Generic XOR 125 Service Manual

Text of Generic XOR 125 User Guide:

• Generic XOR 125, 67 Reassembly and remounting Reassemble and remount this front wheel in the reverse order of removal, and also carry out the following steps: install this wheel bearing with the special tools as shown in this illustration. CAUTION: Install this wheel bearing for left side.. Install the brake disc as shown in photo. When installing this speedometer gear box, align the two driving pawls with the two recesses of the wheel hub. Tighten the nut with special tool.

• Generic XOR 125, 55 SWITCH DARK GREEN OFF ON HORN SWITCH RED/WITHE OFF OFF ON RED/SWITCH LOCK BREAK SWITCH RED ON RED/WHITE MAIN SWITCH BROWN TURN RIGHT TURN LEFT DIRECTION SWITCH ORANGE GREEN /BLACK GREEN/WHITE PASSING LIGHT YELLOW/RED PURPLE DIPPED HEADLIGHT HIGH BEAM OFF BULE AZURY EXCHANGE LIGHT SWITCH GREEN/RED BLACK HEAD LIGHT YELLOW/RED YELLOW LIGHT CONTROL SWITCH YELLOW PINK

• 10 Cylinder head nuts and exhaust pipe bolts Tighten at each service. If cylinder head nuts are not tightened to the specified torque, may result in leakage of compressed fuel-air mixture and reduce output, tighten the cylinder head nuts in the following procedures:： 1． Remove the frame lower covers. 2． Remove the cylinder head cover bolt. 3． Remove spark plug

• Generic XOR 125, 88 CHASSIS Complaint Symptom and possible causes Remedy Handling feels too heavy. 1. Steering stem nut overtightened. 2. Broken bearing/race in steering stem. 3. Distorted steering stem. 4. Not enough pressure in tires. Adjust. Replace. Replace. Adjust. Wobbly handle. 1. Loss of balance between right and left front suspension. 2. Distorted front axle or crooked tire. Replace. Replace. Wobbly front wheel. 1. Distorted wheel rim. 2. Worn front wheel bearings. 3. Defective or incorrect tire. 4. Loose nut on axle. 5. Loose nuts on the rear shock. 6. Worn engine mounting bushing. 7.

• Generic XOR 125, 96 TIGHTENTING TORQUE O F SCREW THREAD PARTS ENGINE ITEM N．M Cylinder guide cover tapping screw 1-4 Fan guide cover lock bolt 10-12 Cylinder cover locknut 15-18 Spark plug 15-18 Inlet pipe lock bolt 10-12 Cooling fan impeller lock screw 10-12 Flywheel lock bolt 45-50 Magneto stator coil lock screw 10-12 Magneto exciting lock screw 3-5 Oil pump lock screw 5-9 Right crankcase lock bolt 10-12 Bearing press board lock bolt 10-12 Cylinder d

• Generic XOR 125, 30 Inspect each valve for turning, burning, scratches or abnormal stems wear. Check the valve movement in the guide. Measure and record each valve stem O.D. SERVICE LIMITS: 4.90 mm Measure and record the valve guide I.D. SERVICE LIMITS: IN / EX 5.30 mm Calculate the stem-to-guide clearance. SERVICE LIMITS: IN 0.08 mm EX 0.10 mm NOTE: If the stem-to-guide clearance exceeds the service limits, determine if a new guide with standard dimensions would bring the clearance within tolerance. If so, replace guides as necessary and ream to fit. If the valve guide is replaced, the valve guide

• Generic XOR 125, 83 TROUBLESHOOTING ENGINE Complaint Symptom and possible causes Remedy Engine does not start, or is hard to start. Compression too low 1. Excessively worn cylinder or piston rings. 2. Stiff piston ring in place. 3. Gas leaks from the joint in crankcase, cylinder or cylinder head. 4. Damaged reed valve. 5. Spark plug too loose. 6. Broken, cracked or otherwise failed piston. Plug not sparking 1. Damaged spark plug or spark plug cap. 2. Dirty or wet spark plug. 3. Defective CDI & ignition coil un

• Generic XOR 125, 51 STARTER SYSTEM DESCRIPTION The starter system is shown in the diagram below: namely, the starter motor, relay, starter switch and battery. depressing the starter button while squeezing the front or rear brake lever energizes the relay, causing the contact points to close which connects the starter motor to the battery. Starter motor removal and disassembly Remove the starter motor Disassemble the starter motor as shown in the illustration

• 60 under cover removal 1. unscrew screw  and bolt  2. removing under cover by loosing the left and right tapping screws ； under cover installation 3. The sequence if installation is ther reverse of removal. front cover removal 1．Unscrew tapping screw , and remove front cover  by re

• Generic XOR 125, 76 INSPECTION □ inspect the removed parts for the following abnormalities.  bearing race wear and brinelling.  Worn and damaged steel balls  Distortion of steering stem or handlebar. □ Inspect the suspension for damage

• Generic XOR 125, 32 Align the “T” mark on the flywheel with the index mark on the alternator cover by turning the flywheel counter - clockwise. Position the camshaft gear with cam chain so that its “I” mark aligns with the cylinder head surface and the circle hole forwards front. Install the dowel pins and camshaft holder. Tighten the washers and nuts. TORQUE: 20 n-m (2.0 kg-m) Adjust the clearance between the rocker arm and valve stem by applying a feeler gauge

• Generic XOR 125, 84 Complaint Symptom and possible causes Remedy Engine runs poorly in high-speed range. 1. Excessively worn cylinder or piston rings. 2. Stiff piston ring in place. 3. Spark plug gaps to narrow. 4. Ignition not advanced sufficiently due to poorly working CDI & ignition coil unit. 5. Defective magneto stator coil. 6. Float-chamber fuel level too low. 7. Clogged air cleaner element. 8. Clogged fuel hose, resulting in inadequate fuel supply to carburetor. 9. Clogged fuel cock vacuum pipe. Replace. Replace. Adjust. Replace. Replace. Adjust or replace. Clean. Clean and prime. Clean. Dirty or heavy exhaust smoke. 1.

• 61 LEGSHIELD AND PEDAL REMOVAL 1. Remove power lock housing  by unscrewing bolt. 3. remove legshield and pedal by unscrewing the four bolts Legshield and pedal installation 4. the sequence of legshield and pedal is the reverse of reomval； ② ①

• Generic XOR 125, 58 CHAPTER 6 CHASSIS CONTENTS LEG SHIELD AND FRAME SIDE COVERS LEG SHIELD REMOVAL LEG SHIELD REMOUNTING FARME SIDE COVER REMOVAL FARME SIDE COVER REMOUNTING HANDLEBAR COVERS REMOVAL REMORNTING FRONT WHEEL REMORAL INSPECTION AND DISASSEMBLY REASSEMBLY AND REMOUNTING FRONT BRAKE BRAKE PAD REPLACEMENT CALIPER REMOVAL AND DISASSEMBLY CALIPER AND DISC INSPECTION CALIPER REASSEMBLY MASTER CYLINDER REMOVAL AND DISASSEMBLY MASTER CYLINDER INSPECTION MASTER CYLINDER REASSEMBLY AND REMOUNTING STEERING STEM AND FRONT SUSPENSION REM

• Generic XOR 125, 50 NO-LOAD PERFORMANCE z Disconnect the magneto lead wire coupler. z Start the engine and keep it running at 5000r/min. z Using a pocket tester, measure the AC voltage between the white and red tracer lead wire and ground. If the tester reading is as follows, magneto is in good condition. Standard no-load performance: more than 65v(AC)AT 5000R/MIN. STATOR COILS Inducing coils Use procket tester to measure the resistance between the lead wire and ground. If the resistance checked is not

• Generic XOR 125, 12 AIR CLEANER Clean every 3000KM If the air cleaner is clogged with dust, intake resistance will, be increased with a resultant decrease in power output and an increase in fuel consumption. Check and clean the element in the following manner.  Remove screw 1 and screw 2，take down air cleaner  Unscrew tapping screw 3，remove air cleaner cap 4  Fill a washing pan of a proper size with Non-flammable cleaning solvent. Immerse the air Cleaner in the cleaning solvent and wash them clean.  Squeeze the cleaning solvent out of the washed element By pre

• 36 PISTON REMOVAL Stuff a shop towel into the crankcase. Remove the piston pin clip with needle nose pliers. NOTE: Do not allow the clip fall into the crankcase. Remove the piston pin from the piston. Remove the piston. Spread each piston ring and remove it by lifting up at a point opposite the gap.

• Generic XOR 125, 43 FUEL SWITCH When the engine has started, a negative pressure (vacuum) is generated at the intake port. The negative pressure acts upon the diaphragm of the fuel switch and it pressed down the spring which supports the diaphragm so that the fuel passageway is opened and fuel is fed to the carburetor. When the engine has stopped, the spring presses the valve, the fuel passageway is closed, and no fuel flows to the engine. Fuel switch

• Generic XOR 125, 70 CALIPER AND DISC INSPECTION Inspect the calipe cylinder bore wall or micks,scratches or other damage. Inspect piston for damage and wear. Inspect each rubber part for damage and wear. Check the disc for wear with a micrometer.Its thickness can be checked with disc and wheel in place. Ralpace the dise if the thickness exceeds the service limit. Service Limit:3.5 mm (0.14 in) With the disc mounted on the wheel, check the dids

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