125 4T 4V En g i n e
125 4T 4V Eng ngin inee 1. Engine Techn Technical ical Charact Characteeristic ris ticss
3.7. Timing
2. Periodical riodical checks
3.8. Lubrication circuit
2.1. Valve clearance adjustment
3.9. Cooling circuit
2.2. Idle speed adjustment
3.10. List of special tools
2.3. Engine oil change
3.11. Tightening torque settings
2.4. Coolant replacement 2.5. Spark plug 3. Engine Engin e 3.1. Engine overview 3.2. Cylinder Cylinder head - Camshafts Camshafts 3.3. 3.3. Cylind Cylinder er – Piston Piston 3.4. Crankshaf Crankshaftt – Crankcase Crankcase 3.5. 3.5. Clutc Clutchh – Gearbo Gearboxx 3.6. Balancing countershaft
4. F Fue uell syste syst em - Emissions 4.1. Carburettor 4.2. Secondary air system – Cataly Catalytic tic conver converter ter 5. Igni Ignitio tionn 5.1. System description 5.2. Components
125 4T 4V Eng ngin inee 1. Engine Engin e Technical echni cal Characteri Characterist stic icss •
Type: 4-stroke and 4-valve single-cylinder, liquid-cooled engine (Euro3)
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Timing system: Double overhead camshaft, morse chain-driven
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Engine capacity capacity:: 124.2 cm³
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Bore x stroke: stro ke: 58 x 47 mm
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Compression ratio: 12 : 1
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Cylinde Cylind er head head material: material: Aluminium Aluminium casting casting
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Cylinde Cylind er mate m aterial: rial: Cast iron casting
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Idle: 1680 1680 +/+/- 50 rpm rpm
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CO value: val ue: 3.1 - 4.5 % (at idle idle and oil tempe temperatur raturee at about about 90º C)
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Power supply: supply : Keihin CVK 30 carburettor
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Lubrication system: With semi-dry sump
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Transmission: With gears, and with 6 gear manual change, multi-disk wet clutch and final drive by chain
125 4T 4V Eng ngin inee 1. Engine Engin e Tech Techni nical cal Characteris Characteristitics cs •
Ignition gniti on type typ e: Electronic CDI type (Capacitive (Capacitive Discharge Ignition) Ignition )
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Ignition Igniti on advance: advance: Variable electronic advance
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Curr urreent generator: generator: 190W three phase (13V, 14A at 8000 rpm)
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Spark plug: NGK CR8EB
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Battery: 12V 6Ah, maintenance free
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Maximum nomina nomin al power: p ower: bhp: 15.5 kW: 11.4 at 9250 rpm, at the crankshaft bhp: 14.0 kW: 10.3 at 9250 rpm, at the rear wheel
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Maximum nomina nomin al torque: t orque: kg·m: 1.22
N·m: 12 at 8500 rpm, at the crankshaft
kg·m: 1.10
N·m: 10.8 at 8500 rpm, at the rear wheel
125 4T 4V Eng ngin inee 2.1. 2.1. Va Valv lvee clea cl earanc rancee adjust adju stment ment •
Valv Va lvee clea cleara ranc ncee shal shalll be adju adjuste stedd at 6000 6000,, 2400 24000, 0, 480 48000 00,, 7200 72000K 0Km… m…
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Valv Va lvee clea cleara ranc ncee is adj adjus uste tedd by selec selectition on of of the the cali calibr brat ated ed tap tappe pets ts..
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Tappet Tappetss are are avail availabl ablee in in vario various us size sizes, s, from from 2.20 2.20 mm mm min minimu imum m to to 2.75 2.75 mm, and withi withinn this range every 0.05 mm (see table).
Tap Tappets inner su surrface sh sho ows two codes, a 4-digit one and a 3-digit one. The The 3-d -diigit code indicates thickness, e.g.: 450 corresponds to 2.45 mm.
125 4T 4V Eng ngin inee 2.1. 2.1. Va Valv lvee clea cl earan rance ce adj adjus ustm tment ent Procedure (with cold engine) • Remove Remove the plasti plasticc caps caps from from flyw flywhee heel-s l-side ide cover. cover. • Set the the piston piston at at TDC in the the compres compression sion stroke stroke;; to obtain obtain this, turn the cranks crankshaft haft counter clockwise (on (on flywheel side) and make sure the reference dot on flywheel flywheel matches with the reference on flywheel cover. In these conditions, cams must be divergent. • Using a feeler feeler gauge gauge,, check check that that clearanc clearancee between between cam cam and and tappets tappets complies complies with with the the values below: Intake: Exhaust:
0.10 - 0.15 mm (Value (Value A in the figure) figure) 0.15 0.15 - 0.20 0.20 mm mm (Val (Value ue B in in the the figur figure) e)
125 4T 4V Eng ngin inee 2.1. 2.1. Va Valv lvee clea cl earanc rancee adj adjus ustm tment ent Inspection plugs
125 4T 4V Eng ngin inee 2.1. 2.1. Va Valv lvee clea cl earan rance ce adj adjus ustm tment ent •
If clea cleara ranc ncee is is not not corr correc ect, t, disa disass ssem embl blee tthe he timi timing ng syst system em:: – Set the camshaft timing ti ming pins in their housing – Remove the timing chain ch ain tensioner – Using a calliper spanner, span ner, lock the camshaft sprockets and remove the screws – Remove the sprockets and chain – Remove the cam tower retaining screws, the t he cam tower and the camshafts ca mshafts – Remove the tappets and a nd check its thickness thic kness by means of the 3-digit code
125 4T 4V Eng ngin inee 2.1. 2.1. Va Valv lvee clea cl earan rance ce adj adjus ustm tment ent •
Now calcul calculate ate the suitab suitable le requir required ed tappet tappet thickn thickness ess accord according ing to the follow following ing formula: – New tappet thickness thick ness = (B – A) + C [mm] Where Where A = Required Required (intake (intake or exhaust exhaust)) clear clearance ance B = Value measured with the feeler gauge C = Thickness of installed tappets Example (exhaust valve): A= 0.20
B= 0.10
C= 2.40
– New tappet thickness = (0.10 - 0.20) + 2.40 = 2.30 mm
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Once Once you you select select the suitab suitable le tappet tappets, s, reas reassem semble ble the timing timing system system follow following ing the disassembly procedure in the reverse order. Smear some sealant on sprocket
125 4T 4V Eng ngin inee 2.2. 2.2. Idle spee sp eedd adjustm adjus tment ent •
Idlin ling sh shall be 16 1680 + / - 50 rrppm wit withh wa warm en engine ine
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Adjust ust by by me means of of th the ca carburett rettoor scr screew
Adjuster screw
125 4T 4V Eng ngin inee 2.3. 2.3. Engine Engin e oil change c hange •
Cha Change at at 1, 1,000 000 km km an and the thenn ev every 6,00 ,000 km. km.
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Oil type: AGIP TEC 4T 4T (SAE 10W40)
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Oil + filter = 1150 cm3 (check level by fully screwing up the dipstick)
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Tota Totall qua quant ntitityy in in cas casee of engi engine ne disa disass ssem embl blyy = 1200 1200 cm3
Replaceme Replacement nt procedure pro cedure (with engine warm): •
Slac Slacke kenn dip dipsstick tick A to to hel help oi oil dra drain inag agee
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Remov emovee scr screw ew B. Remove move the the oil oil pre-f re-fiilter lter..
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Loosen the oil filter C.
A
2nd notch MAX 1st notch MIN
C
125 4T 4V Eng ngin inee 2.4. Coolant replacement •
It is rec recom omm mende endedd to to ch change ange it eve everry 2 yea years. rs.
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Remo Remove ve the the 2 slee sleeve vess conn connec ecte tedd to pump pump cove cover. r.
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Coolant qu quantity: 1130 ml – 770 ml: radiator + engine engine – 360 ml: expansion tank
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Reco ecommen mmende dedd coo coolant lant:: AGIP GIP plus lus 30%. 30%.
125 4T 4V Eng ngin inee 2.5. 2.5. Spark plu p lugg Spark Spark plug pl ug type: ty pe: •
NGK CR8EB
Electr Electrode ode gap: •
0.7 ÷ 0.8 mm
Inspection Inspectio n / Replaceme Replacement: nt: •
6000 km/ 12000 km
125 4T 4V Eng ngin inee 3. Engin ng inee 3.1. 3.1. Engine Engi ne overvi ov erview ew Weight: 26 kg Height: 385 mm Width: 322 mm Depth: 278 mm
125 4T 4V Eng ngin inee 3.2. Cylinder yli nder head head - Camshafts msh afts •
Made Made in in alum alumin iniu ium, m, itit feat featur ures es fou fourr valv valves es and and dou doubl blee over overhe head ad cam camsh shaf aft. t. Camshafts are different, please identify them by making reference to the letter punched punched onto them: “A” or “S “S””
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Smea Smearr som somee oil oil onto onto the the was washe hers rs for for the the 4 scre screws ws reta retain inin ingg hea headd to to crankcase.
“A” “A” = Int Intak akee
125 4T 4V Eng ngin inee 3.2. Cylinder yli nder head head - Camshafts msh afts •
When When ins insta tallllin ingg any any timi timing ng sys syste tem m comp compon onen ents, ts, make make sur suree that that the the driv drivee gear gear (sp (spro rock cket et)) is correctly in place on the crankshaft.
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The punche punchedd dot dot must must be be facin facingg outwa outwards rds (visib (visible) le).. If itit is insta installlled ed with with the dot dot inwar inwards, ds, gear (1) and timing sprockets (2) will be offset and not in line. 2
1
125 4T 4V Eng ngin inee 3.3. Cylind Cylindeer – Piston •
The The cyli cylind nder er is is made made in in cast cast iro ironn and and is avai availa labl blee in four four siz sizes es (cat (categ egor orie ies) s):: M, N, N, O, P. P.
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The The pis pisto tonn is is als alsoo ava availilab able le in four four size sizes: s: M, N, O, P.
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In orde orderr to correc correctly tly positi position on the the pist piston, on, please please refer refer ttoo the the arrow arrow punche punchedd on piston piston crown crown that shall be pointing to the exhaust. CA TEGORY
CYL INDER
PISTON
MIN (mm) (mm )
MAX (mm )
MIN (mm) (mm )
MAX (mm) (mm )
PISTON CODE
M
58.010
58.017
57.953
57.960
8745340001
N
58.017
58.024
57.960
57.967
8745340002
O
58.024
58.031
57.967
57.974
8745340003
P
58.031
58.038
57.974
57.981
8745340004
Assembly clearance 0.050 - 0.064 mm
125 4T 4V Eng ngin inee 3.3. Cylind Cylindeer – Piston •
Cylind Cylinder er base base gask gasket et thickn thickness ess shall shall be calcul calculate atedd in in orde orderr to to ensu ensure re the correc correctt compression ratio. Three thickness sizes of base gasket are available: 0.3 / 0.4 / 0.5 mm
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Make Make this this cal calcu cula latition on usi using ng a dial dial gau gauge ge:: do not not inst instal alll any any gask gasket et..
125 4T 4V Eng ngin inee 3.4. Cranksha ranksh aft – Crankcase •
The The cran cranks ksha haft ft is is mate matedd to the the cra crank nkca case se by by mean meanss of dul dulyy size sizedd bush bushin ings gs..
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To open open the crankc crankcase ase,, remov removee the the 13 13 coupl coupling ing screws screws of the crankc crankcase ase halves halves,, worki working ng from flywheel side. Screws pos. 79 and 81 are of the same length; screw pos. 80 is the longest one while screw pos. 82 is the shortest.
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The The cra crank nkca case se to be remo remove vedd is is the the one one on on tthe he flyw flywhe heel el side side..
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Gask Gasket et pos pos.. 84 shal shalll be be repl replac aced ed ever everyy time time the the cran crankc kcas asee is is open opened ed..
125 4T 4V Eng ngin inee 3.4. Cranksha ranksh aft – Crankcase •
Before Before closin closingg the the crank crankcas case, e, rrefi efitt the the plasti plasticc nozzl nozzlee for for gearb gearbox ox lubr lubrica icatio tionn (Figu (Figure re 1) 1)
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When When closi closing ng the the crankc crankcase ase,, use use the the suitab suitable le tool tool code code 00H056 00H056003 00351 51 (50 2T gear gearbox box secondary shaft oil seal tool) to avoid damaging the seal ring (Figure 2)
1
2
125 4T 4V Eng ngin inee 3.4. Cranksha ranksh aft – Crankcase •
Crankc Crankcase asess are are clas classif sified ied in two size size class classes, es, which which differ differ in the diamet diameter er of of the the main main bearing seat. The class 1 or 2 is indicated outside both crankcase halves, in the area shown in the figure, according to the sizes indicated in the table. MIN (mm)
MAX (mm)
TY TY P E 1
36.50 .500
36.50 .508
TY TY P E 2
36.50 .508
36.51 .516
125 4T 4V Eng ngin inee 3.4. Cranksha ranksh aft – Crankcase •
Cranks Crankshaf hafts ts are are clas classif sified ied in two two size size classes classes,, which which differ differ in the the diam diamete eterr of the main main journals. The class 1 or 2 is indicated on every counterweight counterweight (referred to its journal), journal), in the area shown in the figure and according to the sizes indicated in the table. TY TY P E 1 TY TY P E 2
MIN (mm) 32.48 .480 32.48 .485
MAX (mm) 32.48 .485 32.49 .490
CRANKSH KSHAFT CODE CRANKCA KCASE CODE 8711475001 CM15 CM1569015001 8711475002 CM15 CM1569015002
125 4T 4V Eng ngin inee 3.4. Cranksha ranksh aft – Crankcase •
Crankc Crankcase ase and cranks crankshaf haftt class classes es dete determi rmine ne the the thic thickne kness ss of of the the main main semi-b semi-bush ushing ingss to be installed, i.e. their suitable colour.
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Plea Please se refe referr to to the the tabl tablee bel below ow for for sel selec ectition on.. CRANKCASE
TY TY P E 1
TY P E 2
TY TY P E 1
RED + BLUE
BLUE + BLUE
TY TY P E 2
RED + RE D
RE D + BLUE
SHAFT
NB: Diametral Diametral clearance between between main journal and and bushing: 0.020 0.020 - 0.050 mm
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Upper Upper and lower lower semi semi-bu -bushi shings ngs of the the same same colou colourr have have diff differe erent nt code codess (see (see table) table)
RED
MIN MIN (mm) (mm)
MAX (mm) (mm)
LOWER LOWER SEMISEMI-BUSHI BUSHIN NG COD CODE (without oilways)
UP P ER SEMI SE MI--BUSHI BUSHIN NG COD CODE (with oilways)
2.005
2.010
864591
864589
125 4T 4V Eng ngin inee Example •
If an an engi engine ne has class class 1 crankc crankcase ase (diame (diameter ter betwe between en 36.5 36.500 00 and and 36.508 36.508 mm) and class class 2 crankshaft (diameter between 32.485 and 32.490 mm), you shall use two RED semibushings, code 864591 and 864589.
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If cran crankca kcases ses featur featuree mixe mixedd semi semi-bu -bushi shings ngs,, they they can be swappe swappedd comp compare aredd ttoo tthei heir r original position.
125 4T 4V Eng ngin inee 3.5. Clutch lut ch – Gearb rbox ox •
The The clu clutc tchh bel belll (an (andd its its driv drivee gea gear) r) are are cla class ssififie iedd in in two classes according to the crankcase class, featuring a different centre distance between crankshaft and gearbox primary shaft.
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The The cla class ss X or or Y is indic ndicaated ted out outsi side de both oth crankcase halves, in the area shown in the figure, according to the sizes indicated in the table.
TY TY P E X TY TY P E Y
MIN (mm (mm) 86.00 .00 85.96 .96
MAX (mm (mm) 86.04 .04 86.00 .00
125 4T 4V Eng ngin inee 3.5. Clutch lut ch – Gearb rbox ox •
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To red reduce uce nois noisee and fri frictio ctionn betwe etween en pinion and clutch bell, use the following data to find out the correct coupling parts according to crankcase class: BE LL
P INION
TY TY P E X
X
X
TY TY P E Y
Y
Y
Classes X an and Y fo for clutch bell and pinion correspond to the codes indicated in the table TY TY P E X TY TY P E Y
P INION CODE 8714475001 8714475002
BE LL CODE 8714605001 8714605002
N.B.: Spare crankcases are always X class
125 4T 4V Eng ngin inee 3.5. Clutch lut ch – Gearb rbox ox •
Ther Theree are are 5 fric frictition on (dr (driv ive) e) pla plate tess (56) (56) and and 4 stee steell (dri (drive ven) n) pla plate tess (57) (57)
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Pay attent attention ion upon upon fricti friction on plat plates es inst install allati ation: on: lubr lubrica icatio tionn chann channels els shall shall be be facin facingg back back with respect to the direction of rotation (see figure)
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The thrust thrust plate plate (58) (58) featur features es just just one assemb assembly ly posi positio tionn on on drum drum and this this ensur ensures es correct compression of the plates pack
125 4T 4V Eng ngin inee 3.5. Clutch lut ch – Gearb rbox ox •
The gearbox features 6 speeds
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The primary sh shaft ca can not be be overhauled
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The The seco econdar ndaryy shaf shaftt asse ssembly mbly leng length th is 92.2 +0.10/-0.18 mm TR 1st = 73/24 1st = 33/11 2nd = 30/15 3rd = 27/18 4th = 24/20 5th = 27/25 6th = 22/23
In order to keep operation clearance within the specified limits, you shall select shim code CM15710X
125 4T 4V Eng ngin inee 3.6. Balanci Balancing ng countersh cou ntershaaft •
To obtain obtain correc correctt timin timing, g, align align refere reference nce mark mark on on bala balanci ncing ng counte countersh rshaft aft gear gear with the one on crankshaft pinion.
125 4T 4V Eng ngin inee 3.6. Balanci Balancing ng countersh cou ntershaaft •
The The bal balan anci cing ng coun counte ters rsha haft ft gea gears rs (and (and its its driv drivee gea gear) r) are classified in two classes according to the crankcase class, featuring a different centre distance between crankshaft and countershaft.
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The The cla class ss S or or T is indi indica cate tedd out outsi side de both both cran crankc kcas asee halves, in the area shown in the figure, according to the sizes indicated in the table.
TY TY P E S TY TY P E T
MIN (mm (mm) 64.00 .00 63.97 .97
MAX (mm) (mm) 64.03 .03 64.00 .00
125 4T 4V Eng ngin inee 3.6. Balanci Balancing ng countersh cou ntershaaft •
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To redu reduce ce nois noisee an and fri frict ctio ionn bet betwe ween en pinio inionn and countershaft gear, use the following data to find out the correct coupling parts according to crankcase class: COUNTER ERSH SHA AFT
PIN PINION
TYP TYPE ES
S
S
TYP TYPE ET
T
T
Class lasses es S an and T for for co counte unters rshhaft aft ge gear and and pinion correspond to the codes indicated in the table TY TY P E S TY TY P E T
P INION 8714465001 8714465002
COUNTE RS HAFT 8711565001 8711565002
125 4T 4V Eng ngin inee 3.7. 3.7. Tim Timin ingg •
Set the Set the cams amshaft haftss on thei theirr seat seatss in the the cylinder head so that timing holes (90) are facing upwards The camshaft are not the same and can be identified identified by means means of the marking marking “A” or “S”
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Inst Instaall the the cam cam tow tower (91 (91) and and tigh tighte tenn the the 8 screws screws (92) to a torqu torquee of 10 – 12 Nm, in in a cross pattern.
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Fit Fit the the tim timing ing pin pinss (9 (93) in th their eir re refere ferenc ncee holes on the cam tower, turn camshafts until they are aligned and locked in the correct position.
125 4T 4V Eng ngin inee 3.7. 3.7. Tim Timin ingg •
Take Take the the pist piston on to TDC TDC by by tur turni ning ng the the cra crank nksh shaf aftt counter counter clockwise clockwi se with an Allen wrench, until aligning the notch on the flywheel (95) with reference mark (94) on the cover.
Up to engine no. 7015 the mark (95) is not there. For these engines (from 0001 to 7015), the mark (95) is a line (96) that shall be aligned with the edge of the sight glass.
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Fit Fit ggea ears rs (97) (97) and and cha chain in (79) (79) onto onto the the cam camsh shaf afts ts,, start the 2 screws (98) in their holes after smearing their thread with Loctite 270; tension up
125 4T 4V Eng ngin inee 3.8. Lubric Lub ricaation tio n circui cir cuitt •
Lubricatio tion is is wi with semi-dry su sump.
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The The gea gearb rbox ox/cl /clut utch ch comp compar artm tmen entt is is use usedd as as oil oil rese reserv rvoi oir. r.
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The pump pump is driven driven by the the clutch clutch bell bell and and featu features res two coaxia coaxiall rotor rotorss each each havi having ng trochoidal tooth profile (EATON) and made from sintered material: – one is 13 mm thick, and sucks sucks oil from crankshaft compartment compartment – one is 8.5 mm thick, and sends sends oil under pressure pressure to the engine
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Maxi Maximu mum m pre press ssur uree is is 4.2 4.2 bars bars and and at at eeng ngin inee ttop op end end itit is is 1 bar. bar.
125 4T 4V Eng ngin inee 3.8. Lubric Lub ricaation tio n circui cir cuitt
125 4T 4V Eng ngin inee 3.8. Lubric Lub ricaation tio n circui cir cuitt •
Pre-filte Pre-fi lter, r, filt filter, er, pressu pressurere-rel relief ief valve valve (by(by-pas pass) s) and and oil minimu minimum m pres pressur suree sens sensor or are also part of the circuit.
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Suction is is pe performed fr from: – Crankcase front end (crankshaft ( crankshaft compartment) – pos. 1 – Crankcase rear end (gearbox compartment) – pos. 2
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Delivery is is pe performed ttooward: – Gearbox compartment – Oil filter (traditional (tradi tional circuit)
Suct. from gearbox compartment
To gearbox gearbox compartment
To filter
125 4T 4V Eng ngin inee 3.8. Lubric Lub ricaation tio n circui cir cuitt •
Tigh Tighte tenn the the 3 scr screw ewss (36 (36)) to to a tor torqu quee of of 3.5 3.5 Nm appl applyi ying ng some Loctite 242
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Afterr tig Afte tight hten enin ing, g, chec checkk tha thatt rot rotor orss can can turn turn free freely ly with withou outt forcing
Oilways
At cylinder base
RH crankcase half
From crankcase
From cover
Clutch cover
From filter to crankcase
125 4T 4V Eng ngin inee 3.8. Lubric Lub ricaation tio n circui cir cuitt Crankcase
At cylinder base At cylinder base Piston cooling From cylinder base to the head From cylinder base to the main bushings and gearbox RH crankcase half Cylinder
To crankcase To cam tower
To head From crankcase
125 4T 4V Eng ngin inee 3.8. Lubric Lub ricaation tio n circui cir cuitt
To camshafts To cam tower
Head
LH crankcase half
Cam tower
125 4T 4V Eng ngin inee 3.9. Cool Cooling ing circui cir cuitt •
Ther Theree is is a smal smalll byby-pa pass ss to warm warm up the the car carbu bure rett ttor or..
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The The pum pumpp fea featu ture ress an an int inteegra gral ce ceram ramic seal seal..
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Thermostat (6 (6) op opens be between 80 80º C an and 85 85º C
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The The radi radiat ator or feat featur ures es a fan fan and and exp expan ansi sion on tank tank..
125 4T 4V Eng ngin inee 3.9. Cool Cooling ing circui cir cuitt •
Temp Temper erat atur uree senso ensorr resis esista tannce (NTC (NTC): ): – At 60º C = 600-470 – At 90º C = 215-175 – At 120º C = 93-73
125 4T 4V Eng ngin inee 3.10. List of special tools to ols (code 865207)
Pos.
Code
DESCRIPTION
A
865260
CAMSHAFT SPROCKET LOCKING TOOL
B
865259
MAGNETO FLYWHEEL LOCKING TOOL
C
864592
DIAL GAUGE SUPPORT
D
00H05300041
CLUTCH LOCKING TOOL
E
864486
COUNTERSHAFT LOCKING TOOL
F
864567
CAMSHAFT TIMING/LOCKING PINS
G
864487
CRANKSHAFT PINION LOCKING TOOL
H
864868
FLYWHEEL EXTRACTOR
J
865261
FORK FOR PISTON FITTING
125 4T 4V Eng ngin inee 3.11. T Tigh ightening tening torque tor que settings setti ngs COMPON PONENT TO BE TIGH IGHTENE ENED Sp ark plug He ad cove r Camshaft b e aring Timing syste m g e ar 1 Timing syste m g e ar 2 Cylind e r he ad Cylind e r he ad Carb ure tto r hose - air filte r b ox Inlet no zzle The rmo stat co ve r Co o lant temp e rature se nso r Timing chain te nsio ne r Timing chain te nsio ne r sp ring Water p ump co ve r Water p ump imp e lle r Clutch co ntrol le ve r Oil filter co ve r Oil p re ssure se nso r
DESCR SCRIPTIO PTION N
Scre w Scre w Scre w Scre w Scre w Scre w Flang e Scre w Scre w Scre w Co ve r Scre w Scre w -
THREAD
M10 M6 M6 M8 M8 M8 M6 M6 M6 M10 M6 M5 M5 M6 M56x1.5 M10
UANT. 1 4 8 1 1 4 2 1 3 2 1 2 1 3 1 1 1 1
TIGHT.TORQUE Kg f . m
N.m
1.2-1.4 1-1.2 1-1.2 2.5-2.7 2.5-2.7 2.7 +90° 1.1-1.3 1.2-1.8 1.1-1.3 1-1.2 0.8-1.0 1.1-1.3 0.8-1 0.5-0.6 0.4-0.6 0.8-1.0 2.4-2.6 1.2-1.4
12-14 10-12 10-12 25-27 25-27 27 +90° 11-13 12-18 11-13 10-12 8-10 11-13 8-10 5-6 4-6 8-10 24-26 12-14
125 4T 4V Eng ngin inee 3.11. T Tigh ightening tening torque tor que settings setti ngs COMPON PONENT TO BE TIGH IGHTENE ENED
DESCR SCRIPT IPTION ION THREAD QUANT.
Clutch b e ll - hub Balancing shaft Clutch b e ll - crankshaft p inio n Timing chain slid e r Oil p ump Fio re d e l tamb uro se le tto re Le va inne sto fio re d e l tamb uro se le tto re Starte r mo to r Timing ad juste r co ve r Flywhe e l-sid e o il filte r co ve r Mag ne to flywhe e l co v e r Oil se nso r cab le faste ne r Ne utral se ns o r ind icato r Oil le ve l d ip s tick Mag ne to flywhe e l stato r Pick -up (R.P.M. s e nso r) Starte r sp ro cke t c lip Mag ne to flywhe e l ro to r
Nut Nut Nut Scre w Scre w Scre w Scre w Scre w Scre w Scre w Scre w Scre w Scre w Nut
M12 M10 M12 M6 M5 M5 M6 M6 M18X1.5 M28X1 M6 M4 M10x1.25 M12x 1.5 M5 M5 M6 M14x1.5
1 1 1 1 3 1 1 2 1 1 10 1 1 1 2 2 1 1
TIGHT.TORQUE K g f .m
N.m
3.5-4.5 3.5-4.5 7.5-8.3 1-1.2 0.35 0.35-0.45 0.8-1.0 1.1-1.3 0.35-0.45 2.4-3.0 1.1-1.3 0.3-0.5 0.8-1.0 0.4-0.6 0.5-0.7 0.3-0.4 0.5-0.6 8.3-9.0
35-45 35-45 75-83 10-12 3.5 3.5-4.5 8-10 11-13 3.5-4.5 24-30 11-13 3-5 8-10 4-6 5-7 3-4 5-6 83-90
125 4T 4V Eng ngin inee 4. Fuel uel syste sys tem m - Emissions 4.1. Carburettor •
Vacu Va cuum um-t -typ ypee carb carbur uret etto tor, r, Ke Keih ihin in CVK3 CVK300 mode modell
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It fea featu ture ress aut autom omat atic ic star starte terr and and acc accel eler erat atin ingg pum pumpp
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It is heate eatedd thr throough ugh tthhe co coolin olingg cir circcuit uit Starter
Pilot screw
Carburettor heating Accelerating pump
125 4T 4V Eng ngin inee 4.2. Secondary con dary air syste syst em – Catalytic conv c onveerter •
The The vehi vehicl clee feat featur ures es a seco second ndar aryy air air syste system m (S. (S.A. A.S.) S.) to red reduc ucee CO CO and and HC HC emissions.
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CO rate rate (oil (oil at 90º 90º C) = 3.1 3.1 – 4.5% 4.5%.. Manu Manual ally ly adju adjust stab able le via via the the pilo pilott scre screw. w.
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2-w 2-way cata catallyti ytic co conve nverte rter in in th the si silen lencer cer.
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It feat feature uress oil oil vapou vapours rs blow blow-by -by system system from the head head cove coverr to the air filter filter box. box.
125 4T 4V Eng ngin inee 5. Ignit gn itio ionn 5.1. System description System operatio operationn •
The The basi basicc val value ue is the the rpm rpm meas measur ured ed thro throug ughh the the pick pick-u -up. p.
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Using Using the inform informati ation on from from this this sensor sensor,, the the CDI CDI calcul calculate atess when when to trigge triggerr the the spark in the spark plug.
125 4T 4V Eng ngin inee 5.2. Components •
Engine speed speed sensor (pick-up)
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Sensor resistance: 105-124 Ω at 20 20º C (flywheel side connector, across R and B cables)
Red cable (R)
Black cable (B)
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Ignition coi l
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Primary coil resistance 0.21 Ω +/+/- 0.02 0.0255 Ω at 25+/-5 ºC
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Secondary coil resistance 3.1 K Ω +/+/- 0.31 0.31 K Ω at 25+/-5 ºC
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Spark pl plug cap resistance 5 K Ω at 20 °C
