XQ125 XQ150 2001 5HT1-AE2 SERVICE MANUAL EASM0000 XQ125 / XQ150 SERVICE MANUAL © 2001 by MBK Industrie 2nd edition
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GN125F 99500H3030DE001 FOREWORD GROUP INDEX This manual contains an introductory description on the SUZUKI GN125F a
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HEAD OFFICE (FACTORY) #58, SUNG SAN-DONG, CHANGWON, KYUNGNAM, KOREA TEL : (82-55) 239-7000 / FAX : (82-55) 239-7524 OVER
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XQ125 / XQ150 SERVICE MANUAL © 2001 by MBK Industrie 2nd edition, April 2001 All rights reserved. Any reproduction or unauthorized use without the written permission of MBK Industrie is expressly prohibited.
NOTICE This manual was produced by the MBK Industrie primarily for use by Yamaha and MBK dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha and MBK vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use. MBK Industrie is continually striving to improve all of its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha and MBK dealers and will appear in future editions of this manual where applicable. NOTE: Designs and specifications are subject to change without notice. TECHNICAL DOCUMENTATION MBK INDUSTRIE
IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death to the scooter operator, a bystander or a person checking or repairing the scooter.
A CAUTION indicates special precautions that must be taken to avoid damage to the scooter.
A NOTE provides key information to make procedures easier or clearer.
HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. 햲 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each page indicate the current chapter. Refer to "SYMBOLS". 햳 Each chapter is divided into sections. The current section title is shown at the top of each page, except in Chapter 3 ("PERIODIC CHECKS AND ADJUSTMENTS"), where the sub-section title(s) appears. 햴 Sub-section titles appear in smaller print than the section title. 햵 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section. 햶 Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a disassembly step. 햷 Symbols indicate parts to be lubricated or replaced. Refer to "SYMBOLS". 햸 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc. 햹 Jobs requiring more information (such as special tools and technical data) are described sequentially.
CYLINDER AND PISTON
CYLINDER AND PISTON
CYLINDER AND PISTON 햳
REMOVING THE CYLINDER AND PISTON 1. Remove: • piston pin clip 햲 • piston pin 햳 • piston 햴 CAUTION: Do not use a hammer to drive the piston pin out.
NOTE: • Before removing the piston pin clip, cover the crankcase opening with a clean rag to prevent the piston pin clip from falling into the crankcase. • Before removing the piston pin, deburr the piston pin clip’s groove and the piston’s pin bore area. If both areas are deburred and the piston pin is still difficult to remove, remove it with the piston pin puller.
6 4 5 3
Piston pin puller 90890-0