Generic XOR 125, Service Manual

Page 1: ...Service Manual Holtvej 8 10 H ruphav 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 November 2010 XOR 125 Maxi scooter...

Page 2: ...icing the scooter should carefully review the manual before performing any repair or services Major modifications and changes incorporated later will be advised to GENERIC product distributor in each...

Page 3: ...2 GENERAL INFORMATION TYPE IDENTIFICATION FUEL AND ENGINE OIL BREAK IN PROCEDURE PRECAUTIONS AND GENERAL INSTRUCTIONS SPECIFICATIONS CONTENT...

Page 4: ...are as follows FUEL Unleaded the minimum octane number is 95 or more ENGINE OIL For GENERIC SYSTEM we recommend special engine oil you can choose high quality Four stroke engine oil SHELL ULTRA 4 15W4...

Page 5: ...ch other s safety when several persons do Inspect looseness and operating state of components after reassembling them Take high care of gasoline which is explosive and never use gasoline as lotion The...

Page 6: ...5...

Page 7: ...roke 57 8mm Discharge 124 6ccm Compression ratio 9 5 1 Air cleaner dry Starting system electric and kicking start Lubricating systempressure lubricating ELECTRIC Ignition mode CDI Spark plug CR7HSA St...

Page 8: ...nd service procedures Storage battery Spark plug Cylinder head nut and exhaust pipe bolt Cylinder head and cylinder Fuel level line Air cleaner Throttle cable Engine idle speed Oil pump Gear oil Braki...

Page 9: ...I R I R 11 Fuel tank switch and lines I I I I 12 Throttle valve operation and cable I I I I R I I R 13 Engine bolts and nuts I I I I 14 piston Replace all 12500Km 15 Exhaust system I 16 Shock absorbe...

Page 10: ...year the contact Clean if any corrosion Remove the battery and charge before you store the vehicle for long time Uncover seat and then remove the battery box cap in the Middle of helmet barrel Discon...

Page 11: ...ove spark plug cap 4 Tighten the nuts evenly one by one to the their specified torque Tighten the nuts in the order indicated Tightening torque Cylinder head nut 15 18N m Exhaust pipe bolt 15 18N m Cy...

Page 12: ...irly worn down the plug should be replaced and the plug gap set to the specified gap using a thickness gauge Thickness gauge Spark plug gap 0 6 0 7 mm 0 024 0 028 inch Check the spark plug for burnt c...

Page 13: ...he core which may be slightly wet with oil Install air cleaner filter core in the reverse order of removal CAUTION Before and during the cleaning operation inspect the core for tears A tore core must...

Page 14: ...13 Tachometer Adjust the throttle stop screw to obtain the idle r min as follows Idle speed 1600 100r min Finally adjust the throttle cable play...

Page 15: ...pright and place the handlebar staight Check brake fluid level by observing the lower limit line on the brake fluid reservoir When the level is below the lower limit line replenish with brake fluid th...

Page 16: ...rapped air exposes the machine and rider it is essential that after remounting the brake and restoring the brake system to the normal condition the brake fluid circuit be purged of air in the followin...

Page 17: ...th care the fluid reacts chemically with paint plastics rubber materials etc Rear brake Turn adjusting nut so that the the play of the brake lever is 15 25MM as shown in the illustration Brake shoe we...

Page 18: ...is highly recommended to replace the tire when the remaining depth of tire tread reaches the following specification Front and rear 1 6MM 0 064IN Tire depth gauge Steering inspect at initially 500km...

Page 19: ...parts if necessary No Item N m Kg m 1 Front axle nut 55 60 5 5 6 2 Handle tightenging nut 37 44 3 7 4 4 3 Steering sterm locknut 37 44 3 7 4 4 4 Disc brake caliper fixing bolt 22 29 2 2 2 9 5 Disc br...

Page 20: ...19 14...

Page 21: ...efore lubricating each part clean off any rusty spots and wipe off any grease oil dirt of grime WARNING Be careful not to apply too much grease to the rear brake camshaft otherwise brake slippage will...

Page 22: ...inspection and servicing Bearings Oil seals crankshaft automatic clutch inspection cylinder head cylinder piston reed valve engine remounting oil seals bearings bushings crankshaft crankcase rear axle...

Page 23: ...he engine from the frame Engine left side Kicking starter lever Clutch brake pad kit Driver left face V belt Driver belt right face Electric starter gear Super clutch Driven face Engine center Carbure...

Page 24: ...ft nut 50 N m 36 9 lbf ft Steering shaft holder bolt 33 N m 24 lbf ft Wheel rim bolt 18 N m 13 3 lbf ft Tie rod lock nut 35 N m 25 8 lbf ft King pin nut 40 N m 29 lbf ft Handlebar lower holder nut 40...

Page 25: ...ed and the gasket O ring and dowel pins are in place SPECIFICATIONS ITEM STANDARD SERVICE LIMIT CYLINDER COMPRESSION 12 0 5 kg cm 2 IN 29 795 29 395 CAM LOBE HEIGHT EX 29 560 29 160 ROCKER ARM I D 10...

Page 26: ...valve timing Weak valve spring Cylinder head Leaking or damaged head gasket Warped or cracked cylinder head Faulty cylinder or piston Excessive noise Incorrect valve adjustment Sticking valve or broke...

Page 27: ...hroud compositions Relax the cam chain adjuster screw Remove the screw and O ring and tighten the cam chain adjusting bolt with clockwise direction Remove the nuts and washers Remove the camshaft hold...

Page 28: ...damage Inspect the camshaft and bearings for wear or damage and replace them if necessary Screw a 5mm bolt into the rocker arm shaft threaded end Pull on the bolt to remove the shafts and rocker arms...

Page 29: ...er arm SERVICE LIMIT 10 10 mm Measure the O D of each rocker arm shaft SERVICE LIMIT 9 91 mm CYLINDER HEAD REMOVAL Remove the flange bolts and cylinder head Remove the cylinder head gasket and dowel p...

Page 30: ...valve springs with a valve spring compressor INSPECTION Clean off all carbon deposits from the combustion chamber Check the spark plug hole and valve area for cracks Measure the cylinder head diagonal...

Page 31: ...OTE If the stem to guide clearance exceeds the service limits determine if a new guide with standard dimensions would bring the clearance within tolerance If so replace guides as necessary and ream to...

Page 32: ...TALLATION Install the new gasket and dowel pins Install the cam chain guide Install the cylinder head CAMSHAFT COMPOSITION INSTALLATION Install the rocker arms and rocker arm shafts into the camshaft...

Page 33: ...the camshaft gear with cam chain so that its I mark aligns with the cylinder head surface and the circle hole forwards front Install the dowel pins and camshaft holder Tighten the washers and nuts TO...

Page 34: ...33 Relax the cam chain adjusting bolt with counterclockwise direction and install the o ring and screw Install the cylinder head cover...

Page 35: ...15 008 15 04 PISTON PIN O D 14 994 15 000 14 960 PISTON TO PIN CLEARANCE 0 002 0 014 0 02 PISTON TO PIN CLEARANCE TOP 0 015 0 050 0 12 SECOND 0 015 0 050 0 12 PISTON RING TO RING GROOVE CLEARANCE TOP...

Page 36: ...INDER REMOVAL Remove the cylinder head Remove the cylinder Remove the cylinder gasket and dowel pins Clean off any gasket materials from the cylinder surface NOTE Be careful not to damage the gasket s...

Page 37: ...clip with needle nose pliers NOTE Do not allow the clip fall into the crankcase Remove the piston pin from the piston Remove the piston Spread each piston ring and remove it by lifting up at a point...

Page 38: ...0 10 mm Calculate cylinder taper at three levels in an X and Y axis Take the maximum reading to determine the taper SERVICE LIMIT 0 10 mm Calculate the cylinder out of round at three levels in an X an...

Page 39: ...nd measure the ring end gap NOTE Push the rings into the cylinder with the top of the piston to be sure they are squarely set in the cylinder SERVICE LIMITS TOP 0 5 mm SECOND 0 5 mm Measure the piston...

Page 40: ...RVICE LIMIT 15 06 mm PISTON INSTALLTION PISTON RING INSTALLATION Clean the piston ring grooves thoroughly and install the piston rings with the marks facing up NOTE Don t interchange the top and secon...

Page 41: ...pin with new pin clips Do not align the piston pin clip end gap with the piston cutout NOTE Do not allow the clip to fall into the crankcase CYLINDER INSTALLATION Clean any gasket material from the cr...

Page 42: ...ylinder bore and piston rings with engine oil and install the cylinder NOTE Avoid piston rings damage cylinder bore during installation Do not allow the cam chain fall into the crankcase Install the c...

Page 43: ...42 CHAPTER 4 FUEL AND LUBRICATION SYSTEM CONTENTS FUEL SWITCH CARBURETOR...

Page 44: ...pressure acts upon the diaphragm of the fuel switch and it pressed down the spring which supports the diaphragm so that the fuel passageway is opened and fuel is fed to the carburetor When the engine...

Page 45: ...RBURETOR CARBURETOR Carburetor manufacturer type Identification code Main jet size Idle needle jet size Idle air adjusting screw Float height Corundum or QJ PD24J 158 37 5 extrude 1 2 1 2 1 turnout 17...

Page 46: ...and jet settings ard made so as to satisfy and balance all of these conditions Therefore the jet should not be replaced with a size other than the original And the positions of adjustable parts shoul...

Page 47: ...46 CHAPTER 5 ELECTRICAL SYSTEM CONTENS IGNITION SYSTEM CHARGING AND LIGHTING SYSTEM STARTER SYSTEM FUEL GAUGE OIL LEVEL CHECK LIGHT AND TURN SIGNAL INDICATOR SWITCHS BATTERY...

Page 48: ...te of SCR As the SCR conducts the energy which has been charged in the capacitor is instantaneously discharged through the primary winding of the ignition coil CDI UNIT AND IGNITION COIL INSPECTION CH...

Page 49: ...ronic tester Ignition coil testing lead Use portable tester to check it Test the resistance between igntion ground wire and spark plug cap Ignition coil second resistance 12 18 KQ MAGNETO EXCITING COI...

Page 50: ...ywheel rotor turns AC generated in the charging coil flows to the regulator recifier which changes AC to DC The DC Then charges the battery Charging output check start the engine and keep it running a...

Page 51: ...cket tester to measure the resistance between the lead wire and ground If the resistance checked is not correct replace the coil Rregulator rectifier Di sconnect the lead wire couple Using the pocket...

Page 52: ...witch and battery depressing the starter button while squeezing the front or rear brake lever energizes the relay causing the contact points to close which connects the starter motor to the battery St...

Page 53: ...ground by plcing probe pins on each commutator segment and rotor core and on any two segments at various places With the brushes lifted off the commutator surface If the coil is found to be open circu...

Page 54: ...l and empty positions Connect a 90 ohm resistor between the Y B and B W lead wires The fuel meter is normal if its pointer indicates the E empty position when the specified voltage is applied to the c...

Page 55: ...nd remains lit When the turn signal switch is turned on and the turn signal light flashes the turn signal indicator light oil level check light also flashes both being not concurrently but alternative...

Page 56: ...WITCH RED ON RED WHITE MAIN SWITCH BROWN TURN RIGHT TURN LEFT DIRECTION SWITCH ORANGE GREEN BLACK GREEN WHITE PASSING LIGHT YELLOW RED PURPLE DIPPED HEADLIGHT HIGH BEAM OFF BULE AZURY EXCHANGE LIGHT S...

Page 57: ...filler holes Do not remove or pierce the sealed areas of the electrolyte container Insert the nozzles of the electrolyte container into the battery s electrolyte filler holes holding the container fi...

Page 58: ...urrent should be not more than 4A at any time After recharging wait for more than 30 minutes and apply multimeter to measure the battery voltage If the battery voltage is less than12 5V please rechare...

Page 59: ...EASSEMBLY AND REMOUNTING FRONT BRAKE BRAKE PAD REPLACEMENT CALIPER REMOVAL AND DISASSEMBLY CALIPER AND DISC INSPECTION CALIPER REASSEMBLY MASTER CYLINDER REMOVAL AND DISASSEMBLY MASTER CYLINDER INSPEC...

Page 60: ...xad screw and remove decorating cap rear carrier and oil tank lock remove side cover by loosing side cover screw 3 unlock oil pump cap and remove it two tapping screw are exposed remove them remove ta...

Page 61: ...2 removing under cover by loosing the left and right tapping screws under cover installation 3 The sequence if installation is ther reverse of removal front cover removal 1 Unscrew tapping screw and r...

Page 62: ...PEDAL REMOVAL 1 Remove power lock housing by unscrewing bolt 3 remove legshield and pedal by unscrewing the four bolts Legshield and pedal installation 4 the sequence of legshield and pedal is the re...

Page 63: ...62 HANDLE COVER REMOVAL 1 Remove front handle cover by unscrewing the six tapping screws 1 Remove master cylinder by removing the bolt...

Page 64: ...63 3 Disconnect throttle cable and oil pump cable 4 Remove rear brake cable adjusting nut...

Page 65: ...64 Handle cover removal 5 remove all cables 6 Remove handle cover by unscrewing bolt Handle cover unstallation 7 The sequence of removal is the reverse of reomval...

Page 66: ...ng 10 gearcase 11 valve mouth cap remove Remove the front brake caliper by removing the mounting bolts NOTE Do not operate the front brake lever while dismounting caliper remove mounting bolt remove t...

Page 67: ...dust seal and bearing should be replaced with new ones AXLE SHAFT Check the axle shaft runout with a micrometer and replace it if the runout exceeds the limit Service limit 0 25mm 0 010in WHEEL RIM M...

Page 68: ...llowing steps install this wheel bearing with the special tools as shown in this illustration CAUTION Install this wheel bearing for left side Install the brake disc as shown in photo When installing...

Page 69: ...he calliper 1 disc brake assy 2 disc brake handle lever 3 tightening bolt 4 nut M6 5 master cylinder 6 tightening seat 7 bolt M6X23 8 brake hose assy 9 brake caliper 10 connecting board tightening bol...

Page 70: ...and catch the brake fluid in a suitable receptacle CAUTION Nevere re use the brake fluid left over from the last servicing and stored for long periods Remove the calliper Remove the brake pads Remove...

Page 71: ...nd wear Check the disc for wear with a micrometer Its thickness can be checked with disc and wheel in place Ralpace the dise if the thickness exceeds the service limit Service Limit 3 5 mm 0 14 in Wit...

Page 72: ...per refer to preceding bove pages WARNING Bleed air after remounting the calliper refer to above pages MASTER CYLINDER REMOVAL AND DISASSEMBLY Remove the handlebar cover Refer to above page Disconnect...

Page 73: ...e dust boot Remove the circlip with the special tool Remove the piston primary cup with return spring Remove the reservoir cap and diaphragn Drain brake fluid MASTER CYLINDER INSPECTION Inspect the ma...

Page 74: ...also carry out the following steps CAUTION Wash the master cylinder components with fresh brake fluis before reassembly Never use cleaning solvent or gasoline to wash them Apply brake fluid to the cy...

Page 75: ...r brake light switch lead wires Remove the rear brake cable Remove throttle grip case Remove throttle cable 1 handle jointing assy 2 bolt GB5789 M10X1 25X45 3 nut GB6187 M10X1 25 4 left handlebar 5 th...

Page 76: ...w locknut with special tool remove fornt fork assy by removing upper outer steel bowl NOTE Not drop the steering stem balls remove front fork remove bearing lower race by chisel Remove steel balls Num...

Page 77: ...NSPECTION inspect the removed parts for the following abnormalities bearing race wear and brinelling Worn and damaged steel balls Distortion of steering stem or handlebar Inspect the suspension for da...

Page 78: ...ball Apply grease when installing the upper and lower steel balls QTY upper 21 lower 21 Tighten the steering outer race with special tool then extrude it 1 8 1 4round NOTE adjustment will vary from sc...

Page 79: ...ed torque 37 44N M NOTE After performing the adjustment and installing the handlebar rock the front wheel forward and backward to ensure that there Is not play and that the procuder is accomplished co...

Page 80: ...1 Tire 130 70 12 2 rear rim assy 3 brake pad kit assy 4 brake pad kit spring 5 rear brake tension 6 rear indicator 7 anti dust cover 8 rear brake camshaft 9 bolt M6 30 10 valve 11 nut M16 1 5 12 rear...

Page 81: ...eel Remove brake shoes INSPECTION REAR RIM Measure inner diameter of rear rim hub with micrometer if measured diameter exceeds 110 7 replace it with a new one Brake shoes Check the brake shoe and deci...

Page 82: ...rear axle shaft side Install the protrusion of indicator plate to the groove of Camshaft When installing the brake cam shaft aligh the groove of camshaft with the slit of on cam shaft When installing...

Page 83: ...82 SERVICING INFORAMTION Troubleshooting Battery Vehicle Wiring diagram Wire cable and brake hose routing Special tools Thread parts tightening torque Service data CONTENTS...

Page 84: ...CDI ignition coil unit 3 Clogged fuel hose 4 Clogged jets in carburetor 5 Clogged exhaust pipe Clean Replace Clean Clean Clean Noisy engine Noise appears to come from piston 1 Piston or cylinder worn...

Page 85: ...rings 2 Stiff piston rings in place 3 Gas leaks from crankshaft oil seal 4 Spark plug gaps incorrect 5 Clogged air cleaner element 6 Float chamber fuel level out of adjustment 7 Clogged air cleaner el...

Page 86: ...int or starter 3 Pilot outlet is clogged 4 Starter plunger is not fully close Check and clean Check and replace Check and clean Check and replace Medium or high speed trouble 1 Main jet or main air je...

Page 87: ...ten Replace Replace Magneto charge but charging rate is below the specifications 1 Lead wires tend to get shorted or open circuited or loosely connected at terminal 2 Grounded or open circuited stator...

Page 88: ...is too old Check the magneto and regulator rectifier circuit connections and make necessary adjustments to obtain specified charging operation Replace the battery and correct the charging system Repl...

Page 89: ...engine mounting Replace Replace Replace Retighten Retighten Replace Tighten Front suspension too soft 1 Weakened springs 2 Oil leakage of shock absorber Replace Replace Front suspension too stiff 1 N...

Page 90: ...ce entered into brake fluid 6 Clogged return port of master cylinder 7 Brake shoe surface glazed 8 Loose front wheel axle or rear wheel axle nut 9 Worn shoe Repair surface with sandpaper Modify and fi...

Page 91: ...90 WIRE CABLE AND BRAKE HOSE ROUTING...

Page 92: ...91 carburetor...

Page 93: ...92...

Page 94: ...93 Ignition coil Starting relay CDI HORN POWER SWITCHH...

Page 95: ...R DESCRIPTION 1 2 3 4 5 6 7 8 9 10 T01 T02 T03 T04 T05 T07 T08 T09 T10 T shape of sleeve sleeve tools 7mm 8mm 10mm 12mm 13mm flywheel remover sleeve 18mm 24mm screw remover cylinder pressure gauge pis...

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Page 97: ...mp lock screw 5 9 Right crankcase lock bolt 10 12 Bearing press board lock bolt 10 12 Cylinder double head bolt 15 18 Motor tightening bolt 10 12 Left crankcase cover lock screw 10 12 Left crankcase c...