Table Of Contents - Sachs Bikes MadAss 125 Repair Instructions

Table of Contents

Table Of Contents3
Technical Data6
Service Data8
General Notes11
Torque Values12
Maintenance14
Spark Plug14
Valve Clearance15
Carburetor Idle Speed16
Air Cleaner17
Adjusting The Clutch Lever Play18
Checking, Adjusting The Drive Chain19
Brake System20
Checking/Replacing The Lining Of The Front Brakeshoes21
Brake Light Switch21
Setting The Footbrake Pedal Position23
Removing/Installing The Front Wheel24
Removing/Installing The Rear Wheel25
Front Wheel/Rear Wheel Bearings26
Lubrication System Diagram27
Lubrication System - Service Information/Troubleshooting28
Recommended Engine Oil28
Oil Level Check29
Oil Change29
Engine Oil Filter Cleaning29
Oil Pump Removal30
Oil Pump Inspection31
Oil Pump Assembly/Installation32
Fuel System Service Information33
Fuel System Troubleshooting33
Fuel System Specifications33
Carburetor Specification33
Throttle Valve34
Float Valve/Float Inspection36
Float Valve Assembly37
Float Level Inspection38
Carburetor Installation39
Removing/Installing The Fuel Petcock40
Engine Disassembly/Assembly41
Cylinder Head/Valves42
Cylinder Head/Valves - Troubleshooting43
Camshaft Removal/Inspection44
Cylinder Head Removal/Disassembly45
Cylinder Head Inspection46
Rocker Arm Shaft Inspection47
Valve Spring Inspection47
Valves Inspection47
Valve Guide Replacement48
Valve Seat Inspection/Refacing49
Valve Seat Grinding50
Cylinder Head Assembly51
Valve Spring Compressor Attachment52
Cylinder Head Installation53
Camshaft Installation54
Cylinder Compression55
Cylinder/Piston Diagram56
Cylinder/Piston - Service Data/Troubleshooting57
Cylinder Removal/Inspection58
Piston Removal59
Piston/Piston Ring Inspection59
Piston Ring Installation61
Piston Installation61
Cylinder Installation62
Clutch/Gearshift Linkage - Service Information/Troubleshooting63
Right Crankcase Cover Removal64
Clutch Removal64
Clutch Reassembly66
Clutch/Gearshift Linkage - Diagram And Parts List67
Clutch/Gearshift Linkage Inspection67
Primary Drive Gear/Center Guide Inspection68
Clutch Spring Inspection68
Clutch Assembly68
Gearshift Linkage Disassembly/Assembly70
Clutch Installation71
Right Crankcase Cover Installation73
Alternator/Cam Chain Tensioner - Exploded Diagram/Service Data/Troubleshooting74
Alternator Removal75
Flywheel Removal75
Cam Chain Tensioner Inspection75
Transmission/Crankshaft T/Kick Starter - Service Data/Troubleshooting76
Crankcase Separation77
Crankshaft Inspection78
Timing Sprocket Replacement79
Kisk Starter Disassemlby/Reassembly80
Shift Drum/Fork Disassembly And Inspection82
Crankcase Bearing Replacement83
Transmission Assembly83
Transmission/Crankshaft/Kick Starter Exploded Diagram84
Crankcase Assembly85
Electrical System86
Fuse Replacement86
Battery/Charging The Battery87
Commissioning Maintenance-Free Batteries (Mf)88
Cockpit - Speedometer, Instrument Lights90
Speedometer Set-Up90
Speedometer Battery Change91
Changing The Bulbs92
Headlight, Tail/Brake Light92
Indicator93
Adjusting The Headlamps94
Ignition System - Schematic Diagram95
Ignition System - Service Information/Troubleshooting96
Cdi Unit Removal/Inspection97
Ignition Coil Removal98
Primary/Secondary Coil Inspection98
Alternator99
Pulse Generator (Pick-Up)99
Ignition Timing Inspection99
Wiring Diagram - 4-Gear Engine100
Troubleshooting101