks e Piston cylinder or piston ring with carbon material damaged e Pist
50. urning at high 1 6 Reason of Trouble air cleaner blocking fuel supply isn t smooth air hole of air tank blocking exhaust pipe blocking auto plunger starter damage film of carburetor damage fuel cup damage C D I damage pulser coil damage valve gap adjusting isn t correct valve set over abrade valve set damage cylinder piston abrade cylinder gasket leakage valve timing isn t correct cleaning carburetor cleaning the stain spark plug type isn t correct oil flowing is too rich oil flowing is too lean oil doesn t circulate oil tubing blocking oil supply is too lean cylinder piston abrade mixutre gases is too lean carbon residue in combustion chamber is too more igniting time is too earily fuel isn t good clutch sliding mixutre gases is too lean carbon residue in combustion chamber is too more igniting time is too earily fuel isn t good INFORMATION FOR PREPARATION REVOLUTION NOT STABLE LOW R P M Diagnose Check and Adjust Reason of Trouble C D I damage normal abnormal pulser coil damage adjust the carburetor fuel adjuste screw mixture gases too lean E had adjusting isn t i adjusting is correct J 8 coosme N correct mixture gases too rich locking screw gasket damage l f the screw of carburetor is no sucking air sucking air oei pressure tube broken loosen spark plug connecct with spark cap and contract with frame l
51. ut If the float valve or valve seat is grimy or wear out that will cause the fuel level higher and leakage e Remove the main jet main jet seat nozzle pilot jet and the fuel adjusting screw Beware not to damage the jet and adjusting screw Before remove the fuel adjusting screw remember mow many turns into the end To avoid the damage of carburetor do not force to lock the fuel adjusting screw e Use clean fuel to wash all parts e After grimy material cleaned use compression air to clean each tunnel The vacuum pressure chamber and air valve can be cleaned at the same time Y gt FUEL SYSTEM Assembling Drawing e Install the pilot jet main jet seat main jet and fuel adjusting screw Before remove the fuel adjusting screw remember turns of setup into the end position The normal setup is 3 1 8 3 4 turns out elnstall the float float valve and float pin 5 6 FUEL SYSTEM Mounting the carburetor e When install the carburetor the embossment of carburetor have to fit into the correct position of intake manifold e Locking the screws of 2 clamps e Mounting the throttle cable on the control wheel e Install the vacuum pressure pipe and fuel hose fue tube Vacuum tube e Connect with the auto plunger wire e Adjust the position of throttle cable e Adjust the idle speed Setup of the fuel adjusting screw Adjust Fuel adjusting screw was setup in the
52. y 26mm o o Spark Plug Gap 0 6 0 7 mm O toa CTHSA CR7HSA EN 0 06mm intake valve Idle Speed 1700 100 rpm ey TEE EE 0 75 L only change engine oil Gear Oil 300cc only change gear oil 12 8kg cm 570 RPM Ignite Timing 13 BTDC 2 1700100 rpm CHASSIS ITEM SPECIFICATION REMARK Parking Brake Free Play 10 20 mm i Ue 68 klem OAD ust igen 2 Torque of Front Tire Nut 3 5 kg m Torque of Rear Tire Nut 11 0 kg m 2 1 CHECK AND ADJUST MAINTENANCE SCHEDULE Please follow the maintenance schedule to do the routine maintenance I Inspection and clean lubricate correct replace if necessary A Adjust R Replace C Clean Regular Service Mileage km 1000011000 12000 ema fa fefefe fefefe e ee eTe Clean the plug for each 3000 km replace it if necessary a E o a suspension if f fal S Sf fa a ee see 7 11 11e11 111 1 Note 1 If the vehicle is new then the motor and gear oil have to replace at the first 300 km 2 For safety reason we suggest the maintenance should be done at local service center 3 If the driving condition is very abominable such as rainy dust zone or heavy load that we suggest operating maintenance more frequency 2 2 CHECK AND ADJUST FUEL FILTER N e The filter is located underneath the gt e fuel filter carburetor oa e Check the fuel pipe If the tube has lt 9 any damage then change it g NN WARNNING Smoking prohibited THROTTLE LEV

SERVICE MANUAL - Sarner Trading AB

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