Scooter Service and Maintenance Manual

ARN125/150

Copyright: K E E WAY I N T E R N AT I O N A L D E V E L O P M E N T C O . , LT D . FEB.2006

If you have any problems can not fnd the solution in this manual, please fell free to contact with:

KEEWAY INTERNATIONAL DEVELOPMENT CO.,LTD 2000 SZENTENDRE U.8 KOZUZO. HUNGARY TEL:0036-26-500005 FAX:0036-26-312034 EMAI: info@keewaymotor.com

Our engineer are very glad to give you the necessary assistance and help.

CONTENTS
Perface A General knowledge 1. 2. 3. 4. Basic term-----engine Engine type4 STROKE ENGINEWORK CYCLES/ILLUSTRATIONS. Safety for repair shop Electric safety

B PRODUCT 1. Technical parameter 2. Special service tools 3. Engine and transmission system a) Specified torque volume b) Small but vital parts c) Non-directional accessory-engine part d) Engine removal and installation e) ------ Cowling assembly ------Cylinder head assembly -------Sub-cylinder shaft retainer assembly ----- Piston assembly ------Left crankcase cover assembly ---------Right crankcase cover assembly --------Right crankcase ---Left crankcase parts assembly ----Crankcase assembly ----Transmission case ----Driven wheel disc clutch assembly ---- Kick starter shaft subassembly, transition gear shaft subassembly installation ---Driver wheel disc part assembly ---Exceeding clutch assembly f) ---Power transfer chart g) Lubricating system h) Engine valve clearance setting i) Cyliner pressure testing j) Important standard dimension----engine 4. Oil----fuel system --- Carburetor ----Carburetor removal/installation/adjustment 5. Scooter body installation 6. Fixing torque---scooter body part a) Front wheel assy.
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b) Rear wheel assy. c) Muffler assy. d) Front fork assy. e) Front shock absorber assy. f) Disc brake system g) Points for motorcycle installation h) Important dimension for scooter body 6 Electric work/electric a) Magneto b) Circuit diagram c) Electronic ignition part test d) Battery charge circuit and testing process for battery charge e) Signal system circuit diagram f) Various bulbs removal and installation g) Inspection process for electronic accessories h) Main electric accessories specification i) Important electric parameters C else 7. Inspection/inspection points before using 8. Periodical service 9. Permission and forbiddance 10. Safe driving 11. Fault inspection

A GENERAL INFORMATION

1 BASIC TERMS OF ENGINE A. DEAD CENTER

DEAD CENTER IS THE TWO LIMITED POINTS, WHERE PISTON MOVES UP AND DOWN IN LINE. TOP DEAD CENTERWHICH IS FARTHEST AWAY FROM THE ROTATION CENTER OF CRANKSHAFT. BOTTOM DEAD CENTERWHICH IS NEAREST AWAY FROM THE ROTATION CENTER OF CRANKSHAFT. B. CYLINDER DIAMETER INNDRE DIAMETER OF CYLINDER IS CALLED CYLINDER DIAMETER. C. JOURNEY JOURNEY IS THE DISTANCE THAT PISTON TRAVELS. WE USUALLY CALL ONE JOURNEY FROM TOP DEAD CENTER TO BOTTOM DEAD CENTER. D. WORKING CAPACITY OF THE CYLINDER THE SPACE VOLUME OF PISTON WORKING PATH, WHICH PISTON MOVES FROM TOP DEAD CENTER TO BOTTOM DEAD CENTER IS CALLED WORKING CAPACITY OF CYLINDER. USUALLY THE UNIT OF CYLINDER WORKING VOLUME IS CC(CM), SUCH AS 75CC, 125CC, WHICH IS DIFFERENT FOR WITH DIFFERENT ENGINE MODEL. E. TORQUE TORQUE IS THE FORCE OF WHIRLING OR ROTATING. WHEN WE LOOSEN OR SCREW NUTS/ SCREWS, WE HAVE PUT TORQUE ON IT. IN ORDER TO DRIVE THE WHEELS, THE ENGINE PUT TORQUE, WHICH MAY STRENGTHEN LARGER FORCE ON WHEELS WHEN CLIMBING SLOPE. THE TORQUE IS EQUAL THAT THE FORCE MULTIPLIES THE
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ARM OF FORCE. THE UNIT OF TORQUE IS KILOGRAM POWER-METER.

F. IGNITION TIMING IN ORDER TO CONTROL THE BURNING OF FIRE CHAMBER,, IGNITION IS TIMING. THE IGNITION TIMING OF ENGINE QJ162FMJ CHANGES AS FOLLOW: WHEN F IS 1400RMP, TOP DEAD CENTER ADVANCES 15.. WHEN II IS 4000RMP, THE TOP DEAD CENTER ADVANCES 35.

ENGINE CYCLE ANY FOUR-STROKE GASOLINE ENGINE HAS FOUR STROKES, WHICH CONSIST OF ONE WHOLE OF CYCLE. 1.INLET: AIR AND MIXTURED AIR OF OIL ARE ABSORBED INTO INLET CYLINDER. 2.COMPRESSION: MIXTURED AIR IS COMPRESSED IN THE CYLINDER. 3.POWER: WHEN IGNITING ENGINE, GAS BURNS AND EXPANDS, AND PUSH THE PISTON MOVING DOWN, CONNECTING ROD DIRVES ALONG CRANKSHAFT AND OUTPUT MECHANICAL

ENERGY. 4.EXHAUST: THE EXPELLED FROM CYLINDER.

EXHAUST

GAS

IS

24-STROKE ENGINE CYCLE

AINLET STROKE 1CRANKSHAFT TURNS ANTICLOCKWISE. 2CRANKSHAFT BRINGS ALONG PISTON TO MOVE THROUGH CONNECTING ROD. 3WHEN PISTON TRAVES FROM TOP DEAD CENTER TO BOTTOM DEAD CENTER, INLET PORT OPENS, MIXED GAS GOES INTO CYLINDER. B. COMPRESSION STROKE 1. CRANKSHAFT REVOLVES CONTINUALLY, BRING ALONG THE PISTON TO MOVE FROM TOP DEAD CENTER TO BOTTOM DEAD CENTER THROUGH CONNECTING ROD. 2. MIXTURE AIR IS COMPRESSED INTO A NARROW SPACE BETWEEN CYLINDER HEAD AND PISTON HEAD, WHICH IS CALLED BURNING CHAMBER. C POWER STROKE 1. SPARK PLUG INNITES COMPRESSED MIXED GAS OF AIR AND FUEL. 2. Burning of mixed gas of air and fuel results in sudden change of temperature and pressure in Burning chamber, and then burning gas expands, the power acted on piston push piston to move down. The power acted on piston transfers to crankshaft through connecting rod, which leads that crankshaft moves more fastly. Expansion of burning mixed gas provides enough power. D: EXHAUST STROKE b) When burning gas pushes piston continually to bottom, exhaust port opens. c) For inertia crankshaft push piston to Move toward cyliner head. d) As piston moves toward cylinder head, burning gas is excelled from exhaust port. When piston travels to top end, exhaust port is shut off.

3 SERVICE WORK SHOP SAFETY WARNING

Dont use the tool, which is damaged or easy to be emerged, that may hurt you.

WARNING There is vitriol in storage battery, please protect your eyes, skin and clothes. If touching vitriol inadvertently, please wash it with water and see doctor. WARNING Keep close privity with your colleague to ensure safety. WARNING Please never touch brake fluid with your eyes, otherwise wash it with water and see doctor. Never touch brake fluid with hands for some long time. Never splash brake fluid on the surfaces of oil pait parts and rubber accessories. Never use superfluous fluid, which is exposed in air, remaining fluid has absorbed moisture from air, which may damage its speciality.

WARNING Gasoline is flammable, and may explode in some condition. Please never get it near smoke or spark. WARNING Please often keep ground tidy and clear. Never leak fuel on ground to avoid skidding and damage. WARNING Never totate engine in close or bad ventilated room, for exhaust contains poison gas. WARNING Please never clean brake hub, brake shoe and so on with dry brush or compressed air to avoid inhaling asbestos fibre, which may results in cancer or other breath system disease.

SERVICE RULES 1. Please use QianJiang genuine parts, and use recommended lubricant in pointed place. 2. Use special or universal tools. 3. When reassembling, use new sealed washer, O-ring, oil seal, clip, cottern pin etc. 4. Use metric bolt and nut. 5. When assembling bolt and nut, firstly tighten big diameter or central bolt and nut. Secondly tighten bolt and nut with diagonal. 6. After assembly, check bolts and nuts tightening degree with torque wrench check if parts can move freely. 7. Before measuring, oil and dirt should be removed; when assembly, make parts lubricated by lubrication. 8. When parts are removed and need be reserved for a long time, please smear some lubrication on the surface so that it is rusted and with dust deposition.

4. ELECTRIC SAFETY
a) The relaxation of calbe is hidden trouble; so remember to clamp each calbe to ensure safety. b) Dont bend cable nip toward welding point. c) Band cable on oppointed position. d) Never lay cable in the bottom of frame or in needle angle position. e) Never lay calbe in the end of bolts or nuts. f) Keep calbe away from hot source part or some position where calbe may be clipped when moving. g) Lay cable along handlebar, dont pull it too tight or too loose, and never terrer with other parts when ratoating in any position. h) Lay calbe smooth, never distort or tie it. i) Before connecting joint, inspect if joint is damaged and joint is stretched. j) If calbe is layed in needle angle or turning position, protect calbe with adhesive tape or tube. k) After repairing, band up it with adhesive tape. l) Never keep contolling calbe bended or distorted. If controlling calbe is damaged, you may lose stable.

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B PRODUCT

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1. SPECIAL TOOLS LIST

NECESSARY TOOLS TO DISASSEMBLE AND INSTALL MOTORCYCLE ENGINE AS FOLLOWS

CODE

TOOLS CODE

PURPOSE

1 2 3 4 5 6 7 8 9

T01 T02 T03 T04 T05 T06 T07 T08 T09

TSHAPE GUIE CYLINDER GUIDE CYLINDER TOOLS8,10,12,13 SCREWED ROD FOR FLY WHEEL DISASSEMBLAGE TOOLS TO DISASSEMBLE VALVE SPRING DISASSEMBLING TOOLS FOR OIL DRAINAGE CYLINDER PRESSURE GAUGE DISASSEMBLING TOOL FOR PISTON PIN SOCKET FOR DISMOUNTING SPARK PLUGS ELECTRIC TOOL FOR DISASSEMBLING LOCKING BOLT OF FLY WHEEL

10 11 12

T10 T11 T12

CULTCH CLAMP DISASSEMBLING SCREW TOOL GUIDE CYLINDER (17,18)

12

1 2

3 4

5 6

13

7 8

9 10

11 12

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3 ENGINE AND TRANSIMISSION SYSTEM (A SPECIAL TORQUE)

The following table liss torques of some locking accessories/fixers, which you can refer to in assembly. NO. 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 27 28 29 30 31 32 33 34 35 36 37 38 39 40 NA ME Tapping screw for fan snail cover assy. Lucknut for fan snail cover assy. Tapping screw for up and down guide air cover Lucknut for up and down guide air cover Tapping screw and nut for ventilating air chamber of cylinder head covr Locknut for cylinder head cover Locknut for double head blot on cam fixing holder Locknut for atmolysis chain pulling rod Lucknut for atmolysis chain adjustor Lucknut for cylinder head Locknut for cylinder observing oil read Spark plug Double head bolt for cylinder head inlet port Double head bolt ofr cylinder head exhaust port Lucknut for carburetor joint Lucknut for cooling impeller of fan Locknut for flywheel Locknut for magnet stator coil Locknut for magnet motor trigger Locknut for right crankcase cover Oil filter cover cap Locknut for oil pump seperating board Locknut for oil pump sprocket Locknut for oil pump Locknut for oil pump cover Locknut for super-clutch Locknut for super clutch outside Locknut for right crankcase Double head bolt for left and right crankcase Fixing bolt for motro Locknut for left crankcase cover and line coil Tapping screw for ventilating guide board of left crankcase cover Locknut for driver disc Locknut for driven disc Locknut for driven disc clutch Locknut for press-board of kick starter Locknut for transmission case cover Locknut for flowing oil hole of transmission case Locknut for flowing oil hole of left crank. Locknut for position shaft of left crank QTY 2 2 3 1 3 4 4 1 2 2 1 1 2 2 2 4 1 2 2 9 1 2 1 2 1 1 3 2 4 2 11 4 1 1 1 1 5 2 1 1 TORQUE 1-3NM 10-12NM 1-3NM 10-12NM 1-3NM 10-12NM 22-25NM 10-12NM 10-12NM 10-12NM 10-12NM 10-15 NM 10-12NM 10-12NM 10-12NM 10-12NM 45-55NM 6-8NM 10-12NM 10-12NM 55-60NM 10-12NM 8-10NM 10-12NM 1-3NM 35-40NM 10-12NM 10-12NM 22-25NM 10-12NM 10-12NM 3-6NM 45-55NM 45-55NM 55-60NM 10-12NM 10-12NM 22-25NM 40-45NM 15 22-25NM

b . I M P O R TA N T PA R T S
The following is detail information of vital position pin, O-ring, bearing, pin shaft and gasket of ENGINE/UNDERPAN: POSITION PIN-14NOS.

S.NO. 1 2 3 4 5 6 7

Size (mm) 10x16 10x16 10x16 10x16 8x14 10x16 8x14

Qty. 2 2 2 2 2 2 2

Description Camshaft fixing seat and cylinder head

Cylinder head and cylinder head

Location Engine Engine Engine Engine Engine Engine Engine

Crankcase and cylinder body

Left and right crankcase

Left crankcase and gearbox Left crankcase and left cover Rignt crankcase and right cover O-ring-7NOS. Description Inlet and exhast valve pipe Atmolysis chain pulling lever Atmolysis chain adjustor Oil gauge Filter spring cap Starting moto Oil seal- 4NOS.

S.NO. 1 2 3 4 5 6

Size (mm) 9x1.6 13.7x1.5 9.5x1.5 18x3 30x3 26502470

Qty. 2 1 1 1 1 1

Location Engine Engine Engine Engine Engine Engine

S.NO. 1 2 3 4

Size (mm) 27x42x7 20x32x6 19.8x30x7 19.8x30x7

Qty. 1 1 1 1

Description
Output shaft---gearbox cover Output shaftleft crankcase Crankleft crankcase Crankright cover

Location Engine Engine Engine Engine

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BEARING- 13NOS S.NO. 1 2 3 4 5 6 7 8 8 9 10 11 12 S.NO. 1 2 S.NO. 1 2 3 4 5 6 7 Code

6004 6201 6301 6203 6202 6204 TM-SCO7A87 TM-SCD5ASSCS12 K28x33x14 K28x32x17 6902NSE28 x15x7 HK20 x29x18RS 6002

Qty. 1 1 1 1 1 1 1 1 1 1 1 1 2 Qty. 1 1 Type

Description
Output shaftgearbox cover Middle shaftgearbox cover Output shaftgearbox cover Output shaftleft case Middle shaftleft case Output shaftleft case Left crankleft case Right crankright case Crank pincrank connecting big rod Clutch hubcluch gear Driven discoutput shaft Driven discoutput shaft Camshaftatmolysis shaft fixing holer

Location Engine Engine Engine Engine Engine Engine Engine Engine Engine Engine Engine Engine Engine

PINSHAFT- 2NOS

Size (mm) 5x6 4x6.5 Gasket

Cyliner head cover Cylinder head Cylindr body Crankcase Right crankcase cover Left crankcase cover Atmolysis chain adjuster

Description
Super clutch Oil pump
GASKET- 7NOS

Location Engine Engine Qty. 1 1 1 1 1 1 1 Location Engine Engine Engine Engine Engine Engine Engine

Rubber endurable against oil Steel Asbestos rubber endurable against oil Endurable oil asbestos rubber Endurable oil asbestos rubber Endurable oil asbestos rubber Endurable oil asbestos rubber

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Shifting gears inforamtion

Gear down ratio 2.8 3.077 Gear A1 B1 Gear qty. 15 13 GEAR INFORMATION NO. 1 2 3 4 5 6 7 GEAR
Kick starter gear Kick starter small gear transition

Gear A2 B2

QTY. 42 40

QTY. 38 13 49 20 9 54/13 52

POSITION ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE

Kixk starter transition big gear Crank kick starter driven gear Starting motor drvie gear Electricity transition gear Clutch gear starter

SPROCKET INFORMATION No.

1 2 3 4

Sprocket wheel
Right crank oil pump driver sprocket wheel Oil pump sprocket wheel Left crank atmolysis shaft driver sprocket Atmolysis shaft sprocket

QTY. 17 19 17 34

POSITION ENGINE ENGINE ENGINE ENGINE

CHAIN INFORMATION
NO. 1 2 CHAIN ATMOLYSIS SHAFT CHAIN OIL PUMP CHAIN NODE 90 42 POSITION ENGINE ENGINE

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c . S PA R E PA R T S O F E N G I N E
Please read the following instruction carefully, and ensure spare parts in right position. Otherwise engine cannot perform.
1. All marks of the following parts should be towards combined surface of left crankcase and transmission case:Output shaft of left crankcase, middle shaft, output shaft bering 6203,6202,6204, and output shaft of transmission case, middle shaft, output shaft bearing 6004,6002,6301. 2. The side of driven wheel disc rolling needle bearing with mark needs to be toward seeable direction, and the side of ball bearing with mark needs to be towards clip. 3. The convex prick side of the gasket between driver wheel disc and driven wheel disc is towards locknut. 4. The side of kick-starter gear and transition gear with mark is towards left cover. 5. Chain guiding groove is towards chain, and column rod of chain guiding part is not higher than the surface of cylinder.

6. White piston circle is the first one, black piston circle is the second one; hatches of circle 1 and circle 3 are towards exhaust port, hatches of circle 2 and circle 4 are towards inlet port; the side with English letter is towards the top of piston.
7. IN mark on piston is towards carburetor side. 8. Valve spring (dense end) is towards valve pipe. 9. The side of camshaft bearing 6002 with mark is towards cam. 10. The side of oil pump with letters is towards outside. The side of left and right crankcase bush with W mark is towards the reverse of combined surface of left and right crankcase

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d . E N G I E N R E M O VA L A N D I N S TA L L AT I O N
REMOVAL Guiding-wind cover/fan cover/carburetor Left crankcase cover/gasket/piston pin Outside part of left crankcase Chain adjustor /cylinder head cover Camshaft holder/cam Cylinder cover/gasket/pin Cylinder/gasket/pin Spring clip/piston pin/piston fan impeller/flywheel/coil Right crankcase cover/oil filter/oil gauge Right crankcase outside Start motor/left and right crankcase/crank Gearbox Left crankcase/gearbox cover NOTICE: a) Before installation, wash engine parts, and then lubricate engine, refer to recommended torque volume to lock screw. b) Pay special attention to single direction fixing accessories. INSTALLATION left crankcase assy./gearbox assy. gearbox crankshaft/left and right crank motor oil pump/super-clutch/electric start transition gear right crankcase cover/oil filter/oil gauge coil/flywheel/fan impeller piston/piston pin/spring clip cylinder/gasket/pin cylinder cover/gasket/pin cam/camshaft supporter chain adjustor/cylinder head cover left crankcase outside assy. left crankcase cover/gasket/pin guiding-wind cover/fan cover/carburetor

Start and inspect oil road lubricating system after having reinstalled engine.

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C O W L I N G A S S E M B LY
REMOVAL:

Scrrew (10) Bolt (1) Top cowling (11) Bottom cowling (4) Top cowling seal gasket (2) Bottom cowling seal gasket (3) Coil clip (12)

screw (6) bolt (7) fan whorl cover assy. (8) pastern cover (9) cooling pipe (5)

Whorl cover screw(6)

2N.M

Whorl cover bolt (7) Cowling screw (10) Cowling bolt(1)

11N.M 2N.M 11N.M

Pastern cover (13) installationThe installation sequence is essentially the reverse of removal. Notice: avoid missing cowling seal bar.

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B.cylinder head installation REMOVAL

Cylinder head cover (1)/cylinder head cover seal bar

Installation Cylinder head Valve pipe/valve oil seal assy./gasket Inlet valve and exhaust valve/valve spring/spring holder/lock clip Cylinder head assy.

Right against T mark on magneto in the bottom of exhaust stroke timing chain tensioner2 atmolysis shaft assy.3/atmolysis shaft chain 4 shuf off
Atmolysis shaft holder assy./Atmolysis shaft fixer assy.

Cylinder head assy.

valve lock clip/valve spring holder5/inletexhaust valve spring

Atmolysis shaft chain/atmolysis shaft assy. mesh Atmolysis shaft assy. and atmolysis shaft fixer assy. Right against mark T on magneto and correct timing mark on timing gears (keep timing scale of timing gears on the same level with joint surface of cylinder head cover) Timing chain tensioneradjust Adjust valve clearance

special tool T04

inlet valve and exhaust valve7 Valve oil seal assy.8 Valve pipe9 Cylinder head10

inlet valve clearance: 0.03~0.05mm, exhaust valve clearance: 0.05~0.06mm

Cylinder head cover and seal rubber bar *Remove it if necessary TORQUE 1. Cylinder head cover fixing bolt 10~12NM 2. Tension bolt and fixing bolt 10~12 NM
NOTICE

3. Cam fixer locknut 4. Inlet pipe locknut

22~25 NM 10~12 NM

1.Skive valve before installing vavle, and shake it, valve and valve seat should be even after skiving. 2. Daub valve lever with some cream to avoid scratch it, after having installing it, valve lever should be turned flexibly without block. 3. Be sure to keep dense end of valve spring down

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c . AT M O LY S I S S H A F T F I X E R A S S E M B LY REMOVAL INSTALLATION Atmolysis shaft fixer assy. and atmolysis shaft Atmolysis shaft and right bearing12 assy. Adjusting gasket16 Atmolysis shaft fixer assy. Auto reductor outside ring 14 ball bearing, and Rocker arm shaft2 spring15 Gasket3and rocker arm4 Stopper board5 Axes 6and bush7 Mass 8and spring9 Atmolysis shaft fixer10 Atmolysis shaft assy. Atmolysis shaft sprocket comp.11 Atmolysis shaft right bearing 12 atmolysis and shaft left bearing13 Auto reductor outside ring 14 ball bearing, and spring15 Adusting gasket16and atmolysis shaft17 NOTICE
When installing rocker shaft, remember to daub rocker with lubrication, and keep groove of center rocker shaft on the same level as the hole of rocker seat.

Atmolysis shaft left bearing13 Atmolysis shaft sprocket assy.11 Atmolysis shaft assy. Atmolysis shaft fixer10 Axes6, bush7,mass8and spring9 Stopper board5 Rocker arm4and gasket3 Rocker arm shaft2 Atmolysis shaft fixer assy. Atmolysis shaft fixer and atmolysis shaft assy.

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d . P I S T O N I N S TA L L AT I O N REMOVAL: The first ring The second ring Oil ring slice Oil ring slice Oil ring bush Piston Installation The installation sequence is essentially the reverse of removal.

Notice
1 The first ring is white ring, and the second ring is black one. 2 The sides of the first ring and the second one with English Letters are up. 3 Never make mistake in positioning the first ring and the second ring 4 Letter IN is towards inlet port, and the first ring is dead against oil ring slice (). 5 The gap of spring clip is 80-100 against the gap of groove.
ITEMS VOLUME

The first ring Hatch clearance during working The second ring Oil ring slice Clearance between piston ring and groove The first ring The second ring

0.1~0.2mm 0.1~0.2mm 0.3~0.4mm 0.013~0.045mm 0.013~0.045mm

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e . L E F T C R A N K C A S E C O V E R I N S TA L L AT I O N Removal Left crankcase cover assy.

Clip (1) Left crankcase cover (3) pin4/gasket5 The installation sequence is essentially the reverse of removal. Notice

fender (2)

1 When installing left crankcase cover, tap it to its proper postion with wood hammer or rubber hammer not metal
hammer to avoid damaging the cover.

2Position clip (1) and fender (2). 3Lock bolts diagonally and for all bolts torque is 10-12N.M.

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f . R I G H T C R A N K C A S E C O V E R A C C E S S O R I E S I N S TA L L AT I O N

REMOVAL Screw (9) Fan assy.(10) Nut (22) Gasket(21) Flywheel assy.(11) Screw(8) Trigger assy.(7) Bolt(15) Clip holder (20) Bolt (12) Magneto stator (13) The installation sequece is the reverse of removal.
NOTICE1. The clearance between flywheel trigger and trigger head is 0.50.2mm. 2. Fan and trigger head cannot collide.

filter net screw cap(19) nut(22) O-ring(18) spring(17) filter net assy.(16) fuel gauge(5) seal ring(4) other bolts ring crankcase cover(2) gasket (1) Magneto bolt (2) Fan bolt (9) Trigger screw (8) Filter net screw cap (19)
Other bolts for right crankcase

50N.M 7N.M 11N.M 6N.M 57N.M

11N.M

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g . R I G H T C R A N K C A S E A C C E S S O R I E S I N S TA L L AT I O N REMOVAL Locknut1 special tool T05 gasket2 Starting cluch assy.3 electricity starting transition gear (5) electricity starting gear shaft6 Bolt7 oil pump sprocket end cover8 nut9

Semicircular key4 oil pump sprocket chain10 InstallationThe installation sequence is essentially the reverse of removal. Notice oil pump sprocket 11 1.driving gears of oil pump turn flexible.. 2.when installing oil pump, the top arrow of oil pump cover should be towards crankcase. bolt12 3.some axial clearance exists for clutch and clutch gears only turns one direction. Screw axes13 Screw14 Oil pump cover15 rotor16 pin17 oil pump cover body 18

TORQUE 1.Clutch locknut 35~40N.M 2.oil pump fixing bolt 10~12 N.M

10~12 N.M 4.sprocket end cover bolt 8~10 N.M 5.pump cover fixing screw 3~5 N.M
3.sprocket locknut

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h . L E F T C R A N K C A S E A C C E S S O R I E S I N S TA L L AT I O N REMOVAL INSTALLATION Nut6/gasket5/driving flywheel4 Starting transition gear assy.7/kicing starter sprocket assy.8 Nut13/gasket12/acentric disc11 Starting spring slice9 Strap14/driven disc assy.10 Starting driven gear (1) Bush3/driver wheel assy.2 Driveng wheel assy.2/bush3 Starting driven sprocket1 Driving impeller4/ gasket5/ nut6 Starting spring slice9 strap14/driven disc assy.10 Kicking starter gear assy.8/starting transition gearassy.7 acentric disc11/gasket12/nut13 Notice
1 When installing start transition gear wheel and kicing start gear assy., daub axes end with little butter; keep arrow mark on transition gear dead against crankshaft, lineation on kicking start gear dead against rushing point on transition gear; carefully pull kicking start shaft spring to correct position with some tool, be careful that spring doesnt turn back; position starting spring slice correctly and lock bolt, and the torque is 10~12NM.

2When installing strap, anticlockwise place strap into groove of driven wheel strap, then cover driving impeller groove
with strap and install driven wheel assy. into input axes, and then assemble acentric disc, dish gasket and nut.

3Finally, lock nut (15)and nut torque is 45~55NM drive strp, now driven wheel strap disc releases freely. 8the then 4Assembled bush glides freely and convex prick side of dish gasket7and gasket14is towards outside.

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i . C R A N K C A S E I N S TA L L AT I O N REMOVAL Bolt1 Right crankcase assy.2 pin7/gasket3 Crankcase assy.4 chain6 Left crankcase assy.8 Oil seal(5 IN INSTALLATION Left crankcase assy.8 chain6 Crank assy.4 Pin7/gasket3 Right crankcase assy.2 Bolt1 Oil seal5

Notice 1When installing crankshaft, remember to daub left crankcase bearing with some little oil, and then vertically push
the oil into bearing hole, cover chain with crankshaft gear; crankshaft connecting rod turns freely, and feel that axial clearance exists for connecting big rod.

2It is permitted to decompose or assemble left and right crankcase with wood hammer or rubber hammer, but never
with metal hammer, otherwise crankcase may be damaged.

3Crankshaft connecting rod can turn freely after composing the case, and without block 4Bolt touque10~12 NM

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j . T R A N S M I S S I O N C A S E I N S TA L L AT I O N REMOVAL Transmission case assy. Transmission case assy.1 left crankcase assy.2
output shaft bearing

Middle shaft assy.4 output shaft assy.5 input shaft bearing input shaft3 middle shaft bearing

Middle shaft bearing output shaft oil seal and bearing input shaft oil seal and bearing InstallationThe installation sequence is essentially the reverse of removal. Notice
1 Correctly position each bearing, the mark of bearing is towards seeable direction and it turns freely, without block. 2 When installing oil seal, daub oil seal side round with little oil, dont damage the seal and cline or turn it over.

3Various gears should be positioned properly and turn freely. 4To assemble locknut, first of all pre-fix the bolt of pin hole, then lock various bolts, locking torque: 12N M

A1 Gears QTY. Deceleration ratio 15T 2.8

A2 42T

B1 13T 3.077

B2 40T

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k . D R I V E N D I S C C L U T C H A S S Y. I N S TA L L AT I O N Remove clutch-driving board assy. REMOVAL DRIVEN DISC ASSY. clip circle16 Clutch disc 1 fixing shaft 12 /sliding bearing 11 clutch side board17 nut2 seal ring7/driven stepless transmission disc8 spring18/clutch mass19 Clutch driving board assy. 3 rolling needle bearing 15 damper rubber20 Spring seat bush4 clip ring14/rolling ball bearing13 limiter21/pin shaft22 Compression spring 5 rear transmission main disc 10 driving board bottom holder23 Spring bush6 InstallationThe installation sequece is essentially the reverse of removal. Notice
1 When reinstalling clutch driving board assy., be sure to use new limitter and pin shaft, and ensure stable connection.

2When installing ball bearing and rolling needle bearing, daub them with some lubrication to ensure free turning, and
without block, at the same time guarantee clip circle (15) in proper position.

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L . K i c k i n g s t a r t e r s h a f t a s s y. a n d t r a n s i t i o n g e a r s h a f t a s s y. i n s t a l l a t i o n

REMOVAL Kicing starter shaft assy. Bush6 bush1 gasket2 spring3 pin5 kicking starter shaft4 installation removal. Notice bush (1).

Removal Transition gear shaft assy. Fixing pin6 Adjusting gasket4 Transition gear assy.3 including5 Tension spring2 Transition gear shaft1 clip5

installation The installation sequence is the reverse of The installation sequence is the reverse of removal.

Notice
gear groove.

1Daub bush with proper lubricationto install 1 Before installing transition gear, install clip (5) in transtion
Daub shaft end with proper lubrication to install bush 6 2Transtion gear can turn back well. . Install pin (5) in proper position to avoid lossen.

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m . M A I N W H E E L D I S C A S S Y. I N S TA L L AT I O N REMOVAL Flywheel1 bush2 pulling FALAN8 cushion gasket7 acentric rolling pole6 steel bush3 inner hole bush4 strap driving brake disc5 Installation Strap driving brake disc5 Inner hole bush4 Steel bush3 Acentric rolling pole6 Cushion gasket7 Pulling FALAN8 Bush2 Flywheel1

NOTICE 1 Before installing pulling FALAN, clip 3 cushion gaskets onto pulling FALAN. 2Bush2slides freely.

34

n . S U P E R C L U T C H I N S TA L L AT I O N REMOVAL Clutch gear assy.1 Rolling needle bearing2 Screw M63 Clutch hub4 Pin5 rolling pole6, spring bush7 and spring8 Clutch husk9 Spring retainer10 Cluch outside circle11 *Remove it if necessary InstallationThe installation sequence is essentially the reverse of removal. Notice 1. There is no looseness for clutch side cover, screw M6 and spring seat after installing them.
2. Cluch gears can turn only single direction.

35

E Tr a n s f e r i n g p o w e r d i a g r a m By kicking starter Kicking starter lever Kicking starter shaft (9) Starting gear Transition small gear Transition big gear Crankshaft starting driven gear Crankshaft (3) Connecting rod (2) Piston (1) By kicking starter Kicking starter lever Kicking starter shaft (9) Starting gear Transition gear Transition big gear Crankshaft starting driven gear Crankshaft (3) Connecting rod (2) Piston (1)

36

F Lubrication system

Rocker arm Camshaft assy.

Crankshaft assy. Oil pump assy.

Fileter assy.

37

Lubricate
Here are main functions for engin oil. 1 Lubricatereduce friction with metal 2 Coolingprevent too hot 3 Anti-dustprevent rusting 4 Clearprevent deposit and clear carbon deposit 5 Seal intermediateseal combustion chamber 6 Anti-abrisionprolong accessorys life span There are modes of wet groove, splash, pressure to lubricate engine. Engine oil cycle Oil pump assembled in right crankcase absorbs oil through main gears on right crankshaft. Oil in crankcase is filtrated throutgh the oil filter core of left crankcase, then flows across oil pump rotor where prodeces large pressure, and then the oil is squashed into oil path of side cavity of right crankcase , where oil is detached into three roads to lubricate engine: AOn the first road, oil goes into the oil road of right crankcase cover, then flows across vitta of filter rotor cover assy., and then goes into oil filter rotor cover, flows out of rotor cover, then flows into the hole of right crankshaft axes, then oil hole of crankcas axes core and reaches to connecting big rod, where lubricates the big rod and crankpin. Finally oil flows bacd crankcase. BOn the second road, oil goes into small oil hole in the side of right crankcase double-head bolt hole, then goes up along double-head bolt hole and flows into oil path hole of cylinder head cover, oil splashes out from the two oil holes on cylinder head cover, and lubricates rocker arm and rocker shaft, then flows back crankcase along two pushing lever hole. COn the third road, oil passes through small hole on right crankcase and flows into side oil cavity on right crankcase, after Oil reaches here, and then oil road becomes two roads to luricate principal axis and countershaft. C1On the first spur track, oil passes through the oil path on right crankcase to reach bush for right crankcase countershaft, flow across small hole of bush, then goes into axial hole of countershaft and through several small holes of countershaft where lubricates gears. Finally oil flows back crankcase. C2On the second spur track, oil goes into oil path on left crankcase to reach bearing of left crankcase principal axis, then flows into axial hole of principal shaft and through several small holes on principal axis, where lubricates gears of principal axis. Finally oil flows back crankcase. For some part of crankshaft is dipped in oil, when crankshaft rotates at high speed, oil may splash around, some oil lubricates piston skirted and cylinder arm, and other oil spashes on piston lumen and passes across small holes on piston and connecting small rod, where lubricates connecting small hole and piston pin. For clutch assy., kicking starter assy, gearshift organ assy. etc., a small proportion or the whole is dipped in engine oil to lubricate.

38

G VA LV E C L E R A N C E S E T U P Engine is in cooling state. 1Remove cylinder head cover 2Remove pastern cap of fan whorl shell. 3Keep T mark on flywheel the same line with the mark on righ crankcase cover 4Ensure timing reticle of cam sprocket in the same line with joint surface of cylinder head cover. 5Inspect the clearance of inlet valve and exhaust valve, inlet valve0.03~0.05mmexhaust valve 0.05~0.06mmif clearance is not at the range of specified volume, adjust rocker adjusting screw until the clearance reaches its specified range.

39

H MEASURE AIR PRESSURE IN CYLINDER STEP ONE

1 Start engine until temperature reaches its requirement. 2 Remove spark plug and join pressure gauge. 3 Inspect the following switchs (a) Fuel switch is in OFF position. (b) Ignition switch is in OFF position 4 Play up throttle completely, start engine for several times (6-8 times) 5 Note reading, and do the

6above steps three times and calculate

their average value as actual compression pressure, which should be 111Kg/cm2

STEP 2 When air pressure in cylinder is below 12Kg/cm2,install spark plug, restart and warm up engine, remove spark plug and drop several drops of oil in combustion chamber, messure it againe following step ONE with manometer
If the pressure in cylinder adds, inspect: a If cylinder is abraded b If piston/ring is abraded c If there is scratch or block for cylinder/piston d If piston is blocked completely in piston groove. if the pressure in cylinder doesnot increase, inspect a If valve clearance is correct b If cylinder head scres is fastened too tight or loosened c If valve holder is abraded d If valve is curved e If valve timing is correct

f If cylinder head gasket is abraded.

STEP 3 When the pressure in cylinder is over 12Kg/cm2clear deposited carbon in cylinder head, pistion, combustion chamber, at the same time inspect exhaust port.

40

I S o m e i m p o r ta n t s ta r d a r d d i m e n s i o n s E N G I N E Cylinder head/valve ITEM Air pressure in cylinder Valve clearance Inlet Exhaust Camshaft cam impeller height Inlet Exhaust Valve tappet Inlet Exhaust Inlet Exhaust Valve shaft-valve pipe clearance Natural distance of spring Inlet Exhaust Inner spring Outer spring Cylinder/piston Item A Cylinder inner diameter Cylinder and piston Piston diameter Clearance of piston and cylinder Piston pin Piston pin hole Piston pin Clearance of piston ring and groove Piston ring 52.400~52.405mm 52.370~52.375mm 0.025~0.035mm 15.002~15.005mm 14.997~15.000mm Standard B 52.405~52.410 mm 52.375~52.380mm 0.025~0.035mm 15.005~15.008mm 15.000~15.003mm STANDARD 131kg/cm2 0.12~0.16mm 0.12~0.16mm 29.6250.05 29.0380.05 4.975~4.990 mm 4.955~4.970 mm 5.000~5.012mm 5.000~5.012mm 0.010~0.037mm 0.030~0.057mm 32.30.05mm 35.00.05mm

Valve

Valve pipe

0.013-0.045mm 0.013-0.045mm 0.1-0.2mm 0.1-0.2mm 0.3-0.4mm

41

4 Oil

fuel system

C a r b u r e t o r a s s y. Fuel consume curve

Manufacturer Type Model
Diameter of throat tube
CHINA QIANJIANG

Main nozzle Idle nozzle

Mixture screw rounds

Float height

Vacuum piston PD24JC 24mm 179# 30# 1~2 rounds 131mm

perfect state Mileage (Km) 60 50

Economic consume area

Actual state

a 30 40 50 60 70 80 90 Speedkm/h For each engine, at economic exhaustion speed, the ratio ofair against fue is the one of max inlet air against min fuel. 20 30

42

MIXED GASARI AND FUELSYSTEM MIXED GAS OIL ROAD

Fuel flows out of tank for its own weight and across inlet oil switch, at last goes into carburetor. In this process, fuel is filtrated three times (first of all fuel is filtrated when it passes through netty nylon tupe before going into fuel filter, secondly fuel goes through the cavity of fuel filter, finally fuel is filtrated when it passes through the filter installed between inlet oil switch and carburetor). Air cleaner is installed in the left side of motorcycle. Fuel and clean air are mixed into mixed fog gas, which is controlled by inlet port and camshaft rocker arm, and then goes into combustion chamber.

Mixed gas forms and its flowing table

Gas Air fuel fuel tank

Clean

fuel filter

Filter

cavity of fuel filter

Separate flame

filter

Air cleaner joint port

floater chamber

Foam tube

Throat tube

Combustion chamber

Air and fuel ratio

start 7-8 1 idle speed 10-12 1 slow speed 12-14 1 common speed15-17 1 high speed 13-15 1

Carburetor oil road

maily including 1. Inlet oil road 2. Condensing oil road 3. Idle speed oil road 4. Slow speed oil road 5. Common speed oil road 6. Great mixed gas road

43

Carburetor working principle

1. Inlet oil road

Fuel flows into floater chamber of carburetor for its own weight, which communicates with atmosphere for balance tube of carburetor that guarantees pressure in floater chamber is the same as atmosphereic pressure. Floater goes up along with oil level, when oil level raise certain high, the floater drives needle valve to shut off inlet oil path. which may avoid that fuel overflows from carburetor. In reverse, when fuel goes down, floater drives needle valve to go down, needle valve opens, and then fuel is supplied into floater chamber of carburetor.

2. Condensing oil road

When engine starts, electronic valve (electric condense valve) open, one part of fuel passes through condensing nozzle hole and goes into throat tube, for this mixed gas becomes thick and reaches flammable. After starting, electric condensing valve oil needle extends gradually until condensing path is shut off, here engine performs in economic mixture gas.

3. Idle speed
After engine starts, slowly condensing path is shut off, mixed gas becomes thin (the ratio of air to fuel becomes big), fuel flows through idle jet, then transition hole, finally is imbibed into throat tube. Other part of fuel passes through mixture ratio little hole, then is imbibed into throat tube, the thickness of this part of fuel can be adjusted through miture ratio screw.

44

4. Slow speed
Slow idle speed fuel system and main fuel system supply mixed gas at the same time, when one part of uprising stopper brings along oil needle up and produce negative pressure on main nozzle hole, then absorb out mixed gas. Mixed gas becomes more and more and supply engine

5. Middle speed economic exhaust speed

Along with acceleration, mixed gas is only supplied through main fuel system, in this process, idle speed oil system does not supply mixed gas for there is negative pressure distributed on throat tube. Firstly, air flows across air jet (copper canal) and atomizes with fuel in foam tube, then is atomized for another time in throat tube. At economic exhaust speed, air is most and consume is lest.

6. High speed
Accerelate it until stopper rises up completely, engine rotates at high speed, which drives velocity of air flow in throat tube and froms great negative pressure in main nozzle hole, and more mixed gas is absorbed out.

45

Carburetor removal and installation

Removal 1. Remove rear seat of motorcycle; 2. Postion fuel switch on OFF position 3. Pull out inlet oil paste tube with jaw 4. loose clamp ring between carburetor and air cleaner 5. Pull out the stopper at the tail of discharging oil paste tube, spill fule in floater chamber into another box. 6. Loose the screw for jointing carburetor and engine and take out carburetor 7. Pull out high coil cap; 8. Pull out electric condensing valve joint; 9. Loose the screw for jointing carburetor and engine and remove carburetor; 10. Loose throttle cable. Installation The installation sequence is essentially the reverse of removal. Notice 1Confirm electric condensing valve wire is connected correctly; 2Confirm carburetor is intalled correctly and no oil leaking out. CARBURETOR ASSY. STEPS FOR REMOVAL 1Remove 4 screws, take out stopper spring and stopper assy; 2Unscrew oil needle compaction cap, take out oil needle and oil needle spring; 3Unscrew misture ratio adjusting screw, spring, gasket and seal ring; 4Unscrew idle adjusting screw and screw 5Remove electric condensing valve assy. 6Remove choke valve assy. 7Remvoe the 4 screws on under cover; 8Remove floater pin, floater and needle valve in turn 9Remove main jet, foam tube and main nozzle in turn 10Unscrew idle jet 11clean various parts with gasoline, and then blow them with high pressure pneumatic gun. Notice 1In the process of removing other accessories in floater chamber, first of all remove floater and needle valve to ensure floater is not damaged 2To preserve main nozzle, remove it from one side of stopper hole.

46

Steps for installation

1 After confirm inner hole of idle speed jet and horizontal hole are smooth, screw idle speed jet 2 Install main jet in main nozzle hole (the end of smaller diameter against main nozzle hole) 3 After confirm the horizontal hole of foam tube is smooth, screw foam tube 4 Screw main jet hole 5 Assemble needle valve with floater into needle seat, needle valve pothook is hang on floater tongue 6 Assemble floater pin in floater pin seat, floater pin threads into floater pin seat and floater in order 7 Inspect if height of floater is 151mmadjust floater tongure if it is not 8 Assemble under shell correctly 9 Respectively assemble idle speed adjusting screw, spring, mixture ratio adjusting screw and spring, gasket, seal ring correctly (reverse mixture ratio 1-2 round after it has been assembled correctly) 10install electric condensing valve assy. and blocking wind valve assy. in order 11install oil needle, spring, oil needle compaction cap in order 12install stopper assy., Stopper spring, upper cover correctly and inspect if stop moves freely.

Steps for adjusting carburetor: Install carburetor in engine, and then adjust it as the following steps: 1Start and warmup engine for about three seconds so that engine rotates at normal driving temperature; 2Adjust idle speed adjusting screw so that engine rotates at 1600rpm 3Screw mixture ratio adjusting screw into bottom, the strength is not too weight 4Now engine shuts off (if it doesnot shut off, inspect if gas leaks out of the joint of air cleaner and if screw is tight, inspect if the inlet port of air cleaner is blocked) 5Screw mixture ratio adjusting screw back for one round 6Restart ingine, adjust idle speed adjusting screw to be 2000-2500rpm 7Slowly adjust mixture ratio screwanticlockwiseuntil engine rotates at the highest speedscrew mixture ratio screw back for less than or equal to 2 rounds 8Readjust idle speed adjuting screw so that engine rotates at 1600100rpm 9Play up throttle to accelerate rotating, inspect if its rotating speed is stable 10measure exhaust and compare it to standard volume. Notice 1Adjust mixture ratio screw properly not too tight, never energize too much, otherwise it may damage mixture ratio screw head enve break the adjusting screw 2 If engine is adjusted to be too slow rotating speed, engine may be off, in reverse, engine may may consume too much fuel. WARNING After engine rotates normally at idle speed for some time, turn throttle completely, then loose throttle handlebar completely, at this time if idle speed changes, it means that throttle calbe has not been adjusted well. So before measner engine, pay spedial attention to corresponding adjustment.

47

5 Install vehicle body a Specified fixing torque

NO.

ITEM

QTY.

FIXING TORQUE

1 2 3 1 1 1 2 1 2 1 2

FRONT WHEEL/FRONT ABSORBER Front wheel axis locknut Fixing boblt between front absorber and support under connecting board assy. Fixing bolt for disc brake and front absorber Handlebar Fixing bolt for handlebar and supporting under connecting board Frame Fixing bolt for frame and engine bracket Fixing bolt for frame and rear absorber Rear wheel/rear absorber Rear wheel locknut Fixing bolt for left, rear absorber and engine Fixing bolt for right, rear absorber and muffler connecting board Engine Fixing bolt for engine and muffler Fixing bolt for engine and engine bracket FRONT WHEEL/FRONT ABSORBER

1 4 2 1

55-62Nm 37-44N.m 22-29N.m 37-44N.m 45-58N.m

2 2 1 1 2 1

37-44N.m 37-44N.m 100-130Nm 22-29N.m 22-29N.m 37-44N.m

48

b F r o n t w h e e l a s s y. Removal sequence locknut17 front wheel axes3 front wheel left bush4,gear retainer assy. Fornt wheel assy. tire1, steel rim assy. front wheel, seal ring5 front wheel, seal ring8 tire 16, steel rim assy. Front wheel assy. steel rim1, front wheel middle bush6 bearing18, valve port2, valve cap20 front wheel left bush7, gear retainer assy. front wheel axes6 driving slice 7 gear retainer oil seal 10 gear , , retainer(12) locknut13 steel rim 4 front wheel middle bush , 5 , bearing9, valve port3,valve cap2 Installation sequence driving slice 11gear retainer oil seal , 10 ,gear retainer12

49

c R e a r w h e e l a s s y.

Removal sequence
locknut10

Installation sequence rear wheel rim7, valve port11, valve port cap12 Rear braking camshaft (6)

Rear wheel assy. Rear braking rocker arm (5) tire8, rear wheel rim assy. Bolt M6X35 (9) Braking shoe assy.1 Braking shoe calbe 2 Braking tension spring3 Spring bush (4) Bolt M6X35 (9) TIRE (1), rear wheel rim assy. Rear brake rocker arm (5) Rear wheel rim assy. Rear braking camshaft (6) Locknut 10 Rear wheel rim 7 valve port 11 valve port cap , , 12 Braking shoe assy.11 Rear braking tension spring3 Spring bush (4) Braking shoe cable4

50

d M u f f l e r a s s y.

Removal sequence
Screw (10) bolt M8X506 lid nut5 position bush4 Exhaust port gasket assy.6 Muffler assy.1 Decoration cover assy.3, rear decoration cover assy., 9, screw7 Position hole assy.8

Installation sequence Position hole assy.8 Decoration cover assy.3, rear decoration cover assy., 9, screw7 Muffler assy.1 Exhaust port gasket assy.6 Position bush4 Lid nut5 Bolt M8X506 screw10

51

52

e F r o n t f o r k a s s y. Removal sequence Bolt M10X125X4017

Installation sequence Frame assy.20

Front left absorber shock assy. 12 front right , absorber shock assy.13 Locknut1

Under bearing upper steel bowl7

Upper bearing under steel bowl6

Steel ball16 Stopper gasket2 Connecting board assy.(14) Groove nut3

Upper bearing upper steel bowl3 under bearing under steel bowl

Anti-dust cover4 Upper bearing steel bowl3 Under connecting board assy.14
Steel ball 16 under bearing steel bowl 11 Handle joint under gasket10 Upper bearing under steel bowl6 Under bearing upper steel bowl7 Frame assy.20

11

Handle joint under gasket10 Anti-dust cover 4 Groove nut3 Stopper gasket2 Locknut 1
Front left absorber assy. (12), front right absorber assy.13 Bolt M10X125X4017

53

f F r o n t a b s o r b e r a s s y. Removal Bolt (1) O-rseal ring (2) Absorber spring (3) Piston lever4 Screw5and gasket Inner tube assy. (6) Piston lever/piston ring (7) Guiding bush Buffer spring (8) Oil seal gasket Outer tube assy. Oil seal assy. Anti-dust gasket assy.10 Oil seal stopper ring Oil seal stopper ring11 Anti-dust ring assy. Oil seal assy.12 Add absorber oil(1002 ml) Oil seal gasket13 Absorber spring (seal ring upturned) guiding bush14 O-seal ring Aluminium outer tube15 Buffer prick9 Bolt Fixing torque: 23N.m Installation Install piston ring into piston lever Install buffer spring into piston lever Install the above parts assy. into inner tube assy. Install buffer prick into piston lever Install the above parts into aluminium outer tube Fasten screwgasket Fixing torque: 20N.m

54

Working principle for front absorber

structure
See fig. 2, which is front absorber structure. Through controlling organ and handlebar two front shock absorbers (one pair) are connected with front assembling tube of frame, which absorb shock relying on the liquid damping which results from flexibility of absorber spring, air compression and relative movement of inner
FIG. 2

tube and outter tube.

The performance of front absorber is just like one kind of flexing movement, that is to say, relative movement of innet tube (6) and outter tube (3). As a result of stroke inner tube fixin in outter tube turns its position. Outter tube is made up of upper oil pressure cavity and lower oil pressure cavity, piston lever head with piston ring performs tightly with the top end of inner tube, buffer bush is assembled in inner tube assy., which is to seal upper cavity. Bufferprick is fixed in the bottom of outter tube, buffer prick is fixed in the bottom of outter tube, which cum piston lever compose lower cavity. When compression stroke is over, buffer prick and inner tube form oillock, which prevent inner tube from stroking the bottom of outer tube, damping strength which results from the two small damping holes in the processs of recover stroke. Anti-dust ring assy. (10) fixed on the top of outer tube is to prevent drip, dust etc. from going into tube, otherwise these dust may damage oil seal ring assy. (12) or outer surface of inner tube. Oil seal assy. (12) fixed in the bottom
55

of outer tube is to prevent oil from leaking out. Compression stroke When bearing load on the top of front absorber, inner tube moves down (that is to say,
inner tube goes into outer tube), or when front wheel strikes on ground, outer tube moves up, in the process of compression, the damping spring and air are compressed in inner

tube. At the same time the capacity of upper cavity increases, which reduces pressure between piston lever and outer tube. For fall of capacity between piston lever and outer tube oil flows into upper cavity, and as a result of the fall of capacity of lower cavity, damping oil goes up into upper cavity without damp through buffer bush, and compressed oil passes through big damp hole into piston lever inner hole and main cavity chamber without damp until inner tube moves to buffer prick. When compression stroke completes, the clearance between bush and buffer prick in inner tube assy. is near zero, in this way damping strength may slow down flowing speed of damping oil. Finally oil lock forms and compression stroke is over.
Comeback stroke In the comeback stroke, compressed damping spring extends to push inner tube back from its bottom, when inner tube moves away, the pressure in upper cavity rises up for the capacity of upper cavity degrades, which forces that damping oil flows into main cavity or lower cavity only through two small damp hole of piston lever (for damping oil cannot flow back directly through original single direction valve). The two small damping holes limit that damping oil flows into inner tube and preduces damping strength in the process of comeback stroke. When comeback stroke completes, buffer spring and the two small damping hole go on limiting comeback, when buffer bush goes up, the two small damping hole may be sealed father, then the capacity of upper cavity decreases, finally oillock forms and comeback storke completes. Damping strength of fromt absorber directly relies on the quantity of oil. Bad effect ---freeze may happen if used oil quantity or viscidity is too high. Bad effect soft may happen if used quantity or viscidity is too low. It is recommended to use OIL N46 or equivalent engine oil.

Replacing period: per ten thousand kilometers or below one year.

56

g. Disc brake system

brakedisc Liquid pressure brakedisc Brake principle: liquid cannot be compressed, so strength can be transmitted through liquid medium.
CylinderWhen bearing on brake lever, cylinder stopper moves along pressuring direction, stopper squeezes braking liquid in cylinder, pressed braking liquid transfers pressure to caliper through braking hose. When there is no pressure on braking lever, stopper turns back for bearing on rebound from prick spring.

When releasing braking lever, for the sping of sealing ring of caliper, oil stopper turns back, at the same time when wheel rotates, brake disc knocks at braking shods in the two side, which makes brake shoes turn back (see fig.)

1.oil cap 5.clip ring 9.tension spring 2.oil gasket 6.bowl 10.Outlet oil hole 3.inlet oil hole 7.stopper hole 4.stopper anti-dust cover 8.bowl 12.oil pump 11.supplement

Fig.6
57

Fig. 7 Caliper assy. 1.

cover Valve anti-dust

2. Inlet oil bolt 3. Braking liquid path 4. Braking cylinder 5. Oil stopper 6. Long guiding axes 7. Oil seal ring 8. Oil stopper anti-dust ring 9. Brake disc

Fig . 9

Fig. 10

58

Liquid pressure arrester (brake) insepction

NOTICES 1Dont touch arrester for long time. 2Once braking liquid splash eyes, wash eyes with cold water and see a doctor. 3Never let braking liquid splash painting part, otherwise paint may fall off. Wipe it with wet cloth if it happens. 4Never wash liquid pressure arrester parts with mineral oil, like coal oil, gasoline, disel oil and so on. Be sure to use sealed braking liquid to wash it. 5 Never use mineral oil or lubrication to lubricateteh inner parts of liquid pressure arrester. 6For it is easy for braking liquid to absorb moisture, to ensure braking capability, it had better replace braking liquid per year. 7 Reinstall it at once after liquid pressure arrester parts are removed. 8It is forbidden to wipe brake pad kits with sand paper, for sand paprer includes hard grain, which may damage brake disc. 9It is forbidden to rub caliper and inner hole of oil cylinder to avoid that some impurity of cotton leaves in the surface of inner hole. 10Be sure to use new oil stopper seal and seal gasket and so on. Oil cylinder assy. removal: 1 Remove handle lever screw and left handle lever. 2 Take down stopper anti-dust cover. 3 Remove spring clip ring. 4 Reove stopper assy. The installation sequence of oil cylinder is essentially the reverse of removal. Notice Lubricate the surface of stopper peel bowl, and then install it into the hole of oil cylinder. Caliper assy. removal: Place the open end of braking hose into container and draw out braking liquid carefully. (1) Remove inlet oil bolt and seal gasket. (2) Cut off braking hose. Put the throat hose of open into container, and then draw out braking liquid. (3) Disassemble bolt, braking caliper assy., brake shoe, and
brake shoe spring. (4) Disassemble oil stopper, oil stopper anti-dustcover and square seal ring. Reoval steps are the following:

insufflate compressed air into braking hosejoint, push oil

stopper from braking caliper. Never try to prize oil stopper, otherswide it may damage oil stopper. It had better cover oil stopper with cloth to avoid that caliper springs out of caliper, which may result in injury.

Disassemble oil stopper seal part and anti-dustcover.

Notice: when disassembling oil stopper seal parts and anti-dust cover, never damage the surface of inner hole of braking caliper.

The installaing sequecnce is essentially the reverse of removal.

NoticeLubricate oil stopper sealing anti-dust parts with braking liquid, and then insert oil stopper into braking caliper slowly. Exhausting air steps:

1Add proper braking liquid in oil reservoir. 2Assemble oil reservoir gasket carefully to avoid that any braking liquid splash or oil overflows 3Connect clear plastic pipe with braking caliper exhaust port valve closely, and put the other end of the pipe in container. 4Slowly start brake lever for several times. Pull the lever back to keep it on some position. 5 Unscrew exhaust port and operate brake lever In its limit postion. 6When brake lever is in its limit position, screw exhaust port, and then release the lever. 7Do step4to step6 again and again until air bubble disappears from system. 8. Add proper braking liquid.

59

h . I m p o r ta n t d i m e n s i o n o f v e h i c l e pa r ts
Front wheel/ absorber/ control
ITEM Tire air pressure Tire air pressure Standard

175KPa 175KPa

Free distance of front absorber spring Oil capacity for front absorber Oil level for front absorber Manufacturer of oil for front absorber

Disc brake system

ITEM Appointed disc brake oil Manufacturer for disc brake oil Deepness of brake shoe Deepness of brake disc Reae wheel Item Air pressure in tire STANDARD DOT3 or DOT4 6MM 4MM

Driver Driver and passenger Free distance of rear brake rocker arm Diameter of rear brake drum Deepness of brake shoe

Standard 200Kpa 225Kpa 20MM 130MM 4MM

60

6 Electronic/electric a Magneto ACG

Structure Magnet motor is made up of stator and rotor. The tupe of stator coil: star connection. Stator installation 12-coil statorthey are for charging coil of light/batteryTouching off coil and stator are fixed on the right crankcase cover. Charging and touching off coils of CDI parts are to ignit e. The electicity emitted from lighting coil passed through rectifier to be light, and electricity emitted from battery charging coil passes through rectifier to charge. Color code of lead of magnet motor and resistances of various coils are the following table: No. 2. 3. Coil type Toucing coil Light Charging battery coil Resistance 20020 at 20 <2 <2 Lead color Blue white/green white Blue Blue

NoticeTesting for all resitance is referred to ground (black) Oil groove type of magnet motor assy. There is no stator slice (capacitor) in stator assy, which is installed on the left crankcase cover. The structure of stator includes two assembling holes.

61

62

Charging system circuit diagram AC circuit diagram

63

E l e c t r i c a l s ta r t p o w e r p r o c e s s ta b l e
Circuit process
Storage battery Fuse Main switch Stop swtich Start switch Start relay Start motor Connect ground magnet motor Alarm

64

c . C D I pa r t t e s t i n g
b.inspect the resistance of secondary coil between ignition coil and ground: shoud be -7.5 1KQ, and including 5 KQ resistance of series-sound disturbing suppresser, replace ignition coil if resistance is not that. Various parts following hereinafter processes step by step. 1.Spark plug 1.Spark plug After clean spark plug in special cleaner, inspect spark plug And try to drive vehicle, replace it if fault happens short circuit electrode is abraded insulator is damaged 2.spark cappin 2.spark plug cappin Inspect if resistance is near 5.0Kand replace it if not. 5.touching off coil coil 3.composite a. inspect resistance between blue/white and green/white at 20 3.composite switch
inspect its continuity of black/white and black lead end of and see if the resistance ranges between 100 and180, otherwise replace the touching off coil. Ignition switch with multimeter, replace it if it doesnot with

FOR any fault about ignition system, you may inspect

the following requirements in the table Switch position state OFF connection
LOCK ON connection disconnection

b.remove spark plug, and then connect a 1.5 voltage L.E.D. between blue/white and green/white leads, use

Kicking starter to rotate magnet motor, LED may flash,. Otherwise replace

touching off coil. 4.ignition coil 4.ignition coil there is sole ground wire for motorcycleblack. A.inspect the resistance of secondary coil of green and yellow/black lead ends, it should be below 1.0otherwise replace ignition coil.
65

Ignition timing test

1.Remove the viewing cap of ignition timing hole. 2. Connect timing light following as the specifications from manufacturer stroboscope. 3.Start engine and aim timing light at ignition mark on flywheel of magnet motor. during idle speed Ignition mark F is right against I mark on timing viewing hole, and ignate it at 13 ahead of top dead center at 1400RPMsee tachometer. during speedup High speed markII is right against markI on timing viewing hole, ignate it at 28 ahead of top dead center at 4000RPM. If ignition timing is not correct, replace CDI, and then inspect new one.

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dRelated notice about battery Remove battery form vehicle, connect positve pole and negative pole respectively with red lead and black lead of adjustor. Inspect the voltage between the two ends of battery, normally it should be 12~14.5 V. Press the button of adjuster and read the reading of voltameter, the voltage of battery shouldnt be below 9V, which ensure it can start engine. Inspect the proportion of electrolytem, each of which shouldnt be below 1.220, otherwise you should charge battery. Install load to adjute it if necessary, diagnose question according to the following meaning: Discard battery as useless: if battery voltage is below 9.5V and the proportion one or more batteries is below 1.220. Turn on circuitDont charge battery too fast. Replace battery if the above state happens. Recommended adjuster for battery: madeELAKmodelBCT7 warnif battery is bad, please inspect charging wiring road before removal.
Commonly, fully charged battery: 1.220-1.240 Charging condition1.220 With densimeter to inspect battery. Remove negative pole, then positive pole. Replace it if battery connector is eroded by Sulfate; replace it if there is too much deposit in the bottom of battery. When the proportion of old battery is less 1.220, charge it, and you can adjust it According to the temperatue of electrolyte. For the type of 2.5AH0.25A For the tpe of 7.0AH0.7A 12-14 hours for old battery. Unscrew all cap cover before charging Keep battery far away from spark or fire Turn on power switch when charging Forbid charging when the temperature of electrolyte is 45 Dont charge it too fast.

Propotion

Warn Charge Charging current Charging minute

time 8-12 hours for new battery

Warn

Connect positive pole, then connect negative pole. Install 12V 2.5A.H Battery capacity Battery charger is madeELAK modelC1/48 recommended Liquid densimeteris madeTHIMSON model108 recommended Notice1fill battery with distilled water to its top levelforbid fill old battery with acidity liquid 2ensure new battery with full electrolyte to be charged at low temperatrue 3ensure ventilated pipe of battery not to be blocked or bended, ventilated pipe must be smooth and without block 4if vehicle neednot use for some long time, charge it fully, and then connect its positive pole with vehicleremove the negative pole of battery.

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eVarious bulbs removal and replacement headlight, flasherand meter light Headlight removal Remove front cover Headlight connector Headlight ratainer fixing screw Legshield Headlight bulb seat (turn it anticlockwise) Remove headlight bulb 12V25W/25Wturn it anti-clockwise through adjusting nut to adjust focus Remove and replace night small lamp bult-12V3 W Heallight installation Install it in the reverse of removal and adjust the focus of headlight. Flash light bulb Remove flasher Remove and replace bult-12V10 W Meter removal Headlight jointing line Remove headlight connector Headlight outside cover Remove odometer cable Remove odometer indicator fixing screw and connecting line of oil gauge Remove odometer panel Replace bulb high beam indicator light, turning signal light, meter indicator lightfuel gauge, odometer , Meter installation Install it in the reverse of removal and adjust its focus.

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f E l e c t r o n i c c o m p o n e n ts i n s p e c t i o n p r o c e d u r e
Inspect continuity of the down electric switch with multimeter Main switch
Trans-beam swtich

Front/rear braking switch

Turning switch

Lighting switch
Horn switch

Starting swtich

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g Requirement for main electric component specification Storage battery charging system ITEM Capacity Storage battery Specific gravity (27 Condition ) charge Current for charge Time for charge Capacity Charger for SPECIFICATION 12V-2.5AHKS/7AHKS full 1.220-1.240 1.220 0.25A/0.7A 8-12 hours 114Wat 5000RPM

Ignition coil Between black line and 2 resistance black/white 20/68F Lamp line Yellow green/white and 2

Adjust the output of rectifier Adjust output voltage to be less than 14.5V and supply the voltage to lighting circuit; Adjust the DC charging voltage of storage battery to be more than 11.5V; Adjust the DC charging current of storage battery (at 5000rpm) to be 0.6~2A.

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h S O M E I M P O R TA N T PA R A M E T E R - E L E C T R I C PA R T S BATTERY/CHARGE SYSTEM ITEM CAPACITY SPECIFIC GRAVITY Condition for full 27 charge Charge current Charge time Specification Battery charge coil White resistance28/68oF Black Lighting /lignting coil Green red/white SPECIFICATION 12V/7AH(ES) 1..220-1.240 <1.220 0.25A(KS)/0.7A(ES) 8~12hrs 85W@4000RPM Less than 2 Less than 2 < 13.50.2 V >14.40.4 V

BATTERY

MAGNETO

Retifying regulator Stable voltage of lighting circuit DC voltage of battery charge

IGNITION SYSTEM STORAGE BATTERY Type Spark plug Spark plug clearance Fmark Ignition timing complete advance ignition Primary coil resistance Ignition coil Secondary coil resistance with plug Secondary coil resistancewithout plug Charging coil resistance 0.6~0.7mm 15010BTDC at1700RPM 28010 BTDC AT 4000RPM 0.250.05 7.51K 3.40.31K SPECIFICATION C7HSA (NGK)

Touching off coilat 20

Green white

white/blue

100~180

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C OTHERS

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1 Inspection before delivery

It is very important for each vehicle do thorough inspection before delivey. Please do the following procedures and send main informations to dealer. 1. Wash vehicle body with warm scour and brush, and then rinse it with compressed air. Wash paint with water, and then wipe it with flix or soft cloth (never with soap, bleaching powder or super-high pressure air). 2. 3. Inspect the light of paint, glaze paint if necessary. Inspect the degree of tightness of exposed bolt and nut, including bolts for carburetor, cylinder head cover and engine etc. 4. 5. 6. 7. 8. 9. Warm up engine, and then inspect engine oil, add some oil if necessary. Inspect air pressure of tire, and correct it if necessary. Install battery. Inspect the clearance of spark plug, and adjust it if necessary. Inspect whole electrical system, the capability of control switch. Inspect throttle cable and rear brake cable.

10. Inspect and adjust idle speed if necessary. 11. Inspect if disc brake system and rear brake rocker arm is reliable, and adjust them if necessary. 12. Inspect the level of braking liquid in brake cylinder, and add liquid if necessary. 13. Inspect the performance capability of front and rear shock absorber. 14. Inspect if front and rear wheels are on the same line, and inspect if tire turns freely. 15. Try to drive vehicle. 16. Inspect speedmeter and odometer. 17. Inspect if engion oil or fuel leaks out, and add them if necessary. 18. Inspect performance of all locks.
19. Inspect and adjust headlight.

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INSPECTION POINTS
Inspect the performance of left and right handle switch

Inspect free distance of rear braking lever

Inspect fixing torque of front wheel axes

Inspect air Pressure of rear Tire

Inspect performance speedometer and odometer

of

Inspect the performance of disc brake at 10-20MM free distance

Inspect lighting of headlight

Inspect fixing force of rear wheel locknut

Inspect the performance of front absorber shock

Inspect air pressure of front tire

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2 Periodic maintenance
It is necessary to do inspecting, checking, lubricating and regulated maintenance according to the following instructions. Icheck, wash, adjust, lubricate or replace if necessary Cclean Rreplace Aadjust LLubricate
NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 ITEM Fuel path* Fuel cleaner* Throttle handlebar* Air cleaner Spark plug Valve clearance* Engine oil Oil filter net* Carburetor idle* Battery Brake pad kit abrasion Braking system Front brakign liquid pressure oil hose* Front braking liquid* Stop switch* Headlight adjustment* Shock absorber system* Bolt, nut, pin* Wheel, rim** I I I I I I I I I I I I I Per two years I I I I I I I I I I I I Remark 3 Remark 3 I I I I I I I I Maintenance mileage (reading of odometer)(NOTE 1) 1000Km 4000Km I C I C I I 8000Km I C I C R I Per 5000Km:R C I I I I I I Remark 3 12000Km I C I C R I Remark 2 REMARK

Replace it per 4 years

* only sales department do the examining and repairing ** For this entire item, it is recommended that sales department do the examining and repairing. note 1. If the reading of odometer exceeds this number, do repairing and examining againg according to this table. 2. Do the examining and repairing more frequently when driving in dusty area. 3. Do more maintenance to prolong vehicle when driving in accidented ground.

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3 Permit and forbid

Permit i. Use special tool to remove and install bearing ii. iii. Use special tool to install oil seal Keep the free clearance between braking levers and throttle handlebar, between braking rocker arm and throttle handlebar. iv. Use recommended lubrication on appointed lubricating parts. v. Replace whole set of taper rolling bearing of front fork if necessary. vi. Yellow marks of tyres must be dead against valve port. vii. Ensure there are no jam-up, crispation, and distortion, and keep all oil hoses smooth. viii. When installing disc brake caliper, ensure brake disc between braking shoes. Keep tire with normal air pressure. Forbid 1 It is forbidden to operate front disc braking lever when removing disc or caliper. 2 Never place front disc on ground. Otherwise disc may be damaged. 3 When brake shoe or brake pad kit is abraded to its mark level, never go on using it. 4 Never add disc brake oil to brake cyliner exceeding the position of UPPER LEVEL. 5 Never polish disc with sand paper. 6 It is forbidden to reuse hatch pin, seal ring, paper gasket etc. 7 Never delay to replace damaged chain. Replace it at once if chain is damaged.
8 Never start vehicle without muffler.

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4 Safe driving Driving posture

How to drive is good driving posture 1. Be useful to get necessary correct information for driver.

2. Keep driver and vehicle incorporate. 3. Allow driver to finish various operation freely. For a good driver he/she muse have the above three conditions. Each driver can practice seven points in head. Although for each drivers shape and motorcycle type, driving postures are slight different, the seven points principles are coherent. Seven point requirements for driving posture 1. Eye: pay attention to going and coming vehicles 2. Shoulder: dont be too nervous and keep it soft and natural. 3. Elbow: put two elbows on natural position and a little close to body. Keep upper part of body relaxation. 4. Hand: grasp the middle part of handlebar gently 5. Hip: sit in the position, which doesnt disturb control direction and braking. relax hip and slightly bend forward. 6. Knee: relax knees. 7. Feet: put tiptoes forward and feet on footboard. The basic principle of driving posture is that hands, knee, feet, and hip is placed in proper position. Effective braking
1. 2. 3. 4. Loosen throttle handlebar and put right hand on disc brake lever. Grasp rear brake lever with left hand, at the same time with right hand hold disc brake lever. If suddenly grasp front disc brake lever, front wheel may be blocked and results in turnover. To get efficient braking capability, use front and rear brake at the same time. But be sure to avoid use front disc brake when turning. 5. 6. When braking vehicle, front absorber is compressed, rear wheel goes up, which ensures easy to brake. Driver must keep correct posture to driver vehicle forward.

7. When vehicle stops, put feet on ground and front absorber, rear absorber turn back
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5.Examine and repair for fault Engine doesnt start or difficult to start inspect if ignition switch is in ON position possible cause 1.unscrew discharging fuel screw for carburetorand fuel doesnot flow into -fuel switch has been turned off Inspect if fuel flows into carburetor -there is not fule in fuel tank -Fuel filter is blocked Fuel flows into carburetor -fuel hose is blocked -Carburetor floater or needle is blocked
-Ventilating hole on fule tank cover is blocked

2.do ignition testing

Ignition is good

spark is a little weaker or cannot ignite - something is wrong with spark plug -there is carbon deposit on spark plug -Spark plug and coil are cut off or short circuit exsists for them -ignition switch is wrong -Wiring connection of ignition system is not well or open circuit, short circuit happens. -CDI is wrong -Charging coil is wrong -Touching off coil is wrong idle mixture ratio screw is not adjusted correctly -Carburetor is blocked -Ignition advances or delays -Mixed gas is too thin or thick -carburetor choke is shut too tight -Fuel leaks out from carburetor -Mixed gas is too thick
-There is too much dust on air cleaner

3.use correct start mode to start engine Engine s starts but stops soonEngine cannot start

4.Remove and inspect spark plug Spark plug is dry

Spark plug is moist -

-Fuel flows into combustion chamber

5.Measure air pressure in cylinder Air pressure is normal

air pressure is too low

----valve seat mesh is not correct -valve clearance is too small -opening time of valve delays -Cylinder and piston are abraded -Cylinder head gasket is damaged -Valve is blocked -Ignition advances or delays

6. Pull choke to start

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Engine power is not enough Engine

1.leave wheel from ground and rotate it Wheel can rotate freely

Possible Possible cause

-braking resistance Wheel cannot rotate freely -Wheel bearing is abraded or damaged -Wheel bearing need lubricate -Driving chain is too tight -tire leaks. - Tire valve is wrong.

2.inspect the pressue of tire Pressure is normal

pressure is too low

3.inspect if carburetor is blocked. BLOCK No block

-carburetor has not been maintained fully.

4. Slightly speed up engine

speedup is not enough for engine

Engine speeds up normally

- mixed air is too thick or toothin. -Air cleaner is blocked -the supplement of fuel is not engough - Ventilating hole of fuel tank cap is blocked -muffler is blocked

5.disassemble and inspect spark plug flooded or there is carbon deposit - spark plug has not beenmaintained fully -The heat range of used spark plug is not correct The state is well 6.disassemble oil gauge and inspect oil level and its quality State is good 7.inspect ignition time Correct 8.inspect if clutch skids Clutch doesnot skid clutch skids not correct oil level is too high not good -Oil level is too low -engine oil is polluted -something wrong with ignition -Something wrong with touching of fcoil -touching off coil is assembled incorrectly -clutch spring is too loose -Clutch braking pad kit is abraded -strap is abraded

9.inspect if engine is too hot Engine is normal

engine is too hot

-there is carbon deposit in combustion chamber -use wrong trademark fuel/oil -clutch skids -Mixed air is too thin -Engine oil is too less

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10.inspect the pressure of cylinder pressure is too low - valve mesh is not correct -Valve clearance is too small Pressure is normal -cylinder abrades piston ring -Cylinder head gasket is damaged
-Providing gas position is not correct 11.disassemble cylinder head and inspect its lubrication oil path is blocked

Distribution mechanism doesnt lubricate well

Good lubricating

-Something with oil pump -oil filter or filtering paper is blocked

12.speedup or high-speed No clash

engine clash es

-there is carbon deposit in combustion room -Use wrong trademark fuel -cylinder and piston are abraded -Mixed air is too thin -Ignition time advances -Something wrong with ignition equip

capability is not good at idle speed or low speed 1.inspect ignition time and vavle clearance. Not corrects -something wrong with ignition coil. -something wrong with the adjustment of valve clearance. Correct -ignition coil is not assembled correctly. 2.inspect adjusting screw of mixed air of carburetor Correct 3.inspect carburetor gasket/seal gasket
-fixing bolt looses or heat insulation machine leaks out air

not correct -mixed air is too thin -Mixed air is too thick

-Incorrect installation - Heat insulation body of carburetor is damaged 4.ignition test faint spark or discontinuous leaping spark -something wrong with spark plug
-Spark plug is flooded

Ignition is normal

-something wrong with ignition

-Wrong with charging or touching off coil -Something wrong with ignition coil -Spark plug and coil cut off or short circuit happens for them -Ignition system doesnt connect well

5.inspect if carburetor is blocked

blocked Not blocked

-oil path of carburetor is blocked - carburetor nozzle is blocked

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high speed is not good 1.inspect ignition correct 2.carburetor oil pipe is ruptured fuel is smooth

possible cause incorrect

- ignition is wrong -Touching off coil is wrong -touching off coil is installed incorrectly -Fuel tank lacks gasoline -Oil pipe is blocked -Filter is blocked -Filter net is blocked -Ventilating hole of fuel tank cap isblocked -Carburetor jet is blocked

fuel throttles

3.inspect if carburetor nozzle is blocked not blocked 4.inspect distribution mechanis phase Correct 5.inspect valve spring Normal too loose

block

not correct

-Timing chain is not installed correctly

-Valve spring is wrong

It is difficult to control
1.If turning is difficult --Turning bearing adjust nut is too tight --Turning bearing is damaged --Wheel bearing moves too much --Rim is bended --Chain is loose or bended --Rocker arm shaft bush nut is too loose --Rocker arm shat bush is abraded exceedingly --Bracket is bended --Frong wheel and rear wheel have not been adjusted well --Fork or controlling stick is bended --Rocker arm or bracket is bended --Front/rear shock absorber is instable or oil leaks out

2.If one wheel swings

3.If scooter inclines one side

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FUEL SYSTEM ENGINE CANNT START Carburetor lacks oil

Cylinder head cover/Valve Fault from engine cylinder head/valve may effect on the capability of engine. If engine is bad at slow speed, inspect whether ventilated hole of crankcase gives out smoke. If it does, inspect whether piston ring is blocked

Cylinder pressure is too low and difficult to start or is not well at slow speed Oiil level is incorrect VALVE floater valve is clipped Valve adjustment is not correct Engine fuel is too much Valve is ablated or distorted Air cleaner is blocked Valve timing is not correct Oil leaks out of carburetor Valve spring is ruptured Fuel loses its efficience or is polluted Valve spring is loosened Mix gas is too thin Cylinder cap Float lever is too low Air leaks out of cylinder cap gasket or the gasket is damaged Oil leaks out of inlet valve Cylinder cap is bended or ruptured Oil tube is blocked Cyliner or piston is wrong Inlet oil tube of carburetor is blocked/bended Pressure is too high or engine is too hot or clashes Throttle valve is wrong There is carbon deposit on cylinder head or piston head. Fuel jet is blocked Cylinder head gives out smoke Carburetor is not adjusted well Valve lever or valve pipe is abraded Mix gas is too thick Valve lever oil seal is damaged Choke is in open position Cyliner, piston or piston ring is wrong Float lever is too high Cylinder head sounds abnormal noise Emulsification organ is blocked Valve is not adjusted correctly Air cleaner filter core is blocked Valve is clipped or valve spring is ruptured Gas leaks out of carburetor Camshaft is abraded or damaged Carburetor is not adjusted correctly Tiiming chain is too loose or abraded Engine crushes out, difficult to starte and bad idle speed Cam chain gears and sprocket are abraded Oil tube throttles -Timing chain tensioner is abraded or damaged Ignition is wrong Rocker arm or rocker shaft is abraded Mix gas is too thin/thickadjust mix ratio screw Cylinder or piston is wrong Fuel loses its efficience or is polluted Idle speed is not normal Air leaks out of inlet valve Cylinder pressure is too low Idle speed is too slow There is leakage on inlet valve Float lever is incorrect Fuel supplement system is blocked Ventilated hole of fuel tank is blocked Carburetor is wrong Oil pipe is blocked Air cleaner is blocked
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There is no fuel for the tank Filter is blocked Oil tube is blocked Ventilated hole of fuel tank cap is blocked

The capability of driving is bad and consuption is too high

Fuel system is blocked Ignition system is wrong Cylinder/Piston Cylinder pressure is low or not stable Cylinder or piston ring is abraded Smoke is too much Cylinder, piston or piston circle is abraded Piston circle is installed incorrectly Piston or cylinder wall is scratched

Atmolysis chain Atmolysis chain noise Atmolysis chain tensioner is loose or damaged Tensioner head is damaged Atmolysis chain guiding board is damaged

Chain is too loose Tensioner is damaged Atmolysis chain becomes longer

Too hot There is carbon deposistion in piston or combustion chamber CRANKSHAFT/KICKING STARTER Noise is too much CLASH OR ABNORMAL NOISE Piston or cylinder is abraded Carbon deposit CLUTCH/SHIFT GEARS CLUTCH It is difficult for scooter to slide at idle speed Clutch is not adjusted correctly Clutch brake pad kit is distorted Clutch locknut is too loose gears is wrong Clutch acentric mass spring is not stable Transmission bearing is abraded Crrankshaft big end or crankshaft pin is abraded

Engine librates Crank moves too much

Kicking starter/Skid The mark for Kicking starter gears/Transition Kicking starter spring is not stable Start timing is not correct Kicking starter/Transition gear is abraded or damaged Transition gears are clipped on shaft for sliding axiall

Clutch skids at speedup Clutch is not adjusted correctly Clutch brake pad kit is abraded Clutch acentric mass spring is wrong - Clutch acentric disc is abraded absorber/Driving Front wheel swings Rim or wheel axes is bended and distorted Axes bearing is abraded It is difficult to shift gears Spoke looses or bends Driver wheel disc acentric rolling pole is abraded Something is wrong with tire Driven wheel disc compression spring is damaged Wheel inclines too much
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Front

wheel/Drum

brake/Shock

Driven wheel disc sliding bearing is damaged

Something is wrong with speedometer

Brake is soft
-The level of braking liquid is too low -There is foam for Disc braking system -Disc braking oil leaks out -Disc braking caliper piston seal ring is aging. -Stopper husk bowl is aging -Braking shoe/braking disa is abraded -Stopper/oil stopper is abraded b It feels hard for brake/The tension of Disc brake level si slow -Brake oil path is blocked -Caliper cannt move normally -Brake disc is distorted -The tension spring of handle level is damaged

Rear wheel/rear brake/rear shock absorber Rear wheel jumps/swings -Rear wheel bearing is damaged -Tire is bad -Rim is distorted -Rear wheel bearing is loose -Rear wheel axes nut is loose -Rear swing arm bush is abraded -Chain adjuster is not adjusted correctly-

It is toward on side or it is not straightforward

-Rear wheel axes is distorted -Chain adjuster is not adjusted equally -Rear swing arm is distorted Brake capability is bad -Rear brake is not adjusted correctly -Brake shoe is abraded -There is oil dirty on brake shoe -Braking cam is abraded -Braking hub is abrade -Braking rocker arm spline meshs improperly -Touching position of Braking shoe and camshaft is abraded.

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Electric fault
lighting/battery charging system battery has no electricity short circuit happens for wire no electrolyte in battery storage battery discharge completely relay is wrong main fuse is connected completely or cuts off ignition switch is wrong battery charging coil is wrong Voltage is low charging is not engough for battery electrolyte is not enough discharge happens for battery charging system is wrong it is not connected well Turnoff something is wrong with the connection of battery calbe something is wrong with charging system the connection of starting system is wrong ignition switch is wrong or short circuit happens short circuit happens for lighting system or its connection is wrong

Electrical starting system Starting motor doesnot rotate Fuse is broken off The cable of starting motor id loose Batteru discharges Press starting button There is crack noise Directly connect battery for motor, inspect its rotating. Something is wrong with lead contact Something is wrong with relay Something is wrong with starting motor Press starting button There is no crack noise Starting button is wrong Inspect the voltage of short currentt relay short current relay is wrong Battery voltage Inspect uninterrupted speciality of short current relay. Short circuit relay is wrong
Continuity is abnormal touching of starting button is wrong clutch switch is wrong Starting motor rotates but its speed is slow proportion of battery electrolyte is low circuit impedance is too high starting motor agglutinates rotates Starting motor rotates but engine doesnt rotates starting unilateral clutch is wrong startign gears are wrong starting chain or starting sprocket is wrong Both starting motor and engine can rotate but engine cannt start something is wrong with ignition system engine fault-compression ratio is too low spark plug is wrong Note NoteWhen ignition switch is in open position and clutch is released, press starting button, staring motor works.

Fault for charging system lead or connector is wrong: Turnoff or short circuit. rectifier is wrong ACGis wrong
Bulb is burnt connecting lead is loose or short circuit happens recitifying adjuster is wrong Charging coil for bulb/battery is wrong Headlight is dark grounding is not good rectifying adjuster is wrong charging coil for bulb/battery is wrong

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