Summary of Contents for HARTFORD CG-125
- Page 1 HARTFORD INDUSTRIAL CO.,LTD. Service manual part engine For CG-125/150 Issued date:April 1999...
- Page 2 Chapter 4 Cylinder,cylinde rhead, valves and piston Chapter 5 Generator /Star t motor Chapter 6 Clutch and gear box Chapter 7 Carburetor Chapter 8 Removing and Installing the engine Chapter 9 Maintenance Chapter10Electrical system Service manual part Engine for CG-125/150 HARTFORD INDUSTRIAL CO., LTD.
- Page 3 Chapter 1 Foreword Service manual part Engine for CG-125/150 HARTFORD INDUSTRIAL CO., LTD.
- Page 4 , which is set up with Flexible Manufacturing System (FMS) . The FMS is planned and designed by Hartford is engineering staff , and is composed of a series of Hartford machining centers .
-
Page 5: Table Of Contents
2.5 Other -------------------------------------------------------- 2-6 2.5.1 Ignition system ----------------------------------- 2-6 2.5.2 Generator ------------------------------------------ 2-6 2.5.3 Base------------------------------------------------- 2-6 2.5.4 Torque settings ----------------------------------- 2-7 2.5.5 Points for attention ------------------------------ 2-8 2.5.6 Special tools--------------------------------------- 2-9 Service manual part Engine for CG-125/150 HARTFORD INDUSTRIAL CO., LTD. -
Page 6: Chapter 2 General Specifications
Hartford Industrial Co., Ltd. 2. General Specifications Page 2.1 Profile diagram and Main part name 2.1.1 Profile diagram... -
Page 7: Main Part Name
Hartford Industrial Co., Ltd. 2. General Specifications Page 2.1.2 Main part name... -
Page 8: Engine Specifications
Hartford Industrial Co., Ltd. 2.General Specifications Page 2.2 Engine Specifications Item 125C.C.(4/5speed) 150C.C.(4/5speed) Model (CG type) Air-cooled, single-cylinder Air-cooled, single-cylinder OHV four-stroke OHV four-stroke Cylinder layout Single cylinder canted 15 Single cylinder canted 15 degrees degrees Fuel requirement 90 octane or higher... -
Page 9: General Specifications
Hartford Industrial Co., Ltd. 2.General Specifications Page 2.3 Lubrication system Item 125C.C.(4/5speed) 150C.C.(4/5speed) Oil pump type Gerotor Gerotor Oil filter type Centrifugal and screen Centrifugal and screen Oil flow rate 4.4l/min @ 8500rpm 4.4l/min @ 8500rpm Oil grade SAE 10W/30... -
Page 10: Transmission
Hartford Industrial Co., Ltd. 2.General Specifications Page 2.4 Transmission 2.4.1 Clutch Item 125C.C.(4/5speed) 150C.C.(4/5speed) Clutch type Wet multiple Wet multiple Operation Left hand Left hand Torque rating 7.6kgm 7.6kgm Number of plates 2.4.2Gear system Item 125C.C.(4/5speed) 150C.C.(4/5speed) Gearbox type (1)4 Gearbox(International) -
Page 11: Other
Hartford Industrial Co., Ltd. 2.General Specifications Page 2.5 Other 2.5.1 Ignition system Item 125C.C.(4/5 speed) 150C.C.( 4/5 speed) Type CDI electronic ignition CDI electronic ignition Ignition advance at idle 15deg BTDC @ 1400rpm 15deg BTDC @ 1400rpm Maximum advance 32~35deg @ 3500rpm... -
Page 12: Torque Settings
Hartford Industrial Co., Ltd. 2.General Specifications Page 2.5.4 Torque settings Torque Reference settings kg-m 0.45~0.6 UNT BOLT 0.8~1.2 UNT BOLT 1.8~2.5 UNT BOLT 10mm 3.0~4.0 UNT BOLT 12mm 5.0~6.0 UNT BOLT 0.35~0.5 SCREW 0.7~1.1 SCREW 1.0~1.4 RAISED EDGE SCREW 2.4~3.0... -
Page 13: Points For Attention
Hartford Industrial Co., Ltd. 2.General Specifications Page 2.5.5 Points for attention 1.After disassembling , replace all the washer , oil-ring and clips. 2.Fasten the nuts by the diagonal way. 3.Use the specified parts and lubricating oil. 4.Use the tools by the rules. -
Page 14: Special Tools
Hartford Industrial Co., Ltd. 2.General Specifications Page 2.5.6 Special tools... - Page 15 Hartford Industrial Co., Ltd. 2.General Specifications 2-10 Page VALVE IN & OUT TOOL VALVE IN & OUT TOOL (PART NO.:60000340) CRANKCASE ASSEMBLY FRAMF (PART NO.:60000310)
- Page 16 3.3 Idle or show running poor ------------------ 3.4 Poor high speed running-------------------- 3.5 Starter motor inoperable -------------------- 3.6 Start motor turns constantly ---------------- 3.7 Engine noisy ----------------------------------- 3.8 High noxious emissions --------------------- Service manual part Engine for CG-125/150 HARTFORD INDUSTRIAL CO., LTD.
-
Page 17: Engine Is Difficult Or Impossible To Start
Hartford Industrial Co., Ltd. 3.Reason a breakdown Page 3.1 Engine is difficult or impossible to start Check Possible cause Possible reason Remove carburetor screws, check if there 1. No fuel in tank is fuel 2. Fuel tap blocked 3. Fuel hose blocked... -
Page 18: Engine Output Poor
Hartford Industrial Co., Ltd. 3.Reason a breakdown Page 3.2 Engine output poor Check Possible cause Possible reason 1.Air filter blocked Test idle 2.Fuel delivery insufficient 3.Fuel cap vent blocked 4.Exhaust blocked Engine won’ t idle Engine idles 1.Clutch slipping Vehicle does not 2.Clutch face damaged or faulty... -
Page 19: Idle Or Show Running Poor
Hartford Industrial Co., Ltd. 3.Reason a breakdown Page 3.3 Idle or slow running poor Check Possible cause Possible reason Check ignition timing 1.CDI or AC generator faulty Ignition timing correct Ignition timing 2.Valve clearance incorrect incorrect Check carburetor 1.Choke not returning to... -
Page 20: Poor High Speed Running
Hartford Industrial Co., Ltd. 3.Reason a breakdown Page 3.4 Poor high speed running Check Possible cause Possible reason Check ignition timing 1.CDI faulty Correct Incorrect 2.AC generator faulty 3.Spark plug fouled or fuel mixture incorrect Check fuel flow to carburetor 1.Not enough fuel in tank... -
Page 21: Starter Motor Inoperable
Hartford Industrial Co., Ltd. 3.Reason a breakdown Page 3.5 Starter motor inoperable Check Possible cause Possible reason Switch on turn signal, check battery leads Flash 60 to 20 times per Starter motor turns No flash or no light 1. Fuse broken... - Page 22 Hartford Industrial Co., Ltd. 3.Reason a breakdown Page 3.6 Starter turns constantly Check Possible cause Possible reason Motor still turns Starter solenoid short circuit Switch off ignition Motor stops Starter drive gear return faulty...
-
Page 23: Engine Noisy
Hartford Industrial Co., Ltd. 3.Reason a breakdown Page 3.7 Engine noisy Possible cause Possible reason 1.Valve adjustment excessively loose Tapping 2.Valve rocker arms worn 1.Cylinder or piston worn 2.Combustion chamber carbon deposits Piston slap excessive 3.Piston pin or connecting rod worn or... -
Page 24: High Noxious Emissions
Hartford Industrial Co., Ltd. 3.Reason a breakdown Page 3.8 High noxious emissions CO level HC level Possible cause 1. Ignition system faulty a. Ignition timing incorrect b. Spark plug fouled or gap incorrect c. Voltage regulator faulty High Normal d. Ignition coil faulty e. - Page 25 4.4.8 Inspect the valves and valve guides ---------------4-8 4.4.9Inspect/overhaul the valve seats ---------------------4-9 4.5 Installing the cylinder --------------------------------------------4-10 4.5.1Installing the cylinder ------------------------------------4-10 4.5.2Installing the piston rings -------------------------------4-11 4.5.3Installing the cylinder head ----------------------------4-12 Service manual part Engine for CG-125/150 HARTFORD INDUSTRIAL CO., LTD.
-
Page 26: Chapter 4 Cylinder,Cylinder Head,Valves And Piston
Hartford Industrial Co., Ltd. 4.Cylinder,cylinder head,valves and piston Page 4.1Reason a breakdown Compression pressure low Valves Cylinder head. Valve clearance incorrect. Cylinder head gasket damaged and leaking. Valve bent or burnt. Cylinder head warped. Valve timing incorrect. Compression too high. -
Page 27: Specifications
Hartford Industrial Co., Ltd. 4.Cylinder,cylinder head,valves and piston Page 4.2Specifications Part Item Specification Service limit Rocker arms Inner diameter 12.000~12.018mm 12.1mm Rocker spindle Outer diameter 11.984~11.966mm 12.0mm Pushrod Cup radius and length 6.5mm/141.5mm ---------- Outer valve spring Free length 40.9mm 39.7mm... -
Page 28: Removing Cylinder
Hartford Industrial Co., Ltd. 4.Cylinder,cylinder head,valves and piston Page 4.3 Removing the cylinder 4.3.1 Removing the cylinder head cover Remove the 6mm x 12mm screws Remove three 6mm x 28mm cylinder head screws Remove the valve cover and gasket Cylinder head... - Page 29 Hartford Industrial Co., Ltd. 4.Cylinder,cylinder head,valves and piston Page 4.3.3 Removing the cylinder Removing the cylinder Note: to prevent distortion or damage to the cylinder or piston, Piston pin avoid the use of excessive force disassembling Remove the piston pin clips and...
-
Page 30: Inspection And Overhaul
Hartford Industrial Co., Ltd. 4.Cylinder,cylinder head,valves and piston Page 4.4 Inspection and overhaul 4.4.1Check the holder comp pkr Inspect the rocker support and pushrod cups for wear or damage Check the rocker spindle bore for wear, scuffing or burning Rocker bore service limit: 12.1mm 4.4.2 Check the pushrod... -
Page 31: Check The Piston
Hartford Industrial Co., Ltd. 4.Cylinder,cylinder head,valves and piston Page 4.4.5Check the piston Measure the piston ring to groove clearance Remove the piston rings Inspect the piston rings for scoring or damage. Measure the piston pin hole diameter and ovality Service limit : 15.05mm... -
Page 32: Check The Cylinder Head
Hartford Industrial Co., Ltd. 4.Cylinder,cylinder head,valves and piston Page 4.4.6Check the spring valve Measure the free length of the valve springs Inspect the piston rings for scoring or damage Measure the piston pin hole diameter and ovality Outer spring service limit: 39.7mm Inner spring service limit: 32.5mm... -
Page 33: Inspect The Valves And Valve Guides
Hartford Industrial Co., Ltd. 4.Cylinder,cylinder head,valves and piston Page 4.4.8 Inspect the valves and valve guides Inspect the valve stems for scoring, damage or burning. Check that the valves move freely inside the valve guides. Measure the diameter of the valve stems Valve guide inside diameter service limit. -
Page 34: Valve Seats
Hartford Industrial Co., Ltd. 4.Cylinder,cylinder head,valves and piston Page 4.4.9 Inspect / overhaul the valve seats Remove the carbon deposits from the inlet and exhaust valves. Place a smear of red ink on the valve contact face and rotate the valve in it’... - Page 35 Hartford Industrial Co., Ltd. 4.Cylinder,cylinder head,valves and piston 4-10 Page 4.5Install the cylinder 4.5.1Install the cylinder Guide putrid Always install new valve stem seals when replacing the valves Lubricate the valve stems with oil and replace them Install the valve springs retainers...
- Page 36 Hartford Industrial Co., Ltd. 4.Cylinder,cylinder head,valves and piston 4-11 Page 4.5.2Reinstall the piston rings Reinstall the piston rings with the gaps spaced at 120 degrees around the piston Avoid damaging the piston or rings during installation The mark on the piston ring...
- Page 37 Hartford Industrial Co., Ltd. 4.Cylinder,cylinder head,valves and piston 4-12 Page 4.5.3Install cylinder head Replace the three 10mm x 20mm Guide pushrod cylinder head locating dowels. Replace the cylinder head with a new gasket. Replace the rocker arms and support assembly.
- Page 38 Hartford Industrial Co., Ltd. 4.Cylinder,cylinder head,valves and piston 4-13 Page Smear some grease into the rocker arm and before engaging the pushrods Pour a little fresh engine oil into the cylinder head. Check that the“T”mark on the alternator still aligns with pointer in...
- Page 39 5.1.3Installing the generator rotor--------- 5-1 5.1.4Installing the lift crank case ---------- 5-1 5.2 Start motor--------------------------------- 5.2.1Removing the start motor ----------- 5-2 5.2.2Removnig the start drive gears ---- 5-2 5.2.3Installing the start motor ------------- 5-2 Service manual part Engine for CG-125/150 HARTFORD INDUSTRIAL CO., LTD.
- Page 40 Hartford Industrial Co., Ltd. 5.Generator/Start motor Page 5.1Generator 5.1.1Removing the lift crank case Remove the starter gear cover Remove the gearshift pedal Remove the alternator cover The alternator is retained in the cover by four screws which can be removed to dissemble it 5.1.2 Removing the generator rotor...
- Page 41 Hartford Industrial Co., Ltd. 5.Generator/Start motor Page 5.2 Start motor 5.2.1Removing start motor Remove the starter motor cable from the terminal Bolt flange Remove the starter motor retaining screws. Remove the starter motor 5.2.2 Removing the starter drive gears Remove the starter motor drive gear shaft...
- Page 42 6.1Reason a breakdown ------------------------- 6.1.1Removing the right crank case cover 6.2Clutch--------------------------------------------- 6.2.1Removing the clutch ------------------------ 6.2.2Check the clutch----------------------------- 6.3Transmission ----------------------------------- gearshift mechanism 6.3.1Removing the 6.3.2Installing the right crank case cover ---- Service manual part Engine for CG-125/150 HARTFORD INDUSTRIAL CO., LTD.
-
Page 43: Chapter 6 Clutch/Transmission
Hartford Industrial Co., Ltd. 6.Clutch/Transmission Page 6.1 Reason a breakdown If the clutch operation is faulty, first attempt to cure the condition by adjusting the clutch cable. A)Clutch slips under acceleration 1.No slack in the clutch cable 2.Clutch plates worn 3.Clutch springs weak... -
Page 44: 1Removing The Right Crank Case Cover
Hartford Industrial Co., Ltd. 6.Clutch/Transmission Page Special tools Four-leg socket wrench Air impact wrench Tightening torque Clutch cover screws:0.8~1.2 kg/m Oil filter cover screws:4.0~5.0 kg/m Item New specification Service limit Clutch operating arm free slack 10~20mm Clutch spring free length 35.5mm... -
Page 45: Clutch
Hartford Industrial Co., Ltd. 6.Clutch/Transmission Page 6.2Clutch 6.2.1Removing the clutch Remove the clutch pushrod. Remove the centrifugal oil filter body. Use the four-leg socket wrench and air impact wrench to remove the16 mm retaining nut. Rod clutch filter Remove the oil filter body. -
Page 46: 2Check The Clutch
Hartford Industrial Co., Ltd. 6.Clutch/Transmission Page 6.2.2Check the clutch Pressure Clutch Friction Clutch plate plate plate center l Inspecting the friction plates Measure the thickness of the friction plates and inspect for wear, scoring or damage. Replace as complete set if necessary Service limit: 2.5mm... -
Page 47: Transmission
Hartford Industrial Co., Ltd. 6.Clutch/Transmission Page 6.3 Transmission 6.3.1Removing the gearshift mechanism Remove the gearshift mechanism Remove the clutch Remove the gearshift pedal Remove the gearshift shaft Spindle comp gear Note:when removing the gearshift shift shaft,note the gearshift shaft return... - Page 48 Hartford Industrial Co., Ltd. 6.Clutch/Transmission Page Remove the gearshift detent arm Remove the gearshift cam Spindle Check all parts for wear or damage comp gear shift Cam gear Stopper comp gear shift drum Reassembling the gearshift mechanism Locate the rollers and install the...
- Page 49 Hartford Industrial Co., Ltd. 6.Clutch/Transmission Page Installing the gearshift shaft Install the gearshift pedal and check the smooth operation of the gearshift mechanism Cam gear shift Stopper comp gear shift drum Replace the clutch Spindle comp gear shift Replace the oil pump...
- Page 50 7.2.4 Removing the float and float needle -- 7.2.5 Installing the float and float needle ---- 7.2.6 Replace the throttle slide ---------------- 7.2.7 Inspecting the float needle -------------- 7.2.8 Adjusting the float height----------------- Service manual part Engine for CG-125/150 HARTFORD INDUSTRIAL CO., LTD.
-
Page 51: Reason A Breakdown
Hartford Industrial Co., Ltd. 7.Carburetor Page 7.1 Reason a breakdown Engine fires but doesn’ t run. No fuel in the fuel tank. Fuel not reaching the carburetor. Fuel mixture excessively rich. No spark at spark plug (ignition system faulty). Air-filter blocked. -
Page 52: Names Of Carburetor Parts
Hartford Industrial Co., Ltd. 7.Carburetor Page 7.2Carburetor Air control 7.2.1Names of carburetor parts lever Oil cup Throttle valve Air control lever Throttle Oil cup Float valve Float Needle Float bowl Needle screws Spring Spring Carburetor top Carburetor top Float bowl screws 7.2.2Removing the carburetor... - Page 53 Hartford Industrial Co., Ltd. 7.Carburetor Page 7.2.3Throttle valve Needle lock spring Throttle valve Remove the needle lock spring Remove needle,needle lock clip Needle Examine needle and throttle valve for wear or damage Needle lock clip 7.2.4Removing the float and float needle...
- Page 54 Hartford Industrial Co., Ltd. 7.Carburetor Page Remove the jets,float needle and needle valve seat. Main needl Note: Do not damage the jets Remove the idle mixture screw Note: Before removing the idle Float needle mixture screw. Screw the adjuster screw in. Fully counting the turns...
- Page 55 Hartford Industrial Co., Ltd. 7.Carburetor Page 7.2.7Inspecting the float needle Examine the float and float needle for wear or damage Abrade 7.2.8Adjusting the float height The float height is set by bending the float tang Use the special gauge to measure the float height Correct float height----- 125C.C:14.5mm(Model PD026A)
- Page 56 Chapter 8 Removing and installing the engine 8.1Removing and installing the engine --- 8.1.1Removing the engine ------------------- 8.1.2Installing the engine --------------------- Service manual part Engine for CG-125/150 HARTFORD INDUSTRIAL CO., LTD.
- Page 57 Hartford Industrial Co., Ltd. 8.Removing and installing the engine Page 8.1Removing and installing the engine 8.1.1Removing the engine Drain the engine oil Turn the fuel valve to the “OFF” position. Remove the cover left rear crank case and pedal gear change.
- Page 58 Hartford Industrial Co., Ltd. 8.Removing and installing the engine Page Removing the spark plug cap Removing the spank plug Spank plug Spank plug cap Removing the carburetor mounting nuts and dismount the carburetor. Mounting nut Remove the crankcase exhaust hose.
- Page 59 Hartford Industrial Co., Ltd. 8.Removing and installing the engine Page Removing the exhaust pipe nuts Removing the exhaust pipe Removing the bar comp step Removing the front engine mounting Exhaust pipe plate Exhaust pipe nut Note: Before removal, support the...
- Page 60 9.1.2Change the engine oil ---------------- 9-1 9.1.3Clean the oil filter room -------------- 9-3 9.1.4Clean the oil filter screen ------------ 9-3 9.1.5Check the spark plug ----------------- 9-3 9.2 Periodic maintenance and check--------- 9-4 Service manual part Engine for CG-125/150 HARTFORD INDUSTRIAL CO., LTD.
-
Page 61: Chapter 9 Maintenance
Hartford Industrial Co., Ltd. 9.Maintenance Page 9.1Engine oil/Oil filter 9.1.1Check the engine oil 1.Place the motorcycle on the main stand. 2.Remove the dipstick and wipe it clean with cloth. 3.Insert the dipstick back into the engine. 4.Remove the dipstick once more and observe the level. - Page 62 Hartford Industrial Co., Ltd. 9.Maintenance Page 20W -50 15W -40 10W -30 5W-30 °C °F Engine oil to suit thermometer Recommended oil for use: Use APISG rated oil or a premium grade engine oil. Recommended oil viscosity 1. In normal climates use SAE 10W-30 or premium grade.
-
Page 63: 3Clean The Oil Filter Room
Hartford Industrial Co., Ltd. 9.Maintenance Page 9.1.3Clean the oil filter room Remove the exhaust pipe Remove the footrests Remove the clutch cable Remove the kickstarter Remove the clutch cover Oil filter Remove the oil filter cover room Clean as necessary Clean the oil filter screen 9.1.4Clean the oil filter screen... -
Page 64: Periodic Maintenance And Check
Hartford Industrial Co., Ltd. 9.Maintenance Page 9.2Periodic maintenance and check I:Inspect A:Adjust C:Clean R:Replace T:Tighten Inspection period After the first Every month Every Every 300km and 1000~1500km 3000km 6000km every 1000km Item to inspect /replace Engine oil transmission oil Clutch... - Page 65 Chapter 10 Electrical system 10.1 CDI ------------------------------------------- 10-1 10.2 Starter switch assy------------------------ 10-2 10.3 Regulator------------------------------------ 10-3 10.4 Coil comp ----------------------------------- 10-4 10.5 Electrical assembly draw------------ 10-5 Service manual part Engine for CG-125/150 HARTFORD INDUSTRIAL CO., LTD.
-
Page 66: Chapter 10 Electrical System
Hartford Industrial Co., Ltd. 10.Electrical system 10-1 Page 10.1 CDI... -
Page 67: Starter Switch Assy
Hartford Industrial Co., Ltd. 10.Electrical system 10-2 Page 10.2 Start switch assy... -
Page 68: Regulator
Hartford Industrial Co., Ltd. 10.Electrical system 10-3 Page 10.3 Regulator... -
Page 69: Coil Comp
Hartford Industrial Co., Ltd. 10.Electrical system 10-4 Page 10.4 Coil comp... -
Page 70: Electrical Assembly Draw
Hartford Industrial Co., Ltd. 10.Electrical system 10-5 Page Electrical assembly draw 10.5 R E A R B R A K E A S S Y (IN ) W I N K E R R E L A Y ( IN)