caution - Hyosung
Contents
1. 61 02 49 09 69 OS 96 90 066 0 GS G G 0 090 940 540 160 080 970 0 170 070 900 GEO LEO 050 0460 502 005 581 os se 081 512 01 597 091 se 057 ovi sev set 02 ____600 900 MT Im la en Pn ww SONVEVSTO occ 90 0072 961 061 9814 O8 L GZL OZ L G9 09 SS L OS L SE OF SEL OE VL SC V OC V 13ddV1 SSANMOIHL WIHS X3 22735 LaddVL G G C LC au E v lt G G G G G G G O ONNSOAH 4 uii 022 502 002 91 0071 90 022 9 2 002 961 06 59 60 os M 0 2 INSLE N 022 9 2 0 2 502 ooz 961 06 98 081 541 22 080 90 1NVHO H1 ISN OL 022 92 0 2 902 002 961 061 981 0819 1071 80 00 so 091 or osi svi O Q EN lt gt 2 y jueuusn py payloads O 10 8 824 40 90 90 90 090 9890 90 00 2 090 0 ___ 90 40 0 0 0 ___ 0 40 2 080 200 D 69 80 5 00 _____600 500 ____ 91 Prepared by HYOSUNG2. Remove the cylinder head cover 4 by removing the four wrench bolts Bring the piston at TDC Top Dead Center s CAUTION Align the index mark on the magneto rotor with the triangle mark 5 on the magneto cover as turn the crankshaft clockwise or counter clockwise 29 3 7 ENGINE Remove the cam chain tension adjuster 1 Remove the cam chain guide NO 2 2 Remove the camshaft housings Remove the dowel pins intake camshaft and exhaust camshaft Do not drop the dowel pins and cam chain into the crankcase 30 3 8 Remove the camshaft C rings 1 Loosen the three cylinder head bolts Loosen the three cylinder head base nuts Remove the cam chain guide NO 1 31 3 9 ENGINE Remove the tappet and the shim s CAUTION Draw out the tappet and shim with the strong magnet not to be scratched s CAUTION The tappet and shim should be lined so that each will be restored to the original position during reassembly Compress the valve spring by using the special tools Valve spring compressor 09916 14510 Valve spring compressor attachment 09916 35 00 Take out the valve cotter 1 from the valve stem Remove the valve spring retainer 2 32 ENGINE 3 10 e Pull out the valve from the other side Remove the two cylinder base nuts and the cylinder CAUTION If tapping with the plas
3. 0 180 jejuozuou 194 ur eoeds 10 4001 E 3 1195910 5590010 99 INSE N 2 02 90 002 96 067 981 080 970 02 eoueJesj Jodde y INSL N lozz svz orz 0 00 66 064 985 081 4270 1720 90 LC v 0 70 990 590 190 0970 950 990 1970 05 0 970 0 0 0 9 0 960 180 060 920 920 120 020 0 0 502 002 961061 981 081 19 71 0 1991 091 91 061 021 00 90 502 002 961 061 987 08 9 1 0 1 991 091 081 91 2070 000 Emm 4 210 SSANMOIHL WIHS ONINNSVAIN CNI L4VHO 23138 LaddVL LYWHO SHL ASN 022 977 9072 002 9611061 p m 8 2 soz 561 061561 or 06 08 06 Jn 98 0871 SZ 110 081 9 09 0 O O xv lt 2 G 2 G G G 110 p p 0 OV 5 10 Eod 28 0 2 LO NR b qy 1 06 1 041 9671 06 Dr 061 687 087 SZ 91 0971 06 ce 521 0 1 591 09 681 05 LO 8 G 0 00 8 08 00 961 061 981 021 96 094 06 5 os 5 02 99 jesseoeuun jueuusnf py eoueJee o
4. RX 125 D RX 125 SM HI 125 D Kun motor Udgivet 2009 ServiceManual Holtvej 8 10 Horuphav 6470 Sydals Telefon 45 73 15 11 00 Fax 45 73 15 11 01 E mail info scanmi dk www scanmi dk CVR 27 73 31 07 FOREWORD GROUP INDEX This manual contains an introductory description on HYOSUNG amp r125D xe c125sv 5 GENERAL INFORMATION amp and procedures for its inspection service and overhaul of its engine components It covers the differences from Kapon amp Fe3 X125 5 engine and please refer to the service manual of 99000 94610 and Fe 2 125 99000 97100 for others which not covered in this manual ENGINE Other information considered as generally known is not included Read GENERAL INFORMATION section to familiarize yourself with outline of the vehicle and SERVICING INFORMATION MAINTENANCE and other sections to use as a guide for proper inspection and service This manual will help you know the vehicle better so that you can assure your customers of your optimum and quick service PERIODIC MAINTENANCE This manual has been prepared on the basis of the latest specification at the time of publication If modification has been made since then difference may exist between the content of this manual and the actual vehicle Illustrations in this manual are used to show the basic principles of operation
5. VALVE TIMING DIAGRAM Exhaust open B B D C 35 3 13 amp SHIM WEAR When measuring the valve clearance the clearance should be within the standard range Valve clearance Standard When cold 0 1 0 2 mm Intake valve 0 004 0 008 in 0 2 0 3 mm Exhaust valve 0 008 0 012 in Thickness gauge 09900 20806 Inspect the tappet for wear and scratch If modification or scratch is present replace the tappet e When you checked the valve clearance if the valve clearance is wide please replace the present shim into thick one if the valve clearance is narrow please replace the present shim into thin shim Refer to page 90 91 SHIM KIND There are 41 kinds of shim which thickness is increased by each 0 025 mm from 1 20 mm to 2 20 mm 36 VALVE HEAD RADIAL RUNOUT Support the valve using a V block and measure the valve head radial runout using the dial gauge as shown If the runout exceeds the service limit replace the valve with a new one Valve head radial Service limit runout IN amp EX 0 03 mm 0 0012 in Dial gauge 09900 20606 Magnetic stand 09900 20701 V block 09900 21304 VALVE STEM DEFLECTION Lift the valve about 10 mm 0 39 in from the valve seat Measure the valve stem deflection in two directions and perpendicular to each other Position the dial gauge as shown If the deflection exceeds the servic
6. Valve clearance When cold Valve spring tension 12 1 13 9 kgf 26 68 30 64 Ibs at length 33 7 mm 1 33 in 9 CAMSHAFT CYLINDER HEAD Unit mm in STANDARD LIMIT 34 47 34 51 1 357 1 359 34 17 1 345 Cam height 34 42 34 46 1 355 1 356 34 12 1 343 Camshaft runout IN amp EX 0 10 0 004 Cylinder head distortion pee 0 06 0 002 Cylinder head cover distortion 0 05 0 002 Gam 81 7 14 SERVICING INFORMATION CYLINDER PISTON PISTON RING Unit mm in STANDARD Piston to cylinder clearance 0 050 0 060 0 0020 0 0024 0 120 0 0047 Cylinder bore 57 000 57 015 2 2441 2 2447 57 080 2 2472 Son 56 945 56 960 2 2419 2 2425 Measure at 15 mm 0 6 in from the skirt end 96 880 2 2394 Cylinder distortion 0 05 0 002 7 2 0 284 5 7 0 224 Piston ring free end Approx 5 8 0 228 4 6 0 181 i 0 20 0 32 0 008 0 013 0 50 0 020 Piston ring end gap Assembly condition Piston ring to groove clearance 0 20 0 32 0 008 0 013 0 50 0 020 Piston ring groove width 2 0080 008 2012 08 0079 0080 151 0 970 0 990 0 0382 0 0390 Piston ring thickness 2nd 0 970 0 990 0 0382 0 0390 1st 2nd 1st m 2nd 1st 6 ax 9 CONROD CRANKSHAFT STANDARD 15 95 16 00 0 628
7. 0990 20806 41 ENGINE 3 18 3 19 PISTON HOLE BORE Using a dial calipers measure the piston pin hole bore both the vertical and horizontal directions If the measurement exceeds the service limit replace the piston with a new one Piston pin Service limit hole bore 15 030 mm 0 5917 in Dial calipers 09900 20605 PISTON PIN DIAMETER INSPECTION Using a micrometer measure the piston pin outside diameter at three position both the ends and the center If any of the measurements is founds less than the service limit replace the pin with a new one Service limit 14 980 mm 0 5898 in Micrometer 0 25 mm 09900 20201 Piston pin diameter CONROD SMALL END INSIDE DIAMETER INSPECTION Using a dial calipers measure the conrod small end inside diameter both in vertical and horizontal directions If any of the measurements exceeds the service limit replace the conrod Standard Service limit Conrod small end I D 15 006 15 014mm 15 040 mm 0 5908 0 5911 in 0 5921 in Dial calipers 09900 20605 42 9 CONROD DEFLECTION INSPECTION Wear on the big end of the conrod can be estimated by checking the movement of the small end of the conrod Turn the conrod and see if it moves smoothly without play and noise This method can also be used to check the extent of wear on the parts of the conrod s big end Service limit 3 0 mm 0 12 in Conrod
8. Adjust valve timing install the camshaft housing and the cam chain tension adjuster After the crankshaft rotate about 10 times measure the valve clearance If the clearance be not correct adjust the standard clearance as the same manner above case of valve adjustment which is not the tappet shim selection chart please follow instructions of example in the below For example the intake clearance is 0 4 and the shim is 170 1 70 mm select 195 1 95 mm of the shim which 170 1 70 mm of the shim add up the excess clearance 0 25 mm when adjust with the standard 0 15 as the intake standard clearance 0 1 0 2 s CAUTION If you don t rotate the crankshaft about 10 times before measuring the valve clearance there is no meaning of valve clearance 62255426 ir LS 19 2 7 PERIODIC MAINTENANCE SPARK PLUG Inspect Interval Clean Initial 1 000 km and Every 4 000 km thereafter Replace Every 8 000 km Disconnect the spark plug cap 1 and remove the spark plug TYPE SPARK PLUG SPECIFICATION Hot type Standard type Cold type CARBON DEPOSITS Check to see if there are carbon deposits on the spark plug If carbon is deposited remove it using a wire or pin with a pointed end E SPARK PLUG GAP Measure the spark plug gap using a thickness gauge If the spark plug gap is out of specification adjust the gap O 7 0 8 mm 0 02
9. HOLOIN d31HVl1S 19 Y 80 d3lHVlS EN A M S 45 TOO NOUNS 7775 ond Z e OL3N YW YOLV INDY 6 aq lt AV 134 M S NOILINSI OTO NO 330 HOLIMS 5 LLLI ann pool aajma o M 8 OMA Masa 67 8 5148 MS INIT 4015 9918915 HY HOLIMS 3 IQNVH H1 IWNOIS 14 a cL 4 __ NOILISOd 49 49 Qv3H ae zz 42 111111 A 51 1 61 g Amg ET 9 8313NOQ33dS IWNSIS 14 89 ONNSOAH 022 5 2 OL L 901 08 pesn eq sseuyoiU 022 5 2 0 2 501 101 WIYS y 0 SI jueseuJd wius 022 5 2 0 2 502 001 960 pue ez Q si jedde y ueuM 022 5 2 0 2 02 002 960 160 Gnanvx 025 9020021961 060 98 10 pue SSOUYIIU 10 020 072 9072 0072 961 061
10. 0 630 oo Crank web to web width 83 0 0 1 2087 0004 C OIL PUMP STANDARD d 2 Oil pressure 0 4 0 6 at 60 C 3 000 rpm Oil pump reduction ratio 2 00 36 15 82 CLUTCH Clutch cable play Clutch drive plate thickness Clutch drive plate claw width Clutch driven plate distortion Clutch spring free length SERVICING INFORMATION 7 15 Unit mm STANDARD 2 9 3 1 0 114 0 122 11 8 12 0 0 465 0 472 rs gt TRANSMISSION DRIVE CHAIN Unit mm in ITEM Reduction ratio Gear ratio Shift fork to groove clearance Shift fork groove width Shift fork thickness Drive chain 125D Drive chain 2 amp Fe2 125 Drive chain 2 F amp 2 125 sw Drive chain slack A4 125D Drive chain slack 292 1250868 2 F amp 3 125 sw STANDARD LIMIT 3 500 70 20 LII 1 046 23 22 5 omea NoTRNO2 500 5 10 0187 020 20 pitch length 256 5 10 10 Type Links 20 pitch length 256 5 10 10 Links 20 pitch length 254 0 10 00 256 5 10 10 20 30 0 79 1 18 50 60 1 97 2 36 83 7 16 1 SERVICING INFORMATION CARBURETOR 125 Unit mm in ITEM SPECIFICATION Float height 12 5 0 492 i Throttle cable play 0 5 1 0 0 02 0 04 84 SERVICING INFORMATION 7 16 2 9 CARBURETOR 5x e3 1
11. S amp T Motors Co Ltd 1st Ed JUN 2009 Manual No 99000HR7810 Printed in Korea S amp T Motors Co Ltd
12. The cam chain must not be caught between the cam chain sprocket and crankcase when the crankshaft 15 rotated Tighten the cylinder base nut 3 to the specified torque V Cylinder base nut 72 11 N m 0 7 1 1 m 45 ENGINE 3 22 3 23 VALVE AND SPRING Apply MOLY PASTE to the valve as shown and then insert them into the valve guides MOLY PASTE s CAUTION When inserting each valve into the valve guides make sure not to damage the lip of the oil seal e Install the valve spring with the smaller pitch facing the cylinder head Cylinder head direction Put on the valve spring retainer 1 and using the valve spring compressor press down the spring fit the cotter halves to the stem end and release the valve spring compressor to allow the cotter 2 to wedge in between retainer and stem Be sure that the rounded lip 3 of the cotter fits snugly into the groove in the stem end Valve spring compressor 09916 14510 Valve spring compressor attachment 09916H35C00 CAUTION After installing the valve cotter tap the valve stem end by using the plastic hammer at 2 3 times for assembly of the valve and cotter 46 Install the dowel pins 1 and new gasket A CAUTION Use a new cylinder head gasket to prevent gas leakage CYLINDER HEAD Install the cylinder head 2 With the cylinder head snugly seated
13. always insure that it is completely seated in its groove and securely fitted 67 3 45 iD Washers and circlips thickness 1 2mm D 1 0 mm 1 0 mm 1 0 mm 0 5 mm 00606008 When reassembling the bearing retainer apply a small quantity of THREAD LOCK 1324 to the threaded parts of the bearing retainer screws In reassembling the transmission attention must be given to the locations and positions of washers and circlips The cross sectional view shows the correct position of the gears washers and circlips THREAD LOCK 1324 9 COUNTERSHAFT B MOUNTING 2ND DRIVE GEAR Press fit 2nd drive gear into the countershaft Before reassembling coat the internal face of the 2nd drive gear with THREAD LOCK 1324 and install it so that the length is as shown in the figure THREAD LOCK 1324 Countershaft length Low to 2nd 68 s CAUTION This procedure may be performed only twice before shaft replacement is required ENGINE 3 46 GEAR SHIFT CAM AND FORK Fit the gear shift cam on the crankcase Position the gear shift cam as shown in the figure so that the gear shift fork can be installed easily 69 3 47 A CAUTION Two kinds of the gear shift forks 1 2 used They resemble each other very closely in external appearance and configuration Carefully examine as shown in the illustration for
14. pressed and lifted up measure the clearance on the bottom side of the ring using a thickness gauge If any clearance reading exceeds the service limt replace both the piston and piston rings Piston ring groove clearance Service limit 0 180 mm 0 007 in 0 150 mm 0 006 in Piston groove width Standard 1 01 1 03 mm 0 040 0 041 in 1 01 1 03 mm 0 040 0 041 in 2 01 2 03 mm 0 079 0 080 in Piston ring thickness Standard 0 970 0 990 mm 0 0382 0 0390 in 0 970 0 990 mm 0 0382 0 0390 in Micrometer 0 25 mm 09900 20201 Thickness gauge 09900 20806 40 PISTON RING FREE END GAP INSPECTION Before installing the piston rings measure the free end gap of each ring using vernier calipers If the gap is less than the service limit replace the ring Piston free Service limit 5 7 mm 0 224 in 4 6 mm 0 181 in Vernier calipers 09900 20101 PISTON RING END GAP INSPECTION Assembly condition Insert the piston ring squarely into the cylinder using the piston head Measure the end gap with a thickness gauge If the gap exceeds the service limit replace the piston ring with a new one Piston ring end gap Assembly condition Standard 0 20 0 32 mm 0 008 0 013 in 0 20 0 32 mm 0 008 0 013 in Piston ring end gap Assembly condition Service limit 0 50 mm 0 020 in 0 50 mm 0 020 in Thickness gauge
15. 12 m 0 8 1 2 kgf m If turn the lock shaft handle 1 of the cam chain tension adjuster in clockwise Y direction the pushrod is inserted in Turn the mechanical spring continually until the handle is turned to the end e Fix the cam chain tension adjuster into the cylinder block e Tighten the cam chain tension adjuster mounting bolt with the specified torque 7 Cam chain tension adjuster mounting bolt 8 12N m 0 8 1 2 kgf m 52 LQ D OW ic x 2 4 Get out the pushrod for the front to turn the lock shaft handle of the cam chain tension adjuster in counter clockwise 4 Turn the crankshaft about 10 times clockwise counter clockwise on the basis of the magneto rotor e the valve clearance is within standard after measured the valve clearance begin the next operation If it is out of standard adjust the valve clearance within standard limit after disassembled the camshaft and replaced the proper shim Standard When cold 0 1 0 2 mm 0 004 0 008 in 0 2 0 3 mm 0 008 0 012 in Thickness gauge 09900 20806 s CAUTION If you don t rotate the crankshaft about 10 times before measuring the valve clearance there is no meaning in valve clearance Apply BOND 1215 to the surface of the cylinder head cover packing block BOND 1215 Tighten the cylinder head cover bolts
16. 3 16 Clean the air cleaner element the following When the air cleaner element clean with the air gun necessarily blow at the inside by compressed air Carefully examine the air cleaner element for tears during cleaning Replace it with a new one if it is torn Assemble the element completely or damage severely the engine Be careful not to allow water to go inside the air clea ner element CAUTION More frequent servicing may be performed on motorcycles that are used under severe conditions also clean the air cleaner element when replacing the engine oil to prevent damage of the engine AIR CLEANER OIL DRAIN TUBE Inspect the air cleaner oil drain tube 1 and drain water and oil at the periodic interval The air cleaner oil drain tube is located beneath the air cleaner case 17 PERIODIC MAINTENANCE 2 5 3 2 6 1 PERIODIC MAINTENANCE VALVE CLEARANCE Inspect Interval Inspect Initial 1 000 km and Every 4 000 km thereafter Excessive valve clearance results in valve noise and insufficient valve clearance results in valve damage and reduced power Check the intake and exhaust valve clearances at the distances indicated above and adjust the valve clearances to specification if necessary Remove the seat and fuel tank Remove the spark plug Remove the cylinder head cover 1 The valve clearance specification is different for both intake and exhaust val
17. AG SUPER GREASE e Install the magneto cover 3 and engine sprocket cover 4 e Install the engine guard 78 SERVICING INFORMATION CONTENTS TIGHTENING TORQUE e RR 80 7 11 SERVICE DATA d 7 19 WIRING DIAGRAM Ari2sp 88 7222 1 WIRING DIAGRAM m 125 amp XRX125sm 89 7 22 2 19 7 11 SERVICING INFORMATION TIGHTENING TORQUE 9 ENGINE Camshaft sprocket bolt Camshaft housing bolt Engine mounting bolt M10 Engine mounting bolt M8 Engine mounting bracket bolt M8 80 SERVICING INFORMATION 7 13 SERVICE DATA VALVE GUIDE Unit mm in STANDARD 22 0 0 87 19 0 0 75 0 1 0 2 0 004 0 008 0 2 0 3 0 008 0 012 0 010 0 037 0 0004 0 0015 Valve guide to valve stem clearance 0 030 0 057 0 0012 0 0022 Valve stem deflection IN amp EX 0 36 0 014 Valve guide IN amp EX 4 500 4 512 0 1771 0 1776 4 475 4 490 0 1762 0 1768 Valve stem O D 4 455 4 470 0 1754 0 1760 Valve stem runout IN amp EX 0 05 0 002 Valve head thickness IN amp EX 0560 0 02 Valve seat width 0 9 1 1 0 035 0 043 Valve seat angle IN amp EX 45 Valve head radial runout INLN amp EX 0 08 0 0012 _ Sr80 4B Valve spring free length Kk ee 12 1 13 9 kgf 26 68 30 64 Ibs IN at length 33 7 mm 1 33 in Valve diam
18. Replace Initial 1 000 km and Every 4 000 km thereafter Drain the engine oil as described in the engine oil replacement procedure Remove the oil filter 2 by removing the three nuts Remove the oil filter Install the new O ring 2 Install the new oil filter Install the new O ring 5 and spring to the oil filter Install the oil filter 2 s CAUTION Before installing the oil filter cap apply engine oil lightly to the new O ring 22 PERIODIC MAINTENANCE 2 10 OIL FILTER INSTALLATION INSERTED DIRECTION LUSTER MATERIAL CAUTION When installing the oil filter necessarily HYOSUNG character and 16510 05240 part s NO is installed toward the outside otherwise can damage the engine WARNING Engine oil and exhaust pipes can be hot enough to burn you Wait until the engine oil drain plug and exhaust pipes are cool enough to touch with bare hands before draining oil Add new engine oil and check the engine oil level as described in the engine oil replacement procedure A CAUTION ONLY USE A GENUINE HYOSUNG MOTORCYCLE ENGINE OIL FILTER Other manufacturer s engine oil filters may differ filtering performance and durability which may lead to engine damage or oil leaks CARBURETOR Inspect Interval Inspect Initial 1 000 km and Every 4 000 km thereafter IDLE SPEED CAUTION Make th
19. and rotor apply the THREAD LOCK 1324 to the bolts and tighten to the specified torque THREAD LOCK 1324 V Starter clutch bolt 15 20 m 1 5 2 0 kgf m 75 ENGINE 3 52 3 53 MAGNETO ROTOR Fit the key into the key slot on the crankshaft With the magneto rotor install the starter clutch on the crankshaft Apply a small quantity of THREAD LOCK 1324 to the threaded parts of crankshaft THREAD LOCK 1324 Hold the magneto rotor and tighten the magneto rotor bolt 1 to the specified torque V Magneto rotor bolt 56 60 N 5 6 6 0 kgf m STARTER IDLE GEAR AND MOTOR Install the starter idle gear Install the starter motor 76 ENGINE 3 54 DRIVESHAFT OIL SEAL Oil seal AND ENGINE SPROCKET s CAUTION Always replace the driveshaft oil seal with a new one every disassembly to prevent oil leakage Also grease the oil seal lip On installation refer to the figure for correct position and direction Replace the engine sprocket O ring with a new one every disassembly Tighten the engine sprocket nut to the specified torque and bend up the lock washer Rotor holder 09930 40113 V Engine sprocket nut 60 100 N m 8 0 10 0 kgf 9 GEAR POSITION SWITCH e Install the spring 1 and contact 2 Apply SUPER GREASE to the O ring and install the gear position switch
20. and work procedures They may not represent the actual vehicle exactly in detail A WARNING This manual is intended for those who have enough knowledge and skills for servicing HYOSUNG vehicles Without such knowledge and skills you should not attempt servicing by relying on this manual only Instead please contact your nearby authorized HYOSUNG motorcycle dealer HYOSUNG COPYRIGHT S amp T Motors Co Ltd HOW USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR 1 The text of this manual is divided into sections 2 As the title of these sections are listed on the previous page as GROUP INDEX select the section where you looking for 3 Holding the manual as shown at the right will allow you to find the first page of the section easily 4 On the first page of each section its contents are listed Find the item and page you need SYMBOL hi aan C it C L ua 5 Listed in the table below the symbols indicating instructions and other information necessary for servicing The meaning of each symbol is also included in the table DEFINITION Torque control required Data beside it indicates specified torque Apply oil Use engine oil unless otherwise specified Apply SUPER GREASE Apply SUPER GREASE Apply SILICONE GREASE Apply MOLY PASTE Apply BOND 12157 Use for
21. on the cylinder secure it by tightening the bolts in diagonal stages Tighten the cylinder head bolts diagonally to the specified torque V Cylinder head bolt 21 251 m 21 2 5 kgf m Apply engine oil to the threaded parts of the cylinder head bolts and its washers Be sure to install the washer with rounded side facing up Pay caution to prevent the cam chain from dropping into the crankcase After tightening the cylinder head bolts to the specification tighten the cylinder head base nuts 3 to the specified torque V Cylinder head base nut 7 11N m 0 7 1 1 kgf m Install the tappet and shim CAUTION With the tappet fitted it should be replaced if it doesn t turn smoothly by hand 47 ENGINE 3 24 3 25 CAUTION The tappet and shim should be installed at the Original position when removed If otherwise it is difficult to adjust the valve clear ance With pulling up the cam chain align the index mark of the magneto rotor into the triangle mark D of the magneto cover to turn the crankshaft CAUTION If turn the crankshaft without pulling up the cam chain the cam chain may be fallen off between the crankcase and cam chain drive sprocket Fit the cam chain guide 1 48 CAMSHAFT ASSEMBLY Distinguish the EX mark for the exhaust camshaft the IN mark for the intake camshaft In
22. service classification of Over SL and that has a viscosity rating of SAE 10W 40 V Engine oil drain plug 25 30N m 2 5 3 0 kgf m e Install the engine oil filler plug Start up the engine and allow it to run for a few minutes at idling speed Turn off the engine and wait about three minutes and then check the engine oil level through the engine oil level lens If the level is below mark add engine oil to F level If the level is above mark drain engine oil to F level The motorcycle must be in a level position for accurate measurement 21 PERIODIC MAINTENANCE 2 8 2 9 PERIODIC MAINTENANCE CAUTION Never operate the motorcycle if the engine oil level is below the Lower line mark the engine oil level lens Never fill the engine oil above the Upper line mark Engine oil level being most suitable about 1 mm under the Upper line mark of the engine oil level lens In case of the engine oil pouring in excessively the engine output being made insufficient Be careful not to pour the engine oil excessively into the engine A CAUTION Necessarily confirm and clean the oil strainer 1 when replace the engine oil specially when first replacement s CAUTION More frequent servicing may be performed on mo torcycles that are used under severe conditions Comm ADD ENGINE OIL FILTER Inspect Interval
23. signal lamp Head lamp Passenger footrests gn 1 A EN SAR 5 E Sd 7 A af N 9 lt 2 Q 00 Li W N _ 1 425 WHEELBASE 430 2 190 LENGTH _ GENERAL INFORMATION 1 7 3 EXTERIOR ILLUSTRATION XRX125sm License plate lamp Rear turn signal lamp el SO SS H i 6 0990 Sah na FTT oe 299099 co S DA rge Front turn signal lamp Head lamp ES 7 CIE m Passenger footrests A J lt 2 4 IN L Mey HMC d LJ L _ 1 415 WHEEL BASE 2 175 LENGTH _ 1 8 GENERAL INFORMATION SPECIFICATIONS DIMENSIONS AND Overall length Overall width MASS 1250 2 085 82 1 840 33 1 2 190 mm 86 2 XL FE 6 12 5SM 2 175 mm 85 6 in Overall height 1 125 mm 44 3 in 1 160 mm 45 7 in 1 145 mm 45 1 in Wheelbase Grou
24. with the specified torque 9 Cylinder head cover bolt 12 16N m 1 2 1 6 kgf 53 ENGINE 3 30 3 31 LEFT END COMPONENTS ENGINE DISASSEMBLY Disconnect the magneto couplers Remove the engine guard 1 Remove the engine sprocket cover 2 Remove the magneto cover 3 Remove the starter idle gear shaft and starter idle gear 54 With the magneto rotor held immovable loosen the rotor nut 4 Remove the magneto rotor 2 by using the special tool Rotor remover 09930 30162 Remove the key Remove the starter clutch gear 3 Remove the starter one way clutch 55 ENGINE 3 32 3 33 The starter one way clutch is constituted as shown in the right illustration Separate the stator and magneto cover by removing the stator screws Remove the gear position switch by removing the screws Remove the switch contact 1 and its spring A CAUTION Be careful not to lose the O ring switch contact and its spring Flatten the lock washer and then remove the engine sprocket nut Remove the engine sprocket 56 ENGINE 3 34 RIGHT END COMPONENTS OF ENGINE DISASSEMBLY Drain the engine oil by removing the drain plug 7 located on the bottom of the engine Remove the engine guard 2 Remove the clutch cover bolts and oil filter cap nuts and detach the clutch cover by tapping with
25. 2 50 amp XRX125sm Unit mm in ITEM SPECIFICATION Float height 12 5 0 492 J 0 5 1 0 0 02 0 04 85 7 16 3 SERVICING INFORMATION FUEL OIL Fuel type Fuel tank capacity 125p Fuel tank capacity 2921250 1255 Engine oil Engine oil capacity SPECIFICATION Gasoline used should be graded 91 octane or higher An unleaded gasoline is recommened 8 0 0 API Over SL SAE 10W 40 Oil change Oil and filter change Engine overhaul 86 850 ml 950 1 200 mQ SERVICING INFORMATION 7 17 ELECTRICAL Unit mm in STANDARD Ignition timing 6 1 900 rpm 27 4 250 rpm 0 7 0 8 0 028 0 032 Cold type 12V 6Ah Battery lanean 1 320 at 20 C 68 F electrolyte S G Fuse size 15A 87 7 22 1 SERVICING INFORMATION WIRING DIAGRAM 2 1250 AV 134 dWY I QV3H YOLOW YALYVLS HISV3 3NION3 3W Au31lv8 M UV9 AZ I 1 H3lHVIS UE 49 IWNOIS 9 1 B Hi 0 95 1 819 9 80 LINN H3lJILO3H 9 WWNOIS HOLY INAY 78 11 T umen TT T t oho Loola 1 13 WS pve Ty M S 3AVSS SrA M S NOILI
26. 36 3 37 LOWER END COMPONENTS OF ENGINE DISASSEMBLY 9 CRANKCASE Remove the oil strainer cap 1 Remove the gear shift cam stopper plug washer 3 spring and neutral cam stopper 6 Remove the engine oil strainer by loosening the screws Loosen the crankcase bolts Separate the crankcase into left and right halves using the special tool Crankcase separator 09920 13120 Fit the crankcase separator so that the tool arms are in parallel with the side of crankcase The crankshaft and transmission components should remain in the left crankcase half This 15 necessary because the gear shift cam stopper is mounted on the left crankcase half and will be damaged if the transmission components remain in the right half 60 TRANSMISSION Remove the gear shift arm stopper spring 1 Draw out the gear shift fork shaft NO 1 amp 2 Take off the gear shift cam and gear shift fork NO 1 amp NO 2 Remove the driveshaft assembly 3 and countershaft assembly 2 61 ENGINE 3 38 3 39 9 CRANKSHAFT Remove the crankshaft using the special tool Crankcase separator 09920 13120 OIL SEAL AND BEARING Remove the retainer oil seals and bearings right and left e Remove the clutch release camshaft 62 LOWER END COMPONENTS OF ENGINE INSPECTION AND SERVICING CLUTCH DRIVE PLATES Measure the thickness and claw wi
27. 6 B T D C at 1 900 rom and 27 B T D C at 4 250 rom Spark plug CR8E Battery 12 V 6 Ah MF Fuse Ignition timing 12 V HS1 35W x1 12V H4 60W x1 Head lamp 12V 51 x1 12V 55 1 Position 12V W5W 1 Turn signal lamp 12V RY10W x 4 Brake Tail lamp 12 V P21 5 W x 1 EP CE High beam indicator lamp 12V 17W x 1 Vor a Neutral indicator lamp 12V 17W x1 LED Light Emitting Diode CAPACITIES ITEM 72 F1 1 XRX1250 4 9 72717 Fuel tank 9 00 8 0 0 Oil change 850 ml a Engine oil Oil and filter change 950 ml PANEM Engine overhaul 1 200 Front fork oil capacity One side 215 2 5 The specifications are subject to change without notice 11 12 5 MAINTENANCE PROCEDURES CYLINDER HEAD COVER BOLTS CYLINDER HEAD amp CYLINDER BASE NUTS EXHAUST PIPE NUTS AND MUFFLER BOLTS e AIR CLEANER VALVE ENGINE OIL COMPRESSION PRESSURE CHECK OIL PRESSURE CHECK 13 14 2 3 PERIODIC MAINTENANCE 14 2 3 2 15 2 5 1 2 18 2 6 1 20 2 7 21 2 8 ENGINE FILTER ehe eR A CX QU C a Ee ed xc des 22 2 9 23 2 10 24 2 19 25 2 20 2 3 PERIODIC MAINTENANCE MAINTENANCE PROCEDURES This section describes the servicing procedure
28. 8 0 032 Thickness gauge 09900 20806 E ELECTRODE Check to see the worn or burnt condition of the elec trodes If it is extremly worn or burnt replace the spark plug with a new one And also replace the spark plug if it has a broken insulator damaged thread etc CAUTION To avoid damaging the cylinder head threads first finger tighten the spark plug and then tighten it to the specified torque using the spark plug wrench 20 0 7 0 8 0 028 0 032 in Insert the spark plug and finger tighten it to the cylinder head and then tighten it to the specified torque V Spark plug 20 25 m 2 0 2 5 kgf m ENGINE OIL Inspect Interval Replace Initial 1 000 km and Every 4 000 km thereafter Necessary amount of engine oil Oil change 850 Oil and filter change 950 Engine overhaul 1 200 ml Engine oil type SAE 10W 40 API Over SL Engine oil should be changed while the engine is warm Engine oil filter replacement at the above intervals should be together with the engine oil change Keep the motorcycle upright Place an oil pan below the engine and drain the engine oil by removing the engine oil filler plug and drain plug 2 Reinstall the drain plug gasket and engine drain plug e Tighten the drain plug to the specified torque and pour fresh engine oil through the engine oil filler hole Use an engine oil that meets the API
29. ARING Rotate the bearing inner race by finger to inspect for abnormal play noise and smooth rotation while the bearings are in the crankcase Replace the bearing if there is anything unusual STARTER CLUTCH BEARING Inspect the bearing for any abnormality particularly cracks to decide whether it can reused or should be replaced ENGINE 3 42 19 20 21 Mo eo Play Play 65 3 43 LOWER END COMPONENTS OF ENGINE REASSEMBLY 9 CRANKSHAFT e Inspect the between the webs referring to When mounting the crankshaft in the crankcase it below figure when rebuilding the crankshaft is necessary to pull its left end into the crankcase Standard Crankshaft installer 09910 32812 Width between webs 53 0 0 1 mm Conrod holder 09910 20115 2 087 0 004 in 53 0 0 1 mm 2 087 0 004 in 66 ENGINE 3 44 CAUTION Never fit the crankshaft into the crankcase by striking it with a plastic hammer Always use the special tool otherwise crankshaft alignment accuracy will be affected TRANSMISSION s CAUTION Never reuse a Circlip After a circlip has been removed from a shaft it should be discarded and a new circlip must be installed When installing a new circlip do not expand the end gap larger than required to slip the circlip over the shaft After installing a circlip
30. Clean the air cleaner element for the follwing e Fill washing pan of a proper size with a non flammable cleaning solvent 4 Immerse the air cleaner element in the cleaning solvent and wash it Gently squeeze the air cleaner element between the palms of both hands to remove the excess solvent do not twist or wring the element or it will develop tears e Immerse the element in HYOSUNG genuine oil B and then squeeze out the excess oil leaving the element slightly wet Reinstall the cleaned or new air cleaner element in the reverse order of removal 15 PERIODIC MAINTENANCE 2 5 1 2 5 2 PERIODIC MAINTENANCE CAUTION Inspect the air cleaner element for tears A torn element must be replaced If driving under dusty conditions clean the air cleaner element more frequently The surest way to accelerate engine wear is to operate the engine without the element or with torn element Make sure that the air cleaner element is in good condition at all times Life of the engine depends largely on this component AIR CLEANER OIL DRAIN TUBE Inspect the air cleaner oil drain tube 1 and drain water and oil at the periodic interval The air cleaner oil drain tube is located beneath the air cleaner case 2 Fm22 125sm Remove the seat e he air cleaner is located under the seat Remove the four air cleaner element bolts 2 e Pull up the air cleaner element
31. NSI M S WHLNAN OL3NOVA 2 HOLIMS swe JINNO 5 1 19 19 1 19 19 M80 M OMA 61 H1 IVNOSIS 34 5 14 22 xm ETETEN e J ES sep LL nd 5 M Ae ot Ee LL rr ow an Wi fe et ee em I 5 22 22 E EE E ER H us _ p E ng dWV1 31V 1d 5 51 61 pape respi mess B 39 8 49 0 803A p 139 8 49 0 809A HOLIMS 3 IQNVH 4313 003395 MOOD 88 SERVICING INFORMATION 7 22 2 WIRING DIAGRAM r2 2 125 amp XRX125sm ANIONS AW3llv8 H1 IVNSIS NYNL Om 1 2 16 dWV1 VL 8 3 Vvda 29 19 1 14 35 49 49 IWNOIS C 6 61 M8
32. ON When installing the primary drive NO 2 gear align the index mark on the gear to the key slot as show in the illustration e Fit the oil pump driven gear 1 and install the circlip 2 CAUTION After mounting the oil pump in the crankcase rotate the oil pump driven gear by hand to see if it turns smoothly 72 CLUTCH Assemble the clutch in the reverse order of disassembly Pay attention to the following points When inserting the spacer on the countershaft apply a small quantity of engine oil to both inside and outside of the spacer Tighten the clutch sleeve hub nut using the special tool to the specified torque Clutch sleeve hub holder 09920 53710 V Clutch sleeve hub nut 30 50 m 3 0 5 0 m Be sure to lock the nut by firmly bending the tongue of the washer With the clutch sleeve hub held immovable install the primary drive gear washer and nut tighten the primary drive gear nut to the specified torque and bend up to the washer A CAUTION The primary drive gear nut is a left hand thread nut 9 Primary drive gear nut 40 60 m 4 0 6 0 m ENGINE 3 50 73 3 51 e Install the clutch drive plates and driven plates one by one into the clutch sleeve hub CAUTION The groove of the first installed clutch drive plate in five drive plates is inserted between the part without the groove
33. R Using a thickness gauge check the clearance between the groove of its gear and gear shift fork The clearance for each of the three gear shift forks plays an important role in the smoothness and positiveness of shifting action If the checked clearance is noted to exceed the limit specified replace the fork or its gear or both Standard Shift fork groove 0 10 0 30 mm 0 004 0 012 Service limit 0 50 mm 0 020 in Shift fork groove width Standard 5 00 5 10 mm NO MO 0 197 0 201 in 5 50 5 60 mm 0 217 0 221 in Shift fork thickness Standard 4 80 4 90 mm MOT OE 0 189 0 193 in 5 30 5 40 mm 0 209 0 213 in Vernier calipers 09900 20101 Thickness gauge 09900 20806 64 PRIMARY DRIVEN GEAR The primary driven gear is composed the following parts Primary driven gear 4 Rivet 2 Plate 5 Washer 3 Clutch housing Spring If the tension of the inner spring of the primary driven gear is not working get a play and noise between the gear and spring If necessary replace the primary driven gear assembly with a new one 9 CAM CHAIN 20 PITCH LENGTH Pull the cam chain tight to remove any slack then using the vernier caliper measure the 20 pitch 21 pins length of the cam chain If it measures than the limits replace the cam chain Cam chain 20 pitch Service limit length 129 9 mm 5 11 in 9 CRANKCASE BE
34. a plastic hammer e Remove the clutch spring mounting bolts diagonally while holding the primary driven gear and remove the clutch pressure plate Remove the clutch drive plates and driven plates 57 3 35 Remove the thrust washer 1 thrust bearing 2 clutch push piece 3 and clutch push rod 4 e Flatten the lock washer 5 e With the crankshaft held immovable remove the primary drive gear nut 6 CAUTION The primary drive gear nut 6 has a left hand thread If turning it counter clockwise it may cause damage e Flatten the lock washer e With the clutch sleeve hub held immovable using the special tool remove the clutch sleeve hub nut Clutch sleeve hub holder 09920 53710 e Remove the clutch sleeve hub and thrust washer e Take off the primary driven gear assembly 7 58 Remove the circlip 1 and oil pump driven gear 2 Remove the primary drive NO 2 gear and primary drive gear Primary drive gear _ Primary drive NO 2 gear Loosen the oil pump screws and then remove the oil pump 4 Draw out the gearshift shaft Loosen the four screws and then remove the gear shift pawl lifter and gear shift cam guide 7 e Take off the gear shift cam driven gear 8 CAUTION When removing the gear shift cam driven gear 8 be careful not to lose the gear shift pin return spring 49 59 ENGINE 3
35. acer Yellow with Green tracer GENERAL INFORMATION CONTENTS EXTERIOR PHOTOGRAPH 6 1 3 EXTERIOR ILLUSTRATION Arizsp 7 1 7 1 EXTERIOR ILLUSTRATION mercazssm o 8 1 7 2 EXTERIOR ILLUSTRATION s 9 1 7 3 SPECIFICATIONS ipse ire beu tesa 10 1 8 1 3 GENERAL INFORMATION EXTERIOR PHOTOGRAPH GENERAL INFORMATION 1 7 1 EXTERIOR ILLUSTRATION A7125D Rear turn signal lamp Brake Tail lamp Rear reflector f License plate lamp i 42 LO a to 4 2 qs N NIN gt 55 Y Y Ne 9 Y Y Y Front turn signal lamp Head lamp Ve mets Passenger footrests x 1 350 WHEEL 2 085 LENGTH 1 7 2 GENERAL INFORMATION EXTERIOR ILLUSTRATION 2 50 Rear reflector A 940 WIDTH Front turn
36. ake sure to follow the bolt tightening order where specified If the correct length of the bolt is confused when tightening the crankcase or cover insert all the bolts and check that the tightening margin is equal in each bolt 2f 3 5 ENGINE ENGINE REMOVAL AND REMOUNTING ENGINE REMOUNTING Remount the engine in the reverse order of removal e Temporarily fasten the engine mounting bracket before inserting the engine mounting bolts Tighten the engine mounting bolts and nuts to the specified torque 9 Engine mounting bolt M10 48 72 N m 4 8 7 2 kgf m Engine mounting bolt M8 3 22 33 m 2 2 3 3 kgf m Tighten the engine mounting bracket bolts and nuts to the specified torque 7 Engine mounting bracket bolt M8 22 33 N m 2 2 3 3 kgf m B INSTALLING POSITION FOR CLUTCH RELEASE ARM e Align the clutch release arm slit surface with the notch mark on the clutch release camshaft 28 Notch Mark ENGINE 3 6 UPPER END COMPONENTS OF ENGINE DISASSEMBLY NOTE If only the upper end components of the engine is repaired there is no necessary to remove the engine from the frame Remove the seat and fuel tank so that the upper end components of the engine is disassemble Drain the engine oil by removing the drain plug 7 located on the bottom of the engine Remove the magneto cover plug and the timing inspection plug 3
37. ar shift cam driven gear the large shoulder must face to the outside as shown Next install the gear shift cam guide and gear shift pawl lifter Apply a small quantity of THREAD LOCK 1324 to the threaded parts of the securing screws THREAD LOCK 1324 GAER SHIFT SHAFT When installing the gear shift shaft match the center teeth of the gear on the gear shift shaft with the center teeth on the gear shift cam driven gear as shown CAUTION After the gear shift cam driven gear gear shift cam guide gear shift shaft and neutral cam stopper have been fitted confirm that gear change is normal while rotating the countershaft and driveshaft If gear change is not obtained it means that assembly of gears or installation of gear shift fork is incorrect If this is the case disassemble and trace the mistake 71 3 49 ENGINE Before mounting the oil pump apply engine oil to the sliding surfaces of the case outer rotor inner rotor and shaft Apply a small quantity of THREAD LOCK 1324 to the threaded parts of the oil pump mounting SCrews THREAD LOCK 1324 e Tightening the oil pump mounting screws to the specified toruqe V Oil pump mounting screw 5 7 0 5 0 7 kof m Align index mark 9 OIL PUMP AND PRIMARY to the slot DRIVE GEAR e Install the primary drive gear and primary drive NO 2 gear and fit the key in the key slot on the crankshaft completely A CAUTI
38. arm up the engine as follows summer 10 min at 2 000 rpm Winter 20 min at 2 000 rpm After warming up increase the engine speed to 3 000 rpm with the engine tachometer and read the oil pressure gauge Engine tachometer 09900 26006 Oil pressure gauge 09915 74511 25 26 ENGINE CONTENTS ENGINE REMOVAL AND REMOUNTING 28 3 5 ENGINE REMOUNTING m Rem 28 3 5 UPPER END COMPONENTS OF ENGINE DISASSEMBLY 29 3 6 UPPER END COMPONENTS OF ENGINE INSPECTION AND SERVICING rtt 124 2411 UPPER END COMPONENTS OF ENGINE REASSEMBLY 44 3 21 LEFT END COMPONENTS OF ENGINE DISASSEMBLY 54 3 31 RIGHT END COMPONENTS OF ENGINE DISASSEMBLY 57 3 34 LOWER END COMPONENTS OF ENGINE DISASSEMBLY 60 3 37 LOWER END COMPONENTS OF ENGINE INSPECTION AND SERVICING ituri biete tastes vitri 6 9 40 LOWER END COMPONENTS OF ENGINE REASSEMBLY 66 3 43 RIGHT END COMPONENTS OF ENGINE REASSEMBLY 71 3 48 LEFT END COMPONENTS OF ENGINE REASSEMBLY 75 3 52 CAUTION Mark an identification of assembly location on each removed part so that each will be restored to the original position during reassembly Wash clean and dry the removed parts before inspecting and measuring Oil the rotating or sliding parts before assembly Make sure to use the correct type of lubricant where specified Check that each rotating or sliding part moves or operates smoothly after assembly M
39. correct installing positions and directions After the gear shift arm stopper and gear shift forks have been fitted hook the gear shift arm stopper spring into the crankcase 9 CRANKCASE When reassembling the crankcase pay attention to the following Coat SUPER GREASE to the lip of oil seals SUPER GREASE Remove the sealant material on the fitting surface of right and left halves of the crankcase and thoroughly remove the oil stains Fit the dowel pins on the left side of the crankcase Apply the engine oil to the big end of the crankshaft conrod and all parts of the transmission gears Apply BOND 1215 uniformly to the fitting surface of the left side of the crankcase and after waiting a few minutes fit the right half on the left half BOND 1215 Tighten the crankcase bolts to the specified torque V Crankcase bolt 9 13N m 0 9 1 3 kgf m NOTE Tightening the crankcase bolts tighten each bolt little by little diagonally e After the crankcase bolts have been tightened check if the driveshaft and countershaft rotate smoothly 70 ENGINE 3 48 large resistance is felt to rotation try to free the shafts by tapping the driveshaft or countershaft with a plastic hammer as shown in the figure RIGHT END COMPONENTS OF ENGINE REASSEMBLY GEAR SHIFT CAM DRIVEN GEAR When installing the gear shift pawls into the ge
40. deflection Dial gauge 09900 20606 Magnetic stand 09900 20701 V block 09900 21304 CONROD BIG END SIDE CLEARANCE INSPECTION Push the big end of the conrod to one side and measure the side clearance using a thickness gauge If the clearance exceeds the service limit replace the crankshaft assembly with a new one or bring the deflection and the side clearance within the service limit by replacing the worn parts conrod big end bearing crankshaft crank pin etc with new ones Conrod big Standard Service limit side 0 10 0 45 1 00 mm 0 004 0 018 in 0 040 in Thickness gauge 09900 20806 9 CRANKSHAFT RUNOUT INSPECTION With the right and left crank journals supported using a V block turn the crankshaft slowly At this time measure the crankshaft end runout using a dial gauge If the runout exceeds the service limit replace the crankshaft with a new one Service limit 0 05 mm 0 002 in Crankshaft runout Dial gauge 09900 20606 Magnetic stand 09900 20701 V block 09900 21304 ENGINE 3 20 43 3 21 UPPER END COMPONENTS OF ENGINE REASSEMBLY 9 PISTON RING e Install the oil ring first the 2nd ring second and the 1st ring last The 1st and 2nd 2 piston rings differ in shape The 1st and 2nd piston rings should be installed with the mark facing up e First install a spacer 3 into the oil ring groove and then in
41. dth of the clutch drive plates using the vernier calipers If the clutch drive plate is not within the the service limit replace the clutch plates as a set Standard 2 9 3 1 mm 0 114 0 122 in Thickness of clutch drive plate Service limit 2 6 mm 0 102 in Thickness of clutch drive plate Standard 11 8 12 0 mm 0 465 0 472 in Claw width of clutch drive plate Service limit 11 0 mm 0 433 in Vernier calipers 09900 20101 Claw width of clutch drive plate CLUTCH DRIVEN PLATES Measure each clutch driven plate for distortion using the thickness gauge If a clutch driven plate is not within the service limit replace the clutch plates as a set Service limit 0 1 mm 0 004 in Clutch driven plate distortion Thickness gauge 09900 20806 CLUTCH SPRING FREE LENGTH Measure the free length of each clutch spring using the vernier calipers If any spring is not within the service limit replace all of the spring Service limit 29 5 mm 1 161 in Clutch spring free length Vernier calipers 09900 20101 63 ENGINE 3 40 3 41 CLUTCH RELEASE BEARING Inspect the clutch release bearing for any abnormality especially cracks When removing the bearing from the clutch decide whether it can be reused or if it should be replaced Smooth engagement and disengagement of the clutch depends on the condition of this bearing 9 GEAR SHIFT FORK amp GEA
42. e limit determine whether the valve or the guide should be replaced with a new one Valve stem deflection Service limit 0 35 mm 0 014 in 0 35 mm 0 014 in Dial gauge 09900 20606 Magnetic stand 09900 20701 VALVE STEM DIAMETER Measure the valve stem outside diameter using the micrometer If the diameter measured exceeds the standard replace the valve Valve stem diameter Standard 4 475 4 490 mm 0 1762 0 1768 in 4 455 4 470 mm 0 1754 0 1760 in Micrometer 0 25 mm 09900 20201 37 ENGINE 3 14 3 15 VALVE SPRING The force of the coil spring keeps the valve seat tight A weakened spring results in reduced engine power output and often accounts for the chattering noise coming from the valve mechanism Check the valve springs for proper strength by measuring their free length and also by the force required to compress them If the spring length is less than the service limit or if the force required to compress the valve spring is not within specification replace the valve spring Valve spring free Service limit length IN amp EX 37 80 mm 1 488 in Vernier calipers 09900 20101 Standard Valve spring tension 12 1 13 9 kgf IN amp EX 26 68 30 64 Ibs at length 33 7 mm 1 33 in CYLINDER DISTORTION Check the gasketed surface of the cylinder for distortion using a straightedge and thickness gauge taking a clearance readi
43. harged condition Remove the related parts and test the compression pressure in the following manner Remove the spark plug A WARNING The hot engine can burn you Wait until the engine are cool enough to touch e Fit the compression gauge in the spark plug hole Make sure that the connection is tightened Keep the throttle grip in the full opened position Press the starter switch and crank the engine for a few seconds Record the maximum gauge reading as the cylinder compression Compression gauge 09915 64511 listed above 24 PERIODIC MAINTENANCE 2 20 OIL PRESSURE CHECK Check the engine oil pressure periodically This will give a good indication of the condition of the moving parts Standard Cil pressure 0 4 0 6 at 60 C 3 000 rpm If the engine oil pressure is lower or higher than the specification the following causes may be considered LOW OIL PRESSURE Clogged oil filter leakage from the oil passage way Damaged O ring Defective oil pump Combination of the above items B HIGH OIL PRESSURE Engine oil viscosity is too high Clogged oil passage way Combination of the above items B OIL PRESSURE TEST PROCEDURE Check the engine oil pressure in the following manner Remove the oil check plug 1 and install the oil pressure gauge and adapter into the oil check plug removed position Connect an engine tachometer W
44. is inspection when the engine is hot Connect an engine tachometer to the high tension cord Start up the engine and set its speed at anywhere of the specified value by turning throttle stop screw 1 Ar 125 Engine idle speed 1 400 1 600 rpm XRX1250 XRX125SM Engine idle speed 1 400 1 500 rpm Engine tachometer 09900 26006 23 2 19 PERIODIC MAINTENANCE COMPRESSION PRESSURE CHECK The compression of a cylinder is a good indicator of its internal condition The decision to overhaul the cylinder is often based on the results of a compression test Periodic maintenance records kept at your dealership should include compression reading for each maintenance service Compression pressure 14 16 Standard Service limit 12 Low compression pressure can indicate some of the following conditions Excessively worn cylinder wall Worn down piston or piston rings Piston rings stuck in grooves Poor valve seating e Ruptured or otherwise defective cylinder head gasket When the compression pressure goes below specification check the engine for conditions COMPRESSION TEST PROCEDURE Before testing the engine for compression pressure make sure that the cylinder head bolts are tightened to the specified torque values and valves are properly adjusted Have the engine warmed up by idling before testing Be sure that the battery used is in fully c
45. k oil SYMBOL DEFINITION Apply THREAD LOCK 1324 Apply or use brake fluid Measure in voltage range Measure in resistance range Measure in current range Measure in diode test range Measure in continuity test range Use special tool WIRE COLOR B L Br G BL BG BR BY LG LW BrB GB GY GrR OB OG OW RB WB WR YL YR Black Gr Gray Blue Lg Light green Brown Orange Green R Black with Blue tracer Black with Green tracer Black with Red tracer Black with Yellow tracer Blue with Green tracer Blue with White tracer Brown with Black tracer Green with Black tracer Green with Yellow tracer Gray with Red tracer Orange with Black tracer Orange with Green tracer Orange with White tracer Red with Black tracer White with Black tracer White with Red tracer Yellow with Blue tracer Yellow with Red tracer Sb BBr BO BW LB LR LY GR GrB GrW OL OR OY RW WL YB YG Light blue White Yellow Black with Brown tracer Black with Orange tracer Black with White tracer Blue with Black tracer Blue with Red tracer Blue with Yellow tracer Brown with White tracer Green with Red tracer Gray with Black tracer Gray with White tracer Orange with Blue tracer Orange with Red tracer Orange with Yellow tracer Red with White tracer White with Blue tracer Yellow with Black tr
46. nd clearance Mass 9 ENGINE ITEM 1 350 mm 53 2 in 230 mm 9 1 in 135 kg 298 Ibs 1 425 mm 56 1 in 295 mm 11 6 in 130 kg 287 Ibs 1 415 mm 55 7 in 275 mm 10 8 in Type Number of cylinder Ar 47 XRX1255SM Four stroke DOHC Air amp oil cooled 1 cylinder Bore 57 0 mm 2 24 in Stroke Piston displacement Fuel system 48 8 mm 1 92 in 124 5 7 6 in Carburetor Starter system Electric starter Lubrication system Wet sump TRANSMISSION Clutch Wet multi plate type Transmission 5 constant mesh Gearshift pattern Reduction ratio 1 down 4 up Gear ratio 1 046 0 913 Drive chain 428S0 130 links 10 428H 132 links 428H 130 links GENERAL INFORMATION 1 9 CHASSIS 1250 5 Front suspension Telescopic type Rear suspension Swingarm type Steering angle 47 right amp left 45 right amp left Caster 25 275 Trail 84 mm 3 31 in 94 mm 3 70 in 88 mm 47 in Front brake Disk brake Rear brake Drum brake Disk brake Front tire size 130 80 18M C 66P 2 75 21 45 110 70 17M C 58H Rear tire size 180 80 14M C 78P 4 10 18M C 59P 130 70 17 62H Front fork stroke 160 mm 6 3 in 250 mm 9 8 in Lt 9 ELECTRICAL ITEM P2 ud F1 1 XRX125D XRX1255SsM Ignition type CDI type
47. ng at several places as indicated If the largest reading at any position of the straightedge exceeds the limit replace the cylinder Service limit 0 05 mm 0 002 in Cylinder distortion Thickness gauge 09900 20806 38 ENGINE 3 16 CYLINDER BORE Measure the cylinder bore diameter at six place If any one of the measurements exceeds the limit overhaul the cylinder and replace the cylinder Standard Service limit 000 57 015 57 080 mm 2 2441 2 2447 in 2 2472 in Cylinder gauge set 09900 20508 PISTON DIAMETER INSPECTION Measure the outside diameter of the piston in the direction perpendicular to the piston pin axis at the height from the skirt as shown in the illustration using a micrometer If the measurement is found less than the service limit replace the piston 15 mm 0 6 in Service limit Piston diameter 56 880 mm 2 2394 in Micrometer 50 75 mm 09900 20203 PISTON TO CYLINDER CLEARANCE To determine the piston to cylinder clearance calculate the difference between the cylinder bore and outside diameter of the piston Piston to Standard Service limit cylinder 0 050 0 060 mm 0 120 mm 4 35 Tater 0 0020 0 0024 in 0 0047 in 39 3 17 PISTON RING GROOVE CLEARANCE INSPECTION Remove carbon deposit both from the piston ring and its groove Fit the piston ring into the groove With the ring com
48. of the primary driven gear e Insert the clutch push rod in the countershaft s CAUTION Insert the longer side of the clutch push rod toward the inside e Install the clutch push piece thrust bearing and thrust washer to the countershaft e Install the clutch pressure plate e Tighten the clutch spring set bolts NOTE Tighten the clutch spring set bolts diagonally 9 CLUTCH RELEASE ADJUSTER SCREW Loosen the adjuster nut and turn clutch release adjuster screw to feel high resistance e From that position turn out the clutch release adjuster 1 4 1 2 turn and tighten adjuster nut 74 Part without groove of primary driven gear Clutch drive plate groove Inside Outside lt Ec Longer Shorter Install the clutch cover and tighten the clutch cover bolts securely GEAR SHIFT CAM STOPPER PLUG e Insert the cam neutral stopper 1 spring and washer 3 e Tighten the gear shift cam stopper plug to the specified torque V Gear shift cam stopper plug 20 25 m 2 0 2 5 m OIL DRAIN PLUG Tighten the engine oil drain plug to specified torque V Engine oil drain plug 25 30 m 2 5 3 0 m LEFT END COMPONENTS ENGINE REASSEMBLY STATOR Apply a small quantity of THREAD LOCK 1324 to the thread parts of screws THREAD LOCK 1324 9 STARTER CLUTCH When installing the starter clutch
49. ograph and illustrations 16 Pins 50 ENGINE 3 28 NOTE The cam chain should now be on all three sprockets Be careful not to move the crankshaft until the camshaft housings and cam chain tensioner are secured 16 Pins P SUIT TE e YE be BE MSF Wek 07 3 29 Each camshaft housing is punched with B Put on the housing to the of head surface the housing to the the housing to the and the housing D to the D as that D is punched also to the cylinder head upper surface Fix the four camshaft housing and cam chain guide NO 2 by tightening of the bolt in order Install each bolt diagonally by using the wrench pulling the shaft down Tighten the bolt of each camshaft housing with the same torque CAUTION If get damaged the cylinder head or surface of camshaft housing thrust produce an result that the camshaft housing not was tightened e Tighten the camshaft housing bolt with the specified torque s CAUTION The camshaft housing bolt is made of the special material This bolt is superior at the degree of hardness more than the different high tension bolt Pay special caution that the different type of bolt should not be used This bolt head is punched the 9 mark V Camshaft housing bolt 8
50. s for each item CYLINDER HEAD COVER BOLTS CYLINDER HEAD amp CYLINDER BASE NUTS EXHAUST PIPE NUTS AND MUFFLER BOLTS Inspect Interval Tighten Initial at 1 000 km and Every 4 000 km thereafter CYLINDER HEAD COVER BOLT e Tighten the cylinder head cover bolts 1 to the specified torque V Cylinder head cover bolt 12 16N m 1 2 1 6 kgf m B CYLINDER HEAD amp CYLINDER BASE NUT e Tighten the cylinder head base buts 2 and cylinder base nuts 3 to the specified torque 9 Cylinder head base nut 7 11 N m 0 7 1 1 kgf m Cylinder base nut 7 11 m 0 7 1 1 kgf m E EXHAUST PIPE NUTS amp MUFFLER BOLTS e Tighten the exhaust pipe nuts muffler connecting bolt 5 and muffler mounting bolts 6 7 to the specified torque Exhaust pipe nut 18 281 1 8 2 8 kof m Muffler connecting bolt 18 28 N 1 8 2 8 kof m Muffler mounting bolt 18 28 N 1 8 2 8 kof m 14 AIR CLEANER Inspect Interval Clean Every 3 000 km Replace Every 12 000 km If the air cleaner is clogged with dust intake resistance will be increased with a resultant decrease in power output and an increase in fuel consumption Check and clean the air cleaner element in the following manner ATI25D Remove the seat and right side cover e Remove the six screws 1 and remove the air cleaner case cover e Take off the air cleaner element
51. stall the camshaft C rings When installing the camshaft and camshaft sprocket apply a small quantity of the THREAD LOCK 1324 to the thread portion of the camshaft sprocket bolts THREAD LOCK 1324 Tighten the camshaft sprocket bolts to the specified torque V Camshaft sprocket bot 10 12N m 1 0 1 2 kgf m Apply the engine oil to the camshaft bearings Install the exhaust camshaft first following the intake camshaft A CAUTION Do not rotate the magneto rotor while doing this operate 49 ENGINE 3 26 3 27 With the index mark on the magneto rotor is aligned with the triangle mark on the magneto cover hold the camshaft steady and lightly pull up the cam chain to remove any slack between the cam chain sprocket and exhaust camshaft sprocket The exhaust camshaft sprocket has an arrow marked 1 D Turn the exhaust camshaft so that the arrow marked 1 1 is aligned with the gasket surface of the cylinder head Engage the cam chain with the exhaust camshaft sprocket The other arrow marked 2 should now be pointing straight up Starting from the roller pin that is directly above the arrow marked 2 2 count out 16 roller pins from the exhaust camshaft side going towards the intake camshaft side Engage the 16th roller pin on the cam chain with the arrow marked 3 on the intake sprocket Refer to the following phot
52. stall the two side rails 4 The spacer and side rails do not have a designated top and bottom They can be installed in any position CAUTION CAUTION When installing the spacer be careful not to allow its two ends to overlap in the groove INCORRECT CORRECT Position the piston ring gaps as shown Before inserting the piston into its cylinder check that the gaps are properly positioned 6 2nd ring and lower side rail Upper side rail 1st ring and spacer 44 PISTON AND CYLINDER Apply MOLY PASTE on the piston pin and small end of the conrod MOLY PASTE Place a clean rag over the cylinder base to prevent the piston pin circlip from dropping into the crankcase and then fit the piston pin circlip with the long nose pliers CAUTION Use a new piston pin circlip to prevent circlip failure with a bent one NOTE Install the piston with the punch mark 1 the piston head facing toward the exhaust side Apply the engine oil to the sliding surface of the piston and big end of the conrod Install the dowel pins and new gasket onto the crankcase CAUTION Use a new gasket to prevent oil leakage Hold each piston ring with the piston ring sections positioned correctly and put it into the cylinder Make sure that the piston rings are caught by the cylinder skirt When mounting the cylinder after attaching the cam chain keep the cam chain taut
53. tic hammer is necessary pay attention to break the fins Place a clean rag over the cylinder base to prevent the piston pin circlips from dropping into the crankcase Remove the piston pin circlips with the long nose pliers Remove the piston pin by using the special tool Piston pin puller 09910 34510 33 3 11 5 OF ENGINE INSPECTION AND SERVICING 9 CYLINDER HEAD DISTORTION Decarbonize in combustion chamber Check the gasket surface of the cylinder head for distortion using a straightedge and thickness gauge Take clearance reading at several places as indicated If any clearance reading exceeds the service limit replace the cylinder head with a new one Cylinder head Service limit distortion 0 05 mm 0 002 in Thickness gauge 09900 20806 VALVE FACE WEAR Visually inspect each valve face for wear or damage If any abnormal wear is found replace the respective valve with a new one The thickness of the valve face decreases as the face wears Measure the valve head thickness D If the valve head thickness is within the specified value replace the valve with a new one Valve head thickness Service limit 0 5 mm 0 02 in Vernier calipers 09900 20101 VALVE STEM RUNOUT Check the valve stem for abnormal wear or bend Support the valve using a V blocks and measure the valve stem runout using the dial ga
54. uge as shown If the service limit is exceeded or abnormal condition exists replace the valve with a new one Valve stem runout Service limit IN amp EX 0 05 mm 0 002 in Dial gauge 09900 20606 Magnetic stand 09900 20701 V block 09900 21304 34 CAMSHAFT RUNOUT Support the camshaft using a V blocks and measure the camshaft runout using the dial gauge If the runout exceeds the service limit replace the camshaft with a new one Camshaft runout Service limit IN amp EX 0 10 mm 0 004 in Dial gauge 09900 20606 Magnetic stand 09900 20701 V block 09900 21304 9 CAMSHAFT The camshaft should be checked for runout and also for wear of cams and journals if the engine has been noted to produce abnormal noise or vibration or a lack of out put power Any of these abnormality could be caused by a worn camshaft 9 CAMSHAFT WEAR Worn down cams are often the cause of mistimed valve operation resulting in reduced output power The limit of cam wear is specified for both intake and exhaust cams in terms of cam height which is to be measured with a micrometer Replace camshafts if found it worn down to the limit Cam height Service limit Intake cam 34 17 mm 1 345 in 34 12 mm 1 343 in Micrometer 25 50 mm 09900 20202 ENGINE 3 12 TDC 0 Intake open Exhaust close B T D C gt A T D C Intake close A B D C BDC 180
55. ves Valve clearance adjustment must be checked and adjusted 1 at the time of periodic inspection 2 when the valve mechanism is serviced and 3 when the camshafts are removed for servicing Remove the magneto cover plug and valve timing inspection plug 3 The piston must at top dead center TDC on the compression stroke in order to check or adjust the valve clearance The valve clearance should only be checked when the engine is cold 18 PERIODIC MAINTENANCE 2 6 2 Rotate the magneto rotor clockwise or counter clockwise with a socket wrench to set the piston at TDC on the compression stroke Rotate the magneto rotor until the T index mark on the magneto rotor is aligned with the triangle mark 1 on the crankcase inspect the valve clearance insert a thickness gauge between the tappet and the camshaft Standard When cold 0 1 0 2 mm 0 004 0 008 in 0 2 0 3 mm 0 008 0 012 in Thickness gauge 09900 20806 e f the clearance is out of specification first remove the cam chain tension adjuster camshaft housing camshaft To install the tappet shim at original position record the shim NO and clearance to present by D mark on the cylinder head Select the tappet that agree with tappet clearance vertical line and shim NO horizontal line as refer to the tappet shim selection chart Refer to page 90 91
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