Brixton BX125 Manuale utente

Model BX125 Motorcycle

Service Manual

ROHENTWURF/ DRAFT

KS MOTORCYCLES - http://ksmotorcycles.com

Contents

Preface ............................................................................ 3

Service Data ........................................................................ 4

Inspection/Adjustment ............................................................... 17

Vehicle body Inspection and Maintenance.................................................... 32

I Braking System ....................................................................... 33

1.1 Maintenance Instructions .......................................................... 33

1.2 Fault Diagnosis.................................................................. 34

1.3 Front Hydraulic Brake ............................................................ 35

1.4 Rear Hydraulic Brake............................................................. 37

II Motorcycle Exteriors .................................................................. 39

III Front wheel/ front suspension ........................................................... 41

3.1 Service Data .................................................................... 41

3.2 Fault Diagnosis.................................................................. 42

3.3 Front wheel..................................................................... 43

3.4 Steering handlebar .......................................................... 45

3.5 Front fork ...................................................................... 46

IV Rear Wheel/Rear Suspension ........................................................... 50

4.1 Service Data .................................................................... 50

4.2 Fault Diagnosis.................................................................. 51

4.3 Rear Wheel..................................................................... 52

4.4 Rear Shock Absorber ............................................................. 52

4.5 Rear swing arm................................................................ 53

4.6 Drive Chain .................................................................... 54

V. Battery/Charging System ............................................................... 58

5.1 Service Data .................................................................... 58

5.2 Fault Diagnosis.................................................................. 59

5.4 Charging System ................................................................ 61

5.5 Voltage-current Regulator ......................................................... 62

5.6 Generator Charging and Lighting Coils ............................................... 63

5.8 Generator Removal .............................................................. 64

VI Ignition System .................................................................. 65

6.1 Service Data .................................................................... 65

6.2 Fault Diagnosis.................................................................. 66

6.3 Ignition System Inspection......................................................... 67

6.4 Ignition Coil .................................................................... 69

6.5 Trigger ........................................................................ 70

VII. Starting System................................................................. 70

7.1 Service Data .................................................................... 70

7.2 Fault Diagnosis.................................................................. 71

7.3 Starter Motor ................................................................... 71

7.4 Starter Relay.................................................................... 73

VIII. Bulbs/Switches/Instruments .......................................................... 75

8.1 Service Data .................................................................... 75

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8.2 Fault Diagnosis.................................................................. 75

8.3 Headlamp bulb replacement........................................................ 76

8.4 Replacement of the front .......................................................... 76

turn signal light..................................................................... 76

8.5 Replacement of taillight/license plate light/rear turn signal light............................ 76

8.6 Instrument...................................................................... 77

8.7 Main Switch .................................................................... 77

8.8 Electric Horn ................................................................... 78

8.9 Handle Switch .................................................................. 78

Inspection and Maintenance of Engine ...................................................... 79

IX Lubricating system ............................................................... - 81 -

9.1 Service Data ................................................................ - 81 -

9.2 Fault Diagnosis.............................................................. - 82 -

9.3 Engine Oil Pump ............................................................ - 83 -

Cylinder head ...................................................................... - 84 -

10.1 Service Data ............................................................... - 85 -

10.2 Fault Diagnosis............................................................. - 86 -

10.3 Cylinder Head ............................................................. - 86 -

XI Cylinder Block and Piston ......................................................... - 95 -

11.1 Service Data ............................................................... - 95 -

12.2 Fault Diagnosis............................................................. - 96 -

12.3 Cylinder Block ............................................................. - 96 -

XII Crankcase..................................................................... - 101 -

12.1 Service Data .............................................................. - 101 -

12.2 Fault Diagnosis............................................................ - 102 -

12.3 Crankcase ................................................................ - 103 -

12.4 Clutch ................................................................... - 104 -

12.5 Gearshift Mechanism ....................................................... - 110 -

13.6 Crankshaft Connecting Rod Assembly.......................................... - 111 -

13.7 Transmission chamber ...................................................... - 114 -

Exhaust System Inspection and Maintenance ............................................ - 117 -

XIII Exhaust control system.......................................................... - 117 -

13.1 Exhaust control system Guarantee ............................................. - 117 -

13.2 Periodical Maintenance Instructions ........................................... - 118 -

13.3 Mechanical Functions of Exhaust Control System................................. - 119 -

13.4 Catalytic Conversion System ................................................. - 120 -

Inspection and Maintenance of Electronic Fuel Injection System ............................. - 123 -

XIV. Electronic Fuel Injection System.................................................. - 125 -

14.1 Introduction to Electronic Fuel Injection System.............................. - 125 -

14.2 Parts of Electronic Fuel Injection System ....................................... - 125 -

14.3 Fault diagnosis method...................................................... - 134 -

14.4 Common Trouble Shooting Methods ........................................... - 141 -

14.4.3 Simple troubleshooting methods............................................. - 142 -

BX125 Circuit Diagram ............................................................. - 147 -

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Preface

The service manual contains descriptions of maintenance essentials on

BX125 motorcycle.

Service data include attentions that shall be paid on all the maintenance

operations in the service manual. Please read the manual carefully before

operation.

Check and adjustment contains statements on the main points of

inspection and adjustment, safety of the vehicle, maintenance means of

each component’s performance. This shall be implemented from the time

of periodical inspection.

The parts after Part 1 demonstrate disassembly, assembly and main points

of inspection of engine, finished motorcycle, engine and other

components.

System diagrams, disassembly drawings, maintenance, fault diagnosis

and explanations are presented before each part when compiled.

Notes:

If patterns or structures of the motorcycles change, or differences exist

between pictures, drawings, instructions or others and physical products,

please take the later as the standard. The product is subject to change

without further notice.

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Service Data

General Safety Maintenance Regulation

Specification Sheet Fault Diagnosis

General Safety

Carbon monoxide (CO)

When it is necessary to start the engine, please make sure the workplace is well ventilated. You

shall never run the engine in an enclosed place.

Attentions

Gas exhausted from the motorcycle contains toxic carbon monoxide, which may lead to loss of consciousness

and even death.

It is necessary to run the engine in an open area. If the engine is run in an enclosed site, ventilation

system shall be used.

Gasoline

Work in well-ventilated site. Fire and smoking are strictly forbidden in working sites or gasoline

storage places.

Battery

Battery electrolyte contains sulfuric acid, so do not let the eyes, skin, clothes infected with

electrolyte. Once the skin, clothes infected with electrolyte, thoroughly rinse with water; if

infected eyes, you should immediately go to hospital.

Special Tools

Correctly select the common tools and special tools when assembling or disassembling parts, and

the special tools shall not be alternated by common tools. In addition, the force should be

appropriate to avoid damaging parts.

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High-temperature Burn

Pay attention to your safety during maintenance. Carefully, do not be burnt by the ghi-temperature

engine, exhaust pipe, muffler and other hot parts. You should take care of each other in case of

cooperation with others.

Maintenance Regulations

While repairing and servicing, try to use tools of metric system as possible as you can. Incorrect

tools may damage the motorcycle.

Before take down or open protecting plate for maintenance work, please clean the dirt on external

surface of the component or the assembly to prevent the dirt from falling into the engine, chassis

or braking system.

After disassembly and before measuring friction, please clean

the components and purge with air compressor.

Do not bend or distort during operation to avoid difficult

operation or earlier damage.

Plastic parts may deteriorate due to aging, which are apt to be damaged by solvent or oil. Check

before re-installation and replace if necessary.

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While removing a component with many assemblies, do from

outside to inside. Loosen firstly smaller assemblies.

For the complicated assemblies, such as gearbox, keep them in

a proper assembling order for the sake of easy assembly later.

Pay special attention to the key fitting position before disassembly. The components that are not

used any more shall be replaced on time before disassembly.

Length of bolts and screws are different for assemblies and protecting

plates. They shall be installed at correct positions. If confused, just put

the bolt inside the hole and see if it matches.

Fill lubricating grease into the groove during oil seal

installation. Check if the oil seal is smooth and if it is

possible to be damaged when installed.

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Installation of rubber hose (fuel, vacuum, or coolant): insert its

end into bottom of connector so that there is enough room for the

hose clamp to grip the connector. Install the rubber or plastic

dustproof boot back to its originally designed position.

Disassembly of ball bearing: use a tool to push against one or

two (inner and external) bearing races. If the force works only

on one bearing race (whatever inner or external), the bearing

may be damaged when disassembled and it must be replaced.

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Specifications (BX125)

Model

BX125

Engine

Engine type

157FMI-C

Overall Length(mm)

2020

Fuel

93# unleaded gasoline

Overall Width(mm)

910

Number of

cylinders

Overall height(mm)

1105

Bore*stroke

57.3 mm *48.4 mm

Wheelbase(mm)

1320

Total

Displacement

124.8

Weight (kg)

Front

shaft

58kg

Starting mode

Electric

Rear

shaft

76kg

Cooling mode

Air cooling

Total

134kg

Lubricating

mode

Combined force splash

Tire

Spec.

Cover tire of the front wheel

100/90-18

Air cleaner

Paper - element

Cover tire of the rear wheel

120/80-17

Drive Train

Clutch type

Wet multi-plate

friction type

Fuel tank

capacity

14L

Gearshift

pattern

Manual

Performance

Max. speed

101 km/h

Climbing

capacity

Maximum climbing

angle should not be less

than 20 degrees

Transmission

Chain drive

Idle speed-rpm

1500± 100rpm/min

Electricals

Battery

capacity/type

12V-10AH/

lead-acid type

Max. torque

11.4N.m/7000r/min

Max. power

8.3KW/ 8500 r/min

Generator type

permanent magnet

AC motor

Compression

ratio

9.3:1

Spark plug

D8RTC

Spark plug

stroke

0.6-0.8mm

Brake

Diameter of

front brake

disc

φ276mm

Ignition type

ECU

Diameter of

rear brake disc

φ220mm

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BX125

KS MOTORCYCLES - http://ksmotorcycles.com

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