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

Downloaded from www.Manualslib.com manuals search engine

 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: [email protected]

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

Downloaded from www.Manualslib.com manuals search engine

 CONTENTS
Perface
A General knowledge

1. Basic term-----engine
2. Engine type—4 STROKE ENGINE，WORK CYCLES/ILLUSTRATIONS.
3. Safety for repair shop
4. 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.

Downloaded from www.Manualslib.com manuals search engine

 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

Downloaded from www.Manualslib.com manuals search engine

 A
GENERAL
INFORMATION

Downloaded from www.Manualslib.com manuals search engine

 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 CENTER－WHICH IS FARTHEST
AWAY FROM THE ROTATION CENTER OF
CRANKSHAFT.
BOTTOM DEAD CENTER－WHICH 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(CM³), 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

Downloaded from www.Manualslib.com manuals search engine

 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 ENERGY.
HAS 4.EXHAUST: THE EXHAUST GAS IS
EXPELLED FROM
FOUR STROKES, WHICH CONSIST OF ONE
CYLINDER.
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

Downloaded from www.Manualslib.com manuals search engine

 ．4-STROKE ENGINE CYCLE
2．

：INLET STROKE
A：
1、CRANKSHAFT TURNS ANTICLOCKWISE.
2、CRANKSHAFT BRINGS ALONG PISTON TO MOVE THROUGH CONNECTING ROD.
3、WHEN 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.

Downloaded from www.Manualslib.com manuals search engine

 3． SERVICE WORK SHOP SAFETY

WARNING WARNING

Don’t use the tool, which is damaged or easy to be There is vitriol in storage battery, please protect
emerged, that may hurt you. your eyes, skin and clothes. If touching vitriol
inadvertently, please wash it with water and see
WARNING doctor.
Gasoline is flammable, and may explode in WARNING
some condition. Please never get it near smoke
or spark. Keep close privity with your colleague to ensure
safety.
WARNING
WARNING
Please often keep ground tidy and clear. Never
leak fuel on ground to avoid skidding and Please never touch brake fluid with your eyes,
damage. otherwise wash it with water and see doctor.
Never touch brake fluid with hands for some
WARNING long time.
Never totate engine in close or bad ventilated Never splash brake fluid on the surfaces of oil
room, for exhaust contains poison gas. pait parts and rubber accessories.
Never use superfluous fluid, which is exposed
WARNING in air, remaining fluid has absorbed moisture
from air, which may damage its speciality.
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.

Downloaded from www.Manualslib.com manuals search engine

 4. ELECTRIC SAFETY
a) The relaxation of calbe is hidden trouble;
so remember to clamp each calbe to
ensure safety.
b) Don’t 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, don’t 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.

10

Downloaded from www.Manualslib.com manuals search engine

 B
PRODUCT

11

Downloaded from www.Manualslib.com manuals search engine

 1. SPECIAL TOOLS LIST

NECESSARY TOOLS TO DISASSEMBLE AND INSTALL MOTORCYCLE ENGINE AS FOLLOWS：

CODE TOOLS CODE PURPOSE

1 T01 “T”SHAPE GUIE CYLINDER

2 T02 GUIDE CYLINDER TOOLS（8,10,12,13）

3 T03 SCREWED ROD FOR FLY WHEEL DISASSEMBLAGE

4 T04 TOOLS TO DISASSEMBLE VALVE SPRING

5 T05 DISASSEMBLING TOOLS FOR OIL DRAINAGE

6 T06 CYLINDER PRESSURE GAUGE

7 T07 DISASSEMBLING TOOL FOR PISTON PIN

8 T08 SOCKET FOR DISMOUNTING SPARK PLUGS

9 T09 ELECTRIC TOOL FOR DISASSEMBLING LOCKING BOLT OF

FLY WHEEL

10 T10 CULTCH CLAMP

11 T11 DISASSEMBLING SCREW TOOL

12 T12 GUIDE CYLINDER (17,18)

12

Downloaded from www.Manualslib.com manuals search engine

 ○
1 ○
2

○
3 ○
4

○
5 ○
6

13

Downloaded from www.Manualslib.com manuals search engine

 ○
7 ○
8

○ ○
9 10

○
11 ○
12

14

Downloaded from www.Manualslib.com manuals search engine

 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. NA ME QTY TORQUE

1 Tapping screw for fan snail cover assy. 2 1-3N••M
2 Lucknut for fan snail cover assy. 2 10-12N•M
3 Tapping screw for up and down guide air cover 3 1-3N••M
4 Lucknut for up and down guide air cover 1 10-12N•M
5 Tapping screw and nut for ventilating air chamber of cylinder head 3 1-3N••M
covr
6 Locknut for cylinder head cover 4 10-12N•M
7 Locknut for double head blot on cam fixing 4 22-25N•M
holder
8 Locknut for atmolysis chain pulling rod 1 10-12N•M
9 Lucknut for atmolysis chain adjustor 2 10-12N•M
10 Lucknut for cylinder head 2 10-12N•M
11 Locknut for cylinder observing oil read 1 10-12N•M
12 Spark plug 1 10-15 N•M
13 Double head bolt for cylinder head inlet port 2 10-12N•M
14 Double head bolt ofr cylinder head exhaust port 2 10-12N•M
15 Lucknut for carburetor joint 2 10-12N•M
16 Lucknut for cooling impeller of fan 4 10-12N•M
17 Locknut for flywheel 1 45-55N•M
18 Locknut for magnet stator coil 2 6-8N•M
19 Locknut for magnet motor trigger 2 10-12N•M
20 Locknut for right crankcase cover 9 10-12N•M
21 Oil filter cover cap 1 55-60N•M
22 Locknut for oil pump seperating board 2 10-12N•M
23 Locknut for oil pump sprocket 1 8-10N•M
24 Locknut for oil pump 2 10-12N•M
25 Locknut for oil pump cover 1 •M
1-3N•
26 Locknut for super-clutch 1 35-40N•M
27 Locknut for super clutch outside 3 10-12N•M
28 Locknut for right crankcase 2 10-12N•M
29 Double head bolt for left and right crankcase 4 22-25N•M
30 Fixing bolt for motro 2 10-12N•M
31 Locknut for left crankcase cover and line coil 11 10-12N•M
32 Tapping screw for ventilating guide board of left
crankcase cover 4 3-6N•M
33 Locknut for driver disc 1 45-55N•M
34 Locknut for driven disc 1 45-55N•M
35 Locknut for driven disc clutch 1 55-60N•M
36 Locknut for press-board of kick starter 1 10-12N•M
37 Locknut for transmission case cover 5 10-12N•M
38 Locknut for flowing oil hole of transmission case 2 22-25N•M
39 Locknut for flowing oil hole of left crank. 1 40-45N•M 15
40 Locknut for position shaft of left crank 1 22-25N•M

Downloaded from www.Manualslib.com manuals search engine

 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. Size (mm) Qty. Description Location
Camshaft fixing seat and
1 10Фx16 2 Engine
cylinder head
2 10Фx16 2 Cylinder head and cylinder head Engine
3 10Фx16 2 Crankcase and cylinder body Engine
4 10Фx16 2 Left and right crankcase Engine
5 8Фx14 2 Left crankcase and gearbox Engine
6 10Фx16 2 Left crankcase and left cover Engine
Rignt crankcase and right
7 8Фx14 2 Engine
cover
O-ring-7NOS.
S.NO. Size (mm) Qty. Description Location
1 9Фx1.6 2 Inlet and exhast valve pipe Engine
2 13.7Фx1.5 1 Atmolysis chain pulling lever Engine
3 9.5Фx1.5 1 Atmolysis chain adjustor Engine
4 18Фx3 1 Oil gauge Engine
5 30Фx3 1 Filter spring cap Engine
6 26502470 1 Starting moto Engine

Oil seal- 4NOS.

S.NO. Size (mm) Qty. Description Location
1 27x42x7 1 Output shaft---gearbox cover Engine
2 20x32x6 1 Output shaft—left crankcase Engine
3 19.8x30x7 1 Crank—left crankcase Engine
4 19.8x30x7 1 Crank—right cover Engine

16

Downloaded from www.Manualslib.com manuals search engine

 BEARING- 13NOS
S.NO. Code Qty. Description Location
1 6004 1 Output shaft—gearbox cover Engine
2 6201 1 Middle shaft—gearbox cover Engine
3 6301 1 Output shaft—gearbox cover Engine
4 6203 1 Output shaft—left case Engine
5 6202 1 Middle shaft—left case Engine
6 6204 1 Output shaft—left case Engine
7 TM-SCO7A87 1 Left crank—left case Engine
8 TM-SCD5ASSCS12 1 Right crank—right case Engine
8 K28x33x14 1 Crank pin—crank connecting big rod Engine
9 K28x32x17 1 Clutch hub—cluch gear Engine
10 6902NSE28 x15x7 1 Driven disc—output shaft Engine
11 HK20 x29x18RS 1 Driven disc—output shaft Engine
12 6002 2 Camshaft—atmolysis shaft fixing holer Engine
PINSHAFT- 2NOS
S.NO. Size (mm) Qty. Description Location
1 5Фx6 1 Super clutch Engine
2 4Фx6.5 1 Oil pump Engine
GASKET- 7NOS

S.NO. Gasket Type Qty. Location

1 Cyliner head cover Rubber endurable against oil 1 Engine
2 Cylinder head Steel 1 Engine
Asbestos rubber endurable
3 Cylindr body 1 Engine
against oil
4 Crankcase Endurable oil asbestos rubber 1 Engine
5 Right crankcase cover Endurable oil asbestos rubber 1 Engine
6 Left crankcase cover Endurable oil asbestos rubber 1 Engine
7 Atmolysis chain adjuster Endurable oil asbestos rubber 1 Engine

17

Downloaded from www.Manualslib.com manuals search engine

 Shifting gears inforamtion
Gear down
Gear Gear qty. Gear QTY.
ratio
2.8 A1 15 A2 42

3.077 B1 13 B2 40
GEAR INFORMATION
NO. GEAR QTY. POSITION

1 Kick starter gear 38 ENGINE

Kick starter transition ENGINE
2 13
small gear
Kixk starter transition big ENGINE
3 49
gear
Crank kick starter driven ENGINE
4 20
gear

Starting motor drvie gear

ENGINE
5 9
Electricity starter ENGINE
6 54/13
transition gear

Clutch gear
ENGINE
7 52
SPROCKET INFORMATION
No. Sprocket wheel QTY. POSITION
Right crank oil pump driver
1 17 ENGINE
sprocket wheel

2 Oil pump sprocket wheel 19 ENGINE

Left crank atmolysis shaft
3 17 ENGINE
driver sprocket

4 Atmolysis shaft sprocket 34 ENGINE

CHAIN INFORMATION
NO. CHAIN NODE POSITION

1 ATMOLYSIS SHAFT CHAIN 90 ENGINE

2 OIL PUMP CHAIN 42 ENGINE

18

Downloaded from www.Manualslib.com manuals search engine

 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

19

Downloaded from www.Manualslib.com manuals search engine

 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 INSTALLATION
Guiding-wind cover/fan cover/carburetor left crankcase assy./gearbox assy.

Left crankcase cover/gasket/piston pin gearbox

Outside part of left crankcase crankshaft/left and right crank motor

Chain adjustor /cylinder head cover oil pump/super-clutch/electric start transition gear

Camshaft holder/cam right crankcase cover/oil filter/oil gauge

Cylinder cover/gasket/pin coil/flywheel/fan impeller

Cylinder/gasket/pin piston/piston pin/spring clip

Spring clip/piston pin/piston cylinder/gasket/pin

fan impeller/flywheel/coil cylinder cover/gasket/pin

Right crankcase cover/oil filter/oil gauge cam/camshaft supporter

Right crankcase outside chain adjustor/cylinder head cover

Start motor/left and right crankcase/crank left crankcase outside assy.

Gearbox left crankcase cover/gasket/pin

Left crankcase/gearbox cover guiding-wind cover/fan cover/carburetor

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

20

Downloaded from www.Manualslib.com manuals search engine

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

REMOVAL:

Whorl cover screw(6) 2N.M

Scrrew (10) screw (6)
Whorl cover bolt (7) 11N.M
Bolt (1) bolt (7)
Cowling screw (10) 2N.M
Top cowling (11) fan whorl cover assy. (8)
Cowling bolt(1) 11N.M
Bottom cowling (4) pastern cover (9)

Top cowling seal gasket (2) cooling pipe (5)

Bottom cowling seal gasket (3)

Coil clip (12)

Pastern cover (13)

：The installation sequence is essentially the reverse of removal.
installation：
Notice: avoid missing cowling seal bar.

21

Downloaded from www.Manualslib.com manuals search engine

 B.cylinder head installation
REMOVAL Installation
Cylinder head cover (1)/cylinder head cover seal bar Cylinder head
Right against “T” mark on magneto Valve pipe/valve oil seal assy./gasket
（in the bottom of exhaust stroke ） Inlet valve and exhaust valve/valve
spring/spring holder/lock clip
timing chain tensioner（2）
Cylinder head assy.
atmolysis shaft assy.（3）/atmolysis shaft chain
（4） Atmolysis shaft chain/atmolysis shaft
（shuf off） assy.
Atmolysis shaft holder assy./Atmolysis shaft fixer assy. （mesh）
Atmolysis shaft assy. and atmolysis shaft
Cylinder head assy. fixer assy.
valve lock clip/valve spring holder（5）/inlet、exhaust Right against mark “T” on magneto and
valve spring） correct timing mark on timing gears
（special tool T04） (keep timing scale of timing gears on the
same level with joint surface of cylinder
inlet valve and exhaust valve（7） head cover)
Timing chain tensioner（adjust）
Valve oil seal assy.（8）
Adjust valve clearance
Valve pipe（9）
（inlet valve clearance: 0.03~0.05mm,
Cylinder head（10） 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 10~12N·M 3. Cam fixer locknut 22~25 N·M
2. Tension bolt and fixing bolt 10~12 N·M 4. Inlet pipe locknut 10~12 N·M
：
NOTICE：
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

22

Downloaded from www.Manualslib.com manuals search engine

 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 bearing（12）
assy.
Adjusting gasket（16）
Atmolysis shaft fixer assy.
Auto reductor outside ring（14）and ball bearing,
Rocker arm shaft（2） spring（15）
Gasket（3）and rocker arm（4） Atmolysis shaft left bearing（13）
Stopper board（5） Atmolysis shaft sprocket assy.（11）
Axes （6）and bush（7） Atmolysis shaft assy.
Mass （8）and spring（9） Atmolysis shaft fixer（10）
Atmolysis shaft fixer（10） Axes（6）, bush（7）,mass（8）and spring（9）
Atmolysis shaft assy. Stopper board（5）
Atmolysis shaft sprocket comp.（11） Rocker arm（4）and gasket（3）
Atmolysis shaft right bearing（12）and atmolysis Rocker arm shaft（2）
shaft left bearing（13）
Atmolysis shaft fixer assy.
Auto reductor outside ring（14）and ball bearing,
spring（15） Atmolysis shaft fixer and atmolysis shaft assy.
Adusting gasket（16）and atmolysis shaft（17）
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.

23

Downloaded from www.Manualslib.com manuals search engine

 24

Downloaded from www.Manualslib.com manuals search engine

 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（一）

Oil ring slice（二）

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 (一).
5、 The gap of spring clip is 80º-100º against the gap of groove.
ITEMS VOLUME

The first ring 0.1~0.2mm

Hatch clearance during working The second ring 0.1~0.2mm
Oil ring slice 0.3~0.4mm

Clearance between piston ring The first ring 0.013~0.045mm

and groove The second ring 0.013~0.045mm

25

Downloaded from www.Manualslib.com manuals search engine

 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) fender (2)

Left crankcase cover (3)

pin（4）/gasket（5）
The installation sequence is essentially the reverse of removal.
：
Notice：
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.
2、 Position clip (1) and fender (2).
3、 Lock bolts diagonally and for all bolts torque is 10-12N.M.

26

Downloaded from www.Manualslib.com manuals search engine

 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) filter net screw cap(19) nut(22) 50N.M

Fan assy.(10) O-ring(18) Magneto bolt (2) 7N.M

Nut (22) spring(17) Fan bolt (9) 11N.M

Gasket(21) filter net assy.(16) Trigger screw (8) 6N.M

Flywheel assy.(11) fuel gauge(5) Filter net screw cap (19) 57N.M

Screw(8) seal ring(4) Other bolts for right crankcase 11N.M

Trigger assy.(7) other bolts

Bolt(15) ring crankcase cover(2)

Clip holder (20) gasket (1)

Bolt (12)

Magneto stator (13)

The installation sequece is the reverse of removal.
NOTICE： ：1. The clearance between flywheel trigger and trigger head is 0.5±0.2mm.
2. Fan and trigger head cannot collide.

27

Downloaded from www.Manualslib.com manuals search engine

 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

Locknut（1） electricity starting transition gear (5) Bolt（7）

special tool（ T05）
gasket（2） electricity starting gear shaft（6） oil pump sprocket end cover8）

Starting cluch assy.（3） nut（9）

Semicircular key（4） oil pump sprocket chain（10）

：The installation sequence is essentially the reverse of removal.
Installation：
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. bolt（12）
3.some axial clearance exists for clutch and clutch gears only turns one direction.
Screw axes（13）

Screw（14）

Oil pump cover（15）

rotor（16）

pin（17）

oil pump cover body（18）

TORQUE： ：
1.Clutch locknut 35~40N.M
2.oil pump fixing bolt 10~12 N.M
3.sprocket locknut 10~12 N.M
4.sprocket end cover bolt 8~10 N.M
5.pump cover fixing screw 3~5 N.M

28

Downloaded from www.Manualslib.com manuals search engine

 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
Nut（6）/gasket（5）/driving flywheel（4） Starting transition gear assy.（7）/kicing starter
sprocket assy.（8）
Nut（13）/gasket（12）/acentric disc（11）
Starting spring slice（9）
Strap（14）/driven disc assy.（10）
Starting driven gear (1)
Bush（3）/driver wheel assy.（2）
Driveng wheel assy.（2）/bush（3）
Starting driven sprocket（1）
Driving impeller（4）/ gasket（5）/ nut（6）
Starting spring slice（9）
strap（14）/driven disc assy.（10）
Kicking starter gear assy.（8）/starting transition
gearassy.（7） acentric disc（11）/gasket（12）/nut（13）
：
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 doesn’t turn back;
position starting spring slice correctly and lock bolt, and the torque is 10~12N•M.
2、 When 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.
3、 Finally, lock nut (15)and nut（8），the torque is 45~55N•M，then drive strp, now driven wheel strap disc releases freely.
4、 Assembled bush glides freely and convex prick side of dish gasket（7）and gasket（14）is towards outside.

29

Downloaded from www.Manualslib.com manuals search engine

 i . C R A N K C A S E I N S TA L L AT I O N
REMOVAL IN INSTALLATION
Bolt（1） Left crankcase assy.（8）

Right crankcase assy.（2） chain（6）

pin（7）/gasket（3） Crank assy.（4）

Crankcase assy.（4） Pin（7）/gasket（3）

chain（6） Right crankcase assy.（2）

Left crankcase assy.（8） Bolt（1）

Oil seal(5） Oil seal（5）

：
Notice：
1、 When 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.
2、 It 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.
3、 Crankshaft connecting rod can turn freely after composing the case, and without block
4、 Bolt touque：10~12 N•M

30

Downloaded from www.Manualslib.com manuals search engine

 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）

Middle shaft assy.（4） output shaft assy.（5） input shaft bearing input shaft（3） middle shaft bearing output shaft bearing

Middle shaft bearing output shaft oil seal and bearing input shaft oil seal and bearing
：The installation sequence is essentially the reverse of removal.
Installation：
：
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, don’t damage the seal and cline or turn it over.
3、 Various gears should be positioned properly and turn freely.
4、To assemble locknut, first of all pre-fix the bolt of pin hole, then lock various bolts, locking torque: 12N
•M；

A1 A2 B1 B2
Gears QTY. 15T 42T 13T 40T
Deceleration ratio 2.8 3.077

31

Downloaded from www.Manualslib.com manuals search engine

 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
REMOVAL Remove clutch-driving board assy.
DRIVEN DISC ASSY. clip circle（16）
Clutch disc（1） fixing shaft（12）/sliding bearing（11）
clutch side board（17）
nut（2） seal ring（7）/driven stepless transmission disc（8）
spring（18）/clutch mass（19）
Clutch driving board assy.（3） rolling needle bearing（15）
damper rubber（20）
Spring seat bush（4） clip ring（14）/rolling ball bearing（13）
limiter（21）/pin shaft（22）
Compression spring（5） rear transmission main disc（10）
driving board bottom holder（23）
Spring bush（6）
：The installation sequece is essentially the reverse of removal.
Installation：
：
Notice：
1、 When reinstalling clutch driving board assy., be sure to use new limitter and pin shaft, and ensure stable connection.
2、 When 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.

32

Downloaded from www.Manualslib.com manuals search engine

 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 Removal
Kicing starter shaft assy. Transition gear shaft assy.

Bush（6） Fixing pin（6）

bush（1） Adjusting gasket（4）

gasket（2） （including（5）
Transition gear assy.（3） ）

spring（3） Tension spring（2）

pin（5） Transition gear shaft（1）

kicking starter shaft（4） clip（5）

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

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

33

Downloaded from www.Manualslib.com manuals search engine

 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 ：
Installation：
Flywheel（1） Strap driving brake disc（5）

bush（2） Inner hole bush（4）

pulling FALAN（8） Steel bush（3）

cushion gasket（7） Acentric rolling pole（6）

acentric rolling pole（6） Cushion gasket（7）

steel bush（3） Pulling FALAN（8）

inner hole bush（4） Bush（2）

strap driving brake disc（5） Flywheel（1）

：
NOTICE：
1、 Before installing pulling FALAN, clip 3 cushion gaskets onto pulling FALAN.
2、 Bush（2）slides freely.

34

Downloaded from www.Manualslib.com manuals search engine

 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 bearing（2）

Screw M6（3）

Clutch hub（4）

Pin（5）

rolling pole（6）, spring bush（7） and spring（8）

Clutch husk（9）

Spring retainer（10）

Cluch outside circle（11）

*Remove it if necessary
：The installation sequence is essentially the reverse of removal.
Installation：
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

Downloaded from www.Manualslib.com manuals search engine

 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：： By kicking starter：：
Kicking starter lever Kicking starter lever

Kicking starter shaft (9) Kicking starter shaft (9)

Starting gear Starting gear

Transition small gear Transition gear

Transition big gear Transition big gear

Crankshaft starting driven gear Crankshaft starting driven gear

Crankshaft (3) Crankshaft (3)

Connecting rod (2) Connecting rod (2)

Piston (1) Piston (1)

36

Downloaded from www.Manualslib.com manuals search engine

 F． Lubrication system

Rocker arm
Camshaft assy.

Crankshaft assy.

Oil pump assy.

Fileter assy.

37

Downloaded from www.Manualslib.com manuals search engine

 Lubricate
Here are main functions for engin oil.
1、 Lubricate……reduce friction with metal
2、 Cooling……prevent too hot
3、 Anti-dust……prevent rusting
4、 Clear……prevent deposit and clear carbon deposit
5、 Seal intermediate……seal combustion chamber
6、 Anti-abrision……prolong accessory’s 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:：
A：On 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.
B：On 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.
C：On 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.：
C1：On 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.
C2：On 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

Downloaded from www.Manualslib.com manuals search engine

 G ． VA LV E C L E R A N C E S E T U P
Engine is in cooling state.
1、 Remove cylinder head cover；
2、 Remove pastern cap of fan whorl shell.；
3、 Keep “T” mark on flywheel the same line with the mark on righ crankcase cover；
4、 Ensure timing reticle of cam sprocket in the same line with joint surface of cylinder head cover.；
5、 Inspect the clearance of inlet valve and exhaust valve, inlet valve：0.03~0.05mm，exhaust valve：
0.05~0.06mm，if clearance is not at the range of specified volume, adjust rocker adjusting screw until the
clearance reaches its specified range.

39

Downloaded from www.Manualslib.com manuals search engine

 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
6． above steps three times and calculate
their average value as actual
compression pressure, which should
be 11±1Kg/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/cm2，clear deposited carbon in cylinder head, pistion, combustion
chamber, at the same time inspect exhaust port.

40

Downloaded from www.Manualslib.com manuals search engine

 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 STANDARD
Air pressure in cylinder 13±1kg/cm2
Inlet 0.12~0.16mm
Valve clearance
Exhaust 0.12~0.16mm
Inlet 29.625±0.05
Camshaft cam impeller height
Exhaust 29.038±0.05
Inlet 4.975~4.990 mm
Valve tappet
Exhaust 4.955~4.970 mm
Inlet 5.000~5.012mm
Valve Valve pipe
Exhaust 5.000~5.012mm

Valve shaft-valve pipe Inlet 0.010~0.037mm

clearance Exhaust 0.030~0.057mm
Inner spring 32.3±0.05mm
Natural distance of spring
Outer spring 35.0±0.05mm

Cylinder/piston

Item Standard
A B
Cylinder inner diameter 52.400~52.405mm 52.405~52.410 mm
Cylinder and piston
Piston diameter 52.370~52.375mm 52.375~52.380mm

Clearance of piston and cylinder 0.025~0.035mm 0.025~0.035mm

Piston pin hole 15.002~15.005mm 15.005~15.008mm

Piston pin
Piston pin 14.997~15.000mm 15.000~15.003mm

Clearance of piston 第一道环 0.013-0.045mm

ring and groove 第二道环 0.013-0.045mm
Piston ring 第一道环 0.1-0.2mm
活塞环开口间隙 第二道环 0.1-0.2mm
油 环 0.3-0.4mm

41

Downloaded from www.Manualslib.com manuals search engine

 4． Oil — — fuel system

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

Manufacturer CHINA QIANJIANG

Type Vacuum piston perfect state

Model PD24JC Mileage
Diameter of throat tube 24mm (Km) 60 Economic
Main nozzle 179# consume
Idle nozzle 30# 50 area Actual state
Mixture screw rounds 1~2 rounds a
Float height 13±1mm
30

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

42

Downloaded from www.Manualslib.com manuals search engine

 （ARI AND FUEL）
MIXED GAS（ ）SYSTEM
：
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 fuel

Air 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： Carburetor oil road
start： 7-8 ：1 maily including
idle speed： 10-12 ：1 1. Inlet oil road
slow speed： 12-14 ：1 2. Condensing oil road
common speed：15-17 ：1 3. Idle speed oil road
high speed： 13-15 ：1 4. Slow speed oil road
5. Common speed oil road
6. Great mixed gas road

43

Downloaded from www.Manualslib.com manuals search engine

 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

Downloaded from www.Manualslib.com manuals search engine

 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

Downloaded from www.Manualslib.com manuals search engine

 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：
1、 Confirm electric condensing valve wire is connected correctly;
2、 Confirm carburetor is intalled correctly and no oil leaking out.

CARBURETOR ASSY.
STEPS FOR REMOVAL： ：
1、 Remove 4 screws, take out stopper spring and stopper assy;
2、 Unscrew oil needle compaction cap, take out oil needle and oil needle spring;
3、 Unscrew misture ratio adjusting screw, spring, gasket and seal ring;
4、 Unscrew idle adjusting screw and screw；
5、 Remove electric condensing valve assy.；
6、 Remove choke valve assy.；
7、 Remvoe the 4 screws on under cover;
8、 Remove floater pin, floater and needle valve in turn；
9、 Remove main jet, foam tube and main nozzle in turn；
10、Unscrew idle jet；
11、clean various parts with gasoline, and then blow them with high pressure pneumatic gun.
：
Notice：
1、 In the process of removing other accessories in floater chamber, first of all remove floater and needle valve
to ensure floater is not damaged；
2、 To preserve main nozzle, remove it from one side of stopper hole.

46

Downloaded from www.Manualslib.com manuals search engine

 ：
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 15±1mm，adjust 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)；
10、install electric condensing valve assy. and blocking wind valve assy. in order；
11、install oil needle, spring, oil needle compaction cap in order；
12、install 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:
1、 Start and warmup engine for about three seconds so that engine rotates at normal driving temperature;
2、 Adjust idle speed adjusting screw so that engine rotates at 1600rpm；
3、 Screw mixture ratio adjusting screw into bottom, the strength is not too weight；
4、 Now 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)；
5、 Screw mixture ratio adjusting screw back for one round；
6、 Restart ingine, adjust idle speed adjusting screw to be 2000-2500rpm；
7、 Slowly adjust mixture ratio screw（anticlockwise）until engine rotates at the highest speed（screw mixture
ratio screw back for less than or equal to 2 rounds） ；
8、 Readjust idle speed adjuting screw so that engine rotates at 1600±100rpm；
9、 Play up throttle to accelerate rotating, inspect if its rotating speed is stable；
10、measure exhaust and compare it to standard volume.

：
Notice：
1、 Adjust 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

Downloaded from www.Manualslib.com manuals search engine

 5． Install vehicle body
a． Specified fixing torque

NO. ITEM QTY. FIXING TORQUE

FRONT WHEEL/FRONT ABSORBER

1 Front wheel axis locknut 1 55-62Nm
Fixing boblt between front absorber and support under
2 4 37-44N.m
connecting board assy.
3 Fixing bolt for disc brake and front absorber 2 22-29N.m
Handlebar
Fixing bolt for handlebar and supporting under connecting
1 1 37-44N.m
board
Frame
1 Fixing bolt for frame and engine bracket 45-58N.m
Fixing bolt for frame and rear absorber
1 Rear wheel/rear absorber 2 37-44N.m
2 Rear wheel locknut 2 37-44N.m
Fixing bolt for left, rear absorber and engine
Fixing bolt for right, rear absorber and muffler connecting
1 1 100-130Nm
board
2 Engine 1 22-29N.m
Fixing bolt for engine and muffler
1 Fixing bolt for engine and engine bracket 2 22-29N.m
2 FRONT WHEEL/FRONT ABSORBER 1 37-44N.m

48

Downloaded from www.Manualslib.com manuals search engine

 b ． F r o n t w h e e l a s s y.
Removal sequence： Installation sequence：

locknut（17） driving slice（11）, gear retainer oil seal（10）,gear

retainer（12）
front wheel axes（3）

front wheel left bush（4）,gear retainer assy. steel rim（4）, front wheel middle bush（5）,
bearing（9）, valve port（3）,valve cap（2）
Fornt wheel assy.
tire（1）, steel rim assy.
front wheel, seal ring（5）
front wheel, seal ring（8）
tire （16）, steel rim assy.
Front wheel assy.
steel rim（1）, front wheel middle bush（6）
bearing（18）, valve port（2）, valve cap（20） front wheel left bush（7）, gear retainer assy.

front wheel axes（6）

driving slice（7）, gear retainer oil seal（10）, gear
retainer(12) locknut（13）

49

Downloaded from www.Manualslib.com manuals search engine

 c ． R e a r w h e e l a s s y.
Installation sequence：
：
Removal sequence： rear wheel rim（7）, valve port（11）, valve port cap（12）
locknut（10）
Rear braking camshaft (6)
Rear wheel assy.
Rear braking rocker arm (5)
tire（8）, rear wheel rim assy.
Bolt M6X35 (9)
Braking shoe assy.（1）
Rear braking tension spring（3）
Braking shoe calbe （2） Spring bush (4)
Braking shoe cable（4）
Braking tension spring（3）
Spring bush (4) Braking shoe assy.（11）
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）

50

Downloaded from www.Manualslib.com manuals search engine

 d ． M u f f l e r a s s y.
Installation sequence：
：
Removal sequence：
Position hole assy.（8）
Screw (10)
Decoration cover assy.（3）, rear decoration cover assy.,
bolt M8X50（6） （9）, screw（7）

lid nut（5） Muffler assy.（1）

position bush（4） Exhaust port gasket assy.（6）

Exhaust port gasket assy.（6） Position bush（4）

Muffler assy.（1） Lid nut（5）

Decoration cover assy.（3）, rear decoration cover assy., Bolt M8X50（6）

（9）, screw（7）
screw（10）
Position hole assy.（8）

51

Downloaded from www.Manualslib.com manuals search engine

 52

Downloaded from www.Manualslib.com manuals search engine

 e ． F r o n t f o r k a s s y.

：
Removal sequence： ：
Installation sequence：
Bolt M10X125X40（17） Frame assy.（20）

Front left absorber shock assy.（12）, front right Under bearing upper steel bowl（7）
absorber shock assy.（13）
Upper bearing under steel bowl（6）
Locknut（1）
Steel ball（16）
Stopper gasket（2）
Connecting board assy.(14)
Groove nut（3）
Upper bearing upper steel bowl（3） under bearing under steel bowl
Anti-dust cover（4） （11）
Handle joint under gasket（10）
Upper bearing steel bowl（3） Anti-dust cover （4）

Under connecting board assy.（14） Groove nut（3）

Steel ball （16） under bearing steel bowl（11） Stopper gasket（2）

Handle joint under gasket（10） Locknut （1

Upper bearing under steel bowl（6）
Front left absorber assy. (12), front right absorber assy.（13
Under bearing upper steel bowl（7）
Frame assy.（20） Bolt M10X125X40（17）

53

Downloaded from www.Manualslib.com manuals search engine

 f ． F r o n t a b s o r b e r a s s y.
：
Removal： ：
Installation：
Bolt (1) Install piston ring into piston lever

O-rseal ring (2) Install buffer spring into piston lever

Absorber spring (3) Install the above parts assy. into inner tube assy.

Piston lever（4） Install buffer prick into piston lever

Screw（5）and gasket Install the above parts into aluminium outer tube

Inner tube assy. (6) Fasten screw（gasket）

Fixing torque: 20N.m
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 ring（11）
Anti-dust ring assy.
Oil seal assy.（12）
Add absorber oil(100±2 ml)
Oil seal gasket（13）
Absorber spring (seal ring upturned)
guiding bush（14）
O-seal ring
Aluminium outer tube（15）
Bolt
Buffer prick（9） Fixing torque: 23N.m

54

Downloaded from www.Manualslib.com manuals search engine

 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

Downloaded from www.Manualslib.com manuals search engine

 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

Downloaded from www.Manualslib.com manuals search engine

 g. Disc brake system
Liquid pressure brake（
brake（disc）
disc）
Brake principle: liquid cannot be compressed, so
strength can be transmitted through liquid medium.
Cylinder：When 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 11.supplement
hole
4.stopper anti-dust cover 8.bowl 12.oil pump
Fig.6

57

Downloaded from www.Manualslib.com manuals search engine

 Fig. 7

Caliper assy.

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

Fig. 10

58

Downloaded from www.Manualslib.com manuals search engine

 Liquid pressure arrester (brake) insepction
NOTICES： (2) Cut off braking hose. Put the throat hose of open
1．Don’t touch arrester for long time.
into container, and then draw out braking
2．Once braking liquid splash eyes, wash eyes with
liquid.
cold water and see a doctor.
3．Never let braking liquid splash painting part, (3) Disassemble bolt, braking caliper assy., brake shoe, and
otherwise paint may fall off. Wipe it with wet brake shoe spring.
cloth if it happens.
(4) Disassemble oil stopper, oil stopper anti-dustcover and
4．Never wash liquid pressure arrester parts with
square seal ring. Reoval steps are the following:
mineral oil, like coal oil, gasoline, disel oil
and so on. Be sure to use sealed braking liquid ① insufflate compressed air into braking hosejoint, push oil
to wash it. stopper from braking caliper. Never try to prize oil stopper,
5 ． Never use mineral oil or lubrication to
otherswide it may damage oil stopper. It had better cover oil
lubricateteh inner parts of liquid pressure
stopper with cloth to avoid that caliper springs out of
arrester.
6．For it is easy for braking liquid to absorb caliper, which may result in injury.

moisture, to ensure braking capability, it had ② Disassemble oil stopper seal part and anti-dustcover.
better replace braking liquid per year. Notice: when disassembling oil stopper seal parts and
7 ．Reinstall it at once after liquid pressure anti-dust cover, never damage the surface of inner hole of
arrester parts are removed. braking caliper.
8．It is forbidden to wipe brake pad kits with sand The installaing sequecnce is essentially the reverse
paper, for sand paprer includes hard grain, of removal.
which may damage brake disc. Notice：Lubricate oil stopper sealing anti-dust parts with
9．It is forbidden to rub caliper and inner hole braking liquid, and then insert oil stopper into braking
of oil cylinder to avoid that some impurity of caliper slowly.
cotton leaves in the surface of inner hole. Exhausting air steps:
10．Be sure to use new oil stopper seal and seal 1．Add proper braking liquid in oil reservoir.
gasket and so on. 2．Assemble oil reservoir gasket carefully to avoid
Oil cylinder assy. removal: that any braking liquid splash or oil overflows
1． Remove handle lever screw and left handle 3．Connect clear plastic pipe with braking caliper
lever. exhaust port valve closely, and put the other end
2． Take down stopper anti-dust cover. of the pipe in container.
3． Remove spring clip ring. 4．Slowly start brake lever for several times. Pull
4． Reove stopper assy. the lever back to keep it on some position.
The installation sequence of oil cylinder is 5． Unscrew exhaust port and operate brake lever
essentially the reverse of removal. In its limit postion.
Notice：Lubricate the surface of stopper peel bowl, 6．When brake lever is in its limit position, screw
and then install it into the hole of oil cylinder. exhaust port, and then release the lever.
Caliper assy. removal: 7．Do step（4）to step（6） again and again until air
Place the open end of braking hose into container bubble disappears from system.
and draw out braking liquid carefully. 8. Add proper braking liquid.
(1) Remove inlet oil bolt and seal gasket.

59

Downloaded from www.Manualslib.com manuals search engine

 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 Standard
Tire air pressure Tire air pressure 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 STANDARD
Appointed disc brake oil DOT3 or DOT4
Manufacturer for disc brake oil
Deepness of brake shoe 6MM
Deepness of brake disc 4MM

Reae wheel
Item Standard
Air pressure in tire Driver 200Kpa
Driver and passenger 225Kpa
Free distance of rear brake rocker arm 20MM
Diameter of rear brake drum 130MM
Deepness of brake shoe 4MM

60

Downloaded from www.Manualslib.com manuals search engine

 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 stator：they are for charging coil of light/battery，Touching 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. Coil type Resistance Lead color
2. Toucing coil 200±20Ω at 20℃ Blue white/green white
Light <2Ω Blue
3.
Charging battery coil <2Ω Blue

：Testing for all resitance is referred to ground (black)

Notice：
● 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

Downloaded from www.Manualslib.com manuals search engine

 62

Downloaded from www.Manualslib.com manuals search engine

 Charging system circuit diagram（ AC circuit diagram）

63

Downloaded from www.Manualslib.com manuals search engine

 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 Alarm

Stop swtich

Start switch

Start relay

Start motor

Connect ground magnet motor

64

Downloaded from www.Manualslib.com manuals search engine

 c . C D I pa r t t e s t i n g

FOR any fault about ignition system, you may inspect 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
1.Spark plug
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
2. cap（
spark plug cap pin）
（pin ） ：
Inspect if resistance is near 5.0KΩ，and replace it if not. 5.touching off coilcoil：：
3.composite
3. composite switch a. inspect resistance between blue/white and green/white at 20
℃，
inspect its continuity of black/white and black lead end of and see if the resistance ranges between 100 and180Ω, otherwise
replace the touching off coil.
Ignition switch with multimeter, replace it if it doesnot with b.remove spark plug, and then connect a 1.5 voltage
the following requirements in the table L.E.D. between blue/white and green/white leads, use
Switch position state
“OFF” connection
“LOCK” connection

“ON” disconnection Kicking starter to rotate magnet motor,

LED may flash,. Otherwise replace

touching off coil.

4.ignition
4.ignition coil：
coil：

there is sole ground wire for motorcycle（black）.

A.inspect the resistance of secondary coil of

green and yellow/black lead ends, it should be below 1.0Ω，otherwise replace

ignition coil.

65

Downloaded from www.Manualslib.com manuals search engine

 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 13º ahead of top dead center
at 1400RPM（see tachometer）.
•during speedup
High speed mark“II” is right against
mark“I” on timing viewing hole, ignate
it at 28º ahead of top dead center at
4000RPM.
If ignition timing is not correct, replace CDI, and then inspect new one.

66

Downloaded from www.Manualslib.com manuals search engine

 ．Related notice about battery
d．

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
shouldn’t be below 9V, which ensure it can start engine. Inspect the proportion of electrolytem, each of
which shouldn’t 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 circuit：Don’t charge battery too fast.
Replace battery if the above state happens.
Recommended adjuster for battery: made：ELAK，model：BCT7。
warn： ：if battery is bad, please inspect charging wiring road before removal.

Commonly, fully charged battery: 1.220-1.240。

Propotion Charging condition：＜1.220。
With densimeter to inspect battery.
Remove negative pole, then positive pole. Replace it if battery connector is eroded by
Warn Sulfate; replace it if there is too much deposit in the bottom of battery.
Charge When the proportion of old battery is less 1.220, charge it, and you can adjust it
According to the temperatue of electrolyte.
Charging current For the type of 2.5AH：≤0.25A；
For the tpe of 7.0AH：≤0.7A。
Charging time 8-12 hours for new battery；
（minute）） 12-14 hours for old battery.
Unscrew all cap cover before charging；
Keep battery far away from spark or fire；
Warn Turn on power switch when charging；
Forbid charging when the temperature of electrolyte is 45℃；
Don’t charge it too fast.
Install Connect positive pole, then connect negative pole.
Battery capacity 12V 2.5A.H
Battery charger is made：ELAK， model：C1/48
recommended
Liquid densimeteris made：THIMSON， model：108
recommended
Notice：：1、fill battery with distilled water to its top level（forbid fill old battery with acidity liquid）
；
2、ensure new battery with full electrolyte to be charged at low temperatrue；
3、ensure ventilated pipe of battery not to be blocked or bended, ventilated pipe must be smooth and without block；
4、if vehicle neednot use for some long time, charge it fully, and then connect its positive pole with vehicle（remove the
negative pole of battery）.

67

Downloaded from www.Manualslib.com manuals search engine

 ．Various bulbs removal and replacement
e．
（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 12V，25W/25W（turn it anti-clockwise）

（through adjusting nut to adjust focus）

Remove and replace night small lamp bult-12V，3 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-12V，10 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 light）, fuel gauge, odometer
Meter installation： ：
Install it in the reverse of removal and adjust its focus.

68

Downloaded from www.Manualslib.com manuals search engine

 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

Trans-beam swtich
Main switch

Front/rear braking switch Turning switch

Lighting switch
Horn switch

Starting swtich

69

Downloaded from www.Manualslib.com manuals search engine

 g． Requirement for main electric component specification
Storage battery charging system
ITEM SPECIFICATION
Capacity 12V-2.5AH（KS）/7AH（KS）
Specific gravity (27 Condition for full 1.220-1.240
Storage ℃) charge ＜1.220
battery
Current for charge 0.25A/0.7A
Time for charge 8-12 hours
Capacity 114W（at 5000RPM）
Charger Ignition coil Between black line and ≤2Ω
resistance black/white
（20℃/68°F）

Lamp line Yellow and ≤2Ω

green/white
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.

70

Downloaded from www.Manualslib.com manuals search engine

 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 SPECIFICATION
CAPACITY 12V/7AH(ES)
SPECIFIC GRAVITY Condition for full 1..220-1.240
（27℃） charge <1.220
BATTERY
Charge current
0.25A(KS)/0.7A(ES)
Charge time 8~12hrs
Specification ≧ 85W@4000RPM
MAGNETO Battery charge coil White Less than 2Ω
resistance（28℃/68oF） Black
Lighting /lignting coil Green red/white Less than 2Ω
Retifying regulator
Stable voltage of lighting circuit < 13.5±0.2 V
DC voltage of battery charge >14.4±0.4 V

IGNITION SYSTEM

STORAGE BATTERY SPECIFICATION

Type C7HSA (NGK)

Spark plug
Spark plug clearance 0.6~0.7mm

“F”mark 150±10BTDC at1700RPM

Ignition timing 280±10 BTDC AT
“Ⅱ” complete advance ignition
4000RPM
Primary coil resistance 0.25±0.05Ω

Ignition coil Secondary coil resistance （with plug） 7.5±1KΩ

Secondary coil resistance（without plug） 3.4±0.31KΩ

Charging coil resistance

Green white/blue
Touching off coil（at 20℃） 100~180Ω
white

71

Downloaded from www.Manualslib.com manuals search engine

 C

OTHERS

72

Downloaded from www.Manualslib.com manuals search engine

 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. Inspect the light of paint, glaze paint if necessary.
3. Inspect the degree of tightness of exposed bolt and nut, including bolts for carburetor, cylinder head
cover and engine etc.
4. Warm up engine, and then inspect engine oil, add some oil if necessary.
5. Inspect air pressure of tire, and correct it if necessary.
6. Install battery.
7. Inspect the clearance of spark plug, and adjust it if necessary.
8. Inspect whole electrical system, the capability of control switch.
9. 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.

73

Downloaded from www.Manualslib.com manuals search engine

 INSPECTION POINTS

Inspect the performance of left and

right handle switch
Inspect free
distance of rear
braking lever

Inspect fixing Inspect air

torque of front Pressure of rear
wheel axes Tire

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

Inspect lighting
of headlight

Inspect fixing force

of rear wheel
Inspect the performance of Inspect air pressure of
locknut
front absorber shock front tire

74

Downloaded from www.Manualslib.com manuals search engine

 2． Periodic maintenance
It is necessary to do inspecting, checking, lubricating and regulated maintenance according to the following
instructions.
I：check, wash, adjust, lubricate or replace if necessary C：clean R：replace A：adjust L：Lubricate

NO. ITEM Maintenance mileage (reading of odometer)(NOTE 1)

REMARK
1000Km 4000Km 8000Km 12000Km
1 Fuel path* I I I
2 Fuel cleaner* C C C
3 Throttle handlebar* I I I
4 Air cleaner C C C Remark 2
5 Spark plug I R R
6 Valve clearance* I I I I
7 Engine oil I Per 5000Km:R
8 Oil filter net* C
9 Carburetor idle* I I I I
10 Battery I I I Remark 3
11 Brake pad kit abrasion I I I
12 Braking system I I I I
Front brakign liquid I I I I
13
pressure oil hose* Replace it per 4 years
I I I I
14 Front braking liquid*
Per two years
15 Stop switch* I I I
16 Headlight adjustment* I I I
17 Shock absorber system* I I I
18 Bolt, nut, pin* I I Remark 3
19 Wheel, rim** I I I I Remark 3

* 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.

75

Downloaded from www.Manualslib.com manuals search engine

 3． Permit and forbid

Permit Forbid

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

brake disc between braking shoes.

Keep tire with normal air pressure.

76

Downloaded from www.Manualslib.com manuals search engine

 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 driver’s 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: don’t 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 doesn’t 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. Loosen throttle handlebar and put right hand on disc brake lever.

2. Grasp rear brake lever with left hand, at the same time with right hand hold disc brake lever.

3. If suddenly grasp front disc brake lever, front wheel may be blocked and results in turnover.

4. 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. When braking vehicle, front absorber is compressed, rear wheel goes up, which ensures easy to brake.

6. Driver must keep correct posture to driver vehicle forward.

7. When vehicle stops, put feet on ground and front absorber, rear absorber turn back

77

Downloaded from www.Manualslib.com manuals search engine

 5.Examine and repair for fault
·Engine doesn’t 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 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 is good -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

3.use correct start mode to start engine Engine starts

s but stops soon- idle mixture ratio screw is not adjusted correctly
-Carburetor is blocked
Engine cannot start -Ignition advances or delays
-Mixed gas is too thin or thick

4.Remove and inspect spark plug Spark plug is moist - -carburetor choke is shut too tight
-Fuel leaks out from carburetor
Spark plug is dry -Mixed gas is too thick
-There is too much dust on air cleaner
-Fuel flows into combustion chamber

5.Measure air pressure in cylinder air pressure is too low ----valve seat mesh is not correct
-valve clearance is too small
Air pressure is normal -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

78

Downloaded from www.Manualslib.com manuals search engine

 ·Engine
Engine power is not enough Possible
Possible cause
1.leave wheel from ground and rotate it Wheel cannot rotate freely -braking resistance
-Wheel bearing is abraded or damaged
Wheel can rotate freely -Wheel bearing need lubricate
-Driving chain is too tight

2.inspect the pressue of tire pressure is too low -tire leaks.

- Tire valve is wrong.
Pressure is normal

3.inspect if carburetor is blocked. BLOCK -carburetor has not been maintained fully.

No block

4. Slightly speed up engine speedup is not enough for engine - mixed air is too thick or toothin.
-Air cleaner is blocked
Engine speeds up normally -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 not good - oil level is too high
-Oil level is too low
State is good -engine oil is polluted

7.inspect ignition time not correct -something wrong with ignition

-Something wrong with touching of fcoil
Correct -touching off coil is assembled incorrectly

8.inspect if clutch skids clutch skids -clutch spring is too loose

-Clutch braking pad kit is abraded
Clutch doesnot skid -strap is abraded

9.inspect if engine is too hot engine is too hot -there is carbon deposit in combustion chamber
-use wrong trademark fuel/oil
Engine is normal -clutch skids
-Mixed air is too thin
-Engine oil is too less

79

Downloaded from www.Manualslib.com manuals search engine

 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 Distribution mechanism doesn’t lubricate well oil path is blocked
-Something with oil pump
Good lubricating -oil filter or filtering paper is blocked

12.speedup or high-speed engine clash es -there is carbon deposit in combustion room

-Use wrong trademark fuel
No clash -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 气门 of valve clearance.
Correct -ignition coil is not assembled correctly.

2.inspect adjusting screw of mixed air of carburetor not correct -mixed air is too thin
-Mixed air is too thick
Correct

3.inspect carburetor gasket/seal gasket -fixing bolt looses or heat insulation machine leaks out air
-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 doesn’t connect well

5.inspect if carburetor is blocked blocked -oil path of carburetor is blocked

Not blocked - carburetor nozzle is blocked

80

Downloaded from www.Manualslib.com manuals search engine

 ·high speed is not good possible cause
1.inspect ignition incorrect - ignition is wrong
-Touching off coil is wrong
correct -touching off coil is installed incorrectly

2.carburetor oil pipe is ruptured fuel throttles -Fuel tank lacks gasoline
-Oil pipe is blocked
fuel is smooth -Filter is blocked
-Filter net is blocked
-Ventilating hole of fuel tank cap isblocked

3.inspect if carburetor nozzle is blocked block -Carburetor jet is blocked

not blocked

4.inspect distribution mechanis phase not correct -Timing chain is not installed correctly

Correct

5.inspect valve spring too loose -Valve spring is wrong

Normal

·It is difficult to control

1.If turning is difficult --Turning bearing adjust nut is too tight
--Turning bearing is damaged

2.If one wheel swings --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

3.If scooter inclines one side --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

81

Downloaded from www.Manualslib.com manuals search engine

 •FUEL SYSTEM •Cylinder head cover/Valve
ENGINE CANN’T START –Fault from engine cylinder head/valve may effect on the
capability of engine.
–Carburetor lacks oil –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
–There is no fuel for the tank
–Filter is blocked
–Oil tube is blocked
–Ventilated hole of fuel tank cap 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/thick（adjust 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

82

Downloaded from www.Manualslib.com manuals search engine

 The capability of driving is bad and consuption is too high Atmolysis chain
–Fuel system is blocked •Atmolysis chain noise
–Ignition system is wrong –Atmolysis chain tensioner is loose or damaged
•Cylinder/Piston –Tensioner head is damaged
–Cylinder pressure is low or not stable –Atmolysis chain guiding board is damaged
–Cylinder or piston ring is abraded

Smoke is too much Chain is too loose

–Cylinder, piston or piston circle is abraded –Tensioner is damaged
–Piston circle is installed incorrectly –Atmolysis chain becomes longer
–Piston or cylinder wall is scratched

Too hot
–There is carbon deposistion in piston or combustion chamber •CRANKSHAFT/KICKING STARTER
Noise is too much

CLASH OR ABNORMAL NOISE –Transmission bearing is abraded

–Piston or cylinder is abraded –Crrankshaft big end or crankshaft pin is abraded
–Carbon deposit

•CLUTCH/SHIFT GEARS Engine librates

CLUTCH –Crank moves too much
It is difficult for scooter to slide at idle speed
–Clutch is not adjusted correctly
–Clutch brake pad kit is distorted Kicking starter/Skid
–Clutch locknut is too loose –The mark for Kicking starter gears/Transition
gears is wrong
–Clutch acentric mass spring is not stable –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
• Front wheel/Drum brake/Shock
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

83

Downloaded from www.Manualslib.com manuals search engine

 –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 cann’t 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.

84

Downloaded from www.Manualslib.com manuals search engine

 Electric fault
lighting/battery charging system •Electrical starting system
battery has no electricity Starting motor doesnot rotate
–short circuit happens for wire –Fuse is broken off
–no electrolyte in battery storage –The cable of starting motor id loose
–battery discharge completely –Batteru discharges
–relay is wrong Press starting button – There is crack noise
–main fuse is connected completely or cuts off –Directly connect battery for motor, inspect its
–ignition switch is wrong rotating.
–battery charging coil is wrong –Something is wrong with lead contact
–Something is wrong with relay
Voltage is low –Something is wrong with starting motor
–charging is not engough for battery Press starting button – There is no crack noise
–electrolyte is not enough –Starting button is wrong
–discharge happens for battery –Inspect the voltage of short currentt relay
–charging system is wrong –short current relay is wrong
–it is not connected well Battery voltage
Turnoff –Inspect uninterrupted speciality of short current
–something is wrong with the connection of relay.
battery calbe –Short circuit relay is wrong
–something is wrong with charging system Continuity is abnormal
–the connection of starting system is wrong –touching of starting button is wrong
–ignition switch is wrong or short circuit –clutch switch is wrong
happens Starting motor rotates but its speed is slow
–short circuit happens for lighting system or –proportion of battery electrolyte is low
its connection is wrong –circuit impedance is too high
–starting motor agglutinates
Fault for charging system rotates
Starting motor rotates but engine doesn’t rotates
–lead or connector is wrong: Turnoff or –starting unilateral clutch is wrong
short circuit. –startign gears are wrong
–rectifier is wrong –starting chain or starting sprocket is wrong
–（ACG）is wrong Both starting motor and engine can rotate but
engine cann’t start
Bulb is burnt –something is wrong with ignition system
–connecting lead is loose or short circuit –engine fault-compression ratio is too low
happens –spark plug is wrong
–recitifying adjuster is wrong
Charging coil for bulb/battery is wrong Note：
Note：When ignition switch is in open position
and clutch is released, press starting button,
Headlight is dark staring motor works.
–grounding is not good
–rectifying adjuster is wrong
–charging coil for bulb/battery is wrong

85

Downloaded from www.Manualslib.com manuals search engine