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Generic XOR 125 User Manual
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72
Remove the brake lever and brake
switch.
Remove the dust boot.
Remove the circlip with the special tool.
Remove the piston/primary cup with return spri
ng.
Remove the reservoir cap and diaphragn.
Drain brake fluid.
MASTER CYLINDER INSPECTION
Inspect the master cylinder bore for any scrat
ches or other damage.
72
74
Table of Contents
Service Manual
1
Content
3
Type Identification
4
Engine Number
4
Fuel and Engine Oil
4
Fuel
4
Precautions and General Instructions
5
Replacement Components
5
Specifications
7
Dimension and Net Weight
7
Table of Contents
8
Periodic Maintenance and Service
8
Periodic Maintenance and Service Schedule
9
Maintenance and Adjustment Procedures
10
Storage Battery
10
Cylinder and Cylinder Head
11
Cylinder Head Nuts and Exhaust Pipe Bolts
11
Thickness Gauge
12
Spark Plug
12
Fuel Level Line
12
Clean Every 3000KM
13
Air Cleaner
13
Throttle Cable
13
Engine Idle Speed
13
Tachometer
14
Brakes
15
Front Brake Fluid Level
15
Gear Oil
15
Brake Pads
16
Bleeding Air from the Brake Fluid Circuit
16
Brake Shoe Wear：
17
Bleeder Valve
17
Rear Brake
17
Tire Pressure
18
Tire Tread Condition
18
Tire
18
Steering
18
Front Shock Absorber
19
Rear Shock Absorber
19
Lubrication
21
Engine
22
Engine Center
23
Engine Components Removable with the Engine in Place
23
Engine Left Side
23
Engine Right Side
23
Torque Values
24
Cylinder Head / Valves
25
Specifications
25
Camshaft Composition Removal
26
Cylinder Head
26
Low Compression
26
Trouble Shooting
26
Cylinder Head Assembly
31
Camshaft Composition Installation
32
Cylinder / Piston
35
Knocking or Abnormal Noise
35
Low or Unstable Compression
35
Troubleshooting
35
Cylinder Removal
36
Piston Removal
37
Piston / Piston Ring Inspection
38
Cylinder Installation
41
Piston Installation
41
Fuel Switch
44
Carburetor
45
Carburetion
46
Electrical System
47
CDI & Ignition Coil Unit
48
CDI Unit and Ignition Coil Inspection
48
Checking with Electro Tester
48
Ignition System
48
Electronic Tester
49
Ignition Coil Testing Lead
49
Magneto Exciting Coil
49
Charging and Lighting System
50
Charging Output Check
50
Inducing Coils
51
No-Load Performance
51
Rregulator/Rectifier
51
Stator Coils
51
Starter System Description
52
Armature Coil
53
Carbon Brushes
53
Commutator
53
Starter Motor Inspecition
53
Fuel Guage Sending Unit Inspection
54
Fuel Level Meter/Gauge
54
Fuel Meter Inspection
54
Oil Level Switch Inspection
55
Signal System
55
Break Switch
56
Light Control Switch
56
Main Switch
56
Battery Specifications
57
Fillng Electrolyte
57
Initial Charging
57
Recharging Operation
58
Chassis
59
Side Cover Removal
60
Side Installation
60
Front Cover Removal
61
Under Cover Installation
61
Under Cover Removal
61
Legshield and Pedal Installation
62
Legshield and Pedal Removal
62
Handle Cover Removal
63
Front Wheel
66
Axle Shaft
67
Inspection and Disassembly
67
Wheel Bearing
67
Wheel Rim
67
Reassembly and Remounting
68
Brake Pad Replacement
69
Front Brake System
69
Caliper Removal and Disassembly
70
Caliper and Disc Inspection
71
Brake Caliper Reassembly
72
Master Cylinder Removal and Disassembly
72
Master Cylinder Inspection
73
Master Cylinder Reassembly and Mounting
74
Removal and Disassembly
75
Steering Stem and Front Suspension
75
Reassembly and Remounting
78
Steel Ball
78
Install Handlebar and Tighten the Screw and Bolt
79
Rear Wheel and Brake
80
Brake Shoes
81
Rear Rim
81
Reassembly and Remounting
82
Servicing Inforamtion
83
Wire, Cable and Brake Hose Routing
91
Special Tools for Removal and Reinstallation
95
Tightenting Torque of Screw Thread Parts
97
5
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Generic XOR 125 Specifications
General
Brand
Generic
Model
XOR 125
Category
Scooter
Language
English
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