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2
Routine maintenance: schedule modifications
1
With reference to the Routine maintenance section at the
front of this mapual, note that the service schedule has been
altered slightly.The pre-ride (daily) check, the monthly/600 mile
check
and
the
unchanged. Note, however, that the battery is now retained by
a metal strap which is secured by a single bolt.
2
The tasks described under the six-monthly/3600 mile check
must be carried out at four-monthly intervals, or every 2500
miles/4000 km. They also include checking the petrol tap filter
(Section 4) and checking the side stand (Section 6). Note also
the revised procedure required for air filter cleaning, and
checking brake wear. See Sections 3 and 5.
3
At every eight months, or 5000 miles/8000 km carry out all
tasks listed under the four monthly heading (ie the previous six
monthly check, plus two items above) then renew the spark
plug and clean the engine oil centrifugal filter. Both of these
items being given under the annual heading for earlier models.
4
Once annually, or every 7500 miles/12 000 km carry out all
maintenance operations listed, then check the steering head
bearings and change the front fork oil. Note: When changing
the fork oil the front of the machine must be supported securely
so that the front wheel is clear of the ground before the fork top
bolts are removed. Note also the different fork oil capacity.
3
Routine maintenance: changing the engine oil -
CG125(BR)-K model
1
Unlike previous models, the BR-K does not have an engine
oil drain plug in the crankcase. Instead, the engine oil is drained
by removing the large hexagon-headed cap which houses the
oil filter gauze.
2
Refer to the procedure given in Routine maintenance, noting
the revised torque setting for the oil filter gauze cap in this
chapter's specifications.
4 Routine maintenance: air filter and fuel tap
Cleaning the air filter element
1
Although the filter element is still of the oil-damped
polyurethane foam type, as found on earlier models, the
servicing procedure is slightly modified as follows:
2
Remove the right-hand side panel, using the ignition key to
release the lock at its lower front corner, then remove the six
screws which secure the air filter cover. Withdraw the cover,
noting its sealing gasket.
3
Note the presence of the two wire mesh flame traps fitted
on the carburettor side of the filter casing; these should be
withdrawn and cleaned in a high flash-point solvent. Although
they should not get dirty or suffer any damage, they should be
checked for the presence of any particles of foreign matter and
should be renewed if they are split or torn.
4.9a Ensure filter gauze is correctly
located on refitting
Chapter 7 The 1985 on models
4
two-piece metal frame that slides into a groove in the filter
casing, with one of the flame traps. Withdraw the assembly and
remove the single retaining screw to separate the component
parts.
5
renew it if necessary. Clean the element as described in Routine
mile
check
remain
maintenance and reassemble the element components. Refit
them to the filter casing so that no unfiltered air can leak past,
then refit the filter cover, with its sealing gasket, and the side
panel.
Cleaning the petrol tap filters
6
bowl from the tap base, then remove the O-ring and filter gauze.
Check the condition of the seaiing O-ring and renew it if it is
seriously compressed, distorted or damaged. Clean the filter
gauze using a fine-bristled toothbrush or similar; remove all
traces of dirt or debris and renew the gauze if it is split or
damaged. Thoroughly clean the filter bowl; if excessive signs of
dirt or water are found in the petrol, remove the tank, empty the
petrol into a clean container and remove the fuel tap by
unscrewing its retaining gland nut.
7
noting the presence of a small spacer and of the sealing O-ring,
and clean it using a fine-bristled brush; if the gauze is split,
twisted or damaged it should be renewed. Flush the tank until
all traces of dirt or water are removed. The tap cannot be
dismantled further and must be renewed as a complete
assembly if the lever is leaking or defective in any way. If its
passages are blocked, use compressed air to blow them clear.
8 On reassembly, renew the sealing O-ring if damaged or
worn. Fit the filter gauze, spacer and O-ring into the tap and refit
the assembly to the tank. Check that the tap is correctly aligned
before tightening the gland nut; do not overtighten the gland
nut or its threads may be stripped, necessitating the renewal of
the tap.
9
correctly, then press the O-ring into place to retain it. Use only
a close-fitting ring spanner to tighten the filter bowl, which
should be secured by just enough to nip up the O-ring; do not
overtighten it as this will only damage the filter bowl, distort the
O-ring and promote fuel leaks. The recommended torque
setting is only 0.3 - 0.5 kgf m (2 - 3.5 Ibf ft). If any leaks are
found in the tap they can be cured only by the renewal of the
tap assembly or the defective seal.
5
applying the brake firmly and looking at the wear indicator
marks on the backplate. If the indicator pointer on the camshaft
is aligned with, or has moved beyond, the fixed index mark cast
on the backplate, the shoes are worn out and must be renewed
as a pair. This involves the removal of the wheel from the
4.9b Do not overtighten filter bowl
note sealing O-ring
The element itself consists of a foam block supported by a
Check the element for splits, tears or severe clogging and
Switch the tap to the 'Off position and unscrew the filter
Remove the tubular filter gauze from the tap stack pipe,
Fit the filter gauze to the tap, ensuring that it is located
Routine maintenance: checking brake shoe wear
On these models brake shoe wear can be checked by
5.1 Wear indicators are fitted to permit
quick check of brake shoe wear
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