Page 1 TR 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 Maj 2013...
Page 2 Two-wheel Motorcycle QJ125GY-16A Instruction and Maintenance Manual ZHEJIANG QIANJIANG MOTORCYCLE CO., LTD.
Page 3: Table Of Contents
Contents Preface ·································································································· - 1 - Preparatory Data ······················································································· - 2 - Inspection/Adjustment ··············································································· - 15 - Check and Maintenance of Body ··································································· - 32 - I Braking System ···················································································· - 34 - 1.1 Maintenance Instruction ········································································· - 34 - 1.2 Fault diagnosis ····················································································...
Page 4 7.3 Starting Motor ···················································································· - 79 - 7.4 Starting Relay ····················································································· - 81 - VIII Bulbs/Switches/Instruments ································································· - 82 - 8.1 Preparatory Data ················································································· - 82 - 8.2 Fault Diagnosis ··················································································· - 82 - 8.3 Headlamp Bulb Replacement ··································································· - 83 - 8.4 Front Turn Signal Lamp Bulb Replacement ··················································...
Page 5 Inspection and Maintenance of EFI System ···················································· - 133 - XVI EFI System Description ···································································· - 134 - 16.1 Introduction to EFI System of finished enginecycle ····································· - 134 - 16.2 EFI system parts ·············································································· - 134 - 16.3 Troubleshooting diagnosis ··································································· - 146 - 16.4 Common troubleshooting ····································································...
Page 6: Preface
Preface The Instruction and Maintenance Manual contains an introductory description of maintenance on QJ125GY-16A 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. Check and adjustment contains main aspects for inspection and adjustment, safety of the vehicle, performance and maintenance of each component.
Page 7: Preparatory Data
ZHEJIANG QIANJIANG MOTORCYCLE CO., LTD. Finished Automobile Institute 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.
Page 8 When disassembly and installation is in process, general tools and special tools should be selected correctly. When it is time to use the special, the general can not be substitution. Besides, appropriate power is welcomed to avoid the damage of components. High Temperature Burn Tips: Do not be burned by engine, exhaust pipe,silencer and other components with high temperature.
Page 9 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 10 Pay special attention to the key fitting position before disassembly. The components that are not used any more shall be replaced on time before disassembly. 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.
Page 11 Disassembly of ball bearing: use a tool to push against one or two (internal and external) bearing races. If the force works only on one bearing race (whatever internal or external), it may be damaged when the bearing is disassembled, in which case, it must be replaced - 6 -...
Page 12 Specifications (QJ125GY-16A) QJ125GY-16A QJ160MI-A Model Engine type 92# or 95# unleaded Overall Length (mm) 2030 Fuel type gasoline Overall Width (mm) Number of cylinders Overall height (mm) 1120 Bore*stroke Ф60 mm *44 mm Wheelbase (mm) 1385 Displacement 124.4 Front 63kg Starting mode Electric axle...
Page 13 QJ125GY-16A - 8 -...
Page 14 Fault Diagnosis Start difficultly or start failed Fault Diagnosis Adjustment Check Fault Cause Check if petrol pump work well No fuel in gasoline box Pipeline block in fuel injector of gasoline box Block in the pipeline of gasoline pump Oil supplying No fuel Pipeline block in evaporation controlling for fuel injector...
Page 15 Rotation unsmooth (No speed or low speed) Fault Diagnosis Adjustment Check Fault Cause Start engine and add oil Block of air filter Unhealthy gasoline Speed of Engine speed Pipeline block in evaporation controlling rotation of can not arise system of fuel tank engine arises completely Block of exhaust pipe...
Page 16 Rotation unsmooth (especially in low speed) Fault Diagnosis Adjustment Check Fault Cause Ignition time adjustment Unhealthy CDI group Normal Abnormal Unhealthy trigger Air damper restriction screw adjustment Gas mixture is too thin (loosen bolt) Adjust well Adjust not well Gas mixture is too strong (tighten bolt) Air into shim Heat filter not well Loose restrictor fixed nut...
Page 17 Rotation unsmooth (especially in high speed) Fault Diagnosis Adjustment Check Fault Cause Ignition time adjustment CDI group not well Normal Abnormal Trigger not well Gasoline is little in gasoline box Gasoline pipe filter block Normal Abnormal Block of fuel tank evaporation control system pipe Automatic oil ring not well Fuel injector block...
Page 18 Unhealthy charging (storage battery over discharge or over charge) Fault Diagnosis Adjustment Check Fault Cause Measurement on both ends of the battery voltage Battery life has come started the engine Battery voltage Battery voltage up to normal; restore no rise the original voltage Unhealthy storage battery after flameout...
Page 19 Spark plug without flashover Fault Diagnosis Adjustment Check Fault Cause Replace new spark plugs to check The spark plug Hot spark Spark plug the bad jump weak or no fire jump Check the spark plug check again Without sag With sag Spark plug cover relaxation Check whether the plug CDI group flabby...
Page 20: Inspection/Adjustment
Inspection/Adjustment Preparatory data Front/Rear brake free stroke Periodic maintenance schedule Front/Rear brake shoe’s abrasion Engine oil / Oil-filter screen Headlamp Gasoline filter Clutch Front/Rear suspension system Check/Adjustment of accelerator stay wire Air cleaner Bolt/Nut/Fastening part Spark plug Wheel rim/Tyre Battery Tyre specification Restrictor Steering stem bearing and handle fixation...
Page 21: Specifications
Specifications Engine 1,700±100rpm/min Idle speed Spark plug clearance 0.7~0.8mm engine oil volume 1.2L(oil change1L) NGK CR8E Spark plug type Cylinder compression 1.1~1.3Mpa pressure Ignition time BTDC12 degrees (+/-)1degree 1,700±100rpm Frame Clearance of front brake 10-20mm handle Clearance of rear brake pedal 10-20mm Specification Tyre pressure...
Page 22 Periodic Maintenance Schedule Every Every Every Every Every Mileage and Every 1000 3000 6000 12000 14500 300 KM interval Tools Items three Twelve Fifteen Vehicle month months months months months Air cleaner Common tool Gasoline filter Common tool Engine oil filter Common tool Engine oil replacement Once every 1000KM...
Page 23: Engine Oil Replacement
Expected Inspection Ignition system -- perform maintenance inspection on obvious and continuous ignition malfunctions, engine on fire, overheated back burning and others. Carbon deposit removal -- obvious underpowered, get rid of carbon deposit at cylinder head, piston head and air exhaust system. Piston and cylinder -- when cylinder is over worn or stuck, please replace it.
Page 24: Air Filter
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. Gasoline filter Check of degradation and damage of fuel pipe. If there is any degradation, damage or fuel leakage, new products should replace the old ones.
Page 25 Disassemble backplate of the left fuel tank Disassemble left knee board. Disassemble gusset plate of right and left fuel tank backplate Disassemble air filter cover; fix bolts; take down the cover. Disassemble bolts; take down air filter. Disassemble filter sponge from air filter. Check whether the filter sponge is polluted or damaged.
Page 26 How to wash the filter sponge: Wash it in the clean washing oil. Make it fully dry. Soak it in the clean gear oil until soaking well. Squeeze out the extra oil in sponge. Replacing Time If driving under dusty condition or in rainy days frequently, replace the air cleaner earlier.
Page 27 Check the burning, pollution and carbon deposit of spark plug. If the conditions above happen, please clear with spark plug scavenger or steel brush. Clearance inspection of spark plug Gap: 0.7-0.8mm CR8E (NGK) Spark plug type: Spark plug gap *Attention When installing spark plug, you’d better install with hands and then use spark plug sleeve to tighten.
Page 28: Idle Speed Adjustment
Voltmeter shall be used for charging inspection. Charging Connection method: Positive pole of battery charger is connected to battery positive lead wire; Negative pole of battery charger is connected to battery negative lead wire. Warning! • Battery shall be away from fire. •...
Page 29 If idle speed RPM is unsteady, or idle speed is not smooth when gently raise engine speed, adjust idle speed adjusting screw again. Cylinder pressure Operation when engine is warming. Disassemble spark plug. Install roof cylinder pressure gage. Fully open accelerator; start engine to measure cylinder pressure.
Page 30 Please adjust chain as the following methods: (1) Put up motorcycle with carriage (2) Loosen the back axle nut1. (3) Loosen the locking nut2 (4)Turn the adjustment bolt3 to right or left to adjust the looseness of chain. When adjusting chain, make sure front and back chain wheel should aim at centre as a line.
Page 31 Clearance of Front/Rear Brake Front brake clearance Measure the clearance of front brake at the tip of front brake handle. Clearance: 10-20mm Please adjust free travel of front brake handle in the following way: (1) Loose mandrill to lock nut1. (2) Twist in or out the mandril2 to adjust free travel of front brake handle, after adjusting free travel to 10-20mm.
Page 32 Rear brake clearance Measure the clearance of rear brake at the tip of front brake handle. Clearance: 10-20mm Braking clearance Please adjust free travel of back brake footstep in the following way: (1) Loose mandrill to lock nut1. (2) Twist in or out the mandril2 to adjust free travel of front brake handle, after adjusting free travel to 10-20mm.
Page 33 Front/back brake shoe’s abrasive wear Front brake shoe’s abrasive wear When braking exactly, check oil level from oil immersion Oil pump lens. If liquid level of brake fluid is below the arrow position in the right picture, brake shoe should be replaced immediately by a new one.
Page 34: Front Suspension
Clutch Start engine and increase rotation speed gradually to check running condition of clutch. If motorcycle can not walk or engine shuts down, check clutch block. Replace a new one when necessary. Free travel of clutch: 10-20mm Please adjust free travel of clutch in the following way: (1) Loosen mandrill to lock nut1 (2) Twist in or out the mandril2 to adjust free travel of front brake handle, after adjusting free travel to 10-20mm.
Page 35: Rear Suspension
Rear suspension Pressure up and down Compress upward and downward the rear shock absorber to check its actuator. Check if components on the rear shock absorber are loosened or injured. Lift and support the rear wheel and swing the wheel to check if engine suspension bushing is loosened.
Page 36 Change a new tyre when decorative pattern depth on tyre middle reaches the degree of the right picture. Minimum decorative pattern depth Front tyre 1.6mm Back tyre 2.0mm Warning: Do not try to mend damaged tyre because wheel balance and tyre reliability may be worsen. To inflate tyre in a wrong way will cause unusual tread abrasive wear and threaten safety.
Page 37: Check And Maintenance Of Body
Check and Maintenance of Body Front liquid brake block Thickness of brake shoe: 7.8mm Use limits: 3.8mm Torsion force to Install Bolt 1: 22-34N·m Torsion force to Install Bolt 7: 30-35N·m Torsion force to Install Bolt 14: 5-10N·m Torsion force to Install Bolt 16: 2-5N·m Torsion force to Install Bolt 18: 5-10N·m...
Page 38 Back liquid brake block Thickness of brake shoe: 7.0mm Use limits: 3.7mm Torsion force to Install Bolt 3: 5-10N·m Torsion force to Install Bolt 4: 5-10 N·m Torsion force to Install Bolt 7: 30-35 N·m Torsion force to Install Bolt 12: 22-34N·m Torsion force to Install Bolt 23: 30-35 N·m...
Page 39: Rear Drum Brake
I Braking System Maintenance instruction--------------------1.1 Fault diagnosis-------------------------------1.2 Front hydraulic disc brake----------------- 1.3 Rear drum brake-----------------------------1.4 1.1 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.* 1.1.1 Specifications Available...
Page 40: Fault Diagnosis
Under the brake fluid before pump installation bolt 22-34N·m Liquid brake oil pump before installation bolt 5-10N·m Front wheel spindle 100-113N·m Front wheel head bolt 5-10N·m The brake disc retaining bolt 5-10N·m Liquid brake pump installation after the bolt 22-34N·m Back oil pump installing bolts liquid brake 5-10N·m Back wheel spindle...
Page 41: Front Hydraulic Brake
Deviation of wheels Block or restriction in brake hose joints Bending/incompletion of braking plate Caliper slides abnormally 1.2.6 Brake drag Braking footstep/plate is dirty Deviation of wheels Abrasive wear of braking footstep/plate Bending/incompletion of braking plate Caliper slides abnormally 1.2.7 Brake handle/footstep is hard Block or restriction of brake system Adhere/abrasive wear of caliper piston...
Page 42 * Attention •Please do not contaminate braking shoe assembly with oil while assembly or disassembly •Please use specified detergent to clean the braking assembly, or it may reduce braking performance. Disassemble front axle Take down front axle Disassemble front liquid brake block from front wheel Thickness 1.3.2 Check measurement...
Page 43: Back Liquid Brake
Install front wheel Install front liquid brake oil pipe and brake cylinder units Do not get grease on brake shoe * Attention If there is grease on brake shoe, brake ability will reduce and cause brake failure Fasten bolts to the setting torsion force Torsion force: Former brake disc retaining bolt 5-10N·m...
Page 44 1.4.2 Check Thickness measurement Check the abrasive wear condition of brake shoe. Replace it when necessary. Measure brake shoe、brake plate and then write down the maximum number. Measure the thickness of brake shoe. Brake shoe Use limits: brake shoe 4.5mm Specification Diameter of front liquid brake plate: φ280mm *Attention...
Page 45 Front wheel spindle 100-113N·m Front wheel head bolt 5-10N·m No oil stain shall be on brake shoe and brake disk. If any, use brake cleaner fluid. *Attention Oil stain on brake shoe will eliminate braking performance. - 40 -...
Page 46 Body outer panels 1 Front and right turn light 2 Front and left turn light 3 Front night-light fixed position 4 Pod 5 Right mounting plate of pod 6 Left mounting plate of pod 7 Headlight 8 Instrument assembly 9 Front splash guard 10 Right and left oil tank guard plate gusset piece 11 Right back plate 12 Left back plate...
Page 47: Vehicle Housing
II Vehicle Housing Disassemble body as the following order: rearview mirror →front pod →instrument support →instrument →back pod →front splash guard →seat cushion →decorating plate of left and right front back plate →left and right front back plate→ front and back junction plate of right and left back plate→...
Page 48 Front wheel/front suspension - 43 -...
Page 49 Front wheel 1 Front wheel axleM14*1.5*219 2 Odometer wheel gear units 3 Front wheel sealed units 4 Front wheel middle shaft sleeve 5 Cycle valve6 vacuum tyre 100/80-17 7 Front wheel ring Liquid brake plate erection bolt 9 Front wheel left shaft sleeve 10 Antifriction bearing 6202-2RS 11 Front brake plate - 44 -...
Page 50: Front Wheel/Front Suspension
III Front Wheel/Front Suspension Preparatory data-----------------3.1 Fault diagnosis------------------3.2 Front wheel----------------------3.3 Control assembly---------------3.4 Front fork assembly------------3.5 3.1 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. Take care not to rotate the wheel reversely. Attention: Please do not let oil contaminate braking shoe.
Page 51 Wobbly Direction Handle 3.2.2 Damaged handle bearing Not enough tyre pressure. Front fork bent, front wheel shaft bent. Distorted and crooked front wheel tyre. 3.2.3 Wobbly Front Wheel Distorted wheel rim Worn front wheel bearing Defective front tyre Unbalance of tyre or wheel 3.2.4 Difficult Rotation of Wheel Breakdown of front wheel bearing Braking breakdown of brake...
Page 52: Front Wheel
3.3 Front wheel 3.3.1 Disassembly Support the bottom of body to float front wheel Disassemble bolt and take down front splash guard and odometer guide line. Disassemble front brake hose Disassemble front axle jam nut Disassemble front axle Disassemble front wheel Disassemble oil seal with oil seal stripping attachment and bearing with bearing stripping attachment.
Page 53: Bearing Replacement
3.3.2.3 Front Bearing Inspection Disassemble front wheel central lining and take down oil seal. Front wheel intermediate bushing Grease seal Check the rolling condition of bearing. If not rolling, or the bearing is worn or loose, replace with a new one. 3.3.3 Bearing Replacement Disassemble front wheel 、...
Page 54: Direction Handle
Attention Without folding and locking odometer wheel gear units to front axle, odometer wheel gear units will be out of shape After installment of axle, rotate it to make sure the rotation condition of autometer drive shaft. Install front axle and then lock tight. * Note: the dismounting picture is on page 41 of this manual Torsion force Front axle: 37-44 N·m...
Page 55 Disassemble direction handle Tools: Direction handle fixed bolt wrench Fixed nut wrench * Attention: • Clean the opening part of protecting plate of motorcycle block with a cloth. 3.5.3 Installation Tools: Locknut wrench Rotate the front fork left and right to be sure of its smoothness and there shall be no looseness. Steps: Install direction handle.
Page 56 Rear Wheel / Rear Suspension - 51 -...
Page 57 Real Shock Absorber / Real Rocker Arm 1. Self-locking nutM14*1.5 2. Dust ring units 3. Multi-roll bearing HK2020 4. Real rocking arm axle sleeve 5. Oil seal 6. Real rocking arm installment axle 7. Chain tension axle sleeve 8. Chain tension wheel units 9.
Page 58 Rear wheel 1. Rear axle 2. Rear wheel plate pinch 3. front wheel oil seal assembly 4. Rolling bearing 6003-2RS 5. Chain erection bolt M8*22 6. Rear wheel central axle sleeve units 7. Self-locking nutM16*1.5 8. Chain wheel 9. Chain 428HG-1*132 10. Rear brake disc 11. Vacuum tyre 130/80-17 12 .
Page 59: Preparatory Data
IV Rear Wheel/Rear Suspension Preparatory data----------------------------------- 4.1 Fault diagnosis-------------------------------------4.2 Rear wheel------------------------------------------4.3 Rear shock absorber/rear swing arm----------- 4.4 Chain drive assembly-----------------------------4.5 4.1 Preparatory Data Precautions on operation Do not contaminate braking shoe ad brake disc with oil. Basic preparatory data Item Standard Value（mm）...
Page 60: Fault Diagnosis
4.2 Fault Diagnosis 4.2.1 Shimmy Rear Wheel Distorted wheel rim Worn rear bearing Troubled tyre Worn or injured swing arm pivot bush Improper adjustment of drive chain adjuster Unbalance of tyre and wheel Tyre pressure is too low Bent frame or swing arm 4.2.2 Inflexible Wheel Rotation Flexible rear liquid brake plate Worn rear bearing...
Page 61 4.3 Rear wheel 4.3.1 Disassembly Loosen rear axle nut Disassemble rear axle nut and take down chain from chain wheel seat Disassemble rear axle Disassemble rear wheel Rear axle Rear swing 4.3.2 Inspection 4.3.2.1 Check the bending of axle Put axle on V-style seat and measure its eccentricity ratio with dial indicator Use limits: change over 0.2mm Axle...
Page 62: Rear Shock Absorber
4.3.3 Installation Install the rear wheel in the reverse order of removal and tighten the nut. Rear wheel shaft locknut Tightening torque: 100-113N·m 4.4 Rear Shock Absorber 4.4.1 Disassemble rear shock absorber Disassemble body guard board Disassemble rear splash guard Disassemble tool box Disassemble air filter Disassemble rear wheel shock absorber fixed bolt...
Page 63: Rear Swing Arm
4.5 Rear Swing Arm 4.5.1 Remove Rear Swing Arm Disassemble chain guard board Disassemble chain tension wheel and rear axle Disassemble rear wheel and rear shock absorber 12 13 28 29 30 28 Disassemble rear swing arm installment axle Take down rear swing arm weld assembly 4.5.2 Rear Swing Arm Inspection Check rear swing arm installation shaft.
Page 64: Drive Chain
4.6 Drive Chain 4.6.1． Disassembly Lay motorcycle on the flat ground and fasten Disassemble shift lever swing arm, left rear cover and drive chain Disassemble rear wheel、chain shield and drive chain 4.5.2． Inspection Wash drive chain and put it into kerosene. Brush dust and then take it out from kerosene and dry it out.
Page 65 Check drive chain and driven chain wheel. Replace chain wheel when 1/4 gear teeth are worn. Replace it when gear teeth is bending. Check wheel axle. Replace when there is bearing gap in hub or unbalance of rotation. Check oil seal and replace when there is abrasive wear or damage.
Page 66 Check and maintenance of electrical equipment Charging system - 61 -...
Page 67: Storage Battery/Charging System
V Storage Battery/Charging System Preparatory data---------------5.1 Fault diagnoses-----------------5.2 Battery-------------------------5.3 Charging system---------------5.4 Voltage/current adjuster-----5.5 Alternator charge coil---------5.6 Alternator light coil----------5.7 Disassembly of alternator----5.8 5.1 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 68: Fault Diagnosis
Preparatory Standard Item Specification Capacity/type 12V-6AH/ 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 100W/8000rpm Magneto Coiling impedance value（20 ）...
Page 69: Storage Battery
5.3 Storage Battery 5.3.1 Battery Removal Open seat cushion Disassemble left guard board Disassemble negative guide line first and then the positive guide line Take out storage battery Warning! Storage battery During positive lead wire disconnection, be sure to prevent the tools being used from touching the frame;...
Page 70: Charging System
Warning! • Battery shall be away from fire. • Shut off charger switch first before or after charging in case sparks may be generated at connection parts, which may result in explosion. • During charging, please take the current time labeled on the battery as basic time. * Attention •...
Page 71: Voltage-Current Regulator
Set multimeter to position of AC voltage Limited voltage: 13.1 (+/-) 0.5V/5.000rpm If limited voltage is beyond the specified range, check voltage-cuttent regulator. 5.5 Voltage-current Regulator 1.5.1 Loop inspection on main wiring terminals Disconnect the 6P plug on the voltage-current regulator. Check continuity between main wiring terminals in the following way: Judgment Item (wire color)
Page 72: Alternator Charging Coil
Multimeter White1 Black White2 Red/white Unit: MΩ White1 0.1~3 10~90 0.1~3 red/white 0.1~3 1.2~5 0.1~3 Black White2 60~80 0.1~3 5.6 Alternator Charging Coil * Attention Inspection of alternator charging coil can be performed on the engine. Inspection Disassemble alternator 4P joint Measure Alternator white coil and impedance between bodies with multimeter Standard value: 0.6-1Ω（20 ）...
Page 73: Disassembly Of Alternator
5.8 disassembly of alternator 5.8.1 Disassembly 螺栓 Bolt Disassemble fixed bolt and bolt Take down left cover Fix flywheel with universal fixed wrench Disassemble flywheel fixed nut Take down flywheel with flywheel puller Disassemble solid key Disassemble alternator guide line joint Disassemble alternator stator 固定...
Page 74 5.8.2 Installation Install the alternator stator onto the engine box. Connect lead-wire connector alternator. Clean crankshaft and conical part of flywheel. Make sure the fixation key is installed into the key slot on the crankshaft. Align the groove on the flywheel to the fixation key on the crankshaft. 固定...
Page 75 Power Lock Horn Ignition Coil Storage Battery Rectifier Starting Relay MAIN SW SPARK PLUG FUSE BL/W R/W BL/W IGNITION COIL MAGNETO BATTERY 点火系统 - 70 -...
Page 76: Ignition System
VI Ignition System ----------------6.1 Preparatory data Ignition coil ------------6.5 -----------------6.2 Fault diagnosis Trigger -----------------6.6 ---- 6.3 Charging Ignition system inspection coil---------- 6.7 ------------------6.4 CDI assembly 6.1 Preparatory Data Precautions on operation 1. Ignition system inspection: please perform inspection in the sequence listed in the fault diagnosis table. 2.
Page 77 Accessory for voltmeter with maximum range Multimeter 6.2 Fault Diagnosis Spark plug not sparking 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 78: Ignition System Inspection
Avometer 6.3 Ignition System Inspection * Attention • When the spark plug is not sparking, check if components of wiring are loosened or badly contacted and make sure if all the voltage values are normal. High voltage shunt • There are many brands of multimeters with different interior impedance.
Page 79 * Attention Install spark plug on the head of cylinder. Check condition normal compression pressure Disassemble 4P、2P joints of CDI group. Connect high pressure shunt between 2P (red/white side) and 4P (black side). Button start motor or step on actuating lever to measure the maximum voltage of charging coil. Connection method: connect red/white with negative pole and black with black pole Minimum voltage: more than 95V *Attention...
Page 80: Cdi Assembly
vehicle and remove connector of alternator. Trigger (blue/white) is connected with a shunt. • When the measured voltage at CDI assembly terminal is abnormal, but measured voltage at alternator terminal is normal, it indicates that the connector is of poor contact or wiring is broken. •...
Page 81: Trigger
6.5.2 Primary coil inspection Measure the impedance between terminals of primary coil. Standard value: 0.4Ω±10% (20 ) Impedance value within the range is good. Impedance value “∞” indicates broken wire inside the coil. The coil shall be replaced. 6.5.3 Secondary coil Attached with the spark plug, and measure the impedance between lead-wire side of spark plug cap and terminal.
Page 82 Power Lock Horn Ignition Coil Storage Battery Rectifier Starting Relay BRAKE SWITCH BRAKE SWITCH BATTERY RELAY STARTOR MOTOR STARTER SWITCH 启动示意图 - 77 -...
Page 83: Starting System
VII Starting System Preparatory data-------- 7.1 Fault diagnosis----------7.2 Starting motor-----------7.3 Starting relay------------7.4 7.1 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 carbon brush 12.5mm 8.5mm...
Page 84: Fault Diagnosis
7.2 Fault Diagnosis Starting motor will not run Starting motor runs weakly Starting motor runs but the engine does •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 85 adhered to its surface. Inspect for continuity between contact surfaces of other assemblies. Confirm the discontinuity of armature shaft among surfaces of commutator. Inspect for continuity of starting motor housing. Confirm the continuity between conducting terminal and starting motor housing. Inspect continuity between conducting terminal and brush.
Page 86: Starting Relay
7.4 Starting Relay 7.4.1 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. “Click” sound indicates normal. No sound: • Check starting relay voltage. •...
Page 87: Bulbs/Switches/Instruments
VIII Bulbs/Switches/Instruments Preparatory data-------------------------------------------------------8.1 Fault Diagnosis -------------------------------------------------------8.2 Headlamp Bulb Replacement --------------------------------------8.3 Front Turn Signal Lamp Bulb Replacement ---------------------8.4 Taillight/license plate lamp/rear turn-lamp bulb replacement--8.5 Instrument ------------------------------------------------------------8.6 Master switch---------------------------------------------------------8.7 Horn--------------------------------------------------------------------8.8 Handle switch--------------------------------------------------------8.9 8.1 Preparatory Data Precautions on operation Remove switches from the motorcycle and perform continuity test. 8.2 Fault Diagnosis “ON”...
Page 88: Headlamp Bulb Replacement
8.3 Headlamp Bulb Replacement 8.3.1 Removal Disassemble pod Disassemble blot to disassemble headlamp Disassemble sheet glass of headlamp Fix headlamp and rotate socket in clockwise to disassemble bulb. 8.3.2 Installment Install bulb back in the verse order of disassemble. Adjusting screw - 83 -...
Page 89: Front Turn Signal Lamp Bulb Replacement
8.4 Front Turn Signal Lamp Bulb Replacement 8.4.1 Removal Loosen turn signal lamp fixed bolt Take down bulb from bulb socket Head 8.4.2 Installation lamp Left and right turn Install bulb back in the verse order of disassemble. signal lamps 8.5 Taillight/license plate lamp/rear turn-lamp bulb replacement 8.5.1 Disassembly Disassemble bolt and taillight shade.
Page 90: Instrument
8.6 Instrument Remove rear mirror. Take down the handle hood and pull out waterproof connector. Remove the bolts. Remove meter housing Remove the instrument. Install the instrument orderly in the reverse order of removal. 8.7 Main Switch 8.7.1 Inspection Disassemble front guard board Disassemble master switch guide line joint Break over test of joint side 8.7.2 Master switch replacement...
Page 91: Horn
8.8 Horn Inspection Disconnect wire to the electric horn. Connect lead wire of horn with the battery. When the electric horn sounds, it indicates the horn is in good condition. 8.9 Handle switch Remove protecting plate of steering handle. Screw off mounting bolt on the brake lever and take down the bracket.
Page 92: Engine Inspection And Maintenance
Engine Inspection and Maintenance Table of tightening torque for fastening parts used in engine Table of tightening torque for fastening parts Names of fastening parts and fasteners Fastening torque (N·m) Cylinder head cover screw M6 10-14 Cam cover fastening screw M5 Cylinder head cover screw M6 Cylinder head cover acorn nut M8 25-28...
Page 93 Lubricating System Chart Cam bearing Orifice Main secondary axis Orifice Cam bearing Connecting Bent axle rod bearing Plunger orifice Oil pump 2 Oil filter Crankcase Oil pump 1 Oil pan - 88 -...
Page 94: Lubricating System
IX Lubricating System Preparatory data--------9.1 Fault diagnosis---------9.2 Oil engine pump-------9.3 9.1 Preparatory Data 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. It is used to reduce wear of component, cool components of higher heat, absorb impact from bearing and other parts, weaken noise, increase tightness between piston ring and cylinder wall, clean and take away impurities from surface of component, etc.
Page 95: Oil Pump
9.3 Oil Pump Disassembly Remove the right cover, the clutch, and the retaining ring, and then remove the oil pump gears and oil pump transition gear; Oil pump transition gear Retaining ring distribution Oil pump adjustment gasket drive gear Remove the fixed pin, the screw and the pup cover, and disassemble the oil pump; Oil suction pressure pump...
Page 96 Check the radial clearance between the inner and outer rotor Testing Allowable limit: 0.15 mm 测试规 gauge Testing Check the clearance between the outer rotor 测试规 gauge and pump body Allowable limit: 0.15 mm Testing gauge Check the clearance between the rotor ends 测试规...
Page 97 Assemble Engine Oil Pump As shown in the following figure: 1 Oil suction pump assembly 2 Oil pressure pump assembly 3 Retaining ring 4 Gasket 5 Oil pump gear 6 Fixed pin 7 Oil suction pump shaft 8 Pin 9 Bolt M6x16 10 Oil pump cover 11 Inner rotor 12 Outer rotor 13 Oil pressure pump shaft 14 Oil pump cover 15 Inner rotor 16 Outer rotor 17 Gasket 18 Oil pump transition gear 19 Transition gear shaft * Attention:...
Page 98: Cooling System
X Cooling system Preparatory data---------------------------10.1 Fault diagnosis-----------------------------10.2 Water pump---------------------------------10.3 10.1 Preparatory data Functions of cooling system: It can build some channels which can allow liquid circulation inside the cylinder and the inner wall of the cylinder cover; a special radiator is set outside the engine body so that the forced circulation of cooling water can be made through water pump and pipeline, and then the heat of the engine can be released to cool it through air blowing the surface of the cooling fin of the radiator at high speed.
Page 99: Water Pump
10.3 Water pump Disassemble Loosen the fastening bolt, remove the crankcase right cover and remove the gasket. Bolt Right cover Remove the water pump gear, loosen the Fastening bolt and remove the water pump cover and the gasket. Bolt Water pump cover Water pump gear...
Page 100 Inspection Check whether the parts wear. If badly worn, replace it. Note: No damage should be made to the gasket and the box joints in operation. Installation Installation should be made in accordance with the reverse order of the removal. Water pump disassembling 1 Hexagon socket cylinder bolt 2 Gasket 6...
Page 101 Cylinder head - 96 -...
Page 102: Cylinder Head
Cylinder Head Preparatory data 11.1 Fault diagnosis 11.2 Cylinder Head/Valve 11.3 11.1 Preparatory Data Function of cylinder head: Cylinder head is used to seal cylinder and form a combustion chamber with piston to hold high-temperature and high-pressure fuel gas. It accomplishes air intake and exhausting operation with valve mechanism. Precautions on Operation To ensure sealing between cylinder head and cylinder body, there is a great bolt pretension on the cylinder head.
Page 103: Cylinder Head
11.2 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 Over-high compression pressure Air leakage at cylinder head Too much carbon deposited in the combustion chamber Improperly installed spark plug 11.3 Cylinder Head Removal...
Page 104 Cam shaft measurement Measure the size of the cam matching journal Admission can shaft: Allowable limit: Φ24.957 mm Exhaust cam shaft: Allowable limit: Φ24.957 mm Admission cam Measure the height of the cam shaft shaft Allowable limit: Intake 36.9 mm Exhaust cam shaft Exhaust 35.9 mm...
Page 105 Valve disassembling Valve tappet Valve Lower seat of valve spring Valve lock clamp Upper seat of valve Valve spring spring Inspection Clean carbon deposition on the cylinder cover. Ruler Measure flatness of junction surface of cylinder cover Allowable limit: 0.05mm. If flatness of junction surface of cylinder cover exceeds the service limit, put a piece of fine sandpaper on the flat plate and fit the sandpaper with junction surface of...
Page 106 Measure the free length of the valve spring. Allowable limit: Spring: 37 mm Vernier caliper Measure the outer diameter of the valve stem. Allowable limit: Intake Ф4.455 mm Microcalliper Exhaust Ф4.448 mm Valve reamer Check valve guide. Please eliminate the carbon deposition in the valve guide with a reamer before inspection.
Page 107 Testing Measure valve guide ID. gauge Allowable limit: Intake/Exhaust: Ф4.53mm. Clearance between valve and valve guide Allowable limit: Intake Valve: 0.08m. Exhaust valve: 0.1mm. Valve Guide Replacement Attention: When the clearance between valve and valve guide exceeds service limit value, please Opener replace the valve guide.
Page 108 When the valve guide is inserted, fix and adjust it Valve reamer with a valve guide reamer. Attention: When a reamer is used to cut, please apply some amount of cutting lubricant onto it. Rotate the reamer in clockwise direction. Remove carbon deposited in combustion chamber and valve and clean thoroughly intake and exhaust valves.
Page 109 Remove 1/4 of external edge of valve race with a 30° angle milling cutter. 30° Remove 1/4 of bottom of valve race with a 70° angle milling cutter. Remove the milling cutter and check the places processed. 70° Grind and cut valve race with a 45° angle precise milling cutter till it gains a proper width.
Page 110: Valve Clearance Adjustment
If contacted place is the higher part of valve, please use a 32° angle plain milling cutter to lower the valve race. If contacted place is the lower part of valve, please use High contact face a 60° angle internal milling cutter to raise the valve 32°...
Page 111: Cylinder Block And Piston
Cylinder Block and Piston - 106 -...
Page 112: Preparatory Data
XII Cylinder Block and Piston 12.1 Preparatory data 12.2 Fault diagnosis 12.3 Cylinder block 12.4 Piston 12.1 Preparatory Data Function of cylinder block: Cylinder block provides the space for gas compression, combustion and expansion and guides piston movement. It also transfers part of heat in the cylinder to surrounding coolant. Function of piston: 1.
Page 113: Fault Diagnosis
12.2 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 between crankcase and gas Higher compression pressure Noisy piston Damaged cylinder, piston and piston ring...
Page 114 Piston Removal Remove piston pin retainer. Attention: Please do not drop the retainer into crankcase during removal. Take out piston pin and remove piston. Remove piston ring. Inspect piston, piston pin and piston ring. Attention: Please do not break or hurt piston ring. Remove deposited carbon inside the piston ring.
Page 115 Measure piston pin hole ID. Allowable limit: Φ15.04 mm Tester Measure piston pin OD. Allowable limit: Ф14.976mm Measure the clearance between piston pin hole and piston pin. Allowable limit: 0.064mm Measure piston OD 90° Attention: Measuring position forms a 90° angle with piston pin, about 11mm below piston skirt.
Page 116 Inspect wear and scratch on inner wall of cylinder. Attention: Measure cylinder ID at three positions, i.e. upper, Testing gauge intermediate and lower positions. The position forms a 90° angle with piston pin. Allowable limit: Φ60.063mm Measure the clearance between cylinder and piston. Take the maximum clearance as standard.
Page 117: Installation Of Piston
Measure Connecting rod small end ID. Allowable limit: Φ15.068mm Connecting rod small end ID Installation of piston Install location pin. Top ring Apply engine oil evenly on each piston ring and piston. Install piston to its place with bevel upward. Second ring Attention:...
Page 118: Crankcase
XIII Crankcase 13.1 Preparatory data 13.2 Fault diagnosis 13.3 Crankcase Clutch 13.4 Gearshift mechanism 13.5 Bent axle connecting rod assembly 13.6 Variable speed chamber 13.7 13.1 Preparatory Data Function of crankcase: Crankcase is the force bearing part of engine. It is mainly used to support crankshaft, clutch, transmission, cylinder block and cylinder head.
Page 119 Table of standard values of baseline projects and allowable limit Unit: mm Item Standard Allowable limit Clearance between the left and the right of the big end of the 0.1-0.35 connecting rod Connecting rod big end radial 0.008-0.018 clearance Bent axle Jump 0.03 connecting rod...
Page 120 13.3 Crankcase Starting engine Disassemble the left cover of the crankcase Release the fastening bolts of the starting engine to remove the starting engine. Release the fastening bolts of the left cover to remove the left cover. Bolt Electric idle gear Release the locking nuts of the flywheel using electric or pneumatic tools.
Page 121 Disassemble the right cover of the crankcase Starting engine Loosen the fastening bolts to remove the right cover of the crankcase, gasket and locating pin. Bolt Right cove 13.4 Clutch Removal Socket spanner Loosen the five bolts of the pressure plate according to the diagonal cross mode.
Page 122 Disassemble Clutch 1 Bolt 2 Spring washer 3 Clutch spring 4 Pressure plate 5 Bearing washer 6 Surface needle bearing 7 Clutch separation shaft sleeve 8 Jam nut 9 Locking washer 10 Friction plate assembly 11 Driven plate 12 Clutch driven hub 13 Thrust washer 14 Clutch driving drum assembly 15 Internal separation mandrilǁ...
Page 123 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. Housing assembly Check if teeth of pressure plate and center bracket are injured. If they are, replace them. Measure the free length of pressure spring.
Page 124 Measure the thickness of friction plate with a vernier Thickness caliper. Allowable limit: Replace it when below 2.5mm. Check the flatness of the driven friction plate with the plug gauge. Allowable limit: Replace it if above 0.2mm. Driven friction Plug gauge plate measure the thickness of the surface needle roller bearing.
Page 125 Crankshaft connecting rod combination and variable speed chamber Crankshaft connecting rod Locating assembly Bolt Left crankcase Right crankcase Left crankcase Layshaft assembly Main shaft assembly Declutch shift shaft Shifting fork Gearshift drum - 120 -...
Page 126: Gearshift Mechanism
13.5 Gearshift mechanism Disassemble Remove the stop arm. Stop arm Remove the gearshift locating plate. Remove the gearshift shaft combination Remove the parts. Gearshift (Please refer to the exploded view of the locating plate Gearshift shaft variable-speed shift assembly) combination Inspection The gearshift plate should be pulled back flexibly without clamping stagnation before being disassembled.
Page 127: Crankcase Connecting Rod Combination
Left case Bolt Loosen the mould assembling bolt. Separate the crankcase. Attention: There should be no damage on joint case surface. Remove the left case. Chain gear 13.6 Crankcase connecting rod combination Disassemble Remove the trunnion shaft combination and crankcase connecting rod combination from the right crankcase.
Page 128 Measure the clearance in the X-Y direction of the big ends of connecting rod. Allowable limit: 0.008-0.018mm. Position for measurement in the big ends of connecting rod Testing point Measure the jumping of the crankshaft. Allowable limit: 0.03 mm. Check whether there is abnormal sound or loose for the revolution of the crankshaft bearing.
Page 129 Set aside the shifting fork shaft. Remove the gearshift drum. Remove the gearshift fork. Shifting fork Shifting fork shaft Gearshift drum Inspection Measure the outer diameter of the shifting fork shaft. Allowable limit: 9.96mm. Microcalliper Measure the inner diameter of the shifting fork hole. Allowable limit: 10.05mm.
Page 130: Variable Speed Chamber
Measure the thickness of the shifting fork. Vernier caliper Allowable limit: 4.6mm Measure the outer diameter of gearshift drum. Allowable limit: 41.75mm。 Width of locked Measure the width of the locked groove of the groove gearshift drum. Allowable limit: 5.7mm. 13.7 Variable speed chamber Layshaft assembly Remove the spindle assembly.
Page 131 Exploded view of variable-speed gear shift assembly 1 Gearshift stop pin 2 Stop collar 3 Gearshift shaft combination 4 Gearshift running board 5 Gearshift running spring 6 Gearshift shaft return spring 7 Gearshift plate pin 8 Plastic sleeve 9 Gearshift shaft assembly 10 Gearshift changeover contact 11 Contact spring 12 Gearshift drum 13 Gearshift positioned assembly 14 Washer 15 Bolt M6X25 16 Positioning wheel return spring 17 Star wheel positioning plate assembly 18 Gearshift positioning roller arm axis 19 Shifting fork shaft 20 Shifting fork Ⅲ...
Page 132 Inspection Check respectively whether the tooth surface of the wheel gear and the drive claw are worn. Tooth surface If badly worn or damaged, replace it. Drive claw Remove the bearings and oil seals of the left and right crankcase. Check whether they are damaged;...
Page 133: Exhaust System Inspection And Maintenance
Exhaust System Inspection and Maintenance Muffler 1. Socket head cap screw M8*30 2. Spring washer 8 3.Washer 8 4. Exhaust gasket 5. Exhaust pipe assembly 6. Graphite gasket 7. Clip assembly 8. Muffer cylinder assembly 9. Cylinder liner installation 10. Bolt M6*19 11. Rubber space bush 12. Fasten space bush 13. Card nut M6 14. Heat insulation rubber gasket 15.
Page 134: Emission Control System
XV Emission Control System Emission control system guarantee ---------------------------------------15.1 ------------15.2 Periodical maintenance instructions/ensure emission standard Emission control system mechanical function --------------------------15.3 Catalyst conversion system-------------------------------------------------15.4 Solutions to Idle exhaust exceeding specified value -------------------15.5 15.1 Emission Control System Guarantee 1. The emission control system of the enginecycle is up to the EC/97/24/5/I and 2003/77/EC Stage B. The company will guarantee it in its effective service life, under normal use and specified maintenance.
Page 135: Emission Control System Mechanical Functions
· Relevant emission specifications: Emission Specifications HC+NO Emission standard ≤1.0g/km ≤1.2g/km ※ The latest version shall prevail when emission standard is updated. · The enginecycle that does not perform regular inspection in local dealer or service center of the company may be prohibited to use.
Page 136: Catalyst Conversion System
15.4 Catalyst conversion system 15.4.1 Construction: 15.4.2 Instructions: 1. The function of conversion catalyst is to convert the waste gas HC, CO, NO into H O, CO and other 2、 harmless gas before release. 2. Conversion catalyst contains platinum, rhodium and other rare metals, restricted unleaded petrol. ※...
Page 137: Solutions To Idle Exhaust Exceeding Specified Value
Solutions to Idle Exhaust Exceeding Specified Value 15.5 Qualified Perform regular inspection (Repair and maintenance plan) Qualified Measure Idle exhaust (Note 1) Qualified Adjust carburetor (Note 2) Qualified For Delivery; Unpick and wash fuel injector Qualified Qualified Replace fuel injector Disassemble and repair engine.
Page 138: Inspection And Maintenance Of Efi System
Inspection and Maintenance of EFI System QJ125GY-16A EFI circuit diagram - 133 -...
Page 139: Efi System Description
XVI EFI System Description EFI system --------------------------------------- 16.1 EFI system parts --------------------------------- 16.2 Fault diagnosis ----------------------------------- 16.3 Common troubleshooting ----------------------16.4 16.1 Introduction to EFI System of finished enginecycle QJ125GY-16A uses the small engine EFI system from Delphi Corporation, which makes closed-loop control through the oxygen sensor with independent fuel injection and ignition control.
Page 140 16.2.1.2 Appearance of ECU: 16.2.1.3 The ECU pin definitions: J1-1 Stepper engine A high pin J2-1 Ignition coil driver pin J1-2 J2-2 System ground pin J1-3 J2-3 K-wire communication pin J1-4 J2-4 High potential pin of the crankshaft signal J1-5 J2-5 Injector drive pin J1-6...
Page 141 16.2.1.4 EFI circuit diagram: 16.2.1.5 Note for use of ECU: 1. Do not place ECU in the high temperature parts, such as a muffler or engine; 2. The ECU cannot be placed near the water droplets, oil or any liquid; 3.
Page 142 16.2.2 Oil Injector 16.2.2.1 Working principle of oil injector Inside the injector surrounding the iron core there is an electromagnetic coil which leads to the two electrodes, namely, the injector input control interface. When the electromagnetic coil is energized, the generated electromagnetic force makes the ball valve rise by overcoming the spring force of the ball valve and fuel pressure, so the high-pressure fuel (250Kpa) inside the fuel pipe can pass through the injector valve seat hole, flowing through the spray orifice board and forming a conical mist sprayed into the intake valve.
Page 143: Throttle Body
16.2.2.2 Note for use of injector: 1. Inside the injector there is a filter, but it is not a serviceable part, because it is only designed to filter out the accumulated impurities between the fuel filter and injector of the oil line. The impurities can cause injection bonding, flow offset and leakage and other faults, so the fuel filter is very important.
Page 144 16.2.3.3 Clearing of throttle body Use throttle cleaner to clean the throttle body; spray the cleaner on the internal wall of the throttle body and brush gently off the dust, coke, etc.; make sure no dirt clogging the side-channel. 16.2.4 cylinder head temperature sensor 16.2.4.1 Working principle of cylinder head temperature sensor: The engine cylinder head temperature sensor is used for air-cooled engine to measure the engine cylinder head temperature;...
Page 145: Intake Air Temperature Sensor
16.2.5 Intake air temperature sensor 16.2.5.1 Working principle of intake air temperature sensor: It is used to measure the temperature of incoming air, and its resistance will vary with the temperature of the intake air; its characteristic is also negative temperature coefficient resistance characteristics. It is also a part which cannot be repaired.
Page 146 16.2.6 Intake air pressure sensor 16.2.6.1 Working principle of intake air pressure sensor: The sensor is used to measure the absolute pressure of intake air elbow to reflect different inlet pressure according to the resistance value, and the inlet pressure can be thus indirectly converted into calculation of the size of the intake air into the engine combustion chamber.
Page 147 16.2.7 Oxygen sensor 16.2.7.1 Working principle of oxygen sensor: The sensor can be used to detect the amount of oxygen in the exhaust gas in the engine exhaust pipe for the ECU internal fuel closed-loop control, so that the combustion of engine has always been maintained at the most reasonable proportion of air and petrol.
Page 148 16.2.8 Ignition coil 16.2.8.1 Working principle of ignition coil: Ignition coil can provide energy to the spark plug, and it is the high-voltage that connects the ignition coil and spark plug. 16.2.8.2 Appearance of ignition coil: - 143 -...
Page 149 16.2.9 Idling stepper engine 16.2.9.1 Working principle of idling stepper engine: Function of idling control valve is to control the circulation area of the airway next to the throttle body to regulate the amount of air entering the engine to achieve the engine idling control. 16.2.9.1 Appearance of idling stepper engine: - 144 -...
Page 150: Fuel Pump
16.2.10 Fuel pump 16.2.10.1 Working principle of fuel pump: The electric oil pumps and pressure regulator works together to provide 250Kp gas pressure to the engine, installed at the bottom of the fuel tank. 16.2.10.2 Appearance of fuel pump: - 145 -...
Page 151: Troubleshooting Diagnosis
16.2.10.3 Fuel pumps fault diagnosis: 1. After the key is turned on, the pump will operate for about 3 seconds or so; if you can hear the pump running, please go directly to 4: 2. Disconnect the pump connector, detect whether the supply voltage of the pump is about 12V; 3.
Page 152 16.3.1 Directly use fault light (F1) flashing on the instrument for diagnosis. After confirming there is a fault, if open and close the key for three times switch three times, namely, open — close—open—close—open the key, the fault light will come to a flash code corresponding to the fault. And then through the fault code table identify the corresponding fault.
Page 153 3. Open the key for diagnosis. 16.3.3 Use diagnostic software PCHUD on the laptop to check fault. PCHUD software is used to detect and record engine operating data, and it needs to connect the laptop with the six-hole diagnostic port of the engineccyle through K-line prior to the use. It needs to install the driver software for the K-line in the laptop before use.
Page 154 (5) If the software interface cannot display real-time communication data in the case of power, it needs to continue the following work, under "Setup" check whether there is problem with COM port connection settings, and the usual settings are COM Port: 4, the Baud Rate: 10400; do not Select the DTR High at the startup.
Page 155 Attached Table 1：PCHUD software parameters explanations: VRPM engine speed VTHROT throttle position VBARO BARO VMAP manifold air pressure VMAPEXP expect manifold air pressure VIGN ignition key voltage VCLTS cylinder temperature or coolant temperature VIAT intake air temperature STATUSBYTE5 STATUSBYTE5 VAFCMET airflow correction met VBAROCMET Baro update met...
Page 156 STATUSBYTE2 STATUSBYTE2 FCLCEN1 cylinder 1 close loop correction enable PPDSEBL prime pulse disable FPENABL fuel pump enable FTRNSAES acceleration enrich enter FTRNSDES deceleration enlean enter FTRNSAEDCLOAD acceleration enrich exit FTRNSDEINLOAD deceleration enlean exit FCLCEN2 cylinder 2 close loop correction enable - 151 -...
Page 157 Attached Table 2: Fault code table The MT05 fault code table Corresponding The fault description to the decimal code number Open circuit for intake pressure sensor or signal end pins shorted to battery P0107 negative P0108 Intake air pressure sensor signal end pins shorted to battery positive P0112 Intake air temperature sensor signal end pins shorted to the battery negative Open circuit for Intake air temperature sensor or signal end pins shorted to...
Page 158: Common Troubleshooting
16.4 Common troubleshooting 16.4.1 Maintenance tools Disassemble of the electronic control system components - withdrawal tools of automotive mechanical parts are often used Electronic control system circuit and system signals - digital multimeter (with buzzer) Fault diagnosis of electronic control system and detection of engine's working condition Electronic control system malfunction diagnostic apparatus (recommended) Failure diagnostic software (PCHUD,) and interface connection wire (conditional use) Electronic control system failure fault code table (emergency use)
Page 159: Concise Troubleshooting
b) Whether the oxygen sensor installation is in place - may affect system's judgment of the air-fuel ratio. c) Engine fault indicator - impacts system failure alarm d) Battery voltage - to determine the adequacy of battery power e) According to experience to judge whether the displayed value of coolant temperature sensor, intake air temperature sensor, intake manifold absolute pressure sensor and oxygen sensor is normal f) Operating range of the throttle position sensor - that it cannot be fully opened or fully closed may affect engine dynamic performance and some system functions...
Page 160 16.4.3.1 Daily use and maintenance Petrol should be such high quality unleaded petrol as 92# or 95#. ECU has a moisture barrier, but its shell may not be washed with water cannon.3} Replace the fuel filter every 7,000 ~ 10,000km. Under normal conditions of use, clean the throttle body once every 10,000 km or 1 year.
Page 161 e) Determine whether the cylinder is submerged • Fully open throttle, connected to the starter, after a few seconds, the engine should begin If so: to work f) Whether the crankshaft position sensor clearance is too large 16.4.3.3 Fault phenomenon - unable to start and accompanied by a tempering a) Check whether high-voltage lines of the ignition coil high-voltage are tightened b) Whether the timing gear ring is loose.
Page 162 c) Check whether the exhaust system is blocked, for example, whether the three-way catalytic converter is blocked due to burning oil or broken; d) Check oil pressure and nozzle. e) Check whether the fault lights are normal, or whether it is because only one cylinder can make normal ignition 16.4.3.8 Fault phenomenon—slight fire phenomenon Check whether the spark plug clearance is in line with the specification, 0.7 ~ 1 mm...
Page 163: Qj125Gy-16A Circuit Diagram
QJ125GY-16A circuit diagram...

Generic TR 125 Service Manual

Check and Maintenance of Body

1 I Braking System

2 Vehicle Housing

3 Front Wheel/Front Suspension

4 IV Rear Wheel/Rear Suspension

5 Storage Battery/Charging System

6 Ignition System

7 Starting System

8 Bulbs/Switches/Instruments

Engine Inspection and Maintenance

9 Lubricating System

10 Cooling System

11 Cylinder Head

12 Cylinder Block and Piston

13 Crankcase

Exhaust System Inspection and Maintenance

15 Emission Control System

Inspection and Maintenance of EFI System

16 EFI System Description

QJ125GY-16A Circuit Diagram

Quick Links

Troubleshooting

Need help?

Questions and answers

Related Manuals for Generic TR 125

Summary of Contents for Generic TR 125

Table of Contents