KYMCO QUANNON 125 User Manual

123

4

QUANNON 125

PREFACE

This Service Manual describes the technical
features and servicing procedures for the
KYMCO Quannon 125.

Section 1 contains the precautions for all
operations stated in this manual. Read them
carefully before starting any operation.

Section 2 is the inspection/ adjustment
procedures, safety rules and service information
for each part, starting from periodic
maintenance.

Sections 3 and 4 state the servicing procedures
and cautions for the removal and installation of
lubrication and fuel systems.

Sections 5 through 18 give instructions for
disassembly, assembly and inspection of engine,
chassis frame and electrical equipment.

Most sections start with an assembly or system
illustration and troubleshooting for the section.
The subsequent pages give detailed procedures
for the section.

TABLE OF CONTENTS

GENERAL INFORMATION 1
INSPECTION/ADJUSTMENT 2
LUBRICATION SYSTEM 3
FUEL SYSTEM 4
ENGINE REMOVAL/INSTALLATION 5

ENGINE

CYLINDER HEAD/VALVES 6
CYLINDER/PISTON 7
STARTER MOTOR/GENERATOR/

LEFT CRANKCASE
COVER/STARTER
CLUTCH/CAMSHAFT

CLUTCH/GEAR SHIFT MECHANISM 9
CRANKCASE/CRANKSHAFT/TRANS-

MISSION SYSTEM/STARTER
SPINDLE

FRONT WHEEL/SUSPENSION/
STEERING

CHASSIS

REAR WHEEL/BRAKE/SUSPENSION 12
HYDRAULIC BRAKE 13
REAR CARRIER/REAR FENDER/

EXHAUST MUFFLER

ELECTRICAL

EQUIPMENT

IGNITION SYSTEM 15
CHARGING SYSTEM 16
STARTING SYSTEM 17

8

10

11

14

The information and contents included in
this manual may be different from the
motorcycle in case specifications are
changed.

KWANG YANG MOTOR CO., LTD.
Quality Technology Division
Education Section

LIGHTS/INSTRUMENTS/SWITCHES/
HORN

18

5

1. GENERAL INFORMATION

QUANNON 125

1

________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________

GENERAL INFORMATION

1

________________________________________________________________________________

SERIAL NUMBER------------------------------------------------------------------------------------1-1
SPECIFICATION -------------------------------------------------------------------------------------1-2
SERVICE PRECAUTIONS------------------------------------------------------------------------- 1-3
TORQUE VALUES-----------------------------------------------------------------------------------1-7
SPECIAL TOOLS------------------------------------------------------------------------------------- 1-8
LUBRICATION POINTS ---------------------------------------------------------------------------- 1-9
CABLE & HARNESS ROUTING------------------------------------------------------------------- 1-10

1-0

6

1. GENERAL INFORMATION

r

r

SERIAL NUMBER

QUANNON 125

Location of Frame Serial Numbe

Location of Engine Serial Numbe

1-1

7

1. GENERAL INFORMATION

g

y

y

g

y

QUANNON 125

SPECIFICATIONS

Name & Model No. RL25BA
Motorcycle Name & Type QUANNON 125
Overall length 2057mm
Overall width 725mm
Overall height 1174mm
Wheel base 1355mm

Engine type SOHC 4V
Displacement 124.1cc
Fuel Used 92# nonleaded

gasoline
1 person (55kg) Front wheel 96
weight (kg) Rear wheel 126

Total 222
2 person (110kg) Front wheel 98
weight(kg) Rear wheel 194

Total 292

Tires spec.

Ground clearance 170mm

Braking distance (m)

Perfo
rman

Min. turning radius

ce

(R/L)

Starting system Starting motor
Type Gasoline, 4-stroke

Cylinder arrangement Single cylinder
Co m b u s t i o n ch a m b e r t y p e Semi-sphere
Valve arrangement O.H.C. 4V
Bore x stroke (mm) φ56.5x 49.5
Compression ratio 11:1

Compression pressure
(kg/cm

En

Max. output (ps/rpm) 13.0/9500
Max. torque (N.m/rpm) 1.0/8500

ine

Port
timing

clearance
Idle speed (rpm) 1600±100rpm

Lubrication

S
stem

Cooling Type Oil cooling

Front wheel 110/80-17

Rear wheel 140/70-17

7.8m

2550/2525mm

2

)

Intake

Exhaust

Lubrication type
Oil pump type Inner/outer rotor type

Oil filter type Wire gauze filter
Oil capacity 1.1 liters

BTDC 0q
ABDC 23q
BBDC -6q
ATDC 43.5q

Intake 0.06 mmValve

Exhaust 0.06 mm

Forced pressure &

13±2

Wet sump

Air cleaner type & No Paper element

Fuel S

Fuel capacity 13.5 liters

Carburetor

stem

Electrical Equipment

Power Drive System

Moving

Device

Brake system
type

Damping

Device

Frame type Double cradle

Type CVK
Piston dia. φ26.5
Venturi dia. φ25
Throttle type Vacuum
Type CDI

I
nition S

Ignition timing 30q±2/4000rpm
Contact breaker ---

stem

Battery Capacity 12V7AH
Clutch Type Wet-multi-disc clutch

Gear

Reduction Gear

Tire pressure
(kgf/cm

Turning Left 32q
angle

Suspension
type

Shock absorber
type

Spark plug

Spark plug gap 0.7mm

Transmission

Type Permanent gear

Operation Foot operated
Type International type

Reduction 1st
Ratio

2

)

2nd
3rd 1.44

4th 1.13
5th 0.92

Front 1.75

Rear 2.0

Right 32q
Front Disk (276mm)

Rear Disk (220mm)

Front Telescope

Rear Single swing

Front Telescope

Rear

NGK

CR8E

meshing

2.85

2.06

Single swing

1-2

8

1. GENERAL INFORMATION

QUANNON 125

SERVICE PRECAUTIONS

Make sure to install new gaskets, O-rings,

circlips, cotter pins, etc. when
reassembling.

When tightening bolts or nuts, begin with

larger-diameter to smaller ones at several
times, and tighten to the specified torque
diagonally.

Apply or add designated greases and

lubricants to the specified lubrication
points.

After reassembly, check all parts for proper

tightening and operation.

When two persons work together, pay

attention to the mutual working safety.

Use genuine parts and lubricants.

When servicing the motorcycle, be sure to

use special tools for removal and
installation.

After disassembly, clean removed parts.

Lubricate sliding surfaces with engine oil
before reassembly.

Disconnect the battery negative (-) terminal

before operation.

When using a spanner or other tools, make

sure not to damage the motorcycle surface.

After operation, check all connecting points,

fasteners, and lines for proper connection
and installation.

When connecting the battery, the positive

(+) terminal must be connected first.

After connection, apply grease to the

battery terminals.

Terminal caps shall be installed securely.

1-3

9

1. GENERAL INFORMATION

QUANNON 125

If the fuse is burned out, find the cause and

repair it. Replace it with a new one
according to the specified capacity.

Confirm
Capacity

After operation, terminal caps shall be

installed securely.

When taking out the connector, the lock on

the connector shall be released before
operation.

The connector shall be inserted

completely.

If the double connector has a lock, lock

it at the correct position.

Check if there is any loose wire.

Before connecting a terminal, check for

damaged terminal cover or loose negative
terminal.

Check the double connector cover for

proper coverage and installation.

Hold the connector body when connecting

or disconnecting it.

Do not pull the connector wire.

Check if any connector terminal is bending,

protruding or loose.

Insert the terminal completely.
Check the terminal cover for proper

coverage.

Do not make the terminal cover opening

face up.

Secure wire harnesses to the frame with

their respective wire bands at the
designated locations.
Tighten the bands so that only the
insulated surfaces contact the wire
harnesses.

1-4

10

1. GENERAL INFORMATION

QUANNON 125

After clamping, check each wire to make

sure it is secure.

Do not squeeze wires against the weld or

its clamp.

After clamping, check each harness to

make sure that it is not interfering with any
moving or sliding parts.

Route harnesses so they are neither

pulled tight nor have excessive slack.

Do not pull
too tight！

Protect wires and harnesses with electrical

tape or tube if they contact a sharp edge or
corner.

When rubber protecting cover is used to

protect the wire harnesses, it shall be
installed securely.

When fixing the wire harnesses, do not

make it contact the parts which will
generate high heat.

No Contact

Route wire harnesses to avoid sharp edges

or corners. Avoid the projected ends of
bolts and screws.

Route wire harnesses passing through the

side of bolts and screws. Avoid the
projected ends of bolts and screws.

Do not break the sheath of wire.
If a wire or harness is with a broken sheath,

repair by wrapping it with protective tape or
replace it.

When installing other parts, do not press or

squeeze the wires.

Do not press or
squeeze the wire

1-5

11

1. GENERAL INFORMATION

QUANNON 125

After routing, check that the wire harnesses

are not twisted or kinked.

Wire harnesses routed along with

handlebar should not be pulled tight, have
excessive slack or interfere with adjacent
or surrounding parts in all steering
positions.

When a testing device is used, make sure

to understand the operating methods
thoroughly and operate according to the
operating instructions.

Do you understand
the instrument？

Symbols:

The following symbols represent the
servicing methods and cautions included in
this service manual.

: Apply engine oil to the

specified points. (Use

Engine Oil

Grease

Gear Oil

Special

＊

designated engine oil for
lubrication.)

: Apply grease for lubrication.

: Transmission Gear Oil (90#)

: Use special tool.

: Caution

Be careful not to drop any parts.

When rust is found on a terminal, remove

the rust with sand paper or equivalent
before connecting.

Remove Rust！

: Warning

1-6

12

1. GENERAL INFORMATION

TORQUE VALUES

STANDARD TORQUE VALUES

Item Torque (kg-m) Item Torque (kg-m)

5mm bolt, nut
6mm bolt, nut
8mm bolt, nut
10mm bolt, nut
12mm bolt, nut

Torque specifications listed below are for important fasteners.

ENGINE

Item Q‘ty Thread dia.(mm) Torque (kg-m) Remarks

0.45阡0.6

0.8阡1.2

1.8阡2.0

3.0阡4.0

5.0阡6.0

5mm screw
6mm screw, SH bolt
6mm flange bolt, nut
8mm flange bolt, nut
10mm flange bolt, nut

QUANNON 125

0.35阡0.5

0.7阡1.1

1.0阡1.4

2.0阡3.0

3.5阡4.5

Cylinder head bolt A
Cylinder head bolt B
Oil filter lock nut
Exhaust muffler joint lock nut
Valve adjusting lock nut
Oil removal bolt
Cylinder head bolt

Flywheel lock bolt

Cylinder head cover bolt
Oil pump bolt
Oil filter lock nut
Rocker arm lock bolt
Cylinder head lock bolt
Cylinder side bolt
Crankcase assembly bolt
Crankshaft damper bolt
Right crankcase cover bolt
Left crankcase cover bolt
A. C. generator coil lock bolt
Starter gear set plate bolt
Carburetor lock bolt

2
2
1
2
4
1
4
1
4
2
1
3
1
2

10

1
8
4
4
2
2

8
8

36

6
5

12

8

14

6
6

16

8
8x79
6x22

6
6x25

6

6

5

6

6

2.8阡3.2

2.8阡3.2

1.5 ~ 3.0

0.8阡1.2

1.4阡1.8

2.0阡3.0

2.3阡2.8

4.0阡5.0

0.8阡1.2

0.7阡1.1

4.0阡5.0

1.5阡2.0

1.5阡2.0

0.8阡1.2

0. 8阡1.5

0.8阡1.2

0.8阡1.2

0. 8阡1.2

0.4阡1.7

1.0阡1.6

0.8阡1.2

1-7

13

1. GENERAL INFORMATION

FRAME

Item Q‘ty Thread dia.(mm) Torque (kg-m) Remarks

QUANNON 125

Steering stem lock nut
Front axle nut
Rear axle nut

Rear shock absorber upper mount bolt
Rear shock absorber lower mount bolt

Rear fork pivot nut
Handlebar lock bolt
Rear driven gear bolt
Rear brake panel bolt

SPECIAL TOOLS

Tool Name Tool No. Remarks Ref. Page

Flywheel puller E005
Bearing puller 18mm E008
Lock nut wrench E010
Valve adjuster E012

Oil seal & bearing installer E014
Bearing puller 15mm E018
Bearing puller 12mm E020
Flywheel holder E021
Crankshaft bearing puller E030

1
1
1
2
2
1
4
4
1

22
14
16
10
10
12

6

8

8

6.0阡8.0

5.5阡7.0

6.0阡8.0

3.0阡4.0

3.0阡4.0

5.5阡7.0

0.8阡1.2

1.8阡2.0

2.4阡3.0

Ph 8-3
Ph10

Ph 2-5

Ph10
Ph10
Ph 8-3

Ph10

Bearing puller 10mm E031
Valve spring compressor E040

Race cone install F005
Steering stem wrench F006

Steering stem lock nut wrench F007

Ph10
Ph 6-9

1-8

14

1. GENERAL INFORMATION

LUBRICATION POINTS

Throttle Cable

Clutch Cable

QUANNON 125

Seat Lock

1-9

Rear Fork Bearing

Speedometer Gear/
Front Wheel Bearing

15

1. GENERAL INFORMATION

r

CABLE & HARNESS ROUTING

Relay High Light

Speed Cable

Relay Low Light

QUANNON 125

Wire Harness

Resisto

Horn

1-10

16

1. GENERAL INFORMATION

A

r

r

r

r

QUANNON 125

Front Brake
Fluid Tube

Front Brake Master Cylinder

Battery

Relay Winke

Rear Brake
Fluid Tube

CDI Unit

Cable Speed

Regulator/Rectifie

Starter Moto

Ignition Switch

ir Cleane

Cable Clutch

Rear Brake
Master Cylinder

Spark Plug

Front Brake
Caliper

1-11

17

1. GENERAL INFORMATION

A

r

r

QUANNON 125

Regulator/Rectifie

CDI

Starter Relay

Fuse

Battery (+) Cable

.C.G Wire Couple

1-12

18

1. GENERAL INFORMATION

TROUBLESHOOTING

ENGINE WILL NOT START OR IS HARD TO START

QUANNON 125

Inspection/Adjustment

Check if fuel reaches

carburetor by loosening

drain screw

Remove spark plug and

install it into spark plug

cap to test spark by

connecting it to engine

ground

Test cylinder
compression

Fuel reaches

carburetor

Spark jumps

Normal

compression

Symptom

Fuel does not

reach carburetor

Weak or no spark

Low or no
compression

Probable Cause

Empty fuel tank
Clogged fuel line between fuel
tank and carburetor
Clogged float oil passage
Clogged fuel filter
Clogged charcoal canister
Clogged auto fuel valve strainer
Faulty auto fuel valve passage
Clogged carburetor air balance
tube

Faulty spark plug
Fouled spark plug
Faulty CDI unit
Faulty pulser coil
Faulty exciter coil
Faulty ignition switch
Broken or shorted ignition coil
wire

Faulty or slipping clutch
Valve clearance too small
Valve stuck open
Worn cylinder and piston rings
Leaking cylinder head gasket

Start engine by follow-ing

normal starting

procedure

Remove spark plug and

inspect again

Engine does not

fire

Dry spark plug

Engine fires but

does not start

Wet spark plug

Faulty choke control system
Leaking intake manifold
Incorrect ignition timing
Incorrectly adjusted pilot screw

Flooded carburetor
Throttle valve excessively open
Clogged air cleaner

1-13

19

1. GENERAL INFORMATION

p

POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS)

QUANNON 125

Inspection/Adjustment Symptom

Check ignition timing

Correct

Check carburetor pilot

screw adjustment

Correctly adjusted

Check carburetor gasket

for air leaks

No air leak

Remove spark plug and

install it into spark plug

cap to test spark by

connecting it to engine

ground

Good spark

Incorrect

Incorrectly adjusted

Air leaks

Weak or inter-

mittent s

ark

Probable Cause

Faulty CDI unit
Faulty pulser coil

Mixture too lean (turn screw in)
Mixture too rich (turn screw out)

Faulty intake manifold gasket
Carburetor not securely
tightened
Damaged insulator rubber
Broken vacuum tube

Faulty or fouled spark plug
Faulty CDI unit
Faulty A.C. generator
Faulty ignition coil
Faulty ignition switch

Check A.C. generator

Good

Faulty

Faulty A.C. generator
Damaged vacuum tube
Clogged air vent hole

1-14

20

1. GENERAL INFORMATION

t

p

POOR PERFORMANCE (ENGINE LACKS POWER)

QUANNON 125

Inspection/Adjustment

Start engine and
accelerate lightly for
observation

Check ignition timing
using a timing light

Check valve clearance

Test cylinder

ression

com

Check carburetor for
clogging

Engine speed

increases

Correct

Correct

Normal

compression

Symptom

Engine speed does no
increase sufficiently

Incorrect

Incorrect

Abnormal

compression

Probable Cause

Clogged air cleaner
Poor fuel flow (Restricted)
Clogged fuel tank cap breather

hole
Clogged exhaust muffler
Carburetor fuel level too low
Clogged carburetor high speed
fuel passage

Faulty CDI unit
Faulty pulser coil

Improper valve clearance
adjustment
Excessively worn valve seat
(protruded valve stem)

Improper valve and seat contact
Worn cylinder and piston rings
Leaking cylinder head gasket
Improper valve timing

Remove spark plug and
inspect

Check crankcase for oil
level and condition

Remove cylinder head oil
pipe bolt and inspect

Check for engine
overheating

Rapidly accelerate or run
at high speed

Not clogged

Plug not fouled or

discolored

Correct and not

contaminated

Valve train
lubricated properly

Engine does not

overheats

Engine does not knock

Clogged

Plug fouled or

discolored

Incorrect or

contaminated

Valve train not
lubricated properly

Engine overheats

Engine knocks

Clean and unclog

Fouled spark plug
Incorrect heat range plug

Oil level too high
Oil level too low
Oil not changed

Clogged oil cooler
Clogged oil line
Faulty oil pump

Worn cylinder and piston rings
Mixture too lean
Poor quality fuel
Excessive carbon buildup in
combustion chamber
Ignition timing too advanced

Excessive carbon build-up in
combustion chamber
Poor quality fuel
Clutch slipping
Mixture too lean
Ignition timing too advanced

1-15

21

1. GENERAL INFORMATION

POOR PERFORMANCE (AT HIGH SPEED)

Inspection/Adjustment Symptom Probable Cause

Check ignition timing

QUANNON 125

Check valve clearance

Check fuel filter for

fuel supply

Check carburetor for

clogged jets

Correct

Correct

Fuel flows freely

Not clogged

Incorrect

Incorrect

Fuel flow restricted

Clogged

Faulty CDI unit
Faulty pulser coil

Improperly adjusted valve clearance
Worn valve seat

Empty fuel tank
Clogged fuel filter
Clogged fuel tank cap breather
hole

Clean and unclog

Check valve timing

Check valve spring

tension

Correct

Not weakened

Incorrect

Weak spring

Cam timing gear aligning marks
not aligned

Faulty spring

1-16

22

1. GENERAL INFORMATION

POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING)
Undercharging

QUANNON 125

Inspection/Adjustment

Start engine and test limit
voltage between battery
terminals

Measure resistance
between AC generator
coil terminals

Connect battery (+) wire
to regulator/rectifier
coupler red wire and
battery (-) wire to engine
ground and test voltage

Check regulator/rectifier
coupler for loose
connection

Normal voltage

Normal

Normal voltage

Normal

Symptom

Voltage does not
increase

Resistance too high

No voltage

Abnormal

Probable Cause

Dead battery
Faulty battery

Faulty coil
Broken pink and yellow wires
Shorted pink and yellow wires

Broken red wire

Faulty regulator/rectifier
Poorly connected coupler

Overcharging

Inspection/Adjustment

Connect battery (+) wire
to regulator/rectifier
coupler black wire and
battery (-) wire to engine
ground and test voltage

Check regulator/rectifier
coupler for loose
connection

1-17

Battery has voltage
with ignition switch
“ON”

Normal

Symptom

Battery has no
voltage with ignition
switch “ON”

Abnormal

Faulty A.C. generator

Probable Cause

Broken black wire

Poorly connected coupler

Faulty regulator/rectifier

23

1. GENERAL INFORMATION

NO SPARK AT SPARK PLUG

QUANNON 125

Inspection/Adjustment Symptom

Replace with a new
spark plug and inspect
again

Weak or no spark

Check spark plug cap
and ignition coil wire for
looseness

Not loose

Check CDI unit coupler
for looseness

Normal

Measure resistance
between CDI unit coupler
wire terminals

Good spark

Loose

Abnormal

Probable Cause

Faulty old spark plug

Loose spark plug cap

Poorly connected coupler

Check related parts

Check CDI unit with a
CDI unit tester

Check ignition coil with a
CDI unit tester

Normal

Normal

Normal

Abnormal

Abnormal

Abnormal

Abnormal

Faulty ignition switch
Faulty exciter coil
Faulty pulser coil
Faulty ignition coil

Broken wire harness
Poorly connected coupler

Faulty CDI unit

Faulty ignition coil

1-18

24

2. INSPECTION/ADJUSTMENT

2

________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________

QUANNON 125

2

INSPECTION/ADJUSTMENT

________________________________________________________________________________

SERVICE INFORMATION----------------------------------------------------------------------- 2- 1
MAINTENANCE SCHEDULE------------------------------------------------------------------- 2- 2
FUEL TUBE/FILTER------------------------------------------------------------------------------ 2- 3
THROTTLE OPERATION ----------------------------------------------------------------------- 2- 3
AIR CLEANER ------------------------------------------------------------------------------------- 2- 4
SPARK PLUG -------------------------------------------------------------------------------------- 2- 4
VALVE CLEARANCE----------------------------------------------------------------------------- 2- 5
CARBURETOR IDLE SPEED------------------------------------------------------------------ 2- 5
IGNITION TIMING--------------------------------------------------------------------------------- 2- 6
CYLINDER COMPRESSION------------------------------------------------------------------- 2- 6
ENGINE OIL ---------------------------------------------------------------------------------------- 2- 7
DRIVE CHAIN -------------------------------------------------------------------------------------- 2- 7
BRAKE SHOE/BRAKE PEADAL -------------------------------------------------------------- 2- 8
CLUTCH --------------------------------------------------------------------------------------------- 2- 8
BRAKE FLUID-------------------------------------------------------------------------------------- 2- 8
SUSPENSION-------------------------------------------------------------------------------------- 2- 9
NUTS/BOLTS/FASTENERS-------------------------------------------------------------------- 2- 9
WHEELS/TIRES ----------------------------------------------------------------------------------- 2- 9
STEERING HANDLEBAR----------------------------------------------------------------------- 2- 10

2-0

25

2. INSPECTION/ADJUSTMENT

SERVICE INFORMATION

GENERAL

！ WARNING

xBefore running the engine, make sure that the working area is well-ventilated. Never run the

engine in a closed area. The exhaust contains poisonous carbon monoxide gas which may
cause death to people.

xGasoline is extremely flammable and is explosive under some conditions. The working area

must be well-ventilated and do not smoke or allow flames or sparks near the working area or
fuel storage area.

SPECIFICATIONS

ENGINE CHASSIS

Throttle grip free play : 2阡6mm Rear brake free play: 10阡20mm
Spark plug gap : 0.6阡0.7mm Brake fluid : DOT-3 or DOT-4
Spark plug specification : CR8E
Valve clearance: IN: 0.06mm

EX: 0.06mm

QUANNON 125

Cylinder compression : 13kg/cm²
Ignition timing :

Idle speed : 1600 r100rpm
Engine oil capacity:
At disassembly : 1.1 liter
At change : 1.0 liter

TIRE PRESSURE

Front 1.75kg/cm² 1.75kg/cm²

Rear 2.0kg/cm² 2.25kg/cm²

TIRE SIZE:
Front : 110/80-17 57P
Rear : 140/70-17 66P

TORQUE VALUES

30q±2/4000rpm

1 Rider 2 Riders

Front axle nut 5.5阡7.0 kg-m
Rear axle nut 6.0阡8.0 kg-m
Rear fork pivot nut 5.5阡7.0 kg-m

2-1

26

2. INSPECTION/ADJUSTMENT

r

MAINTENANCE SCHEDULE

Perform the periodic maintenance at each scheduled maintenance period.
I: Inspect, and Clean, Adjust, Lubricate, Refill, Repair or Replace if necessary.
A: Adjust C: Clean R: Replace T : Tighten

QUANNON 125

Frequency

Item

Engine oil
Engine oil filter screen C C C C C C
Fuel filter screen R R
Valve clearance
Carburetor I I I
Air Cleaner Note 2,3 C C C R C C R
Spark plug Clean at every 6000km and replace if necessary
Brake system A A A A A A A
Drive chain A A A A A A

Whicheve
comes
first

Ö

Ø

1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000

R
300km

RRRRR R

Regular Service Mileage (km)

AA A

Suspension I I
Nuts, bolts, fasteners T T T T T T T
Tire IIIIII I

xIn the interest of safety, we recommend these items should be serviced only by an authorized

KYMCO motorcycle dealer.
Note: 1. For higher odometer readings, repeat at the frequency interval established here.

2. Service more frequently when riding in dusty or rainy areas.

3. Service more frequently when riding for long distance, in rain or at full throttle.

2-2

27

2. INSPECTION/ADJUSTMENT

r

A

FUEL TUBE/FILTER

Check the fuel tube and replace any parts
which show signs of deterioration, damage
or leakage.

＊

Do not smoke or allow flames or sparks
in your working area.

QUANNON 125

THROTTLE OPERATION

Check for smooth throttle grip movement in
all steering positions.
Measure the throttle grip free play.

Free Play: 2阡6mm

Adjust the throttle grip free play by turning
the adjusting nut on the throttle cable.
Slide the dust boot out and adjust by
loosening the lock nut and turning the
adjusting nut.

Fuel Filte

Fuel Tube

Check if the punch mark on the carburetor
accelerating pump is aligned.
Align the punch mark by turning the adjusting
nut at the accelerating pump cable.

Dust Boot

djusting Nut

Lock Nut

2-3

28

2. INSPECTION/ADJUSTMENT

r

AIR CLEANER
AIR CLEANER REPLACEMENT

Remove the fuel tank. Remove the six
screws attaching the air cleaner cover.
Remove the air cleaner cover.
Remove the air cleaner of element.
Check the element and replace it with a new
one if it is excessively dirty or damaged.

CHANGE INTERVAL

More frequent replacement is required when
riding in unusually dusty or rainy areas.

xThe air cleaner element has a viscous

type paper element. Do not clean it
with compressed air.

xBe sure to install the air cleaner

element and cover securely.

QUANNON 125

Element

SPARK PLUG

Remove the spark plug.
Check the spark plug for wear, damage and
fouling deposits.
Clean any fouling deposits with a spark plug
cleaner or a wire brush.

Specified Spark Plug: CR8E

Measure the spark plug gap.

Spark Plug Gap: 0.6阡0.7mm

＊

When installing, first screw in the spark
plug by hand and then tighten it with a
spark plug wrench.

Spark Plug

Gap, Wear, and
Fouling Deposits

Cracks
Damage

Washe
Deformatio

2-4

29

2. INSPECTION/ADJUSTMENT

VALVE CLEARANCE

＊

Inspect and adjust valve clearance while
the engine is cold (below 35℃).

Remove the fuel tank.
Remove four bolts on the cylinder head
cover.
Remove the cylinder head cover protector.
Remove the cylinder head cover.

Rotate the generator flywheel to locate the
camshaft on the top dead center (TDC) and
align the “T” mark on the flywheel with the
mark on the left crankcase cover.

＊

After adjustment, rotate the crankshaft
several turns to make sure that the valve
clearance is correct.

QUANNON 125

Bolts

“T” Mark

Inspect and adjust the valve clearance.
Valve Clearance: IN : 0.06mm

EX: 0.06mm

Loosen the lock nut and adjust by turning the
adjusting bolt.

Special Tool

Tappet Adjust E012

＊

Check the valve clearance again after
the lock nut is tightened.

CARBURETOR IDLE SPEED

＊

The engine must be warm for accurate
idle speed inspection and adjustment.

Turn the throttle stop screw to obtain the
specified idle speed.

Idle Speed: 1600r100rpm
When the engine misses or run erratic,

adjust the pilot screw.

Feeler Gauge

＊

When adjusting the carburetor, make
sure to use the E/M tester.

2-5

Pilot Screw

Throttle Stop Screw

30

2. INSPECTION/ADJUSTMENT

IGNITION TIMING

＊

xThe CDI unit is not adjustable.
xIf the ignition timing is incorrect, check

the ignition system.

Remove the ignition timing eyes hole cap on
the left crankcase cover.

Check the ignition timing with a timing light.
When the engine is running at idle speed,
the ignition timing is correct if the index mark
on the left crankcase cover aligns with the
“F” mark on the flywheel.

QUANNON 125

Eyes Hole

CYLINDER COMPRESSION

Warm up the engine before compression
test.
Stop the engine, then remove the spark plug
and insert a compression gauge.
Open the throttle valve fully and crank the
engine with the starter motor or kick lever.
Measure the compression.

Compression: 13kg/cm

If the compression is low, check for the
following:

匠Leaky valves
匠Valve clearance too small
匠Leaking cylinder head gasket
匠Worn piston rings
匠Worn piston/cylinder

If the compression is high, it indicates that
carbon deposits have accumulated on the
combustion chamber and the piston head.

²

Timing Light

“F” Mark

Compression Gauge

2-6

31

2. INSPECTION/ADJUSTMENT

A

ENGINE OIL

＊

When checking the oil level, place the
motorcycle on its main stand on level
ground for oil level check.

After the engine is stopped for 10 minutes,
check if the oil level is between the upper and
lower limits through the wash window.
If the oil level is low, add the recommended
oil to the proper level.

Recommended Oil: SAE15W40#

After oil change, be sure to tighten the drain
bolt securely.
Check the drain bolt washer for damage.

Oil Capacity: At disassembly : 1.1 liter

At change : 1.0 liter

Engine Oil Filter Screen Cleaning

Remove the oil filter screen cap.
Remove the oil filter screen and spring and
then clean with compressed air.

QUANNON 125

Watch Window

＊

Be careful not to install the oil filter
screen in the reverse direction to avoid
engine damage.

DRIVE CHAIN

Check the drive chain slack.
Specified Slack: 1阡2cm
Drive Chain Adjustment:

1. Loosen the rear axle nut.

2. Adjust the right and left adjusting nuts to

align the right punch mark with the left
punch mark.

3. The rear wheel turn to see if the drive

chain slack is within the specified range.

4. Tighten the rear axle nut.

＊

After drive chain adjustment, check the
rear brake pedal free play and adjust if
necessary.

Oil Filter Screen Cap

Rear Axle Nut

djusting Nut

2-7

32

2. INSPECTION/ADJUSTMENT

A

A

BRAKE SHOE

Inspect the front brake linings for wear.

BRAKE LEVER/PEDAL

Measure the rear brake pedal free play.

Free Play: 10阡20mm

QUANNON 125

CLUTCH

Measure the clutch lever free play.
Free Play: 10阡20mm
When minor adjustment is required, adjust

by turning the adjusting nut on the clutch
lever side.
When major adjustment is required, adjust
by turning the adjusting nut on the clutch
cable from the right crankcase cover.
Adjust by loosening the lock nut and turning
the adjusting nut. After adjustment, tighten
the lock nut.

BRAKE FLUID

Turn the steering handlebar upright and
check if the brake fluid level is between the
upper and lower limits.

Specified Brake Fluid: DOT-3 or DOT-4

djusting Nut

Lock Nut

djusting Nut

Lock Nut

Lower Limit

2-8

33

2. INSPECTION/ADJUSTMENT

SUSPENSION
FRONT

Fully apply the front brake lever and check
the action of the front shock absorbers by
compressing them several times.
Check the entire shock absorber assembly
for oil leaks, looseness or damage.

REAR

Check the action of the rear shock absorber
by compressing it several times.
Check the entire shock absorber assembly
for oil leaks, looseness or damage.
Jack the rear wheel off the ground and move
the rear wheel sideways with force to see if
the engine hanger bushings are worn.

NUTS/BOLTS/FASTENERS

Check all important chassis nuts and bolts
for looseness.
Tighten them to their specified torque values
if any looseness is found.

QUANNON 125

WHEELS/TIRES

Check the tires for cuts, imbedded objects or
other damages.
Check the tire pressure.

＊

Tire pressure should be checked when
tires are cold.

TIRE PRESSURE

1 Rider 2 Riders
Front 1.75kg/cm² 1.75kg/cm²
Rear 2.00kg/cm² 2.25kg/cm²

TIRE SIZE

Front 110/80-17

Tire Pressure Gauge

Rear 140/70-17

2-9

34

2. INSPECTION/ADJUSTMENT

Check the front and rear axle nuts for
looseness.
If the axle nuts are loose, tighten them to the
specified torques.

Torques: Front : 5.5阡7.0kg-m

Rear : 6.0阡8.0kg-m

STEERING HANDLEBAR

Check that the control cables do not interfere
with handlebar rotation.
Raise the front wheel off the ground and
check that the steering handlebar rotates
freely.
If the handlebar moves unevenly, binds, or
has vertical movement, adjust the steering
head bearing.

QUANNON 125

Front Axle Nut

2-10

35

3. LUBRICATION SYSTEM

3

________________________________________________________________________________

QUANNON125

________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________

SERVICE INFORMATION----------------------------------------------------------------------- 3- 2
TROUBLESHOOTING --------------------------------------------------------------------------- 3- 2
ENGINE OIL/OIL FILTER SCREEN ---------------------------------------------------------- 3- 3
OIL PUMP/OIL FILTER ROTOR--------------------------------------------------------------- 3- 4

3

3-0

36

3. LUBRICATION SYSTEM

LUBRICATION SYSTEM

QUANNON125

3-1

37

3. LUBRICATION SYSTEM

SERVICE INFORMATION

GENERAL INSTRUCTIONS

xThe service and maintenance of this section can be performed with the engine installed in the

frame.

xUse care when removing and installing the oil pump not to allow dust and foreign matters to enter

the engine and oil line.

xThe oil pump must be replaced as a set when it reaches its service life.
xAfter the oil pump is installed, check each part for oil leaks and improper lubrication.
xWhen removing and installing the oil cooler, be careful not to bend or deform the oil pipe.

SPECIFICATIONS

Item Standard (mm) Service Limit (mm)

Inner rotor-to-outer rotor clearance  0.20

Oil pump Outer rotor-to-pump body clearance  0.20

Rotor end-to-pump body clearance 0.015阡0.10 0.15

QUANNON125

TROUBLESHOOTING
Oil level too low Engine burns

xNatural oil consumption x Low or no lubrication pressure
xOil leaks x Clogged oil passages
xWorn or poorly installed piston rings x Not use the specified oil
xWorn valve guide or seal
xClogged or leaky oil pipe

3-2

38

3. LUBRICATION SYSTEM

ENGINE OIL/OIL FILTER
OIL LEVEL

＊

xPlace the motorcycle upright on level

ground for engine oil level check.

xRun the engine for 2阡3 minutes and

check the oil level after the engine is
stopped for 2阡3 minutes.

Check the oil level through the watch window.
If the level is near the lower limit, fill to the
upper limit with the specified engine oil.

OIL CHANGE

＊

The engine oil will drain more easily
while the engine is warm.

QUANNON125

Upper Limit

Lower Limit

Remove the drain bolt to drain the engine oil
thoroughly.
Check the drain bolt washer for damage or
deformation and replace with a new one if
necessary.

Remove the oil filter screen cap and then
remove the oil filter screen and spring.
Clean the oil filter screen with compressed
air.
Check the filter screen cap O-ring for
damage or deformation and replace if
necessary.
Install the oil filter screen, spring and filter
screen cap.
Torque: 1.5kg-m

＊

Do not install the oil filter screen upside
down.

Oil Capacity: At disassembly : 1.1 liter

At change : 1.0 liter
Check for oil leaks and then start the engine
and let it idle for few minutes.
Stop the engine and recheck the oil level.

Drain Bolt

Oil Filter Screen Cap

3-3

39

3. LUBRICATION SYSTEM

r

r

r

r

p

OIL PUMP/OIL FILTER ROTOR
REMOVAL

1. Disconnect the clutch cable.

2. Remove the right crankcase cover 13 bolts

and right crankcase cover.

3. Check the cover gasket, oil seal and O-ring

for oil leaks or damage. Replace with new
ones if necessary.

＊

When installing, make sure to use a new
right crankcase cover gasket.

Remove the three screws attaching the oil
filter rotor cover to remove the cover.
Remove the oil filter rotor lock nut with a
square socket and then remove the washer
and oil filter rotor.

Remove the oil pump cap two bolts.

QUANNON125

Bolts

Right Crankcase Cove

Screws

＊

During installation, install the washer
with the mark “OUTSIDE” facing up.

Remove the 6mm nut on top of the oil pump
driven gear.

Remove the oil pump driven gear and chain.
Remove the oil pump mounting two bolts.
Remove the oil pump body.

Oil Pum

Oil Pump Driven Gea

Oil Pump Body

Oil Filter Roto

Drive Gea

Bolts

3-4

40

3. LUBRICATION SYSTEM

r

r

r

DISASSEMBLY

Remove the pump cover attaching screw.

INSPECTION

Measure the pump body-to-outer rotor
clearance.

Service Limit: 0.20mm

QUANNON125

Screw

Feeler Gauge

Measure the inner rotor-to-outer rotor
clearance.

Service Limit: 0.20mm

Measure the rotor end-to-pump body
clearance.

Service Limit: 0.15mm

Outer Roto

Feeler Gauge

Outer Roto

Oil Pump Body

Inner Roto

3-5

Feeler Gauge

41

3. LUBRICATION SYSTEM

r

r

r

r

r

Nut

QUANNON125

ASSEMBLY

Install the outer rotor and inner rotor into the
pump body. Insert the pump shaft.

＊

Insert the pump shaft by aligning the flat
on the shaft with the flat in the inner
rotor.

Install the pump cover.
Tighten the screw.
After installation, make sure that the pump
shaft rotates freely.

INSTALLATION

Install the pump body and tighten the two
mounting bolts.
Install the oil pump driven gear and chain.

Inner Roto

Outer Roto

Pump Cove

Bolts

Tighten the 6mm nut on top of the oil pump
driven gear.

Install the oil pump gear cover and tighten
the two bolts.
Install the oil filter rotor lock nut.

Torque: 4.0阡5.0kg-m

＊

During installation, install the washer
with the mark “OUTSIDE” facing up.

Pump Shaft

Driven Gea
Lock Nut

Pump Gear Cove

3-6

42

4. FUEL SYSTEM

4

________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________

QUANNON 125

4

FUEL SYSTEM

________________________________________________________________________________

SERVICE INFORMATION----------------------------------------------------------------------- 4-2
TROUBLESHOOTING --------------------------------------------------------------------------- 4-3
THROTTLE CABLE DISASSEMBLY--------------------------------------------------------- 4-4
CARBURETOR REMOVAL--------------------------------------------------------------------- 4-4
FLOAT/FLOAT VALVE/JETS/ACCELERATING PUMP--------------------------------- 4-5
FLOAT LEVEL INSPECTION ------------------------------------------------------------------ 4-7
CARBURETOR INSTALLATION -------------------------------------------------------------- 4-8
THROTTLE VALVE ASSEMELY -------------------------------------------------------------- 4-9
AIR CUT-OFF VALVE(A.C.V.) ----------------------------------------------------------------- 4-9
FUEL TANK----------------------------------------------------------------------------------------- 4-10
AIR CLEANER REMOVAL---------------------------------------------------------------------- 4-10

4-0

43

4. FUEL SYSTEM

QUANNON 125

4-1

44

4. FUEL SYSTEM

SERVICE INFORMATION
GENERAL INSTRUCTIONS

Gasoline is very dangerous. When working with gasoline, keep sparks and flames away

from the working area.

Gasoline is extremely flammable and is explosive under certain conditions. Be sure to work in

a well-ventilated area.

xDo not bend or twist control cables. Damaged control cables will not operate smoothly.
xWhen disassembling fuel system parts, note the locations of O-rings. Replace them with new

ones during reassembly.

xBefore float chamber disassembly, loosen the drain screw to drain the residual gasoline into a

clean container.

xAfter the carburetor is removed, plug the intake manifold side with a clean shop towel to prevent

foreign matters from entering.

xThe carburetor air jets and fuel jets must be cleaned with compressed air.
xWhen the motorcycle is not used for over one month, drain the residual gasoline from the float

chamber to avoid erratic idling and clogged slow jet due to deteriorated fuel.

QUANNON 125

SPECIFICATIONS

Item Standard
Type CVK
Venturi dia. I25

Float level 17 mm
Main jet 108#
Slow jet 35#
Idle speed 1600r100rpm
Throttle grip free play 2阡6mm
Pilot screw opening 2r½

4-2

45

4. FUEL SYSTEM

TROUBLESHOOTING
Engine cranks but won’t start Engine lacks power

xNo fuel in tank x Clogged air cleaner
xNo fuel to carburetor x Faulty carburetor
xCylinder flooded with fuel x Faulty ignition system
xNo spark at plug
xClogged air cleaner Lean mixture
xIntake air leak x Clogged carburetor fuel jets
xImproper throttle operation x Float level too low

x Intake air leak
Engine idles roughly, stalls or runs poorly x Faulty charcoal canister
xExcessively used choke x Restricted fuel line
xIgnition malfunction
xFaulty carburetor Rich mixture
xPoor quality fuel x Float level too low
xLean or rich mixture x Clogged air jets
xClogged air cleaner x Clogged air cleaner
xIncorrect idle speed x Restricted A.C.V. tube
xFaulty charcoal canister x Worn throttle needle

QUANNON 125

Misfiring during acceleration

xFaulty ignition system
xFaulty carburetor
xFaulty accelerating pump
xFaulty charcoal canister

Backfiring at deceleration

xFloat level too low
xIncorrectly adjusted carburetor
xFaulty A.C.V.
xFaulty exhaust muffler
xFaulty A.I.C.V.

4-3

46

4. FUEL SYSTEM

A

r

A

A

r

THROTTLE CABLE DISAASEEMBLY

Remove the fuel tank.
Loosen the air cleaner connecting tube band
screws then remove the air cleaner.

Loosen the throttle cable adjusting nut and
lock nut, then disconnect the throttle cable
from the carburetor.

QUANNON 125

ir Cleane

Intake Manifold Band

Throttle Cable

Loosen the drain screw and drain the fuel
from the float chamber.
Disconnect the fuel tube and vacuum tube at
the carburetor.
Loosen the carburetor intake manifold band
and remove the carburetor.
Disconnect the auto bystarter wire coupler
and P.T.S wire coupler.

CARBURETOR REMOVAL

Loosen the drain screw to drain the gasoline
from the float chamber.

＊

xKeep sparks and flames away from the

work area.

xDrain gasoline into a clean container.

Look Nut

Intake Manifold Band

P.T.S

djusting Nut

uto Bystarte

Fuel Tube

Disconnect the fuel inlet tube and auto
bystarter wire coupler and P.T.S wire
coupler.

4-4

47

4. FUEL SYSTEM

r

Loosen the air cleaner connector band
screw.
Remove the two carburetor lock nuts.
Remove the carburetor

Pull out the throttle valve.
Pry off the needle retainer and remove the

jet needle.
Check the throttle valve and jet needle for
wear or damage.

QUANNON 125

Screws

CARBURETOR DISASSEMBLY
FLOAT/FLOAT VALVE/JETS/

ACCELERATING PUMP
Float/Float Valve Disassembly

Remove the float chamber attaching three
screws and remove the float chamber.

Float/Float Valve Inspection

Remove the float pin, float and float valve.
Inspect the float valve seat for wear or
damage.
Inspect the float for damage or fuel level
inside the float chamber.

Float Chambe

Screws

Float

4-5

Float Pin

48

4. FUEL SYSTEM

A

Main Jet/Jets/Pilot Screw/Throttle Stop
Screw Removal

Remove the main jet, needle jet holder, and
needle jet.
Remove the slow jet.
Remove the pilot screw and throttle stop
screw.

QUANNON 125

CAUTIONS !

＊

xBe careful not to damage the jets and

jet holder when removing them.

xBefore removing, turn the throttle stop

screw and pilot screw in and carefully
count the number of turns until they
seat lightly and then make a note of
this.

xDo not force the screw against its seat

to avoid seat damage.

xBe sure to install the O-ring in the

reverse order of removal.

Accelerating Pump Removal

Remove the two accelerating pump cover
screws and accelerating pump cover.
Remove the spring and accelerating pump
diaphragm.

Main Jet

Slow Jet

Pilot Screws

Screws

Inspection

Inspect the accelerating pump diaphragm for
cracks, damage or deterioration. Replace
with a new one if necessary.

Diaphragm

Spring

ccelerating

Pump Cover

4-6

49

4. FUEL SYSTEM

Carburetor Cleaning

Blow compressed air through all passages of
the carburetor body.

Slow Jet/Main Jet Installation

Install the slow jet.
Install the needle jet, needle jet holder and
main jet.
Install the throttle stop screw and pilot screw.

＊

xWhen installing the pilot screw, return it

to the original position as noted during
removal

xAfter the carburetor is installed, be sure

to perform the Exhaust Emission Test.

Main Jet

Slow Jet

Float

QUANNON 125

Pilot Screws

Install the float valve, float and float pin.

FLOAT LEVEL INSPECTION

Turn the carburetor upside down so that the
float will go down to make the float valve
contact the float valve seat.
Then slowly tilt the carburetor and measure
the float level with the float level gauge while
the float pin just contacts with float valve.

Float Level: 17mm
When adjusting, carefully bend the float pin.

Check the float for proper operation and then
install the float chamber.

Float Pin

4-7

50

4. FUEL SYSTEM

A

r

r

Accelerating Pump Installation

First install the accelerating pump
diaphragm.
Install the spring.
Install the accelerating pump cover and
tighten the two screws.

＊

When installing the diaphragm, be sure
to position it correctly.

CARBURETOR INSTALLATION

Install the carburetor onto the intake
manifold and tighten the two lock nuts.

Torque: 0.8阡1.2kg-m
Install the air cleaner connector and tighten

the band screw.

QUANNON 125

ccelerating Pump Cove

THROTTLE VALVE ASSEMBLY

Install the jet needle into the throttle valve
and secure with the needle retainer.

Assemble the rubber cover, carburetor cap
and throttle valve spring.
Connect the throttle cable to the throttle
valve.

Throttle Valve

Jet Needle

Needle Retaine

Carburetor Cap

4-8

51

4. FUEL SYSTEM

A

r

QUANNON 125

AIR CUT-OFF VALVE (A.C.V.)
REMOVAL

Remove the throttle stay plate set.
Disconnect the tubes that go to the air cut-off
valve.
Remove the two attaching screws.
Remove the air cut-off valve.

DISASSEMBLY

Remove the two attaching screws to remove
the air cut-off valve cover.
Remove the spring and diaphragm.

INSPECTION

Inspect the check valve for proper operation.
Inspect the air cut-off valve diaphragm and
O-ring for deterioration or damage.
Replace with new ones if necessary.
Clean each air passage with compressed air.

.C.V.

Screws

Spring

THROTTLE POSITION SENSOR
INSPECTION

Measure the resistance on the T.P.S. of
terminals.

Wire Color Full Open Full Close

V/R-V/G 4.8~6.2kΩ 4.8~6.2kΩ
V/B-V/G 4.16~6.24kΩ 1.47~2.21kΩ
V/R-V/B 2.3~3.5kΩ 5.1~7.5kΩ

AUTO BYSTARTER INSPECTION

Measure the resistance between the auto
bystarter wire terminals.

Resistance: 14-20: (10 minutes
minimum after stopping the engine)

If the reading is not within the limit, replace
the auto bystarter with a new one.

Diaphragm

V/R

Throttle Position Senso

Screws

V/B

V/G

4-9

52

4. FUEL SYSTEM

QUANNON 125

FUEL TANK
FUEL TANK REMOVAL

Warning

xKeep sparks and flames away from the

work area.

xWipe off any spilled gasoline.

Remove the right and left side covers and
the right and left decorative covers under the
fuel tank.
Remove the rear seat.
Remove the rear seat lock bolt and remove
the front seat.

Remove the auto fuel valve.
Disconnect the fuel tube and remove the bolt
on the end of the fuel tank.
Disconnect the fuel unit wire connector and
fuel gauge wire.
Remove the fuel tank.

FUEL TANK INSTALLATION

Install the fuel tank in the reverse order of
removal.
Check that there is no fuel leakage.
Check the wire connectors for proper
connection.

Nut

AIR CLEANER REMOVAL

Remove the right side cover.
Remove the two bolts attaching the emission
control system.
Remove the rear carrier. (Refer to 4-10.)
Remove the seat. (Refer to 4-10.)
Remove the two air cleaner case attaching
bolts.
Remove the air cleaner and carburetor
connecting tube band.

Remove the air cleaner from the right side.

4-10

53

5. ENGINE REMOVAL/INSTALLATION

QUANNON 125

5 .

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

5

ENGINE REMOVAL/INSTALLATION

________________________________________________________________________________

SERVICE INFORMATION----------------------------------------------------------------------- 5-1
ENGINE REMOVAL------------------------------------------------------------------------------- 5-2
ENGINE INSTALLATION------------------------------------------------------------------------ 5-3

5-0

54

5. ENGINE REMOVAL/INSTALLATION

SERVICE INFORMATION

GENERAL INSTRUCTIONS

xA engine stand or floor jack is required to support and maneuver the engine.
xThe following parts can be serviced with the engine installed in the frame:

 Cylinder head/valves (Section 6)
 Cylinder/piston (Section 7)
 Starter motor/generator/left crankcase cover/starter clutch/camshaft (Section 8)
 Clutch/gear shift mechanism (Section 9)

xWhen removing and installing the engine, do not use a hammer or screw driver to strike or pry the

engine.

xDo not damage the crankcase mating surfaces and clean off all gasket materials from the mating

surfaces.

xAfter crankcase assembly, check that the transmission system operates smoothly.
xAfter engine installation, start the engine and check that the lubrication system is normal.

QUANNON 125

Engine oil capacity:
At disassembly : 1.1 liter
At change : 1.0 liter

TORQUE VALUES

Engine bracket bolt 2.0阡2.5 kg-m
Drive gear lock bolt 0.8阡1.2 kg-m
Exhaust muffler hanger lock bolt 2.4阡3.0 kg-m
Rear fork pivot nut 5.5阡7.0 kg-m
Exhaust muffler joint lock nut 0.8阡1.2 kg-m

5-1

55

5. ENGINE REMOVAL/INSTALLATION

r

r

A

r

r

t

QUANNON 125

ENGINE REMOVAL

Remove the carburetor. (Refer to 4-4.)
Disconnect the clutch cable.
Remove the crankcase breather.
Remove the two exhaust muffler joint lock
nuts.
Remove the exhaust muffler hanger lock bolt
and exhaust muffler.

＊

xDrain the engine oil before engine

removal.

xThe exhaust muffler temperature is

extremely high. Remove it when the
engine is cold.

Remove the spark plug cap.
Remove the starter motor wire.

Remove the two bolts attaching the left rear
crankcase cover and remove the rear
crankcase cover.

Intake Manifold

Clutch Cable

Bolts

Exhaust Muffler Join

Spark Plug Cap

Remove the two bolts attaching the drive
gear set plate and the set plate.
Remove the drive gear and chain.

Disconnect the A.C. generator wire
connector.

Rear Crankcase Cove

Generator Wire Connecto

Bolt

Set Plate

Drive Chain

Drive Gea

.C.G Wire Connecto

5-2

56

5. ENGINE REMOVAL/INSTALLATION

r

t

t

r

Remove the two nuts on the cooling oil
container and move the cooling oil container.
Remove the AICV tube.

QUANNON 125

Remove the three bolts attaching the engine
front bracket and the bracket.
Remove the two engine hanger bolts and the
hanger.
Remove the two bolts attaching the engine
rear bracket.
Remove the engine from left to right.

ENGINE INSTALLATION

Install the engine in the reverse order of
removal. Install the engine to its original
position with a jack or other adjustable
support.

Cooling Oil Containe

Rear Bracke

Upper Hange

＊

xWhen installing the engine, do not

damage the bolt thread and route the
wires and cables properly.

xInstall the gear shift lever by align the

punch mark on the lever with that on the
spindle.

xFill the crankcase to the proper level with

recommended engine oil.

xAfter installation, perform the following

inspections and adjustments:

1. Throttle operation

2. Clutch lever free play adjustment

3. Drive chain adjustment

5-3

Front Bracke

57

6. CYLINDER HEAD/VALVES

QUANNON 125

6 .

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

CYLINDER HEAD/VALVES

__________________________________________________________________________________

SCHEMATIC DRAWING------------------------------------------------------------------------- 6-1
SERVICE INFORMATION----------------------------------------------------------------------- 6-2
TROUBLESHOOTING --------------------------------------------------------------------------- 6-3
CYLINDER HEAD COVER REMOVAL ------------------------------------------------------ 6-4
CAMSHAFT REMOVAL-------------------------------------------------------------------------- 6-4
CAMSHAFT INSPECTION---------------------------------------------------------------------- 6-5
CYLINDER HEAD REMOVAL------------------------------------------------------------------ 6-6
CYLINDER HEAD DISASSEMBLY ----------------------------------------------------------- 6-7
CAMSHAFT INSTALLATION------------------------------------------------------------------- 6-10
CYLINDER HEAD COVER INSTALLATION ----------------------------------------------- 6-11

6

6-0

58

6. CYLINDER HEAD/VALVES

SCHEMATIC DRAWING

QUANNON 125

6-1

59

6. CYLINDER HEAD/VALVES

SERVICE INFORMATION
GENERAL INSTRUCTIONS

xThe cylinder head can be serviced with the engine installed in the frame.
xWhen assembling, apply molybdenum disulfide grease or engine oil to the valve guide movable

parts and valve arm sliding surfaces for initial lubrication.

xThe valve rocker arms are lubricated by engine oil through the cylinder head engine oil passages.

Clean and unclog the oil passages before assembling the cylinder head.

xAfter disassembly, clean the removed parts and dry them with compressed air before inspection.
xAfter removal, mark and arrange the removed parts in order. When assembling, install them in

the reverse order of removal.

QUANNON 125

SPECIFICATIONS

Item 125 cc

Valve clearance (cold)

Cylinder head compression pressure 11~13 kg/cm²
Cylinder head warpage 

Camshaft cam height

Valve rocker arm I.D.
Valve rocker arm shaft

O.D.
Valve seat angle

Valve stem O.D.

Valve guide I.D.
Valve stem-to-guide

Clearance

IN

EX 0.06

IN 30.800阡30.920 ＜30.75

EX 30.411阡30.531 ＜30.26

IN 12.00阡12.015 ＞12.10

EX 12.00阡12.015 ＞12.10

IN 12.00阡11.980 ＜11.90

EX 12.00阡11.980 ＜11.90

IN 89° ~ 90° ＞90°

EX 89° ~ 90° ＞90°

IN 5.00阡5.012 ＜4.925

EX 5.00 ＜4.925

IN 5.00阡5.012 ＞5.03

EX 5.00阡5.012 ＞5.03

IN 0.010阡0.037 ＞0.08

EX 0.030阡0.057 ＞0.10

Standard (mm) Service Limit (mm)

0.06 

125 cc



＞8 kg/cm²

＞0.05

6-2

60

6. CYLINDER HEAD/VALVES

TORQUE VALUES

Cylinder head nut 2.3~2.8 kg-m
Cylinder head side bolt 0.8~1.2 kg-m
Valve clearance adjusting nut 0.9 kg-m
Cylinder head cover bolt 0.8阡1.2 kg-m

SPECIAL TOOLS

Valve spring compressor E040

TROUBLESHOOTING

xThe poor cylinder head operation can be diagnosed by a compression test or by tracing engine

top-end noises.

Poor performance at idle speed White smoke from exhaust muffler

xCompression too low x Worn valve stem or valve guide

x Damaged valve stem oil seal

Compression too low

xIncorrect valve clearance adjustment Abnormal noise
xBurned or bend valves x Incorrect valve clearance adjustment
xIncorrect valve timing x Sticking valve or broken valve spring
xBroken valve spring x Damaged or worn camshaft
xPoor valve and seat contact x Worn cam chain tensioner
xLeaking cylinder head gasket x Worn camshaft and rocker arm
xWarped or cracked cylinder head
x Poorly installed spark plug

QUANNON 125

Compression too high

xExcessive carbon build-up in combustion

chamber

6-3

61

6. CYLINDER HEAD/VALVES

r

r

r

r

CYLINDER HEAD COVER REMOVAL

Remove the cylinder head cover bolts and
then remove the cylinder head cover.

CAMSHAFT REMOVAL

Turn the A.C. generator flywheel so that the
“T” mark on the flywheel aligns with the index
mark on the crankcase.
Hold the round hole on the camshaft gear
facing up and the location is the top dead
center on the compression stroke.

QUANNON 125

Cylinder Head Cove

Bolts

Nuts

Remove the bolts attaching cam chain
tensioner to remove the tensioner.

Then remove the four cylinder head nuts and
washers.

＊

xDiagonally loosen the cylinder head

cap nuts in 2 or 3 times.

Remove the camshaft holder and dowel pins.

Cam Chain

Cam Chain Tensione

Camshaft Holde

Camshaft Gea

6-4

62

6. CYLINDER HEAD/VALVES

Remove the camshaft gear from the cam
chain to remove the camshaft.

QUANNON 125

Cam Chain

CAMSHAFT INSPECTION

Check each cam lobe for wear or damage.
Measure the cam lobe height.

Service Limits:

IN: 30.75mm replace if below
EX:30.26mm replace if below

Check each camshaft bearing for play or
damage. Replace the camshaft assembly
with a new one if the bearings are noisy or
have excessive play.

Camshaft

Camshaft Bearings

CAMSHAFT HOLDER DISASSEMBLY

Take out the valve rocker arm shafts using a
6mm bolt.
Remove the valve rocker arms.

6-5

Valve Rocker Arms

Rocker Arm Shafts

6mm Bolt

63

6. CYLINDER HEAD/VALVES

CAMSHAFT HOLDER INSPECTION

Inspect the camshaft holder, valve rocker
arms and rocker arm shafts for wear or
damage.

＊

If the valve rocker arm contact surface is
worn, check each cam lobe for wear or
damage.

Measure the I.D. of each valve rocker arm.
Service Limits:
IN 12.10mm replace if over
EX 12.10mm replace if over

Measure each rocker arm shaft O.D.
Service Limits:
IN 11.90mm replace if below
EX 11.90mm replace if below

QUANNON 125

Rocker Arm Shafts

CYLINDER HEAD REMOVAL

Remove the camshaft. (Ö6-4)
Remove the carburetor and intake manifold.
Remove two bolts on the cylinder head.
Remove the cylinder head.

Remove the dowel pins and cylinder head
gasket.
Remove the cam chain guide.
Remove all gasket material from the cylinder
head mating surface.

＊

Be careful not to drop any gasket
material into the engine.

Cam Chain Tensioner Slipper

Bolts

Cylinder Head Gasket

Cam Chain

Cylinder

Cam Chain Guide

6-6

64

6. CYLINDER HEAD/VALVES

r

r

CYLINDER HEAD DISASSEMBLY

Remove the valve spring cotters, retainers,
springs, spring seats and valve stem seals
using a valve spring compressor.

＊

xBe sure to compress the valve springs

with a valve spring compressor.

xMark all disassembled parts to ensure

correct reassembly.

Remove carbon deposits from the exhaust
port and combustion chamber.

＊

Be careful not to damage the cylinder
head mating surface.

QUANNON 125

Cylinder Head

Valve Spring Compresso

Combustion Chambe

6-7

65

6. CYLINDER HEAD/VALVES

QUANNON 125

INSPECTION

CYLINDER HEAD
Check the spark plug hole and valve areas for

cracks.
Check the cylinder head for warpage with a
straight edge and feeler gauge.

Service Limit: 0.05mm repair or replace if

over

VALVE SPRING FREE LENGTH
Measure the free length of the inner and outer

valve springs.
Service Limits:

(IN, EX) : 29.1mm replace if below

Straight Edge

Feeler Gauge

VALVE /VALVE GUIDE
Inspect each valve for bending, burning,

scratches or abnormal stem wear.
Check valve movement in the guide.

Measure each valve stem O.D.
Service Limits:

IN 4.925mm replace if below
EX 4.925mm replace if below

Measure each valve guide I.D.
Service Limits:

IN 5.03mm replace if over
EX 5.03mm replace if over

Subtract each valve stem O.D. from the
corresponding guide I.D. to obtain the stem­to-guide clearance.
Service Limits:
IN 0.08mm replace if over
EX 0.10mm replace if over

＊

If the stem-to-guide clearance exceeds
the service limits, replace the guides as
necessary. Reface the valve seats
whenever the valve guides are replaced.

6-8

66

6. CYLINDER HEAD/VALVES

r

r

CYLINDER HEAD ASSEMBLY

Install the valve spring seats and valve stem
seals.

＊

Be sure to install new valve stem seals.

Apply engine oil to the inside of the valve
stem seals and insert the valves into the
valve guides.

Install the valve springs and retainers.
Compress the valve springs using the valve
spring compressor, then install the valve
cotters.

＊

xWhen assembling, a valve spring

compressor must be used.

xInstall the cotters with the pointed ends

facing down from the upper side of the
cylinder head.

QUANNON 125

Special Tool

Valve Spring Compressor E040

Tap the valve stems gently with a plastic
hammer to firmly seat the cotters.

＊

Be careful not to damage the valves.

CYLINDER HEAD INSTALLATION

Install the cam chain guide.
Install the dowel pins and a new cylinder
head gasket.

Valve Spring Compresso

Plastic Hamme

Cylinder Head

Dowel Pins

6-9

Cam Chain Guide

Gasket

67

6. CYLINDER HEAD/VALVES

r

Install the cylinder head and take out the cam
chain

Torque: Cylinder side bolt 0.8~1.2kg-m

Assemble the camshaft holder.
First install the intake and exhaust valve
rocker arms; then install the rocker arm shafts.

＊

xInstall the exhaust valve rocker arm

shaft on the “EX” side of the camshaft
holder and the exhaust rocker arm
shaft is shorter.

xClean the intake valve rocker arm shaft

off any grease before installation.

xAlign the cutout on the exhaust valve

rocker arm shaft with the bolt of the
camshaft holder.

QUANNON 125

Cylinder side bolt

Valve Rocker Arms

CAMSHAFT INSTALLATION

Turn the A.C. generator flywheel so that the
“T” mark on the flywheel aligns with the index
mark on the crankcase.
Keep the round hole on the camshaft gear
facing up and align the punch marks on the
camshaft gear with the cylinder head surface
(Position the intake and exhaust cam lobes
down.) and install the cam chain over the
camshaft gear.
Install the dowel pins.

Camshaft Holde

Cam Chain

Dowel Pins

6-10

68

6. CYLINDER HEAD/VALVES

A

r

r

r

Install the camshaft holder, washers and nuts
on the cylinder head.
Tighten the four cylinder head nuts and the
two bolts between the cylinder head and
cylinder.

Torque: Cylinder head nut 2.3~2.8kg-m

x

＊

pply engine oil to the threads of the

cylinder head cap nuts.

xDiagonally tighten the cylinder head

cap nuts in 2阡3 times.

xFirst tighten the cylinder head cap nuts

and then tighten the bolts between the
cylinder and cylinder head to avoid
cracks.

Install a new cam chain tensioner gasket.
Tighten the cam chain tensioner screw.

QUANNON 125

Washer

Install the cam chain tensioner and tighten
the two bolts.
Install the tensioner spring and tighten the
sealing bolt.

CYLINDER HEAD COVER INSTALLATION

Adjust the valve clearance. (Ö3-6)
Install a new cylinder head cover O-ring and
install the cylinder head cover.

＊

Be sure to install the O-ring into the
groove properly.

Install and tighten the cylinder head cover
bolts.

Torque: 0.8阡1.2kg-m

Cam Chain Tensione

Cam Chain Tensione

Cylinder Head Cove

Sealing Bolt

Bolt

6-11

69

7. CYLINDER/PISTON

QUANNON 125

7

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

CYLINDER/PISTON

________________________________________________________________________________

SCHEMATIC DRAWING------------------------------------------------------------------------- 7-1
SERVICE INFORMATION----------------------------------------------------------------------- 7-2
TROUBLESHOOTING --------------------------------------------------------------------------- 7-2
CYLINDER REMOVAL--------------------------------------------------------------------------- 7-3
PISTON REMOVAL------------------------------------------------------------------------------- 7-3
PISTON INSTALLATION ------------------------------------------------------------------------ 7-7
CYLINDER INSTALLATION -------------------------------------------------------------------- 7-7

7

7-0

70

7. CYLINDER/PISTON

SCHEMATIC DRAWING

QUANNON 125

7-1

71

7. CYLINDER/PISTON

r

SERVICE INFORMATION
GENERAL INSTRUCTIONS

xThe cylinder and piston can be serviced with the engine installed in the frame.
xWhen installing the cylinder, use a new cylinder gasket and make sure that the dowel pins are

correctly installed.

xAfter disassembly, clean the removed parts and dry them with compressed air before inspection.

SPECIFICATIONS

Standard (mm) Service Limit (mm)

Item

I.D. 52.400阡52.410 ＜52.50

Cylinde

Piston, Ring end gap Second
piston ring Oil side rail

. Piston-to-cylinder clearance

Piston pin O.D
Piston-to-piston pin clearance
Connecting rod small end I.D. bore

Warpage
Cylindricity
True roundness
Ring-to-groove top

clearance

Piston O.D.
Piston O.D. measuring position

Piston pin hole I.D.

Second
top







0.015阡0.050 ＜0.09

0.015阡0.050 ＜0.09

0.15阡0.30 ＜0.50

0.15阡0.30 ＜0.50

0.2阡0.9

52.370阡52.390 ＞52.30

10mm from bottom of skirt

0.010阡0.040 ＜0.01

15.000阡15.008 ＜15.06

14.994阡15.000 ＞14.96

0.002阡0.014 ＜0.02

15.016阡15.034 ＜15.06

QUANNON 125

＜0.05
＜0.05
＜0.05



TROUBLESHOOTING

xWhen hard starting or poor performance at low speed occurs, check the crankcase breather for

white smoke. If white smoke is found, it means that the piston rings are worn, stuck or broken.

Compression too low or uneven
compression Excessive smoke from exhaust muffler

xWorn or damaged cylinder and piston rings x Worn or damaged piston rings
xWorn, stuck or broken piston rings x Worn or damaged cylinder and piston

Compression too high Abnormal noisy piston

xExcessive carbon build-up in combustion x Worn cylinder, piston and piston rings

chamber or on piston head x Worn piston pin hole and piston pin

x Incorrectly installed piston

7-2

72

7. CYLINDER/PISTON

r

CYLINDER REMOVAL

Remove the cylinder head. (Ö6-7)

Remove the cam chain guide.
Remove the cylinder.

QUANNON 125

Cylinde

Remove the cylinder gasket and dowel pins.
Clean any gasket material from the cylinder
surface.

PISTON REMOVAL

Remove the piston pin clip.
Press the piston pin out of the piston.

＊

Place a clean shop towel in the
crankcase to keep the piston pin clip
from falling into the crankcase.

Cam Chain

Dowel Pins

Piston

7-3

Piston Pin

Shop Towel

73

7. CYLINDER/PISTON

Inspect the piston, piston pin and piston rings.
Remove the piston rings.

＊

xTake care not to damage or break the

piston rings during removal.

Clean carbon deposits from the piston ring
grooves.

Install the piston rings onto the piston and
measure the piston ring-to-groove clearance.

Service Limits:

Top: 0.09mm replace if over
2nd: 0.09mm replace if over

QUANNON 125

Remove the piston rings and insert each
piston ring into the cylinder bottom.

＊

xUse the piston head to push each

piston ring into the cylinder.

Measure the piston ring end gap.
Service Limit: 0.5mm replace if over

Measure the piston pin hole I.D.

Service Limit: 15.06mm replace if below

7-4

74

7. CYLINDER/PISTON

Measure the piston pin O.D.
Service Limit: 14.96mm replace if below

Measure the piston O.D.

＊

xTake measurement at 9mm from the

bottom and 90q to the piston pin hole.

Service Limit: 52.30mm replace if below
Measure the piston-to-piston pin clearance.

Service Limit: 0.02mm replace if over

QUANNON 125

CYLINDER INSPECTION

Inspect the cylinder bore for wear or damage.
Measure the cylinder I.D. at three levels of
top, middle and bottom at 90q to the piston
pin (in both X and Y directions).

Service Limit:

52.50mm repair or replace if below
Measure the cylinder-to-piston clearance.

Service Limit:

0.1mm repair or replace if over

The true roundness is the difference between
the values measured in X and Y directions.
The cylindricity (difference between the
values measured at the three levels) is
subject to the maximum value calculated.

Service Limits:
True Roundness:

0.05mm repair or replace if over
Cylindricity: 0.05mm repair or replace if over

IN

Top

Middle

Bottom

EX

7-5

75

7. CYLINDER/PISTON

Inspect the top of the cylinder for warpage.
Service Limit: 0.05mm repair or replace if over

Measure the connecting rod small end I.D.

Service Limit: 15.06mm replace if below

QUANNON 125

PISTON RING INSTALLATION

Install the piston rings onto the piston.
Apply engine oil to each piston ring.

＊

xBe careful not to damage the piston

and piston rings during assembly.

xAll rings should be installed with the

markings facing up.

xAfter installing the rings, they should

rotate freely without sticking.

xStagger the ring end gaps as the figure

shown.

Top

Second

Side Rail
Oil Ring
Side Rail

7-6

76

7. CYLINDER/PISTON

r

PISTON INSTALLATION

Remove any gasket material from the
crankcase surface.

＊

xBe careful not to drop foreign matters

into the crankcase.

Install the piston, piston pin and a new piston
pin clip.

＊

xPosition the piston “IN” mark on the

intake valve side.

xPlace a clean shop towel in the

crankcase to keep the piston pin clip
from falling into the crankcase.

QUANNON 125

Piston

CYLINDER INSTALLATION

Install the dowel pins and a new cylinder
gasket on the crankcase.

Coat the cylinder bore, piston and piston
rings with clean engine oil.
Carefully lower the cylinder over the piston by
compressing the piston rings.

＊

xBe careful not to damage or break the

piston rings.

xThe piston ring end gaps should not be

parallel with or at 90q to the piston pin.

Piston Pin

Cylinde

Piston Pin Clip

Dowel Pin

7-7

77

7. CYLINDER/PISTON

Loosely install the cylinder base bolt.

Install the cam chain guide.

＊

xInsert the tab on the cam chain guide

into the cylinder groove.

Install the cylinder head. (Ö6-13)
Tighten the cylinder base bolt.

QUANNON 125

Cam Chain Guide

7-8

78

8. STARTER MOTOR/GENERATOR/LEFT CRANK­CASE COVER/STARTER CLUTCH

8

________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________

QUANNON 125

________________________________________________________________________________

STARTER MOTOR/GENERATOR/LEFT CRANKCASE COVER/STARTER

CLUTCH/CAMSHAFT

________________________________________________________________________________

SERVICE INFORMATION----------------------------------------------------------------------- 8-2
TROUBLESHOOTING --------------------------------------------------------------------------- 8-2
STARTER MOTOR REMOVAL---------------------------------------------------------------- 8-3
LEFT CRANKCASE COVER/AC GENRATOR REMOVAL----------------------------- 8-3
STARTER CLUTCH REMOVAL--------------------------------------------------------------- 8-4
CAM CHAIN REMOVAL ------------------------------------------------------------------------- 8-5
STARTER GEAR INSTALLATION------------------------------------------------------------ 8-5
AC GENERATOR INSTALLATION ----------------------------------------------------------- 8-5
LEFT CRANKCASE COVER INSTALLATION--------------------------------------------- 8-6
STARTER MOTOR INSTALLATION --------------------------------------------------------- 8-6

8

8-0

79

8. STARTER MOTOR/GENERATOR/LEFT CRANK­CASE COVER/STARTER CLUTCH

QUANNON 125

8-1

80

8. STARTER MOTOR/GENERATOR/LEFT CRANK­CASE COVER/STARTER CLUTCH

SERVICE INFORMATION
GENERAL INSTRUCTIONS

xThe starter motor, generator, left crankcase and starter clutch can be serviced in the frame.
xDo not install the starter clutch forcedly.
xInstall the generator by aligning the groove in the flywheel with the key on the crankshaft.
xInstall the starter motor reduction gear shaft by aligning the shaft pin with the shaft seat groove.

SPECIFICATIONS

Item Standard (mm) Service Limit (mm)
Reduction gear shaft O.D. 9.972阡9.987 ＜9.932
Reduction gear shaft hole I.D. 10.031阡10.056 ＞10.096
Camshaft O.D. 13.966阡13.984 ＜13.926
Cam gear shaft hole I.D. 14.06阡14.078 ＞14.118
Roller O.D. 9.99阡10.005 ＜9.95
Starter gear shaft I.D. 22.01阡22.022 ＞22.062
Starter gear shaft O.D. 42.574阡42.6 ＜42.534

QUANNON 125

TORQUE VALUES

Flywheel lock bolt 4.0阡5.2 kg-m

SPECIAL TOOLS

Flywheel holder
Flywheel puller E005

TROUBLESHOOTING
Hard starting and poor performance at high speed Starting noise

xImproperly tightened flywheel lock bolt x Worn reduction gear

Starter clutch slips x Worn starter clutch roller
xWorn starter clutch roller x Faulty reduction gear shaft bearing
xFaulty starter clutch roller or spring
xWorn starter gear shaft O.D.

E021

x Worn starter gear

8-2

81

8. STARTER MOTOR/GENERATOR/LEFT CRANK-

g

r

y

r

r

r

CASE COVER/STARTER CLUTCH

STARTER MOTOR REMOVAL

Remove the starter motor mounting two bolts
and the motor.
Inspect the starter motor O-ring for damage
or deterioration.
Inspect the starter motor pinion for wear or
damage.

QUANNON 125

Remove the three bolts attaching the starter
motor reduction gear cover.
Remove the reduction gear cover.
Remove the reduction gear, shaft and
washers.
Inspect the reduction gear for wear or
damage.
Inspect the reduction gear cover O-ring for
damage or deterioration.

LEFT CRANKCASE COVER/ AC
GENERATOR REMOVAL

Disconnect the neutral light switch wire.
Remove the left crankcase cover eight bolts.
Remove the left crankcase cover and two
dowel pins.
Clean off all gasket material from the left
crankcase cover.
Remove the reduction pinion.

Cove

O-ring

Washers

Mountin

Reduction Gea

Bolts

Bolts

Shaft

Neutral Light Wire

Hold the flywheel with a flywheel holder.
Remove the flywheel lock bolt.
Remove the flywheel using a flywheel puller.

Special Tool

Flywheel holder
Flywheel puller E005

E021

Fl

wheel Holde

Flywheel Pulle

Flywheel

8-3

82

8. STARTER MOTOR/GENERATOR/LEFT CRANK-

r

r

r

CASE COVER/STARTER CLUTCH

STARTER CLUTCH REMOVAL

Remove the reduction pinion.
Remove the starter gear.

Starter Gea

INSPECTION

Measure the starter gear shaft I.D.

Service Limit: 22.062mm replace if over

QUANNON 125

Measure the starter gear shaft O.D.
Service Limit: 42.534mm replace if below

Measure the starter clutch roller O.D.
Service Limit: 9.95mm replace if below

Rolle

Starter Gea

Micrometer Calipers

8-4

83

8. STARTER MOTOR/GENERATOR/LEFT CRANK-

r

r

CASE COVER/STARTER CLUTCH

Cam Chain

CAM CHAIN REMOVAL

Remove the starter gear.
Remove the cam chain.

Cam chain guide bolt

Remove the cam chain guide bolt.

QUANNON 125

STARTER GEAR INSTALLATION

Install the cam chain guide and cam chain.
Install the starter gear.

AC GENERATOR INSTALLATION

Install the generator flywheel. Hold the
flywheel with a flywheel holder and tighten
the flywheel lock bolt.

＊

xInstall the flywheel by aligning the

groove in the flywheel with the key on
the crankshaft.

xWhen installing, be careful not to

damage the starter clutch rollers.

Starter Gea

Lock Bolt

Torque: 4.0阡5.2kg-m

8-5

Flywheel Holde

84

8. STARTER MOTOR/GENERATOR/LEFT CRANK­CASE COVER/STARTER CLUTCH

LEFT CRANKCASE COVER
INSTALLATION

Install the left crankcase cover and tighten
the eight bolts. (Refer to 8-3.)

Torque: 0.8阡1.2kg-m

QUANNON 125

Groove

Install the reduction gear, shaft and washers.
Then install the reduction gear cover and
tighten the three bolts.

Torque: 0.8阡1.2kg-m

＊

xInstall the reduction gear shaft by

aligning the shaft pin with the shaft
seat groove.

xApply engine oil to the reduction gear

cover O-ring before installation.

STARTER MOTOR I NSTALLATION

Apply engine oil to the starter motor O-ring
and then install it.
Install the starter motor.
Tighten the two mounting bolts.

Torque: 0.8阡1.2kg-m

Bolts

Mounting Bolts

8-6

85

9. CLUTCH/GEAR SHIFT MECHANISM

QUANNON 125

9 .

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

9

CLUTCH/GEAR SHIFT MECHANISM

________________________________________________________________________________

SERVICE INFORMATION----------------------------------------------------------------------- 9-2
TROUBLESHOOTING --------------------------------------------------------------------------- 9-2
RIGHT CRANKCASE COVER REMOVAL -------------------------------------------------- 9-3
CLUTCH REMOVAL------------------------------------------------------------------------------ 9-3
RIGHT CRANKCASE COVER INSTALLATION------------------------------------------- 9-9

9-0

86

9. CLUTCH/GEAR SHIFT MECHANISM

QUANNON 125

9-1

87

9. CLUTCH/GEAR SHIFT MECHANISM

SERVICE INFORMATION
GENERAL INSTRUCTIONS

● The clutch and gear shift mechanism can be serviced in the frame.

● Install the clutch plates in the chamfer direction.

● Install the thrust washer with the chamfer facing up and the flat facing down.

SPECIFICATIONS

Item Standard (mm) Service Limit (mm)
Clutch spring free length 35.5 ＜34.2
Clutch friction disk thickness 2.8阡2.9 ＜2.5
Clutch plate bending 0阡0.1 ＞0.2
Clutch outer I.D. 111阡111.5 ＞112.5

QUANNON 125

Clutch outer guide I.D. 30.0阡30.021 ＞30.40

TORQUE VALUES

Clutch center lock bolt 0.8阡1.2 kg-m

TROUBLESHOOTING
Clutch slips during acceleration Clutch won’t operate; motorcycle moves

xNo free play
xWorn friction disk x Excessive free play
xWeak spring x Bent clutch plate

Clutch won’t operate Too much pressure on clutch lever

xExcessive free play x Kinked, twisted or damaged clutch cable
xBent clutch plate x Damaged clutch lifter

Improper shifting Clutch does not operate smoothly

xEx

cessive clutch lever free play x Improper clutch outer groove machining

xBent gear shift spindle
xWorn or deformed gear shift plate Gear tripping
xDamaged transmission drum grooves x Faulty gear shift cam stopper
xFaulty gear shift cam stopper x Bent gear shift spindle
x Worn gear teeth

moves slow

ly

9-2

88

9. CLUTCH/GEAR SHIFT MECHANISM

r

r

r

RIGHT CRANKCASE COVER REMOVAL

Drain the engine oil.
Disconnect the clutch cable.
Remove the right crankcase cover attaching
13 bolts and right crankcase cover.
Remove the clutch lever and bearing.

QUANNON 125

Bolts

Remove the oil filter rotor cover. (Refer to
3-3.)
Remove the square nut.
Remove the square nut (left hand threads)
on the balance shaft driven gear.
Remove the oil filter rotor.

Remove the oil pump gear cover.
Remove the 6mm nut on top of the oil pump
driven gear.
Remove the oil pump driven gear and chain.
Remove the oil pump drive gear and clutch
outer drive gear from the crankshaft.

Guide Pin

Screws

Clutch

CLUTCH REMOVAL

Remove the four clutch lifter bolts.
Remove the clutch lifter and four tension
springs.

9-3

Clutch Oute

Tension Springs

Nut

Clutch Lifte

Bolts

Driven Gea

89

9. CLUTCH/GEAR SHIFT MECHANISM

p

r

y

r

r

y

r

r

Clutch Cente

Remove the 20mm circlip using a pair of pliers
and then remove the clutch center, clutch
friction disks and plates.

＊

xWhen removing the circlip, do not expand

it excessively to avoid deformation.

xInstall the circlip with the chamfered

side facing down.

20mm Circli

Remove the balance shaft drive gear and
woodruff key from the crankshaft.
Remove the special flange gasket on the
balance shaft driven gear, driven gear and
woodruff key from the balance shaft.
Remove the oil pump shaft.

Woodruff Ke

QUANNON 125

Woodruff Ke

＊

Be careful not to drop or lose the
woodruff keys.

Remove the thrust washer, clutch outer and
outer guide.

INSPECTION

CLUTCH TENSION SPRING
Measure each clutch tension spring free

length.
Service Limit: 34.20mm
Replace the spring with a new one if it is

shorter than the service limit.

Drive Gea

Clutch Oute

Balance Gea

Thrust Washe

9-4

90

9. CLUTCH/GEAR SHIFT MECHANISM

r

r

CLUTCH FRICTION DISK
Measure each clutch friction disk thickness.

Service Limit: 2.5mm replace if below

QUANNON 125

CLUTCH PLATE
Measure each clutch plate bending using a

feeler gauge.
Service Limit: 0.20mm replace if over

CLUTCH OUTER/OUTER GUIDE
Inspect the clutch outer groove for scratches

caused by
Measure the clutch outer I.D.

Service Limit: 112.5mm replace if over
Measure the clutch outer guide I.D.
Service Limit: 30.40mm replace if over

the friction disks.

Clutch Friction Disk

Feeler Gauge Clutch Plate

Vernier Calipe

GEAR SHIFT MECHANISM

Remove the gear shift pedal.
Remove the gear shift spindle and washer.

9-5

Gear Shift Spindle

Stoppe

91

9. CLUTCH/GEAR SHIFT MECHANISM

r

r

r

Remove the stopper and spring.
Remove the gear shift cam bolt.
Remove the gear shift cam and set pin.

QUANNON 125

Gear Shift Cam

Inspection

Inspect the gear shift cam stopper for wear
or looseness and replace if necessary.

Check the gear shift plate for wear or
deformation and replace if necessary.

Spring

Looseness

Stoppe

Stoppe

Wea

Wear/Deformation

Gear Shift Plate

Inspect the corners of the gear shift cam for
wear or damage. Replace the cam if the
corners are rounded.

Gear Shift Cam

9-6

92

9. CLUTCH/GEAR SHIFT MECHANISM

A

r

r

Installation

Install the gear shift cam stopper and spring.
Tighten the 6mm lock bolt.

Torque: 0.8阡1.2kg-m

QUANNON 125

Install the set pin into the transmission drum
hole.

Install the gear shift cam, aligning the pin
hole in the gear shift cam with the set pin.
Then, tighten the bolt.

Torque: 0.8阡1.2kg-m

＊

x

fter the gear shift cam is installed, put
the stopper in the gear shift cam groove
and tighten the stopper bolt.

xRotate the transmission drum to make

sure that the stopper operates properly.

Install the gear shift spindle and washer.
During installation, make sure that the return
spring aligns with the crankcase tab.

Gear Shift Cam

Gear Shift Cam Stoppe

Gear Shift Spindle

Install the oil pump body and insert the pump
shaft.
Install the balance shaft drive gear and
woodruff key onto the crankshaft.
Install the balance shaft driven gear and
woodruff key onto the balance shaft.

＊

Be sure to align the punch marks on the
drive and driven gears before installing
the woodruff key onto the balance shaft.

Drive Gea

Pump Shaft

9-7

93

9. CLUTCH/GEAR SHIFT MECHANISM

r

Install the clutch outer drive gear onto the
crankshaft.
Install the oil pump drive gear onto the
crankshaft.
Install oil pump driven gear and chain.

Oil Pump

Install the clutch outer and thrust washer.

＊

Install the thrust washer with the chamfered
side facing up.

Install the oil pump chain and driven gear
and secure it with the 6mm nut.
Install the clutch assembly.
Stagger the clutch friction disks and clutch
plates and then put them on the clutch center.
Then install the clutch center together with
the well-arranged friction disks and plates
into the clutch outer.

QUANNON 125

Thrust Washe

Install the circlip.

＊

Install the circlip with the chamfered side
facing down.

Install the tension springs and clutch lifter.
Install the washers to the bolts and tighten
the four bolts.

Torque: 0.8阡1.2kg-m
Install the clutch lifter guide pin.

20mm Circlip

Bolts

9-8

94

9. CLUTCH/GEAR SHIFT MECHANISM

r

r

r

Install the oil filter rotor.
Install the washer and tighten the square nut.

Torque: 4.0阡5.0kg-m

＊

Install the washer with the mark
“OUTSIDE” facing up.

Install the special flange gasket onto the
balance shaft driven gear with the flange
facing down and then loosely install the
square nut (left hand threads).
Tighten the square nut using the square
socket.

Install the oil filter rotor cover.
Check the gasket for wear or damage and
replace if necessary.
Install and tighten the three oil filter rotor

er screws.

cov
Torque: 0.3阡0.4kg-m
Install the oil pump gear cover and tighten

the two bolts.

Oil Filter Rotor Cove

QUANNON 125

Square Nut

Oil Filter Roto

Screws

RIGHT CRANKCASE COVER INSTALLATION

First install the dowel pins and then install
the gasket.
Install the right crankcase cover and tighten
the cover bolts.

Torque: 0.8阡1.2kg-m

＊

Tighten the right crankcase cover bolts
diagonally.

Right Crankcase Cove

9-9

95

9. CLUTCH/GEAR SHIFT MECHANISM

QUANNON 125

9-10

96

10. CRANKCASE/CRANKSHAFT/TRANS­MISSION SYSTEM/STARTER SPINDLE

10

________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________

QUANNON 125

________________________________________________________________________________

CRANKCASE/GRANKSHAFT/TRANS-MISSION

SYSTEM/STARTER SPINDLE

________________________________________________________________________________

SERVICE INFORMATION----------------------------------------------------------------------- 10-2
TROUBLESHOOTING --------------------------------------------------------------------------- 10-3
CRANKCASE REMOVAL ----------------------------------------------------------------------- 10-4
TRANSMISSION SYSTEM REMOVAL------------------------------------------------------ 10-4
STARTER SPINDLE------------------------------------------------------------------------------ 10-8
CRANKSHAFT ------------------------------------------------------------------------------------- 10-10
CRANKCASE INSTALLATION----------------------------------------------------------------- 10-12

10

10-0

97

10. CRANKCASE/CRANKSHAFT/TRANS­MISSION SYSTEM/STARTER SPINDLE

QUANNON 125

10-1

98

10. CRANKCASE/CRANKSHAFT/TRANS-

r

r

r

r

r

r

r

r

r

r

MISSION SYSTEM/STARTER SPINDLE

SERVICE INFORMATION
GENERAL INSTRUCTIONS

xDuring crankcase

crankcase deformation or damage.

xAfter separation, be careful not to damage the right and left crankcase mating surfaces to avoid

oil leakage.

xReplace the gasket with a new one during reassembly of the crankcase halves.
xAfter transmission system disassembly, make sure that the gear shifting operation is normal

before reassembly of the remaining parts.

xApply engine oil to the transmission system and crankshaft before reassembly.

SPECIFICATIONS

Balance shaft
Transmission

fork
Transmission fork shaft O.D. 11.976阡11.994 ＜11.936

Transmission
drum O.D.

Transmission
gear

Crankshaft

separation, do not separate the crankcase halves with an iron hammer to avoid

Item Standard (mm) Service Limit (mm)
Left 16.964阡16.984 ＜16.924
Right 16.964阡16.984 ＜16.924
Claw thickness 4.93阡5.0 ＜4.43
Shaft hole I.D. 12阡12.018 ＞12.058

Left 12.966阡12.984 ＜12.926
Right 20.959阡20.98 ＜20.919

Main shaft starter gea
Main shaft 4th gea
Main shaft 5th gea

Gear I.D.

Main Shaft
O.D.

Countershaft
O.D.

Connecting rod big end side clearance 0.05阡0.3 ＞0.8
Connecting rod big end radial 0阡0.008 ＞0.05
Runout 0.03 ＞0.1

Countershaft starter idle 19.52阡19.541 ＞19.581
Countershaft 1st gea
Countershaft 2nd gea
Countershaft 3rd gea
Left crankcase side 14.978阡14.989 ＜14.938
Starter gea
4th/5th gea
Right crankcase 14.966阡14.984 ＜14.926
Left crankcase 21.959阡21.98 ＜21.919
1st gea
2nd gear 21.959阡21.98 ＜21.919
3rd gea

20.055阡20.095 ＞20.135
20阡20.021 ＞20.061

20.02阡20.041 ＞20.061

20.02阡20.041 ＞20.081

22.020阡22.041 ＞22.081
20阡20.021 ＞20.061

19.959阡19.98 ＜19.919

19.959阡19.98 ＜19.919

16.466阡16.484 ＜16.426

19.959阡19.98 ＜19.919

QUANNON 125

10-2

99

10. CRANKCASE/CRANKSHAFT/TRANS­MISSION SYSTEM/STARTER SPINDLE

SPECIAL TOOLS

Bearing remover
Bearing remover block
Universal bearing puller
Bearing outer driver, 32x35mm
Bearing outer driver, 37x40mm
Bearing outer driver, 42x47mm
Bearing outer driver, 52x55mm
Pilot, 15mm
Pilot, 17mm
Pilot, 20mm
Pilot, 22mm
Inner bearing driver handle
Bearing outer driver, I.D. 30mm

QUANNON 125

TROUBLESHOOTING
Excessive engine noise

xWorn main shaft journal bearing
xWorn crankshaft pin bearing
xWorn transmission bearings

Transmission gear tripping

xWorn gear teeth
xBent transmission fork
xBent transmission fork shaft
xDamaged gear shift cam stopper

Hard shifting

xImproperly adjusted clutch
xBent or damaged transmission fork
xBent transmission fork shaft
xBent gear shift spindle
x Damaged transmission drum grooves

10-3

100