JS125-6B Service Manual
JS125-6B Service Manual
JS125-6B Service Manual
MAINTENANCE MANUAL
NOTICE
This manual was produced by the chongqing Jianshe motorcycle co., Ltd primarily for use by Jianshe
Group dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic
in one manual, so if is assumed that anyone who uses this book to perform maintenance and repairs on
JS125-6B motorcycle has a basic understanding of the mechanical ideas and the procedures of machine
repair.Repairs attemped by anyone without this knowledge are likely to render the machine unsafe and
until for use.
Chongqing Jianshe Industries(Group)Co., Ltd is continually striving to improve all its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Jianshe
Group dealers and will appear in future editions of this manual where applicable.
IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following notations.
The Safety Alert Symbol means ATTENTION!BECOME ALERT!YOUR SAEFTY IS INVOLED!
Failure to follow WARNING instructions could result in severe injury or death to the machine operator,
a bystander or a person inspecting or repairing the machine.
A CAUTION indicates special precautions that must be taken to avoid damage to the machine.
A NOTE provides key information to make procedures easier or clearer.
ILLUSTRATED SYMBOLS
1
10
13
11
12
14
Special tool
Tighten
Filling electrolyte
Engine speed
Tester
10
11
12
13
14
COLOR INDICATIONS
CONTENT
CHAPTER 2 SPECIFICATIONS
General specifications ................................................................................................................ 10
Check the Specification ............................................................................................................. 13
Lock torque .............................................................................................................................. 18
Lubrication point and type of lubricants ...................................................................................... 21
Engine lubrication flow ............................................................................................................... 23
CHAPTER 4 ENGINE
Disassemble the engine ................................................................................................ 54
Ready to disassemble the engine ............................................................................................ 54
Disassemble the engine .......................................................................................................... 55
CHAPTER 5 CHASSIS
Front wheel ............................................................................................................................. 116
Front brake ............................................................................................................................. 117
Rear wheel .............................................................................................................................. 124
Rear brake .............................................................................................................................. 125
Divingchain ............................................................................................................................ 128
Front fork ............................................................................................................................... 132
Steering seat and handlebar ..................................................................................................... 139
Rear shock absorber and rear arm ........................................................................................... 146
CHAPTER 7 TROUBLESHOOTING
Electric Appliance System ....................................................................................................... 196
Compression System ............................................................................................................... 197
Intake \Exhaust System ........................................................................................................... 198
PP
CHAPTER
GENERAL
INFORMATION
GENERAL INFORMATION
Motorcycle identification
Frame identification
The number is stamped on the front tube of frame.
The frame number is make up of 3 parts, the first part
3 ones
second part (6 ones) is the direction code of motorcycle (VDS) the third part (8 ones) is the inspecting
position. (VIS).
Engine Ser. No
The No.s of engines stamped on the crankcase.
Engine No.
JS154FMI/JYM154FMI
00000001
Note
There will be no further notice if the design or rule is
changed.
GENERAL INFORMATION
Important Information
Important information to ensure safe and high
active work
(1)Motorcycle wash
Clear out the frame and engine to prevent the entry of
dust
(2)No smoking
Keep out fire from replacement position .
GENERAL INFORMATION
(6)Safe operation
Be careful in operation to avoid accident or get a
burn by the engine, exhaust pipe and silencer..
Always think of the right tools, right ways, right
fixture and the right position to ensure body's steady.
GENERAL INFORMATION
Circlips
Check all circlips carefully before reassembly. Always replace piston pinclips after one use.
Replace distorted circlips, when installing a circlip
make sure that the sharp edged corner is positioned
opposite the thrust it receives view. Shafe.
Caution
Do not use compressed air to spin the bearings dry.
This will damage the bearing surfaces.
GENERAL INFORMATION
Special tools
The proper special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriates
special tools will help prevent damage caused by the use of inappropriate tools or improvised techniques.
Drawing
Liquid meter
Fuel level gauge
GENERAL INFORMATION
Drawing
Turning wrench
Clearance ruler
Pocket tester
Inductive techometer
Ignition checker
PP
CHAPTER
SPECIFICATIONS
SPECIFICATIONS
General specifications
SAE 20W-40
SAE 10W-30
10
SPECIFICATIONS
11
SPECIFICATIONS
12
SPECIFICATIONS
13
SPECIFICATIONS
14
SPECIFICATIONS
15
SPECIFICATIONS
16
SPECIFICATIONS
17
SPECIFICATIONS
Lock torque
Engine
18
SPECIFICATIONS
Body frame
19
SPECIFICATIONS
width)
M5
diameter (two-face width) and thread pitch when fastening a screw and a screw cap.
Lock
Thread pitch
8mm
0.8
3-4N.m(0.3-0.4kg.m)
M6(10mm)
1.0
5-8N.m(0.5-0.8kg.m)
M8(12mm)
1.25
12-19N.m(1.2-1.9kg.m)
M10(14mm)
1.25
24-39N.m(2.4-3.9kg.m)
M12(17mm)
1.5
45-72N.m(4.5-7.2kg.m)
) is fastened to
35N.m.
) is unscrewed
24 N.m.
and
) in
alignment.
) is fastened to
35N.m.
20
24 N.
SPECIFICATIONS
21
SPECIFICATIONS
Body
Special grease
22
SPECIFICATIONS
Rocker shaft
Oil pump
Push rod
Cam shaft
Filter net
23
SPECIFICATIONS
Cam shaft
Main axle
Drive axle
Crankshaft assy
Clutch assy
24
CHAPTER
Introduction
This chapter includes all information necessary to perform recommended inspections and adjustments. These
preventive maintenance procedures, if followed, will ensure more reliable operation and a longer service life. In
addition, the need for costly overhaul work will be greatly reduced. This information applies to machines already
in service as well as new machines that are being prepared for sale. All service should be familiar with this entire
chapter.
Periodic maintenance/lubrication
26
Remark
27
with a key
) points.
) with screw-
driver
Pull out the fixed pin of side cover (serial number
)
Take out the side cover on the direction of the
arrow (serial number
) points.
28
Note
First close the fuel cock to a position of
, and
Install
This installment steps is the reverse of disassembling
steps.
1. Install
Fuel tank
Torque
Bolt torque (see above figure)
2 kgf.m (20 N.m)
2. Install
Seat cushion
Note
The parts of lobes located in the rear of the seat
cushion are inserted into the pin holes of the frame,
and the bolts of the seat cushion are load into every
hole respectively, and then screw down the nuts.
Bolt torque (see the left figure)
1 kgf.m (10 N.m)
29
(intake)
(exhaust)
30
Screw cap
(with o-ring)
Screw cap
(with o-ring)
and bolt
of top
5. Check
Valve clearance
Standard valve clearance
IN (intake): 0.08
EX (exhaust):0.10
Below standard value
0.12 mm
0.14 mm
adjust
******************************************
Adjustment steps
Loosen the fixed nut
Insert a feeler gauge
Install the valve adjusting tool
on the adjuster
31
Engine tachometer
3. Confirm items
Turnover number of standard idle speed
Turnover number of standard idle speed
1300
Out of standard value
1500rpm
Adjust
4. Adjustment
Turnover number of standard idle speed
******************************************
Adjustment order
Screw down P.S adjusting screw
lightly
Note
Don't lock tightly
Turn out it to standard number of turns
Standard number of turns of P.S adjusting screw:
2.0 circle
Start engine
Turn the adjusting screw from left to right until
standard number of turns.
Turn in
Turn out
******************************************
5. Disassemble the parts as fellows
Engine tachometer
32
handle
Free play
Out of specification
3~7mm
Adjust
2. Adjust
Free play
******************************************
Adjusting orders
The first step (the throttle cable)
Loosen the lock screw cap
Adjust the adjuster
Turn in
Turn out
33
Note
When unable to adjust the cable on the throttle handle,
adjust the adjuster on the carburetor.
Turn out
Warning
After adjusted, start the engine, turn the steering bar
from the left to the right, and confirm the engine idle
speed will not rise.
Replace
Pollution, deposit
34
Adjust clearance
6. Check
Compressure
******************************************
Checking steps
pressive leak.
B.Bad adjustment of the throttle clearance.
the reading of the pressure indicator reaches a maximum value, and then read it.
35
and
36
Note
If no oil outflows after 1 minuet, the engine should be
stopped to avoid damaging it.
37
Adjust clutch
1. Check
The free play of the clutch cable
Free play:10 15mm
Measure at the clutch handle end
Exceed specification range
Adjust
2. Adjust
The free play of the clutch cable
******************************************
Adjusting steps
1. Confirm the adjustor
to be
tightened thoroughly.
2. Loosen the locknut
until it reaches
Turn out
Note
If a free play is incorrect, using the adjustor (one of the
part of the clutch handle) to adjust the free play of
the clutch cable.
5. Loosen the locknut
6. Turn in or turn back adjustor
until it reaches a
Turn out
38
1. Disassemble
Side cover (right)
Seat cushion
Air cleaner housing cover
2. Disassemble
Filter element
Note
Air filter element 2 assemble
39
3. Check
Filter element
Damage
Dust
Replace
pressed air
Remove the filter element 1 and 2, blowing wash
them with high-pressure air.
If the dust on the filter element 2 is excessive,
cleaning it with neutral solution, after finishing, it must
be dried by blowing.
Warning
Be mustn't add oil onto the filter element 2.
Warning
Be should confirm the filter element has been fixed in
the air cleaner housing.
Warning
If the filter element is not installed yet, the engine
mustn't be operated to avoid over wearing the piston/
cylinder.
Adjust
2. Adjust
Brake handle free play
40
until it
Turn out
Tighten locknut
Note
After adjusting, should make sure the brake has no
brake drag.
until it
Turn out
41
of the
Check
Right-left steering or vibration under drive, should
Adjust.
front end
10.5 mm
Note
Manufacture guarantees the clearance, and needn't to
be adjusted.
42
Note
Don't mix different brand brake fluids. The brake fluid
can erode painting surface or plastic parts. Therefore
the leaked fluid must be wiped off immediately.
Exhaust
Warning
When the parts related to the brake fluid are
disassembled, must make sure that the other parts is
locked and sealed, and then conduct the exhaust
operation.
******************************************
Exhaust orders
1. Disassemble the brake fluid cylinder cover.
2. Disassemble the brake fluid cylinder diaphragm.
3. Install a rubber hose
drain screw
Note
Mustn't the brake handle before re-newly tighten the oil
drain screw.
5. Repeat above procedures, until the oil drain screw let
off bubbles completely.
Note
Supplement brake fluid in the meantime, mustn't make
it below the lower limit position.
Warning
Hold the brake handle, check whether brake fluid leaks
or not, wiping off the brake fluid splashed on the brake
disc, the tyres and the wheel rim.
6.Reinstall the brake fluid cylinder diaphragm.
7.Reinstall the brake fluid cylinder cover.
******************************************
43
with
Warning
Wipe off the brake fluid splashed on the brake disc, the
tyres and the wheel rim.
3. Lock the oil drain screw
Oil drain screw: 0.6kg.m (6N.m)
Note
Don't mix different brand brake fluids.
6. Pull the brake handle until the brake fluid hose is full
of brake fluid.
Note
Supplement brake fluid in the meantime, mustn't make
it below the lower limit position.
7. Slowly operate the brake handle until the brake
cylinder lets off bubbles from small hole, and feel the
brake handle strong.
8. Exhaust air
9. After adjusting, install it by the reverse orders of
disassemble.
44
30mm
Adjust
2. Adjust
The amount of the brake pedal free play
Adjustment orders
Turn the adjuster until the free play is in specified
range.
Turn in
Decrease
Turn out
Increase
Adjust
2. Adjust
Turn the adjusting nut
Rear brake light switch
45
30mm.
Adjust steps
Turn out
until
Note
There are scale marks on the chain adjustor. Guarantee the mark numbers of the chain adjustors on the
both sides of the rear arm are united when adjust.
After adjusting correctly, tighten the adjustor locknut
and the axle locknut.
Axle locknut: 9.1kgf.m(91N.m)
******************************************
Note
The chain mustn't be lubricated with lubricating grease.
46
Replace
Oil seal
Serious leakage
Replace
Repair
Refer to
Front fork
in chapter 6
to the direction
or
value is increased.
Turn to the direction
value is decreased.
Adjusting advice:
Standard:3 Min :1 Max :5
Caution
The adjusting advice mustn't turn to a minimum
position or a maximum position.
47
Check Tire
1. Measure the tire pressure
Load
Front wheel
Rear wheel
Load below
175KPa
196KPa
0 90kg*
1.75kgf/cm 2
2.0kgf/cm 2
Maximum
196KPa
245KPa
load 100kg *
2.0kgf/cm 2
2.5kgf/cm 2
Out of specification
adjust
2.75-18
42P
90/90-18
51P
Replace
Warning
It is dangerous to ride with a worn out tire. When
a tire is out of specification, replace the tire
immediately.
Pay attention not to pick the tubed tire when repair.
48
Steering handle
in Chapter 6)
Steering handle
in Chapter 6)
49
Ring locknut
Install the steering handle seat
Install the steering handle
Check battery
1. Disassemble
Side cover
Refer to
2. Check
Electrolyte level
The level must be kept between upper level
and lower level
Lower
marks.
Fill
Caution
Refill with distilled water only. Tap water contains
minerals harmful to a battery.
50
3. Check
Battery terminal
Dirty
Improper connection
Correct
Caution
After cleaning the terminals, apply grease lightly to
the terminals.
4. Check
Breather hose
Obstruction
Damage
Remove
Replace
Caution
When inspecting the battery, be sure the breather hose
in routed correctly. If the breather hose touches the
frame or exists in such a way as to cause battery electrolyte or gas to exit onto the frame, structural or cosmetic damage to the machine can occur.
5. Connect
Breather hose
Be sure the breather hose is connected.
6. Check
Specified gravity
Charging current: 0.5A/10h
Specified gravity: 1.280 at 20 (68 F)
Less than 1.08
Charge
51
Warning
Battery electrolyte is dangerous: it contains sulfuric acid and therefore is poisonous and highly caustic.
Always follow these preventive measures.
Avoid bodily contact with electrolyte as it can cause
sever burns or permanent eye injury.
Wear protective your eyes gear when handling or
work near batteries.
Warning
Antidote (External):
Skin--Flush with water.
Eyes--Flush with water for 15 minutes and get immediate medical care.
Antidote(Internal)
Drink large quantity of water or milk of magnesia,
beaten egg, or vegetable oil. Get immediate medical
attention.
Battery also generate explosive hydrogen gas.
You should always follow these preventive
measures.
Charge batteries in a well-ventilated area.
Keep batteries away from fire, spark, or open flames
(e.g. welding equipment, lighted cigarettes, etc.) Do
not smoke when charging or handling batteries.
Keep batteries and electrolyte out of reach of
children.
52
CHAPTER
ENGINE
ENGINE
side cover
2. Engine oil
Drain oil
Refer
54
ENGINE
engine)
Install the bolt
and
and nut
(lower side)
4. Disassemble
Install the bolt (the rear part of the engine and the
frame)
5. Disassemble
Install the bolt (the engine top and the bracket)
Install the bolt (the top support and the frame)
55
ENGINE
4. Disassemble
Valve cover (intake)
Valve cover (exhaust)
5. Disassemble
The side cover of the cylinder head
6. Timing adjustment
Aim
******************************************
mark
mark is
on the cam
on the
56
ENGINE
7. Loosen
Cap bolt
8. Disassemble
Cam chain tensioner
9. Disassemble
Bolt
Cam chain sprocket
Note
The timing chain is fixed by a protecting cable
to
10. Disassemble
Bolt
Cylinder head
Note
Each blot is loosened quarter turn in advance, and is
twisted off when all of them is loose. Loosen them
from the minimum number. The opposite numbers
countermarked on the cylinder head is the orders to
turn the bolt.
11. Disassemble
Chain guide plate
Dowel pin
Cylinder gasket
Cylinder
57
ENGINE
12. Disassemble
Dowel pin
Gasket
13. Disassemble
Elastic circlip of piston pin
Piston pin
Piston
Note
Before disassembling the circlip of piston pin, the
crankcase should be covered a piece of clean cloth
to prevent the circlip from falling into the crankcase.
Before disassembling piston, the groove of circlip
and the pin hole should be cleaned. If they have been
cleaned, but the piston pin is still disassembled
difficultly, the remover for piston pin should be used.
58
ENGINE
2. Disassemble
Crankcase cover (right)
Gasket
Dowel pin
Note
First, loosen each bolt quarter turn by the order of
cross wire, and then turn off all the bolts.
3. Disassemble
Bolt
Clutch spring
Pressure plate
Friction lining
Clutch lining
Push rod 1
Steel ball
Note
First, loosen each bolt quarter turn by the order of
across corners, and then turn off all the bolts.
59
ENGINE
4. Straightening
Level the tongue of lock washer
5
Loosen
Nut
Note
6. Disassemble
Nut
Lock washer
Clutch hub
Spline washer
Driven gear
Washer
Elastic washer
7. Disassemble
Primary driven gear nut
Note
Strap, aluminium plate and copper strip can not be
put into the place between the driven gear and the
primary driven gear.
Should use the sleeve to fix the nut at the place
where the rotor fixes the nut, and then disassemble
the primary driven gear nut
60
ENGINE
8. Disassemble
Primary driven gear nut
Key
Oil filter
Oil pump
1. Disassemble
Bolt
Oil pump
Gasket
Oil pump driven gear
2. Disassemble
Torsion spring
Starting shaft assy
61
ENGINE
Shift shaft
1. Disassemble
Shifting lever
Torsion spring
Bolt
Stopper
Rotor
1. Disassemble
Nut
Note
Fix the rotor with a rotor clamp, and then loosen the
nut.
Rotor clamp
2. Disassemble
Rotor
Woodruff key
Note
A fly wheel remover
3. Disassemble
Starting idle gear 1
Washer
4. Disassemble
Gear pressure plate
Starting idle gear 2
5. Disassemble
Chain guide plate
Timing chain
62
ENGINE
Crankcase (right)
1. Disassemble
Screw (crankcase)
2. Disassemble
Star gear
Dowel pin
Note
The crankcase should be separated from the right
side.
Disassemble the star gear.
Be careful not to damage the mating surface of the
crankcase.
(short)
(long)
Shifting fork C
Shifting fork R
Shifting fork L
Shifting cam
2. Disassemble
Main shaft
Clutch inner push bar 2
Drive shaft
Washer
Clutch push bar
3. Disassemble
Neutral switch
63
ENGINE
Note
Tighten the strutting bolt of the separating tool, but
make sure that the tool shell is perpendicular to the
crankshaft. If necessary, one screw can be turned
back a little to calibrate the state of the stool shell.
2. Disassemble
Camshaft (with bearing
Note
The camshaft is disassembled with bolt of 8mm 3
3.Disassemble
. Rocker arm shaft
.Rocker arm
Note
The rocker arm shaft is disassembled with the slide
hammer bolt and the weight
64
ENGINE
Valve
Note
Before disassembling the inner parts of the cylinder
head (for example valve, valve spring, valve seat),
check the valve seal before hand.
1. Check
Valve sealer
Leakage at valve seat
valve
Valve seat and valve seat width
Refer to
******************************************
Check steps
Pour the clean solvent
exhaust valve.
Check the valve seal.
No leakage around the valve seat
******************************************
2. Disassemble
Valve lock
Note
When disassemble the valve lock, use the valve spring
compression tool to compress the compression valve
spring.
Valve spring compression tool
3. Disassemble
Valve spring upper seat
Valve spring
Valve
Valve seal
Valve spring lower seat
Note
Mark positions of every parts to install it on the original
position once more.
65
ENGINE
Note
Don't use sharp tool to avoid damaging or scoring
spark plug thread and valve seat.
2. Check
Cylinder head
Scratches or damage
Replace
3. Measurement
Cylinder skew
Check whether the 6 directions of the junction surface
of the cylinder head is skew or not.
Skewness: less than 0.03mm
4. Reshape surface
Cylinder head
******************************************
Reshape surface steps:
Place a piece of wet sandpaper of 400
600# onto a
Note
Move the cylinder head several times to avoid grinding
some side excessively
66
ENGINE
Valve seat
1. Clean
Carbon deposit
(Eliminate from valve face and the valve seat)
2. Check
Valve seat
Pit corrosion or wear
3. Measurement
Valve seat width
Valve seat width
Intake: 0.9
Exhaust: 0.9
Out of specification
1.1mm
1.1mm
******************************************
Measuring steps
Smear blue dyes (Dykem) onto the working
surface
4. Grind
Working surface of valve
Valve seat
Note
After replacing the valve and the valve guide, must
grind the valve seat and valve face.
67
ENGINE
******************************************
Grinding steps
Smear rough grinding sand on valve face.
Note
Don't make grinding sand into the gap between the
valve stem and the valve guide.
Smear molybdenum-bearing disulfide oil on the
valve stem surface.
Install the valve into the cylinder head
Turn the valve till valve face and the valve seat are
polished evenly, and then eliminate all grinding agents.
Note
For good effective, knock the valve seat lightly while
turning the valve back and forth with two hands.
Smear fine grinding agent on valve face, and then
repeat the above steps.
Note
After grinding each time, wipe the grinding agent on
valve face and the valve seat clean.
Measure the width of the valve seat again.
If the width is out of specification, repair and grind
the valve seat once more.
******************************************
68
ENGINE
Note
After replacing the valve guide, repair the valve seat
face once more.
2. Clean
Carbon deposit
(Eliminate from valve face)
3. Check
Valve face
Pit corrosion or wear
Polish surface
Replace
4. Measurement
Swing tolerance (valve stem)
Swing tolerance:
less than 0.01 mm
Out of specification
69
Replace
ENGINE
Valve spring
1. Measurement
Free length
(valve spring)
Valve spring free length:
Standard:32.28mm Limit:31.90mm
Out of specification
Replace
2. Check
Valve spring verticality
: 1.2 mm
3. Check
Valve spring contact surface
More than 2/3 of peripheral region is horizontal contact
Replace
Camshaft
1. Cam heave
Pit corrosion, scratching, bluing
2. Measurement
Cam heave A and B
70
Replace
ENGINE
Replace
3. Check
Bearing
Clamping stagnation, shake
Replace
Replace,
2. Measurement
Rocker arm inside diameter
Rocker arm inside diameter standard:
10.000-10.015mmUsed limit:10.030mm
Out of specification
Replace
3. Measurement
Rocker arm shaft outside diameter
Rocker shaft outside diameterStandard
value:9.981-9.991mmLimit:9.95mm
71
ENGINE
sprocket completely
2. Check
Sprocket
Hardening or crack
sprocket completely
Quarter gear
Correct combination
Rotor
Sprocket
3. Check
Chain guide plate
(exhaust side)
(intake side)
Wear or damage
Replace
4. Check
Timing chain tensioner free play
******************************************
Checking steps
Press the tensioner rod lightly with a finger, and turn
the tensioner rod to the end with a small screw driver.
When press and loosen the screw driver, should
make sure that the tensioner can go out smoothly.
If not, the tensioner assy must be replaced.
******************************************
72
ENGINE
2. Check
Piston side wall
Wear, scratching and damage
Replace
3. Check
Cylinder wall
Wear or scuffing
replace
4. Measurement
Piston-to-cylinder clearance
******************************************
Measuring steps
1. Measure the cylinder bore C with a bore gauge.
The position of D3,D4 (40mm distance from the top
of cylinder)
Note
Measure the cylinder bore in the two directions, one
parallels to the crankcase, one squares to the crankcase,
and then demand an average value.
Cylinder inside diameter standard:
54.024
54.056 mm
Replace
Out of specification
54.029 mm
******************************************
73
ENGINE
0.034mm
Replace
Piston pin
1. Check
Piston pin
Bluing or form groove
lubrication system
2. Measurement
Piston pin outside diameter
Piston pin outsidediameter:
14.991 15.000mmLimit:14.969mm
Out of specification
Replace
3. Measurement
Piston pin hole inside diameter
Piston pin hole inside diameter:
15.002-15.013mmUsed limit:15.043mm
Out of limit
74
Replace
ENGINE
Piston ring
1. Measurement
Side clearance
Out of specification
Note
During measuring side clearance, carbon deposit on
the piston-ring groove and the every ring should be
eliminated.
Side clearance:
1 ring:0.03
0.07mm
Used limit:0.12mm
2 ring:0.02
0.06mm
Used limit:0.12mm
2. Measurement
Push the piston ring
Note
Use the piston top to push the piston ring to make the
ring verticality to cylinder bore.
3. Measurement
End gap
Note
The end gap of the oil ring can not be measured at the
expander-ring septum of the oil ring, and only measure the end gap between upper and below barriers. If
the gap is too large, then there are 3 rings must all be
replaced.
End gap:
1 ring: 0.15
0.30mm
Used limit:0.4mm
2 ring: 0.30
0.45mm
Used limit:0.55mm
Oil ring: 0.2 0.7mm
75
ENGINE
Crankshaft
1. Check
Crankshaft swing tolerance
Crankshaft swing tolerance:
0.03mm
Replace
Out of limit
Note
Turn the crankshaft slowly for the measurement.
2. Check
Big-end side clearance
Standard side clearance:0.15-0.45mm
Used limit:0.8mm
Out of limit
Replace
3. Measurement
Crankshaft width (measure it with a vernier caliper)
Standard width:
46.95
Out of standard
47.00mm
Replace
4. Check
Crankshaft sprocket
Damage, wear
Replace crankshaft
Bearing
Abnormal noise, instable rotation, loose
Replace
5. Check
Crankshaft oil-way
Blockage
76
ENGINE
Balancing device
1. Check
Crankshaft driving gear
Crankshaft driven gear
Wear, damage
Replace
2. Check
Balancer
Wear, damage
Replace
Cultch
1. Check
Driving gear
Driven gear
Wear, damage
Replace 2 gears
2. Check
Friction lining
High noise when operating
completely
3. Measurement
Friction lining thick
Friction lining thick: 3.0mm
Used limit:2.8mm
Out of specification
77
ENGINE
4. Check
Clutch lining
Damage
5. Measurement
Clutch warp
Out of specification
pletely
Use plate and caliper gauge
Friction limit value:
less than 0.05mm
6. Measurement
Clutch spring length
Damage
7. Check
Main driven gear
Scrape, wear, damage
stopper
Barbing or replace
Clutch hub
Scrape, wear, damage
Replace
8. Check
Steel ball
Push rod 1
Pressure plate
Wear, damage
78
Replace
ENGINE
Replace
2. Check
Shifting cam groove
Damage or wear
Replac
3. Check
Fork guide rod (short left, long right)
Shifting cam
Distortion, scuffing, bend, damage
Replace
4. Check
Shifting fork action
Unfavorable action
rod
Warning
Be mustn't straighten the curving guide rod.
5. Measurement
swing tolerance (driving shaft and main shaft)
Out of specification
Replace
Warning
Be mustn't straighten the curving shaft.
79
ENGINE
6. Check
Gear tooth
Bluing, pit corrosion, wear
7. Check
Shifting shaft
Damage, bend, wear
Replace
Replace
Kick starter
1. Check
Kick starter gear tooth
Kick starter pinion tooth
Damage or wear
2. Measurement
Kick starter collar tension
Use spring balance
Kick starter collar tension:
0.2-1.2kg
Out of specification
80
Replace
ENGINE
Side clearance B
(Between outside rotor
, outside
2. Check
Centrifugal oil filter
Chap, damage
Have the dirt
Replace
Clean
3.Check
Oil filter net
81
Chap damage
Replace
Clean
ENGINE
Crankcase
1. Thoroughly wash the contact face of crankcase
with a sort of hot solvent.
2. Thoroughly wash the matching faces of sealing
gasket and crankcase with a sort of hot solvent.
3. Check
Crankcase
Crack or damage
Replace
Oil hole
Blockage
Replace
Note
Must not dry them by blow in compressed air, or can
lead to a damage of the bearing face.
2. Check
Oil sealing
Damage or wear
Replace
82
Replace
ENGINE
Valve lock
O-ring
Lock nut
Valve guide
Adjusting bolt
Cam shaft
Valve spring
Rocker arm
Pressure plate
83
ENGINE
2. Smear
Molybdenum sulfide base lubricant
(Smear it on the valve stem and valve oil seal)
Four stroke engine oil
(Smear on the valve stem top)
3. Install
Valve spring seat
Valve oil seal
Valve
Valve spring
Valve upper seat
Note
Upturn the side to make the spring pitch
the valve spring.
big, install
is small pitch.
4. Install
Valve lock
Note
When install the valve lock, compress the valve spring
with the valve spring compressed tool.
Valve spring compressed tool
84
ENGINE
Note
Don't ham it too hard to avoid damaging the valve.
2. Install
Rocker arm
Rocker arm shaft
Align the screw hole of cylinder head to install until
the rocker arm is invisible.
Note
The screw hole is toward outside while installing.
3. Install
Cam shaft
4. Install
Pressure plate
Bolt
85
ENGINE
Crank pin
Crankshaft bearing
Crank
Woodruff key
Connecting rod
Balancer
Balancer bearing
86
ENGINE
Note
Maintain the connecting rod in the position of upper
dead center, when installing, do not touch the
crankcase.
Do not ham the crankshaft with a hammer.
2. Install
Balance shaft
Align the mark
mark
them.
87
ENGINE
Transmission
Driving sprocket
Bearing
Main shaft
Oil seal
Retaining ring
Bearing
Bearing
Driving shaft
Bearing
88
ENGINE
Cam
Fork 3
Star gear
Fork 1
89
ENGINE
2. Install
Main shaft
Note
First, the clutch inside push rod is installed in main
shaft inside hole. Then install the main shaft.
3. Check
The installing width of the main shaft gear
Standard installing width of the
main shaft:82.25-83.45mm
4. Install
Washer
O-ring
Install the O-ring in the mounting groove of the fixed
bracket of the driving shaft sprocket. After installing
the driving shaft, take off the O-ring.
Driving shaft
90
ENGINE
5. Install
Gear shift cam
(Align the salient point on the gear shift cam with the
contact point of neutral switch on the crankcase)
Gear shift fork
6. Check
Gear shift cam operation
Rough operation
Re-installment
Note
Turn the gear shift cam to confirm drive and fork
operation smoothly with hands.
91
ENGINE
Crankcase
Tightening order
Left crankcase
Right crankcase
Dowel pin
Air pipe
92
ENGINE
Crankcase (right)
1. Smear
Sealant
(Smear on the contact surface of left or right crankcase)
Sealant (Yamaha bond.No.1215)
Note
Be must not let any Sealant into lubricating hole. See
figure, the place of
and
2. Install
Dowel pin
3. Install
Install the right crankcase on the left crankcase.
Note
Before installing and tightening the fixed screw of
crankcase, the gear shift cam must be turned with
hands to check the transmission in normal operation.
4. Tighten
Bolt
(crankcase)
Note
Tighten the bolts one by one, beginning from the
minimum number.
5. Smear
Four stroke engine oil
(Smear on the crankshaft pin, bearing and crank hole.)
6. Check
Crankshaft and transmission actions
Tough operation
93
Repair
ENGINE
Shift shaft, kick starter axle and kick starter idle gear
Shift shaft
Circlip
Return spring
Washer
Stopper
Idle gear
Torsion spring
Washer
Star gear
Circlip
94
ENGINE
Shifting cam
1. Install
Dowel pin
2. Install
Star gear
Note
When install the star gear, the pin hole on the star
gear and the pin hole
3. Install
Stopper
Spring
Bolt (stopper):1.0kgf.m(10 N.m)
Note
Make the stopper mesh with the shift star gear.
4. Install
Shift shaft
Note
When install the shift shaft, the torsion spring on the
shift shaft must be jammed into the dowel pin
95
ENGINE
Note
The projection of spring
place
2. Install
Circlip
Washer
Idle gear
Washer
Circlip
96
ENGINE
Spring
Clutch lining
Push rod
Pressure plate
Clutch hub
Push plate
Stop washer
Driving gear
Push rod 1
Oil filter
Friction lining
Steel ball
Dowel pin
97
ENGINE
Oil pump
1. Oil charge
Four stroke engine oil
(Charge into the oil holes in the crankcase and the oil
pump)
2. Install
Oil pump
Oil filter
1. Install
Oil pump driving gear
Centrifugal filter
Note
Install the dowel pin
Note
When lock the nut, the rotor must be fixed not to make
crankshaft turn. The prohibition against placing aluminium flakes, stripes or copper sheets among the
gears to make the crankshaft stop turning.
98
ENGINE
Clutch
1. Install
Main driven gear
Thrust washer
Clutch hub
Lock washer
Nut
2. Install
Nut
Note
Fix the clutch hub with a clutch clamp , locking the
nut, and bending the lock washer
Clutch clamp
nut torque:
6.0 kgf.m(60N.m)
3. Install
Four friction linings
Three clutch plate
Note
Smear the clutch plates with four stroke engine oil,
and then install it.
Install the clutch plate and friction lining on the
clutch hub alternately, beginning with the friction
lining, ending with the friction lining.
99
ENGINE
4. Install
Steel ball
5. Install
Push rod
Push plate
Washer
Nut
6. Install
Pressure plate
Spring
Bolt
Mounting torque of the bolt:
0.6kgf.m(6N.m)
Note
Tighten the bolts by diagonal order.
7. Confirm
Alignment mark of the push rod assy and the
crankcase
Turn the push rod assy anticlockwise thoroughly,
confirming whether the objection
aligns with the one
crankcase or not.
Unaligned
100
Adjust
ENGINE
8. Adjustment
Alignment mark of the push rod
and the
crankcase
Loosen the nut
thoroughly
Turn the push rod
until
aligns with
9. Install
Gasket (new)
Right case cover
Mounting torque of the case cover:
1.0kgf.m(10 N.m)
10. Install
Kick-starting rod
Mounting torque of the kick-starting rod:
5.0kgf.m(50 N.m)
101
ENGINE
Timing system
Timing chain
Washer
Gasket
Starting gear 2
Dowel pin
Dowel shaft
Woodruff key
Rotor
Pressure plate
Stator
102
ENGINE
of starting gear
1 and 2.
Burr, Scraps, out-of-flatness, wear
Replace
2. Check
Starting gear 2 (contact surface)
Pit corrosion, wear, damage
Replace
******************************************
Check steps
Install the starter gear in the clutch of the starter, and
hold the clutch.
When turn the starter gear clockwise , the clutch
of the starter mesh with its gear, or the clutch of the
starter goes wrong and be replaced.
When turn the starter gear anticlockwise
, the
Note
First, the timing chain must be installed, and then the
guide plate is fixed.
2. Install
Starting idle gear
Pressure plate
Mounting torque
0.7kgf.m(7N.m)
103
ENGINE
3. Smear
Four-stroke engine oil
(Smear shaft collar and starter drive mechanism)
4. Install
Washer
Starting gear
5. Install
Woodruff key
Rotor
Note
Eliminate foreign materials and the dirt on the rotor,
and then fixed it.
6. Lock
Nut
Locking torque
7.0kgf.m(70 N.m)
Note
Fix the rotor with sliding stopping tool
rotor
, lock the
7. Install
Dowel pin
Gasket
Left case cover
Case cover locking torque
1.0kgf.m(10 N.m)
Note
The left case cover must be installed after the main
driving gear lock nut of the right case is installed.
104
ENGINE
Note
When install the first ring and second ring, dividing
top and bottom. The mark toward the top.
When install the oil ring, the scraper baffle should
be installed first
of angle difference.
2. Install
Piston
Piston pin
Piston pin circlip
Note
The arrow mark
engine.
Before installing the piston pin circlip, the crankcase is covered with clean towel or cloth.
3. Install
Dowel pin
Gasket
105
ENGINE
Cylinder
Piston ring
O-ring
Gasket
Piston
Dowel pin
Piston pin
106
ENGINE
Cylinder head
Bolt
Cylinder head
Copper washer
Dowel pin
Steel gasket
O-ring
O-ring
spark plug
107
ENGINE
Gasket
Timing sprocket
Tensioner
Timing chain
108
ENGINE
Carburetor body
Idle screw
Spring
Washer
Rubber washer
Choke lever
Wave washer
Screw
Rubber cap
Guide holder
Choke valve
Spring piece
Fixed plate
109
O-ring
Rubber washer
Washer
Spring
Ps adjusting screw
Idling fuel jet
Main nozzle
Main jet
O-ring
Needle valve seat
Needle valve
Fixing catch
Bolt
Float unit
Float pin
Seal shim
Floater cover
Bolt
Spring
O-ring
ENGINE
Disassemble
1. Disassemble
Guide tube of throttle cable
Carburetor body
Disconnect
1. Loosen
Drain screw
2. Disassemble
Throttle valve
3. Disassemble
Choke lever
Choke valve
4. Disassemble
Float chamber
5. Disassemble
Float pin
Floater
Needle valve
Needle valve seating
110
ENGINE
6. Disassemble
Main jet
Main nozzle
O-ring
7. Disassemble
Idle fuel jet
8. Disassemble
P.S adjusting screw
Check
1. Check
Carburetor mixing chamber
Pollution
Clean
2. Check
Floater
Damage
Replace
3. Check
Needle valve
Needle valve seating
Wear
O-ring
Replace
Note
The needle and the needle valve seating must be
replaced.
111
ENGINE
4. Check
Main nozzle
Main jet
O-ring
Idle fuel jet
Pollution
Clean
Note
Blow down each jet with compress air.
Assemble
Assemble them contrary to disassemble steps.
Note
Clean all the parts with clean gasoline before assembling once more.
: 6.6-7.6mm
Adjustment
******************************************
112
ENGINE
Fuel liquidometer
Note
The readings on the pipeline of the two sides of the
carburetor are equal.
******************************************
113
should
ENGINE
Engine assy
Wire clip
wire clip
Circlip
Syphon assy
Bolt M6
Washer plate
Screw M6
Muffler assy
114
16
16
CHAPTER
CHASSIS
CHASSIS
Front wheel
Lock nut
Instrument gears
Spacer assy
Spacer
116
CHASSIS
Front brake
Cam shaft
Oil seal
Spacer
Speedometer clutch
Washer
Drive gear
Meter gear
O-ring
Indicator plate
Oil seal
117
CHASSIS
Removal
Warning
Place the machine on a level place
Place the machine on main stand
Elevate the front wheels by placing suitable stand
under the frame or engine.
1. Disconnect:
Front brake cable
Note
Be sure to relax the brake before disconnet
2. Remove
Speedometer cable
Note
Be sure to remove circlip first
3. Remove
Lock nut
4. Remove
Front wheel axle
Front brake assy
Spacer
Front wheel assy
118
CHASSIS
Inspection
1. Inspection:
Front wheel shaft (check with dial indicator)
Crooked
Replace
Warning
Be sure not to straighten the crooked front wheel shaft
2. Inspection:
Tire
Wear/Damage
Replace
Warning
Never try to repair the tire by yourself
3. Measure:
Wheel runout
Rim runout limit:
Vertical: 1.0mm
Over specified limit
Lateral: 0.5mm
Replace
4. Inspection:
Wheel bearing
The bearing moving in the hub or rotating unstably
Replace
Oil seal
Wear/Damage
119
Replace
CHASSIS
Instrumentation clutch
1. Inspection
Instrumentation clutch
Wear/Damage
Replace
Front brake
1. Inspection
Brake shoe lining surface
Smooth side
Grinding
Note
Wipe off the grinding material pellet before sanding
120
CHASSIS
2. Measure:
Brake shoe lining thickness
Brake shoe thickness : 4mm
Limited
Out off specification
: 2mm
Replace
Note
Be sure to replace the whole brake shoes if any one of
them is out of specification.
3. Measure
Brake drum inside diameter
Brake drum inside diameter:
standard:130mm limit:131mm
Over specified limit
Replace
4. Inspect:
Brake drum inner surface
Oil/scratched
Remove
5. Inspect
Camshaft
Damage
Replace
Warning
Install the camshaft and the pivot lightly greased. Wipe
off the excess grease.
121
CHASSIS
Assembly
1.Install
Camshaft
Indicator
Install steps
When install the wear indicator , place its convex
part into slot of camshaft
Aim the needle at the wear indicator.
2.Install
Camshaft rod
3.Install
Brake shoe
Brake shoe spring
Note
Don t use plier when installing which may cause
disshape and damage of hooks and rings of spring.
Don
4. Install
Instruments driven gear
Speedometer cable
Speedometer cable end
122
CHASSIS
5.Install
Brake assy
Note
Make the slot face the wear indicator when install
brake assy.
Pull and press braked shoe in direction of arrow,
making pivot and brake camshaft rod as fulcrum,
when installing brake shoe.
Install
1.Install
Front brake cable
Speedometer cable
Front wheel axle nut
2.Install
Front wheel
Note
The convex seat of the left front shock absorber must
bite with the locating slot of gear assy correctly.
3.Cable
Brake shoe
The brake shoe moving in the hub or rotating unstably
Replace
Nut torque: 3.5-5.6Kgfm
4.Install
Speedometer cable
circlip
Be sure not to flex the speedometer cable
123
CHASSIS
Rear wheel
Adjusting nut
Sprocket shaft
pin
Rear wheel
Compression spring
Rear brake
split pin
Damper
Tension rod
Oil seal
Lock nut
Spacer
Bearing
124
CHASSIS
Rear brake
Brake shoes
Indicator plate
Camshaft lever
Brake camshaft
125
CHASSIS
Removal
Warning
Support the motorcycle firmly to avoid falling over.
1. Remove;
Adjuster
Tension rod
Nut
Compressing spring
Brake rod
Rear wheel shaft nut
2. Remove
Rear wheel shaft
Spacer
Note
When removing the wheel shaft, Spacer will drop
down. Be careful not to lose it.
3. Remove
Rear wheel
Rear brake
Note
When removing the rear wheel, be care for of the
dropping clutch hub.
126
CHASSIS
4.Remove
Damper
Cracks/Damage
Replace
Remove
2. Measure
Brake drum inside surface
Brake drum inside diameter:
Standard: 130mm Limit: 131mm
Out of specification
Replace
3. Install
Rear wheel
Note
Be sure to engage the convex part of clutch hub with
slot of damper
4. Install
Axle nut
Axle nut :9.1kgf.m(91N.m)
127
CHASSIS
Diving chain
Sprocket cover
Slave sprocket
Adjuster
Link plate
Circlip
Chain adapter
Stop washer
Chain connect
128
CHASSIS
Disassembly
Warning
Stand the motorcycle firmly and avoid turning.
1.Put the motorcycle on the main stand
2.Disassembly:
Sprocket cover
3.Screwing-down
Small sprocket
4.Disassembly
Chain connect snap ring
Link plate
Chain connect
Driving sprocket
Inspection
1.Inspection
The driving chain stuck
Get stuck
2. Inspection
Driving chain
driving sprocket
The clearance that is pressed to right side must not
excess 1/2 of the gear.
Overran
129
Replace
CHASSIS
3. Measure
The length of 10 chain elements
(driving chain)
Replace
Note
Stretch the chain with fingers first, then measure the
length.
As shown in the figure, measure the length of 10
chain elements from the internal side of the roller
to the roller
Measure the length of 10 chain elements in different sections two or three times.
4.Clear:
Clean with neutral detergent
Oiled with lubricant or SAE10W-30W YAMAHA
motor oil.
Warning
Be sure not to clean with volatile substance, such as
gasoline, stream, etc.
Replace
2. Install
Driving sprocket
Antiloosen washer
Nut
Nut: 2.6kgf.m(26N.m)
Note
Screw up the bolts following the cross curve.
130
CHASSIS
3. Install
Install as the illustration shows
Stretch the convex tongue of the antiloosen pad
straight, screw down the construction bolt, then disassemble the driving sprocket.
Install
1.Install
Driving chain
Driving chain cutter
Link plate
2.Assembly
Chain connect work carrier
Note
Pay attention to eh assembling direction of the work
carrier of the carrier of the chain connect
3.Adjustment:
Loose degree of driving chain
Please refer to the section of loose degree adjustment
of driving chain in part III.
Note
Overloading of engine and other main parts will occurs
if the driving chain is too tight. The loose degree of
the chain should be kept within the stipulated scope.
4. Screwing-up
Sprocket shaft nut
Bolt
131
CHASSIS
Front fork
Front fender
Spring
Resistance device
Plug
Dust-preventative cap
Inner tube
Bolt
Circlip
Spring
O-ring
Bolt
Oil seal
Collar
Washer
Outer tube
Spring seat
Button valve
132
CHASSIS
Remove
Warning
Securely support the machine to avoid falling over.
1.Place the machine on a level place.
2.Elevate the front wheels by placing the suitable stand
under the frame and engine.
3.Remove
Front wheel
Front fender
4.Loose
Bolt
Cap bolt
Note
Be sure to loose the two bolts of the front fork before
remove.
Dissassemble
1.Remove
Cap bolt and O-ring
2 Oil-drain
3. Disassemble
Collar
Spring seat
Spring
133
CHASSIS
4. Disassemble
Dust-preventative cap
Circlip
Note
Be careful not to damage the surface of inner tube
5. Remove
Bolt
Hold the shock absorber rod, and loosen the bolt
shock absorber rod, with
spanner
and
spanner
6. Remove
Bolt
Washer
7. Remove
Oil seal
Note
Be careful no the scratch the outer tube of front fork
when removing oil seal.
Inspect
1. Inspect:
Inner tube of front fork
The angularity of inner fork
Angularity limit: 0.2mm
Warning
Don't try to straighten the crooked inner tube of front
fork, otherwise will damage the tube seriously.
134
CHASSIS
2. Measure
Free length of front fork spring
Free length of front fork spring: 339.9mm
Min free length: 330mm
Out of specification
Replace
3. Inspect:
Resistance device rod
Absorber piston
Wear /Cracked /Damage
Replace
Spring
Button valve
Wear/Cracks/Damage
Dirt
Replace
air
Note
Don't try to straighten crocked resistance device rod,
otherwise it will be damaged seriously.
Assemble
Reverse the
REMOVAL
following points.
Note
Be sure to use following components before assembly.
Oil seal
Dust-preventative seal part
Ensure the clean state of all components before
assemble.
135
CHASSIS
1. Install
Spring
Absorber piston
2. Lubricate:
Inner tube of front fork (outer surface)
Front fork oil 10w or equal substitute
3. Install
Resistance device
Button valve
Inner tube of front fork
Outer tube of front fork
4. Install
Washer
Bolt (shock absorber rod)
5. Tighten:
Bolt (Resistance device rod )
Bolt (Resistance device rod):
2.3kgf.m(23N.m)
Note
Lock the shock absorber rod with
spanner
spanner:
136
CHASSIS
6. Install
Oil seal
7. Install
Circlip
Outer tube of front fork
8. Inspect
Inner tube extension
Re-inspect if can not extension freely.
9. Inject
Measuring cup
Every front fork tube: 156ml
10W shock absorber oil
10. Move the front fork up and down slowly after
infection to make the oil all over the tube.
11. Install
Front fork spring
Note
Make the end with shorter pitch of spring up ward
to install the spring.
137
CHASSIS
12. Install
Cap bolt
O-ring
Note
Be careful not to damage the outer surface of inner
tube.
Intall
Reverse the
REMOVE
procedure
1. Install
Front fork
Tighten the bolt temporary
Note
Be sure to justify the inner tube port and bolt port.
2. Tighten
Bolt
Bolt
Cap bolt
Bolt
:2.8kgf.m(28N.m)
Bolt
: 2.3kgf.m(23N.m)
Cap bolt
138
: 2.3lgf/(23N.m)
CHASSIS
Handlebar clamp
Dust
Handlebar
Steering seat
Handlebar seat
Thimble
Ring Nut
Ring washer
Ring nut
139
preventative cap
CHASSIS
Handlebar clamp
Handlebar
Handlebar seat
Steering seat
140
CHASSIS
Removal
1. Remove
Remove the switch of left and right handle
2. Remove
Handlebar clamp
Handlebar
Handlebar throttle seat
3. Remove
Front wheel
4. Remove
Front fork
141
CHASSIS
6. Remove
Ring nut
Remove the ring nut with steering nut wrench
Steering nut wrench
Warning
Never remove the nut with any other instruments
except steering nut wrench.
7. Remove
Ball bearing race cover
Upper ball bearing race (upper)
Steel ball(upper)
Steering seat
Steel ball (lower)
Warning
Never remove the nut with any other instruments
except steering nut wench.
6. Remove
Ball bearing race cover
Upper ball bearing race (upper)
Steering seat
Steel ball (lower)
142
CHASSIS
Inspect
Inspect handlebar
handlebar
Bent
Cracks
Damage
Replace
Warning
Do not attempt to straighten a bent handlebar, this may
weaken the strength of handlebar and cause danger
Corrosive pitting
Damage
Replace as
a set
Replace step:
Shown as illustration, the ball bearing race with a
long rod and hand hammer, and take it out of the
convex slot of frame tube.
Shown as illustration, remove the ball bearing race
of steering of steering seat with plain chisel and hand
hammer.
Install the new dust-preventative seal part, bearing an ball bearing race.
Note
Steel ball race and dust-preventative part should
be always be replaced as a set.
The slant ball bearing race may polish the frame.
So be careful to install the race in level state, be sure
not to strike the surface of ball and race.
143
CHASSIS
Install
Steering bar
Reverse the
REMOVAL
procedure
1. Lubrication
Steel ball (lower, upper)
Bearing race
Lithium based grease
2. Assembly:
Ring-nut (lower)
Ring-washer
Ring-nut (upper)
Thimble
After assembly, make adjustment according to the
steps of Part III.
REMOVAL
procedure
1. Lubrication
Steel ball
Bearing race
2. Install
Dust-preventative cap lock nut
After assembly, make adjustment according to the
steps of Part III.
144
CHASSIS
Handlebar
1. Assembly:
Handlebar
Handlebar clamp
Tighten torque
2.3kgf.m(23 N.m)
Note
Make sure to flexible the front face bolt
Make the difference handlebar clamp
from front
3. Install
Handlebar switch
Be sure to insert the dowel
145
to dowel hole
CHASSIS
Rear shock-absorber
Connection rod
Nut
Chain cover
Rear arm
146
CHASSIS
Disassembly
Warning
Stand the motorcycle firmly avoid turning over.
1. Rear shock absorber
2. Disassembly
Left and right and rear shock absorber
3. Disassembly
Rear wheel
4. Disassembly
Chain
5. Disassembly
Nut
Connection rod
Chain cover
Rear arm
Inspect
1. Inspect
The free play of rear arm
If obvious lateral gap is found the internal ferrule
should be checked
Check the free move from upward to downward
of rear arm
If the vertical shift is found too tight, clipped or
unstable then replace.
2. Inspect
Rear shock absorber
Leakage, deformation
147
Replace
PP
CHAPTER
Clutch cable
Fuel sensor
Fuse
Overflow pipe
Positive wire
Wire clamp
Speedometer cable
Flasher relay
Harness wire
CDI
Fuel pipe
150
Throttle cable
Ignition coil
Syphon assy
Clutch cable
Washer
151
A. Trottle cable brake cable and handbar switch lead wire,must pass through the
guide frame
B. Clutch cable, handlebar switch wire and clutch switch wire must pass through
the guide frame
C. Be sure to tighten left handlebar switch and clutch switch wire with shell ring.
D. Be sure to tighten right handlebar and brake switch wire with shell ring.
Clutch cable
A. Speedometer cable and brake cable must pass through the guide frame
Harness wire
152
Speedometer cable
Cable guide frame
Harness wire guide frame
A.Tighten the handlebar switch and clutch switch
wire
153
A. To front headlight
B. After connect the wire, strap it up with shell ring at this place and cut off the rest.
C. Harness wire and cowling cover at this place and cut off the rest.
Picture A
Front brake switch wire
Throttle cable
Brake cable
Clutch cable
154
Clutch cable
Flasher relay
Speedometer cable
Wire clamp
Fuel pipe
CDI
Fuse
Positive wire
Fuel sensor
Starter relay
Harness wire
155
Throttle cable
Ignition coil
Clutch cable
156
A. Throttle cable ,brake cable and brake switch lead wire,handlebar switch wire
must pass through the guide frame
B. Clutch cable, handlebar switch wire and clutch switch wire must pass through
the guide frame
C. Be sure to tighten left handlebar switch and clutch switch wire with shell ring.
D. Be sure to tighten right handlebar and brake switch wire with shell ring.
Clutch cable
A. Speedometer cable and brake cable must pass through the guide frame
Harness wire
157
158
Electric appliance
159
160
Storage battery
Rectifier regulator
Oil sensor
Starting relay
Key sets
safety assy
Harness wire
161
Ignition coil
Flasher relay
CDI
Shift switch
Horn
162
6. Connection
Socket connectors
7. Check if the socket connectors are powered on
with a multitester.
Note
If the circuit is found not powered, then clean the
binding poles.
Repeat the inspection noted in the above 1
7porcedures after check the wires.
Do inspect the socket connectors after replacing
the CDI device.
Check the socket connectors with a multitester as
shown in the figure.
163
Switch inspection
Inspect if the circuit between wire end is on with
pocket multi meter.
If there is any failure, replace the switch.
Pocket tester
Note
Should turn on and off the switch many times when
inspecting.
Adjust the multi meter to inspecting
Adjust the multi meter to O before when inspecting the circuit
164
red
and
165
Fault obviation
Ignition system inefficiency
(no spark or interrupted spark)
Check steps
1. Spark plug
7. Main switch
4. Ignition wire
Note
The following components should be disassembled before all fault is obviated
Side cover
Seat cushion
Fuel tank
Small-size multitester
1. Spark plug
Code of standard spark plug model: CR6HSA
in
part 3
Spark plug gap: 0.6
(0.02
0.7mm
Abnormal
0.03in)
Replace or adjust
Normal
Spark plug
ON
166
Multimeter
lead
Multimeter
lead
Note
Do not pull off the spark plug from the high tension
wire
Disassemble in an anticlockwise way
Install in a clockwise way
Before assemble the spark plug cap, check the hightension wire firstly.
Cut off 5mm of high-tension wire before assembly.
20% (20
Out of stipulation
The spark plug cap is faulty and should be replace.
Multimeter
lead
Multimeter
Disassemble the wire of the coil away from the wire
harness.
Connect a small-size(
AC.CDI Ignition
primary coil resistance:
0.3
10% (20
167
Ground wire
Multimeter
lead
Multimeter
Ground wire
Connect a small-size(
AC.CDI Ignition
10% (20
Abnormal
1000) to
lead
red
Multimeter
lead
white
Regulation resistance:
310K
20%(20
Out of stipulation
168
169
Troubleshooting
Starter motor doesn't run
Inspection steps
1. Storage battery
5. Starter relay
2. Fuse
6. Starter switch
3. Starter motor
7. Neutral switch
4. Main switch
8 Clutch switch
Note
The following parts should be disassembled before
troubleshooting
Side cover
Seat
1.Protecting Device
Disassemble the protecting device
Connect a small size multimeter (
No electrification
1) to the
protecting pipe
Check if the protecting pipe is powered on
electrification
2. Storage battery
Check the storage battery condition
Please refer to the part III of
Abnormal
Storage battery
Voltage: 12.5V
Normal
170
Warning
The cross-bond should have an equel or more capacivity
3. Starter motor
figure.
Faulty
Check if the starter motor works normally.
The starter motor is faulty and should be checked
or replaced.
Run
4. Starter relay
Disassemble the socket connectors of the start
Connect the storage battery with the cable strat
electric relay with cross-bond as shown in the figure.
starter relay
Faulty work
Check if the starter relay functions normally
The starter relay is fault and should be replaced
Run
171
5. Main switch
Disassemble the socket connectors of the main
switch away from the wire harness.
Check if the switch can connect to
Red / Brown
Abnormal
The main switch is faulty, and should be replaced.
Normal
6. Neutral switch
Disassemble the socket connectors of the neutral
switch away from the lead wire.
Check if the switch can connect to
light blue
ground wire .
Abnormal
The neutral switch is faulty, and should be
replaced.
Normal
172
7. Clutch switch
Disassemble the socket connectors of the clutch
switch away from the lead wire.
Check if the switch can connect to
black
red black
Abnormal
Normal
8. Wire connection condition
Please refer to the section of
Poor connection
Electric circuit .
Adjust or replace.
173
Starting motor
Magnetic yoke
Rear bracket
Armature
Brush spring
Adjusting washer
Brush assy
Front bracket
O-ring
O-ring
174
Remove
1.Remove
Starting motor wire
Starting motor assy
Discharge
1.Before discharge, sign some marks on the front and
rear brockets, so that it can easy to check.
2.Remove
Front brocket
Washer
Rear brocket
3.Remove
Armature
magnetic yoke
Brush
2. Measure:
Diameter of commutator
Wear limit of commutator: 21mm
Out of specification
3. Measure:
Depth of mica sheet undercut
Depth of mica sheet undercut:
1.5mm
Out of specification
Note
In order to ensure the normal work of commutator ,
the isolation mica sheet of commutator must have
undercut.
175
4.Check
Armature coil (insulation/continuity)
Defects
******************************************
Inspection steps:
Connect the pocket tester for the continuity checking
and insulation checking
Measure the armature resistance.
Armature coil resistance:
Continuitychecking
0.017
0.021
20
Insulation checking
More than:1M
20
Note
When replacing brush, pay attention to its side which
swrentched
6. Measure
Brush spring force
Brush spring force: 560
Fatigue / Out of specification
176
840g
Replace as a set.
Mount
Mount as the reserves steps as
1.Mount:
Brush spring
Brush
remove
Note
When mounting brush the brush wire should round
over the projection outside of brush spring clip.
When mounting brush, make the brush terminal
touch slightly the projection of brush spring clip side.
2. Mount
Armature
Note
When mounting the armature, press the brush with
small screwdriver to avoid damaging it.
3. Install
O-ring
Note
Replace a new one.
4. Install
Magnetic yoke
Note
Aimed the marks to the rear brocket
mark and then install.
s matching
5. Install
Washer
Front brocket
Note
Aimed the boss of washer to the groove of front
brocket, and then install.
Make the marks of gear and front and rear brockets matching.
Bolt
0.5Kgf.m(5N.m)
Install
Starting motor
Starting motor wire
Bolt
0.7Kgf.m(7N.m)
177
Charging system
178
Troubleshooting
The battery is not charged
1. Fuse
4. Light switch
2.Stratage battery
3. Main switch
Note
Before troubleshooting, the following components
should be taken off
Side cover
Seats
1.Fuse
No continuity
Check if the fuse tube is electrified.
The fuse tube is broken, replace it.
continuity
2. Battery
Check the battery condition.
Voltage: 12.5V
Electrolyte specific gravity:
Abnormal
1.280 20
Normal
179
3. Charging voltage
Connect inductive tachometer to spark plug lead.
Connect the pocket tester(DC20V) to the battery
Tester
lead
Battery+terminal
Tester
lead
Battery-terminal
Note
Meets specification
Use a fully charged battery.
The charging circuit is correct
Out of specification
1) to the
lead
White terminal
Tester
lead
Green terminal
Charging coil resistance
0.4
20%(20
Out of specification
Meets specification
5.Wiring connection
Check the connections of the entire charging system.
Refer to
Circuit Diagram .
Poor connection
Correct
Repair it.
180
Lighting system
181
Troubleshooting
The headlamp, indicator light, tail lamp and /pr instrument lamp fail to come on
Note
Remove the following parts before troubleshooting
Side cover
Seats
2. Fuse
Discharge the fuse.
Connect the pocket tester (
No continuity
The fuse tube is broken, replace it
3. Battery
Check the battery condition
Refer to
Battery
section in chapter 3
Incorrect
182
4. Main switch
Discharge the main switch coupler from wire harness
Check the continuity of switch between
red and
brown .
Incorrect
Normal
5.Lighting switch
1) to handlebar
blue/black
and blue
Incorrect
Lighting switch is failure, replace the handle bar
Normal
switch (right)
6. High-lower beam switch of
Headlight
1) to handlebar
blue/black
and yellow .
Incorrect
Normal
183
high beam
No Conutinuity
continuity
2. Voltage
Connect the pocket tester (DC20V) to the coupler of
headlamp and
high beam
indicator lamp
Headlamp:
Tester
lead
Tester lead
Black terminal
lamp:
Tester lead
Yellow terminal
Tester
Black terminal
lead
LO (lower beam)
ON
ON
LO
HI
(lower beam)
Out of Specification
Meets specification
(12V)
This circuit is not faulty.
2. The instrument lamp fails to come on
1.Bulb and bulb socket.
No Continuity
continuity
184
2. Voltage
Connect the pocket tester (DC20V) to the bulb socket
coupler
Tester lead
Yellow terminal
Tester
Black terminal
lead
ON
ON
brown
lead on
Out of specification
Meets specification
(12V)
This circuit is not faulty.
3. If the tail lamp fails to come on
1.Bulb and bulb socket
Check the bulb and the bulb socket for continuity.
No Continuity
continuity
2. Voltage
Connect the pocket tester (DC20V) to the bulb socket
coupler
Tester lead
Blue terminal
Tester
Black terminal
lead
ON
ON
Out of specification
socket coupler.
The wiring circuit form the main switch to the bulb
Meets specification
(12V)
this circuit is not faulty
185
Signal system
186
The troubleshooting
Flasher, brake lamp / or indicator lamp fail to come on. The horn doesn
t work
Check steps:
1. Fuse
3. Main switch
2. Battery
4. Wiring connection
Note
Discharge the following parts before troubleshooting
Side cover
Seats
Pocket tester
1. Fuse
Tale off the fuse
Check the fuse tuber (
No continuity
continuity
The fuse tube is broken replace it.
2. Battery
Check the battery condition
Eletrolyte specific gravity: 1.280 20
Incorrect
Correct
Replenish destilled water
Clean battery terminal
3. Main switch
Charge or replace it
on
main switch
Incorrect
Correct
The main switch is failure, replace it
4. Wiring connections
Check the entire signal system coupler
Refer to
Circuit Diagram
section
Poor connection
Correct
Repair it
Check each circuit condition of signal system
Refer to
section.
187
t work
1.Horn switch
Discharge the handlebar switch (left) coupler from
wire harness.Check the continuity between
and black
Incorrect
pink
The horn switch is failure, replace the handlebar
on switch
switch
2.Voltage
Connect the pocket tester (DC20V) to the horn wires.
Tester
lead
Brown terminal
Tester
lead
ON
Out of specification
Meets specification
(12V)
3.The horn
Connect jumper wire to the horn terminal and other
end to ground
Tester
lead
Pink terminal
Tester
lead
ON
t
The horn is failure, replace it
work
Adjust or replace it.
188
2.Brake switch
Discharge the braked switch wire from wire harness
Check the continuity between
Incorrect
on the switch.
Replace the brake switch
3.Voltage
Connect the pocket tester (DC20V) to the bulb socket
coupler
Tester
lead
Yellow terminal
Tester
lead
Black terminal
ON
yellow
terminal on
Out of specification
(12V)
189
No continuity
Continuity
2.Flasher switch
Discharge handlebar switch (left) coupler from wire
harness.Check the continuity between brown/
white and dark green and brown/white and
dark brown on the switch.
Incorrect
Turn signal lamp
Continuity
3. Voltage
Connect the pocket tester (DC20V) to the flashing
relay.
Tester
lead
Brown terminal
Out of specification
Tester lead
Ground wire of frame.
Turn the main switch to ON
Check the voltage (12V) of black terminal on
flashing relay terminal
Meets specification
4.Flashing relay
Connect the pocket tester (DC 20V) to the bulb socket
coupler.The connection of right turn lamp:
Tester
lead
Tester
lead
switch to
ON
L
.Turn the
or
Turn
R .Check
Out of specification
lead
Black terminal
Tester
lead
190
lead
Tester
lead
lead
Tester
lead
ON
Turn the
switch to
or
terminal
Out of specification
6.Wire terminal
Check weather the return wire meets broken.
Refer to the signal system return connection.
191
3. Voltage
Connect the pocket tester (DC20V) to the bulb socket
coupler
Connect tester
Connect tester
ON
brown
terminal on
Out of specification
bulb socket.
coupler
Tester
lead
Green terminal
Tester
lead
Black terminal
);
Out of specification
, 20
)
, 20
Meets specification
192
2.Voltage
Connect the pocket tester (DC20V) to fuel gauge
terminal
Tester
lead
Green wire
Tester
lead
Ground wire
to
Note
FLoat foam stay three minutes between 1 and 2.Check
the fuel sensor needle
ON
work
well
Needle move
193
PP
CHAPTER
TROUBLESHOOTING
TROUBLESHOOTING
Main switch
Ignition coil
Rectifier adjuster
Winding damaged
Illuminator coil
Starting motor
Winding damaged
196
TROUBLESHOOTING
Compression System
Lack of tighten moment
Damage
Damage
Buckle/wear/damage
Wear/clog/damage
Damage
Damage
Wear/clog
Damage
Wear/clog/damage
Wear/clog/damage
197
TROUBLESHOOTING
contaminated or clogged
Valve lash
Air filter
Improperly adjusted
Contaminated or clogged
Silencer
Outlet pipe
clogged
Scratched or damaged
Accumulate carbon
Jet needle-valve
Improperly adjusted
Incorrect of clamping piece
Nozzle
Starter nozzle
Out of work (when
Damaged
clogged
starting / idle)
Float
Improperly adjusted fuel level
PS adjusting bolt
Punch
Faulty adjustment
Idle
Main nozzle
speed nozzle
Improper dimension
Clogged
Improper dimension
Loosened (when idle
and starting)
Loosened
speed
Float chamber
198
PP