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    Engine Removal/Installation: JETIX 125

    Uploaded by

    John Rodriguez
    The document provides instructions for removing and installing the engine on a Jetix 125 motorcycle. The key steps for removal are draining the oil, removing the muffler and carburetor, disconnecting electrical connections, and removing mounting bolts and nuts. Installation is the reverse of removal, ensuring proper routing of wires and cables and filling the crankcase with the recommended oil level. Torque specifications are provided for important fasteners.

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    © All Rights Reserved
    Download as DOC, PDF, TXT or read online from Scribd

    Engine Removal/Installation: JETIX 125

    Uploaded by

    John Rodriguez
    61 views4 pages
    The document provides instructions for removing and installing the engine on a Jetix 125 motorcycle. The key steps for removal are draining the oil, removing the muffler and carburetor, disconnecting electrical connections, and removing mounting bolts and nuts. Installation is the reverse of removal, ensuring proper routing of wires and cables and filling the crankcase with the recommended oil level. Torque specifications are provided for important fasteners.

    Original Title

    05-1

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    The document provides instructions for removing and installing the engine on a Jetix 125 motorcycle. The key steps for removal are draining the oil, removing the muffler and carburetor, disconnecting electrical connections, and removing mounting bolts and nuts. Installation is the reverse of removal, ensuring proper routing of wires and cables and filling the crankcase with the recommended oil level. Torque specifications are provided for important fasteners.

    Copyright:

    © All Rights Reserved
    Download as DOC, PDF, TXT or read online from Scribd
    Download as doc, pdf, or txt
    61 views4 pages

    Engine Removal/Installation: JETIX 125

    Uploaded by

    John Rodriguez
    The document provides instructions for removing and installing the engine on a Jetix 125 motorcycle. The key steps for removal are draining the oil, removing the muffler and carburetor, disconnecting electrical connections, and removing mounting bolts and nuts. Installation is the reverse of removal, ensuring proper routing of wires and cables and filling the crankcase with the recommended oil level. Torque specifications are provided for important fasteners.

    Copyright:

    © All Rights Reserved
    Download as DOC, PDF, TXT or read online from Scribd
    Download as doc, pdf, or txt
    of 4

    5.

    ENGINE REMOVAL/INSTALLATION JETIX 125

    0
    5. ENGINE REMOVAL/INSTALLATION JETIX 125

    SERVICE INFORMATION....................................................................................................5-1
    ENGINE REMOVAL..............................................................................................................5-2
    ENGINE INSTALLATION.....................................................................................................5-3

    SERVICE INFORMATION
    GENERAL INSTRUCTIONS
     A engine stand or floor jack is required to support and maneuver the engine.
     The following parts can be serviced with the engine installed in the frame:
     Cylinder head/valves (Section 6)
     Cylinder/piston (Section 7)
     Starter motor/generator/left crankcase cover/starter clutch/camshaft (Section 8)
     Clutch/gear shift mechanism (Section 9)

    ENGINE OIL CAPACITY:


    At disassembly : 1.0 liter
    At change : 0.9 liter

    TORQUE VALUES
    Engine bracket bolt 2.0～2.5kg-m
    Drive gear lock bolt 0.8～1.2kg-m
    Exhaust muffler joint lock nut 0.8～1.2kg-m
    Exhaust muffler hanger lock nut 2.4～3.0kg-m
    Rear fork pivot nut 5.5～6.5kg-m

    1
    5. ENGINE REMOVAL/INSTALLATION JETIX 125
    Carburetor bolt

    ENGINE REMOVAL
    Remove the carburetor. (Refer to 4-3.)
    Disconnect the right and left decorative
    covers under the seat.
    ＊ Drain the engine oil before
    engine removal.
     The exhaust muffler
    temperature is extremely high. Remove
    it when the engine is cold.

    Exhaust Muffler Joint


    Lock Nuts
    Remove the two exhaust muffler joint lock
    nuts.
    Remove the exhaust muffler hanger lock nut
    and rear fork pivot nut to remove the exhaust
    muffler.
    Remove the spark plug cap.

    Exhaust Muffler bolt


    Hanger Lock Nuts
    AC. Generator wire

    Disconnect the A.C. generator wire


    connector.
    Remove the two left rear crankcase cover
    attaching bolts and the cover.
    Remove the starter motor wire.

    Spark plug cap

    Loosen the rear axle nut and adjust the drive


    chain slack.

    2
    5. ENGINE REMOVAL/INSTALLATION JETIX 125

    Remove the gear shift lever bolt and gear


    shaft lever.
    Remove the two bolts attaching the left rear bolts
    crankcase cover and remove the rear
    crankcase cover.

    Remove the two bolts attaching the drive


    gear set plate and the set plate.
    Remove the drive gear and chain.
    Remove the engine hanger nuts and pull out Rear crankcase cover
    the engine hanger bolts.
    Remove the engine.
    Drive Chain Set Plate

    ENGINE INSTALLATION
    Install the engine in the reverse order of
    removal.
    Install the engine to its original position with
    a jack or other adjustable support.
    ＊ When installing the engine, do
    not damage the bolt threads and route
    the wires and cables properly. Bolts
     Install the gear shift pedal by Drive Gear
    aligning the punch mark on the pedal
    with that on the spindle.
     Fill the crankcase to the proper
    level with the recommended engine oil.
     After installation, perform the
    following inspections and adjustments:
    1. Throttle operation
    2. Clutch lever free play
    adjustment
    3. Drive chain adjustment

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