X Motion 125

Xmotion 125/250
OWNER-MANUAl
MAINTENANCE HANDBOOK
TAIWAN GOLDEN BEE CO.,LTD.

PDF created with pdfFactory Pro trial version www.pdffactory.com
TABLE OF CONTENT
1. REGULAR INSPECTION
1-1 Delivery Introduction ----------------------------------------------------- 2
1-2 Inspection Before Running --------------------------------------------- 4
1-3 Regular Maintenance Schedule -------------------------------------- 5
1-4 General Inspection -------------------------------------------------------6
1-5 Notes for Inspection ----------------------------------------------------- 7
2. MAINTENANCE INFORMATION
2-1 Specification Sheet ----------------------------------------------------- 8
2-2 Safety Precautions--------------------------------------------------------10
2-3 Special Tools -------------------------------------------------------------- 11
2-4 List of Grease & Oil Adopted ----------------------------------------- 24
2-5 Circuit Drawings --------------------------------------------------------- 25
2-6 Troubleshooting ---------------------------------------------------------- 27
2-7 Tighting Torque of Screws -------------------------------------------- 27
2-8 Troubleshooting ---------------------------------------------------------- 30
3. DESCRIPTION OF PARTS AND COMPONENTS
3-1 Engine --------------------------------------------------------------------- 39
3-2 Electric System ---------------------------------------------------------- 126
QQ
\J
\J
Rnrlv
1^1
UUUjf
I \J I
4. DISASSEMBLY REPAIRMENT
4-1 Notice for Disassembly Repairment ----------------------------- 137
4-2 Removal and lnstallation of Engine -------------------------------138
4-3 Removal and Inspection of Electric Items ----------------------- 199
4-4 Removal and Inspection of Body Parts ----------------------------206
4-5 Brake System ----------------------------------------------------------- 214
CHAPTER I
REGULAR INSPECTION
1-1 Delivery Introduction
1-4 General Inspection
1-2 Inspection Before Running
1-5 Notes for Inspection
1-3 Regular Maintenance Schedule _______________________
1-1 Delivery Introduction

To inform customers of correct methods to use: To practically and correctly
ride a scooter according to the Instruction of Manual and Maintenance
Handbook. Customers should also try in person according to this manual.
1. Starting:
A. Turn the power switch to "ON."
B. Hold the front or rear brake and press the "START" button.
C. If the scooter is not started, release the "START" button and try again after a few
minutes. Each start should be less than five seconds to avoid battery consumption.
Note: This is an AUTO-CHOKE scooter, thus there is no choke lever.
The fuel is controlled only by throttle grip.
The accelerator has to return to its original place when the scooter is not in use.
D. If the scooter can not be started by the "START" button, try the kick starter.
2. Fuel:
Inform customers to refill the fuel to no more than 80% of the tank capacity only.
2
2
1-1 Delivery Introduction 3

. Lubricant Adopted:
A. WARNING : The engine oil must be refilled when the oil warning lamp lights, otherwise the
engine will be burned-out due to insufficient lubrication. Recommended oil : TGB Genuine
EXTRA 4X OIL.
B. Genuine TGB HYPOID GEAR OIL(or SAE85W-140) will be adopted as gear oil to be
changed on a periodical basis. Gear oil and engine oil are different in their nature.
Attention should be paid to avoid mistake when used.
4. Regular Inspection and Maintenance:
Inform customers of the importance of inspection before running and regular inspection.
A. Inspection Before Running: Riders should perform nspection by themselves before
running.
B. Regular Inspection: Regular inspection should be performed after the first month and
the sixth month and every six months afterwards.
5. Description of Warranty System:
Clearly identify the content of warranty in accordance with the warranty paper.
A. Content and term of warranty.
B. Maintenance items not guaranteed.
C. Items should be followed by customers.
Instruct customers to carry the OWNER'S Manual with them when they come for regular
inspection and maintenance. It is because such inspection should be recorded onto the
Manual.
3
3
1-2 Inspection Before Running

Items to be Inspected Before Running by Customers:
ITEM
CONTENT
GUIDELINE
1. Starter
Is the oil volume

proper?
1 .Check Oil Warning Lamp to see if the oil

volume is proper?
2 .Fuel
Is the fuel volume

sufficient?
1 .Check fuel volume to see if it is enough

to the destination.
3. Lamp &
Direction
Indicator
Is the lamp condition

well? Is there any
dirt?
1 .Check if the lighting condition of head

lamp, tail lamp, licence lamp, brake lamp,
direction indicator and other lamp is well.
2. Lamps should be kept clean and
undamaged.
4. Back Mirror
Is the reflecting
image well?
1. Look at the back mirror from the

seat to check if the rear view is clear.
5. License Plate &

Reflector
No dirt and damage

should appear.
1. License plate should be installed, letters

and numbers should be kept clear and
clean. 2. Dirt and damage should not
appear on the reflector.
6 . Brake
Check the distance of

brake handle lever
and the brake effect.
1 .Operate the handle lever slowly to the

brake begin to effect in order to inspect the
moving distance. 2.Test the brake with low
speed running to see the brake effect of
front and rear brakes.
7. Tire
1.Is the air pressure

proper?
2.Groove should be
deep enough.
3.Unusual wear is not
desired.
4.Breaking and damage
are not desired.
5.Metal, stone and
other articles are
not desired.
1 .Check if the air pressure of tire is

sufficient with a gauge or by sight.
1 .Check if the groove of tires is enough.
1 .Check landing flat of tire to see if
any unusual wear appears.
1 .Check landing flat and side to see if
any breaking or damage appear.
1 .Cneck if any cracking, stone or any
other article sticks into the tire.
1-3 Regular Maintenance Schedule

The chart below lists the recommended intervals for all the returned periodic service work
necessarily to keep the motorcycle operating at peak performance and utmost efficiency.
Mileages are expressed in terms of kilometers and months. These intervals judged by
odometer reading or month whichever comes first.
Item
\~^^^^
N,
Maintenance
^^\
300KM
kilometer
^^
Maintenance Interval
Check Items \
NEW
Every
Every
Every
Every
1000KM
3000KM
6000KM
12000KM
1 Month
2 Month
3 Month
4 Month
01
Air cleaner element(Remark)
02
Oil filter(Screen)
03
Engine oil
04
Tire, pressure
05
Battery
06
Spark plug
07
Carburetor(idle speed)
08
Steering bearing and handles
09
Check Transmission for leakage
10
Check crankcase for leakage
11
Transmission oil
12
Drive Belt/roller
13
Fuel tank switch and lines
14
Throttle valve operation and cable
15
Engine bolts and nuts
16
Cylinder head, cylinder, and piston
17
Exhaust system/cleaning carbon
18
Cam chain/ignition time
19
Valve clearance
20
Shock absorbers
21
Front/rear suspension
22
Main/side stands
I/L
23
Crankcase Blow - by system(PCV)
24
Coolant
25
Cooling fan, lines
26
Clutch disk
27
Brake mechanism/brake lining(pad)
28
Bolts/nuts for each components
R
Replacement for every 3000KM
R
I
Replacement for every 5000KM

(5 Month)
I
I
I
I
I
R
Remarks
*The above maintenance schedule is established by taking the monthy 1000 kilometers as
areference which ever comes first.
Code : I ~ Inspection, cleaning, and adjustment
C ~ Cleaning(replaced if necessary)
R ~ Replacement
L ~ Lubrication
Remark : 1. Clean or replace the air cleanr element more often whe the scooter is operated on
dusty roads or in the Heavily - polluted environment.
2. Maintenance should be performed more often if the scooter is frequently operated
in high speed and after the scooter has accumulated a higher mileage.
1-4 General Inspection General Inspection and Adjustment
* means adjustable.
Note: The ignition of this scooter by the use of crank-shaft which is 4 ignitions/revolution.
Special attention should be paid while setting the turning speed of Engine by Tachometer.
Brake
Disc
Tail Light/Turn
Fuses
Signal Light
Air Filter
Gear Oil
Spark Plug
Head Light
Raer Brake
Tire
Brake Disc
6
6
PDF created with

version
pdfFactory Pro trial

www.pdffactory.com
Head Lig
Tail Light/Turn
Signal Light
Raer
1-5 Notes for Inspection

ITEM
1
2
INSPECTION DETAILS
Be aware of smoke and fire while performing maintenance.
New Packing, Gasket, O Ring, locking pin should be used while
assembling.
3
4
Only designated TGB oils should be used on spare parts.

Clean the vehicle before maintenance to avoid dirt or mud on
disconnected parts.
The locking sequence of Bolt and Nut should be from inside to

outside, or in diagonal step. Reverse the sequence to loose.
6
7
Special tools should be used when necessary.

Attention should be paid to avoid damage or loss of disconnected parts. Clean
and grease properly before the assembly. No grease on Bolt's Thread.
8
9
Reconfirm each function after the assembly.

Special attention should be paid to the battery's electrolyte
and brake oil which will stam clothes.
CHAPTER 2
MAINTENANCE INFORMATION
2-1 Specification Sheet
CU8 (X-Motion 125)
sion
Length (mm)
Air Filter
Paper Type
Fuel Capacity
11 L
Fuel
2130
System
Dimen
W id t h ( mm)
840
Height (mm)
1380
Wheelbase (mm)
1500
Front
55
Rear
95
Carburetion
Type
CVK164
Venturi (mm)
25
Type
C.D.I.
Unload
mass
Ignition
Electric
Total
150
Front
102
Spark
CR8E
Rear
198
Pointgap (mm)
0.8+0.1
Total
300
system
Ma
s
Total mass
2 person/
150 kg
Tire
Front
120/70-14
Battery Type
GTX14-BS
type
Automatic
Clutch type
Centrifugal type
Transmission type
CVT
Gear Box
Automatic
Transmis Rear
140/60-13
sion
Engine
Engine Type
4 Stroke 4V electroplated
ceramic cylinders engine
Fuel Type
Petrol
Number of Cylinder
Single cylinder
Type
R1
0.79~2.72
R2
9.67
Gear
Bore X Stroke (mm )
57 X 48.8
Ratio
Cylinder Capacity
124.5 c.c.
Starter
Electric &Kick
raked angle ( )
Motion
Cooling System
Liquid
Tire Pressure (psi)
Front
28
Rear
32
system
Lamp
Lubrication system
Forced circulation & splashing
Reference and setting range(IN )
0.120.02 mm
Reference and setting range(EX)
0.120.02 mm
MaxSpeed (km/hr)
105 km/h
Idle speed (rpm )
1800+100 rpm
Max Power ( Kw/rpm )
9 kw/8750 rpm
Max Torque (Nm/rpm)
10.5Nm/8250rpm
Compression Ratio
10.5
Oil Spec.
SAE 10W-30
Oil Capacity ( L )
1L
Gear Oil Spec., Capacity
SAE 90,
Front Lamp
35W/35W-12V
Rear Lamp
5W-12V
Brake Lamp
21W-12V
Direction Lamp
21W-12V
Turn angel ( )
Braking system
Buffer
Suspension
Buffer
Frame Type
Left
Right
...
Front
Disk
Rear
Disk
Front
Hydraulic-pressed Spring type
Rear
Front
Hydraulic-pressed Spring
Rear
Welding Tube
0.11L
CUB (X-Motion 250)

Dimension
Mass
Length (mm)
2130
Width (mm)
840
Height (mm)
1380
Wheelbase (mm)
1500
Unload mass
Front
60
Rear
100
Total
160
Front
Total mass 2
person/ 150
kg
Tire
Engine
Fuel
System
Air Filter
Paper Type
Fuel Capacity
11 L
Type
...
Venturi (mm)
...
Type
E.C.U.
107
Spark
CR8E
Rear
203
Point ga (mm)
0.80.1
Total
310
Front
120/70-14
Rear
140/60-13
Carburetion
Ignition
Electric
system
Transm ission
Battery Type
GTX14-BS
type
Automatic
Clutch type
Centrifugal type
Engine Type
4 Stroke
Transmission type
CVT
Fuel Type
Petrol
Gear Box
Automatic
Number of Cylinder
Single cylinder
Bore X Stroke (mm )
71 X 63.3
Cylinder Capacity
249.4 c.c.
Starter
Electric
Cooling System
Liquid
Lubrication system
Reference and setting
Type
Gear
Ratio
Motion
system
R1
0.8~2.30
R2
7.42
raked angle ( )
Tire Pressure
Forced circulation &
(psi)
splashing
0.1 0.02 mm
Turn angel ( )
Front
28
Rear
32
Left
Right
Front
Disk
Rear
Disk
Front
Rear
Front
Rear
range(IN)
Reference and setting
Lamp
0.150.02 mm
range(EX)
Max Speed (km/hr)
128 km/h
Idle speed (rpm )
1650100 rpm
Max Power ( Kw/rpm )
17.2kw/8750 rpm
Max Torque (Nm/rpm)
22.7Nm/8250rpm
Compression Ratio
10.8
Oil Spec.
SAE 10W-30
Oil Capacity (L)
1.4 L
Gear Oil Spec.,Capacity
SAE 90, 0.18L
Front Lamp
35W/35W-12V
Rear Lamp
5W-12V
Brake Lamp
21W-12V
Direction Lamp
21W-12V
Braking system
Buffer
Suspension
Buffer
Frame Type
Welding Tube
9
9
2-2 Safety Precautions
Warning: Engine Exhaust

Please keep good ventilation during engine operation. Do not operate engine in closed-room.
The toxic carbon-oxygen (CO) in exhaust may lead human to loss conscious and even death.
Warning: Gasoline
The gasoline is very easy to burn or explode. Forbid any fire during inspection of gasoline
tank or gasoline leak.
Warning: Battery H2 and Battery Liquid
1. The battery liquid is toxic sodium liquid. Please do not contact the liquid with skin or eye. If
any contact happens, please wash with massive clean water and contact with doctor.
2. The released H2 from battery is explosive. Please keep good ventilation during charging
battery and forbid any fire.
Watch: Brake Fluid
The brake fluid can damage the painting on plastic. Please cover the plastic parts with towel
or cloth during maintenance of brake disk. If the brake fluid is split on plastic component,
please remove the fluid and wash the surface with water right away.
Watch: High Temperature of Engine
The engine cover, cylinder, and exhaust pipe have high temperature after starting of engine.
Please wear glove in maintenance of parts during engine operation, or maintenance should
be waited until engine is cooled.
10
2-3 Special Tools

125 ce:
11
12
LUOO'
U0JSJ9A
\BU}
U(\\M
P91B9J0
14
16
17
18
19
woo
UOJSJGA
jopejpd
\e\j\ ojd
LUOO Ajojoewpa Nwm UOJSJGA \BU} OJd jojoejpd I^M
22
23
2-4 List of Grease & Oil Adopted:

TGB Supper Grease
No.0
Apply in Oil Seal.
Supper Grease No.3

Apply in Axle Shaft,
inside of Oil Seal.
1104 Sealing ThreeBond Apply on Right

Hand Crank Surface.
TGB Gear Oil 85w-140

Transmission Gear Oil
for Scooters.
TGB Genuine EXTRA 4X OIL

Engine Oil Apply in oil tank
Three-Bond 1322 Under

M10 Screw (For
medium fixing) for
Flywheel Magneto.
TGB Supper Grease

No. I
Apply in Oil Seal.
DOT-3 Brake Oil For

Brake.
TGB Supper Grease

No.2
Apply in Kick Starter.
TGB Supper Grease No.4

For Movable Drive Face Comp.
Cemedine 575 Apply

in Handle Grip
24
"0
D
T|
O
3
3
0)
*~t Wfmmk CRITICAL CHARACTERISTIC
Ifffitt SIGNIFICANT CHARACTERISTEC
Ui
(A
I
o
o
3
5
COLOR
Lk
1
2
i:
L
"i
1
112
2t->
22J
4
S)
6
lu
11
a
s
sii
a
,81
a
s
S/
K/w
/S
BLACK
BLACK
BLACK
RED
RED
RED
RED
RED
RED
BROW
GREEN/WHITE
BLUE/YELLOW
WHITE/BLACK
DEEP GREEN
m
r?
'>>
2J
2b
26
COLOR
COLOR
SS
13 ift/
14 M/
1. /t
16
1 / w/
ia
19 M/ff
2
21 ff/
,
81/
CHOCOLATE
BROWN/WHITE
BLUE/WHITE
GREEN/YELLOW
GREEN/BLACK
YELLOW/WHITE
PINK
BLUE/RED
SKY BLUE
RED/YELLOW
YELLOW
GREEN
BROWN/BLUE
RED/WHITE
28
29
H/51
Jti
37
3S
a;/
a/s
/i.
3U
4U
42
4H
49
bi
b4
bb
/w
^/K
SS
#"
WHITE/RED
GREEN/BLUE
PURPLE
BLACK/GREEN
BLACK /YELLOW
WHITE/BLUE
WHITE/YELLOW
YELLOW/BLUE
BLUE
ORANGE
BLACK/RED
YELLOW
YELLOW
"0
D
T|
O
3
3
0)
CTN
o
o
C0L0R
1
1I-J
2-1
2224
b
6
7
H
9
1U
iift/
&/w
M/H
H/w
/
BLACK
BLACK
BLACK
RED
RED
RED
RED
RED
RED
BROW
GREEN/WHITE
BLUE/YELLOW
BLUE/B LA CK
BLACK/YELLOW
BROWN/BLACK
WHI TE/BLACK
COLQR
W
11
12
13
14
1fi
1
17
1
1
2
'A
22
23
24
V.
2fci
3Sg
#
M/B
#/R
fr
M/,1
SM
E/w
M
,t
^/M
SI/B
DEEP GREEN
CHOCOLATE
BROWN/WHITE
BLUE/WHITE
GREEN/YELLOVJ
GREEN/BLACK
YELLOW/WHITE
PINK
BLUE/RE D
SKY BLUE
RED/YELLOW
YELLOW
GREEN
PINK/WHITE
BROWN/BLUE
RED /WHI TE
^^
2/
2S
2y
.1(1
31
32
,1,1
M
3b
3/
3H
jy
4U
41
42
Hfe
COLQR
WHITE/GREEN
/a WHITE/RED
^/M GREEN/YELLOW
ORANGE/BLUE
BLUE/ORANGE
RED/ORANGE
BLUE/GREEN
ORANGE/WHITE
RE D/GRAY
PURPLE
^/ BLACK/GREEN
^/w BLACK/YELLOW
/M WHI TE/BLUE
&/M WHI TE/YELLOW
ilS/fl GREEN/RED
f/M YELLQW/BLUE
/i
COLQR
4J
44
4b
4ti
4/
4
49
b(
b1
b2
^/*
^g
w/^
WHITE/BROW
YELLOW
YELLOW/BLACK
GREEN/BROW
BLA CK/P URP LE
BLUE
ORANGE
YELLOW/GREEN
BLA CK/RE D
SKYBLUE/ORANGE
BROW/YELLOW
2-6 Troubleshooting
Complaint
No action for starter motor
No sparking or poor sparking
Unable or
Difficult to start
Noisy engine
Engine idles poorly
Possible Reason
Remedy
1. Fuse breaks. 2. No power in

battery. 3. Defective action of brake
switch. 4 Short circuit of starter
relay.
1. Defective spark plug. 2. Defective
CDI & ignition coil unit. 3. Defective
magneto stator coil. 4. Loose
connection of lead wire.
Plug not sparking
1. Damaged spark plug or spark plug cap. 2.
Dirty or wet spark plug. 3. Defective CDI
&ignition coil unit or stator coil. 4.Open or
short in high-tension cord. 5. Defective
ignition switch. No fuel reaching the
carburetor 1. No gasoline in fuel tank.
2.Clogged hole in the fuel tank cap.
3.Clogged or defective fuel cock. 4.Clogged
fuel hose or defective vacuum hose.
Compression too low 1. Excessively worn
cylinder or piston rings. 2.Spark plug too
loose. 3. Broken,cracked or otherwise failed
piston.
Replace
Charging
Replace
Replace
Replace
Replace
Replace
Connect
Replace Clean &
dry Replace
Replace Replace
Replace Clean
Clean or replace
Clean or replace
Replace Tighten
Replace
1 . Piston or cylinder worn down. 2.

Combustion chamber fouled with carbon. 3.
Piston pin,bearing or piston pin worn. 4.
Worn or burnt crankshaft bearings.
1. Stiff piston ring in place. 2. Excessively
worn cylinder or piston rings. 3. Gas leaks
from crankshaft oil seal. 4. Defective CDI &
ignition coil unit. 5. Clogged jets in
carburetor.
Replace
Clean
Replace
Replace
Replace Replace
Replace Replace
Clean or adjust
2-7 Tighting Torque of Screws

*Standard Torque Values of Bolts and Nuts *
Specification
Torque (kg-cm)
Specification
Torque (kg-cm)
5 mm Bolt and Nut
40
8 mm Bolt and Nut
220
5 mm Flange Bolt and Nut
50
270
6 mm Bolt and Nut
100
10 mm Bolt and Nut
350
120
400
6 mm SH Bolt and Nut
90
12 mm Bolt and Nut
550
27
* Torque Values of Chassis Components *

No.
Tightening Location
Specification
Torque
(kg-cm)
Front Wheel Axle Self-lock Nut
M12
500~600
Brake Disk Hex Bolt
M5
180~280
Brake Clipper Tightening Bolt
M 8x35
210~250
Speed Meter Cable Nut
60
Front Fork Bearing Tightening Nut
M25x1.0
600~650
Rear Wheel Axle Self-lock Nut
M16x10
600~900
Rear Brake Connecting Rod Bolt
M16x32
50~80
Rear Brake Pin Self-lock Nut
M8
250~270
Rear Upper Cushion Tightening Bolt
M10*46
200~300
10
Rear Lower Cushion Tightening Bolt
M8*35
200~300
* Torque Values of Engine components *

Tightening Location
Specification
Torque
Quantities
(kg-cm)
Cylinder Head Bolt
M6
80~100
Cylinder Stud Bolt
M8x182.5
500~800
2
2
M8x195.5
M6x50
500~800
M6
100~120
M 8x42
300~400
M 8x38
300~400
Screw
Spark Plug
M10
100~120
Valve Gap Adjust Lock Bolt
M5
50~90
Fuel Filter Nut Cap
M30
150~200
Cooler Fan Lock CR
M6x18
500~800
Wire Assembly Lock Screw
M6x20
800~1000
M22 (R.T.)
800~1000
M12
400~600
Cylinder Intake Pipe Stud Bolt

Muffler and Exhaust Pipe Tightening Screw
Muffler & Right Crankcase Upper Tightening
Screw
Muffler & Right Crankcase Lower Tightening
Start Clutch Gear ightening Nut

Driven Belt Pully Assembly
28
Gearbox Cover Tightening Bolt
M6x28
100~1200
M6x35
Gearbox Oil Fill Cover Screw
3
3
M8
90~150
Gearbox Oil Drain Cover Screw
M8x12
90~150
Clutch Side Cover Screw
M6x40
50~80
M6x65
Starter Arm Tightening Screw
M6x22
100~120
29
2-8 TROUBLESHOOTING 2-8-1 Troubleshooting for

failure in starting the engine
Engine does not
start
Analysis of potential causes
See page 19
Check if the crank shaft works
Does not work
works
Check if the starting motor works
RPM
Poor (too slow)

Fair
Works
Does not work
Check if the starting gear and the Loosen the carburetor
Check battery charging
Check if the battery is speeding clutch of the starting leakage screw to check and contact of pins
properly charged
motor suffer critical wear, if yes, for inlet of fuel.
replace them
_L
Bright light
Poor
Fair
Fair
Dim light or light off
Poor Recharge the battery
_L
Check the
Check
for
existence
Charge
the
battery
or
solenoid switch
and be sure the pin is
Check
of the starting replace it. In case of poor of water or other
for fuel properly secured.(In
impurities in the
motor for noise charging, in addition to
in the case of poor
carburetor buoyant
recharging, check the
during work
fuel tank charging, proceed
charging system of the power
with a new charging
plant for failure.
and check the
J:
1.
charging system of
Fair
No noise
the power plant for
Check
a. Poor
failure.)
the
contact of Noise
engine
heck the starting
Check for fuel Clean the
starting
inside
gear and speeding
carburetor
No fuel
spill in the
switch
Wit
(piston,
gear
of
the
starting
and the
carburetor
I
b. Starting
h
bearing
motor for abnormal
fuel filter
Add in
relay
fuel
and
designated
engagement.
breaks or
others)
fuel
in short
for
Check the fuel
Poor
circuit
failure
filter
and
the
Check skips
c. Loose
Repair or
tubing
contact or replace
in spark
wiring
Poor
Fair
Check fuel tank
Fair
ventilation
tubing for
new
obstruction
buoyant
and needle
valve
Clean fuel
Replacement
filter and fuel
of new
tubing or
starting motor
replacement
and check for
Refer
to
1-8work.
3 No Skip in
Correct the engagement of
Spark Plugs
the starting motor with the
for checking
speeding clutch.
a
30
a
Poor
skip
Fair
Poor
1
Check engine
pistons,
bearings and
others
Fair
Adjustment or
replacement of
carburetor buoyant
needle valve
Refer to 18-2 Poor

Replace the
skip in
original
starting motor Spark
Plugs for
or repair it.
checking
Check spark plug for cleanliness,

normal gap, pollution by gasoline. If
yes, check the choke of the
carburetor
Fair
Poor
Check if the
adjustment
screws of the
carburetor need to
be regulated
Fair
Poor
Check choke of
the carburetor
for troubles
Readjustment
Fair
Clean and adjust

spark plug gap or
replace with new
ones
Poor
_L
Check if the slop nozzle of Adjust or

the carburetor is
replace new
obstructed or the
choke parts
threshold fails
Poor
Fair
Clean or replace the slow

nozzle or correct, replace
with new threshold
Test the
compression
Fair
Check air filter gril
for obstruction
Poor
Check cylinder washer for leakage,
check cylinder, piston, piston ring
for wear, with correction,
adjustment or replacement
Check item :
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
No fuel
Dirty fuel filter
Obstructed ventilation tubing of th efuel tank
Poor carburector buoyant needle valve
Carburetor buoyant with impurities
Poor carburetor buoyant
No skip in spark plugs
Poor skip in spark plugs
Dirty spark plugs
Incorrect spark plugs gap
Dirty and wet spark plugs
Loose adjustment screws in the carburetor
Carburetor choke
Obstructed carburetor slow nozzle
Ailing carburetor threshold
Obstructed air filter grill
Leakage in cylinderwasher
Seriously damaged cylinder, piston
Dead batte ry
Poor contact of batte ry pin and conductors
Starting switch with poor or failure
Starting relay with broken wire or short circuit
Loose contact and wiring
Starting gear and speeding clutch gear seriously worn
Starting gear and speeding clutch gear in poor engagement
Poor starting motor
32
2-8-2 Troubleshooting for poor skip of spark plugs

Poor skip of spark plugs
Loosen spark plugs
Check for spark plug cap, ignition coil
Poor spark plugs Poor

high-voltage wiring Poor
Loose
Normal
Replacement of new spark plug and try skip Load in the spark plug
cap
again
Abnormal
Poor skip
High sparks
Check for loose C.D.I.

plugs, terminal
conduction and
resistance values
Replacement of poor
spark plug
Normal
|
Poor or abnormal
C.D.I. or plugs,
replacement of
C.D.I. and mount
properly the plug
Check high-voltage
coils, main switches,
PICK UP, distributor
coil for normality
Normal
Check for
correct main
wiring contacts
and terminals, if
necessary,
correct them
Abnormal
Poor high-voltage
coils, main
switches, PICK
Ups, distributor
coils
33
distributor coils Poor

PICK Ups Poor main
switches Wiring relay
2-8-3 Troubleshooting for no-skip of spark plugs
-----------------------------------
No skip of spark plugs
Loose spark plug cap
Check for proper loading of the spark plug cap
Poor spark plug

Loose C.D. adapter
Poor
Fair
Load properly the spark
Replacement spark plug and test the
______ plug cap ____
intensity of the spark plugs ________
Poor C.D.I.
Poor PICK UP
Poor distributor
high-voltage wiring
Poor main switch
Weak sparks
Main wiring broken or in
Replacement of
short circuit
poor spark plugs Intense sparks
Ignition coil broken or in

Check for loose C.D.I.
contacts
short circuit
Poor adapter contact
1
Loose
Load properly the
C.D.I. adapter
Normal
|
Check C.D.I. terminals
passage and testing of
resistance
Normal
Use C.D.I. tester
for checks of
Abnormal
a.
b.
c.
C.D.I.
d.
Normal
Check ignition coil for
breaking or short
circuit, replace when
necessary
Poor PICK UP
Poor main switch
Poor contact of
adapter
Broken main wiring
of short circuit
Abnormal
Replacement of the poor
C.D.I.
34
2-8-4 Troubleshooting for slow run (troubled engine)
Poor slow run

-----------------------------------
Dirty spark plugs
Check for contamination in spark plugs and excessive gap
Incorrect spark plug

gaps
Fair Poor
Incorrect ignition
timing
Alarming abnormality of ignition timing Cleaning and

adjustment
Obstructed air filter

grill
Poor carburetor
Poor Fair
adjustment
buoyant needle valve

Is the air filter grill
Poor carburetor choke
obstructed?
valve
I
Poor
Poor engagement of
Fair
carburetor and inlet
Replacement of
Is the carburetor buoyant
tube
the filter grill
level normal ?
Obstructed carburetor
slow injection
Poor engagement of
Fair
Poor
Check if the choke

valve fails (valve
does not open) ?
cylinder head washer

Severe wear of
Adjustment or
replacement of the
buoyant needle valve
cylinder, piston, piston

ring
Poor
Correction
Fair
Check of for air between the
carburetor and the air inlet
Poor
Fair
Add tightening force or

Check for obstruction in the
replacement of the washer carburetor slow injection
X
Poor
Cleaning
35
Fair
Test the compression
Check for air leakage in the cylinder washer,

check wear of cylinder, piston, piston ring
and other elements with correction,
______ adjustment or replacement ______
2-8-5 Poor acceleration and horse power

Breakdown of potential causes
--------------------------
Poor acceleration and horse power

Check for drag of braking drum by braking plate
Braking plate retaining braking

drum
Air filter grill obstructed
Fair Poor
Adjust or replace braking plate
Dirty spark plugs
Incorrect gap in spark plugs
Incorrect ignition timing
Poor skip in spark plugs
Incorrect adjustment of
Check for obstructed air filter

Fair
Poor
1
Check for burn of spark
Replacement of the
plugs and the gap
filter grill
carburetor adjustment screw
Fair
1
Poor
Poor choke valve in carburetor
Dirty or obstructed carburetor

injection nozzle
Check for
normal ignition
timing
Cleaning,
adjustment of
replacement of
new spark plugs
valve
Fair
Poor
Test of spark plugs,

sparks
Poor carburetor buoyant needle
Dirty fuel filter
Obstructed fuel circuitry
Poor engagement of cylinder
Timing
washer
Serious damage of cylinder,

piston, piston ring
Poor skip
See 2-8-2 poor

skip of spark
plug for
checking
methods
Intense
sparks
Check carburetor for

proper adjustment
X
Fair
Poor
Adjustment
Check for normal

choke valve action
Poor
Correction
or
replacement
Fair
Check for
obstructed
injection nozzle
36
a
a
Poor
Fair
Cleaning or
replacement
Check for normal

fluid level in the
buoyant
Fair
Poor (low level)

Check of needle
valve and buoyant
I
Poor
Adjustment or
replacement
Fair
Check fuel pipe
and carburetor for
obstruction
Check the
compression
Check for leakage in
cylinder washer; check
cylinder, piston, piston
ring for wear. Correct,
adjustment or
replacement when
necessary
Cleaning or
replacement
37
CHAPTER 3 DESCRIPTION OF COMPONENTS AND ASSEMBLY

3-1 ENGINE
3-1-1 Fuel system (For 125c.c.)
3-1-2 Fuel injection system (For 250c.c.)
3-1-3 Lubrication System
3-1-4 Cooling System
3-1-5 Spark Plug
3-2 ELECTRIC SYSTEM

3-2-1 Ignition & Charging Device
3.2-2 Lamps
3-3 BODY
3-3-1 Frame & Cover
3-3-2 Compartment and Seat
3-3-3 Front & Rear Suspension System
3-3-4 Brake System
3-3-5 Tire & Tire pressure
38
3-1 ENGINE
3-1-1 Fuel system (For 125c.c.)
39
41
42
43
LUOO
Ajojo&ypa AMMI\ UOJSJGA \BU} OJd jojoejpd
1717
45
46
LUOO'
U0JSJ9A
|BU}
U(\\M
P91B9J0
48
50
3-1-2 Fuel injection system (For 250c.c.)
LUOO'
U0JSJ9A
\BU}
P91B9J0
84
96
97
LUOO'
U0JSJ9A
\BU}
\M
P91B9J0
100
101
102
105
LUOO'
U0JSJ9A
\BU}
\M
P91B9J0
LOI
-\,-
108
LUOO Ajojo&ypa AMMI\ UOJSJGA \eu]
601
110
111
112
AMMI\ U0JSJ9A
\BU}
LUOO'
11
U(\\M
P91B9J0
LUOO'
AMMI\ U0JSJ9A
\BU}
U(\\M
P91B9J0
6u||ooo p-i-
LUOO
Ajojo&ypa AMMI\ UOJSJGA \BU} OJd jojoejipd
AMMI\ U0JSJ9A
|BU}
LUOO'
911
P91B9J0
117
LUOO Ajojo&ypa AMMI\ UOJSJGA \eu]
811
LUOO'
U0JSJ9A
|BU}
U(\\M
P91B9J0
LUOO'
AMMI\ U0JSJ9A
\BU}
U(\\M
P91B9J0
LUOO'
U0JSJ9A
\BU}
TZI
P91B9J0
LUOO'
U0JSJ9A
|BU}
\J(\\N\
P91B9J0
123
124
125
3-1-5 Spark Plug

Disassemble:
Spark plug cap.
Note: Please blow away deposits around spark plug with blower before removing spark plug.
Otherwise, the dust may drop into cylinder and it can damage engine.
Inspection: Check if spark plug has carbon deposits, burned, or cracked. Use steel brush to
remove carbon deposits and adjust spark plug gap. Replace burned or cracked spark plug with
new one.
Note: Spark plug specification:
Spark plug gap: 0.6 ~ 0.7 mm. Warning: First
install the spark plug with hand, and then tighten it with
spark plug wrench. Please do not over twist the spark
plug. Note: Torque of spark plug: 100 ~ 120 kg-cm.
3-2 ELECTRIC SYSTEM

3-2-1 Ignition & Charging Device
1. Ignition Device:
CDI Unit of two ignitions per revolution is adopted.
The ignition Lead is 18374,000rpm (OLD)
15374,000rpm(NEW)
2. Charging Device:
Power is given by flywheel magneto. The voltage is controlled by voltage regulator.
Power is charged to battery.
A. Flywheel Magneto:
Flywheel (rotor) includes four poles, crossed N poles
and S poles. The stator consists of one high-tension
ignition coil and three low-tension coils for charging
and lighting to create change of magnetic field by
rotating the flywheel to generate electricity.
126
B. Battery :
1. Battery Caution:
1. The electrolyte contains sulphuric acid is poisonous. avoid to contact
with eye, skin and clothes. Immediately wash with abundant water
and call a doctor at once in case of contact with the eyes or skin.
Immediately drink beaten eggs or vegetable oil, call a doctor at once
in case of drink.
2. batteries release explosive gases, prohibit to closed to sparks,flames
or cigarettes.
3. When charging or using the battery in a closed location, make sure
that ventilation is good.
4. Keep off children hands.
2. Instruction for Filling Electrolyte (For
Water-adding Free Battery)
1. Remove the Aluminum Seal on the
filling hole of battery.
2. Remove the cover bar and battery
sealing bolt.
3. Insert the filling hole of
electrolyte container into the
filling hole of battery. Try not
to spillage it.
4. There are three pipes on each
side. Tap the bottom of container
lightly when the electrolyte bubbles.
Pulling it out will be unnecessary.
5. Remove the container from the
battery after all electrolyte
is filled into battery.
6. Insert the fixing plug in the
filling hole of battery and
press the fixing plug until
it is not higher than the top of cover.
Note : The Battery is completely ready to use, thus do not remove the Aluminum Seal on
the closed filling hole until it is to be used. Electrolyte, except those specified, is
absolutely forbidden. While filling the electrolyte, only regulated volume of electrolyte can
be adopted. The seal plug should not be removed after the electrolyte is added.
127
3. THE PROCEDURE OF USING NEW BATTERY

(FOR WATER-ADDING BATTERY )
1. Use the open long plastics tube to instead
of the L-Type closed rubber tube; adjacent
to the " + " pole of the battery.
2. Cut off the tip of the electrolyte's bottle, and
put on the open rubber tube. Take off the
fixing plugs on the battery.
3. Pour the electrolyte into battery carefully to
reach the upper level and the density must
be1.28/20C..
4. The battery must be stay to decrease the
temperature of the electrolyte to under 35C. Then begin to charge.
5. Lay the battery for 30 minutes, if battery stay long time, it must recharge again also
according to the table .
Time
Within 3 months
Afte
interval
within
above
1 year
1 year
40 hours
60 hours
after made
Charging
Unnecessary to
3 months 6 months
10 months
time
charge.
Pour electrolyte
10 hours 20 hours
30 hours
into battery.
Lay 30
minutes,then
begin to use.
6. Connect the black lead to the " " pole of battery and red to " + " pole put the battery
to the location and clamp the rubber band.
7. For the connected plastics long tube to the air vent hole of battery , the other end of the tube
must be setted through into the square hole in the plastic leg shield rightly to discharge the
erosive air or sulfuric acid to avoid eroding the body. The tube must be without plugging or
straight bending to avoid exploding.
CAUTION:
It's important to use open long tube to instead of close short
tube to assure normal output of gas to prohibite of exploding.
4. BATTERY MAINTENANCE: (FOR WATER-ADDING BATTERY)
1. Use the same key of main switch to trun right or left
128
to open inner box lid, then disconnect the battery band

and take out the battery, finally take off cable.
2. Checking electrolyte, add distilled water to refill and
adjust to upper level; in case of adding distilled
water frequently, checking the over- charging of the
battery: No voltage indicated on the terminal or no
action on rectifier, means short on the battery, the
voltage will higher than normal, and the life will
shorten.
3. Inspect charged condition:
Add electrolyte to the upper level and check by
battery hyprometer (as attached drawing). The
density of charged battery must be 1.26~1.28
(above 20C), if the density below 1.2/20C, it
means fully dis-charged and must be recharged;
The battery must be checked electrolyte level density and the voltage after charging.
5. RECHARGING OF THE BATTERY
To Take off the fixing plugs of the battery before charging. Use 1/10 current intensity of the
capacity to recharge the battery about 15-20 hours at normal condition; connect "+" pole of the
battery to "+" pole of the charger, and "" with "". CAUTION:
1. Keep the battery away from flames,sparks, and cigarettes.
2. If the temperature of the electrolyte is higher than 45C, it must to change to half of the
current intensity or stop to charge until decrease to get under 35C.
3. After charging the battery, adjusting the electrolyte to upper level and recharge 1-2 hours
again,
then put into the fixing plugs, washing and protect with vaseline.
4. Disassemble the "" pole terminal at first before taking out the battery from scooter, begin
to assemble the "+" pole terminal reversely.
5. If it couldn't reach to 12v, after charging the battery for 15-20 hours, it's necessary to replace
new battery.
6. REGULAR MAINTENANCE OF THE BATTERY
1. Keep the battery clean and dry.
2. Protect the terminals with vaseline.
3. It can reduce the time to 5-6 hours to charge battery at urgent case.
4. Don't use fuse which above standard, otherwise it'll cause broken of scooter or even firing
5. It must to charge before using new battery to keep the maximum
performance, if don't charging adequately or the electrolyte under the low level, it may cause
broken before normal life.
129
6.Tap or drinking water contain mineral will reduce the battery's life, it must to use distilled
water. (For Water- Adding battery)
7.If scooter is stay a long time, it required charged periodically, otherwise it'll fully discharged
by itself above three months.
3-2-2 Lamps
Head lamp:
Remove the bolts of the cover.
Cover.
Remove the head lamp couples
Rear lamp:
Remove the bolts of the cover.
Cover.
Remove the rear lamp couples
Inspection: Check if the lamps is damage,
please replace with new one.
Installation:
Install in reverse order of removal procedures.
130
3-3 BODY
3-3-1 Frame & Cover
1 . Frame :
A. steel pipe and steel sheet are adopted to
compose reinforced frame.
B. A compartment as Personal space for
Helmet is set in the Frame center.
2 . Cover:
1. SEAT SET
2. HELMET CASE
3. BRKT,SEAT
4. CAP, HELMET CASE
5. COVER SIDE,LH. & RH.
6. COVER TAIL,UPPER & UNDER
7. HANDLE,LH. & RH.
8. ORNAMENTAL,HANDLE BAR
9. COVER,HANDLE BAR, UPPER & UNDER
10. WIND SHIELD
11. FRONT,SPEEDOMETER COVER
12. SPEEDOMETER COVER
13. SPEEDOMETER COVER
14. COVER,LEG SHIELD,FRONT
15. LEG SHIELD,FRONT
16. COVER SET,LEG SHIELD
17. FRONT,LUGGAGE BOX
18. LEG SHIELD,REAR
19. COVER RIB,LH. & RH.
20. LEG SHIELD,SIDE LH. & RH.
21. CUSHION,LEG SHIELD,LH. & RH.
22. FRONT FENDER,INNER
23. LEG SHIELD,LOWER
24. FENDER REAR,TANK FUEL
25. FRONT FENDER (FOR CUB)

26. FRONT FENDER,UNDER
27. FRONT FENDER (FOR CUB-B)
131
19
24
25
27
132
PDF created with pdfFactory Pro trial version www.pdffactorv.com
* Dismount floor panels following the sequence shown in the list:

Helmet Case.
Mirror, Rear View.
Carrier.
Cove Handle Bar,

Upper.
Bottom Plate.
Leg Shield Front.
Front Fender.
Right and Left Side

Cover.
Cover Set, Leg Shield
Fender, Fixed, Front.
Cover Handle Bar,
Leg Shield Side,
Under.
Lower.
Leg Shield, Rear.
Leg Shield, Lower.
Cautions:
1. Do not damage cover of body panels while dismounting.
2. Handle with care regarding lugs of to avoid damage dismounting.
3. When remounting, do not scratch or crash wiring.
4. While assembling every lug shall be fixated effectively.
5. While assembling, make matching panels and their slots.
133
3-3-2 Compartment and Seat

1 . Compartment:
A. Located in the center of scooter body, there is a Personal Space for helmet and other, etc.
B. The maximum load capacity of compartment is 10kg.
C. Please don't store precious or easy-to-break articles in the compartment without any
protection.
D. The Seat has to be locked. If the Seat is not locked during riding, it will affect the safety
and even cause injury.
E. Please pay attention not to let fuel or oil drop into the compartment.
F. The cover of the compartment can be cleaned with vacuum cleaner.
It can also be washed and put back after dried.
(Please do not wash with volatile fluid, such as gasoline.)
G. The seat is controlled by the seat lock on the side.
2 . Helmet Holder:
There is a Helmet Holder at the position of Seat Hinge.
open the Seat to hook or unhook Helmet.
134
3-3-3 Front & Rear Suspension System

1. Front- Suspension :
A. No suspension on Front Fork.(For B Type)
B. Brake Con-rod and Bracket of Brake Lining
are equipped between Front Fork and
Disc Brake. Resistant Torque occurrs toward
the revolving direction when acting brake. The
Torque will become the force to push FrontFork up by using connection Rod. Therefore,
the sink of Front-Fork is stopped and
decreases the change of sitting gesture while
the brake is used.
2 . Rear-Suspension :
A. Suspension Mechanism is 'composed of
single telescopic absorber between the crank
case and scooter body.
B. Rear Axle Movable by telescopic shock
absorber.
3-3-5 Tire & Tire pressure

Inspection: Check if tire has been cracked,
damage, worn, inclusions(stone, nail, glass, etc.).
If tire is in poor condition, please replace with
new one.
Note: Tire specifications: See specification table.
* Tire pressure *
Watch: Please measure cool tire pressure.
Note: Tire pressure.
Front tire: 28 PSI
Rear tire: 32 PSI
Warning: Don't over-load the motorcycle.

The tire may explode with over-load and it is dangerous.
135
CHAPTER 4 . DISASSEMBLY REPAIRS

4-1 NOTICE FOR DISASSEMBLY REPAIRS
4-2 REMOVAL AND INSTALLATION OF ENGINE
4-3 REMOVAL AND INSPECTION OF ELECTRIC ITEMS
4-3-1 OPERATING CAUTIOS & TROUBLESHOOTING
4-3-2 BATTERY
4-3-3 SHORT CIRCUIT TEST
4-3-4 STARTER MOTOR
4-3-5 RESISTOR
4-3-6 CDI
4-4 REMOVAL AND INSPECTION OF BODY PARTS 4-4-1
Removal and Inspection of Front Fork and Steering 4-4-2
Removal and Assembly of Wheel and Shock Absorber
4-5 BRAKING SYSTEM
136
4-1 NOTICE FOR DISASSEMBLY lNSPECTION

1. In order to avoid mixing and loss of disassembled parts before reassembling, the
disassembled parts have to be arranged according to their function during the process.
2. The damage to Cover and Frame should be avoided while disassembling and
assembling.
3. Remove the negative (-) terminal of Battery before working.
4. While reassembling, make sure that all parts are normal.
5. Specified oil should be adopted on turning and sliding parts.
Specified grease should also be applied on specified positions.
6. Dust, dirt and unusual articles should be avoided while reassembling.
7 . While assembling, the main lip of oil seal should face inwards (oil chamber) and the
antidust sub-lip should face outwards.
Apply an even layer of specified grease onto the lip before it is pressed to its location
with balanced force by specified jigs.
8 . While pressing the bearing into the hole, apply balanced force to the outer ring of bearing
by specified jigs.
While pressing the bearing into the main shaft, apply balanced force to the inner ring of
bearing by specified jigs.
137
4-2 REMOVAL AND INSTALLATION OF ENGINE

Removal of Engine:
Remove Seat and Cover.
Remove Exhaust Muffler.
Remove Clamp of Air Filter and Air Filter.
138
Remove Mud Guard.
Remove Ignition Coil Lead.

Flywheel Magneto Lead.
Engine Earth Ground Lead.
Remove the Throttle Cable,
on Carburetor Piston.
Remove Oil Hose.
Remove Negative Pressure Hose and

Remove rear belt cooling duct.
Remove Fuel Hose.
Remove Water Hose.
Remove the engine mounting bolts and nuts.
139
Remove the rear-axle shaft bolts and

remove rear wheel.
Installation
140
142
143
U0JSJ9A
|BU}
LUOO
OCT
U(\\M
151
PDF created with pdfFactory Pro trial version www.pdffactory com
157
158
LUOO
U0JSJ9A
|BU}
U(\\M
160
162
LUOO'
U0JSJ9A
|BU}
U(\\M
P91B9J0
LUOO Ajojoewpa NMM UOJSJGA IBUI OJd
891
jojoejpd I^M
169
LUOO'
U0JSJ9A
|BU}
U(\\N\
P91B9J0
173
LUOO'
U0JSJ9A
\BU}
P91B9J0
181
LUOO'
U0JSJ9A
|BU}
\M
P91B9J0
185
CRANKSHAFT/CRANKCASE
Gnerai information
Trouble diaqnosis
Crankshaft
Assembly of crankcase
Disassemblv of crankcase
1.2-1.6 kgf-m
1.0-1.5 kgf-m
1.5-3,0 kgf-m
O.B-1,2 kgf-m
PDF created with pdfFactory Pro trial version www.pdffactorv.com
192
woo AJopB^pa ftmm UOJSJGA
LUOO
NWM UOJSJGA \B\J\
ojd jopejpd
4-3 REMOVAL AND INSPECTION OF ELECTRIC ITEMS 43-1 Operating Cautions & Troubleshooting
Operating Cautions:
1. Warning:
a. The liquid in the battery is diluted sulfuric acid that is dangerous. If, your skin or eye
unfortunately get contact with it, please wash with water abundantly and consult
immediately a doctor, lest you should lose vision.
b. If your clothes is touched by the electrolyte, your skin would also be touched.
Therefore you should get it off and wash with water abundantly.
2. Check if electrolyte in the battery is sufficient. If not, add distilled water till the liquid level
reach the upper limit line.
3.The battery is rechargeable after discharging. If it is unused after discharge, it may
deteriorate and shorten service life. It will become less efficient. After usage of 2~3 years,
battery capacity will decrease. It can be regained by recharging several times.
4. When there is other loads while igniting, if the voltage will rise again after an abrupt falling,
it is normal.
5.If a battery is unused during a long time, its energy storage will decrease by its autodischarge. Therefore, a recharging is necessary around every 3 months.
6.To charge a battery, it shall be removed from the car and its filler plugs removed. To put the
charging current 'ON' or 'OFF', you must operate at the charger's switch. You shall not
connect or pull off directly on the battery because electric spark may provoke hydrogen
explosion.
7.During battery charging, hydrogen (H2) is produced. It is an inflammable gas. Fire must be
forbidden. 8. At recharging a battery, the temperature of electrolyte shall be lower
than 45C.
9.To test if a battery is fully charged, please use a voltmeter. Never use 'Spark method'.
10.When there is current in an electrical installation, please do not pull off a contact then
connect it again, because resulting over voltage may damage electronic parts in the
commuter. Therefore, this operation must be done after the main switch is put "OFF".
199
PDF created with pdfFactory Pro trial version www.pdffactory. com
11 .If fresh electrolyte is poured in a new battery, a voltage will be generated after a certain
lapse of time. If the voltage is not sufficient, then a recharging is necessary. A recharged
new battery has necessarily a longer lifetime.
12.The C.D.I of the ignition system shall not fall swinging and be shocked. It is a cause of
frequent breakdown. Therefore, a special precaution is necessary in its dismounting and
remounting.
13.Bad contact between plug and jack causes often the breakdown of the ignition system.
Therefore, before undertaking repair, the contact is to be checked at first.
14.Spark plugs of a suitable heat value and gap are to be used. Otherwise, engine will not
work smoothly or break.
Troubleshooting:
Battery Recharging System: No
voltage:
1. Battery cable fallen or disconnected.
2. Fuse fused.
3. Defective of flywheel magneto.
4. Excessive battery discharging:
a. Electrolyte leaked.
b. Chemical reaction in battery.
c. Short circuit in battery.
d. Defective rectifier.
Low voltage:
1. Insufficient recharging.
2. Leaking of electrolyte.
3. Defective separator causing short circuit between positive and negative plates.
1. Defective battery terminals.
2. Defective recharging system.
3. Defective rectifier.
Excessive specific weight of electrolyte:
2. Leaking of electrolyte.
3. Reaction between sulfuric acid and pole plates.
200
Too low capacity:

2. Pole plates react with sulfuric acid.
3. Insufficient electrolyte.
4. Active matter fallen from pole plates because of excessive recharging.
Inefficient recharging system:

1. Bad contact at connectors, short circuitry, or broken circuit.
2. Defective rectifier.
a. Armature winding short circuited or broken.
b. Magneto coil short circuited or broken.
Bad electric continuity:
1. Bad contact at battery connection.
2. Ignition system short circuit or bad contact at connectors.
3. Lighting system short circuit or bad contact at connections.
Ignition System: Dysfunctioning

of spark plugs:
2. Defective high-tension coil.
3. Defective C.D.I .
4. Defective spark plugs.
5. Defective conductor contact, breaking, or short circuit, for example:
a.
Conduction between flywheel magneto and C.D.I .
b.
Conduction between C.D.I and the main switch.
c.
Conduction between C.D.I and the high-tension coil.
Engine not running smoothly:

1. Defective ignition first circuit:
a. Bad contact in circuitry or cable.
b. Defective of flywheel magneto.
2. Bad ignition secondary circuit.
(1) The ignition coil insulation defect causing electric leakage.
(2) Defective magneto coil.
I.
Short circuit between coil layers.
II.
Defective coil.
201
c.
d.
Defective spark plug.

I.
Spark plug covered by carbon.
II.
Electric leakage in ceramic part of spark plug.
Electric leakage from spark plug rubber screen.
3. Defective ignition timing.

a.
Defective flywheel magneto.
b.
Defective C.D.I .
c.
Too large gap of spark plug.
d.
Too high electric resistance of spark plug.
Starter System
Starter motor unable to run.
1. Damaged battery.
2. Battery circuit broken, bad contact or too large resistance at connections.
3. Fuse fused.
4. Defective main switch.
5. Defective front and rear brake switches.
6. Defective starter motor switch.
7. Defective starter motor relay.
8. Defective starter motor.
9. Circuitry conductor defective or broken.
10. Starter motor drive pinion locked with the over speed clutch gear.
Weak drive of starter motor:
1.
Insufficient recharging of battery.
2.
Bad contact on circuit conductors.
3.
Strange object introduced in the starter motor pinion.
4.
Armature shaft bent.
5.
Commutator unclean or worn.
6.
Brush worn or spring too weak.
7.
Starting motor of relay defective.
202
4-3-2 BATTERY
A. Cautions in battery inspection and generator charging.
Inspection: Use gravity gauge to measure electrolyte. White
is fully charged, yellow means charge is required, and red is
broken or almost totally discharged. Note: Electrolyte's
specific gravity and charge level comparison table (20C).
1.280
Electrolyte
1.250
1.220
1.190
1.120
3/4
1/2
1/4
Totally
Specific Gravity
Charge Level
Full
Charged Charged Charged
Discharg
B. Charge by generator
Connecting battery and gener terminals by "+" with "+" and "-"
with "-". Warning: Battery releases explosive gas during charging or use
battery. Therefore, it is dangerous to do so in concealed location. Please put
battery in good ventilation location during charging, and forbid fire. Note:(1)
Standard charging current: 0.6 A for 5~10 hours.
(2) Quick charging current: 6.0 A for 30 minutes.
(3) Please do not use quick charge except for emergency.
(4) Measure the battery voltage 30 minutes after battery is charged.
The battery voltage should be higher than 12.8 V.
C. Battery manufactured month and charge time comparison.
6 mo.
10 mo.
Manufactue
Within 3
After 3
Within 1
Over 1
Months
mo.
mo.
Charge
Add electrolyte
10
20
30 hr
40
60
Time
And wait 30 m.
hr.
hr .
hr .
hr .
yr.
yr.
4-3-3 SHORT CIRCUIT TEST

Disassembly:
Disconnect battery negative terminal cable. Measure method: A.
Connect megga meter "+" terminal to battery "-" terminal.
203
B. Connect megga meter "-" terminal to circuit negative cable.

Note: User megga meter "A" current position. Turn main switch
to "OFF" position. Inspection: Check if there is electrical current.
If no current, check the main switch and wire harness for short
circuit.
4-3-4 STARTER MOTOR
(1) Please place main stand to park the
motorcycle for inspection.
(2) Turn the main switch to "OFF" position before maintenance.
Disconnect the battery ground circuit.
To ensure safety, turn the main switch to "ON" position and
check if the motor has operated.
Disassembly:
Remove starter motor cable. 2 starter
motor attaching screws. 2 motor case
attaching bolts. Starter motor.
Check Starter Commutator Inspection:
(1) Check continuity between segments.
Note:A. If continuity is good, then it is normal.
B. If no continuity, then it is broken.
(2) Check continuity between segments and
armature shaft.
Note:A. If no continuity, then it is normal.
B. If continuity is good, then it is broken.
(3) Clean the commutators if there is metal powder between segments.
(4) Check the removed parts for damaging, burning (discoloration), and wearing.
Replace with a new if necessary.
(5) Check brush length.
Note: A. Initial standard brush length is 112.5 mm.
B. If brush length is smaller than 8.5 mm, please replace with new brush.
Inspection: Check continuity of the brush holder. Note: A. If there is no
continuity, it is normal.
B.If there is continuity, it is broken.
Please replace with new one. Installation: install in reverse
order of disassembly procedures.
204
4-3-5 RESISTOR
Disassembly: Remove front windshield cover. Measure: A. Use megga
meter's positive terminal to connect resistor wire.
B. Connect the megga meter's negative terminal with
frame ground and measure the resistance. Note:
Resistor standard:
20 W 5.9 Ohm: 5.0~7.0 Ohm. 5W 5.0 Ohm:
4.0~6.0 Ohm.
4-3-6 CDI
Use megga meter to check the following items. A.
Exciting Coil Inspection Disassembly: The exciting coil
connector. Measure:
A. Use megga meter's positive terminal to connec
t exciting coil's black/red terminal.
B. Connect the megga meter's negative terminal
with frame ground and measure the resistance.
B. Pulse Coil Inspection Disassembly: The pulse coil
connector. Measure:
A. Use megga meter's positive terminal to connect pulse
coil's blue/yellow terminal.
B. Connect the megga meter's negative terminal with body ground and measure the
resistance.
205
4-4 Removal and Installation of body 44-1 Removal and Installation of Seat
and Cover
Seat:
Remove the nuts and pin.
Seat.
Remove 6 bolts on the helmet case.
Helmet case.
Note:
There is a coupler under the helmet case.
And remove it.
Additions of side cover:

Remove the handles.
Remove the bolts on the side cover.
Leg shield:
Remove the bolts on the leg shield.
(each side) leg shield.
Installation:
206
PDF created with pdfFactory Pro trial version

www.pdffactory.com
Front fender:
Remove the bolts on the front fender.
(each side)
Mud guard:
Remove the bolts on the mud guard.
(each side)
Installation:
Install in reverse order of removal
procedures.
Raer leg shield:

Remove the bolts on the rearleg shield.
(each side)
207
PDF created with pdfFactory Pro trial version

www.pdffactory.com
Fronnt leg shield cover:

Remove the nuts and screw
on the fronnt leg shield cover.
Fronnt leg shield cover.
Fronnt leg shield:

Remove the bolts on the fronnt leg shield.
(each side)
Fronnt leg shield.
Leg shield cover set:

Remove the bolts on the leg shield cover set.
Installation:
208
Wind shield:
Remove the bolts on the wind shield.
(each side)
Wind shield.
Front speedometer cover:

Remove the screws on the
Front speedometer cover. (each
side)
Speedometer cover:
Remove the screws on the
speedometer cover.(each side)
Installation:
209
4-4-2 Removal and Inspection of Front Fork & Steering
CU8 & CUB
1. FORK COMP, FRONT

2. SHOCK ABSORBER ASSY
3. SUSPENSION ARM, LH. &
RH.
4. FIXED PLATE, LH. & RH.
CU8-B & CUB-B
1. FORK COMP, FRONT

2. FORK COMP, FRONT LH. &
RH.
1. HANDLE BAR ASSY

2. GRIP
3. CABLE
4. CABLE, THRORRLE
Z1U
CU8 & CUB:

Remove upper and lower bolts
on the shock absorber assy. Shock
absorber assy. Remove the bolts on the
suspension ram. Suspension ram.
CU8-B & CUB-B:
Remove the bolts on the fork comp.
Remove 4 nuts.
Fork comp, front LH. & RH.
4-4-3 Removal and Assembly of Wheel

and Shock absorber
Front wheel:
Watch: Please place main stand to park the motorcycle
for maintenance.
Removal:
Remove 2 bolts on the caliper.
Caliper.
Remove bolt and collar.
Remvoe speed meter cable nut. Note: Do not apply
brake when removing caliper from brake disk. Otherwise,
the lining can contact.
Front wheel.
Inspection: Check eccentricity and wear condition. Note:
If eccentricity is higher than 0.2mm, please replace with
new one to ensure driving safety.
Speed meter gear assembly. *Inspection of Wheel
Rim* Put wheel rim on rotation stand. Rotate the wheel
slowly and use dial-gauge to measure eccentricity Note:
(1) The transverse eccentricity should be
within 3.0 mm. If the condition is poor,
please replace with new one.
(2) The lateral eccentricity should be within 3.0mm.
If the condition is poor, please replace with new one.
211
Rear wheel:
Watch: Please place main stand to park the motorcycle for maintenance.
Removal:
Remove 2 bolts on the caliper.
Caliper.
Remove the nut.
Rearwheel. Note:
(1) Please use vacuum to clean wheel ri m and lining.
Try to reduce the contamination of asbestos fiber, which
may affect the human breath system or lead to cancer.
(2) The transverse eccentricity should be within 3.0mm.
(3) The lateral eccentricity should be within 3.0 mm.
Installation:
Shock absorber:
Front:
Watch: Please place main stand to park the
motorcycle for maintenance.
Removal:
Remove upper and lower attaching bolts
on front shock absorber.(each side 2 bolts) Shock
absorber.
Inspection: Check if the shock absorber is worn,
scratched, leaking, or bent. If its condition is poor, please
replace with new one. Note: Torque of shock absorber
upper and lower attaching bolts: 200 ~ 300 kg-cm.
Rear:
Remove 2 attaching bolts on air filter.
Airfilter.
Remove upper and lower attaching bolts
on rear shock absorber.(each side 2 bolts) Shock
absorber.
212
Inspection: Check if the shock absorber is worn,

scratched, leaking, or bent. If its condition is poor,
please replace with new one. Note: Torque of
shock absorber upper and lower attaching bolts:
200 ~ 300 kg-cm
Installation:
213
4-5 Brake system:

CU8 & CUB
1:MASTER CYLINDER
2:HOSE ASSY
3:CALIPER 4:PAD
ASSY 5:DISC,BRAKE
6:REAR FORK ASSY
214
PDF
pdfFactory
www.pdffactory.com
created with
Pro trial version
CU8-B & CUB-B

1:MASTER CYLINDER
2:HOSE ASSY
3:CALIPER 4:PAD
ASSY 5:DISC,BRAKE
6:REAR FORK ASSY
215
A. Check of braking fluid level

Inspection: The front brake fluid level should above "LOWER". If
it is below, refill the brake fluid and check
leakage of the brake system.
Adding of braking fluid:

Stand the scooter at its main rest on a leveled floor.
Turn open the fuel tank cap and add in designated
braking fluid to the maximum.
Warning: 1) Add in designated braking fluid, a different fluid would cause hazardous
chemical reaction, leading to failure in braking.
2) Keep water off the fluid cup or the boiling point would drop to produce air
block, leading to failure in braking.
3) In case of spill of braking fluid to plastic parts, wipe it off with a rag for
aestheticism.
B. Checking and adjustment of free
braking gaps. Note: front brake free gap of
10 ~ 20 mm
Adjustment of braking gap <Remove>:

Front windshield
Turn lose the securing nuts, tighten the screws.
Remark : 1) Turn it clockwise to enlarge the gap.
2) Turn it counterclockwise to reduce the gap.
3) Keep the free gap at between 10 ~ 20 mm and
tighten the nut.
C. Inspection of the Return Spring of Brake Lining:
a. Testing the free length of the spring with a vernier caliper.
b. Check for any wear and crack on the spring.
Free Length of the Return Spring of Brake Lining (mm)
Standard
32.6-33.0
Limit
Exchanged over 35.0
D. Inspection of the Brake Cam:

a. Check for any rust or unusual wear on the brake cam.
216
b. Make sure the brake cam runs smoothly.

c. Make sure to apply sufficient grease to the brake cam and lining anchor-pin.
E. Inspection of Front Brake:
a. Check the gap between the ends of front brake lever.
Gap of Front Brake Lever
10 ~20 mm ___________
b. Add brake oil.
c. Check the brake lining.
F. Inspection of Rear Brake:
a. Check the gap between the
ends of rear brake lever.
b. Move the adjusting nut of brake cable clockwise to proper gap.
Gap of Rear Brake Lever
10~20 mm
217

X Motion 125

Uploaded by

Copyright:

Available Formats

X Motion 125

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

X Motion 125

Uploaded by

Copyright:

Available Formats

Xmotion 125/250

TAIWAN GOLDEN BEE CO.,LTD.

PDF created with pdfFactory Pro trial version www.pdffactory.com

1-4 General Inspection

1-2 Inspection Before Running

1-5 Notes for Inspection

1-3 Regular Maintenance Schedule _______________________

1-1 Delivery Introduction

PDF created with pdfFactory Pro trial version www.pdffactory.com

1-1 Delivery Introduction 3

PDF created with pdfFactory Pro trial version www.pdffactory.com

1-2 Inspection Before Running

Is the oil volume

1 .Check Oil Warning Lamp to see if the oil

Is the fuel volume

1 .Check fuel volume to see if it is enough

Is the lamp condition

1 .Check if the lighting condition of head

1. Look at the back mirror from the

5. License Plate &

No dirt and damage

1. License plate should be installed, letters

Check the distance of

1 .Operate the handle lever slowly to the

1.Is the air pressure

1 .Check if the air pressure of tire is

PDF created with pdfFactory Pro trial version www.pdffactory.com

1-3 Regular Maintenance Schedule

Air cleaner element(Remark)

Steering bearing and handles

Check Transmission for leakage

Check crankcase for leakage

Fuel tank switch and lines

Throttle valve operation and cable

Engine bolts and nuts

Cylinder head, cylinder, and piston

Exhaust system/cleaning carbon

Cam chain/ignition time

Crankcase Blow - by system(PCV)

Cooling fan, lines

Brake mechanism/brake lining(pad)

Bolts/nuts for each components

Replacement for every 5000KM

PDF created with pdfFactory Pro trial version www.pdffactory.com

PDF created with

pdfFactory Pro trial

1-5 Notes for Inspection

Only designated TGB oils should be used on spare parts.

The locking sequence of Bolt and Nut should be from inside to

Special tools should be used when necessary.

Reconfirm each function after the assembly.

PDF created with pdfFactory Pro trial version www.pdffactory.com

Tire Pressure (psi)

Forced circulation & splashing

Reference and setting range(IN )

Reference and setting range(EX)

Idle speed (rpm )

Max Power ( Kw/rpm )

Max Torque (Nm/rpm)