Manual Motorbike Sachs Xtc

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Sachs Fahrzeug- und Motorentechnik GmbH · Nopitschstrasse 70 D-90441 Nürnberg ·Tel +49 (0)911 42 31 0 · Fax +49 (0) 911 42 31 405

Printed in Germany

2003 11 001

Repair Instructions No. P00 677 008 06 02 000 Edition Oktober 2003

XTC 125 4-stroke

Sachs Fahrzeug- und Motorentechnik GmbH

PREFACE This repair manual serves as guideline for professional repair activities. See the illustrated spare-parts catalog for further assistance. All figures, dimensions and descriptions correspond to the state of the version concerned. All changes are reserved in the interest of further development of the construction models. See also the "technical information", which provides data about technical changes implemented after this repair manual was sent to the printer . The technical information is intended for master mechanics, since its careful and constant observation is a requisite for preserving the operability of the individual assemblies of the motorcycle. Apart from such information, the usual basic safety rules that apply to the repair of motorcycles must be observed. Use the tools provided for in the "Motor" section. The use of unsuitable tools may adversely affect engine operability. This manual is provided only for internal use within the Sachs organisation. It may not be reproduced or made available to third parties. Use only original SACHS spare parts. Sachs Fahrzeug- und Motorentechnik GmbH

SACHS

XTC 125 4-stroke

TABLE OF CONTENTS Technical data Assembly agents

Page 2-4 5

Repair tools and installation equipment for engines

6-7

Torque values for engine, clutch, gearbox, chassis

8-9

Service Data

10-11

General notes

12

Inspection plan

13

Tappet clearance

14-17

Spark plug

18

Air filter

19

Engine oil and oil filter

20-22

Checking/adjusting the clutch

23

Checking/adjusting the chain

24

Brake system

25-29

Fork column bearing

30

Charging the battery

31

Fuel tank, cock, tank filler removing/installing

32-33

Front wheel guard removing/installing

33

Removing/installing ignition fork-column

34

Footrests, footbrake removing/installing

36-37

Handlebar removing/installing

37-39

Checking/adjusting headlamp

40

General checking

41

Exhaust system removing/installing

42

Engine disassembly

43-51

Engine components inspection and service

52-56

Cylinder head disassembly and service

56-65

Cylinder, piston service

65-67

Crankshaft, conrod service

68-72

Transmission, clutch service

73-76

Engine reassembly

77-86

Piston, cylinder, cylinder head reassembly

87-89

Camshaft assembly

89-93

Carburetor data, removal inspection

95-103

Lubrication system chart

104

Electric system

105-117

Wheels removing/installing, checking

118-120

Telescopic fork, fork column bearing, suspension removing/installing, checking

121-127

Chain set replacing

128

Brakes removing/installing, checking

129-131

Lights

132-134

Troubleshooting

135-140

Wiring diagram

141

1

SACHS

XTC 125 4-stroke

TECHNICAL DATA Engine Type:

FX 125

Construction:

One cylinder 4-stroke, DOHC four valve

Pistion displacement:

124,5 cc

Bore:

ø 57 mm

Stroke:

48,8 mm

Compression ratio:

10,4

Maximum net power output:

11 KW at 10500 1/min

Maximum net torque:

11 Nm at 7200 1/min

Ignition system:

transistorized ignition system with electronic ignition control (CDI)

Static timing:

5 ° at 1.500 1/min B.T.D.C

Spark plug:

NGK CR8E or DENSO U24ESR-N Electrode distance 0,6 mm

Carburettor:

Mikuni BS 26 47E3

Air-filter:

paper air-filter

Idling speed:

1450 - 1550 1/min

Typ of starter:

electric starter

Cooling:

air cooled with oil cooler

Power transmission Clutch:

Wet multi-plate type

Gear box:

5-seed constant mesh

Gear ratios:

1. gear = 33/12 (2,75) 2. gear = 25/14 (1,786) 3. gear = 26/19 (1,368) 4. gear = 23/21 (1,095) 5. gear = 21/23 (0,913)

2

Primary transmission ratio:

70/20 (3,5)

Seccondary transmission ratio:

3,3 with tire 150/60 R17 66 HTL 3,4 with tire 150/70-17 M/C 69 HTL

Chain pinion:

14 teeth

Sprocket:

53 teeth with tire 150/60 R17 66 HTL 55 teeth with tire 150/70-17 M/C 69 HTL

Chain:

O-ring chain 144 links

SACHS

XTC 125 4-stroke

TECHNICAL DATA Chassis Motorbike version:

XTC 125 type 677 001 / XTC 125 type 677 003

Frame:

Trellis-type frame made of tubular steel

Front suspension:

Telescopic fork ø 41 mm , hydraulic shock absorption, travel 120 mm

Rear suspension:

Oil-damped mono shock absorber, travel 120 mm, adjustable preload

Wheels:

Light metal (Alu) Front rim size: = 17" x MT 2.75 DOT Rear rim size: = 17" MT 4.00 DOT

Tires:

Front = 110/70 17R 54 W TL / 110 / 70 -17 M/C 54 HTL Rear = 150/60 17R 66 W TL / 150 / 70 -17 M/C 69 HTL

Tire pressure, solo pillion driver

Front = 1.9 rear = 2.1 bar Front = 1.9 rear = 2.3 bar

Brakes, front: Minumim lining thickness

Hydraulic disc brake ø 316 mm four piston caliper 2,5 mm

Brakes, rear: Minumim lining thickness

Hydraulic disc brake ø 220 mm single piston floating caliper 1,5 mm

Lubricants and operating fluids Fuel tank capacity:

20.0 litres, including 4.0 litres reserve

Fuel:

Unleaded fuel

Telescopic-fork oil:

Viscosity SAE 10 W

Filling quantity per fork tube:

280 cm3

Engine oil, oil change w.o. filter: oil change with filter: oil change overhaul:

1.000 cm3 1.200 cm3 1.400 cm3

Brake fluid:

DOT 4

SAE 10 W 40 mineral oil API (SG or higher)

Electrical Equipment Generator:

Flywheel magneto, 12V, 100W at 5000rpm

Battery:

12 V 4 Ah MF

Fuse:

20 A

Lights: - Headlight: - Position light:

Highbeam: H3 12 V 55W E1 / low beam H1 12V 55W E1 12 V 2W

- Pilot lights:

12 V 1,2 W

- Brake/rear light:

12 V 5W / 21 W

- Number plate light:

12 V 2W

- Turn signal light:

12 V 10 W

3

SACHS

XTC 125 4-stroke

TECHNICAL DATA Dimensions and weights

4

Overall length: Width across handlebars

1970 mm

without rear view mirror:

660 mm

Maximum height:

1040 mm without rear view mirror

Wheel base:

1350 mm

Seat height:

800 mm

Seat length:

Driver: 290 mm, pillion passenger: 270 mm

Curb weight:

130 kg

Max. permitted total weight:

330 kg

Top speed:

102 km/h

SACHS

XTC 125 4-stroke

ASSEMBLY AGENTS Designation

Use

Suzuki Bond 1215

Sealing of crank case halves

Thread Look Super “1303”

Housing screws for secondary output gear

Thread Look “1342”

Generater stator setscrew

Thread Look “1360”

Disc assembly screws

Suzuki Bond

Cylinder head cover

Thread Look Super “1324”

Fastening screws and nuts for drive and countershaft bearing

Thread Look Super “1305”

Oil pump housing screws

Thread Look Super “1322”

Oil tube fastening screws

5

SACHS

XTC 125 4-stroke

REPAIR TOOLS AND INSTALLATION EQUIPMENT FOR ENGINES

1

2

6

7

11

12

16

17

21

22

3

8

4

9

13

18

23

5

10

14

15

19

20

24

25

26

Tools without material number have to be purchased from specialised trade.

6

SACHS

XTC 125 4-stroke

Repair tools and installation equipment for engines Fig. No. Order-no.

Designation

1

K 09900-22302-000

Plastigauge

2

K 09910-20116-000

Conrod holder

3

K 09910-32812-000

Crankshaft installer

4

K 09910-34510-000

Piston pin puller

5

K 09911-11310-000

Attachment

6

K 09913-10750-000

Adaptor for compression gauge

7

K 09913-50121-000

Oil seal remover

8

K 09913-75510-000

Bearing installer

9

K 09913-75520-000

Bearing insaller

10

K 09913-75810-000

Bearing insaller

11

K 09913-75821-000

Bearing installer attachment

12

K 09913-76010-000

Bearing installer

13

K 09915-72410-000

Adaptor for oil pressure gauge

14

K 09915-74510-000

Oil pressure gauge

15

K 09916-14510-000

Valve lifter

16

K 09916-14530-000

Valve lifter attachment

17

K 09916-21110-000

Valve seat cutter set

18

K 09916-24410-000

Valve seat cutter (N-111) 60° intake side

18

K 09916-24460-000

Valve seat cutter (N-130) 15° exhaust side

18

K 09916-24470-000

Valve seat cutter (N-131) 45° intake side and exhaust side

18

K 09916-20630-000

Valve seat cutter (N-126) 30° intake side

19

K 09916-20640-000

Solid pilot

20

K 09916-34542-000

Valve guide reamer 4.5 mm

21

K 09916-34580-000

Valve guide reamer 10.8 mm for vlave guide hole

22

K 09916-43210-000

Valve guide installer

23

K 09920-13120-000

Crankcase separator

24

K 09920-53740-000

Clutch sleeve hub holder

25

K 09922-55131-000

Counter shaft (2-4-5 gear) remover

26

K 09930-44512-000

Rotor holder

P98 835 771 07 01 000

Assembly stand set

-

7

SACHS

XTC 125 4-stroke

TOURQE VALUES FOR ENGINE/CLUTCH/GEARBOX/CHASSIS Tightening torques, gerneral

Nm

Srew connection M5

5-6

Srew connection M6

8-10

Srew connection M8

22-25

Srew connection M10

38-42

Tightening torques for plastic connections

Nm

Srew connection M5

3-5

Srew connection M6

5-7

Srew connection M8

13-15

Tightening torques engine/clutch/gearbox Connection

Nm

Cylinder head cover bolt

14

Cylinder head bolt

25

Cylinder head nut

10

Cylinder base nut

10

Cam sprocket bolt

11

Camshaft holder bolt

10

Cam chain tension adjuster bolt

10

Starter clutch bolt

10

Spark plug

11

Cylinder head stud bolt

15

Crank balancershaft set bolt

50

Generator rotor nut

80

Primary drive gear nut

50

Clutch sleeve hub nut

50

Gearshift cam plate bolt

10

Gearshift cam stopper arm shaft

10

Gearshift arm stopper bolt

19

Driveshaft and countershaft bearing retainer screw

8.5

Crankcase bolt

10

Generator cover bolt

10

Clutch cover bolt

10

Engine oil pipe union bolt

20

Engine oil drain plug

18

T.D.C. plug

21

Generator cover cap

11

Engine sprocket nut

90

Oil cooler hose union bolt

23

Exhaust pipe bolt M8 Exhaust pipe mounting bolt and nut M6 Muffler mounting bolt and nut M8

22-25 10 22-25

Engine mounting nut M10

66

Engine mounting bolt M8

31

8

SACHS

XTC 125 4-stroke

Tightening torques for chassis Connection

Part designation

Nm

Half-handlebar fastening

Screw M8

25-28

Fastening screws for upper fork bridge

Screw M10

40

Fastening screws for lower fork bridge

Screw M8

13-15

Screw plug for fork pipe

Screw

40

Closing nut of control-head bearing

Nut M24

40

Covering holder, front

Screw with nut M8

Covering screws

Screw M6

8

Brake shoe, front

Screw M10

35-38

Brake disk on wheel hub, front

Screw

10-11

Brake disk on wheel hub, rear

Screw

10-11

Brake pipe connection

Banjo bolt

18-20

Ventilating valve on calliper

Ventilator screw

10

Footbrake cylinder on frame

Screw with nut M6

12

Screws for brake lining, rear

screw

35-38

Footbrake lever on frame

Screw M8

25-28

Footbrake lever on frame

Screw M8

25-28

Footrest support, front

Screw with nut M8

25

Footrest support, rear

Screw with nut M8

25

Chain wheel to hub

Screw M8

Engine fastening

Screw with nut M8

28

Engine fastening

Screw with nut M10

42

Front-wheel axle

Full floating axle M24

Locking screw for front axle

Screw M6

Rear-wheel axle

Nut M16

88-90

Swing axle

Nut M16

88-90

Telescopic leg

Screw with nut M10

42

Side standard

Nut M10

42

3-15

25-28

60-65 10

9

SACHS

XTC 125 4-stroke

SERVICE DATA VALVE + GUIDE

Unit: mm

ITEM

STANDARD

LIMIT

22

-

EX.

19

-

IN.

0.10-0.20

-

EX.

0.20-0.30

-

IN.

0.010-0.037

-

EX.

0.030-0.057

-

Valve stem deflection

IN. & EX.

-

0.35

Valve guide I.D

IN. & EX.

4.500-4.512

-

Valve stem O.D.

IN.

4.475-4.490

-

EX.

4.455-4.470

-

Valve stem runout

IN. & EX.

-

0.05

Valve head thickness

IN. & EX.

-

0.5

Valve seat width

IN. & EX.

0.9-1.1

-

Valve head radial runout

IN. & EX.

-

0.03

Valve spring free length

IN. & EX.

-

37.8

Valve spring tension

IN. & EX.

12.1-13.9 kg at length 33.7 mm

-

Valve diam. Tappet clearance (when cold) Valve guide to valve stem clearance

IN.

CAMSHAFT+ CYLINDER HEAD

Unit: mm

ITEM

STANDARD

LIMIT

IN.

34.960-35.000

34.650

EX.

33.260-33.300

33.950

Camshaft journal oil clearance

IN. & EX.

0.032-0.066

0.150

Camshaft journal holder I.D.

IN. & EX.

22.012-22.025

-

Camshaft journal O.D.

IN. & EX.

21.959-21.980

-

Camshaft runout

IN. & EX.

-

0.10

16th pin

-

-

0.05

Cam height

Cam chain pin (at arrow "3") Cylinder head distortion

CYLINDER + PISTON + PISTON RING

Unit: mm

ITEM

STANDARD

LIMIT

Compression pressure

13.0 kg/cm

10.0 kg/cm2

Piston to Cylinder clearance

0,050-0.060

0.120

Cylinder bore

57.000-57.015

57.362

Piston diam.

56.945-56.960 Measure at 15 mm from the skirt end.

56.850

-

0.05

1st R

Approx. 7.2

6.2

2nd R

Approx. 5.0

3.96

1st

0.20-0.32

0.5

2nd

0.20-0.32

0.5

2

Cylinder distortion Piston ring free end gap Piston ring end gap

10

SACHS

XTC 125 4-stroke

SERVICE DATA CYLINDER + PISTON + PISTON RING

Unit: mm

ITEM

STANDARD

LIMIT

Piston ring to groove clearance

1st 2nd

-

0.18 0.15

Piston ring groove width

1st 2nd Oil

1.01-1.03 1.01-1.03 2.01-2.03

-

Piston ring thickness

1st 2nd

0.97-0.99 0.97-0.99

-

Piston pin bore

15.002-15.008

15.030

Piston pin O.D.

14.995-15.000

14.980

CONROD + CRANKSHAFT ITEM

Unit: mm STANDARD

LIMIT

15.006-15.014

15.040

-

3.0

0.10-0.45

1.00

15.950-16.000

-

53.0±0.1

-

-

0.08

ITEM

STANDARD

LIMIT

Oil pump reduction ratio

2.000 (30/15)

Conrod small end I.D. Conrod deflection Conrod big end side clearance Conrod big end width Crank web to web width Crankshaft runout OIL PUMP

Oil pressure (at 60° C)

Above 0.3 kg/cm Below 0.7 kg/cm2 at 3 000 r/min.

CLUTCH ITEM

2

-

Unit: mm STANDARD

LIMIT

Clutch lever play

10-15

-

Drive plate thickness

2.9-3.1

2.6

Drive plate claw width

11.8-12.0

11.0

Driven plate distortion

-

0.10

Clutch spring free length

-

29.5

11

SACHS

XTC 125 4-stroke GENERAL NOTES Gaskets, seal rings and O-rings -

Gaskets, seal rings and O-rings must generally be replaced when overhauling the engine. The sealing faces must be thoroughly cleaned.

Lock washers and split pins - After removal replace all lock washers (1) and split pins. After tightening the nut, lock washer (1) must be bent up against the side of the nut.

1 SFM 835 001.3

Bearings and radial seals - When assembling bearings (1) make sure that manufacturer name or number point to the outside. Lubricate the bearings with oil. ATTENTION Do not use compressed air to dry the bearings since this could damage the surface of the bearings.

1

SFM 835 002.3

-

1

SFM 835 003.3

1

4

3

2

SFM 835 004.3

12

When assembling radial seals (1) make sure that manufacturer name or number point to the outside. Apply a thin coat of lightly viscous engine oil to the seal lips. Circlips - Circlips must be thoroughly inspected before installation. - Piston pin circlips must not be assembled again. - Warped circlips must be renewed. - When assembling a circlip (1) make sure that the sharp edged side (2) is positioned opposite the side subjected to the force (3) applied to the circlip. See cross-sectional drawing (4 = shaft).

SACHS

XTC 125 4-stroke

INSPECTION PLAN Component Assembly

Servicing Tasks

Valves

Check and adjust valves as necessary (cold)

Spark plugs

Check condition and accordingly clean or change

Air filter

Clean filter and housing. Replace paper filter

Carburetor

Check and adjust idle and cold start

Before each trip

1st service after 1000 km

Every 4.000 km

Every 8.000 km

inspect every 12.000 km inspect

inspect

inspect

clean

replace

replace

x

x

x

x

Throttle cable

x

x

x

x

Petrol hoses

Check and replace as necessary (change at least every 4 years)

x

x

x

x

Motoroil

Change (operating temperature)

x

x

x

Oil filter

Change

x

Exhaust system

Check for leads and repair as necessary

x

x

Brakes

Check brake function and brake fluid as well as housing, correcting as necessary

x

x

x

x

x

x

x

Check and replace brake pads Brake fluid

Change

Brake hoses

Check and renew* (min. every 4 years)

x

Clutch

Check and adjust

x

Back wheel mounting

Look over, check play and renew or regreas as necessary

Tyres

Check general condition and tread depth and replace as necessary

Wheels

x

Every 24.000km / 2 Years x

x

x

x

x

Every 24.000km / 2 Years x

x

x

x

Check for damage, balance

x

x

x

Stearing and bearings

Check and adjust free play

x

Front forks

Check general condition as well as for leaks and repair as necessary

Chain

Check adjustment and condidtion and grease, adjust and renew as necessary

Side stand

Check, grease, repair as necessary

x

x

x

Nut and bolt tightness

Check that all bolts and nuts are tightened to the correct torque settings

x

x

x

Cables

Check and renew

x

x

x

Headlight

Check and adjust

x

x

x

x

General safety check

Check general safety standards: clutch, gear switch, revs, brakes, headset, lights, air pressure and adjust accordingly

x

x

x

x

x

x inspect x

x clean and lubricate every 1000 km

13

SACHS

XTC 125 4-stroke

TAPPET CLEARANCE Inspect every 12 000 km. INSPECTION - Remove the fuel tank. - Disconnect the spark plug cap and remove the spark plug. - Remove the cylinder head cover. The tappet clearance specification is different for both intake and exhaust valves. Tappet clearance adjustment must be checked and adjusted: - at the time of periodic inspection when the valve mechanism is serviced - when the camshafts are removed for servicing. Tappet clearance (when cold): IN.: 0,10-0,20 mm EX.: 0,20-0,30 mm NOTE The piston must be at top dead center (TDC) on the compression stroke in order to check or adjust the tappet clearance. The tappet clearance should only be checked when the engine is cold. -

Remove the generator cover cap (1) and valve timing inspection plug (2).

-

Rotate the crankshaft with a box wrench to set the piston at top dead center (TDC) on the compression stroke. (Rotate the crankshaft until the "T" line on the generator rotor is aligned with the center of the hole in the generator cover.)

-

lnsert a thickness gauge between the tappet and the cam. If the clearance is out of specification, adjust it to specification as follows.

Tool: Thickness gauge

14

SACHS

XTC 125 4-stroke

ADJUSTMENT The clearance is adjusted by replacing the existing tappet shim with a thicker or thinner shim. - Remove the intake or exhaust camshafts. - Remove the tappet and shim by hand or with a magnet.

-

Check the numbers printed on the tappet shim. These numbers indicate the thickness of the tappet shim, as illustrated. Select a replacement tappet shim that will provide the proper clearance. Tappet shims are available in 21 sizes, ranging from 1.20 to 2.20 mm in increments of 0.05 mm. lnstall the selected shim (1) at the valve stem end, with the numbers facing towards the tappet. Be sure to measure the shim with a micrometer to ensure that it is of the proper size. Refer to the tappet shim selection table for details.

NOTE Be sure to apply engine oil to the top and bottom faces of the tappet shim. When installing the tappet shim, make sure that the side with the numbers face towards the tappet. CAUTION Reinstall the Camshafts as specified. -

After replacing the tappet shim and camshafts, rotate the crankshaft so that the tappet is depressed fully (this will squeeze out any oil trapped between the tappet shim and the tappet that could cause an incorrect measurement). After rotating the crankshaft, check the tappet clearance again to make sure that it is within specification.

-

When installing the cylinder head cover, apply SUZUKI BOND NO.1207B to the cam end caps of the cylinder head cover gasket.

SUZUKI BOND NO.1207B -

Tighten the cylinder head cover bolts to specification in two stages.

Cylinder head cover bolt:

Initial 10 Nm Final 14 Nm

15

SACHS

XTC 125 4-stroke

INTAKE SIDE

TAPPET SHIM SELECTION TABLE TAPPET SHIM NO. (12892-05C00- x x x)

TAPPET SHIM SET NO. (12800-05820)

How to use this chart: 1. Measure tappet clearance (engine is cold). 2. Measure present shim size. 3. Match clearance in vertical column with present shim size horizontal column. Example: Tappet clearance is

0.23 mm

Present shim size

1.70 mm

Shim size to be used

1.80 mm

Surfix no. Measured tappet clearance mm

Present Shim size mm

Specified clearance / No adjustment required

16

SACHS

XTC 125 4-stroke

EXHAUST SIDE

TAPPET SHIM SELECTION TABLE TAPPET SHIM NO. (12892-05C00- x x x)

TAPPET SHIM SET NO. (12800-05820)

How to use this chart: 1. Measure tappet clearance (engine is cold). 2. Measure present shim size. 3. Match clearance in vertical column with present shim size horizontal column Example: Tappet clearance is

0.33 mm

Present shim size

1.70 mm

Shim size to be used

1.80 mm

Surfix no. Measured tappet clearance mm

Present Shim size mm

Specified clearance / No adjustment required

17

SACHS

XTC 125 4-stroke

SPARK PLUG Inspect every

4.000 km

Replace every

8.000 km

-

Remove the fuel tank. Pull off the spark plug socket and unscrew the spark plugs. Spark plug

Type

NGK

CR8E

DENSO

U24ESR-N

Check the spark plug: - Check the spark plug type and replace if necessary. - Check electrodes (1 and 2) for wear and damage. - Check the colour of the insulator (3): Normal state is a medium to light brown coloration. In case of extremely deviating cloration check the engine timing or the ignition cables. - Check the electrode gap (A) with a feeler gauge and adjust it if necessary. Electrode gap (A) 0.6 mm NOTE Before installation clean spark plug and spark plug sealing faces. -

Install the spark plug. Tightening torque 11 Nm

18

3

A 2

1

SACHS

XTC 125 4-stroke

Air filter

� � � � � �

��� ��� �������

Clean initally at

1.000 km

Replace every

4.000 km

Opening the air filter: -

Remove the screws (1). Take off the cover (2) with spring (3) and the cover (4). Clean the filter case and filter element (5) or replace if necessary.

NOTE Before installation, check the gasket (6) for damage and correct position. Assembly of the cleaned or new filter element takes place in reserve order of removal. Tightening torque: 7 Nm

19

SACHS

XTC 125 4-stroke

ENGINE OIL CAUTION Do not use additives. Since the oil also serves to lubricate the clutch, do not use car engine oils supplemented with friction modifiers (such energyconserving oils can lead to the clutch slipping). Use a suitable, light engine oil for motorcycles, such as Motorex SAE 10W/40 mineral oil API (SG or higher). If required, replenish the engine oil (for classification and viscosity, see the table) via the oil filter opening. Recommended grade: Per API: SG or higher or also with additional release status: ACEA A3/96 (CCMC G5). Recommended viscosity: Viscosity depends on the outside temperature. For short while, the temperature may exceed or fall short of the limits of the SAE grades. The recommended viscosity grade SAE 10W/40 covers the ambient temperature range –10 °C to +40 °C and therefore represents the optimum for our latitudes.

20

-10˚ 0˚ 10˚ 20˚ 30˚ 40˚ 50˚C

SAE 10W/30 SAE 10W/40

SAE 20W/40

SAE 20W/50

SACHS

XTC 125 4-stroke

ENGINE OIL REPLACEMENT

ENGINE OIL Replace initally at

1.000 km

Replace every

4.000 km

The engine oil should be changed while the engine is warm. Oil filter replacement at the above intervals, should be done together with the engine oil change.

CAUTION Catch old oil and dispose of environmentally. Do not run the engine in closed rooms without proper extraction of fumes. - Keep the motorcycle upright. - Place an oil pan below the engine, and drain the engine oil by removing the oil drain plug (1) and filler cap (2). - Tighten the oil drain plug (1) to the specified torque, and pour new oil through the oil filler. When performing an oil change (without oil filter replacement), the engine will hold about 1.0 L of oil. Oil drain plug: 18 Nm - Install the oll filter cap. - Start up the engine and allow it to run for several seconds at idling speed. - Turn off the engine and wait about one minute, then check the oil level through the inspection window (3). lf the level is below the "F" mark, add oil to the proper level.

21

SACHS

XTC 125 4-stroke

OIL FILTER REPLACEMENT OIL FILTER Replace initally at

1.000 km

Replace every

8.000 km

ATTENTION

Use only genuine Oilfilter, because the filters from other manufacturers or parts sold in the market may have different threads (thread diameter and pitch), filter performance and resistance, which could lead to engine damage and oil leaks.

-

Drain the engine oil as described in the engine oil replacement procedure. Remove the oil filter cap (1) by removing the bolts. Remove the oil filter (2) and install a new one. lnstall the oil filter cap (1) and tighten the bolts securely.

-

NOTE Before installing the new oil filter and oil filter cap, make sure that the spring (1) and new O-rings (2, 3) are installed correctly. -

Add new engine oil and check the oil level as described in the engine oil replacement procedure.

Oil viscosity and classification: SAE 10W/40 mineral oil API (SG or higher). NECESSARY AMOUNT OF ENGINE OIL Oil change:

1 000 ccm

Oil and filter change:

1 100 ccm

Engine overhaul:

1 400 ccm

22

SACHS

XTC 125 4-stroke

Checking/adjusting the clutch Checking the clutch: 1. Pull the lever until resistance is felt. 2. Measure the play. Target value (A):

3-4 mm

1 2

A

Adjusting the clutch: 3. Loosen the lock-nut (1). 4. Twist the adjusting screw (2) correspondingly. 5. Firmly retighten the lock-nut (1). 6. Check the play. NOTE

SFM 675 005.1

If the clutch play cannot be corrected by means of this adjustment, do the following: 7. Loosen the lock-nut (1). 8. Twist in the adjustment screw (2) all the way, in order to make the pull cable as loose as possible. 9. Firmly retighten the lock-nut (1). 10. Loosen the adjustment nuts (4) of the pull cable (3). 11. Use the adjustment nuts (4) to adjust the pull cable (3) correspondingly, until the clutch-lever play (A = 3-4 mm) has been achieved. 12. Firmly retighten the adjustment nuts (4) of the pull cable (3).

3

4

m 0 10 0

If the clutch-lever play can no longer be adjusted, the clutch must be checked or replaced, and the basic adjustment of the clutch must be carried out.

l

NOTE

SFM 677 020.1

23

SACHS

XTC 125 4-stroke

Checking/adjusting the chain Checking the chain for wear:

1

CAUTION The chain, chain wheel and pinion wheel must be replaced collectively, i.e. not as individual parts. -

Put the motorcycle on its side standard. Hold the chain (5) by the rearmost part of the chain wheel and pull the chain backwards. If the chain tension is correct, it will not be possible to lift the chain over the top of the teeth. If the chain can be pulled any further, replace the chain, chain wheel and pinion wheel.

Adjusting the chain: CAUTION The chain adjustment af fects the wear of chain and the toothed wheel rim. -

Loosen the full floating axle (4) and nuts (1) from the chain take-up. - Evenly adjust the adjusting screws (2) of the chain take-up on both sides in such a way (rear wheel must be aligned with front wheel-adjustment aid is the scale (6)), that the chain slack (A) = 30-40 mm. - Tighten the nuts. Tightening torques: Full floating axle (4): 60-65 Nm Nuts (1): 22-25 Nm

24

2

A 5

1

2

4

3

6 5 SFM 675 008.3

SACHS

XTC 125 4-stroke

Brake system Checking the brake system for leaks 1. Check the brake lines for damage and correct position. 2. Wipe off all screw connections of the brake lines. 3. Firmly operate the front and rear brakes and shortly keep them operated. 4. Check the brake lines for any leaks. 5. Replace any faulty brake lines and seals/ washers.

Checking/adjusting the front brake-fluid level CAUTION Brake fluid damages paint and plastic parts! Before filling the tank with brake fluid, check the brake lining for wear and the brake system for leaks. Only use new brake fluid of specification DOT 4. Brake fluid is exposed to high temperatur es and absorbs moisture from the ambient air. NOTE Cover the tank and painted parts to avoid damage. Checking the brake-fluid level: - Turn the handlebar until the line near the "MIN" mark on the brake-fluid tank (1) is horizontal. - The brake-fluid level must be between the "MIN" and "MAX" marks. - If air bubbles are visible: check the brake lining for wear and replenish the brake fluid as necessary. Replenishing the brake fluid: - Twist off the cover (3) and remove it along with the rubber diaphragm (2). - Replenish the brake fluid up to the "MAX" mark and reinsert the rubber diaphragm (2). - Twist on the cover (3).

3 2 1

SFM 675 011.3

25

SACHS

XTC 125 4-stroke

Checking/adjusting the rear brake-fluid level CAUTION Brake fluid damages paint and plastic parts! Before filling the tank with brake fluid, check the brake lining for wear and the brake system for leaks. Only use new brake fluid of specification DOT 4. Brake fluid is exposed to high temperatur es and absorbs moisture from the ambient air. NOTE Cover painted parts is in order to avoid paint damage. Checking the brake-fluid level: - Make sure the motorcycle is level. - The brake-fluid level should be between the minimum (MIN) and maximum (MAX) marks on the brake-fluid tank. - If the brake-fluid level is lower than the minimum (MIN) mark: check the brake lining for wear and replenish the brake fluid as necessary. Replenishing the brake fluid: - Make sure the motorcycle is level (so that the line near the "MIN" mark on the brake-fluid tank (3) is level). - Twist off the cover (1) and remove it along with the rubber diaphragm (2). - Replenish the brake fluid up to the "MAX" mark. - Reinsert the rubber diaphragm (2). - Twist on the cover (1).

26

1 2 3 SFM 675 012.3

SACHS

XTC 125 4-stroke

Checking/replacing the lining of the front brakeshoes Checking the lining thickness: CAUTION Make sure the minimum lining thickness is observed. - Visually inspect the calliper (1). - Check the minimum lining thickness. Minimum lining thickness (A): 2.5 mm - IIf the thickness is less than the minimum: replace the brake lining. - Check the brake disk for wear and wobble.

2 A

1

A SFM 675 013.3

Replacing the brake linings: NOTE Brake linings may only be replaced in pairs.

1 -

Remove the screws from the holder clamp (1) and the screws (3) from the calliper (2). Remove the calliper (2).

3 2

SFM 675 015.3

-

Remove the lock washer (3) and the holder bolts (2) from the calliper (1). - Remove the brake linings (1). - Use a commercially available tool to set back the pistons in the calliper (1) all the way, then clean the contact faces of the brake linings (4). - Insert the new brake linings (4) and fasten them with the holder bolts (2) and the locking washers (3). - Reassemble in reverse order. Tightening torques of the calliper screws: 35-38 Nm WARNING - RISK OF ON-ROAD ACCIDENT Operate the brakes several times, until the brake linings make contact. -

2

1 3

4

SFM 675 014.3

Check the brake - fluid level and the handbrake play. Check the operation.

27

SACHS

XTC 125 4-stroke

Checking/replacing the lining of the rear brakeshoes Checking the lining thickness:

1

CAUTION Make sure the minimum lining thickness is observed. -

-

A

Visually inspect the lower calliper (1) from the lefthand side of the motorcycle. Check the minimum lining thickness. Minimum lining thickness (A): 1.5 mm If the lining thickness is less than the minimum: replace the brake lining. Check the brake disk for wear and wobble.

Replacing the brake lining: NOTE The brake linings may only be replaced in pairs. Remove the rear wheel. Remove the brake anchor plates along with the calliper (1) from the rear swing. - Bend back the lock plate (2) and remove the screws (3). - Remove the holder plate (4) and remove the brake linings (5). - Use a commercially available tool to set back the pistons in the calliper (1) all the way, then clean the contact faces of the brake linings (5). - Insert the new brake linings (5) and the holder plate (4) and fasten them with the lock plate (2) and the screws (3). Tightening torques of the screws (3): 25-28 Nm

SFM 675 016.3

5

-

- Bend the lock plate (2) to lock the screws (3). - Reassemble in reverse order. WARNING - RISK OF ON-ROAD ACCIDENT Operate the brakes several times, until the brake linings make contact. - Check the brake fluid and the handbrake play. - Check the operation.

28

1 4 2 3

SFM 675 017.3

SACHS

XTC 125 4-stroke

Changing the brake fluid CAUTION Brake fluid can damage paint and plastic parts! Use only brake fluid of specification DOT 4. -

Change the brake fluid and vent the brake system. Check the handbrake lever adjustment and check its operation.

Adjusting the handbrake lever -

-

Loosen the lock nut (1) on the handbrake lever (3). Turn the adjusting screw (2) until the empty run (A) at the handbrake lever is 30 mm until the pressure position. Retighten the lock nut (1).

2

1

3

A

SFM 675 018.3-1

Checking/greasing/adjusting the empty run and smooth run of the footbrake lever -

Check the smooth operation of the footbrake lever; grease it as necessary. Adjusting the footbrake lever position: NOTE Use the adjusting screw (3) to adjust the footbrake lever position as desired by the client. WARNING The adjustment dimension (A) may not exceed 18 mm. - Loosen the lock-nut (2) and use the adjusting screw (3) to adjust the position of the footbrake lever (1). Adjustment dimension (A): max. of 18 mm. - Tighten the lock-nut (2).

.

Max

Min.

2

3

A

1

SFM 675 019.3

29

SACHS

XTC 125 4-stroke

Fork-column bearing Checking/adjusting the fork-column bearing play Checking the fork-column bearing play: - Put the motorcycle on sturdy standards and take the weight off the front wheel. - Take hold of the two fork pipes and try to move them to and fro. If there is a noticeable play in the fork-column bearing, it must be adjusted.

SFM 675 021.3

Adjusting the fork-column bearing play: - Put the motorcycle on sturdy standards and take the weight off the front wheel. - Loosen the clamp screws (1) on the upper fork bridge. - Remove the seat and fuel tank - Loosen the closure nut (2). - Use a sickle spanner to lightly tighten the adjusting nut (3) until the fork-column bearing is free of play.

2

1

NOTE While the front wheel is raised, the fork must fall lightly to the left or right until it hits the stop. WARNING - RISK OF ON-ROAD ACCIDENT If while moving the handlebar to and fro it locks in some position/s, then the fork-column bearing must be replaced. -

Tighten the closing nut (2). Tightening torque: 40 Nm Tighten the clamping screws (1) of the upper fork bridge. Tightening torque: 25-28 Nm

Cleaning and greasing the sealing ring 1. 2.

30

Put the motorcycle on sturdy standards and take the weight off the front wheel. Check that the fork-column bearing runs smoothly. If it does not, or if it locks, remove the telescopic fork, check the fork-column bearings and sealing rings for damage, then clean, grease and - if necessary - replace them.

1 3 SFM 675 022.3-1

SACHS

XTC 125 4-stroke

Charging the battery After a long lay-up (3-4 months), charge the battery. The charging current (in amperes) must not exceed 1/10th of the battery capacity (Ah). The battery must not be fast-charged. The battery may only be charged using a special charger approved for MF batteries. Maintenance Although the battery is maintenance-free. Never leave the battery discharged. Keep the battery clean and dry and make sure that the connection terminals are firmly seated. Removing and installing the battery The battery (1) is located beneath the seat. Remove the seat. - Remove the screw (2) and remove the seat in a rearwards direction (see the arrow).

CAUTION The battery may only be connected or disconnected while the ignition is inactive. First disconnect the minus terminal (black cable). When installing the battery, first connect the plus terminal (red cable). The battery is maintenancefree. Do not try to open it. Checking/charging the battery -

Check the battery fastening. Check that the battery cables (1 and 2) are correctly connected. Check the charging voltage, current loss, charged condition charge the battery as necessary.

2 1

SFM 675 006.3-1

31

SACHS

XTC 125 4-stroke

Fuel tank Removing/installing the fuel tank Removing the fuel tank: 1. Removing the seat. 2. Close the fuel cock (1), loosen the hose clamp and pull off the fuel hose (2). 3. Remove the screw (3), washers and support rings.

4 3 3

NOTE When removing the fuel tank, be careful not to lose the support bodies (rubber bearings). When lowering the fuel tank, be careful not to damage the paint. 4. Remove the fuel tank (4). Installing the fuel tank: 5. Reassemble in reverse order

1 2

SFM 675 026.3-1

Removing/installing the fuel cock Removing the fuel cock: 1. Completely drain the fuel tank. 2. Loosen the hose clamps (3) and pull off the fuel hose (4) and overflow hose (5). 3. Remove the fuel cock (1). 4. Clean the sieve (6). Installing the fuel cock: NOTE In principle, the sealing ring (2) must be replaced. 5. Reassemble in reverse order.

32

5 2 1

6

3 4

3 SFM 675 027.3-1

SACHS

XTC 125 4-stroke

Removing/installing the tank filler neck

1

1 2

5

1. Remove the screws (1) and the tank filler neck (2). 2. Remove the seat (6) and sealing rings (7), then check the sealing ring; replace, if necessary. 3. Remove the screws (3), cover (4) and gasket (5). 4. Check the gasket (5); replace, if necessary. 5. Install the gasket (5) and cover (4) and fasten them with the screws (3).

4

6 7

3

NOTE When installing these, make sure that the bore hole for the tank overflow is free.

SFM 675 028.3-1

6. Install the gasket (7), the seat (6) and the preassembled tank filler neck (2); fasten with the screws (1).

Removing/installing the front-wheel guard Removing the front-wheel guard: 1. Pull off the speedometer-shaft holder (1). 2. Remove the screws (2) along with the washers.

2 3

2 1

NOTE When lowering the front-wheel guard, be careful not to damage the paint. 3. Remove the front-wheel guard (3). Installing the front-wheel guard: 4. Reassemble in reverse order.

SFM 675 029.3-1

33

SACHS

XTC 125 4-stroke

Removing/installing the ignition fork-column lock Removing the ignition fork-column lock: NOTE The pull-off screws (3) must be opened using a centre punch or chisel. 1. Remove the full covering and headlamps. Disconnect the plug (1). 2. Remove the pull-off screws (3) and remove the ignition fork-column lock (2) from the fork bridge (4).

��

�

�

�

�

Installing the ignition fork-column lock: NOTE Always use new pull-of f screws (3). 3. Reassemble in reverse order.

�

Removing the cover holder: 1. Remove the full covering and headlamps. 2. Remove the screws (6) with washers (7) and nuts (8) and remove the cover holder (5).

� �

Installing the cover holder: 3. Reassemble in reverse order. ��� ��� �������

34

SACHS

XTC 125 4-stroke

35

SACHS

XTC 125 4-stroke

Footrests Removing/installing the front-right footrest footbrake unit

15

16

Removing the front-right footrest/footbrake unit: 1. Remove the nut (1) with washer (2) and take out the ball-and-socket joint (3) of the brake cylinder. 2. Remove the screw (4) with washer (5), and remove the footrest (16) and footbrake lever (8) and sliding bush (7) from the footrest support (6). NOTE The rubber support (9) of the footbrake lever (8) can be replaced. 3. Remove the pin (15) and remove the washer (14) and spring (13). 4. Remove the bolt (10) with washer (11) and remove the footrest (16) from the seat (12) of the brake lever (8). Installing the front-right footrest/footbrake unit:

12 14

13 11 1

10

2

3 7

9 8 6

NOTE In principle, use a new pin (15). 5. Reassemble in reverse order.

5 4

Removing/installing the front-left footrest footbrake unit Removing the front-left footrest/footbrake unit: 1. Remove the nut (1) with washer (2) and take out the ball-and-socket joint from the foot-pedal rod (3). 2. Remove the screw (4) with washer (5) and remove the footrest (16) with the footbrake pedal lever (8) and the sliding bush (7) from the footrest support (6). NOTE The rubber seat (9) of the foot-pedal lever (8) can be replaced. 3. Remove the pin (15) and remove the washer (14) and spring (13). 4. Remove the bolt (10) with washer (11) and remove the footrest (16) from the seat (12) of the foot-pedal lever (8).

SFM 675 035.3

4

5 6

3

2

1 7

17

17 9

Installing the front-left footrest/footbrake unit:

15

NOTE

In principle, use a new pin (15). The foot-pedal lever position can be adjusted. Loosen the screw (17), pull of f the switching-lever rod (3) and install it offset on the switching-shaft outlet. Rotate the switching-lever rod (3) to obtain a fine adjustment. 5. Reassemble in reverse order.

8

13

12

14

11 10

16 SFM 675 034.3

36

SACHS

XTC 125 4-stroke

Removing/installing the rear footrests Removing the rear footrests: 1. Remove the pin (8) and washer (9). NOTE When removing the footrest (4), be careful not to lose the spring (5), ball (6) or plate (7) for the footrest lock. 2. Remove the bolt (1) with washer (2) and remove the footrest (4) with spring (5), ball (6) and plate (7) of the footrest lock from the footrest support (3). Installing the rear footrest: NOTE In principle, use a new pin (8). 3. Reassemble in reverse order

Removing/installing the half-handlebar Removing the half-handlebar: 1. Remove the seat and the fuel tank. 2. Remove the left- and right-hand handlebar fittings and the combination switches. 3. Separate the plug connection (14) from the ignition lock and loosen the cable binder. 4. Remove the screws (4) with the washers (5). 5. Remove the cover (15), then remove the closing nut (1) and screws (3) and take off the fork bridge (2) upwards. 6. Remove the screws (6) and from the left-hand stand pipe (9) or from the righthand stand pipe (10) pull off the left-hand half-handlebar (7) or the right-hand halfhandlebar (8) in an upward direction.

13

3

1

4 2 5 9

12

3

2

8

6

7 SFM 675 037.3-1

15 1

6 8

11

3

5 4 14

11 10

6

5 4 7 9

12

13

SFM 675 039.3-1

Installing the half-handlebar: NOTE The closing plugs (11 and 12) can be replaced. When removing the closing plugs (12), the rivets (13) must be bored. While installing, push in the closing plugs (12) and fasten them with the rivets (13). 7. Reassemble in reverse order. Tightening torque for screw (1): Tightening torque for screws (3): Tightening torque for screws (4):

40 Nm 40 Nm 24-26 Nm

37

SACHS

XTC 125 4-stroke

Removing/installing the left-hand handlebar mounting part

� � �

� ��

��

�

�� �� �

� � � ��� ��� �������

Removing the combination switch: 1. Remove the seat and the fuel tank. 2. Bore out the rivet (12) and take off the handlebar plug 11). NOTE Push a screwdriver between the rubber grip (10) and the handlebar pipe (1) and spray in tyre-mounting fluid. 3. Pull off the rubber grip (10). 4. Disconnect the choke cable (9) and remove the choke lever (8). 5. Separate the plug connection from the combination switch (5) and disconnect the cable binder. 6. Remove the screws (6 and 7) and take the combination switch (5) off the handlebar (1). Installing the combination switch 7. Reassemble in reverse order. Removing the clutch fittings: 8. Disconnect the clutch cable (13). 9. Remove the screws (4) and remove the holder (3) and clutch fittings (2). Installing the clutch fittings: 10. Reassemble in reverse order.

38

SACHS

XTC 125 4-stroke

Removing/installing the right-hand handlebar mounting part

�

�

�

�� � � �

�� �

� ��

�

�� ��

�� ��

��� ��� �������

Removing the combination switch: 1. Remove the seat and fuel tank 2.

Separate the plug connections from the combination switch (3), separate the cable binder.

3.

Remove the screws (2), disconnect the cable (4), then remove the combination switch (3) and the throttle (1) from the halfhandlebar (13).

Installing the combination switch: Connect the cable (4) and adjust it. 4. Reassemble in reverse order. Removing the brake fitting: CAUTION Brake fluid damages paint and plastic parts. Use new brake fluid of specification DOT 4. 5. Separate the cable (14) from the brake-light switch. 6.

Remove the screw (9) and the brake-fluid container (15).

7.

Remove the banjo bolt (10) with sealing rings (11) and seal the brake line (12).

8.

Remove the screws (7 and 8) and take off the holder (6) and brake fitting (5).

Installing the brake fitting: NOTE In principle, the sealing rings (11) of the brake-line connection must be replaced. 9.

Reassemble in reverse order.

10. Top up the brake fluid and vent the brake system.

39

SACHS

XTC 125 4-stroke

Position the motorcycle on a level floor 5 m in front of a light-coloured wall (measured from the headlamp) with the rider seated on the bike and the tyres at the correct pressure. - Measure the distance from the floor to the centre of the headlamp (H) then mark this distance on the wall with a cross. Draw a second cross 12 cm underneath the first cross. - Start the motorcycle and allow the engine to run. WARNING - RISK OF ASPHYXIATION Do not run the engine in an enclosed space! Risk of asphyxiation. Adjusting the headlight - Activate the dipped beam. Use the adjusting screw (1 and 2) to adjust the angle of the asymmetrically illuminated surface area of the road top. screw 1 = height adjustment screw 2 = side adjustment

40

12cm

Checking/adjusting the headlamp

H

5m

H

SFM 680 099.3

SACHS

XTC 125 4-stroke

Checking the tyre profile and pressure Checking the tyre profile:

Checking the rear-wheel telescopic leg for operation and leaks -

WARNING - RISK OF ON-ROAD ACCIDENT Observe the legally prescribed minimum-profile depth. - Measure the profile depth. Recommended minimum profile depth: 2.5 mm - If the profile depth is less than the minimum, replace the tyre. Check the tyre pressure: Air pressure

solo

with passenger

Front

1.9 bar

1.9 bar

Rear

2.1 bar

2.3 bar

Checking the wheels for damage -

Check the wheels for any damage; replace if necessary.

-

Requirements for the check: the column top bearing, rear-wheel swing bearings, shock absorbers and tyres should be in order. Take a test ride. If the wheels/chassis do/does not move smoothly, align the wheels and check for wobble and height damage.

-

Checking the control cables for damage and smooth operation -

-

Put the motorcycle on its standard, then check the wheel bearings by pushing the wheel to and fro to check for play. The bearings should not have a noticeable play; if play is noticeable, the bearings must be replaced. Rotate the wheel by hand. The wheel bearings should run evenly rather than roughly. Wheel bearings which run roughly must be replaced.

Check the choke, throttle and clutch cables for damage and smooth operation. Damaged or obstructed cables must be replaced. Adjust the cables.

Checking/greasing the side standard -

Check springs, fastening screws for firm seats. The side standard must independently fold back. Grease all moving parts.

Checking/repairing the exhaust system -

Check exhaust manifolds, silencers and gaskets for leaks; replace any faulty parts. Check rubber bearings for damage; replace, if necessary. Tighten nuts and screws. Tightening torques: Exhaust manifold cylinders: End silencer fastening: Exhaust fastening (rubber bearing):

Checking the wheel bearings for play and damage -

Firmly push down on the rear of the motorcycle several times. The rear-wheel telescopic leg must move in and out evenly without deformation. Check the rear-wheel telescopic leg for leaks, and the springs and fastening points for damage.

15 Nm 10 Nm 20 Nm

Checking the rear-wheel vibration bearing -

Check the rear-wheel swing bearing for smooth operation and wear; if necessary, replace the swing bearing.

Final inspection -

Prepare for traffic safety: check the clutch, gear shifting, idle speed, handbrake and footbrake, handlebar control, indicator lights, light and signal systems; adjust as necessary.

-

Check the tyre pressure; adjust if necessary.

-

Take a test ride.

41

SACHS

XTC 125 4-stroke

Removing/installing the exhaust system �� ��

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��

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��

�

��

�� �� �

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�

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� �

Removing the exhaust system: 1. Hang out the spring (1). 2. Remove screws (2) with washers (3). 3. Remove screws (4) with washers (5), nut (6) and remove the exhaust pipe (7). 4. Hang out the spring (7). 5. Remove the screws (8), rubber bearing (9) with washers (10) and nuts (11). 6. Remove the exhaust pipe (12) and muffler (13). Installing the exhaust system:: NOTE Before reinstalling, check the rubber bearings (14 and 9) and replace if necessary. In principle, the gasket must be replaced. 7. Reassemble in reserve order. Tightening torque:: Screws (2): 22-25 Nm Screw (4): 22-25 Nm Screws (9): 10 Nm

42

��� ��� �������

SACHS

XTC 125 4-stroke

ENGINE DISASSEMBLY The procedure for engine disassembly is sequentially explained in the following steps.

-

Remove the cylinder head cover (2). Remove the spark plug.

-

Remove the valve timing inspection plug (3) and generator cover cap (4).

-

Rotate the crankshaft and align the „T‘ line on the generator rotor with the center of the hole in the generator cover.

-

Remove the cam chain tension adjuster cap and insert a flat-head screwdriver into the slotted end of the cam chain tension adjuster. Turn the screwdriver clockwise to lock the spring tension. Remove the cam chain tension adjuster.

-

43

SACHS

XTC 125 4-stroke

-

Remove the camshaft holders.

-

Remove the intake(1) and exhaust (2) camshafts. Remove the cam chain guide (3).

-

Remove the engine oil pipe (4).

-

Remove the cylinder head (5) by removing the bolts and nuts.

-

Remove the cylinder head gasket. Remove the cylinder (6) by removing the cylinder base nuts.

44

SACHS

XTC 125 4-stroke

-

Remove the cylinder gasket. Place a clean rag over the cylinder base to prevent the piston pin circlip (1) from dropping into the crankcase. Then, remove the piston pin circlip with long-nose pliers.

-

Remove the piston pin using the special tools.

Tool: 09910-34510: Piston pin puller -

Remove the piston.

-

Remove the starter motor (2).

-

Remove the clutch cover (3).

-

While holding the generator rotor nut, remove the clutch spring mounting bolts in a crisscross pattern, and remove the clutch springs and clutch pressure plate (4).

45

SACHS

XTC 125 4-stroke

-

Remove the clutch release rack (1) and clutch release bearing (2) from the clutch pressure plate.

-

Remove the clutch drive and driven plates.

-

Flatten the lock washer (3) and remove the clutch sleeve hub nut using the special tool.

Tool: 09920-53740: Clutch sleeve hub holder

-

Remove the thrust washer (4) and primary driven gear assembly (5).

-

Remove the spacer (6) and washer (7).

46

SACHS

XTC 125 4-stroke

-

Remove the gearshift shaft (1) and washer (2).

-

Remove the gearshift cam plate (3) by removing the gearshift cam plate bolt (4). Remove the gearshift cam stopper arm (5) by removing the gearshift cam stopper arm shaft and nut.

-

Remove the generator cover (6).

-

Remove the strator coil (7) and pick-up coil (8).

-

Remove the spacer (9), shaft (10), starter idle gear (11) and oil sump filter (12).

47

SACHS

XTC 125 4-stroke

CAUTION The nut (1) has a lefthand thread. Turning anticlockwise may cause damage. -

Remove the primary drive gear nut (1) using the special tool.

Tool: 09930-44512: Rotor holder

-

-

-

Remove the washers (2) and primary drive gears (3). Remove the key (4) and oil pump drive gear (5).

Remove the E-ring (6) and oil pump driven gear (7). Remove the spacer (8), pin (9) and oil pump (10).

Remove the balancer shaft bolt and washer using the special tool.

Tool: 09930-44512: Rotor holder

-

Remove the generator rotor nut using the special tool.

Tool: 09930-44512: Rotor holder

48

SACHS -

XTC 125 4-stroke

Remove the generator rotor (1) using the special tool.

Tool: 09930-34951: Rotor remover

-

Remove the generator rotor key (2). Remove the cam chain (3). Remove the cam chain tensioner guide (4).

-

Remove the oil seal retainer (5) and engine sprocket spacer (6). Remove the gear position switch (7).

-

-

Remove the gear position switch contact (8), spring (9) and O-ring (10).

-

Remove the crankcase bolts.

49

SACHS -

XTC 125 4-stroke

Separate the right and left crankcases using the special tool.

Tool: 09920-13120: Crankcase separator

-

Remove the gearshift fork shafts (1) gearshift forks (2) and gearshift cam (3).

-

Remove the transmission.

-

Remove the washer (4) and kick starter drive gear (5).

-

Remove the kick starter guide bolts and kick starter shaft (6) along with the kick starter (7).

50

SACHS -

XTC 125 4-stroke

Remove the crankshaft driven gears along with the balancershaft.

- Remove the crankshaft using the special tool. Tool: 09920-13120: Crankcase separator

51

SACHS

XTC 125 4-stroke

ENGINE COMPONENTS INSPECTION AND SERVICE BEARINGS BEARING INSPECTION While the bearing is in the crankcase, rotate its inner race and check to see that it turns smoothly. If it does not turn quietly and smoothly, or if there are signs of any abnormalities, the bearing is defective and must be replaced as follows. A = Play LEFT DRIVESHAFT BEARING - Remove the bearing retainer (1).

-

Remove the oil seal using the special tool.

Tool: 09913-50121: Oil seal remover CAUTION The removed oil seal should be replaced with a new one. - Remove the washer (2). -

Remove the left driveshaft bearing using the special tool.

Tool: 09922-55131: Countershaft remover CAUTION The removed bearing should be replaced with a new one.

-

Install the left driveshaft bearing using the special tool.

Tool: 09913-75810: Bearing installer

52

A A

SACHS -

XTC 125 4-stroke

Install the oil seal using the special tool. Apply a small quantity of SUZUKI SUPER GREASE "A" to the lip of the oil seal.

SUZUKI SUPER GREASE "A" Tool: 09922-55131: Countershaft remover

-

Tighten the bearing retainer screws to the specified torque.

Bearing retainer screw: 8.5 Nm

RIGHT DRIVESHAFT BEARING Remove the right driveshaft bearing using the special tool. Tool: 09943-88211: Pinion bearing installer CAUTION The removed bearing should be replaced with a new one.

-

Install the right driveshaft bearing using the special tool.

Tool: 09922-55131: Countershaft remover

LEFT COUNTERSHAFT BEARING -

Remove the left countershaft bearing using the special tools.

Tool: 09921-20210: Bearing remover Sliding hammer CAUTION The removed bearing should be replaced with a new one. 53

SACHS -

XTC 125 4-stroke

Install the left countershaft bearing using the special tool.

Tool: 09913-75821: Bearing installer attachment

RIGHT COUNTERSHAFT BEARING - Remove the bearing retainer (1). - Remove the right countershaft bearing using the special tool. Tool: 09913-75821: Bearing installer attachment CAUTION The removed bearing should be replaced with a now one. -

Install the right countershaft bearing using the special tool.

Tool: 09913-76010: Bearing installer

-

Align the recesses (2) on the bearing retainer with the lug (3) on the right crankcase. Tighten the bearing retainer screws to the specified torque.

Bearing retainer screw: 8.5 Nm

CRANKSHAFT BEARINGS - Remove the left and right crankshaft bearings using the special tool. Tool: 09913-75810: Bearing installer CAUTION The removed bearings should be replaced with new ones.

54

SACHS -

XTC 125 4-stroke

Install the left and right crankshaft bearings using the special tool.

Tool: 09913-75510: Bearing installer

BALANCER SHAFT BEARINGS - Remove the left balancer shaft bearing (1). CAUTION The removed bearing should be replaced with a new one.

-

Remove the right balancer shaft bearing using the special tool.

Tool: 09913-75821: Bearing installer attachment CAUTION The removed bearing should be replaced with a now one.

-

Install the left and right balancer shaft bearings using the special tool.

Tool: 09913-76010: Bearing installer

GEARSHIFT CAM BEARING - Remove the bearing retainer (1). - Remove the gearshift cam bearing using the special tool. Tool: 09913-75821: Bearing installer attachment CAUTION The removed bearing should be replaced with a new one.

55

SACHS -

XTC 125 4-stroke

Install the gearshift cam bearing using the special tool.

Tool: 09913-76010: Bearing installer

-

Tighten the bearing retainer screws to the specified torque.

Bearing retainer screw: 8.5 Nm

CYLINDER HEAD DISASSEMBLY - Remove the intake pipe (1).

CAUTION The removed 0-ring (2) should be replaced with a new one.

-

56

Remove the tappets (2) and shims (4) by hand or with a magnet.

SACHS -

XTC 125 4-stroke

Compress the valve spring and remove the valve cotters (1) from the valve stem using the special tools.

Tool: 09916-14510: Valve lifter 09916-14530: Valve lifter attachment Tweezers

- Remove the valve spring retainer (2), valve spring (3) and valve spring seat (4).

-

Pull out the valve (5) through the opposite side.

NOTE Removing the valves completes normal disassembly. If the valve guides need to be removed for replacement after related parts have beeen checked, follow the steps referring to servicing the valve guide.

CYLINDER HEAD DISTORTION Decarbonize the combustion chamber. Check the gasket surface of the cylinder head for distortion using a straightedge and thickness gauge. Take clearance readings at several places. If readings exceed the service limit, replace the cylinder head. Tool: Thickness gauge Service Limit: 0.05 mm VALVE FACE WEAR The thickness of the valve face decreases as the face wears. Visually inspect each valve face for wear and replace any valve with an abnormally worn face. Measure the valve face thickness (T). If it is out of specification, replace the valve with a new one. Tool: Vernier calipers Service Limit: 0.5 mm

57

SACHS

XTC 125 4-stroke

VALVE STEM RUN OUT Support the valve using V-blocks, as shown, and measure, its run out with the dial gauge. If the run out exceeds the limit, replace the valve. Tool: Magnetic stand Dial gauge (1/100 mm) V-block set (100 mm) Service Limit: 0.05 mm VALVE HEAD RADIAL RUN OUT Place the dial gauge at a right angle to the valve head face and measure the valve head radial run out. If it measures more than the service limit, replace the valve. Tool: Magnetic stand Dial gauge (1/100 mm) V-block set (100 mm) Service Limit: 0.03 mm VALVE STEM DEFLECTION Lift the valve about 10 mm from the valve seat. Measure the valve stem deflection in two directions, "X" and "Y", perpendicular to each other. Position the dial gauge as shown. If the deflection exceeds the service limit, then determine whether the valve or the guide should be replaced with a new one. Tool: Magnetic stand Dial gauge (1/100 mm) Service Limit Intake and exhaust valves: 0.35 mm VALVE STEM WEAR Measure the valve stem O.D. using the micrometer. If it is out of specification, replace the valve with a new one. If the valve stem O.D. is within specification but the valve stem deflection is not, replace the valve guide. After replacing the valve or valve guide, re check the clearance. Tool: Micrometer (0-25 mm) Standard Valve stem O.D.

IN.: 4.475-4.490 mm EX.: 4.455-4.470 mm

NOTE If valve guides have to be replaced, refer to the valve guide servicing steps below.

58

SACHS

XTC 125 4-stroke

VALVE GUIDE SERVICE - Remove the valve guide using the special tool. Tool 09916-43210: Valve guide installer NOTE Discard the removed valve guide subassemblies. Only oversized valve guides are available as replacement parts. -

Re-finish the valve guide hole in the cylinder head using the special tools.

Tool 09916-34580: Valve guide reamer (10.8 mm), handle NOTE Insert the reamer from the combustion chamber side and always turn the reamer handle clockwise. -

Install a ring (1) onto each valve guide (2). Oil the stem hole of each valve guide and drive the guide into the guide hole using the special tool.

2

Tool 09916-43210: Valve guide installer 1 CAUTION Be sure to use a new valve guide ring and valve guide.

-

After installing the valve guides, re-finish their guiding bores using the special tools. Be sure to clean and oil the guides after reaming.

Tool 09916-33210: Valve guide reamer (4.5 mm) Handle

VALVE SEAT WIDTH - Coat the valve seat uniformly with Prussian blue. Install the valve and attach a valve lapper onto it. Tap the coated seat with the valve face in a rotating manner, in order to obtain a clear impression of the seating contact.

59

SACHS

XTC 125 4-stroke

- The ring-like dye impression left on the valve face must be continuous without any breaks. In addition, the width of the dye ring, which is the valve seat width, must be within the following specification: Standard Valve seat width (w): 0.9-1.1 mm If the valve seat is out of specification, recut the seat. VALVE SEAT SERVICE The valve seats for both intake and exhaust valves are machined to four different angles. (The seat contact surface is cut 45°.) INTAKE SIDE

EXHAUST

EXHAUST SIDE

45°

N-131

45°

N-131

30°

N-126

15°

N-130

60°

N-111

Tool: 09916-21110: Valve seat cutter set 09916-24410: Valve seat cutter (N-111) 09916-24460: Valve seat cutter (N-130) 09916-24470: Valve seat cutter (N-131) 09916-20630: Valve seat cutter (N-126) 09916-20640: Solid pilot (N-100-4.5) NOTE The valve seat contact area must be inspected after each cut. - When installing the solid pilot (1), rotate it slightly. Seat the pilot snugly. Install the 45° cutter, attachment and T- handle. - Using the 45° cutter, descale and clean up the seat. Rotate the cutter one or two turns. - Measure the valve seat width after every cut. If the valve seat is pitted or burned, use the 45° cutter to condition the seat some more. NOTE Cut only the minimum amount necessary from the seat to avoid having to replace the tappet shim. If the contact area is too high on the valve, or if it is too wide, use the 15° cutter (for the exhaust side) and the 30°/ 60° cutters (for the intake side) to lower and narrow the contact area.

60

INTAKE

VALVE SEAT

VALVE SEAT

SACHS

XTC 125 4-stroke

If the contact area is too low or too narrow, use the 45° cutter to raise and widen the contact area. -

After the desired seat position and width is achieved, use the 45° cutter very lightly to clean up any burrs caused by the previous cutting operations.

CAUTION DO NOT use lapping compound after the final cut is made. The finished valve seat should have a velvety smooth finish and not a highly polished or shiny finish. This will provide a soft surface for the final seating of the valve which will occur during the first few seconds of engine operation. - Clean and assemble the head and valve components. Fill the intake and exhaust ports with gasoline to check for leaks. If any leaks occur, inspect the valve seat and face for burrs or other things that could prevent the valve from sealing. WARNING Always use extreme caution when handling gasoline. NOTE After servicing the valve seats, be sure to check the tappet clearance after the cylinder has been reinstalled.

VALVE SPRINGS Check the valve springs for proper strength by measuring their free length and also the force required to compress them. If the spring length is less than the service limit or if the force required to compress the spring does not fall within the specified range, replace the spring. Tool: Vernier calipers Service Limit Valve spring free length: 37.8 mm Standard Valve spring tension: 12.1-13.9 kg / 33.7 mm

61

SACHS

XTC 125 4-stroke

REASSEMBLY Reassemble the cylinder head in the reverse order of disassembly. Pay attention to the following points: - Install each valve spring seat (1).

- Lubricate the valve stem seal with oil, and press-fit the seal into position by hand. CAUTION Do not reuse the valve stem seals.

- Insert the valves with their stems coated with high quality molybdenum disulfide lubricant (SUZUKI MOLY PASTE). Coat the entire stem making sure that there are no gaps. Also, be sure to oil the valve stem seal lip. SUZUKI MOLY PASTE CAUTION When inserting each valve, take care not to damage the lip of the stem seal.

- Install the valve springs with the smaller pitch (A) facing the cylinder head. Towards

Head

62

SACHS -

XTC 125 4-stroke

Install the valve spring retainer (1), press down the spring using the valve lifter and then install the cotter halves onto the valve stem end. Then, release the valve lifter to allow the cotter (2) to wedge between the retainer and the valve stem. Be sure that the rounded lip (3) of the cotter fits snugly into the groove (4) in the stem end.

Tool 09916-14510: Valve lifter 09916-14530: Valve lifter attachment Tweezers CAUTION Be sure to install all of the parts in their original positions. NOTE Apply engine oil to the tappet shim and tappet before installing them.

CAMSHAFT CAMSHAFT INSPECTION If the engine produces abnormal noises, vibration or lacks power, a camshaft may be distorted or worn to the service limit. The camshaft runout should be checked. Also, check the cams and journals for wear or damage. The exhaust camshaft has the embossed letters "EX" and the intake camshaft has the embossed letters "IN". CAM WEAR Worn-down cams are often the cause of mistimed valve operation resulting in reduced power output. Measure the cam height (H) using the micrometer. Replace a camshaft if the cams are worn to the service limit. Tool: Micrometer (25-50 mm) Service Limit Cam height (H) IN: 34.650 mm EX: 33.950 mm

63

SACHS

XTC 125 4-stroke

CAMSHAFT JOURNAL WEAR Determine whether or not each journal is worn down to the limit by measuring the oil clearance with the camshaft installed in place. Measure the clearance using the plastigauge (1). Tool 09900-22302: Plastigauge NOTE Install each camshaft journal holder to its original position. Tighten the camshaft journal holder bolts evenly and diagonally to the specified torque. Camshaft journal holder bolt: 10 Nm

NOTE Do not rotate the camshafts with the plastigauge in place. Remove the camshaft journal holders and measure the width of the compressed plastigauge using the envelope scale. This measurement should be taken at the widest part of the compressed plastigauge. Service Limit Camshaft-Journal oil clearance (IN & EX): 0.150 mm If the camshaft journal oil clearance exceeds the limit, measure the inside diameter of the camshaft journal holder and the outside diameter of the camshaft journal. Replace the camshaft or the cylinder head depending upon which one exceeds the specification. Tool: Small bore gauge Standard Camshaft journal holder I.D. (IN & EX): 22.012-22.025 mm Tool: Micrometer (0-25 mm) Standard Camshaft journal O.D. (IN & EX): 21.959-21.980 mm

64

SACHS

XTC 125 4-stroke

CAMSHAFT RUNOUT Measure the runout using a dial gauge. Replace the camshaft if the runout exceeds the limit. Tool: Dial gauge (1/100 mm) Magnetic stand V-block set (100 mm) Service Limit Camshaft runout (IN & EX): 0.10 mm CAM SPROCKET - When installing each camshaft sprocket to each camshaft, align, mark "I" with notch (1) and pin (2) on the intake camshaft, or mark "E" with notch (3) and pin (4) on the exhaust camshaft. - Apply THREAD LOCK SUPER "1303" to the threads of the camshaft sprocket bolts and tighten them to the specified torque. THREAD LOCK SUPER "1303" Camshaft sprocket bolt: 11 Nm - Be sure to bend the tabs on the camshaft sprocket lock washer so the bolts lock. CAM CHAIN TENSION ADJUSTER The cam chain tension adjuster is maintained at the proper tension by an automatically adjusted tensioner. Insert a flat-head screwdriver into the slotted end of the cam chain tension adjuster and turn it clockwise to release the tension. Remove the screwdriver to make sure that the push rod moves properly. If the push rod is stuck or the spring mechanism does not work, replace the cam chain tension adjuster assembly with a new one. CYLINDER DISTORTION Check the gasket surface of the cylinder for distortion using a straightedge and thickness gauge. Take clearance readings at several places. If any reading exceeds the service limit, replace the cylinder. Tool: Thickness gauge Service Limit: 0.05 mm

65

SACHS

XTC 125 4-stroke

CYLINDER BORE Measure the cylinder bore diameter at six places. If any one of the measurements exceed the limit, overhaul the cylinder and replace the piston with an oversize piston, or replace the cylinder. Tool: Cylinder gauge set Service Limit: 57.362 mm PISTON AND PISTON PIN DIAMETER Measure the piston diameter using the micrometer at 15 mm from the skirt end. If the piston diameter is less than the service limit, replace the piston. Tool: Micrometer (50-75 mm) Service Limit: 56.850 mm Piston oversize: 0.5, 1.0 mm PISTON-CYLINDER CLEARANCE Subtract the piston diameter from the cylinder bore diameter. If the piston-to-cylinder clearance exceeds the service limit, rebore the cylinder and use an oversize piston or replace both the cylinder and the piston. Service Limit: 0.120 mm

PISTON RING-GROOVE CLEARANCE Measure the side clearances of the 1st and 2nd piston rings using the thickness gauge. If any of the clearances exceed the limit, replace both the piston and piston rings. Tool: Thickness gauge Micrometer (0-25 mm) Service Limit Piston ring-groove clearance 1st: 0.18 mm 2nd: 0.15 mm Piston ring groove width 1st: 1.01-1.03 mm 2nd: 1.01-1.03 mm Oil: 2.01-2.03 mm Piston ring thickness 1st and 2nd: 0.97-0.99 mm NOTE Remove any carbon from the piston crown and ring grooves using soft-metal scraper.

66

SACHS

XTC 125 4-stroke

PISTON RING END GAP Fit the piston ring squarely into the cylinder and measure the piston ring end gap using a thickness gauge. If the piston ring‘s end gap is out of specification, replace the piston ring. Tool: Thickness gauge Service Limit Piston ring end gap 1st and 2nd: 0.50 mm OVERSIZE RINGS Oversize piston ring The following oversize piston ring is used. It bears the following identification number. Piston ring 1st and 2nd 0.5 mm: 50 1.0 mm: 100 Oversize oil ring The following oversize oil ring is used. It bears the following identification mark. Oil ring

0.5 mm: Painted red 1.0 mm: Painted yellow A = Paint

Oversize side rail Measure the outside diameter to identify the size.

Oil ring spacer

PIN BORE Measure the piston pin bore inside diameter using the dial calipers and measure the piston pin outside diameter using the micrometer. If either is out of specification or the difference between these two measurements is more than the limits, replace both the piston and piston pin.

Tool: Dial calipers Micrometer (0-25 mm) Service Limit Piston pin bore: 15.030 mm Piston pin O.D.: 14.980 mm

67

SACHS

XTC 125 4-stroke

CRANKSHAFT AND CONROD

1

Balancer drive gear

2

Key

3

Pin

4

Crankshaft, RH

5

Conrod

6

Bearing

7

Crank Pin

8

Crankshaft, RH

CONROD SMALL END I.D. Measure the conrod small end inside diameter using the dial calipers. If the conrod small end inside diameter exceeds the service limit, replace the conrod. Tool: Dial calipers Service Limit: 16.040 mm

68

SACHS

XTC 125 4-stroke

CONROD DEFLECTION AND CONROD BIG END SIDE CLEARANCE Wear on the big end of the conrod can be estimated by checking the movement of the small end of the rod. This method can also check the extent of wear on the parts of the conrod‘s big end. Tool: Magnetic stand Dial gauge (11100 mm) V-block set (100 mm) Service Limit: 3.0 mm Push the big end of the conrod to one side and measure the side clearance using a thickness gauge. Tool: Thickness gauge Standard: 0.10-0.45 mm Service Limit: 1.00 mm If the service limit is exceeded, replace the crankshaft assembly or bring the deflection and side clearance into specification by replacing the worn parts (e.g., conrod, big end bearing and crank pin).

CRANKSHAFT RUNOUT Support the crankshaft with V-blocks as shown. Position the dial gauge, as shown, and rotate the crankshaft slowly to read the runout. Correct the runout or replace the crankshaft assembly if the runout is greater than the service limit. Tool: Magnetic stand Dial gauge (1/100 mm) V-block set (100 mm) Service Limit: 0.08 mm REASSEMBLY - When rebuilding the crankshaft, the width between the webs should be within the standard range. Standard width between webs (A): 53±0.1 mm

69

SACHS

XTC 125 4-stroke

BALANCER SHAFT AND CRANKSHAFT DRIVEN GEARS

1 2

Balancer shaft Key

3

Driven gear set

DISASSEMBLY - Remove the crankshaft driven gears.

-

Remove the circlip and washer using the special tool.

Tool: Snap ring pliers

-

70

Separate crankshaft driven gear No. 2 (1), crankshaft driven gear No.1 (2) and the springs (3).

SACHS

XTC 125 4-stroke

Inspect the balancer shaft and key for wear or damage.

REASSEMBLY Reassemble the balancer shaft and crankshaft driven gears in the reverse order of disassembly. Pay attention to the following points: - Install the spring washer (1) and circlip (2) using the special tool. Tool: Snap ring pliers

STARTER CLUTCH AND STARTER DRIVEN GEAR BEARING

1

Starter driven gear

2

Bearing

3

Starter clutch

4

Generator rotor

STARTER CLUTCH Install the starter driven gear onto the starter clutch and turn the starter driven gear by hand (the gear turns in only one direction). The starter driven gear should turn smoothly. If excessive resistance is felt while turning the starter driven gear, inspect the starter clutch. Also, inspect the surface of the starter driven gear which contacts the starter clutch, for wear or damage. If any wear or damage is found, replace the defective parts.

71

SACHS

XTC 125 4-stroke

STARTER DRIVEN GEAR BEARING Install the starter driven gear bearing and gear onto the crankshaft and turn the starter driven gear by hand. Inspect the starter driven gear bearing for smooth rotation and any abnormal noise. If the bearing does not turn smoothly or there is any abnormal noise, replace it.

DISASSEMBLY - Hold the generator rotor with the rotor holder and remove the starter clutch bolts. Tool: Z 90 890 01701: Rotor holder

REASSEMBLY - Apply a small quantity of THREAD LOCK SUPER "1303" to the starter clutch bolts and tighten them to the specified torque while holding the rotor holder. THREAD LOCK SUPER "1303" Starter clutch bolt: 10 Nm

72

SACHS

XTC 125 4-stroke

TRANSMISSION DISASSEMBLY - Disassemble the transmission gears as shown in the illustration. NOTE When removing the 2nd drive gear, use a gear puller and a proper attachment.

1

Countershaft

2

5th drive gear

3

3rd/4th drive gear

4

2nd drive gear

5

Driveshaft

6

2nd driven gear

7

3rd driven gear

8

4th driven gear

9

5th driven gear

10

1st (low) driven gear

REASSEMBLY Assemble the countershaft and driveshaft in the reverse order of disassembly. Pay attention to the following points: NOTE Before installing the gears, lightly coat the driveshaft and countershaft with moly paste or engine oil. SUZUKI MOLY PASTE CAUTION Never reuse a circlip. After a circlip has been removed from a shaft, it should be discarded and a new circlip must be installed. When installing a now circlip, do not expand the end gap larger than required to slip the circlip over the shaft. After installing a circlip, make sure that it is completely seated in its groove and securely fitted.

73

SACHS -

XTC 125 4-stroke

When installing a new circlip, pay attention to the direction of the circlip. Fit the circlip to the side where the thrust is, as shown in the illustration. The rounded side should be against the gear surface.

Thrust

Sharp edge

-

Press fit the 2nd drive gear onto the countershaft. Before reassembling, coat the internal face of the 2nd drive gear with THREAD LOCK SUPER "1303" and install the gears so that the length (A) is as shown.

Countershaft length (A): 88.0 +0.1/0.0 mm (1st to 2nd) THREAD LOCK SUPER "1303" NOTE Take care not to smear THREAD LOCK SUPER "1303" onto the 5th (top) drive gear. This procedure may be performed only twice before shaft replacement is required. Assembling view transmission

74

SACHS

XTC 125 4-stroke

GEARSHIFT FORKS Measure the gearshift fork clearance in the groove of its respective gear using the thickness gauge. The clearance for each of the two gearshift forks plays an important role in the smoothness and positiveness of the shifting action. Each fork has its prongs fitted into the annular groove provided in its gear. During operation there is sliding contact between the fork and gear and, when a shifting action is initiated, the fork pushes the gear axially. If the clearance is too great, the meshed gears may slip apart. If the clearance exceeds the specification, replace the fork, its respective gear or both. Tool: Thickness gauge Service Limit Gearshift fork to groove clearance: 0.5 mm Standard Gearshift fork groove width No.1: 5.0-5.1 mm No.3: 5.5-5.6 mm Gearshift fork thickness

No.1: 4.8-4.9 mm No.3: 5.3-5.4 mm

PRIMARY DRIVE GEARS DISASSEMBLY - Separate primary drive gear No. 1 (1), No. 2 (2) and the springs (3).

REASSEMBLY - Align the punch mark (4) in primary drive gear No. 2 with the groove (5) in primary drive gear No. 1.

75

SACHS

XTC 125 4-stroke

CLUTCH CLUTCH DRIVE PLATES Measure the thickness of the clutch drive plates using vernier calipers. If a clutch drive plate is not within the service limit, replace the clutch plates as a set. Tool: Vernier calipers Service Limit Thickness: 2.6 mm Claw width: 11.0 mm

CLUTCH DRIVEN PLATES Measure each clutch driven plate for distortion using the thickness gauge. If a clutch driven plate is not within the service limit, replace the clutch plates as a set. Tool: Thickness gauge Service Limit: 0.10 mm CLUTCH SPRING FREE LENGTH Measure the free length of each clutch spring using vernier calipers. If any spring is not within the service limit, replace all of the springs. Tool: Vernier calipers Service Limit: 29.5 mm CLUTCH RELEASE BEARING Inspect the clutch release bearing for any abnormality, especially cracks. When removing the bearing from the clutch, decide whether it can be reused or if it should be replaced. Smooth engagement and disengagement of the clutch depends on the condition of this bearing.

76

SACHS

XTC 125 4-stroke

ENGINE REASSEMBLY Reassemble the engine in the reverse order of disassembly. The following steps require special attention or precautionary measures should be taken. COUTION Apply engine oil to each running and sliding part before reassembling. CRANKSHAFT - When installing the crankshaft into the crankcase, it is necessary to pull its left end into the left crankcase using the special tools. -

Apply engine oil to the crankshaft bearings.

Tool: 09910-32812: Crankshaft installer 09910-20116: Conrod holder 09911-11310: Attachment CAUTION Never install the crankshaft into the crankcase by striking it with a plastic hammer. Always use the special tool, otherwise the crankshaft may be misaligned.

BALANCER SHAFT - Align the punch mark (1) in the drive gear with the hole (2) in the driven gear.

77

SACHS

XTC 125 4-stroke

KICK STARTER SHAFT �

�

� �

1 2 3

Kick starter shaft Kick starter Spring

4 5 6

Spring Spring guide Kick starter drive gear

-

Align the punch mark (1) in the kick starter shaft with the punch mark (2) in the kick starter.

-

Turn the kick starter shaft counterclockwise and then lock the kick starter with the kick starter guide.

-

Install the kick starter drive gear (3) and washer (4).

78

� �

SACHS

XTC 125 4-stroke

GEARSHIFT CAM AND GEARSHIFT FORKS - Install the transmission. - Install the gearshift forks and gearshift cam. (1): Gearshift fork No.1 (2): Gearshift fork No.3 - Install the gearshift fork shafts (3, 4).

-

Wipe both crankcase mating surfaces with a cleaning solvent. Apply SUZUKI BOND NO.1215 uniformly to the mating surface of the right crankcase and assemble the cases within a few minutes.

SUZUKI BOND NO. 1215

-

Install the dowel pins (1) into the left half of the crankcase. Apply engine oil to the conrod big end and transmission gears.

NOTE When bolting the right and left hand crankcase housing tighten the screws only lightly once after the other, in order to generate even pressure. -

Tighten the crankcase bolts to the specified torque.

Crankcase bolt: 10 Nm

79

SACHS

XTC 125 4-stroke

NOTE After the crankcase bolts have been tightened, make sure that the crankshaft rotates smoothly. If the crankshaft does not rotate smoothly, try to free it by tapping the driveshaft or countershaft with a plastic hammer.

GEAR POSITION SWITCH - Install the spring (1) and gear position switch contact (2) and new O-ring (3). - Install the gear position switch.

ENGINE SPROCKET SPACER - Apply SUZUKI SUPER GREASE "A" to the O-ring (1) of the engine sprocket spacer and the oil seal lip (2), and then install the engine sprocket spacer onto the driveshaft. SUZUKI SUPER GREASE "A" CAUTION Use a new O-ring (1). -

Install the oil seal retainer (3).

CAM CHAIN, CAM CHAIN TENSIONER GUIDE AND GENERATOR ROTOR - Engage the cam chain (1) onto the cam chain drive sprocket. - Install the cam chain tensioner guide (2) and tighten the bolt.

-

80

Remove any grease from the tapered portion of the generator rotor and crankshaft. Install the generator rotor key (3).

SACHS -

XTC 125 4-stroke

Install the generator rotor securely. Apply THREAD LOCK SUPER "1303" to the generator rotor nut and tighten it to the specified torque using the special tool.

THREAD LOCK SUPER "1303" Tool: 09930-44512: Rotor holder Generator rotor nut: 80 Nm

OIL JET - Install the oil jet.

BALANCER SHAFT BOLT - Tighten the balancer shaft bolt to the specified torque using the special tool. Tool: 09930-44512: Rotor holder Balancer shaft bolt: 50 Nm

OIL PUMP AND PRIMARY DRIVE GEAR - Install the spacer (1) onto the crankshaft. - Apply engine oil onto the sliding surfaces of the oil pump case, outer rotor, inner rotor and shaft, before mounting the oil pump (2). - Apply a small quantity of THREAD LOCK "1342" to the oil pump mounting screws and tighten them. THREAD LOCK "1342" -

Install the pin (3).

-

Install the oil pump driven gear (4) and E-ring (5).

81

SACHS -

XTC 125 4-stroke

Install the key (1) and the oil pump drive gear (2).

NOTE Position the spacer (3) and oil pump drive gear (2), as shown in the illustration.

-

Install the primary drive gears (4), washer (5), spring washer (6) and primary drive gear nut (7), as shown in the illustration.

NOTE The primary drive gear nut (7) has left-hand threads.

-

Tighten the primary drive gear nut to the specified torque using the special tool.

Tool: 09930-44512. Rotor holder Primary drive gear nut: 50 Nm

GEARSHIFT SHAFT AND RELATION PARTS �

1 2 3 4 5

Gearshift shaft Return spring Gearshift cam plate Gearshift arm Spring

A

Gearshift arm stopper

B

Gearshift cam plate bolt

C

Gearshift cam stopper arm shaft

ITEM

Nm

A

19

B

10

C

10

� �

�

�

�

82

�

�

SACHS -

XTC 125 4-stroke

Apply THREAD LOCK SUPER "1303" to the threads of the gearshift cam stopper arm shaft and tighten it to the specified torque.

THREAD LOCK SUPER "1303" Gearshift cam stopper arm shaft: 10 Nm

-

Align the hole (1) in the gearshift cam plate with the gearshift cam pin (2).

-

Tighten the gearshift cam plate bolt (3) to the specified torque.

Gearshift cam plate bolt: 10 Nm

-

Install the washer (4) and gearshift shaft (5).

-

Properly install the gearshift spring (6) onto the gearshift arm stopper (7).

NOTE When installing the gearshift arm stopper (7), apply a small quantity of THREAD LOCK SUPER "1303" to its threads and tighten to the specified torque. THREAD LOCK SUPER "1303" Gearshift arm stopper: 19 Nm 83

SACHS

XTC 125 4-stroke

CLUTCH

�

�

� �

�

�

1 2 3 4 5 6 7 8

-

Clutch pressure plate Clutch release bearing Clutch release rack Clutch drive plate Clutch driven plate Damper Clutch sleeve hub Primary driven gear

�� ��

Install the washer (1) and spacer (2) onto the countershaft.

NOTE Apply engine oil to the inside and outside surfaces of the spacer.

-

Install the primary driven gear assembly (3) and thrust washer (4) onto the countershaft.

NOTE When engaging the primary drive and driven gears, turn the primary driven gear assembly counterclockwise.

84

�

�

SACHS -

XTC 125 4-stroke

Install the clutch sleeve hub and lock washer (1).

CAUTION Install the lock washer so that its tongue (2) is aligned with the flat portion of the clutch sleeve hub.

-

Install the clutch sleeve hub nut and tighten it to the specified torque using the special tool.

TOOL: 09920-53740: Clutch sleeve hub holder Clutch sleeve hub nut: 50 Nm -

After tightening the clutch sleeve hub nut, be sure to lock the nut by firmly bending the tongue of the lock washer.

-

Install the four dampers (3) to the clutch drive plate and then install the drive plate onto the clutch sleeve hub (4).

CAUTION When installing the drive plate, make sure that the damper (4 pcs) protrusions face towards the bottom. -

Install the clutch driven and drive plates one by one into the clutch sleeve hub.

-

Install the clutch release rack (5) and clutch release bearing (6) into the clutch pressure plate (7).

NOTE. Face the bearing side of the clutch release bearing (6) towards the clutch release rack.

-

Install the clutch pressure plate, clutch springs and clutch spring mounting bolts.

-

Hold the generator rotor nut and tighten the clutch spring mounting bolts in a crisscross pattern.

NOTE Make sure that the clutch pressure plate is installed correctly.

85

SACHS -

XTC 125 4-stroke

Apply SUZUKI BOND NO.1215 to the right crankcase as shown.

SUZUKI BOND NO.1215

-

Install the two dowel pins and new gasket.

-

When installing the clutch cover, face the clutch release rack towards the pinion gear side.

-

Tighten the clutch cover bolts to the specified torque.

Clutch cover bolt: 10 Nm

86

SACHS

XTC 125 4-stroke

PISTON AND PISTON RING - First, install a spacer (1) into the oil ring groove and then install the two side rails (2). The spacer and side rails do not have a specific top or bottom when they are new. When reassembling used parts, install them in their original place and direction. CAUTION When installing the spacer, be careful not to allow its two ends to overlap into the piston ring groove.

INCORRECT

CORRECT

-

Some ways in which to distinguish the 1st and 2nd piston rings: 1. Their ring face shapes are different. 2. The 1st piston ring‘s face is chrome-plated.

1st

3. The 2nd piston ring appears darker in color.

2nd

-

The 1st and 2nd piston rings should be installed with their marks facing up.

TOP

1st ring TOP

2nd ring

-

Position the piston ring gaps as shown. Before inserting the piston into the cylinder, check that the gaps are properly positioned.

EX. Upper side rail

2nd ring Lower side rail

IN.

1st ring Spacer

87

SACHS

XTC 125 4-stroke

The following are reminders for piston installation: - Before installing the piston pin, apply a light coat of SUZUKI MOLY PASTE onto its surface. SUZUKI MOLY PASTE -

Place a clean rag over the cylinder base to prevent the piston pin circlip from dropping into the crankcase. Install the piston pin circlip (1) with long-nose pliers.

CAUTION Use a new piston pin circlip (1) to prevent circlip failure. -

Install the piston with the arrow mark (2) facing towards the exhaust side.

CYLINDER Before installing the cylinder, oil the big and small ends of the conrod and also the sliding surface of the piston. - Install the dowel pins (1) into the crankcase and then install the cylinder gasket (2). CAUTION Use a new gasket to prevent oil leakage.

-

Make sure that the piston rings are properly positioned, and insert the piston into the cylinder.

-

Temporarily tighten the cylinder base nuts (3).

NOTE When mounting the cylinder, keep the cam chain taut. The cam chain must not be caught between the cam chain drive sprocket and crankcase when the crankshaft is rotated.

88

SACHS

XTC 125 4-stroke

CYLINDER HEAD CAUTION Use a new gasket to prevent oil leakage. -

Install the dowel pins (1) into the cylinder and then install the cylinder head gasket (2) onto the cylinder.

NOTE Apply engine oil to the cylinder head bolts, washers before installing the cylinder head bolts. -

Place the cylinder head onto the cylinder. Tighten the cylinder head bolts to the specified torque in stages and in a crisscross pattern using a torque wrench.

Cylinder head bolt:

-

Initial 13 Nm Final 25 Nm

After tightening the cylinder head bolts to the specified torque, tighten the cylinder base nuts (3) and cylinder head nuts (4) to the specified torque.

Cylinder base nut (3): 10 Nm Cylinder head nut (4): 10 Nm

CAMSHAFT CAUTION If the crankshaft is turned without drawing the cam chain upward, the cam chain will catch between crankcase and cam chain drive sprocket. -

Turn the crankshaft counterclockwise and align the "T"- line (A) on the generator rotor with the index mark (B) on the crankcase while keeping the cam chain tight.

NOTE Just before installing the camshaft into the cylinder head, apply SUZUKI MOLY PASTE to the camshaft journals. Fully coat each journal (C), taking care not to leave any dry spots. Also, apply engine oil to the camshaft journal holders. SUZUKI MOLY PASTE Place each camshaft into the correct position: "EX" is for exhaust side "IN" is for intake side

89

SACHS -

-

-

XTC 125 4-stroke NOTE The cam chain should now be on all three sprockets.

With the "T" line (A) aligned with the index mark (B), hold the camshaft steady and lightly pull up the cam chain to remove any slack between the cam chain drive sprocket and exhaust camshaft sprocket. The exhaust camshaft sprocket has an arrow marked "1" (1). Turn the exhaust camshaft so that the arrow (1) is aligned with the gasket surface of the cylinder head. Engage the cam chain with the exhaust camshaft sprocket. The other arrow marked "2" (2) should now be pointing straight up. Starting from the roller pin that is directly above the arrow marked "2" (2), count out 16 roller pins (from the exhaust camshaft side going towards the intake camshaft side). Engage the 16th roller pin on the cam chain with the arrow marked "3" (3) on the intake sprocket.

CAUTION Be careful not to move the crankshaft until the camshaft journal holders and cam chain tension adjuster are secured.

Refer to the following illustrations.

1st pin

16th pin

B A

90

SACHS -

XTC 125 4-stroke

Install the eight dowel pins. Place each camshaft journal holders and cam chain guide into the correct position.

NOTE Camshaft journal holders which are marked "EX" or "E" are for the exhaust side and one marked "IN" or "I" are for the intake side. -

Tighten the camshaft journal holder bolts to the specified torque.

Camshaft journal holder bolt: 10 Nm

NOTE Before installing the cam chain tension adjuster, lock the tension spring with a flat-head screwdriver. Before installing the cam chain tension adjuster, turn the crankshaft counterclockwise to remove any cam chain slack between the cam chain drive sprocket and exhaust camshaft sprocket. -

Install a new gasket and the cam chain tension adjuster onto the cylinder with the two bolts and tighten them to the specified torque.

Cam chain tension adjuster bolt: 10 Nm

-

After installing the cam chain tension adjuster, turn the screwdriver counterclockwise. As the slot in the cam chain tension adjuster turns, the tension rod advances under the spring force and pushes the cam chain tension adjuster against the cam chain.

CAUTION After installing the cam chain tension adjuster, check the cam chain slack to make sure that the cam chain tension adjuster is working properly. 91

SACHS -

XTC 125 4-stroke

Tighten the oil pipe bolts to the specified torque.

Engine oil pipe bolt: 20 Nm

1

1

-

Pour abut 50 ml of engine oil into each oil pocket in the cylinder head.

NOTE. Turn the crankshaft and check that all the moving parts (e.g., cam follower, camshaft) work properly. CAUTION Be sure to check the tappet clearance. -

Apply SUZUKI BOND N0.1207B to the camshaft end caps of the gasket as shown.

SUZUKI BOND N0.1207B

-

Place the cylinder head cover onto the cylinder head. Apply engine oil to both sides of the head cover bolt gaskets and then install them onto the head cover bolts.

CAUTION Replace the gaskets with new ones to prevent oil leakage.

-

Tighten the head cover bolts to the specified torque in two stages and in a crisscross pattern.

Cylinder head cover bolt: Initial Final

92

10 Nm 14 Nm

SACHS

XTC 125 4-stroke

GENERATOR COVER -

Install the dowel pin (1) and new gasket (2).

-

Tighten the generator cover to the specified torque.

Generator cover bolt: 10 Nm

93

SACHS

94

XTC 125 4-stroke

SACHS

XTC 125 4-stroke

CARBURETOR SPECIFICATIONS ITEM Carburetor type Bore size I.D. No Idle r/min Float height

SPECIFICATION MIKUNI BS 26 26 mm 47E3 1450-1550 r/min. 17.1±0.5 mm

Fuel level (F.L.)

29±0,5 mm

Main jet (M.J.)

# 107.5

Main air jet (M.A.J)

Ø 0,7

Jet needle (J.N.)

5EP8-4

Needle jet (N.J.)

P-0

Throttle valve (T.H.V.)

#100

PiIot air jet (P.A.J.)

1.45

Pilot screw (P.S.)

2 turns back

Starter jet (G.S.)

#27.5

Throttle cable play

3-6 mm

I.D. NO. LOCATION The carburetor has an I.D. number (A) stamped on its body according to its specifications.

95

SACHS

XTC 125 4-stroke

CARBURATOR CONSTRUCION ITEM

SPECIFICATION

1

Cover

2

Spring

3

Diaphragm

4

Jet Needle

5

Piston valve

6

Air jet

7

Starting plunger

8

Pilot jet

9

Needle jet

10

Main jet

11

Pilot screw

12

Float

13

Gasket

14

Float chamber

15

Idle adjuster

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��

��

��

��

96

SACHS

XTC 125 4-stroke

DIAPHRAGM AND PISTON OPERATION The carburetor is a variable-venturi type, whose venture cross sectional area is increased or decreased automatically by the piston valve (1) The piston valve moves according to the negative pressure present on the downstream side of the venturi (A). Negative pressure is admitted into the diaphragm chamber (2) through an orifice (3) provided in the piston valve (1).

Rising negative pressure overcomes the spring (4) force, causing the piston valve (1) to rise into the diaphragm chamber and prevent the air velocity from increasing. Thus, air velocity in the venturi passage is kept relatively constant for improved fuel atomization and the precise air/ fuel mixture.

LOWER POSITION OF THE PISTON VALVE

UPPER POSITION OF THE PISTON VALVE

NEGATIVE PRESSURE 1 2 3 4 A

Piston valve Diaphragm chamber Orifice Spring Venturi

97

SACHS

XTC 125 4-stroke

SLOW SYSTEM This system supplies fuel during engine operation when the throttle valve is closed or slightly opened. The fuel from the float chamber is metered by the pilot jet (1) where it mixes with air coming in through the pilot air jet (2). This mixture, rich with fuel, then goes up through the pilot passage to the pilot screw (3). Part of the mixture is discharged into the main bore through bypass ports. The mixture is metered by the pilot screw (3) and sprayed into the main bore through the pilot outlet port.

AIR AIR/FUEL MIXTURE FUEL

MAIN SYSTEM As the throttle valve (1) is opened, the engine speed rises, and negative pressure in the venturi increases. This causes the piston valve (2) to move upward. The fuel in the float chamber is metered by the main jet (3). The metered fuel enters the needle jet (4), mixes with the air admitted through the main air jet (5) and forms an emulsion. The emulsified fuel then passes through the clearance between the needle jet (4) and jet needle (6) and is discharged into the venturi, where it meets the main air stream being drawn by the engine. Mixture proportioning is accomplished in needle jet (4). The clearance through which the emulsified fuel must flow ultimately depends on throttle position.

98

AIR AIR/FUEL MIXTURE FUEL

SACHS

XTC 125 4-stroke

STARTER SYSTEM Sliding the choke lever pulls the starting plunger (1) which causes fuel to be drawn into the starter circuit from the float chamber. The starter jet (2) meters this fuel. The fuel then flows into the fuel pipe and mixes with the air coming from the float chamber. The mixture, rich in fuel, reaches the starter plunger and mixes again with the air coming through a passage extending from behind the diaphragm.

AIR AIR/FUEL MIXTURE

The two successive mixtures of the fuel with the air provide the proper air/ fuel mixture for starting. This occurs when the mixture is sprayed through the starter outlet port into the main bore.

FUEL

FLOAT SYSTEM The float (1) and needle valve (2) work in conjunction with one another. As the float moves up and down, so does the needle valve (2). When there is a high fuel level in the float chamber, the float (1) rises and the needle valve (2) pushes up against the valve seat. When this occurs, no fuel enters the float chamber. As the fuel level falls, the float (1) lowers and the needle valve unseats itself, admitting fuel into the float chamber. In this manner, the needle valve (2) admits and shuts off fuel to maintain the appropriate fuel level inside the float chamber.

FUEL

99

SACHS

XTC 125 4-stroke

REMOVAL - Remove the fuel tank. - Remove the starter plunger (1) and throttle cable (2).

-

Remove the air cleaner box mounting screws (3).

-

Loosen the clamp screws (5). Remove the carburetor (6).

DISASSEMBLY - Remove the carburetor top cap (1).

-

Remove the spring (2) and piston valve along with diaphragm (3).

100

SACHS

XTC 125 4-stroke

-

Remove the spring seat (1) and jet needle (2).

-

Remove the float chamber (3).

-

Remove the gasket (4). Remove the float assembly (5) be removing the pin (6).

-

Remove the needle valve (7) and the valve seat (8)

CAUTION Dot not use a wire to clean the valve seat.

-

Remove the main jet (9) and pilot jet (10).

CAUTION Dot not use a wire to clean the passages and jets.

101

SACHS

XTC 125 4-stroke

-

Remove the needle jet holder (1) and needle jet (2).

-

Remove the pilot air jet (3) and main air jet (4).

-

Remove the pilot screw (5).

NOTE Before removing the pilot screw (5), its setting must be determined. Slowly turn the pilot air screw clockwise and count the number of turns until it is lightly seated. When reassembling the pilot air screw, you will want to set it to its original position.

-

Remove the throttle valve (6) by removing the screws.

CAUTION These two screws (7) are locked by notches at the end of the screws. After being unscrewed they are damaged. When reinstalling the throttle valve apply THREAD LOCK 1342 to both these screws.

102

7

SACHS

XTC 125 4-stroke

INSPECTION AND ADJUSTMENT Check the following items for any damage or clogging. - Pilot jet - Float - Main jet - Needle valve - Main air jet - Starter jet - Pilot air screw - Gasket and O-ring - Needle jet air bleeding hole - Pilot outlet and bypass holes

NEEDLE VALVE INSPECTION If foreign matter is caught between the valve seat and the needle valve, the gasoline will continue flowing and overflow. If the valve seat and needle valve are worn beyond the permissible limits, similar trouble will occur. Conversely, if the needle valve sticks, the gasoline will not flow into the float chamber. Clean the float chamber and float parts with gasoline. If the needle valve is worn, as shown in the illustration, replace, it along with a new valve seat. Clean the fuel passage of the mixing chamber with compressed air. FLOAT HEIGHT ADJUSTMENT To check the float height, turn the carburetor upside down. Measure the float height (A) while the float arm is just contacting the needle valve using vernier calipers. Bend the tongue (1) as necessary to bring the float height (A) to the specified value. Float height (A): 17.1±0.5 mm Tool: Vernier calipers REASSEMBLY Reassemble the carburetor in the reverse order of disassembly. Pay attention to the following points: - Turn the throttle stop screw until the throttle valve‘s bottom end (A) is aligned with the foremost bypass port (B). NOTE Apply a small quantity of THREAD LOCK "1342" to the throttle valve mounting screws and tighten them. THREAD LOCK "1342" CAUTION Face the stamped side of the throttle valve out. REMOUNTING Remount the carburetor in the reverse order of removal. - Adjust the following items to the specification. - Engine idle speed - Throttle cable play

103

SACHS

XTC 125 4-stroke

LUBRICATION SYSTEM -

OIL PRESSURE OIL FILTER OIL SUMP FILTER

When replacing the engine oil, make sure that the oil sump filter has no tears or damage. Also, be sure to wash the oil sump filter periodically. CAUTION Replace the generator cover gasket with a new one to prevent oil leakage.

ENGINE LUBRICATON SYSTEM CHART

Conrod small end

Cam face tappet Intake camshaft journal

Piston cylinder wall Conrod big end

Exhaust camshaft journal

Nozzle

Oil return path

Main gallery

Oil filter

Countershaft left side bearing

Oil cooler Oil pump

Countershaft right side jet Counter shaft gears

Primary driven gear spacer

Clutch plate

Oil pan

104

Cylinder head

Oil pipe

Piston jet

Camshaft journal right

Oil pump filter

Cam face tappet

Clutch relase bearing

Driveshaft left side bearing Driveshaft gears

SACHS

XTC 125 4-stroke

Electrical installation Fuses CAUTION Never install a fuse with a larger rating, since this could destroy the entire electrical system. The fuse (1) is located on the right cover. Remove the cover on top of the relay. The fuse safeguards the: - electrical starting system - direction indicators - horn - neutral indicator lamp Rated fuse current: 20 A NOTE The spare fuse (2) is on the front side of the relay.

105

SACHS

XTC 125 4-stroke

Battery

Charging the battery

WARNING Always wear safety glasses. Keep children away from acids and batteries.

After a long lay-up (3-4 months), charge the battery. The charging current (in amperes) must not exceed 1/10th of the battery capacity (Ah). The battery must not be fast-charged. The battery may only be charged using a special charger approved for MF batteries.

EXPLOSION DANGER A battery being charged produces a highly explosive gas, which is why fire, sparks, naked flames and smoking are prohibited. FIRE HAZARD Avoid generating sparks and electrostatic discharges when handling cables and electrical devices. Avoid short circuits. DANGER - CAUSTIC ACTION Battery acid is highly caustic, so always wear safety gloves and glasses. Do not tilt the battery as acid can leak from the ventilation openings. FIRST AID If acid comes into contact with an eye, immediately flush the eye for several minutes with fresh water. Then immediately visit / call a doctor. Acid on the skin or clothing must immediately be neutralised using acid converter or soap suds, and the spots must be flushed with plenty of water. If acid is swallowed, immediately visit / call a doctor.

CAUTION Do not expose batteries to direct sunlight. Discharged batteries can freeze, so they must be stored in a place where the temperature remains above 0 °C. Professional maintenance, charging and storage will increase the lifespan of the battery and are a condition for the honouring of guarantee claims. DISPOSAL Take a dead battery to a collection point. Never dispose of one with household refuse.

106

Maintenance Although the battery is maintenance-free. Never leave the battery discharged. Keep the battery clean and dry and make sure that the connection terminals are firmly seated. CAUTION The battery may only be connected or disconnected while the ignition is inactive. First disconnect the minus terminal (black cable). When installing the battery, first connect the plus terminal (red cable). The battery is maintenancefree. Do not try to open it.

SACHS

XTC 125 4-stroke

Commissioning maintenance-free batteries (MF) The steps described below must be strictly observed in order to guarantee the long lifespan of the battery. Work steps:

container with electrolyte

immediately

insert in the filler openings

Pull the shut-off plug of the battery from the acid pack and remove the aluminium foil used to seal the battery (once the aluminium foil has been removed, the battery must be filled immediately!)

air bubbles

Insert the acid pack into the filler opening of the battery and allow the acid to run into the battery (keep the acid pack in this position for at least 20 minutes).

container with electrolyte

Remove the acid pack from the battery and allow the battery to degas for another 20 minutes.

107

SACHS

XTC 125 4-stroke

WRONG

RIGHT

Close the battery using only the fingers, so that all plugs are simultaneously pressed into the battery.

MF-charger unit

V _> 12.5 OK

V < 12.5

Now check the battery voltage using a volt meter; if the voltage is lower than 12.5 volt, the battery must be recharged by means of an MF charger unit.

After charging, wait at least 30 minutes and again check the battery using the volt meter. If the voltage is still lower than 12.5 volt, the battery must be recharged.

- If the battery voltage the second charging cycle is still lower than 12.5 volt, the battery must be replaced. - If the motorcycle remains unused for a longer period, the battery must be checked or recharged every month. - To charge a maintenance-free battery you must use a suitable charger unit. The recharge may not exceed a max. charging current of 1/10th of the battery capacity.

108

SACHS

XTC 125 4-stroke

109

SACHS

XTC 125 4-stroke

STARTER MOTOR REMOVAL AND DISASSEMBLY -

Disconnect the starter motor lead wire (1). Remove the starter motor.

-

Disassemble the starter motor, as shown in the illustration.

1

Brush holder

2

Brush

3

O-ring

4

Starter motor case

5

Armature

6

O-ring

STARTER MOTOR INSPECTION CARBON BRUSHES Inspect the brushes for abnormal wear, cracks or smoothness in the brush holder. If either carbon brush is defective, replace the brush assembly.

110

SACHS

XTC 125 4-stroke

COMMUTATOR Inspect the commutator for discoloration, abnormal wear or undercut (A). If the commutator is abnormally worn, replace the armature. If the commutator surface is discolored, polish it with #400 sandpaper and wipe it using a clean, dry cloth. If there is no undercut, scrape out the insulator (1) with a saw blade.

ARMATURE COIL INSPECTION Measure for continuity between each segment and the armature shaft. If there is no continuity between the segments or there is continuity between the segments and shaft, replace the armature with a new one. Tool: Pocket tester Tester knob indication: x 1 Ω range OIL SEAL INSPECTION Check the seal lip for damage or leakage. If any damage is found, replace the housing end (inside).

STARTER MOTOR REASSEMBLY Reassemble the starter motor in the reverse order of disassembly. Pay attention to the following points: CAUTION Replace the O-rings with new ones to prevent oil leakage and moisture.

-

Apply SUZUKI SUPER GREASE "A" to the lip of the oil seal.

SUZUKI SUPER GREASE "A"

111

SACHS -

XTC 125 4-stroke

Apply a small quantity of SUZUKI MOLY PASTE to the armature shaft.

SUZUKI MOLY PASTE

-

Install the brush holder as shown.

-

Align the match marks on the starter motor case with the match marks on the housing end. - Apply a small quantity of THREAD LOCK "1342" to the starter motor housing bolts. THREAD LOCK "1342"

STARTER RELAY INSPECTION - Remove the frame covers. - Disconnect the starter motor lead wire on the starter relay. -

Turn on the ignition switch, push the starter button and check for continuity between the (+) and (-) terminals. If no continuity is found, the starter relay is defective and must be replaced with a new one. Tool: Pocket tester Tester knob indication: x 1Ω range - Disconnect the starter relay lead wire coupler. - Measure the starter relay resistance between the terminals, as shown. Tool: Pocket tester Tester knob indication: x 1 Ω range Starter relay resistance: 3-6 Ω

112

SACHS

XTC 125 4-stroke

IGNITION SYSTEM This motorcycle is equipped with a new type of ignition system which minimizes timing fluctuations. A CPU is used and accurately controls ignition timing depending on the engine r/min. A DC-DC convertor in the CDI unit increases the battery voltage and charges the capacitor. An SCR, which is connected to the capacitor, becomes conductive (turn on) when a signal is sent to the SCR gate from the CPU. (The ignition timing is controlled by the CPU which processes the pick-up coil pulses to from the SCR gate signal. The signal is then sent to the SCR just when the crankshaft has reached the best ignition timing for the current revolutions). This allows the electric energy, which is stored in the capacitor, to discharge instantly and flow to the primary winding of the ignition coil. A high voltage current is induced in the secondary winding of the ignition coil resulting in a strong spark between the spark plug gap.

Engine stop switch

Ignition switch Fuse

DC-DC convertor

Ignition power sorce circuit Battery Ignition coil Sensor input circuit

CPU Tachometer output circuit

Pick-up coil

Spark plug CDI unit

Tachometer

Generator CPU: Central processing unit

113

SACHS

XTC 125 4-stroke

TROUBLE SHOOTING No spark at the spark plug

Check: -

Check the CDI unit coupler for a poor connection

The ignition switch is in the ON position. The engine stop switch is in the RUN position. The fuse is not blown.

Looseness

- Poor contact of coupler

No good

- Faulty ignition switch - Faulty engine stop switch - Broken wire harness or poor contact of rela ted circuit connectors

Incorrect

- Faulty pick-up coil

Correct Inspect the battery voltage between input lead wires (O/W and B/W) at the CDI unit with the ignition switch "ON" position.

Good Measure the pick-up coil resistance (G/W and BI/Y). Correct

- Faulty CDI unit - Faulty ignition coil

114

SACHS

XTC 125 4-stroke

INSPECTION IGNITION COIL (checking with the electro tester) - Remove the fuel tank. - Remove the ignition coil (1). NOTE Make sure that the three-needle sparking distance of the electro tester is set at 8 mm. Test the ignition coil for proper sparking performance using the electro tester. -

Connect the test leads as shown in the illustration. Check the sparking condition in the test gap for at least five minutes. Black tip (-)

If no spark or an orange color spark occurs, the ignition coil may be defective.

Red tip (+)

Black

Tool: Electro tester Spark performance: Over 8 mm Yellow

WARNING Do not touch the wire clips to prevent an electric shock when testing. CAUTION When using the electro tester, follow the instruction manual. IGNITION COIL (checking with the pocket tester) A pocket tester or an ohm meter may be used, instead of the electro tester. In either case, the ignition coil is to be checked for continuity in both primary and secondary windings. Exact ohm readings are not necessary, but, if the windings are in sound condition, their continuity should be close to the specified values.

Spark

Tap

Tool: Pocket tester Tester knob indication: x 1 Ω range Ignition coil resistance Primary: 0.1-0.5 Ω (+ tap-Ground) Tester knob indication: x 1 Ω range

Ground

Secondary: 13-23 kΩ (Plug cap-ground)

115

SACHS

XTC 125 4-stroke

PICK-UP COIL - Remove the frame covers. - Disconnect the pick-up coil coupler (1). - Measure the pick-up coil resistance between the lead wires. If the resistance is infinity or less than specification, the pick-up coil and stator coil must be replaced. Tool: Pocket tester Tester knob indication: x 100 Ω range Pick-up coil resistance: 180-340 Ω (G/W-BL/Y) BL/Y: Blue with Yellow tracer G/W: Green with White tracer

Generator

CDI UNIT - Remove the frame covers. - Remove the CDI unit (1). Measure the resistance between the terminals. If the resistance is infinity or less than the specifications, the CDI unit must be replaced. NOTE. The readings may differ if a SUZUKI pocket tester is not used. Tool: Pocket tester Tester knob indication: x 1 Ω range Unit:

Probe of tester

Probe of tester

Condenser: When the capacitor is in the discharging state, the needle of the tester swings first then returns to infinity (∞). NOTE. If there is no spark evident, replace the CDI unit or inspect the stator coil, pick-up coil, ignition coil, spark plug and battery. If the stator coil, pick-up coil, ignition coil, spark plug and battery are OK, the CDI unit may be faulty, therefore, replace the CDI unit with a new one. 116

SACHS

XTC 125 4-stroke

RPM METER 1. Disconnect the plug (2) from the rpm meter (1). 2. Measure the voltage between the black cable coming from the plug (2) and terminal 30, using a voltage meter. Black cable - terminal 30 Target value: battery voltage Actual value = target value = test step 3. Actual value ≠ target value = check the cables against the wiring diagram.

1

2

SFM 675 182.3-1

3. Measure the resistance between the black cable and the white cable coming from the plug (2), using an ohmmeter: White cable - black cable Target value at 20 °C: 0.2 - 0.8 Ω Actual value = target value = replace the rpm meter. Actual value ≠ target value = check the charger.

117

SACHS

XTC 125 4-stroke

Chassis - Wheels - Removing/installing the front wheel

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CAUTION Be careful during removal and installation not to damage the brake disks or linings! Do not operate the handbrake lever after a wheel has been removed! Protect the wheel bearings fr om dirt and moisture! Removing the front wheel: 1. Support the motorcycle so that the front wheel is free and the motorcycle stands safely. 2. Hold the full floating axle (2), remove the axle nut (6) and the shaft-clamping screw (1). 3. Push back the protective cover (5), loosen the spigot nut (4) and remove the speedometer shaft. 4. Lift the front wheel, pull out the full floating axle (2) and remove the front wheel in a downwards direction. 5. Remove the speedometer drive (3) and the spacer bush (7) near the brake disk. Installing the front wheel: 6. Clean and grease the running face of the speedometer drive (3). 7. Roll the front wheel between the fork pipes, insert the speedometer drive (3) and the spacer bushing (7). NOTE When inserting the front wheel, make sure that the nose of the speedometer drive (3) is in the guide (9) of the fork. 8. Grease the full floating axle (2), insert it from the left until it contacts the stop, then fasten it with a washer (8) and shaft nut (6). 9. Before tightening the nuts, put the motorcycle on its wheels and firmly compress the telescopic fork several times; this will prevent the fork pipes from becoming deformed. Tightening torque of the shaft nut (6): 60-65 Nm Tightening torque of the shaft-clamping screws (1): 10 Nm

118

SACHS

XTC 125 4-stroke

Removing/installing the rear wheel

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CAUTION Be careful during removal and installation not to damage the brake disks or linings! Do not operate the handbrake lever after a wheel has been r emoved! Protect the wheel bearings from dirt and moisture! Removing the rear wheel: 1. Support the motorcycle so that the rear wheel is free and the motorcycle stands safely. 2. Hold the full floating axle (5) and remove the axle nut (4). 3. Loosen the lock-nuts (1) and twist in the left- and right-hand screws (2) and remove the chain from the chain wheel. NOTE When removing the rear wheel, be careful not to lose the bushings (7 and 9) to the left and right of the wheel hub or the spacer ring (8) near the brake support. 4. Lift the rear wheel, pull out the full floating axle (5) with the guides (3) and the washers (6) and remove the rear wheel in a downwards direction. Installing the rear wheel: 5. Insert the brake support (10) in the holder bolt (11) of the swing. 6. Clean and grease the full floating axle (5). NOTE When inserting the bushing (7), make sure that the large diameter makes contact with the swing. 7. Insert the spacer ring (8) in the brake support (10) (small diameter in the bore of the brake support). 8. Insert the rear wheel with the bushings (7 and 9) and insert the full floating axle (5) with washer (6) and guide (3). 9. Install the guide (3), washer (6) and shaft nut (4) on the full floating axle (5). 10. Adjusting the chain. 11. Tighten the axle nut (4). Tightening torque of the axle nut (4): 60-65 Nm 119

SACHS

XTC 125 4-stroke

Removing/installing the front-wheel bearing NOTE Heat the bearing seat to approx. 100 °C in order to facilitate removal/installation. Removing the wheel bearing: 1. Remove the front wheel. 2. Use an internal extractor to pull the wheel bearing (1) out of the bearing seat of the wheel hub (2). Installing the wheel bearing: 3. Press the wheel bearing (1) into the bearing seat of the wheel hub (2). 4. Install the front wheel.

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Removing/installing the rear-wheel bearing NOTE Heat the bearing seat to approx. 100 °C in order to facilitate its removal and installation. Removing the wheel bearing: 1. Remove the rear wheel. 2. Remove the brake shoe support. 3. Use an internal extractor to pull the wheel bearing (1) out of the bearing seat of the wheel hub (2). Installing the wheel bearing: 4. Press the wheel bearing (1) into the bearing seat of the wheel hub (2). 5. Install the front wheel.

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Statically aligning the wheels 1. Clamp the relevant wheel in the aligning device. 2. Rotate the wheel gently and wait until it comes to a standstill. Make a mark (1) at the low point of the tyre. NOTE Always start with the smallest alignment weight.

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3. Turn the wheel through 90°, stop it and let it find its own position. If the mark (1) again stops at the low point of the tyre, this is the heavy point and an alignment weight (2) must be installed opposite it. 4. Each time turn the wheel through 90° and stop it; the wheel must remain in position, otherwise repeat the alignment procedure.

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120

SACHS

XTC 125 4-stroke

Telescopic fork

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Removing/installing the telescopic fork

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Removing the telescopic fork: 1. Remove the front wheel. 2. Remove the top part of the full covering. 3. Remove the instruments and covering holder. 4. Remove the front wheel safeguard. 5. Only for the XTC: remove the half-handlebar 6. Pull off the protective cover (10), remove the closure nut (1) and the clamp screws (2) and remove the fork bridge (3) at the top.

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NOTE When removing the telescopic fork (5), be careful not to lose the tapered roller bearing (8), the sealing ring (7) or the bearing-cover ring (6). In principle, the sealing rings (7) should be replaced. 7. Remove the adjusting nut (4) and pull the telescopic fork (5) downwards out of the fork column (9). Installing the telescopic fork: 8. Reassemble in reverse order. 9. Grease the fork column top bearing. 10. Adjust the fork column top bearing.

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121

SACHS

XTC 125 4-stroke

Disassembling the telescopic fork NOTE In principle, the sealing ring (4) should be replaced. 1. Remove the clamping screw (2) and remove the fork pipe (3) from the fork bridge.

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The closure screw (1) is under spring pressure. 2. Remove the closure screw (1). 3. Remove the fastening screw (5) of the absorber pipe with the sealing ring (4) and drain the fork oil. 4. Pull off the dust cover and use a screwdriver to remove the securing ring. 5. Remove the spacer bushing, spring plate, pressure spring, absorber pipe and the stand pipe from the sliding pipe.

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CAUTION Deformed fork bridges must be replaced.

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122

SACHS

XTC 125 4-stroke

4. Install the upper fork bridge. NOTE The upper fork bridge must be easy to slide onto the stand pipes. 5. Use a slider gauge to check that the stand pipes are parallel. 6. Check that the steering post is parallel to the stand pipes.

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7. Install the old stand pipe with both ends in the prism, slowly rotate the stand pipe while checking the deformation with a measuring gauge. Allowable deformation of the stand pipes: 0.1 mm

CAUTION Bent stand pipes may not be realigned.

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123

SACHS

XTC 125 4-stroke

Repairing the telescopic fork

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NOTE Before installation, lightly oil the slide bushes (8a and 8f) and the thread of the closure screw (1). In principle, the O-ring (2) and the sealing ring (6c) must be replaced. Before installation, lightly cover the exterior of the radial packing ring (8d) with tyre-installation liquid. Fill the grease pocket in the dust collar (8b) with Molybdene grease. Tightening torque for closure screw (1): Tightening torque for screws (6d):

40 Nm 40 Nm

Telescopic fork oil: Qty. for filling each form pipe:

SAE 10 W 280 cm3

1. Push apart the slide bush (8a), pull it off the stand pipe (7) and install a new side bush (8a). 2. Remove the radial packing ring (8d), the intermediate ring (8e) and the slide bush (8f) from of the sliding pipe. 3. Push the absorber pipe (6a) into the stand pipe (7), install the guide piece (6b) on the absorber pipe (6a) and push the stand pipe (7) with slide bush (8a) into the sliding pipe. 4. Insert the pressure spring (5), spring plate (4) and spacer bush (3) into the stand pipe (7) and lightly twist in the fastening screw (6d) with a new sealing ring (6c). 5. Push the slide bush (8f) over the stand pipe (7), lightly push it into the sliding pipe (9) and carefully push it in using the impact mandrel (A). 6. Insert the intermediate ring (8e), carefully push in the radial packing ring (8d) with the impact mandrel (A) and install the securing ring (8c) via the radial packing ring (8d) into the nut. 7. Carefully tighten the dust collar (8b) with the impact mandrel (A) and tighten the fastening screw (6d) for absorber pipe. 8. Put in the prescribed quantity of fork oil, insert the closure screw (1) with a new O-ring (2) and tighten it. 1 2 3 4 5 6 6a

124

Closure screw O-ring Spacer bush Spring plate Pressure spring Absorber pipe set Absorber pipe

6b Guide piece 6c Sealing ring 6d Fastening screw for absorber pipe 7 Stand pipe 8 Sealing set for sliding pipe 8a Sliding bush for stand pipe

8b 8c 8d 8e 8f 9 A

Dust collar Securing ring Radial packing ring Intermediate ring Slide bush for sliding pipe Sliding pipe Impact mandrel

SACHS

XTC 125 4-stroke

9. Clamp the lower fork bridge (2) by the steering post in the vice. 10. Install the two stand pipes (1) with test length (A) into the lower fork bridge and tighten the clamp screw (3). Test length (A): 189 mm Tightening torque of the screws (3): 13-15 Nm

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11. Install the telescopic fork.

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Removing/installing the fork column bearing

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CAUTION The tapered roller bearing and the bearing outer ring must always be replaced together.

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1. Remove the telescopic fork.

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Fork column bearing, top: 2. Remove the bearing cover ring (1), sealing ring (2) and tapered roller bearing (3) from the fork column (4).

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3. Use an internal extractor (3) to pull the bearing outer ring (1) out of the fork column (2).

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4. Push the new bearing outer ring down to the bottom of the seat of the fork column (2) (e.g. using the fork column mandrel (1) of a frame gauge).

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125

SACHS

XTC 125 4-stroke

Fork column bearing, bottom: 5. The removal/installation of the lower bearing outer ring is realised in accordance with the removal/ installation of the upper bearing outer ring. 6. Destroy the bearing cage and remove it together with the tapered rollers. 7. Use a universal extractor (1) to pull the bearing ring off the steering post (2). 8. Heat the new bearing ring to approx. 80 °C and install it; if necessary, use a pipe to evenly drive the bearing ring down to the stop.

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CAUTION Allow the bearing ring to cool of f before adjusting the play of the fork column bearing.

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NOTE Grease the fork column bearing with wheel-bearing grease. 9. Install the telescopic fork..

Removing/installing the telescopic leg Removing the telescopic leg: 1. Support the motorcycle so that the rear wheel is free and the motorcycle is standing securely. 2. Remove the screw (1) with washers (2 and 3) and nut (4) and carefully lower the swing (10) with the rear wheel. 3. Remove the screws (5) with washers (6 and 7) and the nut (8) and remove the telescopic leg (9) from the frames (11). Installing the telescopic leg: 4. Reassemble in reverse order. Tightening torque of the screws (1 and 5): 42 Nm

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126

SACHS

XTC 125 4-stroke

Removing the rear-wheel swing, replacing and installing the swing bearing

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Removing the rear-wheel swing: 1. Support the motorcycle so that the rear wheel is free and the motorcycle stands securely. 2. Remove the rear wheel and the chain. 3. Disconnect the brake hose from the holders of the rear-wheel swing, take the calliper through the swing triangle and connect it to the frame (if necessary, secure it with wire). 4. Support the rear-wheel swing (1) in order to prevent the exhaust system from becoming damaged. 5. Disconnect the screw (11) with washers (12) and nut (13) then disconnect the telescopic leg (10). NOTE When pulling out the swing axle (2) or removing the rear-wheel swing (1), be careful not to lose the friction washers (4 and 8) or the bushes (5). 6. Pull off the cover plug (9), remove nuts (3) and washers (4), pull out the swing axle (2) and remove the rearwheel swing (1) in a rearwards direction. Replacing the swing bearing: 7. Pull out the bushings (5) and the radial packing rings (7) from the rear-wheel swing. 8. Use an impact mandrel to drive the needle bushings (6) out of the rear-wheel swing (1). 9. Thoroughly clean the rear wheel swing (1), the bushes (5) and the swing axle (2). 10. Lightly grease the exterior of the new needle bushes (6) and the interior of the bearing seat of the rear-wheel swing (1). 11. Push in the new needle bushes (6) so far that the radial packing rings (7) can be installed on both sides. 12. Grease the bearing and install new radial packing rings (7) and bushes (5). Installing the rear-wheel swing: 13. Reassemble in reverse order. Tightening torque for nut (3): Tightening torque for screw (11):

42 Nm 42 Nm

127

SACHS

XTC 125 4-stroke

Replacing the chain set

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CAUTION The chain, chain wheel and pinion wheel may only be r eplaced together. NOTE When opening the stud link (1), be careful not to lose the O-ring (4) or the spring clip (2). The pull-off screw (6) can be loosened with a chisel. The installation of a pull-of f screw (6) is required by law . 1. Separate the stud link (1) from the chain (3) and remove the chain (3). 2. Remove the rear wheel. 3. Remove the screws (13), securing ring (11) with washer (12) and remove the chain wheel (14) from the rear wheel (18). 4. Check the adapter (15) and absorbing rubber (17) for damage, insert new lock-nuts (16) and use the screws (13) to fasten the new chain wheel (14) to the adapter (15). Tightening torque of the screws (13): 25-28 Nm 5. Insert the pre-assembled chain wheel (14) with the absorbing rubber (17) into the rear wheel and fasten it with the washer (12) and the securing ring (11). 6. Remove the screws (5 and 6) and remove the cover (7). 7. Bend open the locking plate (8), hold the pinion wheel (10) using the holder spanner (special tool) and remove the nut (9). 8. Install the new pinion wheel (10) with the locking plate (8), hold the pinion wheel (10) using the holder spanner (special tool), fasten it using the nut (9) and secure it with the locking plate (8). Tightening torque of the nut (9): 90 Nm CAUTION The closed end of the spring clip (2) of the stud link (1) must always point in the r unning direction (arrow) of the chain (3). 9. Install the chain (3) on the pinion wheel (10), thread it through the swing and connect it using the stud link (1). 10.Reassemble in reverse order. Tightening torque of the screw (5): 8-10 Nm

128

SACHS

XTC 125 4-stroke

Brakes Removing, installing and repairing the front calliper

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CAUTION The brake fluid can cause damage to the painted and plastic parts! Use only new brake fluid of specification DOT 4. Removing the calliper: 1. Remove the banjo bolt (6) with the sealing rings (5), remove the brake line (4) and close it off. 2. Remove the screws (2) with spring washers (3) and remove the calliper (1) from the brake disk. Installing the calliper: 3. Remove the circlip (8) and the holder bolt (7) from the calliper (1). 4. Remove the brake lining (9). 5. Remove the screws (11), push apart the calliper (1) and remove the brake piston with the old sealing set. 6. Check the calliper (1) and the brake piston for damage, wear or corrosion; if necessary, replace the calliper. 7. Install the new sealing set (10) with the brake piston. 8. Assemble the calliper (1), insert the screws (11) with Loctite 270 and tighten them. Tightening torque of the screws (11): 25-28 Nm 9. Insert the brake lining (9) and fasten it with circlip (8) and holder bolts (7). Installing the calliper: 10. Reassemble in reverse order. Tightening torque of the screws (2):

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35-38 Nm

WARNING - RISK OF ON-ROAD ACCIDENT Operate the brakes several times, until the brake linings make contact. 11. Adjust the brake-fluid level, vent the brake system and check the handbrake lever play. 12. Carry out a function check.

129

SACHS

XTC 125 4-stroke

Replacing the front brake disk 1. Remove the front wheel. 2. Remove the screws (4) with spring rings (3) and remove the brake disk (2) from the front wheel (1). 3. Install a new brake disk (2) on the front wheel (1), insert the screws (4) with Loctite 270 and insert and fasten the new spring rings (3). Tightening torque of the screws (4):10-11 Nm with Loctite 270. 4. Reassemble in reverse order.

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Removing, installing and repairing the rear calliper CAUTION Brake fluid can cause damage to painted and plastic parts. Use only brake fluid of specification DOT 4. Removing the calliper: 1. Remove the banjo bolt (2) with sealing rings (3), remove the brake line (1) and close it off. 2. Remove the rear wheel and remove the calliper (6). Repairing the calliper: 3. Bend open the locking plate (5), remove the screws (4) and remove the holder plate (9). 4. Remove the brake linings (7). 5. Remove the brake piston with the old sealing set. 6. Check the calliper (6) and brake piston for damage, wear or corrosion; if necessary, replace the calliper. 7. Insert a new sealing set (8) with the brake piston. 8. Insert new brake linings (7) and the holder plate (9) and fasten it with the locking plate (5) and screws (4). Tightening torque of the screws (4): 25-28 Nm 9. Bend the locking plate (5) in order to secure the screws (4). Installing the calliper: 10. Reassemble in reverse order. WARNING - RISK OF ON-ROAD ACCIDENT! Operate the brake several times, until the brake linings make contact. 11. Adjust the brake-fluid level, vent the brake system and check the handbrake lever play. 12. Carry out a function check.

130

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SACHS

XTC 125 4-stroke

Replacing the rear brake disk 1.

Remove the rear wheel.

2.

Remove the screws (2) and remove the brake disc (1) from the rear wheel (3).

3.

Install the new brake disk (1) on the rear wheel (3), insert the screws (2) with Loctite 270 and tighten them. Tightening torque of the screws (2): with Loctite.

4.

10-11 Nm

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Reassemble in reverse order.

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131

SACHS

XTC 125 4-stroke

Lights Removing/installing the headlamps

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NOTE Do not touch the filament bulbs with the bare fingers. For installation and removal purposes, use a clean, dry cloth. Before installation, check the rubber bearings (1) for damage and replace them if necessary. 1. 2. 3. 4. 5. 6.

Remove the upper covering. Disconnect the rubber covers (2) and pull them off, disconnect the connector plugs (3, 4, 5). Remove the screws (6, 7) with the washers (8), the bush (9). Remove the headlamp (10). Pull out the parking-light holder (11) with its filament bulb (12). Unlock the holder clamp (13) and remove the riding-light lamps (14).

INSTALLATION NOTE The condensation outlets (15) on the rubber covers (2) must point downwards. 7. Reassemble in reverse order.

132

SACHS

XTC 125 4-stroke

Removing/installing the rear lights

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NOTE Do not touch the filament bulbs with the bare fingers. For installation and removal purposes, use a clean, dry cloth. Make sure that the cable is correctly installed without abraded contacts or bends/kinks. When installing the filament bulbs (4), observe the different heights of the projections on the lamp base. 1. 2. 3. 4.

Remove the seat. Remove the screw (6) and remove the rear-light cover (5). Remove the filament bulbs (4). Remove the nuts (1) with the washers (2), disconnect the connection cable and remove the rear lights (3) from the seat.

5.

Remove the nuts (7) with the washers (8) and remove the rear reflector (9).

6. 7.

Remove the nuts (10) with the washers (11). Pull out the light holder (12) with its bulb (13) and remove the number plate light (14).

6.

Reassemble in reverse order.

133

SACHS

XTC 125 4-stroke

Direction indicators Removing/installing the direction indicators:

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NOTE The figure is a front view of the direction indicator. Proceed accordingly for the rear direction indicators until you have jacked the cable off. 1. Clip out the direction-indicator glass (1) from the direction-indicator housing (3) and remove it. 2. Only for the front direction indicators: remove the filament bulbs (2), disconnect the plug from the connection cable (8) behind the covering. 3. Only for the rear direction indicators: remove the filament bulbs (2), disconnect the connection cable (8) in the direction indicator housing (3). 4. Remove the screw (4) with the washers (5 and 6) and the nut (7) and remove the direction-indicator housing (3). 5. Reassemble in reverse order.

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SACHS

XTC 125 4-stroke

Troubleshooting Engine Complaint

Symptom and possible causes

Engine will not start or is hard to start.

Compression too low

Remedy

Worn cylinder

Rebore or replace

Worn piston ring

Replace.

Worn valve guide or improper valve seating Repair or replace Loose spark plug

Tighten.

Broken, cracked or damaged piston

Replace

Slow cranking starter motor

See electrical section

Mistimed valves

Adjust

Tappet clearance out of adjustment

Adjust

Spark plug not sparking Damaged spark plug

Replace

Damaged spark plug cap

Replace

Fouled spark plug

Clean or replace

Wet spark plug

Clean and dry or replace

Defective ignition coil

Replace

Open or short in high-tension cord

Replace

Defective pick-up coil or CDI unit

Replace

No fuel reaching a carburetor

Engine stalls easily

Engine is noisy

Clogged or defective fuel valve

Clean or replace

Defective carburetor needle valve

Replace with cauburetor needle valve seat

Clogged fuel hose

Clean or replace

Clogged fuel filter

Clean or replace

Fouled spark plug

Clean or replace

Defective pick-up coil or CDI unit

Replace

Clogged fuel hose

Clean

Clogged carburetor jet

Clean

Tappet clearance out of adjustment

Adjust

Excessive valve chatter Excessive tappet clearance

Adjust

Weak or broken valve spring

Replace

Worn cam surface

Replace

Worn or burnt camshaft journal

Replace camshaft

135

SACHS

XTC 125 4-stroke

Engine Complaint

Symptom and possible causes

Engine is noisy

Noise seems to come from the piston

Remedy

Worn piston

Replace

Worn cylinder

Rebore or replace

Carbon build-up in combustion chamber

Clean

Worn piston pin or piston pin bore

Replace

Worn piston ring or ring groove

Replace

Noise seems to come from the cam chain Stretched cam chain

Replace cam chain and sprockets

Worn cam chain sprocket

Replace cam chain and sprockets

Improperly working cam chain tension adjuster

Repair or replace

Noise seems to come from the clutch Worn countershaft spline

Replace countershaft

Worn clutch hub spline

Replace clutch hub

Worn clutch plate teeth

Replace clutch plate

Distorted clutch plate

Replace

Worn clutch release bearing

Replace

Weak clutch damper

Replace primary driven gear

Weak clutch spring

Replace

Noise seems to come from the crankshaft Rattling bearing

Replace

Worn or burnt crank pin bearing

Replace

Worn or burnt ball bearing

Replace

Noise seems to come from the transmission

Clutch slips

Clutch drags

Worn or rubbing gear

Replace

Worn countershaft spline

Replace countershaft

Worn driveshaft spline

Replace driveshaft

Worn or rubbing primary gear

Replace

Worn bearing

Replace

Clutch cable out of adjustment

Adjust

Weak or broken clutch spring

Replace

Worn or distorted clutch pressure plate

Replace

Distorted clutch plate

Replace

Clutch out of adjustment

Adjust

Some clutch springs are weak, while others are not Replace

Transmission will not shift Transmission will not shift back

136

Worn or distorted clutch pressure plate

Replace

Distorted clutch plate

Replace

Broken gearshift cam

Replace

Distorted gearshift fork

Replace

Worn gearshift fork pawl

Replace gearshift fork

Broken gearshift shaft return spring

Replace

Rubbing or stuck gearshift shaft

Repair or replace

Worn or distorted gearshift fork

Replace

SACHS

XTC 125 4-stroke

Engine Complaint

Symptom and possible causes

Remedy

Transmission jumps out of gear

Worn gear

Replace

Worn or distorted gearshift fork

Replace

Weakened gearshift stopper spring

Replace

Worn gearshift fork pawl

Replace gearshift fork

Tappet clearance out of adjustment

Adjust

Improper valve seating

Repair or replace

Worn valve guide

Replace

Worn cam surface

Replace

Excessive spark plug gap

Adjust or replace

Defective ignition coil

Replace

Defective pick-up coil or CDI unit

Replace

Spark plug too cold

Replace by hot type plug

Incorrect float Chamber fuel level

Adjust float height

Clogged carburetor jet

Clean

Defective generator

Replace

Weak valve spring

Replace

Worn camshaft

Replace

Insufficient spark plug gap

Regap or replace

Ignition not advanced sufficiently due to poorly working timing advance circuit

Replace CDI unit

Defective ignition coil

Replace

Defective pick-up coil or CDI unit

Replace

Low float chamber fuel level

Adjust float height

Dirty air cleaner element

Clean or replace

Clogged fuel hose, resulting in inadequate fuel

Clean and prime

Engine idles poorly

Engine runs poorly in high-speed range

supply to carburetor Exhaust smoke is dirty or thick

Excessive amount of engine oil

Check level and drain

Worn cylinder

Rebore or replace

Worn piston ring

Replace

Worn valve guide

Replace

Scored or scuffed cylinder wall

Rebore or replace

Worn valve stem

Replace valve

Defective valve stem oil seal

Replace

Worn oil ring side rail

Replace oil ring

137

SACHS

XTC 125 4-stroke

Engine Complaint

Symptom and possible causes

Remedy

Engine lacks power

Insufficient tappet clearance

Adjust

Weak valve spring

Replace

Mistimed valves

Adjust

Worn cylinder

Rebore or replace

Worn piston ring

Replace

Improper valve seating

Repair or replace

Fouled spark plug

Clean or replace

Incorrect spark plug

Replace

Clogged carburetor jet

Clean

Incorrect float chamber fuel level

Adjust float height

Dirty air cleaner element

Clean or replace

Worn camshaft

Replace

Air leakage from intake pipe

Tighten or replace

Excessive amount of engine oil

Check level and drain

Carbon build-up on piston crown

Clean

Insufficient amount of engine oil

Check level an add

Defective oil pump

Replace

Clogged oil circuit

Clean

Float chamber fuel level too low

Adjust float height

Air leakage from intake pipe

Tighten or replace

Incorrect engine oil

Change

Engine overheats

Carburetor Starting difficulty Clogged starter jet Clogged starter jet passage

Clean

Air leaking from joint between starter body and carburetor

Tighten, adjust or replace gasket

Air leaking from carburetor joint or vacuum hose joint

Tighten or replace defective part

Improperly working starter plunger

Adjust

Idling or low-speed Clogged or loose pilot jet trouble Clogged or loose pilot air jet

Medium-or high speed trouble

Clean or tighten Clean or tighten

Air leaking from carburetor joint or vacuum pipe joint, or starter

Tighten or replace defective part

Clogged pilot outlet port

Clean

Clogged bypass port

Clean

Starter plunger not fully closed

Adjust

Clogged main jet

Clean

Clogged main air jet

Clean

Clogged needle jet

Clean

Improperly working throttle valve

Adjust

Clogged fuel filter

Clean or replace

Overflow and Worn or damaged needle valve fuel Broken needle valve spring level fluctuations Improperly working float

138

Clean

Replace Replace Adjust or replace

Foreign matter an the needle valve

Clean or replace with needle valve seat

Incorrect float chamber fuel level

Adjust float height

SACHS

XTC 125 4-stroke

Elektric Complaint

Symptom and possible causes

Remedy

No sparking or poor sparking

Defective ignition coil

Replace

Defective spark plug

Replace

Defective pick-up coil

Replace

Defective CDI unit

Replace

Excessively rich air/fuel mixture

adjust carburetor

Excessively high idling speed

Adjust carburetor

Incorrect gasoline

Change

Dirty air cleaner element

clean or replace

Incorrect spark plug (cold type)

Change to hot type spark plug

Worn piston ring

Replace

Worn piston

Replace

Worn cylinder

Rebore or replace

Excessive valve-stem-to-valve-guide clearance

Replace

Worn valve stem oil seal

Replace

Incorrect spark plug (hot type)

Change to cold type spark plug

Overheated engine

Tune-up

Loose spark plug

Tighten

Excessively lean air/fuel mixture

Adjust carburertor

Open or short in lead wires, or loose lead connections

Repair, replace or connect properly

Shorted, grounded or open stator coil

Replace

Shorted or punctured regulator/rectifier

Replace

Lead wires tend to get shorted or opencircuited or loosely connected at terminal

Repair or tighten

Grounded or open-circuited stator coils or generator

Replace

Defective regulator/rectifier

Replace

Defective battery cell plates

Replace battery

Internal short-circuit in the battery

Replace battery

Damaged or defective regulatror/rectifier

Replace

Poorly grounded regulator/rectifier

Clean and tighten ground connection

Lead wire insulation frayed due to vibration resulting in intermittent shorting

Repair or replace

Internally shorted generator

Replace

defective regulator/rectifier

Replace

Run down battery

Recharge or replace

Defective switch contact

Replace

Brushes do not seat properly on the commutator in the starter motor.

Repair or replace

Defective starter relay

Replace

Spark plug is wet or quickly becomes fouled with carbon

Spark plug quickly becomes fouled with oil or carbon

Spark plug electrodes overheat or burn

Generator does not charge

Generator charges but charging rate is below the specifications

Generator overcharges

Unstable charging

Starter button does not work

139

SACHS

XTC 125 4-stroke

Battery Complaint

Symptom and possible causes

Remedy

Sulfation or spots on surfaces of cell plates

Cracked battery case

Replace the battery

Battery has been left in an run-down condition for a long time

Replace

Battery runs down quickly

Incorrect charging method

Check generator, IC regulator, or rectifier circuit, connections, and make necessary adjustment to obtain specified charging operation

Battery cell plates have lost much of their active material as a result of overcharging

Replace battery and correct charing system

Internally shorted battery

Replace

Excessively low battery voltage

Recharge

Battery is too old

Replace

Incorrect charging rate (When not in use, the battery should be checked at least once a month and properly charged if necessary, to avoid sulfation.)

Replace battery

The battery was left unused in a cold climate for too long

Replace the battery if badly sultated

Battery sulfation

140

SACHS

XTC 125 4-stroke

WIRING DIAGRAM

141

SACHS

142

XTC 125 4-stroke