Aeon New Sporty 125, 180 Service Manual
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Aeon New Sporty 125, 180 Service Manual

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AEON MOTOR CO.,LTD

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Summary of Contents for Aeon New Sporty 125, 180

  • Page 1 AEON MOTOR CO.,LTD...

  • Page 2: Table Of Contents

    CONTENTS INFORMATION………………………………………... MAINTENANCE…………………….………………… ENGINE REMOVAL AND INSTALLATION………… ENGINE LUBRICATION AND COOLING SYSTEM.. CYLINDER HEAD & VALVES……………………….. CYLINDER & PISTON………………………………... TRANSMISSION SYSTEM…………………………… FRONT WHEEL, SUSPENSION AND STEERING….. REAR WHEEL SYSTEM……………………………… FENDERS AND EXHAUST PIPE…………………….. ELECTRICAL SYSTEM………………………………. TROUBLE SHOOTING………………………………..

  • Page 3: Information

    1. INFORMATION 1.1 Safety 1.2 Notes 1.3 Specifications 1.4 Serial number Torque valve 1.1 Safety GASOLINE Gasoline is extremely flammable and is explosive under certain condition. Do not smoke or allow sparks or flames in your work area. CARBON MONOXIDE Never run the engine in a closed area.
  • Page 4 1.3 SPECIFICATION ENGINE 125 / 180 Type Air-Cooled 4-syroke with Oil Cooler Displacement 125 cc/169 cc Bore and Stroke 52.4×57.8mm/61×57.8mm Compression 9.1:1 Maximum Torque 6.21 Nm@4017 rpm/10.24 Nm@4403 rpm MIKUNI 125/180 Carburetor Ignition Capacitor Discharge Starting Electrical & Kick-Start Lubrication Forced pressure and wet sump AE-9...
  • Page 5 1.4 SERIAL NUMBER The frame serial number is stamped on the front frame. And stick a bar code paper to cover it. The engine number is stamped under the crankcase.
  • Page 6 1.5 TORQUE VALUES STANDARD 5 N.m (3.5 lbs.ft) 5mm bolt and nut 10 N.m (7.2 lbs.ft) 6mm bolt and nut 22 N.m (16 lbs.ft) 8mm bolt and nut 35 N.m (25 lbs.ft) 10mm bolt and nut 55 N.m (40 lbs.ft) 12mm bolt and nut ENGINE 28 N.m (20.7 lbs.ft)

  • Page 7: Maintenance

    2. Maintenance Maintenance data Maintenance schedule Fuel tube Throttle operation Throttle cable adjustment Air cleaner Spark plug Idle speed Drive chain 2.10 Brake system 2.11 Wheels and tires 2.12 Steering system 2.13 Toe-in 2.14 Gear oil 2.1 MAINTENANCE DATA SPECIFICATION SPARK PLUG Spark plug cap 0.6-0.7mm...
  • Page 8 2.2 MAINTENANCE SCHEDULE The maintenance intervals in the follow table is based upon average riding, condition. Riding in usually dusty areas, require more frequent servicing. Service Item Initial Service Every 100 hours Every 200 hours Every 300 hours (First 30 hours) ENGINE OIL GEAR OIL FUEL FILTER...
  • Page 9 2.3 FUEL TUBE Inspect the fuel lines for deterioration, damage or leakage and replace if necessary. 2.4 THROTTLE OPERATION Inspect for smooth lever operation, full opening and automatic full closing in steering positions. Inspect for deterioration, damage, cuts and nicks, or kink in the throttle cable, replace it if necessary.
  • Page 10 2.5 THROTTLE CABLE ADJUSTMENT Slide the rubber cap of the adjuster off the throttle housing, loosen the lock nut and adjust the free play of the throttle lever by turning the adjuster on the throttle housing. Inspect the free play of the throttle lever. 2.6 AIR CLEANER MAINTENANCE (1) Loosen the screw and remove the air cleaner from carburetor.
  • Page 11 2.7 SPARK PLUG The spark plug is located at the front of the engine. (1) Disconnect the spark plug cap and remove the spark plug (2) Visually inspect the spark plug electrode for wear or cranks in insulator. Replace if needed.
  • Page 12 2.9 DRIVE CHAIN ADJUSTMENT Stop ATV and shift transmission into neutral. Inspect the chain slack midway between the sprockets. The standard is 10-25 mm (5/8-1 inch). If needed remove the chain protective cover and adjust the chain slack. Loosen the axle holder lock nut then adjust the drive chain slack by turning the adjusting nut.
  • Page 13 2.10 BRAKE SYSTEM ADJUSTMENT Inspect the front brake lever and cable for excessive play or other damage. Replace or repair if necessary. Measure the free play of the brake lever at the end of the lever. The standard is 10~20 mm. Adjust the free play of the front brake lever by turning the adjuster on the brake lever assembly.
  • Page 14 Inspect the tire surface for cuts, nails or other sharp objects. Check the tire pressure at cold tire conditions. The standard tire pressure is 3psi. (0.15kgf/cm 2.12 STEERING SYSTEM Check the free play of the steering shaft with the front wheels, turned straight ahead. When there is excessive play, inspect the tie-rod, kingpin bushing and ball joint.
  • Page 15 Park the vehicle on level ground with the front wheels facing straight ahead. Mark the centers of the tires to indicate the axle center height. Measure the distance between the marks. Carefully move the vehicle back, let the wheels turn 180° so the marks on the tires are aligned with the axle center height.

  • Page 16: Engine Removal And Installation

    Gear oil needs to be changed every 200 hours. There is a gear oil drain hole bolt at the rear of the engine. (STEP1) Unscrew this drain hole bolt and let the dirty oil flow out, catching the oil in a proper container for later disposal.
  • Page 17 ENGINE SHOULD ONLY BE REMOVED IN THE CONDITIONS OF NECESSARY REPAIRS OR ADJUSTMENT TO THE TRANSMISSION AND COMBUSTION SYSTEM ONLY! 3.2 ENGINE REMOVAL Remove the front, rear rack, and handle bar. Remove the footrest. Remove the spark plug cap from the spark plug. Remove the exhaust muffler.
  • Page 18 4.1 Service Information 4.2 Trouble Shooting 4.3 Engine Oil Level 4.4 Engine Oil & Filter Change 4.5 Oil Pump Removal /Installation 4.1 SERVICE INFORMATION GENERAL This section describes inspection and replacement of the engine oil, oil filter screen and assembly of the oil pump. Fill the oil pump with clean oil when reassembling the pump.
  • Page 19 Cover-to-rotor clearance --------- 0.12 Rotor tip clearance -------- 0.12 End clearance 0.01-0.10 TORQUE VALUE Oil Drain Bolt 20~30 N.m (14.8~22.1 lbs.ft) 4.2 THROTTLE SHOOTING Oil level too low / high oil consumption Normal oil consumption. External oil leaks. Oil not changed often enough. Worn piston rings.
  • Page 20 Add the recommended oil up to the upper level if the oil level is below or near lower level line on the gauge. LOWER LEVEL UPPER LEVEL 4.4 ENGINE OIL & FILTER CHANGE Remove the oil filter cap and the oil drain bolt. NOTE: drain the oil while the engine is warm to ensure complete draining.
  • Page 21 TORQUE: 20~30 N.m (14.8~22.1 lbs.ft) Fill the crankcase with recommended oil. ENGINE OIL CAPACITY: 1.2 liter at draining. OIL DRAIN Install the oil filter cap. Install the oil level gauge. Start the engine and let it idling for 2 or 3 minutes.
  • Page 22 Remove the left crankcase cover. Remove the starting clutch outer and gear ass’y. Remove the flange bolts and oil separator. Remove the oil pump chain and oil pump driven...
  • Page 23 sprocket. Remove the oil pump ass’y. Disassemble the oil pump. INSPECTION Measure the oil pump rotor-to-body clearance. SERVICE LIMIT: 0.12 mm Install the oil pump shaft and measure the pump...
  • Page 24 rotor tip clearance. SERVICE LIMMIT: 0.12 mm. Remove the oil pump shaft and measure the pump and clearance. SERVICE LIMMIT: 0.2 mm. 4.5 OIL PUMP ASS’Y / INSTALLATION Install the outer rotor, inner rotor and oil pump shaft onto the body. NOTE: Pour a drop of clean engine oil inside the oil pump.
  • Page 25 chain. Install the oil separator. Install the starting clutch outer and gear ass’y. Install the new gasket, dowel pins and right crankcase cover.

  • Page 26: Cylinder Head & Valves

    Install the A.C.G generator ass’y Install cooling fan composition Install fan cover 5. CYLINDER HEAD / VALVES...
  • Page 27 5.1 SERVICE INFORMATION 5.2 TROUBLESHOOTING 5.3 CAMSHAFT ASS’Y REMOVAL 5.4 CYLINDER HEAD REMOVAL 5.5 CYLINDER HEAD INSTALLATION 5.1 SERVICE INFORMATION GENERAL This section describes the maintenance of cylinder head, valves, camshaft and the other parts. The engine must be removed from the frame to service cylinder head. Camshaft lubrication oil is fed to the cylinder head through an oil orifice in the engine case.
  • Page 28 Engine top-end problems usually affect engine performance. These problems can be diagnosed by a compression test, or by tracing engine noise to the top end with a sounding rod or stethoscope. Low compression valve Incorrect valve adjustment. Worn or damaged valve seats. Burned or bent valve.
  • Page 29 Remove the rubber tube of gas waste recovery. Remove the cylinder head cover. Remove the air cleaner and carburetor. Remove the inlet pipe ass’y. Remove the shroud compositions. Relax the cam chain adjuster screw. Remove the screw and O-ring and tighten the cam...
  • Page 30 chain-adjusting bolt with clockwise direction. Remove the nuts and washers Remove the camshaft holder and dowel pins. Relax the camshaft gear from cam chain and remove the camshaft. INSPECTION Inspect the cam lobes surface and height of cam lobes for wear or damage.
  • Page 31 Screw a 5 mm bolt into the rocker arm shaft threaded end. Pull on the bolt to remove the shafts and rocker arms. Inspect the camshaft holder, rocker arms and rocker arm shafts for wear or damage. Measure the I.D. of each rocker arm. SERVICE LIMIT: 10.10 mm Measure the O.D.
  • Page 32 Remove the cylinder head gasket and dowel pins. Remove the cam chain guide. CYLINDER HEAD DISASSEMBLY Remove the valve cotters, spring retainers and valve springs with a valve spring compressor. INSPECTION Clean off all carbon deposits from the com- bustion and check the spark plug hole and valve area for cracks.
  • Page 33 Measure the cylinder head diagonally for warp with a straight edge and feeler gauge. Measure the free length of the inner and outer valve springs. SERVICE LIMITS: Inner 31.2 mm Outer 34.1 mm Inspect each valve for turning, burning, scratches or abnormal stems wear.
  • Page 34 Calculate the stem-to-guide clearance. SERVICE LIMITS: IN 0.08 mm EX 0.10 mm NOTE: If the stem-to-guide clearance exceeds the service limits, determine if a new guide with standard dimensions would bring the clearance within tolerance. If so, replace guides as necessary and ream to fit. If the valve guide is replaced, the valve seat must be refaced.
  • Page 35 Install the cylinder head. CAMSHAFT ASS’Y INSTALLATION Install the rocker arms and rocker arm shafts into the camshaft holder. Align the “T” mark on the flywheel with the index mark on the alternator cover by turning the flywheel counter-clockwise. Position the camshaft gear with cam chain so that its “I” mark aligns with the cylinder head surface and the circle hole towards the front.
  • Page 36 Install the dowel pins and camshaft holder. Tighten the washers and nuts. Torque: 20 N.m (14.8 lbs.ft) Adjust the clearance between the rocker arm and valve stem by applying a feeler gauge. STANDARD VALVE: 0.08 mm Relax the cam chain-adjusting bolt with coun- terclockwise direction and install the o-ring and screw.

  • Page 37: Cylinder & Piston

    6. CYLINDER AND PISTON 6.1 SERVICE INFORMATION 6.2 TROUBLESHOOTING 6.3 CYLINDER REMOVAL 6.4 PISTON REMOVAL 6.5 CYLINDER INSTALLATION 6.1 SERVICE INFORMATION...
  • Page 38 GENERAL Camshaft lubrication oil is fed to the cylinder head through an oil orifice in the cylinder head and engine case. Before installing the cylinder head be sure the orifice is not clogged and the gasket, O-ring and dowel pins are in place. SPECIFICATION ITEM STANDARD...
  • Page 39 Knocking or abnormal noise Worn piston and cylinder. Excessive carbon build-up. Excessive smoke Worn cylinder, piston, or piston rings. Improper installation of piston rings Scored or scratched piston or cylinder wall. Damaged valve stem seal. 6.3 CYLINDER REMOVAL Remove the cylinder head. Remove the cylinder.
  • Page 40 Remove the cylinder gasket and dowel pins. Clean off any gasket materials from the cylinder surface. NOTE: Be carefully not to damage the gasket surface. 6.4 PISTON REMOVAL Stuff a shop towel into the crankcase. Remove the piston pin clip with needle nose pliers. NOTE: Do not allow the clip fall into the crankcase.
  • Page 41 Spread each piston ring and remove it by lifting up at a point opposite the gap. INSPECTION Inspect the cylinder walls for scratches or wear. Measure and record the cylinder I.D. at three levels in both an X and Y axis. Take the maximum reading to the cylinder wear.
  • Page 42 Inspect the top of the cylinder for warp. SERVICE LIMITS: 0.10 mm PISTON / PISTON RING INSPECTION Measure the piston ring-to-groove clearance. SERVICE LIMITS: TOP 0.12 mm SECOND 0.12 mm Inspect the piston for wear or damage. Insert each piston ring into the cylinder and measure the ring end gap.
  • Page 43 SECOND 0.5 mm Measure the piston pin O.D. SERVICE LIMIT: 14.960 mm Measure the piston pin O.D. SERVICE LIMIT: 15.04 mm Calculate the piston-to-piston pin clearance. SERVICE LIMITS: 0.02 mm Measure the connecting rod small end I.D. SERVICE LIMITS: 15.06 mm...
  • Page 44 6.5 PISTON & PISTON RING INSTALLATION Clean the piston ring grooves thoroughly and install the piston ring with the marks facing up. NOTE: Don’t interchange the top and second rings. Avoid piston and piston ring damage during installation. Space the piston ring end gaps 120 degrees apart. PISTON INSTALLATION Install the piston with it’s “IN”...
  • Page 45 Clean any gasket material from the crankcase surface. NOTE: Be carefully not to damage the gasket surface. Install the dowel pins a new gasket. Coat the cylinder bore and piston rings with engine oil and install the cylinder. NOTE: Avoid piston rings damage cylinder bore during installation.
  • Page 46 7. TRANSMISSION & KICK STARTER 7.1 SERVUCE INFORMATION 7.2 TROUBLE SHOOTING 7.3 C.V.T DISASSEMBLY 7.4 KICK STARTER DISASSEMBLY 7.5 KICK STARTER ASSEMBLY 7.6 C.V.T ASSEMBLY 7.1 SERVICE INFORMATION If the drain tube ass’y fills with water, the tube should be drained. SPECIFICATIONS ITEM STANDARD (mm)
  • Page 47 Clutch weight lining thickness -------------- Driven face spring length 168.4-169.4 164.0 TORQUE VALUES Clutch outer nut 55 N.m (40.6 lbs.ft) Drive face nut 55 N.m (40.6 lbs.ft) 7.2 TROUBLE SHOOTING Engine starts but can’t travel Worn driven belt. Worn clutch lining. Damaged driven face spring.
  • Page 48 7.3 C.V.T DISASSEMBLY LH CRANKCASE COVER C.V.T INLET DUCT REMOVAL Relax the band screw and remove the C.V.T inlet duct. Remove the air cleaner case. AIR CLEANER CASE...
  • Page 49 Remove the bolts and LH crankcase cover. LH CRANKCASE COVER Remove the gasket and dowel pins. Clean off any gasket material from L crankcase surface. GASKET DOWEL PINS FLANGE NUT LH CRANKCASE SURFACE C.V.T REMOVAL Relax the flange nut, and remove the drive face. DRIVE FACE Relax the flange nut.
  • Page 50 FLANGE BELT DRIVE PULLEY Remove the drive face boss and movable driven face ass’y. DRIVE FACE BOSS MOVABLE DRIVEN FACE Remove the ramp plate and weight roller set. Relax the special nut and remove the driven plate composition and driven face spring. Inspect the driven belt for wear, tears or damage.
  • Page 51 Inspect the weight roller for wear or damage and replace them if necessary. Measure the O.D. of weight rollers. SERVICE LIMIT:14.6/16.6 mm Measure the I.D. of movable driven face. SERVICE LIMIT:28.03mm Inspect the drive face collar for wear or damage. Measure the I.D.
  • Page 52 Inspect the clutch weight set for wear or damage. Measure the thickness of clutch weight lining. SERVICE LIMIT:1.5mm Measure the length of driven face spring. SERVICE LIMIT:164.0 mm Inspect the driven face ass’y and replace them if necessary. 7.4 KICK STARTER DISASSEMBLY Remove the LH crankcase cover.
  • Page 53 Remove the ex. Circle-clip and washer from kick starter spindle composition. EX. CIRCLIP Remove the kick-starter spindle ass’y. STARTER SPINDLE ASS’Y Remove the kick-starter idle gear ass’y Remove the kick spindle bush. INSPECTION STARTER IDLE GEAR ASS’Y Inspect the kick-starter spindle composition for wear or damage.
  • Page 54 Inspect the kick driven gear and spring for wear or damage. KICK DRIVEN SPRING 7.5 KICK-STARTER ASSEMBLY Install the kick driven gear and spring. Install the kick spindle bush, return spring and spindle ass’y. Install the kick-starter. KICK STARTER 7.6 C.V.T ASSEMBLY Assemble the driven face ass’y, spring and...
  • Page 55 driven plate. Assemble the movable drive face, weight roller set and drive face. Install the movable drive face ass’y and boss. DRIVE FACE BOSS MOVABLE DRIVEN FACE Install the drive face and kick starter ratchet. FLANGE NUT...
  • Page 56 DRIVE FACE Install the driven belt and driven pulley ass’y. FLANGE NUT DRIVE PULLEY DRIVEN BELT Install the dowel pins and gasket. DOWEL PIN GASKET Install the LH crankcase cover. LH CRANKCASE COVER Install the air cleaner case and C.V.T ducts.

  • Page 57: Front Wheel, Suspension And Steering

    8. FRONT WHEEL, SUPENSION AND STEERING 8.1 PARTS DRAWING 8.2 TROUBLESHOOTING 8.3 HANDLEBAR 8.4 THROTTLE HOUSING 8.5 FRONT WHEEL 8.6 FRONT BRAKES 8.7 STEERING SYSTEM 8.8 FRONT SUSPENSION 8.1 PARTS DRAWING...
  • Page 59 8.2 TROUBLESHOOTING HARD STEERING Faulty tire Steering shaft holder too tight Insufficient tire pressure Faulty steering shaft bushing Damaged steering shaft bushing FRONT WHEEL WOBBLING Faulty tire Worn front brake drum bearing Bent rim Axle nut not tightened properly BRAKE DRAG Incorrect brake adjustment Sticking brake cable STEERS TO ONE SIDE...
  • Page 60 Improperly installed front swing arms Bent front shock absorber swing rod SOFT SUSPENSION Wear front shock absorber springs Worn or damage front swing arm bushing 8.3 HANDLEBAR SYSTEM Removal Remove the handlebar cover by unscrew two fix screws. Remove the throttle lever housing on the right handlebar.
  • Page 61 Remove the bolts attaching the handlebar upper holder. Remove the handlebar. Installation Install the switch housing. Tighten two screws securely. Install the throttle lever housing, and brake lever bracket ass’y.
  • Page 62 8.4 THROTTLE HOUSING Disassembly Unscrew the screws on the throttle housing cover. Remove throttle housing cover and gasket. Disconnect throttle cable from the throttle arm and remove from the throttle housing. Assembly is in the reverse order of disassembly. 8.5 FRONT WHEEL Remove Raise the front wheels off the ground by placing a jack or other support under the frame.
  • Page 63 Measure the brake lining thickness. The minimum limit: 1.5 mm If they are thinner than the minimum limit, replace the brake lining. Measure the brake drum inner diameter. The maximum limit: 111 mm. Turn the inner race of each bearing with fingers. The bearings should turn smoothly and quietly.
  • Page 64 Remove brake arm and cam. Remove return spring. Remove indicator plate and felt seal. Install Brake panel Apply grease to the brake cam and anchor pin and install the cam in the brake panel. Soak the felt seal in the engine oil and install the seal on the brake cam.
  • Page 65 Install the brake panel on the knuckle. Connect the brake cable to the brake arm. Install the brake arm cover Tighten the screws securely Position the brake shoes in their original locations and install the brake shoe spring. Install the brake drum and front wheel. Install the castle nut and cotter pin.
  • Page 66 The ball joints should turn smoothly and quietly. Kingpin inspection Inspect the kingpin for damage or cracks. Steering shaft removal Remove the handle bar cover and handle bar. (see page 58) Remove the front fender. (see page 72) Remove handlebar lower holder. Unscrew steering shaft holder bolt, remove steering shaft holder.
  • Page 67 Inspect the steering shaft for damage or cracks. Installation of steering shaft Apply grease to the holder. Install the holder and oil seal tighten with the nuts. Torque : 33 N.m(24 lbs-ft) 8.7 STEERING SYSTEM Installation of steering shaft Install the steering shaft nut and tighten it. This nut is under this steering shaft.

  • Page 68: Rear Wheel System

    9. REAR WHEEL SYSTEM 9.1 PARTS DRAWING 9.2 TROUBLESHOOTING 9.3 REMOVE REAR WHEEL AND REAR BRAKE 9.4 DRIVE MECHNISM 9.5 REAR BRAKE AND WHEEL INSTALLATION 9.6 SHOCK ABSORBER 9.4 SWING ARM 9.1 Parts Drawings...
  • Page 69 9.2 Troubleshooting Bad Brake Performance Brake shoes are worn Bad brake adjustment Brake lining are oily, greasy or dirty Brake drums are worn Brake arm setting is improperly engage Vibration or wobble Axle is not tightened well Bent rim Axle bearings are worn Faulty tires Rear axle bearing holder is faulty Brake Drag...
  • Page 70 The cable connectsto the left side brake lever. The cable connects to wire connector for front brake function. Hydraulic Cylinder Driving Rod The rear brake cable fixing set Brake Pump...
  • Page 71 Brake Oil Tank Left Side Right Side Brake Lever Brake Lever Wire Connector The cable connects to front brake drum. Brake Oil Tube...
  • Page 72 Rear Brake Caliper The Brake Adjustment ) × Phillips Bolts 93100-05016-K Plain Washer 94101-0514010-K Nylon Lock Nut 90350-05000-K 10 sets...
  • Page 73 Hex Flange Bolt (96000-08012-K) × 4 STEP.1) Take off the right side footwell for adjustment. Rear Brake Cable Fixing Set STEP.2) Take off the rear brake fixing set and the bolt of brake pump.
  • Page 74 Hydraulic Clyinder Driving Rod Adjusting Bolt STEP.3) The setup of the adjusting nut of the brake pump: 1)The brake pedal should be in the highest location under the function of the returning spring. 2)The adjusting nut changes the distance between the brake pump and the hydraulic cylinder driving rod.
  • Page 75 STEP.4) Drain the air in the brake oil tube in order to prevent the brake pump malfunction in power delivering. 1).Open the brake oil tank, lose the drain screw of the brake caliper without braking motion. It functions normal if the brake oil could drain automatically, please try this for couple times for confirmation.
  • Page 76 STEP.5) Install the rear brake cable fixing set & adjust the brake cable. 1).Spin the gap adjuster on the left lever till the shortest position. 2).Adjust the adjusting screw and keep the gap being 2-3 mm. Front / Rear Brake Front Brake Ratio Distribution.
  • Page 77 Left / Right Front Brake Balance Adjuster. STEP.7) The brake balance adjuster on right lever. 9.4 DRIVE MECHNISM...
  • Page 78 Removal and inspection. Remove the rear wheel and the rear brake. Remove the skid plate under swing arm. Remove the drive chain cover. Disassemble the chain retaining clips and mas- ter link. Remove the chain. Disassemble the driven sprocket, axle and sprocket collar.

  • Page 79: Fenders And Exhaust Pipe

    Also check that the bearing outer race fits tightly in the axle holder. Replace if necessary. NOTE: Replace the bearings in pairs. Installation Add grease to the dust seal lips and install dust seals. Assemble the rear axle and the driven sprocket.
  • Page 80 10.1 REAR FENDER REMOVAL Pull the “Seat Release Bar” to take off the seat. This seat release bar is under the right side of the rear fender. Procedure for rear fender removal: Remove the rear rack and seat. Unscrew the four bolts, which connect the front fender and rear fender.
  • Page 81 Remove the mounting bolts and nuts from the front fender and footrest plate. 10.3 EXHAUST PIPE REMOVAL You must wait at least 15 minutes after turn off the engine. You need to remove the seat, rear fender and footrest plate, before you take off the exhaust pipe.

  • Page 82: Electrical System

    11. ELECTRICAL SYSTEM 11.1 TROUBLESHOOTING 11.2 IGNITION COIL 11.3 IGNITION TIMING 11.4 ALTERNATOR EXCITER COIL 11.5 BATTERY CAUTION 11.6 BATTERY VOLTAGE 11.7 CHARGING 11.8 ELECTRIC STARTER 11.9 LIGHT BULBS REPLACEMENT 11.10 WIRING DIAGRAMS 11.1 Troubleshooting ENGINE STARTS BUT STOPS IMPROPER IGNITION TIMING FAULTY SPARK PLUG NO SPARK AT PLUG ENGINE STOP SWITCH AT LEFT OR...
  • Page 83 Faulty CDI unit CHARGING SYSTEM FAILURE LOOSE, BROKEN OR SHORTED WIRE. FAULTY ALTERNATOR FAULTY IGNITION SWITCH INTERMITTENT ENGINE POWER LOOSE BATTERY CONNECTION LOOSE CHARGING SYSTEM CONNECTION STARTER MOTOR WILL NOT TURN DEAD BATTERY FAULTY IGNITION SWITCH LOOSE OR DISCONNECTED WIRE STARTER MOTOR AND ENGINE TURN, FAULTY IGNITION SYSTEM BUT ENGINE DOES NOT START...
  • Page 84 11.4 ALTERNATOR EXCITER COIL Remove the seat/ rear fender and front fender. (see page 72) disconnect the exciter coil wire. Measure the resistance between the yellow or white or green wire and ground. STANDARD : 467-700 Electrolyte is poisonous. Drink large quantities of water or milk and call a physician if swallowed.
  • Page 85 11.7 CHARGING Connect the charge positive cable to the battery positive terminal. Connect the charge negative cable to the battery negative terminal. Using 0. 9A charging current about 5 hours. (Normal charging) Or using 4A charging current about 1 hour. (Quick charging) Keep flames and spark away from a battery being charged.
  • Page 86 11.9 LIGHT BULBS REPLACEMENT Remove five bolts on both sides of the head light cover. Remove the headlight bulb and position light. Remove the position light bulb. Change the new one and install to the headlight seat. Press and turn left to remove the bulb.
  • Page 87 Change a new bulb and reinstall. Install the bulb seat to headlight seat. Tighten five bolts. Torque: 5 N.m (3.5 lbt.ft) TAIL LIGHT Remove taillight lens by removing the two nuts. Replace taillight lens and secure with two nuts.
  • Page 88 11.10 WIRING DIAGRAMS...

  • Page 89: Trouble Shooting

    12.TROUBLE SHOOTING 12.1 Engine does not start 12.2 Poor Performance at low and idle speed 12.3 Poor Performance at high speed 12.4 Loss of power 12.5 Poor handling 12.1Engine does not start Possible Causes No fuel in fuel tank Check Fuel Flow to Carburetor Clogged float valve Clogged fuel tank cap breather hole Faulty Spark Plug...
  • Page 90 12.2 Poor Performance at Low / Idle Speed Possible Causes Faulty CDI Unit or Pulse generator Check Ignition Timing Improper Air Screw adjustment Check Carburetor and Air Screw Adjustment Deteriorated insulator O-Ring Check for intake pipe leak Loose or disconnected ignition system wires Preform Spark Faulty spark plug, carbon fouled or wet Weak or Intermittent...
  • Page 91 12.3 Poor performance at high speed Possible cause N.G. Faulty CDI unit or Pulse generator Check Ignition Timing N.G. Lack of fuel in tank Check Fuel Flow to Carburetor Fuel Flow Clogged fuel line Restricted Clogged fuel valve Clogged fuel filter Clogged fuel tank breather hose Remove Carburetor check Clean jets with high pressure air gun...
  • Page 92 12.4 Loose of power Brake dragging – Adjust brake Raise wheels off of ground Drive chain too tight and Spin by hand Does not spin freely Damaged wheel bearing Wheel bearings need lubricated Punctured tire Check Tire Pressure Low tire pressure Faulty tire pressure value Fuel / Air mixture ratio to rich or lean Accelerate Lightly...
  • Page 93 12.5 Poor Handing Possible Causes Damaged steering bearing Steering feels heavy Damaged steering shaft bushing Bent steering shaft Bent rim One wheel is wobbling Improperly installed wheel hub Excessive wheel bearing play Bent swing arm Bent frame Excessive wear of swing arm bushing Bent Axle Bent tie-rod Incorrect tie-rod adjustment...

This manual is also suitable for:

Overland 125, 180Overland-125Overland-180

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