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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)
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
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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 Front = 1.9 rear = 2.1 bar
pillion driver Front = 1.9 rear = 2.3 bar
Brakes, front: Hydraulic disc brake ø 316 mm four piston caliper
Minumim lining thickness 2,5 mm
Brakes, rear: Hydraulic disc brake ø 220 mm single piston floating caliper
Minumim lining thickness 1,5 mm
Electrical Equipment
Generator: Flywheel magneto, 12V, 100W at 5000rpm
Battery: 12 V 4 Ah MF
Fuse: 20 A
Lights:
- Headlight: Highbeam: H3 12 V 55W E1 / low beam H1 12V 55W E1
- Position light: 12 V 2W
- Brake/rear light: 12 V 5W / 21 W
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SACHS XTC 125 4-stroke
TECHNICAL DATA
Dimensions and weights
Overall length: 1970 mm
Width across handlebars
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
4
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
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SACHS XTC 125 4-stroke
1 2 3 4 5
6 7 8 9 10
11 12 13 14 15
16 17 18 19 20
21 22 23 24 25
26
6
SACHS XTC 125 4-stroke
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SACHS XTC 125 4-stroke
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SACHS XTC 125 4-stroke
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SACHS XTC 125 4-stroke
SERVICE DATA
10
SACHS XTC 125 4-stroke
SERVICE DATA
11
SACHS XTC 125 4-stroke
GENERAL NOTES
ATTENTION
Do not use compressed air to dry the bearings since
this could damage the surface of the bearings.
1
4 3
2
12
SACHS XTC 125 4-stroke
INSPECTION PLAN
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.
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.
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.
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.
15
SACHS XTC 125 4-stroke
Example:
Tappet clearance is 0.23 mm
Present shim size 1.70 mm
Shim size to be used 1.80 mm
Surfix no.
Present
Shim size
Measured tappet
mm
clearance mm
16
SACHS XTC 125 4-stroke
Example:
Tappet clearance is 0.33 mm
Present shim size 1.70 mm
Shim size to be used 1.80 mm
Surfix no.
Present
Measured tappet Shim size
mm
clearance mm
17
SACHS XTC 125 4-stroke
SPARK PLUG
NOTE
Before installation clean spark plug and spark plug
sealing faces.
Tightening torque 11 Nm
18
SACHS XTC 125 4-stroke
Air filter
�
�
�
�
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 -10˚ 0˚ 10˚ 20˚ 30˚ 40˚ 50˚C
Do not use additives. Since the oil also serves to
lubricate the clutch, do not use car engine oils
supplemented with friction modifiers (such energy- SAE 10W/30
conserving oils can lead to the clutch slipping). Use
a suitable, light engine oil for motorcycles, such as SAE 10W/40
Motorex SAE 10W/40 mineral oil API (SG or
higher).
If required, replenish the engine oil (for classification SAE 20W/40
and viscosity, see the table) via the oil filter opening.
Recommended viscosity:
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SACHS XTC 125 4-stroke
ENGINE OIL
Replace initally at 1.000 km
Replace every 4.000 km
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.
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SACHS XTC 125 4-stroke
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.
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.
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SACHS XTC 125 4-stroke
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SACHS XTC 125 4-stroke
1 2
CAUTION
The chain, chain wheel and pinion wheel must be
replaced collectively, i.e. not as individual parts. A
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
SACHS XTC 125 4-stroke
Brake system
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.
3
Checking the brake-fluid level:
- Turn the handlebar until the line near the "MIN"
mark on the brake-fluid tank (1) is horizontal.
2
- The brake-fluid level must be between the "MIN" 1
and "MAX" marks.
- If air bubbles are visible: check the brake lining for
wear and replenish the brake fluid as necessary.
25
SACHS XTC 125 4-stroke
NOTE
Cover painted parts is in order to avoid paint dama-
ge.
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 1
replenish the brake fluid as necessary. 2
Replenishing the brake fluid:
- Make sure the motorcycle is level (so that the line 3
near the "MIN" mark on the brake-fluid tank (3) is
level). SFM 675 012.3
- 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).
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SACHS XTC 125 4-stroke
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SACHS XTC 125 4-stroke
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SACHS XTC 125 4-stroke
CAUTION
Brake fluid can damage paint and plastic parts!
Use only brake fluid of specification DOT 4.
1
2
A 3
SFM 675 018.3-1
Min.
grease it as necessary.
Adjusting the footbrake lever position:
3
2
NOTE
Use the adjusting screw (3) to adjust the footbrake
lever position as desired by the client. A
WARNING
The adjustment dimension (A) may not exceed 18
mm.
1 SFM 675 019.3
- 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).
29
SACHS XTC 125 4-stroke
Fork-column bearing
NOTE 1
While the front wheel is raised, the fork must fall lightly to the
left or right until it hits the stop.
1
WARNING - RISK OF ON-ROAD ACCIDENT
If while moving the handlebar to and fro it locks in
3
some position/s, then the fork-column bearing must be SFM 675 022.3-1
replaced.
30
SACHS XTC 125 4-stroke
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 discon-
nected 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 maintenance-
free. Do not try to open it.
31
SACHS XTC 125 4-stroke
Fuel tank
Removing/installing the fuel tank 4
Removing the fuel tank:
1. Removing the seat. 3
2. Close the fuel cock (1), loosen the hose clamp
and pull off the fuel hose (2). 3
3. Remove the screw (3), washers and support
rings.
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 dama-
ge the paint.
1
2
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SACHS XTC 125 4-stroke
6. Install the gasket (7), the seat (6) and the preas-
sembled tank filler neck (2); fasten with the screws
(1).
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SACHS XTC 125 4-stroke
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SACHS XTC 125 4-stroke
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SACHS XTC 125 4-stroke
Footrests
Removing/installing the front-right footrest
footbrake unit
16 15
Removing the front-right footrest/footbrake unit:
1. Remove the nut (1) with washer (2) and take out
12
the ball-and-socket joint (3) of the brake cylinder. 14
2. Remove the screw (4) with washer (5), and remove 13
the footrest (16) and footbrake lever (8) and sliding
bush (7) from the footrest support (6).
11
NOTE
10 1
The rubber support (9) of the footbrake lever (8) can 2 3
be replaced.
3. Remove the pin (15) and remove the washer (14)
and spring (13). 7
4. Remove the bolt (10) with washer (11) and remove
the footrest (16) from the seat (12) of the brake
9
lever (8). 8
Installing the front-right footrest/footbrake unit:
NOTE 6
In principle, use a new pin (15). 5
5. Reassemble in reverse order. 4
36
SACHS XTC 125 4-stroke
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SACHS XTC 125 4-stroke
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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).
38
SACHS XTC 125 4-stroke
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39
SACHS XTC 125 4-stroke
12cm
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 H
the wall with a cross. Draw a second cross 12 cm
underneath the first cross.
- Start the motorcycle and allow the engine to run. 5m
H
40
SACHS XTC 125 4-stroke
Checking the tyre profile and pressure Checking the rear-wheel telescopic leg for opera-
tion and leaks
Checking the tyre profile:
- Firmly push down on the rear of the motorcycle
WARNING - RISK OF ON-ROAD ACCIDENT several times. The rear-wheel telescopic leg must
Observe the legally prescribed minimum-profile move in and out evenly without deformation.
depth. - Check the rear-wheel telescopic leg for leaks, and
the springs and fastening points for damage.
- Measure the profile depth.
Recommended minimum profile depth:
2.5 mm Checking the control cables for damage and smooth
operation
- If the profile depth is less than the minimum, replace
the tyre. - Check the choke, throttle and clutch cables for da-
mage and smooth operation. Damaged or obstructed
Check the tyre pressure: cables must be replaced.
Air pressure solo with passenger - Adjust the cables.
- Check the wheels for any damage; replace if neces- Checking/repairing the exhaust system
sary.
- Check exhaust manifolds, silencers and gaskets for
- Requirements for the check: the column top bea- leaks; replace any faulty parts.
ring, rear-wheel swing bearings, shock absorbers - Check rubber bearings for damage; replace, if ne-
and tyres should be in order. Take a test ride. If the cessary.
wheels/chassis do/does not move smoothly, align the
wheels and check for wobble and height damage. - Tighten nuts and screws.
Tightening torques:
Exhaust manifold cylinders: 15 Nm
End silencer fastening: 10 Nm
Checking the wheel bearings for play and damage Exhaust fastening (rubber bearing): 20 Nm
- Put the motorcycle on its standard, then check the
wheel bearings by pushing the wheel to and fro Checking the rear-wheel vibration bearing
to check for play. The bearings should not have a
noticeable play; if play is noticeable, the bearings - Check the rear-wheel swing bearing for smooth
must be replaced. operation and wear; if necessary, replace the swing
bearing.
- Rotate the wheel by hand.
The wheel bearings should run evenly rather than Final inspection
roughly. Wheel bearings which run roughly must
be replaced. - 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.
41
SACHS XTC 125 4-stroke
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42
SACHS XTC 125 4-stroke
ENGINE DISASSEMBLY
The procedure for engine disassembly is sequentially
explained in the following steps.
43
SACHS XTC 125 4-stroke
44
SACHS XTC 125 4-stroke
45
SACHS XTC 125 4-stroke
46
SACHS XTC 125 4-stroke
47
SACHS XTC 125 4-stroke
CAUTION
The nut (1) has a lefthand thread. Turning
anticlockwise may cause damage.
48
SACHS XTC 125 4-stroke
49
SACHS XTC 125 4-stroke
50
SACHS XTC 125 4-stroke
51
SACHS XTC 125 4-stroke
CAUTION
The removed oil seal should be replaced with a
new one.
- Remove the washer (2).
CAUTION
The removed bearing should be replaced with a
new one.
52
SACHS XTC 125 4-stroke
CAUTION
The removed bearing should be replaced with a
new one.
CAUTION
The removed bearing should be replaced with a
new one.
53
SACHS XTC 125 4-stroke
CAUTION
The removed bearing should be replaced with a
now one.
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
CAUTION
The removed bearing should be replaced with a
new one.
CAUTION
The removed bearing should be replaced with a
now one.
CAUTION
The removed bearing should be replaced with a
new one.
55
SACHS XTC 125 4-stroke
CYLINDER HEAD
DISASSEMBLY
- Remove the intake pipe (1).
CAUTION
The removed 0-ring (2) should be replaced with a
new one.
56
SACHS XTC 125 4-stroke
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.
57
SACHS XTC 125 4-stroke
Tool:
Magnetic stand
Dial gauge (1/100 mm)
V-block set (100 mm)
Tool:
Magnetic stand
Dial gauge (1/100 mm)
V-block set (100 mm)
Tool:
Magnetic stand
Dial gauge (1/100 mm)
Service Limit
Intake and exhaust valves: 0.35 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
NOTE
Discard the removed valve guide subassemblies.
Only oversized valve guides are available as
replacement parts.
NOTE
Insert the reamer from the combustion chamber side
and always turn the reamer handle clockwise.
59
SACHS XTC 125 4-stroke
Standard
Valve seat width (w): 0.9-1.1 mm
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.
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
SACHS XTC 125 4-stroke
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.
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.
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).
CAUTION
Do not reuse the valve stem seals.
CAUTION
When inserting each valve, take care not to
damage the lip of the stem seal.
Towards
Head
62
SACHS XTC 125 4-stroke
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
NOTE
Install each camshaft journal holder to its original
position. Tighten the camshaft journal holder bolts
evenly and diagonally to the specified torque.
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
Standard
Camshaft journal holder I.D. (IN & EX):
22.012-22.025 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.
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.
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.
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.
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
Piston ring-groove clearance
1st: 0.18 mm
2nd: 0.15 mm
NOTE
Remove any carbon from the piston crown and ring
grooves using soft-metal scraper.
66
SACHS XTC 125 4-stroke
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
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.
Service Limit
Piston pin bore: 15.030 mm
Piston pin O.D.: 14.980 mm
67
SACHS XTC 125 4-stroke
68
SACHS XTC 125 4-stroke
Standard: 0.10-0.45 mm
Service Limit: 1.00 mm
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.
REASSEMBLY
- When rebuilding the crankshaft, the width between
the webs should be within the standard range.
69
SACHS XTC 125 4-stroke
1 Balancer shaft
2 Key
3 Driven gear set
DISASSEMBLY
- Remove the crankshaft driven gears.
70
SACHS XTC 125 4-stroke
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.
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
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.
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.
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
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.
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.
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.
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
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
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.
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
�
1 Kick starter shaft
2 Kick starter
3 Spring �
4 Spring
�
5 Spring guide
6 Kick starter drive gear
78
SACHS XTC 125 4-stroke
- 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.
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.
CAUTION
Use a new O-ring (1).
80
SACHS XTC 125 4-stroke
OIL JET
- Install the oil jet.
- 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.
NOTE
The primary drive gear nut (7) has left-hand threads.
1 Gearshift shaft �
2 Return spring
�
3 Gearshift cam plate
4 Gearshift arm
5 Spring
ITEM Nm
A 19
B 10
C 10
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82
SACHS XTC 125 4-stroke
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.
83
SACHS XTC 125 4-stroke
CLUTCH
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1 Clutch pressure plate
2 Clutch release bearing
3 Clutch release rack
4 Clutch drive plate
5 Clutch driven plate
6 Damper
7 Clutch sleeve hub
8 Primary driven gear
�
NOTE
Apply engine oil to the inside and outside surfaces of
the spacer.
NOTE
When engaging the primary drive and driven
gears, turn the primary driven gear assembly
counterclockwise.
84
SACHS XTC 125 4-stroke
CAUTION
Install the lock washer so that its tongue (2) is
aligned with the flat portion of the clutch sleeve
hub.
CAUTION
When installing the drive plate, make sure that
the damper (4 pcs) protrusions face towards the
bottom.
NOTE.
Face the bearing side of the clutch release bearing
(6) towards the clutch release rack.
NOTE
Make sure that the clutch pressure plate is installed
correctly.
85
SACHS XTC 125 4-stroke
86
SACHS XTC 125 4-stroke
CAUTION
When installing the spacer, be careful not to
allow its two ends to overlap into the piston ring
groove. INCORRECT
CORRECT
2nd
1st ring
TOP
2nd ring
1st ring
IN. Spacer
87
SACHS XTC 125 4-stroke
CAUTION
Use a new piston pin circlip (1) to prevent circlip
failure.
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.
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.
NOTE
Apply engine oil to the cylinder head bolts, washers
before installing the cylinder head bolts.
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.
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.
89
SACHS XTC 125 4-stroke
- With the "T" line (A) aligned with the index mark NOTE
(B), hold the camshaft steady and lightly pull up The cam chain should now be on all three sprockets.
the cam chain to remove any slack between the
cam chain drive sprocket and exhaust camshaft CAUTION
sprocket. Be careful not to move the crankshaft until the
- The exhaust camshaft sprocket has an arrow camshaft journal holders and cam chain tension
marked "1" (1). adjuster are secured.
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.
90
SACHS XTC 125 4-stroke
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.
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.
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
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.
CAUTION
Replace the gaskets with new ones to prevent oil
leakage.
92
SACHS XTC 125 4-stroke
GENERATOR COVER
93
SACHS XTC 125 4-stroke
94
SACHS XTC 125 4-stroke
CARBURETOR SPECIFICATIONS
ITEM SPECIFICATION
Carburetor type MIKUNI BS 26
Bore size 26 mm
I.D. No 47E3
Idle r/min 1450-1550 r/min.
Float height 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
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
LOWER POSITION OF THE PISTON VALVE UPPER POSITION OF THE PISTON VALVE
NEGATIVE PRESSURE
1 Piston valve
2 Diaphragm chamber
3 Orifice
4 Spring
A 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.
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.
98
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
FUEL
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.
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).
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).
DISASSEMBLY
- Remove the carburetor top cap (1).
100
SACHS XTC 125 4-stroke
CAUTION
Dot not use a wire to clean the valve seat.
CAUTION
Dot not use a wire to clean the passages and
jets.
101
SACHS XTC 125 4-stroke
- Remove the pilot air jet (3) and main air jet (4).
NOTE
Before removing the pilot screw (5), its setting must
be determined. Slowly turn the pilot air screw clock-
wise 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.
CAUTION
These two screws (7) are locked by notches at the 7
end of the screws. After being unscrewed they are
damaged. When reinstalling the throttle valve ap-
ply THREAD LOCK 1342 to both these screws.
102
SACHS XTC 125 4-stroke
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.
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.
Conrod small Cam face tappet Cam face tappet Cylinder head
end
Oil filter
Countershaft
left side
bearing
Oil cooler
Oil pan
104
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.
NOTE
The spare fuse (2) is on the front side of the relay.
105
SACHS XTC 125 4-stroke
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
SACHS XTC 125 4-stroke
The steps described below must be strictly observed in order to guarantee the long lifespan of the battery.
Work steps:
container with
electrolyte
air bub-
bles
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
Now check the battery voltage using a volt meter; if the voltage is lower than 12.5 volt, the battery must be re-
charged 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
1 Brush holder
2 Brush
3 O-ring
4 Starter motor case
5 Armature
6 O-ring
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.
CAUTION
Replace the O-rings with new ones to prevent oil
leakage and moisture.
111
SACHS XTC 125 4-stroke
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 con-
nected 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 revo-
lutions).
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.
DC-DC
convertor
Ignition power
sorce circuit
Battery
Ignition coil
Sensor input
circuit CPU
Tachometer
Pick-up coil output circuit
Spark plug
CDI unit
Tachometer
Generator
113
SACHS XTC 125 4-stroke
TROUBLE SHOOTING
Correct
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.
CAUTION
When using the electro tester, follow the instruc-
tion manual.
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
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
117
SACHS XTC 125 4-stroke
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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!
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
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CAUTION
Be careful during removal and installation not to damage the brake disks or linings! Do not operate the hand-
brake lever after a wheel has been r emoved! Protect the wheel bearings from dirt and moisture!
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.
119
SACHS XTC 125 4-stroke
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.
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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NOTE
Always start with the smallest alignment weight.
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120
SACHS XTC 125 4-stroke
Telescopic fork
� �
Removing/installing the telescopic fork ��
�
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.
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.
121
SACHS XTC 125 4-stroke
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.
CAUTION
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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122
SACHS XTC 125 4-stroke
NOTE
The upper fork bridge must be easy to slide onto the
stand pipes.
CAUTION
Bent stand pipes may not be realigned.
123
SACHS XTC 125 4-stroke
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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): 40 Nm Telescopic fork oil: SAE 10 W
Tightening torque for screws (6d): 40 Nm Qty. for filling each form pipe: 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 fas-
tening 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 Closure screw 6b Guide piece 8b Dust collar
2 O-ring 6c Sealing ring 8c Securing ring
3 Spacer bush 6d Fastening screw for 8d Radial packing ring
4 Spring plate absorber pipe 8e Intermediate ring
5 Pressure spring 7 Stand pipe 8f Slide bush for sliding pipe
6 Absorber pipe set 8 Sealing set for sliding pipe 9 Sliding pipe
6a Absorber pipe 8a Sliding bush for stand pipe A Impact mandrel
124
SACHS XTC 125 4-stroke
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125
SACHS XTC 125 4-stroke
NOTE
Grease the fork column bearing with wheel-bearing
grease.
9. Install the telescopic fork..
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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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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 rear-
wheel swing (1) in a rearwards direction.
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SACHS XTC 125 4-stroke
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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
CAUTION
The brake fluid can cause damage to the painted
and plastic parts!
Use only new brake fluid of specification DOT 4.
129
SACHS XTC 125 4-stroke
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).
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SACHS XTC 125 4-stroke
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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.
INSTALLATION NOTE
The condensation outlets (15) on the rubber covers (2) must point downwards.
132
SACHS XTC 125 4-stroke
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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.
5. Remove the nuts (7) with the washers (8) and remove the rear reflector (9).
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SACHS XTC 125 4-stroke
Direction indicators
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Removing/installing the direction indicators: �
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.
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SACHS XTC 125 4-stroke
Troubleshooting
Engine
Complaint Symptom and possible causes Remedy
Engine will not start Compression too low
or is hard to start. 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
135
SACHS XTC 125 4-stroke
Engine
Complaint Symptom and possible causes Remedy
Engine is noisy Noise seems to come from the piston
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
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 slips Clutch cable out of adjustment Adjust
Weak or broken clutch spring Replace
Worn or distorted clutch pressure plate Replace
Distorted clutch plate Replace
Clutch drags Clutch out of adjustment Adjust
Some clutch springs are weak, while others are not Replace
Worn or distorted clutch pressure plate Replace
Distorted clutch plate Replace
Transmission will Broken gearshift cam Replace
not shift Distorted gearshift fork Replace
Worn gearshift fork pawl Replace gearshift fork
Transmission will Broken gearshift shaft return spring Replace
not shift back Rubbing or stuck gearshift shaft Repair or replace
Worn or distorted gearshift fork Replace
136
SACHS XTC 125 4-stroke
Engine
Complaint Symptom and possible causes Remedy
Transmission jumps Worn gear Replace
out of gear Worn or distorted gearshift fork Replace
Weakened gearshift stopper spring Replace
Worn gearshift fork pawl Replace gearshift fork
Exhaust smoke is Excessive amount of engine oil Check level and drain
dirty or thick 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 Insufficient tappet clearance Adjust
power 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
Engine Carbon build-up on piston crown Clean
overheats 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
Carburetor
Starting difficulty Clogged starter jet Clean
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 Clean or tighten
trouble Clogged or loose pilot air jet 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
Medium-or high Clogged main jet Clean
speed trouble 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 Replace
fuel Broken needle valve spring Replace
level fluctuations
Improperly working float Adjust or replace
Foreign matter an the needle valve Clean or replace with needle valve seat
Incorrect float chamber fuel level Adjust float height
138
SACHS XTC 125 4-stroke
Elektric
Complaint Symptom and possible causes Remedy
No sparking or poor Defective ignition coil Replace
sparking Defective spark plug Replace
Defective pick-up coil Replace
Defective CDI unit Replace
Spark plug is wet or Excessively rich air/fuel mixture adjust carburetor
quickly becomes Excessively high idling speed Adjust carburetor
fouled with carbon
Incorrect gasoline Change
Dirty air cleaner element clean or replace
Incorrect spark plug (cold type) Change to hot type spark plug
Spark plug quickly Worn piston ring Replace
becomes fouled with Worn piston Replace
oil or carbon
Worn cylinder Rebore or replace
Excessive valve-stem-to-valve-guide Replace
clearance
Worn valve stem oil seal Replace
Spark plug electrodes Incorrect spark plug (hot type) Change to cold type spark plug
overheat or burn Overheated engine Tune-up
Loose spark plug Tighten
Excessively lean air/fuel mixture Adjust carburertor
Generator does not Open or short in lead wires, or loose lead Repair, replace or connect properly
charge connections
Shorted, grounded or open stator coil Replace
Shorted or punctured regulator/rectifier Replace
Generator charges Lead wires tend to get shorted or open- Repair or tighten
but charging rate is circuited or loosely connected at terminal
below the Grounded or open-circuited stator coils or Replace
specifications generator
Defective regulator/rectifier Replace
Defective battery cell plates Replace battery
Generator overcharges Internal short-circuit in the battery Replace battery
Damaged or defective regulatror/rectifier Replace
Poorly grounded regulator/rectifier Clean and tighten ground connection
Unstable charging Lead wire insulation frayed due to vibration Repair or replace
resulting in intermittent shorting
Internally shorted generator Replace
defective regulator/rectifier Replace
Starter button does Run down battery Recharge or replace
not work Defective switch contact Replace
Brushes do not seat properly on the Repair or replace
commutator in the starter motor.
Defective starter relay Replace
139
SACHS XTC 125 4-stroke
Battery
Complaint Symptom and possible causes Remedy
140
SACHS XTC 125 4-stroke
WIRING DIAGRAM
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SACHS XTC 125 4-stroke
142