Free travel of clutch: 10-20mm

Please adjust free travel of clutch in the following way:

(1) Loosen mandrill to lock nut1

(2) Twist in or out the mandril2 to adjust free travel of front brake handle, after adjusting free travel to 10-20mm.

(3) Install mandrill tight and lock nut1.

Front/Rear Suspension System

Front suspension

Grasp the front brake handle and compress upward and downward the front shock absorber to check its actuator.

Check if the front shock absorber leaks oil and if the components are loosened.

 

 

Rear suspension

Compress upward and downward the rear shock absorber to check its actuator.

Check if components on the rear shock absorber are loosened or injured.

Lift and support the rear wheel and swing the wheel to check if engine suspension bushing is loosened.

Bolt/Nut/Fastening Part

Inspect bolts, nuts and fastening parts at every part of the motorcycle for looseness.

If it is loose, tighten it to specified torque.

 

Wheel Rim/Tyre

Check if there is crack, nails and similar sharp objects, and other injuries on the tyres.

 

 

Inspect pneumatic pressure of tyres.

 

 

* Attention

Measure cold inflation tyre pressure

Specified air pressure Unit: Kpa

Tyre specifications	Tyre pressure
QJ125GY-16A	Front tyre	100/80-17	225ЎА10kpa
Rear tyre	130/80-17	225ЎА10kpa

Change a new tyre when decorative pattern depth on tyre middle reaches the degree of the right picture.

 

Minimum decorative pattern depth
Front tyre	1.6mm
Back tyre	2.0mm

 

 

Warning: Do not try to mend damaged tyre because wheel balance and tyre reliability may be worsen. To inflate tyre in a wrong way will cause unusual tread abrasive wear and threaten safety. To inflate tyre less may cause slipping or casting and cause tyre deflate. When tyre is abrased over, it is dangerous to drive and goes against ground adhesion and driving.

Check if lock nut of front shaft is loosened.

Check if lock nut of rear shaft is loosened.

If loosened, tighten it to specified torque.

Torsion force: Front shaft 100-113NЎ¤m

Back shaft nut 100-113NЎ¤m

Steering Stem Bearing and Handle Fixation

Move the left and right handle and check if lead wires disturb it.

Rotate front wheel and confirm handle can move smoothly.

If the handle does not move smoothly and is loosened, check steering stem bearing.

Check and Maintenance of Body

Front liquid brake block

A Thickness of brake shoe: 7.8mm Use limits: 3.8mm B Torsion force to Install Bolt 1: 22-34NЎ¤m C Torsion force to Install Bolt 7: 30-35NЎ¤m D Torsion force to Install Bolt 14: 5-10NЎ¤m E Torsion force to Install Bolt 16: 2-5NЎ¤m F Torsion force to Install Bolt 18: 5-10NЎ¤m

ўЕ Inner hexagon screw M8*35 ўЖ Gasket 8 ўЗ Front liquid brake block units ўИ Brake cylinder units

ўЙ Brake shoe units ўК Sealing gasket ўЛ Erection bolt in oil tube ўМ Brake house units ўН Oil pump units

ўО Handle ўП Thin nut M6 ўР Handle screw ўС Fixed cover ўТ Bolt M6*25 ўУ Brake switch units

ўФ Countersunk flat Phillips heads for exposed screws M4*12 ўХ Mandrill ўЦ Self-locking nut M6
Back liquid brake block

A Thickness of brake shoe: 7.0mm Use limits: 3.7mm B Torsion force to Install Bolt 3: 5-10NЎ¤m C Torsion force to Install Bolt 4: 5-10 NЎ¤m D Torsion force to Install Bolt 7: 30-35 NЎ¤m E Torsion force to Install Bolt 12: 22-34NЎ¤m F Torsion force to Install Bolt 23: 30-35 NЎ¤m

ўЕ Rear liquid brake block units ўЖ Gasket 6 ўЗ Inner hexagon screw M6*16 ўИ Inner hexagon screw M6*16 ўЙ Gasket 6 ўК Oil pump assembly ўЛ Brake switch assembly ўМ Seal ring ўН Lining I ўОLining II ўП Connecting plate ўРInner hexagon screw M8*20 ўСGasket 8 ўТ Brake cylinder B ўУ Friction plate units ўФ Nut M6 ўХ Draw bar ўЦ Draw handle ўЧ Brake hose unit ўШ Oil tube (21) Hoop (22) Oil cup units (23) Hexagon flange head tapping screw (24) Protecting spring

I Braking System

Maintenance instruction--------------------1.1

Fault diagnosis-------------------------------1.2

Front hydraulic disc brake----------------- 1.3

Rear drum brake-----------------------------1.4

1.1 Maintenance Instruction

Precautions on operation

* Attention

• Please do not contaminate braking assembly with oil while assembly or disassembly. • Please use specified detergent to clean the braking assembly, or it may reduce braking performance.

* Please check braking system before driving your motorcycle.*

1.1.1 Specifications

project	Standard value	Available limits	project	Standard value	Available limits
front	Dedicated brake fluid	DOT4	-	back	Dedicated brake fluid	DOT4	-
thickness of liquid brake block	4.0	3.0	thickness of liquid brake block	5.0	4.0
thickness of brake shoe	9mm	4.5mm	thickness of brake shoe	9mm	4.5mm
diameter of liquid brake block	¦Х280mm	-	diameter of liquid brake block	¦Х240mm	-
Jump of liquid brake block	0.1mm	-	Jump of liquid brake block	0.1mm	-
Inner diameter of mercury oil cylinder	§¶12.7+0.027 0mm	-	Inner diameter of mercury oil cylinder	§¶14+0.027 0mm	-
Outer diameter of mercury oil piston	§¶12.7-0.050 -0.077mm	-	Outer diameter of mercury oil piston	§¶14-0.050 -0.077mm	-
Inner diameter caliper cylinder	§¶25+0.05 0mm	-	Inner diameter caliper cylinder	§¶30+0.05 0mm	-
Outer diameter of caliper piston	§¶25-0.07 -0.10mm	-	Outer diameter of caliper piston	§¶25-0.07 -0.10mm	-

1.1.2 Torsion force

Former brake disc retaining bolt 5-10NЎ¤m

Under the brake fluid before pump installation bolt 22-34NЎ¤m

Liquid brake oil pump before installation bolt 5-10NЎ¤m

Front wheel spindle 100-113NЎ¤m

Front wheel head bolt 5-10NЎ¤m

The brake disc retaining bolt 5-10NЎ¤m

Liquid brake pump installation after the bolt 22-34NЎ¤m

Back oil pump installing bolts liquid brake 5-10NЎ¤m

Back wheel spindle 100-113NЎ¤m

1.2 Fault diagnosis

1.2.1Brake in ill performing services

l Brake without adjustment well

l Abrasive wear of brake shoe units and liquid brake plate

l Improper installment of brake shoe units

l Pollution of liquid brake plate of brake shoe units

1.2.2 Brake reaction slowly or handle is tight

l Brake without adjustment well

l Abrasive wear of brake shoe units and liquid brake plate

Improper installment of brake shoe units

1.2.2 Brake with abnormal sound

l Abrasive wear of brake shoe units and liquid brake plate

l Pollution of liquid brake plate of brake shoe units

1.2.4 Braking handle/footstep is soft or light

l Air in hydraulic system

l Leakage of hydraulic system

l Braking footstep/plate is dirty

l Sealing abrasive wear of caliper piston

l Abrasive wear of braking footstep/plate

l Caliper is dirty

l Caliper can not slide well

l Lack of brake fluid

l Block of brake fluid pipe

l Bending/incompletion of caliper piston

l Bending/incompletion of master cylinder piston

l Master cylinder piston is dirty

l Braking handle/footstep is curving

1.2.5 Brake gets stuck or is pulled to one side

l Braking footstep/plate is dirty

l Deviation of wheels

l Block or restriction in brake hose joints

l Bending/incompletion of braking plate

l Caliper slides abnormally

1.2.6 Brake drag

l Braking footstep/plate is dirty

l Deviation of wheels

l Abrasive wear of braking footstep/plate

l Bending/incompletion of braking plate

l Caliper slides abnormally

1.2.7Brake handle/footstep is hard

l Block or restriction of brake system

l Adhere/abrasive wear of caliper piston

l Caliper slides abnormally

l Block/restriction of brake fluid pipe

l Sealing gasket abrasive wear of caliper piston

l Adhere/abrasive wear of master cylinder piston

l Braking handle/footstep is curving

1.3 Front Hydraulic Brake

1.3.1 Removal

 

* Attention

• Replace braking shoe assembly. • If a braking shoe assembly will be used again, please mark it on the side before removal so as to re-install it to its original place.

Loosen brake cylinder units and fix bolts.

Disassemble brake cylinder units from front damper

Disassemble the following units from front damper:

 

Front liquid brake block

1. Braking shoe

2. Front brake block oil pipe

3. Brake cylinder units

* Attention

•Please do not contaminate braking shoe assembly with oil while assembly or disassembly •Please use specified detergent to clean the braking assembly, or it may reduce braking performance.

Disassemble front axle

Take down front axle

Disassemble front liquid brake block from front wheel

 

1.3.2 Check

Check the abrasive wear condition of brake shoe. Replace it when necessary.

Measure brake shoeЎўbrake plate and then write down the maximum number.

Measure the thickness of brake shoe.