KYMCO QUANNON 125 User Manual

123

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

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

1. GENERAL INFORMATION

QUANNON 125

________________________________________________________________________________

GENERAL INFORMATION

________________________________________________________________________________

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

1. GENERAL INFORMATION

SERIAL NUMBER

QUANNON 125

Location of Frame Serial Numbe

Location of Engine Serial Numbe

1-1

1. GENERAL INFORMATION

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

(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

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

)

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

)

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

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

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

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

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

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

1 8 4 4 2 2

8 8

6 5

6 6

8 8x79 6x22

6 6x25

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

0.8阡1.2

0. 8阡1.5

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

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

6.0阡8.0

5.5阡7.0

6.0阡8.0

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

1. GENERAL INFORMATION

LUBRICATION POINTS

Throttle Cable

Clutch Cable

QUANNON 125

Seat Lock

1-9

Rear Fork Bearing

Speedometer Gear/ Front Wheel Bearing

1. GENERAL INFORMATION

CABLE & HARNESS ROUTING

Relay High Light

Speed Cable

Relay Low Light

QUANNON 125

Wire Harness

Resisto

Horn

1-10

1. GENERAL INFORMATION

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

1. GENERAL INFORMATION

QUANNON 125

Regulator/Rectifie

CDI

Starter Relay

Fuse

Battery (+) Cable

.C.G Wire Couple

1-12

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

1. GENERAL INFORMATION

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

1. GENERAL INFORMATION

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

Normal

compression

Symptom

Engine speed does no increase sufficiently

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

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

Fuel flows freely

Not clogged

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

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

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

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

2. INSPECTION/ADJUSTMENT

________________________________________________________________________________

QUANNON 125

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

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

2. INSPECTION/ADJUSTMENT

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

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

2. INSPECTION/ADJUSTMENT

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

2. INSPECTION/ADJUSTMENT

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

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

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