Related Manuals for Baotian BT125T-2
Summary of Contents for Baotian BT125T-2
- Page 1 BT125T-2 SERVICE MANUAL JIANGMEN SINO-HONGKONG BAOTIAN MOTORCYCLE INDUSTRIAL CO., LTD...
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Page 2: Table Of Contents
CONTENTS CHAPTER ONE MAINTENANCE OF THE MOTORCYCLE Ⅰ. ITEMS OF MAINTENANCE Ⅱ. PERIODIC MAINTENANCE SCHEDULE AND MAINTENANCE LOCATIONS Ⅲ. MAINTENANCE SPECIFICATIONS Ⅳ. THROTTLE ACTUATION INSPECTION Ⅴ. AIR FILTER INSPECTION AND CLEANING Ⅵ. BRAKE SYSTEM INSPECTION, ADJUSTMENT AND REPLACEMENT Ⅶ. FRONT AND REAR SHOCK ABSORBER INSPECTION Ⅷ. -
Page 3: Chapter One Maintenance Of The Motorcycle
CHAPTER ONE MAINTENANCE OF THE MOTORCYCLE Ⅰ. ITEMS OF MAINTENANCE When the motorcycle is used, loosening of parts and mechanical wear inevitably occur to varied extents. Neglect of timely maintenance not only reduces its mechanical function, economic performance, stability and durability, but also threatens the safety of the motorcycle and the rider. - Page 4 1. Maintenance Schedule Maintenance Schedule time Mileage 1000km item 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 New R Engine oil 300km Engine oil strainer Gasoline strainer New R Gear oil Note 4 300km Throttle play Carburetor Note 3, Air filter...
- Page 5 2. Maintenance locations Spark plug Front shock absorber Throttle grip Oil tank damage,contamination damage,loosening actuation,play brake oil level £ ¨ £ © £ ¨ £ © £ ¨ £ © £ ¨ £ © Rear brake disc Rear brake caliper Front rim Front tire damage,wear...
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Page 6: Ⅲ. Maintenance Specifications
Ⅲ. MAINTENANCE SPECIFICATIONS The basic methods of motorcycle maintenance include inspection, adjustment, tightening, lubrication, cleaning, supplementing and replacement, which constitute the main elements of maintenance. 1. Inspection Inspection refers to basic inspecting operations in accordance with items and requirements specified in the user’s manual, including inspection with instruments or with eyes for abnormalities in machine parts, directly comparing related data and aligning with tools and gauges. -
Page 7: Ⅳ. Throttle Actuation Inspection
THROTTLE ACTUATION INSPECTION Inspect throttle grip for easy and smooth free travel:2-6mm movement. Inspect throttle free travel. Free travel: 2-6mm The main adjusting position is beside the tightening nut adjusting nut carburetor. Remove rear store case cover. Adjust by loosening the fastening nut and turning the adjusting nut. -
Page 8: Ⅴ. Air Filter Inspection And Cleaning
Ⅴ. AIR FILTER INSPECTION AND CLEANING After a certain mileage, dust and impurities will gather in air filter case and strainer, which will clog strainer pores and reduce inlet of air and thus lead to excessive concentration of mixed gas and reduce the performance of engine. That’s why the strainer must be replaced every 20000km and in dusty or rainy conditions strainer must be replaced earlier. - Page 9 * Do not pull brake lever when brake caliper is removed so as to prevent jamming of brake block. If brake block is jammed, pry it with screwdriver and push piston back into caliper. brake caliper brake block Brake Block Replacement: brake block pin Brake block must be replaced when it is worn to the limit of use.
- Page 10 2. Rear Brake (disk brake) Remove the bolts linking brake caliper and rear brake rear brake mounting board. mounting board Remove brake caliper. * Do not pull brake lever when brake caliper is removed so as to prevent jamming of brake block.
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Page 11: Ⅶ. Front And Rear Shock Absorber Inspection
Ⅶ. FRONT AND REAR SHOCK ABSORBER INSPECTION 1. Front Shock Absorber front brake lever Tighten front brake lever, press front shock absorber up and down and inspect actuation. Inspect front shock absorber to see if there is leakage of oil and if there is damage or loosening. 2. -
Page 12: Ⅸ. Steering Stem Inspection
Damage due to forced dismounting Fissure extending to frame Abnormal inner lining Tire groove wear: front wheel < 0.8mm, rear wheel < 0.8mm. Punctured or otherwise damaged tire flank Inspect tire pressure by means of a tire pressure gauge * Tire pressure should be inspected when the motorcycle is in a cold state. Specified pressure Unit: kPa Front wheel... -
Page 13: Chapter Two Maintenance Information
CHAPTER TWO MAINTENANCE INFORMATION I. FRAME NUMBER AND ENGINE NUMBER LOCATION Frame engine number Number II. PRECAUTIONS IN OPERATION Removed washers, 0-rings, elastic retaining rings and split pins must be replaced with new ones. When mounting bolts, nuts and screws, proceed from trial tightening, from larger diameters to smaller diameters and inner ones to outer ones in a diagonally order. -
Page 14: Ⅲ. Specified Torques
Before connecting connectors, confirm that they are free from breakage, bending, over length or loosening. Connectors must be inserted home. When connecting connectors with locks, confirm that their locks are fastened. Confirm that the wires are not loose. Confirm that connectors’ plastic sleeves completely cover the connectors without fail. Before connecting the connectors, confirm that their sleeves are free from breakage and their terminals are not oversized. - Page 15 SPECIFIED TORQUES Frame: Designations of tightening positions Number Thread specification Torques: N·m Engine suspension lug mounting nut Engine mounting nut Front axle nut Rear axle nut Rear shock absorber upper mounting bolt Rear shock absorber lower mounting bolt Front shock absorber upper lock bolt Steering stem lock nut Handlebar mounting nut Upper bearing top...
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Page 16: Chapter Three Body Troubleshooting
CHAPTER THREE BODY TROUBLESHOOTING SECTION ONE BODY COMMON TROUBLES AND TROUBLE DETECTION Body part common troubles and possible causes are as follows: Troubles Causes Details (reference) Handlebar rotation not Over tightening of handlebar adjusting nut Refer to “Front Fork easy (strenuous turning Service”... - Page 17 Chart continued Troubles Causes Details (reference) Worn seal ring of brake caliper piston Viscous or worn brake caliper piston Inability brake Feeble brake caliper normal sliding lever Worn main cylinder piston seal ring Viscous or worn main cylinder piston Contaminated main cylinder Clogged narrow brake...
- Page 18 Chart continued Troubles Causes Details (reference) Bent front axle, incorrect wheel mounting Deviation of motorcycle Refer to “Front Wheel Roundness error of wheel rim direction (inclining to Service” roadside) Deformation of wheel rim Inadequate tire pressure Deformed wheel rim Loose front wheel bearing Refer to “Front Wheel Front wheel oscillation Poor tire...
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Page 19: Section Two Detailed Descriptions Of Body Parts Troubles
SECTION TWO DETAILED DESCRIPTION OF BODY PARTS TROUBLES Precautions in Operation: Forced mounting or dismounting of body cover parts will cause damage to claws and slots of corresponding hoods. When mounting body cover parts, be sure to align the corresponding parts of hoods. When mounting body cover parts, avoid pressing wires, cables or pipes. - Page 20 Axle Bending Inspection Place axle on a V-seat and measure with a dial gauge. The dial gauge indicates a 1/2 bending value. Limit of use: Replace if >0.2mm. Wheel Rim Oscillation Inspection Measure oscillation value on a correcting bench. Limit of use: Replace if >2.0mm. Traverse direction: Replace if >2.0mm.
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Page 21: Ⅱ. Front Brake Service ( Disk Brake )
Mount spacer. Drive in right bearings. Bearings must be driven in parallel. Dust cover must be driven in with the face out. Apply grease to new dust cover lip. Mount front axle bush. Front Wheel Mounting Mount brake disc, tighten brake disc mounting bolts. Torque: 27N·m Spread front axle with a thin film of grease. - Page 22 The specification of brake oil is indicated on the reservoir cover. Place diaphragm. Connect a transparent hose to exhaust valve. Grip brake lever fast and open exhaust valve 1/2 gripping turn to let out air and lock exhaust valve. Repeat releasing this operation till no bubbles are exhausted from brake lever...
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Page 23: Ⅲ. Front Shock Absorber Service
Remove brake light switch and brake lever. Remove retaining ring from main cylinder. Use special retaining ring remover when removing retaining ring. Remove piston cover, piston and spring. Clean oil reservoir and piston with pure oil pipe bolt brake oil. brake oil pipe Do not effect cleaning with gasoline as it is corrosive to rubber parts. -
Page 24: Ⅳ. Front Fork Service
Remove 4 pieces of bolts on the upper part of front shock absorber. Remove shock absorber. bolts body covering parts Inspection Inspect if there is oil leakage in front shock absorber, if there is deformation of shock absorber arm and if there is damage or loosening of any part. - Page 25 Remove front axle nut; Remove front wheel. front fender Remove front shock absorber, front fender (the mounting screws is inside the fender) etc. screws shock absorber Remove steering stem from head tube. bottom bearing The removing of the bottom bearing cup, bearing head tube cup,bearing top and ball set...
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Page 26: Ⅴ. Handlebar Service
Mount front fender on steering stem. Mount front wheel. Mount front shock absorber and other parts. Apply grease to top bearing cup and bearing top. Mount in order upper bearing cup, bearing ball set and upper bearing top on the upper part of steering stem and fasten them. -
Page 27: Ⅵ. Rear Wheel Service
Mounting Mount handlebar on steering stem guide tube, setting bolt and nut. handlebar Torque: 45 N·m bolt Mount rear brake main cylinder and fasten bolts. Mount left handlebar switch and fasten screws. Torque: 9 N·m Mount front brake main cylinder and fasten bolts. - Page 28 rear brake Remove the bolts linking brake caliper and rear mounting board brake mounting board. Remove rear brake caliper. rear wheel Remove rear axle nut. brake disc mounting bolts rear brake caliper Remove rear brake mounting board and bush. Remove rear wheel. rear wheel Remove 3 mounting bolts of brake disc.
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Page 29: Ⅶ. Rear Brake Service ( Disk Brake )
VII. REAR BRAKE SERVICE (DISK BRAKE) The service of the rear brake is the same as the front brake. VIII. REAR SHOCK ABSORBER SERVICE Dismounting Remove motorcycle body covering parts. frame bolt Remove mounting bolt connecting rear shock rear shock absorber absorber and motorcycle frame, bolt connecting rear shock absorber and engine.