Service manual part engine For CG-125/150
Contents
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3. 4 U 69 TE Hartford Industrial Co Ltd Qaror 10 CG Electrical system a Z O S NMOQ 2 2001 O OT dN D OSZT W31SAS JONAYSIYALNI OIGVY LLNY ALON bueu ON JNOUTJOAO DINIJEJAAWA L JUEJSUOD 508 1941 41 U 39 1915 2141231310 LULUQ uudi000T 00 MOjeq 10 jenba Z NVd Wd NOLLINDI SNONNILNOD LULUQ LUGUOOE Mojaq JO jenba NOLLINDI SNONNILNOD 404 Wdd LSdA O O 0 Forza O 00 FTEO TU JONVLSISAY IVDILVLS WALSAS OIGVeFIINV o 4 172 OS 10 4 Coil comp Hartford Industrial Co Ltd 10 Electrical system 10 5 Electrical assembly draw REAR BRAKE ASSV IN WINKER RELAY IN IGNITION SWITCH OUT START IN FRONT BRAKE ASSY IN NEUTRAL INDICTOR IN
4. 6 3 2 nstalling the right crank case cover 6 7 Service manual part Engine for CG 125 150 HARTFORD INDUSTRIAL CO LTD Hartford Industrial Co Ltd 2640 6 Clutch Transmission 6 1 Reason a breakdown If the clutch operation is faulty first attempt to cure the condition by adjusting the clutch cable A Clutch slips under acceleration 1 No slack in the clutch cable 2 Clutch plates worn 3 Clutch springs weak B Clutch fails to release vehicle creeps in gear 1 Too much slack in clutch cable 2 Distorted clutch parts C Clutch lever loose 1 Clutch cable 2 Clutch operating mechanism worn or damaged D Difficulty changing gear 1 Gearshift plate distorted 2 Clutch cable adjustment incorrect E Gearshift pedal detent poor 1 Gearshift return spring broken or displaced 2 Gearshift shaft distorted F Transmission jumps out of gear 1 Gearshift cam detent spring broken G Low oil pressure 1 Oil pump gears worn 2 Oil pump faulty Hartford Industrial Co Ltd Special tools Four leg socket wrench Air impact wrench Tightening torque Clutch cover screws 0 8 1 2 kg m Oil filter cover screws 4 0 5 0 kg m Clutch operating arm free slack Clutch spring free length Clutch friction plate thickness Clutch plate distortion Oil pump inner rotor clearance Outer rotor to body clearance Oil pump cover plate clearance 6 1 1 Removing the right crank case cover Remove the exhaust Remove the foot
5. 6 3 2Installing the clutch cover Install the clutch cover Lever cork clutch x Install the clutch cable Install the kickstarter and exhaust pipe Refill the engine with fresh oil Adjust the clutch cable free slack crankcase Chapter 7 Carburetor 7 1Reason a breakdown 7 1 7 2Carburetor 7 2 7 2 1 Names of carburetor parts 7 2 17 2 2 Removing the carburetor 7 2 7 2 3 Throttle valve 7 3 7 2 4 Removing the float and float needle 7 3 7 2 9 Installing the float and float needle 7 4 7 2 6 Replace the throttle slide 7 4 7 2 7 Inspecting the float needle 7 5 7 2 8 Adjusting the float height 7 5 Service manual part Engine for CG 125 150 HARTFORD INDUSTRIAL CO LTD Hartford Industrial Co Ltd rd 7 Carburetor sH 7 1 Reason a breakdown Engine fires but doesnt run No fuel in the fuel tank Fuel not reaching the carburetor Fuel mixture excessively rich No spark at spark plug ignition system faulty Air filter blocked Poor idling Idle speed incorrect Ignition system faulty Low cylinder compression Fuel air mixture excessively rich Fuel air mixture excessively lean Air filter blocked Fuel dirty or contaminated Fuel air mixture excessively lean Carburetor jets blocked Carburetor body air passages bloc
6. AG L Mol q JO jenba 39VL10A ONILVH1dO NE MOJ9Q 10 jenba 1N3M1Mn2 NOLLVZIDHIANI VOST LINIHHND IVNIWON ACTOd ADVLIOA IVNIWON NOILVOISID4dS or OST m IVNIWH4L ww QS I VE got 9S je Hartford Industrial Co Ltd x O CG Qand 10 Electrical system 10 3 Regulator YO BY urep UBD 25419 9 ad pjnous YONW MOY 1no pul 0 SI peoj pue Ayayyeq S OOJ UJIUM OUIJ p l H SUILUeXS o sod nd y n3119 JOJJUOD pue jeu is q 0 euis Oy aBueyo JIM U pa d zZa ta o yndul o y ld d u MOJJSAJA IBUDIS OV seonpoid 4oyemb l ul VINJEWIV peo Jo y pue bicu Ayayyeg aul 10 Neyo ajenbape 0 pue o s soye nGa jo qof urew SUL B euo s neg 10 Jamod puss o Sp U JI MOUY O Bujono Aq Asayeg jo BDEJJOA au SUIWIEX9 OL JRUBIS oq Sueu o 1ol e n6 i uSnolul ssed 1snuu u snu jeubis OV 01 DENHOA 5 IIOO lmnicuiy 5 SV HNOD 1734 D4H 99 Fi T 9MNDI4 9 L Mv vf 4 00 A L q
7. 1 882 17 32 1 722 18 31 1 882 17 32 3 gear 1 272 22 28 1 400 20 28 11 272 22 28 11 400 20 28 4 gear 1 000 25 25 1 130 23 26 1 000 25 25 1 1 130 23 26 5 gear 0 960 25 24 0 960 25 24 Final education 2 773 15 41 2 773 15 41 2 773 15 41 12 773 15 41 Hartford Industrial Co Ltd 2 General Specifications aS 2 5 Other 2 5 1 Ignition system CDI electronic ignition 15deg BTDC 2 1400rpm Maximum advance 32 35deg 3500rpm 32 35deg 3500rpm Combustion type Cyclic Cyclic AS41 AS41 NGK D7 or DR 8EA NGK D7 or DR 8EA 12x 19 12x 19 0 6 0 7mm 0 6 0 7mm 125C C 4 5 speed 150C C 4 5 speed ACG flywheel Voltage regulator Solid state Solid state rectifier Maximum output 0 12kw 5000rpm 0 12kvv 5000rpm 2 5 3 Base 125C C 4 5 speed 150C C 4 5 speed Starting Kick and electric Kick and electric Battery capacity 12V 6AH 12V 6AH Fuse rating 15A 15A Hartford Industrial Co Ltd 2 General Specifications 2 5 4 Torque settings Reference settings 5mm UNT BOLT 6mm UNT BOLT omm UNT BOLT 10mm UNT BOLT 12MM UNT BOLT 5mm SCREW 6mm SCREW 6mm RAISED EDGE SCREW 8mm RAISED EDGE SCREW 10mm RAISED EDGE SCREW Hartford Industrial Co Ltd 2 General Specifications 2 5 5 Points for attention 1 After disassembling replace all the washer oil ring and clips 2 Fasten the nuts by the diagonal way 3 Use the specified parts and lubricating oll 4 Use t
8. 1 8 1 1 Removing the engine 8 1 8 1 2Installing the engine 8 3 Service manual part Engine for CG 125 150 HARTFORD INDUSTRIAL CO LTD Hartford Industrial Co Ltd 8 Removing and installing the engine 8 1Removing and installing the engine 8 1 1 Removing the engine Drain the engine oil Turn the fuel valve to the OFF position Remove the cover left rear crank case and pedal gear change Remove the generator wires Remove the control cables and retaining nuts Remove the tachometer cable Loosen the rear wheel axle Loosen the chain adjusters and slide the rear wheel forward Remove the master link and release the drive chain Hartford Industrial Co Ltd 8 Removing and installinc Removing the spark plug cap Removing the spank plug l ig sap 4 ye wily ee lt Removing the carburetor mounting nuts and dismount the carburetor Remove the crankcase exhaust hose Removing the clutch cable Removing the kick starter Hartford Industrial Co Ltd 8 Removing and installinc Removing the exhaust pipe nuts Removing the exhaust pipe Removing the bar comp step Removing the front engine mounting plate Note Before removal support the front of the engine with a suitable stand or block of wood Removing the starting motor cable Remove the rear engine mounting 8mm bolts Remove the above engine mounting bolt
9. Replace the coil with a new part if necessarv Replace the coil taking care to avoid the coil or its leads touching the rotor Replace the rotor and tighten the retaining bolt to 2 6 3 2kgm torque 5 1 4Installing the lift crank case Replace the alternator cover with the stator coil installed Refit the electrical connector block Replace the electrical wire to the neutral indicator switch Replace the rear half of the left side engine cover Replace the gearshift pedal Replace the starter gear cover Hartford Industrial Co Ltd 5 Generator Start motor 5 2 1 Removing start motor Remove the starter motor cable from the terminal Remove the starter motor retaining screws Remove the starter motor 5 2 Start motor IC m 5 2 2 Removing the starter drive gears 3 Remove the starter motor drive gear shaft Remove the starter reduction gear and shaft Reassemble is the reverse of disassembly 5 2 3lnstalling the starter motor Reassemble is the reverse of disassembly Replace the starter motor and tighten the retaining bolts to 0 8 1 2kg m Chapter 6 Clutch Transmission 6 1Reason a breakdown 6 1 6 1 1 Removing the right crank case cover 6 2 0 20 Oa a 6 3 6 2 1 Removing the clutch 6 3 6 2 2Check the clutch 6 4 6 3 FANSMISSIONI 6 5 6 3 1Removing the gearshift mechanism 6 5
10. date testing and measurement devices are used to assure that the engines we ship will meet your most exacting standards We also maintain a comprehensive spare parts inventory with items available for immediate delivery No matter what your type of motorcycle we have the performance engines to meet your needs at the right price Hartford employs a wide variety of sophisticated testing instruments for rigorous testing of the engine performance Chapter 2 General Specifications 2 1 Profile diagram and Main part name 2 1 2 1 1 Profile diagram 2 1 2 1 2 part 2 2 2 2 Engine specifications 2 3 2 3 Lubrication system 2 4 2 4 T ransmission 2 5 2 4 1 Clutch 2 5 2 4 2 2 5 2 5 Other 2 6 2 5 1 Ignition system 2 6 2 5 2 Generator 2 6 2 9 a OS a 2 6 2 5 4 Torque settings 2 2 5 5 Points for attention 2 8 2 5 6 Special tools 2 9 Service manual part Engine for CG 125 150 HARTF
11. or x x R ground body and aulty check for spark x 2 CD unit faulty 3 HT lead or spark plug when cranking 7 cap open circuit or engine faulty ee 4 lgnition coil open circuit or faulty 5 AC generator faulty Spark at plug No spark or weak Ignition switch faulty spark at plug Test cylinder Piston rings or valves compression i os stuck Valve clearance incorrect Compression Compression Cylinder or piston rings excessively worn pressure normal pressure low Cylinder head gasket leaking or damaged Decompressor leaking Attempt to start x cracked 6 Poor starter motor engine performance Transmission faulty Engine fires and Engine fires but will 1 1 Air filter blocked Fuel delivery insufficient runs not run Fuel cap vent blocked Exhaust blocked Carburetor idle mixture screw setting incorrect 1 Clutch slipping 2 Glutch face damaged or faulty 3 Clutch plates damaged or faulty Spark plug wet Spark plug dry Close choke and start Hartford Industrial Co Ltd Hartford 3 Reason a breakdown 3 2 Engine output poor Teade x u 2 Fuel delivery insufficient 3 Fuel cap vent blocked Engine won t idle 4 Exhaust blocked Engine idles 1 Clutch slipping Vehicle does not 2 Clutch face damaged or faulty accelerate in gear 3 Clutch plates damaged or faulty Ignition timing 1 CDI unit faulty incorrect 2 A
12. that the valves move freely inside the valve guides Measure the diameter of the valve stems Valve guide inside diameter service limit Inlet valve service limit 5 42mm Inlet valve service limit 5 40mm Valve guide inside diameter service limit Inlet valve 5 50mm Exhaust valve 5 40mm Before measuring the valve guide diameter remove carbon deposits Subtract the stem diameter from the valve guide inside diameter and obtain the clearance Inlet valve 0 08mm Exhaust valve 0 10mm If the clearance exceeds the service limit replace the valve and or the valve guide Note when replacing the valve or guide the valve seat must be ground Hartford Industrial Co Ltd 4 Cylinder cylinder head valves and piston 4 4 9 Inspect overhaul the valve seats Remove the carbon deposits from the inlet and exhaust valves Place a smear of red ink on the valve contact face and rotate the valve in it s seat twice Observe the width and regularity of the contact patch Replace with new parts valves that are bent or burnt If the valve seat is pitted or burnt it must be ground Use 4 to 5 kg of pressure and a right left rocking motion to re finish the valve seat surface Use oil First use a 45 degree cutter to face the valve seat then a 32 degree cutter to face the next 1 4 of the total seat width The 60 degree cutter is used to face the next 72 of the total seat width Finally the 45 degree c
13. tighten idle mixture screw 1 Insulator gaskets damaged Air leak or leaking Ir leaKINQ 2 Carburetor mounting nuts loose 3 Intake manifold gaskets damaged or leaking 4 Carburetor flange seal _ Remove spark plug x damaged or leaking x ground body and check for spark when cranking x engine 1 Spark plug fouled or worn 2 CDI faulty 3 AC generator faulty Spark at plug Poor or no spark at 4 gnition coil open circuit or plug faulty 5 HT lead or spark plug cap short circuit or faulty Start engine Hartford Industrial Co Ltd Possible reason Hartfordo 3 Reason a breakdown 3 4 Poor high speed running Possible cause Check fuel flow to carburetor nq N Insufficient 2 Fuel line or filter Normal ici 3 Fuel cap vent blocked 1 CDI faulty 2 AC generator faulty 3 Spark plug fouled or fuel mixture incorrect 1 Chain adjustment N Slack present a s orma 3 Shaft or bearings damaged or faulty Start engine 4 4 Insufficient engine oil Hartford Industrial Co Ltd 3 Reason a breakdown 3 5 Starter motor inoperable Switch on turn signal Check battery leads Flash 60 to 20 times per u Starter motor turns minute Operate starter switch check if starter turns Starter motor turns Starter motor does not turn Starter motor Fault in main wiring harness Possible cause No flash or no li
14. 4 Piston ring 2nd assembly tool for 150c c 60000108 TOOL 5 Piston ring press down assembly tool for 125c c 60000109 TOOL 5 Piston ring press down assembly tool for 150c c 60000110 TOOL 6 Rod push screw assembly tool for 125 150c c 60000111 TOOL 7 Cap 30 mm assembly tool for 125 150c c 60000112 TOOL 8 Mixing ratio adjust tool for 125 150c c 65000145 Hartford Industrial Co Ltd 2 General Specifications VALVE IN amp OUT TOOL CRANKCASE ASSEMBLY FRAME PART NO 60000310 Chapter 3 Reason a breakdown 3 1 Engine is difficult or impossible to start 3 1 3 2 Engine output poor 3 2 3 3 ldle or show running poor 3 3 3 4 Poor high speed running 3 4 3 5 Starter motor inoperable 3 5 3 6 Start motor turns constantly 3 6 3 Engine NOISY 3 7 3 8 High noxious emissions 3 8 Service manual part Engine for CG 125 150 HARTFORD INDUSTRIAL CO LTD Hartford Industrial Co Ltd CHartiord gt 3 Reason a breakdown 3 1 Engine is difficult or impossible to start Check Possible cause Possible reason Remove carburetor screws check if there is fuel 1 No fuel in tank sus s eee 2 Fuel tap blocked 3 Fuel hose blocked Insufficient fuel to 4 Fuel valve blocked carburetor No fuel reaching carburetor Remove spark plug x a plug fouled
15. C generator faulty 1 Cylinder or piston rings excessively worn Compression pressure 2 Gasket leaking or damaged low 3 Decompressor leaking or cracked 4 Piston rings scored or damaged Carburetor blocked or 1 Jet blocked faulty 2 Carburetor incorrectly installed Remove and inspect 3 Carburetor incorrectly adjusted x spark plug 155 1 Spark plug fouled or vvorn replace spark plug 2 Clean deposits 3 Spark plug heat range incorrect 855 T 4 Spark plug gap incorrect overheating 25 Nusuus uunun umunNuuNuuNuNuNuNUNuNuNUNUNUNUNUNuNuNuNUNMNENUNUNUNUNUNUNUNuUNuNuNENE 1 Piston or cylinder worn or damaged 2 Fuel mixture too weak 3 Fuel line faulty 4 Combustion chamber carbon deposits excessive 85 5 lgnition timing overly retarded Test acceleration and 6 Clutch slipping high speed running 1 Combustion chamber carbon No fault with performance deposits excessive 2 Fuel line faulty 3 Clutch slipping 4 Fuel mixture too weak Start engine 5 lgnition timing overly advanced Hartford Industrial Co Ltd CHartiord gt 3 Reason a breakdown 3 3 Idle or slow running poor Check Possible cause Possible reason Check ignition x ee timing u Ignition timing correct Ignition timing 1 CDI or AC generator faulty 2 Valve clearance incorrect incorrect x adjustment x 1 Choke not returning to closed position 2 Fuel mixture too rich Incorrect loosen idle mixture screw 3 Fuel mixture too weak
16. HARTFORD INDUSTRIAL CO LTD Service manual part engine For CG 125 150 Issued date April 1999 Chapter Contents Chapter 1 Foreword Chapter 2 General specifications Chapter 3 Reason a breakdown Chapter 4 Cylinder cylinde rhead valves and piston Chapter 5 Generator Start motor Chapter 6 Clutch and gear box Chapter 7 Carburetor Chapter 8 Removing and Installing the engine Chapter 9 Maintenance Chapter10Electrical system Service manual part Engine for CG 125 150 HARTFORD INDUSTRIAL CO LTD Chapter 1 Foreword Service manual part Engine for CG 125 150 HARTFORD INDUSTRIAL CO LTD Hartford Industrial Co Ltd 1 Foreword Hartford motorcycle engines state of the art power drivingpovver torque output smoothness of running and fuelconsumption are the prime factors in determining the performance of a motorcycle engine At Hartford we focus on these critical points striving to create an engine that offers the maximum in motorcycle driving performance At the heart of Hartford is engine production ability is our state of the art production facility which is set up with Flexible Manufacturing System FMS The FMS ts planned and designed by Hartford is engineering staff and is composed of a series of Hartford machining centers Our engine production capabilities do not end with engineering and production Our commitment to quality is as modern and comprehensive as our facility The most up to
17. ORD INDUSTRIAL CO LTD Hartford Industrial Co Ltd 2 General Specifications 2 1 Profile diagram and Main part name 2 1 1 Profile diagram 140 238 5 267 UX Hartford Industrial Co Ltd J RZ Rina J gt gt lt 2222 Zip 7 227 ACP 2 pe REL aini WY A asa aD 29 Oo 2 AN TRY U Q SISK SY IH NG AOO S N 2 B G l 0 113 Oo lt mo EEFE K Wd C 8 3 D 55 2 5 lt O u un D G o s 2 u O gt N O Or y 80 re o D aa x WK a S x o c o mu Q G O G G 9 o S lt 9 2 o S gt oO CODA Soy NN Hartford Industrial Co Ltd 2 General Specifications 2 2 Engine Specifications 125C C 4 5speed Model CG type Cylinder layout Fuel requirement Bore and stroke Capacity Compression ratio Weight dry wet Intake valve timing Exhaust valve timing Intake valve clearance Exhaust valve clearance Idle speed Combustion chamber type Valve operation Max power ps rpm Max torque kg m rpm Fuel economy km l Air cooled single cylinder OHV four strok
18. buretor Remove the fets float needle and needle valve seat Note Do not damage the jets Remove the idle mixture screw Note Before removing the idle mixture screw Screw the adjuster screw in Fully counting the turns The standard position for the idle screws two turns back form fully Idle mixture screw screwed in 7 2 5 nstalling the float and float needle Inspect all parts for wear or damage and replace as necessary Note Take care during reassemble not to damage any of the parts Reassemble the float needle and needle seat Install the jets and idle mixture screws Replace the float bowl ti R r H _ Support pin 2 6Replace the throttle slide Needle lock spring Replace the needle Needle lock clip Throttle valve and needle lock spring Na Replace throttle cable Replace the missing chamber cap Needle lock clip and the air filter connecting hose Check the free closing of the throttle at all handlebar positions Hartford Industrial Co ED 7 Carburetor 7 2 7lnspecting the float needle Examine the float and float needle for wear or damage Abrade 7 2 8Adjusting the float height The float height is set by bending the float tang Use the special gauge to measure the float height Correct float height 125C C 14 5mm Model PDO26A 150C C 14mm Model PD19D Chapter 8 Removing and installing the engine 8 1 Removing and installing the engine 8
19. der 4 10 4 5 2lnstalling the piston rings 4 11 4 5 3lnstalling the cylinder head 4 12 Service manual part Engine for CG 125 150 HARTFORD INDUSTRIAL CO LTD Hartford Industrial Co Ltd 4 Cylinder cylinder head valves and piston 4 1Reason a breakdown Compression pressure low Valves Cylinder head Valve clearance incorrect Cylinder head gasket damaged and leaking Valve bent or burnt Cylinder head warped Valve timing incorrect Compression too high Valve spring broken Combustion chamber carbon deposits excessive Piston Other causes Cylinder and piston worn or damaged Combustion chamber carbon deposits excessive Engine noisy Excessive smoke from exhaust Valve clearance incorrect Valves piston or piston rings worn or Valve spring broken damaged Pushrods and rocker spindles loose Piston rings installed incorrectly Push rods worn or bent Cylinder or piston scored Cam lobes worn Camshaft worn Cylinder or piston worn Excessive carbon deposits Note The rockers rocker support and pushrods can be serviced with the engine installed in the chassis Oil to the valve train passes through the cylinder block into the head Take care not to block the oil passage Replace the locating dowels Put some fresh engine oil into the cylinder head and a smear of grease on the valve cover when installing During serv
20. der or piston avoid the use of excessive force disassembling Remove the piston pin clips and piston pin Remove the piston do not allow the piston pin or clips fall into the crankcase Remove the cylinder base gasket Remove the four cylinder studs Remove the four cylinder locating dowels Remove and discard the cylinder head gasket Remove and discard the cylinder base gasket Remove the traces of gasket sealant from the cylinder and head Note to preserve seal and prevent oil and or air leaks do not damage the cylinder head or valve cover mating faces Hartford Industrial Co Ltd 4 Cylinder cylinder head valves and piston 4 4 Inspection and overhaul 4 4 1Check the holder comp pkr Inspect the rocker support and pushrod cups for wear or damage Check the rocker spindle bore for wear scuffing or burning Rocker bore service limit 12 1mm 4 4 2 Check the pushrod Check the pushrod ends for wear or damage Check the pushrods for bending or distortion If unserviceable replace 4 4 3Check the guide pushrod Check the plate damage or rusting If the pushrods do not move freely replace the plate 4 4 4Check the cylinder Check the cylinder bore for scoring or burning Measure the cylinder bore Use a dial indicator to measure for bore out of round Service limits Out of round 0 050mm Obliqueness 0 050mm Bore diameter 125cc 56 60mm Bore diameter 150cc 62 1mm Medial Below Hart
21. e single cylinder canted 15 degrees 90 octane or higher 56 5 x 49 5mm 0 06 0 08mm 0 06 0 08mm 1400 100 rom Hemispherical Single camshaft OHV 9 5 8200 0 95 8200 45 more or less depends on road conditions 150C C 4 5speed Air cooled single cylinder OHV four stroke single cylinder canted 15 degrees 90 octane or higher 1400 100 rom Hemispherical Single camshaft OHV 12 8300 1 2 8300 45 more or less depends on road conditions Hartford Industrial Co Ltd 125C C 4 5speed 150C C 4 5speed Gerotor Gerotor Centrifugal and screen Centrifugal and screen Crankcase 2 441 min B 8500rpm 2 441 min B 8500rpm Cvlinder head 1 2 8500rpm 1 2 8500rpm Transmission 1 631 min 8500rpm 1 631 min B 8500rpm Hartford Industrial Co Ltd 2 General Specifications aS 2 4 Transmission 2 4 1 Clutch 125C C 4 5speed 150C C 4 5speed Clutch type Wet multiple Wet multiple Operation Left hand Left hand Torque rating 7 6kgm 7 6kgm Number of plates 5 5 2 4 2Gear svstem 125C C 4 5speed 150C C 4 5speed Gearbox type 1 4 Gearbox International 1 4 Gearbox International 2 4 Gearbox Circulate 2 4 Gearbox Circulate 3 5 Gearbox International 3 5 Gearbox International Operation Left foot Left foot Primary 4 055 73 18 14 055 73 18 14 055 73 18 14 055 73 18 reduction gear 2769 13 36 12 4 15 36 12 769 13 36 12 4 15 36 2 gear 1 722 18 31
22. e upper side The rings should move freely in their grooves Install into cylinder as far as the piston pin boss Align with the connecting rod and replace the piston pin Use long nose pliers to reinstall the locating New circlips should used The ends of the circlip should not touch when reinstalled Take care not to drop a circlip into the crankcase Be sure that the piston is at TDC on the compression stroke Pin pision Clid piston pin gap sil n A q ring Clid piston pin gap Piston Hartford Industrial Co Ltd 4 Cylinder cylinder head valves and piston 4 5 3 nstall cylinder head Replace the three 10mm x 20mm cylinder head locating dowels Replace the cylinder head with a new gasket Replace the rocker arms and support assembly Replace the four cylinder head nuts Tighten to 2 8 3 0kgm torque Install the pushrods Install the three bolts Tighten to 1 0 1 4kgm Hartford Industrial Co Ltd 4 Cylinder cylinder head valves and piston Smear some grease into the rocker arm and before engaging the pushrods Pour a little fresh engine oil into the cylinder head Check that the T mark on the alternator still aligns with pointer in the alternator case Be sure that the piston is at TDC on the compression stroke Adjust by loosening the locking screws and rotating the adjusting screw Re tighten and check clearance again Valve clearance s
23. eter 61 990 61 970mm 61 890mm Piston pin hole Diameter 15 002 15 008mm 15 05mm Piston pin Outer diameter 14 993 15 00mm 14 85mm Piston bore 0 020 0 050mm 0 11mm Piston ring to Clearance 1 0 025 0 055mm 0 13mm 2 0 015 0 045mm 0 12mm Installed end gap 1 0 15 0 35mm 0 5mm a 0 15 0 30mm 0 5mm Oil ring 0 20 0 50mm Piston Thickness 1 1 160 1 185mm 1 15mm 27 1 175 1 190mm 1 16mm Hartford Industrial Co Ltd 4 Cylinder cylinder NO CG head valves and piston 4 3 4 3 Removing the cylinder 4 3 1 Removing the cylinder head cover Remove the 6mm x 12mm screws Remove three 6mm x 28mm cylinder head screws Remove the valve cover and gasket Note to preserve seal and prevent oil and or air leaks do not damage the cylinder head or valve cover mating faces 4 3 2 Removing the cylinder head Bolt FR brake stopper arm Rotate the engine and find TDC on the compression stroke Remove the three rocker support bolts Remove the rocker support Remove the pushrods Remove the four cylinder head bolts Remove the pushrod guide plate Remove the cylinder head and gasket Remove the valve retaining collets Remove the three 10 x 20mm cylinder locating dowels Nut cylin er head xxx Hartford Industrial Co Ltd 4 Cylinder cylinder head valves and piston 4 3 3 Removing the cylinder Removing the cylinder Note to prevent distortion or damage to the cylin
24. ford Industrial Co Ltd 4 Cylinder eylinder head valves and piston 4 4 5Check the piston Measure the piston ring to groove clearance Remove the piston rings Inspect the piston rings for scoring or damage Measure the piston pin hole diameter and ovality Service limit 15 05mm Measure the diameter of the piston Service limit 125cc 56 36mm 150cc 61 89mm Measure the 17 piston ring thickness Service limit 1 15mm Measure the 2 piston ring thickness Service limit 1 16mm Insert the piston rings into the bore and measure the ring gap Piston ring gap service limit 0 5mm Measure the piston pin outer diameter Service limit 14 85mm Piston pin hole diameter Hartford Industrial Co Ltd 4 Cylinder cylinder head valves and piston 4 4 6Check the spring valve Measure the free length of the valve springs Inspect the piston rings for scoring or damage Z a Measure the piston pin hole diameter H Mag VU and ovalitv Outer spring service limit 39 7mm Inner spring service limit 32 5mm 4 4 7Check the cylinder head Check the cylinder head for scoring or damage With a straight edge and feeler gauges check the head gasket surface for warping or distortion Service limit 0 10mm Hartford Industrial Co Ltd 4 Cylinder cylinder head valves and piston 4 4 8 Inspect the valves and valve guides Inspect the valve stems for scoring damage or burning Check
25. ght Starter motor does not turn Possible reason 1 Fuse broken 1 Starter switch contact poor 2 Voltage regulator short circuit 3 Loose battery terminals 1 Carbon brushes worn 2 Rotor coils short or open circuit 3 Stator coils short or open circuit 4 Connections loose Hartford Industrial Co Ltd 3 Reason a breakdown 3 6 Starter turns constantly Check Possible cause Possible reason Motor still turns Starter solenoid short circuit Starter drive gear return faulty Motor stops Hartford Industrial Co Ltd 3 Reason a breakdown 3 Engine noisy Possible cause Possible reason 1 Valve adjustment excessively loose 2 Valve rocker arms worn 1 Cylinder or piston worn 2 Combustion chamber carbon deposits Piston slap excessive 3 Piston pin or connecting rod worn or damaged Clutch noisy 1 Clutch drum drive tabs excessively worn 1 Rear wheel cut drive worn or disintegrated 2 Primary gears worn 3 Transmission gears worn Starter or transmission noisy Hartford Industrial Co Ltd 3 Reason a breakdown 3 8 High noxious emissions 1 Ignition system faulty a Ignition timing incorrect b Spark plug fouled or gap incorrect c Voltage regulator faulty High Normal d Ignition coil faulty e Alternator plate or spark plug cap shorted Exhaust valve worn Cylinder worn Fuel mixture weak or ignition system faulty Vacuum leak Low High a pressure
26. he tools by the rules 5 Use organic solvent to clean all the parts and smear with lubricating oil on their surface before assembling 6 Add suitable grease by the rule Gheck the relative position of mechanism after assembling 8 Pay attention to safety when you repair and maintain this machine 2 9 Page Hartford Industrial Co Ltd R CRANKCASE TOOL 3 2 General Specifications J Idle speed needle 20 G e m n a 5 TOOL 7 2 Z f TOOL 8 b N cO Zzzzzz O30cover LO L COVER CN Oir pump A HOLDER COMP PKR S Air door TOOL 1 TOOL 6 NO Description Drg NO TOOL 1 Diamomd fix tool for air door for 125 150c c 60000102 TOOL 2 Fitwheel comp nut assembly tool for 125 150c c 60000103 TOOL 3 Oir pump nut assembly tool for 125 150c c 60000104 TOOL 4 Piston ring 1st assembly tool for 125c c 60000105 TOOL 4 Piston ring 2nd assembly tool for 125c c 60000106 TOOL 4 Piston ring 1st assembly tool for 150c c 60000107 TOOL
27. hould be 0 06 0 08mm inlet and exhaust Reinstall the valve cover with a new rubber O ring and oil lightly Replace the three 6 x 28mm cylinder head screws Tighten to 2 8 3 0kg m torque Replace the 6 x 12mm screws and tighten to 1 0 1 4kg m torque hat Yadda d Chapter 5 Generator Start motor 5 1 Generator 5 1 5 1 1 Removing the lift crank case 5 1 5 1 2Removing the generator rotor 5 1 5 1 3lnstalling the generator rotor 5 1 5 1 4Installing the lift crank case 5 1 5 2 Start motor 5 2 5 2 1Removing the start motor 5 2 5 2 2Removnig the start drive gears 5 2 5 2 3lnstalling the start motor 5 2 Service manual part Engine for CG 125 150 HARTFORD INDUSTRIAL CO LTD Hartford Industrial Co Ltd 5 1Generator 5 1 1 Removing the lift crank case Remove the starter gear cover Remove the gearshift pedal Remove the alternator cover The alternator is retained in the cover by four screws which can be removed to dissemble it 5 1 2 Removing the generator rotor Remove the alternator cover Remove the alternator retaining bolt Remove the alternator rotor Remove the alternator stator coil from the cover 5 1 3Installing the generator rotor Inspect the coils for damage from contact with the rotor Inspect the coils for signs of short circuit or broken wires
28. ice do not scratch or score the cylinder head Torque settings Cylinder head nuts 2 8 3 0kgm Cylinder head screws 2 8 3 0kgm Cylinder head studs 1 0 1 4kgm Rocker support 1 0 1 4kgm Hartford Industrial Co Ltd 4 Cylinder cylinder head valves and piston 4 2Specifications Part Item Specification Service limit Rocker arms Inner diameter 12 000 12 018mm 12 1mm Rocker spindle Outer diameter 11 984 11 966mm 12 0mm Pushrod Cup radius and length 6 5mm 141 5mm Outer valve spring Free length 40 9mm 39 mm Inner valve spring Free length 33 5mm 32 5mm Outer valve spring Pressure length 15 6kg 35 4mm Inner valve spring Pressure length 7 1kg 30 7mm X Inlet valve stem Diameter 5 450 5 465mm 5 42mm Exhaust valve stem Diameter 5 430 5 445mm 5 40mm Inlet valve guide Inside diameter 5 484 5 488mm 5 50mm Exhaust valve guide Inside diameter 5 484 5 488 5 50mm Inlet valve to guide Clearance 0 010 0 035mm 0 08mm Exhaust valve to guide Clearance 0 030 0 035mm 0 10mm Cylinder 125cc Bore 56 500 56 513mm 56 6mm Out of round JA 0 05mm ObliqueneSS S 0 05mm Cylinder 150cc Bore 62 000 62 013mm 62 1mm Out of round JI 0 05mm Obliqueness S S 7 0 05mm Piston 125cc Diameter 56 460 56 480mm 56 360mm Piston pin hole Diameter 15 002 15 008mm 15 05mm Piston pin Outer diameter 14 993 15 00mm 14 85mm Piston bore 0 020 0 050mm 0 11mm Piston 150cc Diam
29. ked Fuel pipe blocked Float level too low Fuel filter blocked Float needle faulty or damaged Fuel air mixture excessively rich Choke valve seized Float level too high Float needle faulty or damaged Remedy Clean the carburetor and restore normal combustion Adjust the float level Hartford Industrial Co Ltd 7 Carburetor 7 2Carburetor 7 2 1Names of carburetor parts Throttle valve Air control Air control lever Oil cup Float wW Tin Needle vray NCATE Float bowl Spring Spring screws Carburetor top retor top Float bovvl screvvs 7 2 2Removing the carburetor Turn the fuel valve to the OFF position Remove the fuel line Drain the fuel from the carburetor Note Fuel is flammable and should be washed off the Air filter hose vehicle if spilled clamp Remove the air filter hose clamp Remove the throttle cable Remove the carburetor mounting nut Remove the carburetor Hartford Industrial Co Ltd 7 Carburetor 7 2 3 Throttle valve eedle lock spring Remove the needle lock spring Remove needle needle lock clip Examine needle and throttle valve for vvear or damage 777m qa 7 2 4Removing the float and float needle Remove the three M4 x 16mm screws Remove the float bowl Return the fuel inside to fuel tank Remove the support pin with long nose pliers Remove the float and Float needle Hartford Industrial Co Ltd 7 Car
30. mbly When replacing the clutch springs tighten the four spring pressure plate screws evenly in sequence tighten to 4 0 5 0kg m Hartford Industrial Co Ltd CHartford gt 6 Clutch Transmission lt lt 6 3 Transmission 6 3 1 Removing the gearshift mechanism Remove the gearshift mechanism Remove the clutch Remove the gearshift pedal Remove the gearshift shaft Note when removing the gearshift shaft note the gearshift shaft return spring hooked on the lug located on the crankcase N AN Gear shift spindle comp Hartford Industrial Co Ltd Yk Hartford 6 Clutch Transmission Remove the gearshift detent arm Remove the gearshift cam Check all parts for wear or damage Reassembling the gearshift mechanism Locate the rollers and install the gearshift cam Reinstall the gearshift shaft and plate Hartford Industrial Co Ltd Installing the gearshift shaft Install the gearshift pedal and check the smooth operation of the gearshift mechanism Replace the clutch Replace the oil pump Replace the clutch cover locating dowels and gasket Note the gearshift shaft return spring should locate against the lug in the crankcase
31. ng the oil run the engine for 5 minutes to bring it operating temperature Remove the drain plug and release the engine oil Check the condition of the drain plug seal Refill with 0 8 1 0 liters of oil Recommended oil SAE10W 30 Hartford Industrial Co Ltd 9 Maintenance 20VV 50 15VV 40 10VV 30 5W 30 29 18 4 16 27 38 F 20 0 20 40 60 80 100 Engine oil to suit thermometer Recommended oil for use Use APISG rated oil or a premium grade engine oil Recommended oil viscosity 1 In normal climates use SAE 10W 30 or premium grade 2 In colder weather use SAE 5W 30 3 The engine oil should be changed after covering the first 300km 4 The engine oil should then be changed every 1000km Hartford Industrial Co Ltd 9 Maintenance 9 1 3Clean the oil filter room Remove the exhaust pipe Remove the footrests Remove the clutch cable Remove the kickstarter x Remove the clutch cover Qw N Remove the oil filter cover Oil filter Clean as necessary Clean the oil filter screen 9 1 4Clean the oil filter screen Remove the oil filter cover and screen Clean with compressed air 9 1 5Chenk the spark plug 1 Fouling or excessive gap A will cause incomplete combustion 2 Use a wire brush to clean deposit
32. pipe b inlet manifold c Caps 1 Air filter blocked 2 Carburetor faulty a Idle mixture too rich High High b Float chamber incorrectly assembled c Choke operation faulty d Main jet loose e Idle speed screw or needle seat worn Chapter 4 Cylinder cylinder head valves and piston 4 1 Reason a breakdown 4 1 4 2 Specifications 4 2 4 3 Removing cylinder 4 3 4 3 1 Removing the cylinder head cover 4 3 4 3 2 Removing the cylinder head 4 3 4 3 3 Removing the cylinder 4 4 4 4 Inspection and overhaul 4 5 4 4 1 Check the holder comp pkr 4 5 4 4 2 Check the pushrod 4 5 4 4 3 Check the Guide pushrod 4 5 4 4 4 Check the cylinder 4 5 4 4 5 Check the piston 4 6 4 4 6 Check the spring valves 4 7 4 4 7 Check the cylinder head 4 7 4 4 8 Inspect the valves and valve guides 4 8 4 4 9lnspect overhaul the valve seats 4 9 4 5 Installing the cylinder 4 10 4 5 1 Installing the cylin
33. rests Remove the clutch cable Remove the kickstarter Remove the right crank case cover Hartford Industrial Co Ltd 6 Clutch Transmission y s 6 2Clutch 6 2 1 Removing the clutch Remove the clutch pushrod Remove the centrifugal oil filter body Use the four leg socket wrench and air impact wrench to remove the16 mm retaining nut Remove the oil filter body Remove the oil seal and clutch pushrod Remove the clutch center 20mm C clip Remove the clutch spring pressure plate screws Remove the clutch spring pressure plate and springs Remove the clutch center Remove the clutch friction plates Remove the clutch plates and pressure plate Remove the 20mm retaining ring washer Remove the clutch basket Hartford Industrial Co Ltd Pressure Clutch Friction Clutch plate plate plate center e Inspecting the friction plates Measure the thickness of the friction plates and inspect for wear scoring or damage Replace as complete set if necessary Service limit 2 5mm e Inspecting the clutch basket Remove the 20mm washer and the clutch basket Check the faces of the drive slots for indentation e Inspecting the clutch springs Measure the free length of the four clutch springs Service limit 32 4mm e Inspecting the clutch plates Measure the distortion of the plates with a feeler gauge and a flat surface Service limit 0 2mm Replacing the clutch Reassembly is the reverse of disasse
34. s Remove the engine Remove the tachometer Rear engine mn F mounting bolts Note when removing the engine take care to avoid damaging any cables or wires 8 1 2Installing the engine Installation is reverse of disassembly Note Take care to correctly reinstall the control cables and electrical wires Adjust the throttle cable slack Adjust the clutch cable slack e Refill the engine with the approved oil SAE10W 30 Chapter 9 Maintenance 9 1Engine oil Oil filter 9 1 9 1 1Check the engine oil 9 1 9 1 2Change the engine oll 9 1 9 1 3Clean the oil filter room 9 3 9 1 4Clean the oil filter screen 9 3 9 1 5Check the spark plug 9 3 9 2 Periodic maintenance and check 9 4 Service manual part Engine for CG 125 150 HARTFORD INDUSTRIAL CO LTD Hartford Industrial Co Ltd 9 1 Engine oil Oil filter 9 1 1 the engine oll 1 Place the motorcycle on the main stand 2 Remove the dipstick and wipe it clean with cloth 3 Insert the dipstick back into the engine 4 Remove the dipstick once more and observe the level 5 Add oil as necessary to replenish to the mark 6 Do not over fill as this may damage the engine 7 Check the level again after filling Engine Oil Ruler AN Insfficient Just To Much 9 1 2Change the Engine oil Note Before changi
35. s from the electrodes 3 Replace spark plugs at 3000 5000km intervals SPARK PLUG TVPE NGK Electrode lt s Hartford Industrial Co Ltd 9 Maintenance 9 2Periodic maintenance and check I Inspect A Adjust R Replace T Tighten Inspection period Every month Every Every 1000 1500km 3000km 6000km Item to inspect every 1000km replace m n n j o ran n DR nR Vawecearrees A A intim A cater A 006 6 ans T GOVERAGE PROVIDED BY THE WARRANTY BEFORE 1000km OF NEW MOTORCYCLE HAVE RIDED PLASE KEEP SPEED LOWER THAN 60km hr IF SPEED IS HIGHER THAN LIMIT THE ENGINE BREAKS WOULD NOT PROVIDED BY THE WARRANTY Chapter 10 Electrical system 10 1 CDI 10 1 10 2 Starter switch assy 10 2 10 3 Regulator 10 3 10 4 Coil comp 10 4 10 5 Electrical assembly draw 10 5 Service manual part Engine for CG 125 150 HARTFORD INDUSTRIAL CO LTD Hartford Industrial Co Ltd C 10 Electrical system A 10 1 CDI uolliuB Jo y INO pul ol 1
36. utter is used again to finish the lower part of the seat If the valve seat edge is too high use a 37 5 degree angle cutter to remove material and a 45 degree cutter to correct the angle If the valve seat edge is too low use a 63 52 degree angle cutter to remove material and a 45 degree cutter to correct the angle Remove the abrasive residue from grinding to prevent premature wear and encourage god sealing of the valve Hartford Industrial Co Ltd 4 Cylinder cylinder head valves and piston 4 5Install the cylinder 4 5 11nstall the cylinder Always install new valve stem seals when replacing the valves Lubricate the valve stems with oil Bu and replace them Install the valve springs retainers and collets Do not over compress the valve springs with the valve spring compressor Make sure the retainers and collets are correctly install or serious engine damage is likely Reinstalling the cylinder Fit a new cylinder base gasket Reinstall the locating dowels and the four cylinder studs Tighten the studs into the crankcase with1 0 1 4 kg m of torque Take care not to drop any debris into the crankcase Hartford Industrial Co Ltd 4 Cylinder cylinder head valves and piston 4 5 2Reinstall the piston rings Reinstall the piston rings with the gaps spaced at 120 degrees around the piston Avoid damaging the piston or rings during installation The mark on the piston ring indicates th
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