Generic XOR 125 Service Manual

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
November 2010
Maxi scooter
1
PREFACE
The service manual has been specially prepared to provide all the necessary information for the proper
maintenance and servicing.
You have now a new type of scooter that has many techinal features such as:
V-belt drive automatic transmission
Forced air-cooling system
CDI ignition system
Electric starter system
Those who will be servicing 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 market. Therefore, if newest information is requested in the future, please contact the local GENERIC
distributor.
The scooters distributed in your country mignt differ in minor respects from the standard specification and, if they
do, it is because some minor modifications had to be made to comply with the statutory requirements of your
country.
2
GENERAL INFORMATION
TYPE IDENTIFICATION
FUEL AND ENGINE OIL
BREAK-IN PROCEDURE
PRECAUTIONS AND GENERAL INSTRUCTIONS
SPECIFICATIONS
CONTENT
3
TYPE IDENTIFICATION
ENGINE NUMBER
ENGINE NUMBER is carved on rear crankcase as Shown in figure.
Both FRAME NUBER AND ENGINE NUMBER are designed specially for registering your scooter and ordering spare parts.
FUEL AND ENGINE OIL
Be sure to use specified fuel and engine oil. Some specifications 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 – 15W40)
GEAR OIL
Use high quality, all-purpose 80W90 engine oil for your vehicle.
BREAK-IN TIME
General requirements are as follows Limit break-in speed
At the first 100KMS mileageplay throttle less than 4/5 throttle
Don’t run engine too long during break-in time, and try to change throttle position.
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4
PRECAUTIONS AND GENERAL INSTRUCTIONS
Correctly abide by the following items when disassembling and assembling scooter:
Don’t run engine indoors without ventilation;
Be sure to replace new bushings, circlips, O-rings and cotter pins with new ones
CAUTION
It is forbidden to use the circlip removed from shaft again, only use new one
Be very carefull to install new circlip for fear that the end hatch of circlip exceeds required sliding surface
for shaft
After installing circlip, inspect whether it has been completely clipped into the groove.
Fix bigger diameter bolt first when tightening cylinder head or cylinder, and tighten to specified torque
gradually from inside to outside at diagonal order.
Use special tools for some special requirements
Use original components and recommended engine oil
Keep each 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 words like warning, notice, note may turn out incessantly in the manual, which means:
WARNING The personal safety of the rider may be involved. Disregarding the information could result in injury to the rider. CAUTION These instructions point out special service procedures or precautions that must be followed to avoid damaging the machine. NOTE it provides some special information, which keeps maintenance easier and important instructions clearer..
REPLACEMENT COMPONENTS
Be sure to use genuine GENERIC components or their equivalent.. Genuine GENERIC components are high quality parts which are designed specially for your vehicle.
CAUTION
Damage to the scooter may result from use of replacement components which are not Equivalent in quality to genuine GENERIC parts, and it can lead to performance problems.
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6
SPECIFICATIONS DIMENSION AND NET WEIGHT
OVERALL LENGTH 1770 mm OVERALL WIDTH 702 mm OVERALL HEIGHT 1085 mm WHEELBASE 1280 mm NET WEIGHT 100 kg
CHASSIS
Front shock absorber spring, oil damp Rear shock absorber spring, oil damp Front wheel 120/70-12 Rear wheel 130/70-12 Front brake Discφ190 Rear brake Drumφ110
ENGINE
Type four-stroke, air cooled Intake system piston-reed valve Cylinder QTY. 1 Bore 52.4mm Stroke 57.8mm Discharge 124.6ccm Compression ratio 9.5:1 Air cleaner dry Starting system electric and kicking start Lubricating system pressure lubricating
ELECTRIC
Ignition mode CDI Spark plug CR7HSA Storage battery YTX7L-BS Generator AC magneto Fuse 15A Headlight 12V—35/35W Turning light 12V/10W Taillight 12V—21/5W
CAPACITY
FUEL TANK 5.2L ENGINE OIL TANK 1L GEAR OIL 0.1L
Transmission system
Clutch system dry auto a centric Gearshift mechanism CVT stepless Operating mode of gears shift mechanism Automatic a centric Step less shift range 0.86~2.64
*the above data may be modified without any notification.
7
Periodic maintenance and service
Periodic maintenance and service schedule Maintenance and 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 Braking Tire Steering Front shock absorber Rear shock absorber Vehicle bolts and nuts
CONTENTS
8
Periodic maintenance and service schedule
The following table lists all required intervals for maintenance and servicefollowing which, you are assured to have your scooter perform in the best way.
Note
Do more frequent maintenance when often riding on bad road
Periodic maintenance table
PERIODICAL MAINTENANCE SCHEDULE
Maintenance Kilometres
Item
Check Items
500KM 3500KM 6500KM 9500KM 12500KM 15500KM 18500KM 21500KM Remarks
1 Air cleaner element
I C R C R C
2 Air cleaner
I C R
3 Tire pressure
I I I I I I I I
4 Battery
I I I I I I I I
5 Spark plug
I I I I R I R I
6 Carburettor (idle speed)
I I I I
7 Steering bearing and handles
I I
8 Transmission oil
R Replace all 6000Km or once a year
9 Engine oil
R Replace all 3000km
10 Drive belt
I 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 absorbers
I I I
17 Front/rear suspension
I I I
18 Main/side stand
I L L I/L L L I/L L
19 Brake mechanism/brake pads
I I I I I I I I
20 Bolts/nuts for each component
I I I I
The above maintenance schedule is established by taking the monthly 800 kilometers as a reference which ever comes first. Have your motorcycle checked and adjusted periodically by your GENERIC Authorized Dealer to maintain the motorcycle at the optimum condition. Code: I ~ Inspection, cleaning, and adjustment R ~ Replacement C ~ Cleaning (replaced if necessary) L ~ Lubrication Remark: 1. Clean or replace the air cleaner element more often when the motorcycle is operated on dusty roads or in the Heavily- polluted environment.
Notes in the remarks are used to indicate the applicable models.
9
Maintenance and adjustment procedures
The section describes the servicing procedures for each item of the Periodic Maintenance requirements.
Storage battery
Inspect twice a 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.
Disconnect negative pole line end, positive end, and then remove battery
Measure the voltage between the two ends of battery with voltage gaugecharge if the voltage is below 11,9V
10
Cylinder head nuts and exhaust pipe bolts
Tighten at each service.
If cylinder head nuts are not tightened to the specified torque, may result in leakage of compressed fuel-air mixture and reduce output, tighten the cylinder head nuts in the following procedures:
1 Remove the frame lower covers. 2 Remove the cylinder head cover bolt. 3 Remove 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 nut15-18N.m
Exhaust pipe bolt15-18N.m
Cylinder and cylinder head
Clean carbon every 6000 km
Carbon deposits in the combustion chamber and the cylinder head will raise the compression ratio and may cause preignition and overheating. Carbon deposited at the exhaust port of the cylinder will prevent the flow of exhaust gases, reducing the output. Remove carbon deposits periodically.
11
SPARK PLUG
Neglecting the spark plug maintenance eventually leads to difficult starting and poor performance. If the spark plug is
used for a long time, the electrode gradually burns away and carbon builds up along the inside part. In accordance
with the periodic table, the plug should be removed for inspection, cleaning and to reset the gap.
z Carbon deposits on the spark plug will prevent good sparking and
cause misfiring. Clean the deposits periodically.
z If the center electrode is fairly worn down, the plug should be
replaced and the plug gap set to the specified gap using a thickness
gauge.
Thickness gauge
Spark plug gap0.6-0.7 mm (0.024-0.028 inch)
Check the spark plug for burnt condition. If abnormal replace the spark
plug as indicated in the chart.
NGK TROCH REMARKS
BPR7HS E7RTC Standard
z Tighten the spark plug to the specified torque.
Spark plug
Tightening torque:15-18N.m
NOTE:
z To check the spark plug, first make sure that the fuel used is unleaded gasoline, and if plug is either sooty with
carbon or burnt white, replace it.
z Confirm the thread size and reach when replacing the plug.
FUEL LINE
Inspect at initially 500 km and every service, replace every 4 years.
12
AIR CLEANER
Clean every 3000KM
If the air cleaner is clogged with dust, intake resistance will, be increased with a resultant decrease in power output and an increase in fuel consumption. Check and clean the element in the following manner.
Remove screw 1 and screw 2,take down air cleaner Unscrew tapping screw 3,remove air cleaner cap 4 Fill a washing pan of a proper size with Non-flammable cleaning solvent.
Immerse the air Cleaner in the cleaning solvent and wash them clean.
Squeeze the cleaning solvent out of the washed element
By pressing it between the palms of both hands: do not twist or wring the air cleaner filter core element or it will develop tears.
Immerse cleaned filter core of air cleaner in CCI or CCI SUPER oil, and
squeeze the oil out of the corewhich 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 be replaced Be sure to position the filter core, so that no incoming air will bypass it. Remember, rapid wear of piston rings and cylinder bore is ofter caused by defective or poorly fitted filter core.
А Non-flammable cleaning solvent Б CCI or CCI SUPER oil
THROTTLE CABLE
Adjust every 1000KM.
Loosen locknut and adjust throttle cable play by turning adjuster in or out to obtain the following cable play. After adjusting the calbe playtighten the locknut. Cable play:0.5-1.0MM(0.02.-0.040 inch
Engine idle speed
Adjust every 1000KM.
Adjust the throttle cable play.
warm up the engine.
Note Warm up engine for 10 minutes.
Connect an electric tachometer to the connecting protion of the magneto lead wire as shown in the illustration. Use the selector key “C’ position.
3
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.
14
GEAR OIL
Change as shown in the service schedule.
Inspect gear oil periodically as follows:
The transmission oil level can not be checked. It must be replaced as listened in the manual. 0,11 L is required.
Tightening toque9-15N.m 0.9-1.5 kg-m 6.5-11.0 lb-ft)
BRAKES
Inspect at initially 500 km and every service, replace brake fluid every 2 years, replace brake hose every 4 years.
Front brake fluid level
Keep the scooter upright 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 that meets the following specification.
Specification and classificationDOT4
WAR NING
The brake system of the scooter is filled with a glycol-based brake the lowest line Fluid. Do not use or mix different types of fluid such as silicone-based and petroleum-based. Do not use any brake fluid taken from old, used or unsealed containers. Never reuse the brake fluid left over from the last servicing and stored for long periods.
15
WARNING
Brake fluid, if it leaks, will interfere with safe running and immediately discolor painted surfaces. Check the brake hoses for cracks and hose joints for leakage before riding.
Brake pads
Wearing condition of brake pads can be checked by observing
the limit line marked on the pad. When the wear exceeds the
limit mark, replace the pads with new ones.
Bleeding air from the brake fluid circuit
Air trapped in the fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cylinder and thus interferes with the full braking performance of the brake caliper. The presence of air is indicated by “sponginess” of the brake lever and also by lack of braking force. Considering the danger to which such trapped 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 following manner:
Fill up the master cyliner reservoir to the upper end of the inspection window. Replace the reservoir cap to prevent entry of dirt.
Attach a pipe to the caliper bleeder valve, and insert the free end of the pipe into a receptacle. Bleed air from the bleeder valve. Squeeze and release the brake level several times in rapid succession. And squeeze the lever fully without releasing it. loosen the bleeder valve by turning it a quarter of a turn so that the brake fluid runs into the receptacles: the will remove the tension of the brake lever causing it to touch the handlebar grip. Then, close the valve, pump and squeeze the lever, and open the valve. Repeat the process until the fluid flowing into the receptacle no longer contains air bubbles.
16
NOTEwhen bleeding the braking system, replenish the brake fluid reservoir if necessary. Make sure that there is always some fluid visible in the reservoir.
Close the bleeder valve, disconnect the pipe. Fill the reservoir with brake fluid to the upper end of the inspection window.
BLEEDER VALVE TIGHTENING TORQUE: 6-9N.m(0.6-0.9kg-m,4.5-6.5lb-ft)
CAUTION Handle brake fluid with 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 wear The vehicle is equipped with the brake lining limit Indicator on the rear brake. Inspect brake lining limit as follows
1. First check if the brake system is properly adjusted.
2. when operating the brake, check to see that the tip of indicator is within the range.
3. if the tip of indicator is beyond the range, the brake shoe assembly should be raplaced with anew set of shoe.
17
Tire
Inspect at initially 500km and every 2500km thereafter
Tire pressure If the pressure is too high, the scooter will tend to rede stiffly and have poor traction. Conversely, if tire pressure is too low, stability will be adversely affected. Thereafter, maintain the correct tire pressure for good roadability and to prolong tire life.
CAUTION
The standard air pressure of tires is 2Bar, the use of other than standard may cause handling instability.
Tire tread condition It 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 and every service.
Steering should be adjusted properly for smooth turning of handlebars and safe running. Too stiff steering prevents smooth turning of handlebars and too loose steering will cause poor stability. Check that there is no play in the front fork assembly by supporting the machine so that the front wheel is off the ground, with wheel staight ahead, grasp lower shock absorber near the axle and pull forward. If play is found, perform steering bearing adjustment.
18
Front shock absorber
Adjust at initially 500km and each service.
Inspect the front shock absorber for oil leakage or other damage, and replace the defective parts, if necessary.
IMPORTANT:
If the front fork is too weak us 60 – 70 ml (depends on the weight of the driver) of W15 fork oil to improve the damping.
Rear shock absorber
Adjust at initially 500km and each service.
Inspect front shock absorber for oil leakage and other damage, and replace the defective 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 brake master cylinder hose fixing bolt 22-29 2.2-2.9
6 Disc brake fixing bolt 5-9 0.5-0.9
7 Front shock absorber fixing bolt 37-44 3.7-4.4
8 Engine pivot fixing nut 55-60 5.5-6
9 Engine bracket fixing nut 37-44 3.7-4.4
10 Rear wheel fixing nut 100-130 10-13
11 Rear brake rocker arm fixing bolt 5-9 0.5-0.9
12 Rear shock absorber under fixing bolt 22-29 2.2-2.9
13 Start pedal mounting screw 15-20 1.5-2
14 Rear shock absorber top fixing bolt 37-44 3.7-4.4
19
14
20
LUBRICATION
Proper lubrication is important for smooth operation and long life of each working part of the scooter. The major lubrication points are indicated below NOTE
1. Lubricate exposed parts which are subject to ruse with engine oil.
2. Before lubricating each part, clean off any rusty spots and wipe off any grease, oil dirt of grime.
WARNINGBe careful not to apply too much grease to the rear brake camshaft, otherwise brake slippage will result from the presence of grease in brake drum.
steering stem bearing front wheel bearing engine bracket rear brake camshaft side stand rear brake shaft and rear brake cable speedometer cable and gear box main stand
ΑA: lubrication
A
A A
A
A
A
21
ENGINE
CONTENS
Engine components removal with the engine in place
Engine removal and remounting
Engine removal
Engine remounting
Engine disassembly
Engine components 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 shaft
transmission
starter pinion and starter gear
Movable driven and clutch
Movable drive
Kicking starter
Piston
Oil pump and oil pump driven gear
Intake pipe
Magneto
22
Engine components removable with the engine in place
The parts listed below can be removed and reinstalled without removing the engine from the frame.
Engine left side
Kicking starter lever
Clutch brake pad kit
Driver left face
V-b elt
Driver belt right face
Electric starter gear
Super clutch
Driven face
Engine center
Carburetor
Intake pipe
Reed valve
Oil pump
Worm wheel
Cylinder head
Cylinder
Piston
Engine right side
cooling fan
Magneto
Starter motor
23
TORQUE VALUES
STANDARD
5 mm bolt and nut
5 N.m (3.5 lbf.ft)
6 mm bolt and nut
10 N.m (7.2 lbf.ft)
8 mm bolt and nut
22 N.m (16 lbf.ft)
10 mm bolt and nut
35 N.m (25 lbf.ft)
12 mm bolt and nut
55 N.m (40 lbf.ft)
ENGINE
Cylinder head nut
28 N.m (20.7 lbf.ft)
Spark plug
12 N.m (8.9 lbf.ft)
Cylinder head bolt
20 N.m (14.8 lbf.ft)
Alternator bolt
8 N.m (5.9 lbf.ft)
FRAME
Handlebar upper holder bolt
24 N.m (17.7 lbf.ft)
Throttle housing cover screw
4 N.m (2.9 lbf.ft)
Steering shaft 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 N.m (29.5 lbf.ft)
Front wheel bolt
24 N.m (17.7 lbf.ft)
Front axle castle nut
40-60 N.m (30-45 lbf.ft)
Front brake arm nut
4 N.m (3.0 lbf.ft)
Rear brake arm nut
7 N.m (5.2 lbf.ft)
Rear axle castle nut
40-60 N.m (30-45 lbf.ft)
Rear wheel bolt
24 N.m (17.7 lbf.ft)
Exhaust muffler mounting bolt
30 N.m (22.1 lbf.ft)
Engine hanger bolt
30 N.m ( 22 lbf.ft)
Rear axle holder bolt
90 N.m (65 lbf.ft)
Swing arm pivot nut
90 N.m (65 lbf.ft)
Rear shock absorber mounting nut
45 N.m (33 lbf.ft)
24
CYLINDER HEAD / VALVES
SERVICE INFORMATION CYLINDER HEAD REMOVAL TROUBLESHOOTING CYLINDER HEAD INSTALLATION CAMSHAFT COMPOSITION REMOVAL
SERVICE INFORMATION GENERAL
This section describes cylinder head, valves, camshaft and the other parts maintenance. The engine must be removed from the frame to service cylinder head. Camshaft lubrication oil is fed to the cylinder head through an oil orifice in the engine case. Before installing the cylinder head be sure the orifice is not clogged 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. 10.000-10.018 10.10 ROCKER ARM SHAFT O.D. 9.972-9.987 9.91 CYLINDER HEAD WARPAGE -------- 0.05
IN 32.3 31.2 VALVE SPRING FREE LENGTH
OUT 35.0 34.1
IN 4.975-4.990 4.90 VALVE STEM O.D.
EX 4.955-4.970 4.90 VALVE GUIDE I.D. IN/EX 5.000-5.012 5.30
IN 0.010-0.037 0.08 STEM-TO-GUIDE CLEARANCE
EX 0.030-0.057 0.10
IN 1.0 1.8 VALVE SEAT WIDTH
EX 1.0 1.8
TORQUE VALUES
Cylinder head bolts 8 ~ 12 n-m (0.8 ~ 1.2 kg-m) Camshaft holder flange nuts 20 ~ 24 n-m (2.0 ~ 2.4 kg-m) Tappet adjusting nut 9 ~ 12 n-m (0.9 ~ 1.2 kg-m)
25
TROUBLE SHOOTING
Engine top-end problems usually affect engine performance. These problems can be diagnosed by a compression test, or by tracing engine noise to the top end with a sounding rod or stethoscope.
LOW COMPRESSION Valve
Incorrect valve adjustment Worn or damaged valve seats Burned or bent valve Incorrect 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 broken valve spring Worn or damaged rocker arm or camshaft Worn or damaged cam chain Worn or damaged cam chain tensioner Worn cam sprocket teeth
Excessive smoke
Damaged valve stem seal Faulty cylinder or piston rings
CAMSHAFT COMPOSITION REMOVAL
Remove the rubber tube of gas waste recovery.
Remove the cylinder head cover.
26
Remove the air cleaner and carburetor. Remove the inlet pipe assy. Remove the shroud 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 holder and dowel pins.
Relax the camshaft gear from cam chain and remove the camshaft.
27
INSPECTION
Inspect the cam lobes surface and height of cam lobes for wear or 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.
Inspect the camshaft holder, rocker arms and rocker arm shafts for wear or damage.
28
Measure the I.D. of each rocker 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 pins.
Remove the cam chain guide.
29
CYLINDER HEAD DISASSEMBLY
Remove the valve cotters, spring retainers and 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 diagonally for warpage with a straight edge and feeler gauge.
SERVICE LIMIT: 0.05 mm
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