Page 1 Worx 125 Service Manual Holtvej 8-10, Høruphav, 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 April 2013...
Page 2 Two-wheel Motorcycle QJ125-26A Instruction and Maintenance Manual ZHEJIANG QIANJIANG MOTORCYCLE CO., LTD.
Page 3: Table Of Contents
Contents Contents ..................................2 Preface .................................... 5 Preparatory Data ..............................6 Inspection/Adjustment ............................43 Inspection and Maintenance of Electric System ......................57 Battery/Charging System ............................59 1.1 Preparatory Data ............................. 59 1.2 Fault Diagnosis ............................... 60 1.3 Storage Battery ............................... 61 1.4 Charging System .............................
Page 4 7.1 Preparatory Data ............................. 97 7.2 Fault Diagnosis ............................... 97 7.3 Front Wheel ..............................98 7.4 Steering Handle ............................100 7.5 Front Fork ..............................101 VIII Rear Wheel/Rear Suspension ..........................107 8.1 Preparatory Data ............................107 8.2 Fault Diagnosis ............................. 107 8.3 Rear Wheel ..............................
Page 5 14.4 Disassemble Main Shaft and Countershaft ....................148 XV Reduction Gear ..............................151 15.1 Preparatory Data ............................151 15.2 Fault Diagnosis ............................151 15.3 Gearshift Mechanism ..........................152 15.4 Installation ..............................154 XVI Crankcase ................................156 16.1 Preparatory Data ............................156 16.2 Fault Diagnosis ............................
Page 6: Preface
Preface The Instruction and Maintenance Manual contains an introductory description of maintenance on QJ 125-26A motorcycle. Preparatory data include attentions that shall be paid on all the maintenance operations in the Instruction and Maintenance Manual. Please read the manual carefully before operation.
Page 7: Preparatory Data
Preparatory Data General Safety Maintenance Rules Specification Table Fault Diagnosis General Safety Carbon monoxide (CO) When it is necessary to start the engine, please make sure the operation area is well ventilated. Never run the engine in an enclosed place. Attention Gas exhausted from the motorcycle contains harmful carbon monoxide, which may lead to loss of consciousness and death.
Page 8 Maintenance Rules While repairing and servicing, use tools of metric system as possible. Incorrect tools may damage the motorcycle. Before taking down or opening protecting plate for repair work, please clean the dirt on the external surfaces of components or combination parts and prevent the dirt from falling into engine, chassis or braking system After disassembly and before measuring friction, please clean the components and blow them with compressed air.
Page 9 Length of bolts and screws are different for assembly components and protecting plates. They shall be installed at correct positions. If confused, just put the bolt in the hole and see if it matches. Fill lubricating grease into the groove during oil seal installation. Check if the oil seal is smooth and if there is any damage to it.
Page 10 Slack cable implies potential safety hazard on electrics. Check the next cable when the cable is clamped to ensure electric safety; Cable clamp shall not be bent towards solder joint; Tie the cable at appointed position; Do not lay the cable at the end of frame or at the closed angle; Do not lay the cable at the end of a bolt or screw;...
Page 11: Important Notice
Identification of motorcycle *LBBJ8300?????????* 1. Frame number ① labeled as: ,,as shown in Figure 1-1. Figure 1-1 2. Frame nameplate is riveted at frame Position ②, as shown in Figure 1-1. Words on the nameplate are as described in Figure 1-2. MODEL QJ150 DISPLACEMENT...
Page 12: Special Tools
Special Tools Special tools are known as specially designed tools used at particular places for assembly or disassembly of certain components on a motorcycle. Suitable special tools are essential for complete and accurate adjusting and assembling work. Use of special tools can realize safe, reliable and quick disassembly or assembly of components, as well as working efficiency improvement and labor saving.
Page 13 Figure 1-5 Figure 1-6 Figure 1-7 Figure 1-8 Figure 1-9 Figure 1-10 ① Handle Figure 1-11 Figure 1-12 ① Pliers ② Piston...
Page 14 Figure 1-13 Figure 1-14 Figure 1-15 Figure 1-16 Figure 1-17 Figure 1-18 Figure 1-19 Figure 1-20 Figure 1-21 Figure 1-22...
Page 15 Figure 1-23 Figure 1-24 2．Tools used for chassis overhaul Common and special tools, as well as their pictures for chassis component assembly and disassembly are listed in Table 1-25 and Table 1-26. Table 1-25 Name Remarks Torque wrench Figure 1-27 Allen wrench Figure 1-28 Socket wrench...
Page 16 Figure 1-31 Figure 1-32 Figure 1-33 Figure 1-34 Figure 1-35 Figure 1-36 （2）Special tools for chassis overhaul: Front fork seal driver Figure 1-37 （3）Steering nut wrench Figure 1-38...
Page 17 3．Tools used for electrical components Special tools and their pictures for electrical component measurement are listed in Table 1-39 and Table 1-40. Table 1-39 Name Remarks Multimeter Figure 1-41 Ignition tester Figure 1-42 Continued Table 1-40 Figure 1-41 Figure 1-42...
Page 18 Specifications (QJ125-26A) Model QJ125-26A Engine type QJ157FMI-2B higher Overall Length 2040mm Fuel type unleaded gasoline Number Overall Width 780mm cylinders Overall height 1,050mm Bore*stroke 57.0×48.0 Total Wheelbase 1,270mm 125cc displacement Front Starting mode Electric shaft Weight (kg) Rear Cooling mode...
Page 19: Fault Diagnosis
Fault Diagnosis Symptom: Engine will not start or is hard to start Diagnosis procedures Engine will not start or is hard to start Check ignition system Remove the spark plug and check if electrodes of the plus are connected by carbon. Perform spark-over test Clean deposited carbon Spark is weak between electrodes or no spark at all.
Page 20 Check leakage 1. Check if breather on external connection parts the fuel tank cap is of engine; 2.Check valve clogged; 2. Check if timing; Check fuel filter fuel tightness between valve switch are clogged; 3. and valve seat; 4. Check Check if fuel switch Remove if valve clearance is too...
Page 21 Symptom: Engine Overheats Diagnosis procedures Engine Overheats Check improper operation method 1. Check if gasoline brand being used is too Check cooling system low or the gasoline has been stored for a too long time; 2. Check if engine runs at a Air cooling the engine high speed for a very long time or overloaded...
Page 22 Clutch slips Remove the spark plug and check color of skirt section of insulating part Handle it according to and other abnormalities to judge Item 1.7. mixture ratio of air/fuel. Skirt section of insulating part is black and when the Skirt section of insulating part is brown.
Page 23 Symptom: Engine lacks power Diagnosis procedures Engine lacks power Lift it with main stand to have the wheels off the ground. Rotate wheels by hands. Wheels rotate freely. Wheels rotate inflexibly. Check tire pressure 1. Check braking drag; 2. Check if bearing of wheels are over worn or injured;...
Page 24 Symptom: Poor idle speed of engine Diagnosis procedures Poor idle speed Engine has no idle speed. Higher idle speed Unsteady idle speed Pull throttle valve of carburetor by hand Use an ignition timing lamp to Check compression pressure in cylinder and see if it is completely closed.
Page 25 Symptom: Too much fuel consumption by the engine Diagnosis procedures Too much fuel consumption Check operation method Lift it by main stand, rotate wheels by hands 1. Check if motorcycle is driven over speed or not at economical speed or driven at low gear; 2. Check if gasoline grade being Wheels rotate inflexibly.
Page 26 Symptom: Clutch slips Diagnosis procedures Clutch slips Manually controlled wet multi-plate clutch slips Automatic centrifugal dry type shoe clutch slips Check if braking shoe of shoe-type clutch is contaminated by oil Check if clearance of clutch handle bar is within 10mm~20mm. Check if braking shoe Clean greasy...
Page 27 Symptom: 4-stroke engine exhaust muffler gives off blue-white smoke Diagnosis procedures 4-stroke engine exhaust muffler gives off blue-white smoke Check if engine oil level in the crankcase exceeds the upper limit line Start engine and run it at high speed; screw off Too much engine oil in the crankcase, bleed surplus oil oil ruler and check if oil filler smokes.
Page 28 Symptom: Difficult gearshift on transmission Diagnosis procedures Difficult gearshift on transmission Start engine and check if idle is too high. Re-adjust Check if the operation is harmonious at gearshift. Check if clutch is completely separated. Improve operation method. 1. Check if clearance of clutch handle bar is Check if gearshift box is distorted and shift lever is deformed or over worn.
Page 29 Symptom: Transmission jumps of gear Diagnosis procedures Transmission jumps of gear Check if spring of position wheel is broken or of insufficient elasticity. Replace Disassemble crankcase and check if meshing depth of each gear meets requirement. Enough meshing depth Insufficient meshing depth Check if meshing end of cam pawl on end face of meshing gear is worn or Check if shift fork is over worn or distorted.
Page 30 Symptom: Battery cannot charge Diagnosis procedures Battery cannot charge Disconnect connectors of magneto lead wire tied to the cables of the whole motorcycle. Measure with an Ohmmeter between out-put wires from charging coil Resistance is less than standard. Resistance meets the standard. Resistance is infinitely great.
Page 31 Symptom: Battery runs down quickly Diagnosis procedures Battery runs down quick Check if braking lamp is always on. Adjust or replace braking Set ignition switch to “OFF” position, disconnect negative wire from battery, and then put lamp switch. negative probe of ammeter onto the negative pole terminal and positive probe on the negative wire to check current leakage.
Page 32 Symptom: Starting motor does not run Diagnosis procedures Starter motor does not run. Turn on ignition switch; press horn button or slide turn signal lamp switch. Electric horn does not sound or sound Electric horn sounds loudly. weakly. Turn signal lamp is dim. Turn signal lamp is bright.
Page 33 Disassemble starter motor and Coil in starter coil Check wiring inside Contact make the following inspections： broken electrical starter control starting relay is 1. Check if the carbon brush is shorted. system burnt or injured. over worn; 2. Check if carbon brush spring is broken or weak.
Page 34 Symptom: Starting motor runs weakly Diagnosis procedures Starting motor runs weakly. Turn on ignition switch; press horn button or slide turn signal lamp switch. Electric horn does not sound or sound Electric horn sounds loudly. weakly. Turn signal lamp is bright. Battery is low or the lead wire Check if the lead wire connector from starter relay connector connected with battery is...
Page 35 Symptom: All the lights are not on Diagnosis procedures All the lights are not on AC power supplied lighting system power supplied lighting system Separate conductors of lead wire bundle of magneto from the cables Press horn button or slide turn signal light. of the whole vehicle.
Page 36 Replace headlamp bulb and Check if there is power output from power check other bulbs one by one. input wire of light switch by lamp test Use a piece of wire to short circuit power line and Wiring from magneto or ignition output line of lighting switch.
Page 37 Symptom: Light bulb is burnt frequently Diagnosis procedures Light bulb is burnt frequently Turn on ignition switch; press horn button or slide turn signal lamp switch. Electric horn does not sound or sound Electric horn sounds loudly. hoarse. Turn signal lamp is dim. Turn signal lamp is bright.
Page 38 Symptom: Headlamp is dim. Diagnosis procedures Headlamp is dim AC power supplied lighting system DC power supplied lighting system Separate conductors of lead wire bundle of magnet from Turn on ignition switch; press horn button cables of the whole vehicle. Measure and check with an or slide turn signal lamp switch.
Page 39 Check if power of bulb in the lighting Replace the bulb. system is up to the requirement. 1. Check if contacts in headlamp Replace bulb. switch and side-lamp switch are poorly contacted; 2. Check if connectors and earth wire are poorly contacted.
Page 40 Symptom: Turn signal lamp is off. Diagnosis procedures Turn signal lamp is not on. Some of the turn signal lamps on one All the turn signal lamps are not on. All the turn signal lamps on side is not on. one side are not on.
Page 41 Separate connectors of turn signal lamp switch and use Scintillator is damaged. a piece of wire to short circuit respectively power input line of the switch and power lines output to left and right turn signal lamps. Turn signal lamp is on after short Turn signal lamp is still off after short circuit.
Page 42 Symptom: Electric horn mutes. Diagnosis procedures Electric horn mutes. Turn on ignition switch; slide turn signal lamp switch and check. Turn signal lamp is not lit or dim. Turn signal lamp shines brightly. Battery is low or the wire from battery Power supply from battery is normal.
Page 43 Symptom: Brake lamp does not work. Diagnosis procedures Brake lamp does not work. Take down cover of brake lamp and check if bulb is burnt. Replace bulb Use a piece of wire to short circuit two terminals of brake lamp switch or plugs of two hatching lines. Lamp is not lit after short circuit.
Page 44: Inspection/Adjustment
Inspection/Adjustment Preparatory standard Compression pressure of cylinder Periodic maintenance schedule Engine oil Engine oil/filter Replacement of engine oil Drive chain slackness Steering stem bearing and handle fixation Throttle cable adjustment Front/rear brake clearance Air cleaner Headlamp Spark plug Clutch Battery Front/rear suspension system Carburetor Bolt/nut/fastening part...
Page 45: Specifications
Clearance of front brake handle 10-20mm Clearance of rear brake pedal 20-30mm Specification Tyre pressure 90/90-17 Front wheel 190±10kPa Pneumatic pressure unit of tyre: QJ125-26A 110/80-17 Rear wheel 210±10kPa Front shaft locknut 55-62 N··m Torque Rear shaft locknut 85-98 N·m...
Page 46: Periodic Maintenance Schedule
Periodic Maintenance Schedule Every Every Every Every Every Every 1000 3000 6000 12000 14500 Mileage and interval Tools three Twelve Fifteen Vehicle month months months months months Items Air cleaner Common tool Gasoline filter Common tool Engine oil filter Common tool Engine oil replacement Once every 1000KM Common tool...
Page 47: Engine Oil Level
Expected Inspection Ignition system -- perform maintenance inspection on obvious and continuous ignition malfunctions, engine fire, overheated back burning and others. Carbon deposition removal -- obvious underpowered, get rid of carbon deposition on cylinder head, piston head and air exhaust system. Piston and cylinder -- when cylinder is over worn or stuck, please replace it.
Page 48: Throttle Cable Adjustment
When the engine oil is completely drained, put back cleaned drain plug and sealing ring. Refill engine oil to specified level. Check if there is engine oil leakage. Start the engine and run the engine on idle for a few minutes. Check engine oil level again.
Page 49: Spark Plug
Replacing Time If driving under dusty condition or in rainy days frequently, replace the air cleaner earlier. * Attention While removing filter element of air cleaner, please do not run the engine, in case unfiltered air comes into the engine, which may result in fast wear of some components or damage the engine.
Page 50 Battery Removal Remove the seat and take down the right protecting plate. Remove the battery from the battery case（1）. Disconnect the battery negative (-) lead wire first and then the positive (+) lead wire. Remove the battery. Warning! During positive lead wire disconnection, be sure to prevent the tools being used from touching the frame; or it will result in short circuit sparks, which may ignite gasoline and damage battery.
Page 51: Idle Speed Adjustment
may result in explosion. • During charging, please take the current time labeled on the battery as basic time. * Attention • Battery quick recharging is not recommended except in case of emergency. • After recharging, wait at least 30minutes and then measure the battery voltage. Recharging current: Standard: 0.3A Quick recharging: 3.0A...
Page 52: Engine Oil Level Inspection
Compression Pressure of Cylinder Warm up engine. Insert the pressure gauge. Turn choke valve to its full open position. Set throttle handle to its full open position and kick start the engine. Compression pressure of cylinder: 1-1.2mpa * Attention Start the engine till reading of pressure gauge does not rise. Causes for low pressure: .
Page 53: Engine Oil Replacement
ruler into the engine. Do not tighten the ruler. Take out the engine oil ruler and inspect oil level. If oil level is lower or approaches the lower limit, add recommended oil to the upper limit mark. * Attention Check if sealing ring is damaged. Install the engine oil ruler.
Page 54 Screw off rear shaft nut and lock-nuts of adjusters on both drive chains. Rotate uniformly both adjusters till the drive chains gain normal slackness. * Attention Do not install new drive chains onto worn sprockets or install worn drive chains onto the new sprockets. Keep both sprocket and drive chain in good conditions, or newly replaced chain or sprocket will be worn soon.
Page 55 Install a new headlamp bulb (7). Screw tightly the new bulb into the adapter. Avoid touching bulb glass with your bare hands during installation and staining it with oil, which may affect transparency, service life and luminous flux of bulb. If oil is adhered to the bulb, clean it with a cloth moistened with alcohol or highly volatile rubber solution.
Page 56: Front Suspension
Front/Rear Suspension System Front suspension Grasp the front brake handle and compress upward and downward the front shock absorber to check its actuator. Check if the front shock absorber leaks oil and if the components are loosened. Rear Suspension Compress upward and downward the rear shock absorber to check its actuator.
Page 57 * Attention Measure the tyre pressure in cool state. Specified air pressure Unit: Kpa Tyre specifications Tyre pressure Front tyre 100/70-17 190±10kPa QJ125-26A Rear tyre 130//60-17 210±10kPa Tyre Specifications Front tubeless tyre 100/70-17 QJ125-26A Rear tubeless tyre 130//60-17 Check if lock nut of front shaft is loosened.
Page 58: Inspection And Maintenance Of Electric System
Inspection and Maintenance of Electric System Table of tightening torque for fastening parts used in electric system Fastening position and fastening part name Tightening torque（N·m） Starting motor clutch cover bolt Starting motor clutch locknut Rectifier bolt High-voltage coil mounting bolt Flywheel locknut Vehicle block protecting plate bolt...
Page 59: Charging System
Charging System 1. Starting relay 2. Scintillator 3. Battery 4. Electric igniter 5 High-voltage ignition coil 6. Power lock assembly...
Page 60: I Battery/Charging System
I Battery/Charging System Preparatory data------------1.1 Fault diagnosis--------------1.2 Battery-------------------1.3 Charging system-------------1.4 Voltage/current adjuster----------------------------------------------1.5 Magneto charging coil-------------------------------------------------1.6 Removal of magneto---------------------------------------------------1.7 1.1 Preparatory Data Precautions on operation * Attentions 1. The battery can be charged and discharged, and used repeatedly. If a battery is laid aside after discharging, its service life will be shortened and its performance is degraded.
Page 61: Fault Diagnosis
Preparatory Standard Item Specification Capacity/type 12V dry-charged type Voltage Fully recharged 13.1V Battery （20 ） Must be recharged 12.3V(not work for one hour) Recharging current Standard: 0.9A, Quick: 9A Recharging time Standard: 10-15hours; Quick: 30minutes Max. capacity 120W Magneto Coil impedance value（20 ） White-white 0.5-10Ω...
Page 62: Storage Battery
1.3 Storage Battery 1.3.1 Battery Removal Take down the right protecting plate (1). Disconnect the battery negative (-) lead wire first and then the positive (+) lead wire. Remove the battery breather. Remove battery mounting bracket（2）. Remove the battery（3）. Warning! During positive lead wire disconnection, be sure to prevent the tools being used from touching the frame;...
Page 63: Charging System
Recharging current: Standard: 0.3A Quick charging: 3.0A Recharging time: Standard: 10-15hours Quick recharging: 30minutes Recharging completed: open circuit voltage: over 12.8V 1.4 Charging System 1.4.1 Short circuit test Disconnect the grounding wire from the battery and use a voltmeter to connect battery negative lead wire with grounding wire.
Page 64: Magneto Charging Coil
Check continuity between main wiring terminals in the following way: Item （wire color） Judgment Battery (red) and ground It is battery voltage. of vehicle block Ground wire (black) and There is a lead wire. ground of vehicle block No power flowing Charging coil (white) and between magneto coil ground of vehicle block...
Page 65: Magneto Removal
1.7 Magneto Removal * Attention Inspection of magneto lighting coil can be performed on the engine. 1.7.1 Inspection Disconnect the 4P connector on the magneto. Use a multimeter to measure impedance value between yellow coil of magneto and ground wire of vehicle block. Standard value：0.4-0.6Ω（20 ）...
Page 66 * Attention There is magnetism on the inner surface of flywheel, ensure there is no bolt on it. Fix the flywheel using a universal non-adjustable spanner and then tighten the locknut. Torque value: 9.0 N·m Install protecting plate on the left side.
Page 67 Ignition System Ignition System 1 Relay 2 Scintillator 3 Battery 4 Igniter 5 High-voltage ignition coil 6. Power lock assembly 7 Voltage regulator...
Page 68: Ignition System
II Ignition System Preparatory data-------------------2.1 CDI assembly--------------2.4 Fault diagnosis--------------------2.2 Ignition coil----------------2.5 Ignition system inspection-------2.3 Trigger----------------------2.6 2.1 Preparatory Data Precautions on operation 1. Ignition system inspection: please perform inspection in the sequence listed in the fault diagnosis table. 2. Ignition system uses electronic-type automatic timing device, which is solidified in the CDI assembly, so it is unnecessary to adjust the ignition time.
Page 69: Fault Diagnosis
2.2 Fault Diagnosis Spark plug no spark-over Symptom Possible causes（Determine the cause from 1 in sequence） Inner impedance is too small. Use appointed tester to test. Crankshaft rpm is too low. Tester is disturbed (it is normal when more than one time’s measured Ignition coil When the high voltage power is too voltage is above the basic）.
Page 70: Ignition System Inspection
2.3 Ignition System Inspection * Attention • When there is no spark-over from the spark plug, check if components of wiring are loosened or badly contacted and make sure if all the voltage values are normal. • There are many brands of multimeters with different interior impedance.
Page 71: Cdi Assembly
Connecting method: positive (+) to blue/white, negative (-) to green/white. Min. voltage: higher than 1.7V. * Attention Please do not touch the metal parts of testing probe with your fingers while measuring the voltage, or you will be shocked. Please take care. When the peak voltage measured at connector of CDI assembly is abnormal, take down the protecting plate on the right side of vehicle and remove connector of magneto.
Page 72: Ignition Coil
2.5 Ignition Coil 2.5.1 Removal Remove protecting plate of vehicle block. Remove spark plug cap. Remove primary lead wire of ignition coil. Remove locknut of ignition coil and take out the ignition coil. Install it in the reverse order of removal. *Attention The primary coil is installed with black/white wire connector.
Page 73: Trigger
2.6 Trigger * Attention Trigger inspection can be performed on the engine. Inspection Remove protecting plate of vehicle block. Remove lead-wire connector of trigger. Measure the impedance between blue/white terminal of lead wire at engine side and grounding vehicle block. Standard value: 100-200Ω（20 ）...
Page 74 Starting System Starting Diagram 1 Starting relay 2 Scintillator 3 Battery 4 Electronic igniter 5 high-voltage ignition coil 6 Power lock assembly 7 Rectifier 8 Electric horn...
Page 75: Starting System
Starting System Preparatory data-------3.1 Fault diagnosis--------3.2 Starting motor-----------3.3 Starting relay------------3.4 3.1 Preparatory Data Precautions on operation Starting motor removal can be performed on the engine. Starting clutch removal refers to removal instruction. Basic data Item Standard Service Limit Length of starting brush 12.5mm 8.5mm Starting idler shaft bushing...
Page 76: Fault Diagnosis
3.2 Fault Diagnosis Starting motor will not run Starting motor runs weakly Starting motor rotates but the engine does not •Broken Fuse •Low battery •Defective starting clutch •Low battery •Poor connecting wire contact •Starting motor counter-rotate •Defective ignition switch •Starting motor gear stuck by •Low battery •Defective starting clutch foreign substances...
Page 77 Inspect continuity between conducting terminal and brush. Replace it with a new one if abnormality exits. Inspect carbon brush holder for continuity. If there is continuity, replace it. Measure brush length Service limit: replace it when it is shorter than 8.5mm Check rotation smoothness of the needle bearing in the front cover and whether it is loosened when it is pressed in.
Page 78: Starting Relay
3.4 Starting Relay 3.4.1 Actuation Inspection Take down the protecting plate of vehicle block. When the ignition switch is set at “ON” position, press starting motor and a “Click” sound can be heard. Inspect Sound. “Click” sound indicates normal. No sound: •...
Page 79 Bulbs/Switches/Instruments 1 Headlamp 2 Instruments 3 Electric horn 4 Left rear turn signal lamp...
Page 80: Bulbs/Switches/Instruments
Bulbs/Switches/Instruments Preparatory data---------------------------------------------------4.1 Fault diagnosis----------------------------------------------------4.2 Headlamp bulb replacement------------------------------------4.3 Front turn signal lamp bulb replacement---------------------4.4 Tail lamp bulb replacement ------------------------------------4.5 Instrument--------------------------------------------------------4.6 Ignition switch---------------------------------------------------4.7 Electric horn------------------------------------------------------4.8 Handle switch----------------------------------------------------4.9 4.1 Preparatory Data Precautions on operation Remove switches from the motorcycle and perform continuity test. All the plastic connectors have pawls on them.
Page 81: Headlamp Bulb Replacement
4.3 Headlamp Bulb Replacement 4.3.1 Removal Screw off with a wrench locknut （1） of headlamp and take down the headlamp. Pull out socket of headlamp adapter and remove the rear cover. Release circlip and take out of the lamp adapter. * Attention When the bulb is lit, keep you hands and inflammable materials some distance away from it.
Page 82: Taillamp Bulb Replacement
4.5 Tail Lamp Bulb Replacement 4.5.1 Removal Screw off the two bolts（1）. Remove the tail lamp hood. Disconnect wire connector to the tail lamp. While pressing down the tail lamp, rotate it counterclockwise Remove the tail lamp 4.5.2 Installation Install the tail lamp in the reverse order of removal. * Attention While installing tail lamp, be sure that sealing washer on the tail lamp hood is in good condition and correct position.
Page 83: Ignition Switch And Steering Lock
4.7 Ignition Switch and Steering Lock 4.7.1 Inspection Remove the headlamp from the cover. Remove ignition switch-wire connector. “ ” (OFF) position：All the circuits are broken. “ ” (ON）position：Ignition circuit is switched on and engine can be started. When the switch is at this position, the key cannot be pulled out. “...
Page 84 Remove the draw-bar bracket for the rear brake lever. Remove throttle handle and bolts. Take down throttle handle from the handle and remove the throttle cable. Remove locknut on the handle and take down the handle.
Page 85: Chassis Inspection And Maintenance
Chassis Inspection and Maintenance Table of Tightening Torque of Fastening Part on Chassis Fastening position and part name Tightening Torque（N·m） Oil pump block assembly mounting bolt Front brake cylinder assembly mounting bolt 22-29 Rear brake rocker arm mounting bolt Rear shaft locknut 85-98 Upper bracket assembly mounting bolt 40-60...
Page 86 Front Hydraulic Brake Front brake disc diameter：240mm Front brake disc thickness：4.0mm Service limit：3.0 Brake shoe thickness：4 mm Service limit：3mm Mounting torque for Bolt 7 in the diagram：22-29 N·m 1 Oil pump block assembly 2 Hydraulic brake handle 3 Handle mounting bolt 4 Nut M6 5 Fixed cover 6 Bolt M6×23 7 Front hydraulic brake mounting bolt 8 Front hydraulic brake assembly 9 Washer 10 Oil hose mounting bolt 11 Brake hose assembly 12 Brake cylinder assembly 13 Brake shoe assembly...
Page 87: Rear Drum Brake
Rear Drum Brake Rear brake ID：130mm Service limit：131 Brake shoe thickness：4mm Service limit：3mm Mounting torque for Bolt 21 in the diagram：22-29 N·m 1 Nut M14 2 Rear hub cap assembly 3 Copper pin 2×18 4 Nut M8 5 Rear hub cap mounting bolt 6 Bolt M6×30 7 Washer 6 8 Rear brake rocker arm 9 Nut M6 10 Washer 11 Cam shaft O sealing ring 12 Rear braking cam shaft 13 Rear wheel right bush 14 Rolling bearing 6302-2RS 15 Braking shoe tension...
Page 88: Braking System
V Braking System Maintenance instruction--------------------5.1 Fault diagnosis-------------------------------5.2 Front hydraulic disc brake----------------- 5.3 Rear drum brake-----------------------------5.4 5.1 Maintenance Instruction Precautions on operation * Attention • Please do not contaminate braking assembly with oil while assembly or disassembly. • Please use specified detergent to clean the braking assembly, or it may reduce braking performance. * Please check braking system before driving your motorcycle.* 5.1.1 Specifications Item...
Page 89: Front Hydraulic Brake
3. Braking shoe assembly improperly installed 3. Braking shoe assembly improperly installed 4. Braking shoe assembly and brake disc contaminated Noisy Braking 1. Braking shoe assembly and brake disc are worn. 2. Braking shoe assembly and brake disc are contaminated 5.3 Front Hydraulic Brake 5.3.1 Removal * Attention...
Page 90 Specifications QJ125 Front brake disc diameter φ260mm Front brake disc thickness 4.0mm * Attention • Micrometer shall be used for the measurement. Measure the thickness of braking shoe. If brake disc and braking shoe are contaminated by grease or their thickness is smaller than service limit, replace them. Service limit: Braking shoe: 3mm Brake disc:...
Page 91: Rear Drum Brake
5.4 Rear Drum Brake 5.4.1 Removal • * Attention • Replace braking shoe. • If a braking shoe assembly will be used again, please mark it on the side before removal so that is can be re-installed easily to its original place. Remove the following rear brake assembly from the rear wheel: 1.
Page 92 Install brake pedal assembly（21） * Attention A contaminated braking shoe will reduce braking performance and result in braking failure. Tighten bolt and nut to their specified torque value. Torque value: Rear wheel locknut: 85-98 N·m Do not contaminate braking shoe with oil. If a braking shoe is polluted by oil, clean it with brake cleaner.
Page 93: Exterior Parts
Exterior Parts Attention Do not damage exterior parts during disassembly and assembly. Do not damage the pawls on the exterior parts of the vehicle during assembly or disassembly. Align built-in panel and cover plate to their grooves respectively. Correctly install pawl of each part during combination. Do not damage the fittings during exterior part installation.
Page 94: Motorcycle Exterior
Motorcycle Exterior Disassemble the motorcycle body in the following sequence: Seat cushion assembly → Left and right protecting plate assemblies → Left and right tail covers → Left and right hanger → Left and right hanger → ↓ Left and right pedals → Front mudguard brace panel → Front mudguard → Rear mudguard assembly → Rear rail → Rear tail cover connectiong board →...
Page 95 Front wheel / Front Suspension 1 Front wheel shaft 2 Gear seat assembly 3 Gear seat oil seal 4 Drive plate 5 Bearing 6 Front wheel middle sleeve 7 Front brake disc 8 Front brake disc mounting bolt 9 Front wheel oil seal assembly 10 Front wheel left sleeve 11 Tubeless tyre 12 Front wheel rim...
Page 96 Control Assembly N·m Tightening torque of hexagon Socket screw 2：37-44 N·m Tightening torque of Nut 19：5-9 N·m Tightening torque of Screw 20：5-9 1 Right rear mirror assembly 2 Left rear mirror assembly 3 Bolt 4 Handle gear block 5 Right handle assembly 5 Right combination switch 6 Right combination switch 7 Steering handle welded assembly 8 Left combination switch 9 Left steering handle jacket 10 Left handle assembly 11 Left handle 12 Slotted Nut 13...
Page 97: Front Fork Assembly
Front Fork Assembly Tightening torque Bolt （Steering stem mounting bolt） in N·m the diagram：40-60 Tightening torque for Bolt 19 in the N·m diagram：22-29 Tightening torque for Bolt 29 in the N·m diagram：37-44 Number of upper steel balls：23 Number of lower steel balls：19 1 Right front shock absorber assembly 2 Inner pipe 3 Oil seal 4 Left front shock absorber assembly 5 Lower steel bowl of upper bearing 6 Upper steel bowl of lower bearing 7 Cable clip 8 Lower steel bowl of lower bearing 9 Headlamp lower bracket...
Page 98: Front Wheel/Front Suspension
VII Front Wheel/Front Suspension Preparatory data-----------------7.1 Fault diagnosis------------------7.2 Front wheel----------------------7.3 Control assembly---------------7.4 Front fork assembly------------7.5 7.1 Preparatory Data Precautions on operation Before removing the front wheel, lift and support the bottom of motorcycle with a jack or other available device. The front wheel is off the ground.
Page 99: Front Wheel
7.2.2 Wobbly Direction Handle Damaged handle bearing. Not enough tyre pressure. Front fork bent, front wheel shaft bent. Distorted and crooked front wheel tyre. 7.2.3 Wobbly Front Wheel Distorted wheel Worn front wheel bearing Defective front tyre 7.2.4 Difficult Rotation of Wheel Shaft or bearing seat fault Braked 7.2.5 Noisy Front Shock Absorber...
Page 100: Bearing Replacement
Place the shaft onto a V block and measure its eccentricity with a dial gauge. Service limit: When the measured value exceeds 0.2mm, replace it. 7.3.2.2 Wheel Shimmy Inspection Place the wheel onto a precise support and check its amplitude of shimmy. Rotate the wheel with your hands and read out shimmy amplitude.
Page 101: Steering Handle
Take down steering handle upper holder. Remove steering handle assembly. 7.4.2 Installation * Note: Refer to Page 96 of the manual for QJ125-26A Motorcycle steering handle disassembly and assembly diagram. Install the steering handle in the reverse order of removal.
Page 102: Front Fork
7.5 Front Fork 7.5.1 Removal Support the motorcycle with the middle stand. Remove front wheel. Remove brake caliper and brake pipe clip. Remove front mudguard（1） and reflector（2）. Remove the handle. Screw off upper bracket mounting bolt and lower bracket pinch bolt. Remove headlamp bracket.
Page 103 7.5.3 Installation Apply lubricating grease onto the bottom bearing steel bowl and confirm the number of steel balls (23balls). Steering handle shall not be rotated in case of steel ball falling off; then install steering rod. Support the steering handle and apply lubricating grease on to the top bearing steel bowl and confirm the number of steel balls (19 balls) Apply lubricating grease on the top holder race.
Page 104 Rear Wheel/Rear Suspension 1 Rear shock absorber assembly 2 Rear brake rocker arm 3 Rear shaft 4 Nut M8 5 Sprocket stopper 6 Sprocket 43 teeth 7 Oil seal 8 Rolling bearing 6204-2RS 9 Chain drive sleeve 10 Sprocket hub Sprocket mounting bolt 12 Rear wheel left sleeve assembly 13 Rear wheel buffer 14 Bearing spacer 15 Tubeless tyre 16 Rear wheel left sleeve 17 Rear braking shoe 18 Rear wheel hub 19 Bolt...
Page 105: Rear Shock Absorber
Rear Shock Absorber 1 Cap nut M10×1.25 2 Rear shock absorber mounting gasket 3 Rear shock absorber assembly 4 Washer 12 Bolt M10×1.25×40...
Page 106: Rear Swing Arm
Rear Swing Arm Side clearance（opening swing arm end） limit value：1.0mm Tightening torque of Nut 1 in the diagram is：70-83 N·m 1 Locking nut M14X1.5 2 Dust ring assembly 3 Bush 4 Oil seal 5 Middle sleeve 6 Rubber gasket for protecting plate 7 Rear swing arm welding assembly 8 Washer φ12...
Page 107: Chain Drive Assembly
Chain Drive Assembly Tightening torque of Bolt 1 in the diagram is：22-29 N·m Drive chain specification： 428H-1×126 1 Sprocket mounting bolt 2 Sprocket hub 3 Chain drive sleeve 4 Rolling bearing 6204-2RS 5 Oil seal 6 Sprocket 43 teeth 7 Sprocket stopper 8 Nut M8 9 Chain 428H-1×126 10 Chain guard 11 Boss bolt...
Page 108: Rear Wheel/Rear Suspension
VIII Rear Wheel/Rear Suspension Preparatory data----------------------------------- 8.1 Fault diagnosis-------------------------------------8.2 Rear wheel----------------------------------------- 8.3 Rear shock absorber/rear swing arm----------- 8.4 Chain drive assembly-----------------------------8.5 8.1 Preparatory Data Precautions on operation Do not contaminate braking shoe ad brake disc with oil. Basic preparatory data Item Standard Value（mm）...
Page 109: Rear Wheel
8.2.2 Inflexible Wheel Rotation Incorrect brake adjustment Worn rear bearing Too tight the drive chain 8.2.3 Poor Braking Performance Incorrect brake adjustment Worn braking shoe Worn brake drum Incorrect installation of braking shoe 8.2.4 Brake Pedal Inflexible or Slow Return Worn or broken return spring Incorrect brake adjustment Worn or contaminated brake drum...
Page 110 Check and replace rear wheel bearing. 8.3.3 Installation Install the rear wheel in the reverse order of removal and tighten the nut. Rear wheel shaft locknut Tightening torque: 85-98N·m QJ125-26A Rear Wheel...
Page 111: Rear Shock Absorber/Rear Swing Arm
8.4 Rear Shock Absorber/Rear Swing Arm 8.4.1 Remove Rear Shock Absorber Remove left and right protecting plates, seat cushion assembly and hood. Screw off top and bottom mounting bolts and cap nut （1） from rear shock absorber. Remove the rear shock absorber. 8.4.2 Rear Shock Absorber Inspection Check rear shock absorber rod.
Page 112: Chain Drive Assembly
8.4.5 Rear Swing Arm Inspection Check rear swing arm installation shaft. Rotate the shaft on a flat surface or measure it with a dial gauge. If it is bent, replace it. * Attention Don’t attempt to straighten bent shaft. Wash in solvent the components for rear swing arm installation shaft.
Page 113 Length limit of 10 chain links is 127 mm. * Attention: • Stretch the chain by hands and then measure it. • The measuring range is from chain link roller to inner side of roller ○ ,11. • Measure length of 10 chain links. •...
Page 114 Check wheel bearing. If there is bearing clearance in the wheel hub or rotation of the wheel is unbalanced, replace it with a new one. Check oil seal. If it is worn or broken, replace it with a new one. 8.5.4.
Page 115 Seat Cushion 1 Seat cushion assembly 2 Rear rail 3 Rear luggage carrier screw II 4 Rear luggage carrier screw I...
Page 116 Fuel Tank Assembly Max. capacity of fuel tank：16L Tightening torque of Bolt 13 in the diagram：5-9 N·m Tightening torque of Bolt 15 in the diagram：5-9 N·m Note：Fuel switch shall be set at “OFF” position while removing fuel tank. 1 Fuel tank lock 2 Fuel tank block assembly 3 Protecting plate rubber gasket 4 Right fuel tank protecting plate 5 Left fuel tank protecting plate 6 Fuel tank installation gasket 7 Fuel sensor assembly 8 Sensor rubber...
Page 117: Fuel Tank/Seat Cushion
Fuel Tank/Seat Cushion Preparatory data----------------------9.1 Fault diagnosis-------------------9.2 Fuel tank/seat cushion-----------9.3 9.1 Preparatory Data Precautions on Operation Working site for removal shall be away from fire source. Fuel switch shall be set at “OFF” position while removing fuel tank. While installation, tighten bolt and nut to their specified torque. After installation, check if all the components are correctly fixed and work normally.
Page 118: Fuel Tank/Seat Cushion
9.3 Fuel Tank/Seat Cushion 9.3.1 Removal Remove left and right protecting plates. Insert ignition key into the seat lock. Rotate clockwise the key and unlock it. Pull downward and take out the helmet hook. Release the pawl from frame and remove seat cushion (1）...
Page 119: Engine Inspection And Maintenance
Engine Inspection and Maintenance Engine Table of tightening torque for fastening parts used in Fastening position and part name Tightening torque（N·m） Cylinder cap nut M8 25～28 Cylinder cap nut M6 8～12 Cylinder cap bolt 8～12 Cylinder block connecting bend bolt 8～12 Cylinder block connecting nut 8～12...
Page 120 Lubricating System Note: When the engine oil pump is removed, clean carefully all the components and purge them with high-pressure gas. During engine oil pump removal and installation, pay attention not to drop anything into the crankcase. 1 Rocker arm 2 Cam mechanism 3 Piston 4 Crankshaft 5 Main shaft assembly 6 Countershaft assembly 7 Filter screen 8 Engine oil pump 9 Filter element assembly...
Page 121: Lubricating System
X Lubricating System Preparatory data--------10.1 Fault diagnosis---------10.2 Oil engine pump-------10.3 10.1 Preparatory Data Precautions on Operation When the engine oil pump is removed, clean carefully all the components and purge them with high-pressure gas. During engine oil pump removal and installation, pay attention not to drop anything into the crankcase. Function of lubricating system：Function of engine lubricating system is to supply lubricating oil to friction surfaces of engine parts so that dry surface friction will turn to liquid friction between plasmids of lubricating oil.
Page 122: Oil Pump
Oil pump gear 10.3 Oil Pump 10.3.1 Removal Remove right cover. Take down the engine oil filter and release oil pump mounting screw. Take down oil pump block, drive gear and pump shaft. Oil pump block Screw off the screw Take down pump seat.
Page 123 Check clearance between external rotor and oil pump seat. Allowable limit: 0.2mm. Testing gauge Check clearance between rotor end faces. Allowable limit: 0.15mm. Flat board Testing gauge...
Page 124 10.3.2 Assemble Engine Oil Pump As shown in the following figure: * Attention: After assembly, inner and external rotors shall rotate smoothly and be out of nimbleness. 10.3.2 Installation Install the oil pump in the reverse order of removal.
Page 125 Carburetor Attention: Gasoline very dangerous. Fire and smoking are forbidden in working site. When the carburetor is removed, plug the intake pipe side with a cloth in case foreign matters coming in. 1- Upper cover 2- Upper cover seal ring 3- Plunger spring 4- Plunger assembly 5- Lower housing connecting screw 6- Lower housing assembly 7- Seal ring 8- Float assembly 9- Float pin 10- Needle valve core 11- Idle jet 12- Main jet 13- Main nozzle 14- Main foam pipe 15-Mixture screw 16- Mixture screw spring 17-Fixture screw washer 18- Mixture screw seal ring 19-Plunger adjusting screw spring 20- Plunger adjusting...
Page 126: Worx
Carburetor Preparatory data--------------11.1 Fault diagnosis--------------- 11.2 Carburetor removal---------- 11.3 Carburetor installation-------11.4 11.1 Preparatory Data Precautions on Operation ·Gasoline is very dangerous. Fire and smoking are forbidden in working site. ·Pay specially attention to sparks. ·Please do not pull and bend wires and cables by force. Distortion and injury may affect operation of cables. ·When the carburetor is removed, plug the intake pipe side with a cloth in case foreign matters coming in.
Page 127: Removal Of Carburetor
Clogged oil filter Too high or too low mixed gas concentration Clogged oil pipe Secondary air sucked by the intake system Sticky needle value Improper idle adjustment Improper oil level adjustment Improper oil level adjustment Clogged idle system or electric enrich valve Too much fuel in engine Too low mixed gas concentration Oil outflow...
Page 128: Installation
11.3.3 Inspection Check if needle valve assembly, needle valve seat and float assembly are worn or broken. If needle valve core is worn or broken, replace it with a new one. If needle valve seat is worn, the main carburetor body shall be replaced.
Page 129 Cylinder Head/Valve 1 Limit screw 2 Washer 3 Cylinder cover hood bolt 4 Valve cover 5 O ring 6 Cylinder cover hood bolt 7 Plug 8 O ring 9 Rocker arm shaft 10 Wave spring washer 11 Rocker arm 12 Rocker arm return spring 13 Cylinder cover hood 14 Spark plug assembly 15 Cover nut 16 Washer 17 C-type gasket 18 Cylinder...
Page 130: Cylinder Head/Valve
XII Cylinder Head/Valve Preparatory data-----------------12.1 Valve guide replacement-------------12.5 Fault diagnosis------------------12.2 Valve race fixing and adjustment---12.6 Cylinder head--------------------12.3 Cylinder head installation------------12.7 Valve Inspection---------------- 12.4 12.1 Preparatory Data Precautions on Operation To ensure sealing between cylinder head and cylinder body, there is a great bolt pretension on the cylinder head. Pretension value: 50Nm.
Page 131: Fault Diagnosis
12.2 Fault Diagnosis Low compression pressure Noisy cylinder head Improperly adjusted valve clearance Improperly adjusted valve clearance Valve burnt or bent Valve spring hurt Poorly sealed valve race Too high compression pressure Air leakage at cylinder head Too much carbon deposited in the combustion chamber Improperly installed spark plug 12.3 Cylinder Head 12.3.1 Removal...
Page 132 Measure rocker arm shaft OD. Allowable limit: 11.95mm. Measure rocker arm hole ID Allowable limit: 12.05mm. Micrometer Clearance between rocker arm and rocker arm shaft Allowable limit: 0.08mm Tester Screw off the two locknuts and remove the lock washer, cam shaft and C-type gasket.
Page 133: Valve Inspection
Valve collet Compress valve spring with a valve spring compressor, and remove the valve collet. Remove in sequence spring disc, external and inner valve springs, external valve spring washer and valve. 12.3.2 Disassemble Valve Valve collet Inner valve spring Washer Valve Spring disc External valve...
Page 134 Allowable limit: Internal spring: 30mm. Vernier caliper External spring: 37.8mm. Measure OD of valve stem Micrometer Allowable limit: 4.9mm. Valve reamer Check valve guide. Please eliminate the carbon deposition in the valve guide with a reamer before inspection Attention: Rotate the reamer in clockwise. Please do not rotate he reamer in counterclockwise.
Page 135: Valve Guide Replacement
Opener 12.5 Valve Guide Replacement * Attention: When the clearance between valve and valve guide exceeds service limit value, please replace the valve guide. When a valve guide is replaced, surface of valve seat retainer shall be fixed and adjusted. Put the valve guide into the freezing chamber of refrigerator for Opener one hour to freeze it.
Page 136: Valve Race Fixing And Adjustment
12.6 Valve Race Fixing and Adjustment Hackly part Remove hackly and ragged parts on the valve race with a 45°angled milling cutter. Note： Apply a layer of transparent or Prussian blue film onto the valve race so that it can be observed clearly. Remove 1/4 of external edge of valve race with a 32°...
Page 137: Cylinder Head Installation
If contacted place is the higher part of valve, please use a 32°angle plain milling cutter to lower the valve race. High contact face If contacted place is the lower part of valve, please use a 60°angle internal milling cutter to raise the valve race. 32°...
Page 138 Cylinder Block and Piston Attention: components shall cleaned before inspection and test, and purged with high-pressure air. 1 Piston 2 Retainer 3 Piston pin 4 Combined oil ring 5 Second compressing ring 6 Top ring 7 Location pin 8 Washer 9 Cylinder cover connecting bent pipe assembly 10 Bolt 11 Cylinder cover connecting bent pipe washer assembly 12 Cylinder block 13 Washer 14 Tensioner assembly 15 Bolt 16 Bolt 17 Screw...
Page 139: Cylinder Block And Piston
XIII Cylinder Block and Piston Preparatory data------------13.1 Piston---------------------- 13.4 Fault diagnosis--------------13.2 Cylinder installation-----13.5 Cylinder block--------------13.3 13.1 Preparatory Data Precautions on Operation All the components shall be cleaned before inspection and test, and purged with high-pressure air. Function of cylinder block: Cylinder block provides the space for gas compression, combustion and expansion and guides piston movement.
Page 140: Fault Diagnosis
13.2 Fault Diagnosis Low compression pressure White smoke from exhaust pipe Worn, burnt or broken piston Worn or damaged piston ring Work or damaged cylinder and piston Worn or damaged cylinder and piston Broken washer, air leakage on crankcase Higher compression pressure Noisy piston Damaged cylinder, piston and piston ring Too much carbon deposited in the combustion chamber...
Page 141: Piston
13.4 Piston 13.4.1 Removal Remove piston pin retainer. * Attention: Please do not drop the retainer into crankcase during removal. Take out piston pin and remove piston. Piston pin ring, piston pin Remove piston ring. Inspect piston, piston pin and piston ring. * Attention: Please do not break or hurt piston ring.
Page 142 Measure piston pin hole ID. Allowable limit: 14.04mm. Tester Measure piston pin OD. Allowable limit: 13.96mm. Measure the clearance between piston pin hole and piston pin. Allowable limit: 0.05mm. 90° Measure piston OD * Attention: Measuring position forms a 90°angle with 11mm piston pin, about 11mm below piston skirt.
Page 143 Measure the roundness of cylinder inner wall. （internal diameter difference between X direction and Y direction）. Allowable limit: 0.05mm. Measure the cylindricity of inner wall of cylinder. （internal diameter difference of three positions (upper, intermediate and lower) along X direction or Y direction）.
Page 144: Install Cylinder
Scrape the washer attached to the crankcase. * Attention: No foreign matters can be dropped into the crankcase. Install piston, piston pin and piston pin retainer. * Attention: “point” Mark Install with the “Point” mark at the bottom of piston facing the exhaust valve.
Page 145 Clutch Attention: You don’t have to remove the engine from frame while overhauling clutch. Viscosity and level of engine oil will affect operation of clutch. Please check first engine oil and oil level before inspect clutch. If one of the cluth springs, discs or plates does not work, you shall replace them in pairs.
Page 146: Clutch
XIV Clutch Preparatory data-----------------------------------------------14.1 Fault diagnosis------------------------------------------------14.2 Clutch---------------------------------------------------------- 14.3 Kick start mechanism----------------------------------------14.4 Disassembly of main shaft and countershaft--------------14.5 14.1 Preparatory Data Precautions on Operation You don’t have to remove the engine from frame while overhauling clutch. Viscosity and level of engine oil will affect operation of clutch. Please check first engine oil and oil level before clutch inspection.
Page 147: Clutch
Bent gearshift spindle Warped clutch plate Injured gearshift cam Faulty clutch push rod Bent or injured gearshift plate Abnormal engine oil and oil level 14.3 Clutch 14.3.1 Removal Screw off the four bolts for separating plate in criss-cross mode. Remove release lever, sleeve, bearing, separating plate and clutch spring.
Page 148 14.3.2 Disassemble Clutch 14.3.3 Inspection Check if there are burs or broken parts on the housing groove of clutch. If there are, fix and adjust with a file. If there is a lot for fix and adjustment, replace it. Check if teeth of pressure plate and center bracket are injured. If they are, replace them.
Page 149: Disassemble Main Shaft And Countershaft
Measure the thickness of friction plate with a vernier caliper. Allowable limit: Replace it when it is below 2.6mm. Thickness 14.4 Disassemble Main Shaft and Countershaft Tooth 齿面 Surface Inspection Check respectively wear of tooth surface and drive pawls. If they are seriously worn or damaged, replace them.
Page 150 * Attention: Hammered-out bearing cannot be reused. Replace it with a new one. Bearing hole, oil seal hole Remove bearing and oil seal with special tools. Remove bearing on right crankcase. Check if bearing is injured. Replace if necessary. * Attention: Hammered-out bearing cannot be reused.
Page 151 Reduction Gear Function: Transfer torque and determinate the final output torque and rotary speed. 1 Gearshift drum 2 Shift fork 3 Shift fork shaft 4 Main shaft assembly 5 Countershaft assembly...
Page 152: Reduction Gear
XV Reduction Gear Preparatory data-----------------15.1 Fault diagnosis------------------15.2 Gearshift mechanism----------15.3 Installation----------------------15.4 15.1 Preparatory Data Function: Transfer torque and determinate the final output torque and rotary speed. Basic data Unit: mm Shift fork shaft OD 9.98-9.995 9.96 Diameter of shift fork inner hole 10-10.015 10.05 Gearshift...
Page 153: Gearshift Mechanism
15.3 Gearshift Mechanism 15.3.1 Removal Remove gearshift shaft assembly. Remove the bolt on the upper baffle plate of ratchet, the ratchet upper baffle plate and gearshift ratchet gear ring. Remove the bolt on lower baffle plate of ratchet, the ratchet lower baffle and the ratchet, etc. Removed parts refer to exploded view.
Page 154 Remove left case block. Pull out shift fork shaft. Shift fork shaft Remove gearshift drum. Remove gearshift fork. Gearshift drum Shifting fork Measure shift fork OD. Allowable limit: 9.96mm. Micrometer Measure shift fork hole ID. Allowable limit: 10.05mm. Tester Vernier caliper Measure shift fork thickness.
Page 155: Installation
Measure OD of gearshift drum Allowable limit: 39.75mm. Measure the width of gearshift drum lock groove Allowable limit: 6.35mm. Lock groove width Remove balance shaft gear Balance shaft gear 15.4 Installation Install it in the reverse order of removal.
Page 156 Crankcase Attention: Crankcase is a thin-wall casting part. Avoid impact on it during operation in case it may be distorted or broken. Clean carefully all the components before inspection and test and purge them with high-pressure gas. Drain lubricating from crankcase before working on it.
Page 157: Crankcase
XVI Crankcase Preparatory data-----------------16.1 Fault diagnosis--------------16.2 Crankcase--------------------16.3 16.1 Preparatory Data Precautions on Operation Attention: Crankcase is a thin-wall casting part. Avoid impact on it during operation in case it may be distorted or broken. Clean carefully all the components before inspection and test and purge them with high-pressure gas. Drain the lubricating oil from crankcase before working on it.
Page 158: Crankcase
16.3 Crankcase 16.3.1 Crankcase Removal Screw off starting motor mounting bolts，and remove starting motor. Release starting motor gear chamber cover mounting bolt and remove gear chamber cover. Remove starting motor gear, needle bearing and washer. Screw off bolts on left front cover and left rear cover of crankcase.
Page 159 Remove gear display. Remove cam shaft limit plate and take down cam assembly. Remove bearing locating device. 16.3.2 Exploded View of Cam Assembly Camshaft gear Cam mechanism shaft Cam shaft spring Measure cam bush ID. Allowable limit: 14.10mm. Measure cam height Allowable limit: 32.5mm.
Page 160 16.3.3 Crankcase Right Cover Removal Tester Bolt Screw off mounting bolt and take down the crankcase right cover. Remove clutch release lever assembly from the right cover. Right cover Right cover Release lever assembly Remove screws, engine oil filter roller cover and its cover washer.
Page 161: Crankshaft Connecting Rod Assembly
16.4 Crankshaft Connecting Rod Assembly Crankshaft connecting Drive gear rod assembly Removal Location pin Remove left crankcase. Remove washer and location pin. Remove drive gear. Washer Remove the crankshaft connecting rod assembly from the right crankcase. * Attention: Please do not hurt washer and closing surface. Inspection Measure connecting rod big end left-to-right clearance.
Page 162: Exhaust System Inspection And Maintenance
Exhaust System Inspection and Maintenance Muffler Assembly Tightening torque of mounting bolt 5 for muffler connector in the diagram：5-9 N·m Dual catalysts are added into the muffler welding assembly in the diagram. Tightening torque of combined screw 6 for muffler protecting plate in the diagram：5-9 N·m 1 Exhaust pipe gasket assembly 2 Bolt M8×30 3 Washer 8...
Page 163: Emission Control System
XVII Emission Control System Emission control system guarantee----------------------------------------- 17.1 Periodical maintenance instructions/ensure emission standard--------- 17.2 Emission control system mechanical function-----------------------------17.3 Solutions to Idle exhaust exceeding specified value ---------------------17.4 17.1 Emission Control System Guarantee 1. The emission control system of the motorcycle is up to the Standard of China Stage III. The company will guarantee it in its effective service life, under normal use and specified maintenance.
Page 164: Periodical Maintenance Instructions
17.2 Periodical Maintenance Instructions ·To reduce environment pollution, it is required by the country that all the motor vehicles manufactured by each company shall meet the regulations of emission standard of air pollutants. Besides the production process is up to the regulations of emission standard of air pollutants, the company is also devoted to purifying air and reducing air pollution.
Page 165: Solutions To Idle Exhaust Exceeding Specified Value (4-Stroke)
Classification Equipment Constituted Part Desired Function Emission control system Catalytic device Catalytic converter Oxidize CO, HC and NO 17.4 Solutions to Idle Exhaust Exceeding Specified Value (4-stroke) Qualified Perform regular inspection（Repair and maintenance plan） Qualified Measure Idle exhaust (Note 1） Qualified Adjust carburetor（Note 2）...
Page 166 QJ125-26A Schematic Circuit Diagram...

Worx Generic QJ125-26A Instruction And Maintenance Manual

1 I Battery/Charging System

2 II Ignition System

3 III Starting System

4 Bulbs/Switches/Instruments

5 Braking System

6 Motorcycle Exterior

7 Front Wheel/Front Suspension

8 Rear Wheel/Rear Suspension

9 Fuel Tank/Seat Cushion

10 Lubricating System

11 Carburetor

12 Cylinder Head/Valve

13 Cylinder Block and Piston

14 Clutch

15 Reduction Gear

16 Crankcase

17 Emission Control System

Quick Links

Need help?

Questions and answers

Summary of Contents for Worx Generic QJ125-26A

Table of Contents