Service Manual: Downloaded From Manuals Search Engine
Service Manual: Downloaded From Manuals Search Engine
Service Manual: Downloaded From Manuals Search Engine
WWW.CFMOTO.COM
CVT system 9
The manufacturer reserves the right to make Gearbox 10
improvements or modifications to the products
without prior notice. Overhaul and maintenance Right side cover、 m agneto、 water
11
should be done according to the actual state pum p
and condition of the scooters.
Crankcase body 、 crankshaft 、
12
piston set
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Caution: When charged, Battery may generate hydrogen Warning: The asbestos dust on the brake drum is carci-
which is explosive.Charge the battery in a well-ventilated nogenic if breathed in. Do not clean off the dust with com-
pressed air. Use cleaning detergent to avoid dust
place.
proliferation.
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1 Service information
Cautions for Disassembling and Assembling
■ Use genuine CFMOTO parts, lubricants and grease ■ Clean the mud, dust before overhauling。
1
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■ Check if the disassembled rubber parts are aged and ■ Apply or inject recommended lubricant to the speci-
replace if necessary. Keep the rubber parts away from fied parts.
grease.
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1 Service information
■ After assembling, check if all the tightened parts are
properly tightened and can move smoothly.
■ Brake fluid and coolant may damage coating, plastic
and rubber parts. Flush these parts with water if
1
splashed.
■ Do not twist or bend the cables too much.Distorted or ■ When assembling the parts of protection caps,insert
damaged cables may cause poor operation. the caps to the grooves, if any.
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Number Engrave Place
CF250T-5
Frame Number: LCETDJPK~
Engine Number: 172MM-A ~
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1 Service information
Major Specifications
1
Item Parameter
Model V5 CF250T-5
Length 2225mm
Width 875mm
Height 1110mm
Wheel base 1490mm
Engine type 172MM-A
Displacement 244.3ml
Fuel type Unleaded gasoline 90 Octane or above
Dry weight 166kg
Number of Passengers 2(including driver)
Max. Load 150kg
Front 100/90 - 18
Tire
Rear 150/80- 15
Ground Clearance 150mm
Min. turning radius 5m
Starting Electrical starting
Engine type 4-stroke, gasoline engine
Arrangement and No. of cylinder Single, horizontal
Combustion chamber type Hemispherical
Valve Driving type OHC chain driving
Bore x stroke 72mm× 60mm
Compression Ratio 10:1
Max. power 11kw/7000r/min
Engine Max. torque 17.6N· m/5500r/min
On 0° (1mm) BTDC
Valve intake
Off 30° (1mm) ABDC
Cam valve
On 35° (1mm) BBDC
Valve exhaust
Off 5° (1mm) ATDC
Lubrication type Pressure & Splash
Oil pump type Rotor
Oil filter type Full flow filter screen
Cooling type Forced water cooling
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Ite m P a ra m e te r
A ir F ilte r typ e U re th a n e fo a m filte r
Va c u u m D ia p h ra g m
Fuel Typ e
typ e
d e v ic e C a rb u re to r
D ia m e te r o f m ix in g
26m m
v a lv e
Typ e D ry, a u to -c e n trifu g a l
C lu tc h
O p e ra tio n m o d e A u to m a tic
G e a r typ e B evel gear
In itia l T ra n sm is s io n
R e d u c tio n ra tio 2 .9 3 8
G e a rin g S econdary G e a r typ e B evel G ear
tra n s m is s io n R e d u c tio n ra tio 2 .9 3 8
Typ e CVT
G e a rb o x F u n c tio n A u to -c e n trifu g a l
T ra n sm is s io n ra tio 2 .2 ~ 0 .9
S te e rin g R ig h t 35°
S te e rin g a n g le
d e v ic e L e ft 35°
F ro n t H yd ra u lic D is c
B ra k e typ e
R ear H yd ra u lic D is c
B u ffe r F ro n t w h e e l Te le s c o p ic
S u s p e n s io n
D e v ic e R ear w heel S w in g a rm
W e ld e d s te e l tu b e a n d
F ra m e typ e
p la te
1-8
Overhaul Datasheet
Lubricating device
Service
Item Standard limit
Volume when 0.8L -
Engine Oil replacing
Capacity Full capacity 1.0L -
· Special for 4-stroke motorcycle
SAE-10W-40、 20W-50
Substitutes must be used in the
following range.
Recommended Oil (see original) · API type: SE or SF grade
· SAE type: Choose from the left
chart according to the
environmental temperature
Fuel Device
Item Standard
Fuel Tank Capacity Full capacity 17.0L
Designated marks VE14C
Main jet
Carburetor Low-speed jet
Drop turn median value
Fuel level of float chamber 18.5± 0.5mm
Idle speed 1500± 150r/min
1-9
Auto CVT
Item Standard Service limit
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1 Service information
Gearbox
Item Standard
1
For replacing 0 .2 L
G ear oil
For disassem bling 0.25 L
R ecomm ended gearbox oil SA E15W-40/SF
Starting motor
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Front wheel
Item Standard Service Limit
Bending, front wheel axle - 0.2mm
Play of wheel Vertical 0.8mm 2.0mm
Front wheel rim Horizontal 0.8mm 2.0mm
Tire Groove - 1.6mm
Pressure 250kPa( 2.5kgf/ cm 2 ) -
Rear wheel
Item Standard Service Limit
Play of wheel Vertical 0.8mm 2.0mm
rim Horizontal 0.8mm 2.0mm
Rear wheel
Tire Groove -- 1.6mm
Pressure 280kpa(2.8kgf/cm3) --
Brake system
Item Standard Service Limit
Brake lever play 10-20mm --
Front brake
Brake disc thickness 4mm 3mm
Brake lever play 10-20mm --
Rear brake
Brake disc thickness 4mm 3mm
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1 Service information
Battery、 Charging system
Item Standard
A C m agneto M otor
M odel
O utput
P erm anent m agnet A C type
3- phase A C 1
C harging coil R esistance (20 ℃ ) 0.2-0.3Ω
T hree-phase annular rectification
R ectifier Silicon controlled parallel-connected
regulated voltage
C apacity 12V 10Ah
Fully
1 2 .8 V
Term inal point charged
B attery voltage Insufficient
< 11.8V
charge
C harging Standard 0 .9 A / 5~ 1 0 H
current/tim e Q uick 4A/ 1H
Ignition system
Item Standard
Ignition C D I ignition
Type E lectricity negative type spark plug
Standard D P R 7E A -9(N G K )
Sparking-plug
O ptional D R 8E A 、 D 7RT C
Spark plug gap 0 .8 -0 .9 m m
M ax. advanced
Ignition tim ing 28° C A
angle
Ignition coil
P eak voltage
P ulse generator
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Tightening torque
Item Torque N·m(kgf·m) Item Torque N·m(kgf·m)
Bolt, nut 5mm 5( 0.5) Screw 5mm 4( 0.4)
Bolt, nut 6mm Screw 6mm 9( 0.9)
10( 1.0)
Bolt, nut 8mm Bolt with flange, 6mmSH 10( 1.0)
Bolt, nut 10mm 22( 2.2) Bolt with flange, nut6mm
12( 1.2)
Bolt, nut 12mm 34( 3.5) Bolt with flange, nut8mm
Bolt with flange, nut10mm 26( 2.7)
54( 5.5)
39( 4.0)
For others not listed in the chart, refer to the standard tightening torque 。
Notes: 1.Apply some engine oil on the part of screw thread and contact surface.
2.Locknut must be replaced with a new one after removed.
Type No. of Bolt Thread Torque Remarks
& Nut diameter N·m(kgf·m)
Checking、 adjusting
Check Gearbox oil /drain Bolt 2 M10× 1.25
Engine oil filter cover M39× 1.5 18~22
1
Drain bolt 20~25
1 M12× 1.5
Spark plug 15~20
1 M12× 1.25
Lubricating system
Oil plump and mounting bolt 2 M6× 12 10
Screw, oil pump plate M3× 12 2
1
Cooling system
Coolant drain bolt 1 6 8( 0.8)
Coolant temperature Alarm R1/8 10( 1.0)
Impeller, water pump 1
1 7 10( 1.0)
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1 Service information
Frame
No. of
Diameter Tighteningtorque
1
Type Bolt & Remarks
(mm) N·m(kgf·m)
Nut
Engine disassembly
Engine suspension mounting bolt 2 10 55( 5.6)
Engine suspension shaft nut 1 12 80( 8.1)
Front wheel, Front suspension,
Steering 1 25 68( 7.0)
Handlebar locknut
1 10 55( 5.6)
Handlebar mounting nut
Front wheel axle nut 1 14 100( 10.1)
Upper mounting bolt, absorber 4 8 40( 4.1)
Muffler
Mounting nut (Front elbow)
2 8 26( 2.7)
Mounting bolt(Muffler barrel)
3 10 55( 5.6)
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Lubricant, Sealant
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1 Service information
1-17
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Wiring, Piping and Cable Routing
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1 Service information
Figure 1
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1 Service information
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2 Vehicle Body,Muffler
Overhaul Info… … … … … … … … … … … … … … 2-1 Rear Bracket… … … … … … … … … … … … … 2-8
Main Stand,Front Fender… … … … … … … … … 2-2 Rear Part, Rear Fender … … … … … … … … … 2-9
Seat, Backrest,Rear Left Panel… … … … … … … 2-3 Tool Box, License Plate & Bracket,
Rear Right Panel, Front Vent Panel, Left Black Reflector… … … … … … … … … … … … … … … 2-10
Panel… … … … … … … … … … … … … … … … … 2-4 Splash Fender, Rear Fender(Center), Rear 2
Ornament Panel (L&R), Right Black Panel, Front Fender(L&H Side)… … … … … … … … … … … 2-11
Left Panel… … … … … … … … … … … … … … … 2-5 Right Cover … … … … … … … … … … … … … 2-12
Front Right Panel, Left Upper Panel, Left Speaker Fuel Tank… … … … … … … … … … … … … … 2-13
Cover & Grille… … … … … … … … … … … … … 2-6 Muffler… … … … … … … … … … … … … … … 2-14
Front Right Panel, Right Speaker Cover & Grille, Description of Visible Parts … … … … … … 2-15
Seat Lock … … … … … … … … … … … … … … … 2-7
Overhaul Info
Operation Cautions
Warning
Gasoline is highly flammable, therefore smoke and fire are strictly forbidden in the work place. Special attention
should also be paid to sparks. Gasoline may also be explosive when it is vaporized, so operation should be done in a well-
ventilated place.
Removal and Installation of muffler should be done after it is fully cooled.
· This chapter is on the disassembly and installation of outer partsˇ˘exhaust pipe, muffler and fuel tank.
· Hoses, cables and wiring should be routed properly .
Trouble shooting
Loud exhaust noise
· Broken muffler
· Exhaust leakage
Insufficient power
· Distorted muffler
· Exhaust leakage
· Muffler clogged
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Main Stand
Caution
Make sure there is no deviation of the
seat by shaking it up and down,
back and forth after installation.
Installation
Install the left and right bush to the main stand.
Note:
Apply grease to the outer surface of bush.
Disassembly
Reverse the installation procedure for disassembly.
Front Fender
Removal
— Clip, flexible shaft
— Front fender
Installation
Reverse the removal procedure for installation.
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2 Vehicle Body,Muffler
Seat
Removal
Unlock the passenger seat with ignition
Note:
Make sure that the seats are firmly installed.
Backrest
Removal:
— Three hex bolts
— Backrest
Installation
Reverse the removal procedure for installation.
Installation
Reverse the removal procedure for installation.
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Rear Right Panel
Removal:
— Seat
— Bolt
— Screw
Separate Rear Left Panel from frame.
Remove rear left panel
Installation
Reverse the removal procedure for installation.
Installation
Reverse the removal procedure for installation.
Installation
Reverse the removal procedure for installation.
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2 Vehicle Body,Muffler
Left Ornament Panel
Removal
— Tapping Screw 1
— Tapping Screw 2
2
— Left Ornament Panel
Installation
Reverse the removal procedure for installation.
Installation
Reverse the removal procedure for installation.
Installation
Reverse the removal procedure for installation.
Installation
Reverse the removal procedure for installation.
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Right Panel
Removal
— Ignition key
— Seat
— Fuel tank
— Front vent panel
— Bolt, Tapping Screw
— Separate front right and left panels by acting on the
front of front right panel.
— Separate front left panel from front left upper panel and
remove front right panel.
Installation
Reverse the removal procedure for installation.
Installation
Reverse the removal procedure for installation.
Installation
Reverse the removal procedure for installation.
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2 Vehicle Body,Muffler
Front Right Panel, Right Speaker
Cover & Grille
Removal
— Seat 2
— Fuel Tank
— Front vent panel
— Rear panel (L&R)
— Black panel (L&R)
— Protection panel (L&R)
— Bolt 1, Bolt 2, Bolt 3
— Front panel (R)
Installation
Reverse the removal procedure for installation.
— Speaker grille
Installation
Reversethe removal procedure for installation.
Seat Lock
Remove:
— Driver seat
— Rear left panel
— Screw 1, Screw 2
— Seat Lock
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— Screw 3, Screw 4
— Seat Lock Plate
Remove Seat lock cable from seat lock
Remove seat lock cable from gap and remove seat lock,
Separate seat lock plate and seat lock from the vehicle
Installation
Allow seat lock cable through rear fender from gap,
install seat lock cable on seat lock as illustrated.
Reverse the removal procedure for installing seat lock and
seat lock plate
Rear Bracket
Removal
— Seat
— Bolt 1, Bolt 2
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2 Vehicle Body,Muffler
— Bolt 3
— Rear bracket
Installation
Reverse the removal procedure for installation
2
— Open the tool box cover, and remove the memory sticker
from USB port, pull out the USB port wire.
— Rear part, rear fender
Installation
Reverse the removal procedure for installation
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Tool box
Removal
— Turn over rear fender, remove tapping screw 1,
tapping screw 2, tapping screw 3,remove tool box
Installation
Reverse the removal procedure for installation
Installation
Reverse the removal procedure for installation
Installation
Reverse the removal procedure for installation
Reflector
Removal:
— Nut 1 and rear reflector
— Nut 2 and rear left reflector
— Nut 3 and rear right reflector
Installation
Reverse the removal procedure for installation
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2 Vehicle Body,Muffler
Fender
Removal
— Seat
— Seat lock plate 2
— Rear fender
— Bolt 1, Bolt 2, Bolt 3
— Splash fender comp.
Installation
Reverse the removal procedure for installation
Installation
Reverse the removal procedure for installation
Installation
Reverse the removal procedure for installation
Installation
Reverse the removal procedure for installation
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Right Cover
Removal
— 3 Screws
— Right side cover
Installation
Reverse the removal procedure for installation
2-12
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2 Vehicle Body,Muffler
Fuel Tank
Disassembly
Warning
Gasoline is highly flammable, therefore smoke and fire 2
are strictly forbidden in the work place. Special attention
should also be paid to sparks. Gasoline may also be explo-
sive when it is vaporized, so operation should be done in a
well-ventilated place.
Remove seat
Note:
Be careful not to damage main cable, pipes and hoses.
Main cable, cables, pipes and hoses should be routed prop-
erly according to the routing drawing.
Take precaution against fuel leakage when removing fuel
pipe I
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Muffler
Caution: Perform disassembly only after the muffler is
cooled down.
Remove:
— Seat
— Bolt 1, Bolt 2, ornament Plate
Installation
Reverse the removal procedure for installation
Install muffler ornament Plate
Note:
Replace sealing gasket when installing the muffler.
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2 Vehicle Body,Muffler
2-15
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3 Inspection & Adjustment
Overhaul info … … … … … … … … … … … 3-1 Ignition … … … … … … … … 3-9
Replacement of parts… … … … … … … … 3-1 Lubrication … … … … … … 3-11
Inspection & Maintenance… … … … … 3-2 Fuel … … … … … … … … … 3-12
Steering Stem… … … … … … … … … … … 3-5 Cooling… … … … … … … … 3-15
Brake system… … … … … … … … … … … 3-6 Lighting… … … … … … … … 3-17
Wheel … … … … … … … … … … … … … 3-7
Suspension system … … … … … … … … 3-8 3
Overhaul info
Operation Instruction
Warning
DO NOT keep the engine running for long time in a poorly ventilated or enclosed place because of the harmful
components like CO, etc, in the exhaust gas.
The muffler and engine are still very hot when the engine is just stopped. Careless contact may cause serious
burn. Be sure to wear fatigue dress with long sleeves and gloves if the work has to be done when the engine
is just stopped.
Gasoline is highly flammable, smoking is strictly forbidden in the work place. Keep alert on the electrical
sparks. Besides, vaporized gasoline is highly explosive, so work should be done in a well-ventilated place.
Be careful that your hands or clothes not get caught by the turning or movable parts of the driving system.
Note:
The vehicle should be parked on hard and level ground and supported with the main stand or a service brack
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Check & M aintenance ○ : Interval
Check & m aintenance item Intervals
Halfayear
Standard
Every
daily
year
Part Item
Transm i- O il leakage and Rem ove filling bolt, add oil till oil
ssion G earbox
oil level level reaches edge of filling hole.
system
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3 Inspection & Adjustment
Check & Maintenance item Intervals
Every year
Half a year
daily
Standard
Part Item
Transmis-
sion device
Final
Looseness of joint
parts
○ ○ 3
Shaft
Sway of spline ○
Spark plug
Status of spark plug ○ ○
Ignition gap:0.8-0.9mm
Ignition timing ○ ○
Electrical
device Battery Terminal joint ○
Looseness and
Electrical
damage connecting ○
wiring
parts
Starting, abnormal
○ ○
noise
Timing chain ad-
○ ○
justment
Body Low-speed & accel-
○ ○
erating
Idle speed ○ ○ 1500± 150r/min
Exhaust ○ ○
Filter element ○ ○
Oil leakage ○ ○
Lubrica- Diprod type: oil
Engine
tion Stained oil and oil level should be
device ○ ○ ○
level between the upper
and lower limits.
Fuel leakage ○ ○
Joint condition of
○
Fuel de- carburetor
vice Throttle grip clear-
Throttle ○ ance 2-6mm.
(Flange part).
Cooling Water level ○ ○ ○
device Water leakage ○
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Check & maintenance item Intervals
Half a year
Every year
daily
Standard
Part Item
3-4
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3 Inspection & Adjustment
Steering Column
Park the scooter with main stand, lift front tire, hold the
lower part of shock-absorber and shake back and forth to
see if there is any sway.
Lift the front wheel, slowly turn the handlebar left and
right to see if it can turn freely.
In case there is any hindrance, check if it is from the main
cable assembly or other cables. Or disassemble the steer-
ing column and check if the bearing race of steering col-
umn is damaged.
Brake system
Brake lever play
Play: 10-20mm
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Master Cylinder
<Fluid level>
Check the brake fluid level
When the brake fluid level is near to the lower limit, check
master Cylinder, brake hoses and joints for oil leakage.
Remove the two mounting screws on oil cup cap, remove
cap, add DOT3 or DOT4 brake fluid till the upper limit.
Note
The brake pad must be replaced with a whole set.
3-6
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3 Inspection & Adjustment
Wheel & Tire
Tire Pressure
Check the tire pressure with a pressure gauge.
Note
Check tire pressure when tires are cooled.
3
Driving under improper tire pressure will
reduce the comfort of operation and riding,
and may cause deflected wear of the tires.
Tire pressure parameter:
Specified pressure/tire
Front Rear
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Looseness of Wheel Nuts and Wheel Axle Nuts
Check front and rear wheel axle nuts for looseness.
Tighten in case of any looseness according to the
specified torque:
Tightening torque:
Front wheel axle nut: 80N· m(8.2kgf· m)
Suspension system
Front suspension
Hold tight the front brake lever, press the front suspen-
sion up and down several times.
In case of any rocking or abnormal noise, check the front
shock absorbers and the steering column.
Check front shock absorbers for oil leakage, damage or
looseness of the tightening parts.
3-8
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3 Inspection & Adjustment
Rear suspension
Press the rear suspension up and down several times.
In case of any rocking or abnormal noise, check the rear
shock absorbers and the hanging pivot part.
Check rear shock absorbers for oil leakage, damage
or looseness of the tightening parts. 3
Ignition Device
Spark plug
Remove:
— seat
— Rear left panel
— Spark plug cap
— Clean the joint face of spark plug with compressed
air when removing.
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Remove the spark plug
Burning → Replace
Note
To avoid damage to the thread of spark plug hole, when
installing the spark plug, screw in with hand and then
tighten it with a spanner.
If the spark plug is a new one, screw in by one-quarter
after the sealing gasket contacts the joint face.
If the spark plug is a used one, tighten it according to the
recommended torque.
Torque: 1 5 - 2 0 N · m ( 1 . 5 - 2 . 0 k g f · m )
Install the spark plug cap.
Install:
— Spark plug cap
— Left and right ornament panels
— Seat
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3 Inspection & Adjustment
Lubrication
Inspection of engine oil
Warm up the engine.
Stop the engine and remove the oil dip rod and clean it.
Park the scooter on level ground.Insert the oil dip rod
(DO NOT screw in) and check engine oil level 2~3
minutes after the engine stopped.
3
If oil level is between the upper and lower limit, oil is
sufficient.
If oil level is near the lower limit, add oil till the upper
limit.
Note
Choose engine oil according to the
viscosity-temperature chart on the right.
Install the oil dip rod, and tighten it.
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Install the cleaned drain bolt and new sealing gasket,
Torque: 2 5 N · m ( 2 . 5 k g f · m )
Add the recommended engine oil.
Engine oil capacity: 0.8L(for replacing)
1.0L(for disassembling)
Check the oil level with the dip rod while adding till the oil
level reaches upper limit.
Install oil dip rod, start the engine, and check if there is any
oil leakage.
Stop the engine, and check oil level again.
Install right cover
Fuel
Condition of the fuel system
Remove seat
Check the fuel pipes for any aging or damage.
Aging, damage → Replace
Check if there is cracks or bending with the vacuum
tube.
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3 Inspection & Adjustment
— Seat
— Rear left panel
— Left black Panel 3
— Left Panel
Idle Speed
Note
Check and adjust the following items before
inspection:
1.Status of the air filter and secondary air filter
2. Status of spark plug
Use an engine tachometer with reading error of 50r/min,
and install properly according to operation manual.
Any incline of the vehicle body will cause change of the
idle speed, so the vehicle should be parked with the main
stand on the level ground and kept vertical.
Remove:
— seat
— Rear right ornament panels
Start the engine and keep it running unloaded at 6000rpm
for about 5~6 minutes to warm up. (Outdoor temperature:
25℃ )
Check idle speed and adjust with a flat screw to the
required idle speed.
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Throttle Grip
Check agility of throttle grip
In case of any stiffness, check the throttle cable for
damage or rust.
Check free play of throttle grip.
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3 Inspection & Adjustment
Cooling
Caution
Check of coolant level should be done on the reservoir
tank instead of the radiator. If the radiator cap is opened
while the engine is hot (over 100℃ ), the pressure of the
cooling system will drop down and the coolant will get
boiled rapidly. DO NOT open the radiator cap until the
3
coolant temperature drops down.
Coolant is poisonous, DO NOT drink or splash it
to skin, eyes, and clothes.
In case the coolant gets to the skin and clothes,
wash with soap immediately.
In case the coolant gets into eyes, rinse with plenty
of water and go to consult the doctor
In case of swallowing the coolant, induce vomit and
consult the doctor.
Keep the coolant in a safe place and away from reach
of children.
Coolant level
Coolant might reduce due to natural evaporation, check
the coolant level regularly.
Caution
Coolant can prevent rust and resist freeze.
Ordinary water may cause engine rust or cracks in
winter due to freezing.
Park the vehicle properly for checking of the coolant.
Inclined vehicle body will cause incorrect judging of the
coolant level.
Check the coolant after the engine is warmed up.
3-15
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When the coolant level is below the lower limit, remove
reservoir tank cap and fill coolant till upper limit.
(coolant or diluted original liquid).
Recommended coolant: CFMOTO coolant
Standard density:30%( Freezing temperature
of coolant varies according to the different
mixture ratio. Adjust the mixture ratio according to
the lowest temperature in the place where the vehicle is
used.)
If the coolant reduces very fast, check if there is any
leakage.
The cooling system may be mixed with air when there is no
coolant in the reservoir tank and the air should be dis-
charged before filling coolant.
Coolant Leakage
Check radiator hose, water pump, water pipes and joint
for leakage.
In case of any leakage, disassemble and do further
check. (Refer to Chapter 6)
Check the radiator hose for aging, damages or cracks;
3-16
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3 Inspection & Adjustment
Lighting
Adjusting headlight beam
Turn screw with a cross driver to adjust the headlight
beam.
3-17
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3-18
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4 Lubrication system
Overhaul info
Caution 4
The maintenance of the oil pump should be done after disassembling the right side cover. (→ 11)
When the measured values exceed the service limit, replace the oil pump.
Do not mix impurities into the engine when disassembling the oil pump.
Check if there is any leakage after installing the oil pump.
Standard
Service
Item Standard
lim it
C learance betw een inner
0 .0 7 - 0 .1 5 m m 0 .2 0 m m
and outer rotors
O il pum p rotor
Body clearance 0 .0 7 - 0 .1 7 m m 0 .2 5 m m
End face clearance 0 .0 5 - 0 .1 0 m m 0 .1 2 m m
Tightening torque
Bolt, oil pump body 10N· m(1.0kgf· m)
Screw, oil pump cover plate 2N· m(0.2kgf· m)
Partition Plate B 10N· m(1.0kgf· m)
Partition Plate A 10N· m(1.0kgf· m)
Troubleshooting
Lower Oil Level
Smudged Oil
.Natural Oil consuming
.Oil is not replaced in time
.Oil leakage
. Wearing of piston ring
.Wearing or improper installation of piston ring
.Mixture of oil with coolant
.Wearing of valve guide or stem
. Poor sealing of water seal comp.
.Damaged oil seal of valve stem
.Poor sealing of cylinder gasket
.Wearing of cylinder, piston or piston ring
4-1
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Oil pump
Disassembly
Remove screw and disassembly oil pump.
4-2
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4 Lubrication system
Inspection
Check clearance between pump body and outer rotor.
Assembly:
Assemble inner rotor, outer rotor and shaft to pump body.
4-3
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Tighten shaft with screw
Installation
Install oil pump and Partition Plate A to right crankcase.
Tighten with 2 bolts.
Make sure shaft can rotate freely.
4-4
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5 Carburetor、 Air Filter
Overhaul info 5
Caution:
Keep caution against fire when using gasoline.
● Check the installation position of o-rings, replace if necessary for installation.
● Remove the drainage screw of the float chamber before disassembly and dis-
● For early functioning of enriching device after the engine is warm up, there is a
Tools:
General-purpose tools:
Float meter
5-1
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Troubleshooting
5-2
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5 Carburetor、 Air Filter
Carburetor Removal
Remove seat, rear left and right panels(→ 2-3→ 2-4,)
Release clamp for carburetor and air filter.
Release screw and remove carburetor joint.
Note:
Do not drop the screw.
5
Loosen throttle cable adjusting nut and lock nut, remove
throttle cable from carburetor.
Note:
Cover the inlet hole with clean cotton yarn after carburetor
is removed to avoid entrance of impurities.
5-3
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Remove 2 screws from enriching device adjusting plate.
Remove enriching device.
Note:
Disconnect top box cover after removing rear right panel.
Be careful not to damage the valve after removing enrich-
ing device.
5-4
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5 Carburetor、 Air Filter
Vacuum Chamber
Disassembly
Remove fuel drainage screw and discharge fuel from float
chamber.
Caution:
Be careful not to damage diaphragm of vacuum piston.
5-5
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Assembly
Reverse the disassembly order for assembly.
Hold bottom of vacuum piston, keep vacuum piston full
open, make sure the diaphragm flange is embedded into
the groove of carburetor body. Set the spring as illustrated.
Overlap diaphragm hole with groove of cover, install
vacuum chamber cover.
Note:
— Do not damage diaphragm
— Always hold the vacuum piston before tightening the
small screws.
Float Chamber
Remove 4 screws and take out float chamber.
Remove float pin, float and float valve.
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5 Carburetor、 Air Filter
Remove main jet, needle valve seat & adjusting nozzle,idle
jet and MAS (mixture adjust screw).
Note:
— Do not damage nozzle & screw;
— Before removing MAS, note down the tightening
position. Over-tightening may cause damage to seat
surface.
5
Clean nozzle with gasoline
Use clean gasoline
Clean all the channels of carburetor body with compressed
air after disassembly of float chamber.
Assembly
Install adjust nozzle, nozzle seat, main jet, slow speed jet,
MAS.
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Inspection of float level
Check float level at main jet.
Float level: 18.5± 0.5mm
General Purpose Tool: Float Meter
Throttle Valve
Inspection
Note:
Throttle valve inspection can be done on the vehicle.
Replacement
Remove
— carburetor. (→ 5-3)
— Breather hose from throttle valve
— 2 screws and throttle valve
— O-ring from valve.
Install a new O-ring to the valve as illustrated.
Install valve to the carburetor and tighten small screws.
5-8
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5 Carburetor、 Air Filter
Installation of Carburetor
Install enriching device to the carburetor
Install fixing plate as illustrated and make sure to tighten
the small screws.
Note:
— Press enriching device to the bottom and fix outer groove
with fixing plate.
— Keep the edge side with fillet of fixing plate downward.
5
5-9
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Fasten clamp for carburetor joint and air filter.
Adjust MAS
Adjustment should be done after the engine is warmed up.
Remove seat and left speaker cover (→ 2-3, 2-9)
Install tachometer.
Turn MAS according to standard return cycle.
5-10
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5 Carburetor、 Air Filter
Air Filter
Disassembly
Remove:
— seat, front left panel, upper left panel, left black panel,
rear left panel, left ornament panel(→ chapter 2)
— 5 fixing screws
— air filter cover
Installation:
5-11
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Air Filter
5-12
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6 Cooling System
Overhauling info… … … … … … … … … 6-1 Thermostat… … … … … … … … … … 6-7
Trouble shooting… … … … … … … … … 6-2 Radiator… … … … … … … … … … … 6-8
Performance overhauling… … … … … … 6-3 Water pump… … … … … … … … … … 6-9
Reservoir tank… … … … … … … … … … 6-5 Cooling system drawing… … … … … 6-10
Overhaul Information
Caution:
.If the radiator cap is opened when the coolant temperature is above 100℃ , the pressure of coolant temperature will go
down and get boiled rapidly. The steam jet may cause danger and injury. Cover the cap with a piece of cloth after the
coolant temperature goes down and open the cap slowly.
. Inspection of coolant should be done after the coolant is fully cooled.
. Coolant is poisonous. Do not drink or splash it to skin, eyes or cloth. 6
If coolant splashes in your eyes, thoroughly wash your eyes with water and consult a doctor.
If coolant splashes on your clothes, quickly wash it away with water and then with soap and water.
If coolant is swallowed, induce vomit immediately and see a physician.
. Store the coolant properly and keep it away from reach of children.
. Check radiator fins for mud block and/or damage. Correct the bent fins. Clean off the mud with water and compressed
air. Replace with a new one if the damaged fin area reached 20%.
. The overhauling of the water pump can done without removing the engine.
. Fill coolant through reservoir tank. Do not open the radiator cap except when disassembling the cooling system for
filling or drainage of coolant.
. Don not stain the plastic parts with coolant. In case of any coolant stains, flush with water immediately.
. After disassembly of the cooling system, check the joints for leakage with a radiator cap tester(available in the
market).
. Refer to Chapter 18 for overhauling of temperature transducer.
Inspection standard
Item Standard
Full capacity 1100ml
Coolant
Reservoir tank capacity 340ml
capacity
Standard density 30%
Opening pressure of radiator cap 108kpa(1.1kgf/cm2)
Valve open temperature 72± 2℃
Thermostat Full open Temperature 88℃
Full open lift 3.5-4.5mm
Tightening torque
Drainage bolt, water pump 8N· m(0.8kgf· m)
Thermoswitch 10N· m(1.0kgf· m)
Water pump impeller 10-14N· m(1.0kgf· m) left thread
6-1
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Troubleshooting
Coolant leakage
l Faulty water pump seal
l O-rings are aged, damaged or improperly sealed.
l Washers are aged, damaged or improperly sealed.
l Improper installation of pipes,
l Pipes are aged, damaged or improperly sealed.
6-2
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6 Cooling System
Performance Overhaul
Note:
Open the radiator cap after coolant is fully cooled.
Remove:
— Left panel
— Radiator cap(counter clockwise)
Caution:
Apply coolant on the sealing surface of radiator cap when
attaching the tester to the radiator cap.
6-3
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Pressure testing of cooling system
Apply the specified pressure (opening pressure of radiator
cap) and make sure there is no pressure drop for 6 seconds
in the cooling system..
Caution:
Do not apply pressure over the specified pressure [108kpa
(1.1kgf/cm2)], or the cooling system may be damaged.
In case there is any pressure leakage, check the pipe, joint
parts, joints of water pump and drainage (→ 6-8).
Drainage of coolant
Remove radiator cap cover
Caution:
Open the radiator cap after the coolant is fully cooled.
Remove
— left panel
— Radiator cap.(clockwise)
6-4
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6 Cooling System
Remove drain bolt
Remove right side cover.(→ 1.1-2)
Remove drain bolt, seal gasket from water pump, drain
coolant.
After drainage, assemble new seal gasket, drain bolt and
tighten.
Reservoir Tank
Remove:
— Right speaker cover(→ 2-7)
— Bolt 1 & 2
— Reservoir tank water hose
Remove reservoir tank; discharge coolant.
Flush reservoir tank.
Install reservoir tank.
Install water hose.
6-5
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Refilling Coolant
Open reservoir tank cap and refill coolant till the upper
limit.
Note:
Check coolant level when the scooter is parked with main
stand on an even ground.
Air Discharge
Discharge the air from cooling system according to the
following steps:
1. Start the engine and run it several minutes at idle
speed;
2. Quickly increase throttle 3~4 times to discharge air
from cooling system;
3. Refill coolant till filling port;
4. Check coolant level in reservoir tank and refill till up-
per limit. Install reservoir tank cap.
6-6
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6 Cooling System
Thermostat
Disassembly and Installation
Caution:
Remove the thermostat after coolant is fully cooled.
Remove
— seat (6-4)
— Bolt 1 and thermostat(5-3)
Remove bolt, upper and lower cases of thermostat.Take
out thermostat.
Reverse the removal procedure for installation.
Fill coolant, and discharge air. (→ 6-4) 6
Overhaul
Note:
1 The thermostat must be replaced even if it is a bit
open at normal temperature.
2 There is time lag due to the small temperature sens-
ing area of the thermostat. So check the lift of the
opening valve after the full open temperature is kept
for about 5 minutes.
3 Keep the thermostat and thermometer from contact-
ing the bottom of the vessel
Put thermostat into water, keep water temperature rising
slowly, and check the opening temperature of thermostat
valve.
Opening temperature of thermostatic valve: 72± 2℃
Thermometer full open /lift Temperature: 3.5-4.5mm/88℃
Install thermostat.
6-7
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Radiator
Caution:
Do not damage the Radiator fins.
Remove:
— Front Vent panel
— Rear Left & right panel
— Left & right black panel
— left & right panel
— left & right upper panel
— Bolt 1
Installation
Note:
Check radiator fins for mud block and/or damage. Cor-
rect the bent fins. Clean off the mud with water and com-
pressed air. Replace with a new one if the damaged fin
area reached 20%.
6-8
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6 Cooling System
6-9
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7 Engine Removal and Installation
Chapter 7 Engine Removal and Installation
Overhaul Info… … … … … … … … … .7-1 Engine Installation… .… … … .7-5
EngineRemoval… … … … … … … … 7-2
Overhaul info
Operation cautions:
Securely support the scooter with jack when installing or removing engine.
Do not damage frame, engine body, bolts and cables.
Wrap the frame to avoid any possible damage when installing or removing the engine.
Following operation doesn’t require removal of engine from the vehicle.
— oil pump(→ Chapter 4)
— carburetor, air filter (→ Chapter 5)
— cylinder head cover, cylinder head, cylinder body, camshaft(→ Chapter 8)
7
— CVT system, left side cover(→ Chapter 9)
— gearbox(→ Chapter 10)
— right side cover, AC magneto, water pump(→ chapter 11)
— piston, piston ring, piston pin(→ chapter 12)
Following operation require that the engine removed from the vehicle.
— crankshaft(→ Chapter 12)
Tightening torque:
Engine suspension bracket bolt: 55N· m(5.6kgf· m)
Engine suspension shaft nut: 55N· m(5.6kgf· m)
Rear shock absorber mounting bolt(up): 55N· m(5.6kgf· m)
Rear shock absorber mounting bolt (down): 30N· m(3.1kgf· m)
7-1
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Engine Removal
Remove:
— Seat (→ 2-3)
— Rear panels (L&H)(→ 2-3)
— Rear bracket (→ 2-8)
— Rear part, rear fender (→ 2-9)
— Rear fender (center) (→ 2-11)
— Splash fender (→ 2-5)
— Muffler (→ 2-20)
— Rear wheel (→ Chapter 14)
Drain coolant(→ 6-4)
Release locknut, remove adjustable throttle cable/throttle
cable from carburetor.
Release clamp and remove tube from air filter.
7-2
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7 Engine Removal and Installation
Remove nut and disconnect negative pole wire of starter
relay
7-3
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Remove:
— nut for rear left absorber;
— rear left absorber from frame;
— engine, engine hanger and rear left absorber.
— lower nut of rear absorber;
— rear absorber from engine.
Note:
Removal of rear left absorber is the final step of engine
removal.
Make sure engine is properly supported.
7-4
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7 Engine Removal and Installation
Engine Installation
Note:
Cables, pipes and electrical harness should be properly
routed according to the routing diagram. (→ 1-20)
Install water outlet and inlet hoses for engine and water
hose (engine warm-up) with proper clamps.
Note:
Hoses with crack or damages → Replace;
Water hoses should be installed properly without any leak-
age at joints.
7-5
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Install air filter tube with clamp.
Connect throttle cable, adjustable throttle cable, adjust
free play of throttle grip.(→ 3-15)
Tighten lock nut after adjustment.
7-6
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7 Engine Removal and Installation
Lift starter relay sleeve, install positive pole wire with bolt.
Install:
— Rear wheel (→ Chapter 13)
— Muffler (→ 2-20)
— Rear left and right panel (→ 2-4)
— Rear Bracket (→ 2-5)
— Rear part of rear fender (→ 2-7)
— Rear fender (center) (→ 2-11)
— Fill coolant and discharge air.
— Seat (→ 2-3)
7-7
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7-8
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8 Cylinder Cover, Cylinder Head, Cylinder Body, Valve Train
8-1
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Troubleshooting
Noise
Ø Improper adjustment of valve clearance
Ø Valve sinter, damaged valve spring or weak spring
Ø Damaged or worn rocker arm and rocker arm shaft
8-2
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8 Cylinder Cover, Cylinder Head, Cylinder Body, Valve Train
Inspection: 8
Rocker Arm → damage or wearing
Inner diameter → Replace when more than service limit of
12.10mm
Note:
In case there is any damage or wearing with rocker arm,
check cam surface for damage or wearing.
Removal of Camshaft
Remove:
— Exhaust pipe, muffler (→ 2-20)
— Tensioning device
8-3
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Remove:
— 2 bolts
— Camshaft bearing cover;
— Chain from sprocket;
— Camshaft
Note:
To prevent the timing chain from dropping into cylinder,
hook the chain with a wire.
Inspection of Camshaft
Check cam surface for damage and height to cam.
Replace when less than service limit of 31.52mm
8-4
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8 Cylinder Cover, Cylinder Head, Cylinder Body, Valve Train
— Drain coolant;
— Remove bolt for thermostat housing;
— Remove thermostat housing from cylinder head
— Remove bolts for oil pipe support and cylinder base.
— Remove 4 nuts and 4 copper washers
Note:
— Do not damage gasket surface;
— Do not drop gasket materials into engine or water jacket.
8-5
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Check camshaft bearing seat for wearing or damage.
Note:
— Take care not to damage the surface of cylinder;
— Carbon deposit can be easily removed if dipped in
gasoline.
Inspection
Cylinder Head
Check spark plug hole and valve port for any cracks.
Check distortion of cylinder head with a square and a plug
gauge.
Correct or replace cylinder head if it’s more than service
limit of 0.5mm.
8-6
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8 Cylinder Cover, Cylinder Head, Cylinder Body, Valve Train
Valve Spring
Check free length of valve inner and outer springs.
Replace when free length less than the following service
limit:
Service limit: Inner Spring 27.6mm
Outer Spring 36.1mm
Note:
Always turn the reamer right. Do not insert or pull out the
reamer while it is not turning.
Measure inner diameter of valve guide.
8-7
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Replacement of Valve Guide
Drive out valve guide.
Note:
Take care not to damage cylinder head.
Special tool: Valve Guide Driver (5.00MM)
Adjust valve guide driver and keep the driving height at
12mm.
Drive in the valve guide.
Note:
— After driving in the valve guide, make sure there is no
damage with drive guide.
— When driving in the valve guide, make sure not to dam-
age cylinder head surface.
General purpose tool: Valve Guide Driver
Correct valve guide with a reamer.
Note:
— When reaming valve guide, use cutting oil.
— Only turn the reamer right.
— Do not insert or pull out reamer while it is not turning.
Wash clean cylinder head and clean off scraps.
Special tool: Valve Guide Reamer
Inspection
Clean off carbon deposit at combustion chamber and
valves.
Apply some red lead on valve face.
Make valve slide with valve hammer.
Remove valve and check valve face.
Replace the valve in case there is eccentric wearing or
rough face.
8-8
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8 Cylinder Cover, Cylinder Head, Cylinder Body, Valve Train
Note:
Do not over cut.
8-9
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Use a 60° cutterhead for surface cutting.
After all the correction, make sure with read lead the 45°
valve-seat face is evenly on contact with center of valve-
seat contact.
8-10
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8 Cylinder Cover, Cylinder Head, Cylinder Body, Valve Train
Cylinder Removal
Remove:
— Cylinder head (→ 8-4)
— Water hose connection from cylinder
— Chain guide
— Cylinder base nut and cylinder
8
Note:
Do not drop any foreign materials into crankcase.
8-11
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Cylinder Installation
Install tensioning device to cylinder, with a new gasket.
Note:
— Take care not to damage piston or piston rings;
— The piston-ring openings should not be in the direction
of piston pin and should be arranged in the equal angle of
120° .
8-12
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8 Cylinder Cover, Cylinder Head, Cylinder Body, Valve Train
Note:
Replace with a new stem seal.
Apply some engine oil to valve stem, insert stem into valve
guide.
Install valve lock with valve spring compressor.
Note:
— Do not over tighten valve spring compressor;
— Install valve spring with the side of smaller pitch of screw
in line with cylinder head side.
Special tool: Valve Spring Compressor
8
Strike slightly valve stem end 2~3 times with a rubber ham-
mer to make valve and valve lock match well.
Take care not to damage valve.
8-13
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Remove timing plug from right side cover
Remove CVT cover (→ 9-3)
Turn pulley counter clockwise, overlap T mark on
Fly wheel with mark on right side cover.
Note:
Tighten nuts in crisscross direction in 2~3 progressive
steps.
8-14
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8 Cylinder Cover, Cylinder Head, Cylinder Body, Valve Train
Install
— Gasket, tensioner and tighten bolts.
Tightening Torque: 0.8-1.2kgf· m
— CVT cover and timing inspection hole cover.
— Muffler (→ 2-20)
8-15
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Cylinder Cover Installation
Fill the cylinder head oil groove with engine oil.
Install 2 dowel pins to cylinder head.
Install gasket to the cylinder head slot and install cylinder
cover.
Tighten 5 bolts.
Tightening Torque: 0.8-1.2kgf· m
Note:
— Fix the carburetor fixing plate to the cylinder cover with
bolts.
— Tighten bolts on the cross in 2 progressive steps.
Install oil pipe to cylinder cover with oil pipe bolt and
copper washer.
Tightening Torque: 0.8-1.2kgf· m
Valve Adjustment
Valve adjustment should be done when the engine is
cooled. (under 35℃ )
Remove:
— Seat (→ 2-3)
— CVT cover(→ 9-3)
— Inspection cover from cylinder cover.
Turn primary sheave counterclockwise slowly, align top
dead-center indicator of camshaft with the mark on cylin-
der cover. Maintain piston at the upper dead-center
position.
Release fixing bolts of valve adjuster.
Open IN, EX adjustors fully outwards, then return by one
mark.
Tighten fixing bolts.
Install the removed parts.
Install Seat. (→ 2-3)
8-16
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8 Cylinder Cover, Cylinder Head, Cylinder Body, Valve Train
8-17
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8-18
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9 Primary Sheave, Clutch, Secondary Sheave
Overhaul Information
Note:
— Maintenance of CVT cover, belt, primary and secondary fixed sheave and clutch could be done without re-
moving engine from vehicle;
— Do not apply greasy material to belt, primary and secondary fixed sheave;
Maintenance Standard:
Tightening torque:
Refer to (→ 9-17)
Special Tool:
Nut spanner 39x41mm Clutch Spring Compressor
Rotor Holder Driving Tool Handle
9-1
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Troubleshooting
9-2
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9 Primary Sheave, Clutch, Secondary Sheave
CVT Cover
Disassembly
Remove:
— Left ornament panel (→ 2-5)
— 5 bolts of CVT cover, remove the other bolt from side
with an open spanner.
— Dowel pin
Installation
Reverse the removal procedure for installation.
Tightening torque: 0.8~1.2kgf· m 9
Belt
Disassembly
Remove CVT cover;
Hold primary fixed sheave with belt holder,
Release Nut;
Special Tool: Belt Holder
9-3
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Inspection
Check belt for cracks, teeth drop and abnormal wearing;
Measure the belt width;
Service Limit: 22.5mm
Note:
Replace with genuine parts.
Installation
Turn the secondary sliding sheave clockwise while
compress it.
Put belt on the secondary sheave.
Put belt on the collar of primary sheave and install primary
sheave.
Install washer, nut and tighten.
Tightening torque: 8.0~10.0kgf· m
Note:
— The belt should not be seized;
— The direction mark on the belt should be same as its
moving direction.
Install CVT cover.
Primary Sheave
Remove:
— CVT cover and belt (→ 9-3)
— Primary sliding sheave
Disassembly
Remove collar
9-4
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9 Primary Sheave, Clutch, Secondary Sheave
Remove ramp plate
Remove weights.
9-5
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Measure the inner diameter of primary sliding sheave collar.
Service limit: >27.06mm → Replace
9-6
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9 Primary Sheave, Clutch, Secondary Sheave
Assembly
9-7
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Install collar to primary sliding sheave.
Installation
Install primary sliding sheave to crankshaft.
Install belt. (9-4).
Install primary fixed sheave to crankshaft.
Install washer.
Hold primary fixed sheave and tighten nut.
Tightening Torque: 8.0~10.0kgf· m
Special Tool: Rotor Holder
Note:
Do not stain greasy material such as engine oil to belt or
sheave.
Make sure the belt is not seized.
Disassembly
Remove:
— CVT Cover (→ 9-3)
— Primary fixed sheave & belt (→ 9-3)
— Nut (clutch carrier) while holding clutching housing.
9-8
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9 Primary Sheave, Clutch, Secondary Sheave
Remove secondary sheave
Inspection:
Check clutch housing for wearing or damage.
9
Check clutch carrier for wearing or damage.
Measure thickness of clutch shoe.
Service limit: <1.5mm → Replace
Disassembly
Attach clutch spring compressor to secondary sheave/
clutch.
Compress clutch spring.
Note:
Do not over compress clutch spring to avoid damage of
secondary sheave.
Special Tool: Clutch Spring Compressor
9-9
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Remove split washers, pressure plate,
disassemble clutch.
Note:
Do not stain clutch shoe with grease.
9-10
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9 Primary Sheave, Clutch, Secondary Sheave
Inspection
9-11
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Check secondary sliding sheave for wearing or damage.
Measure inner diameter.
Service Limit: > 40.06mm → Replace
Check if there is any stepped wearing in the guide groove.
9-12
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9 Primary Sheave, Clutch, Secondary Sheave
Apply lube to roller bearing.
Special Tool: Driving tool handle
Assembly of Clutch
9-13
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Install rubber blocks onto driving plate wrists.
9-14
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9 Primary Sheave, Clutch, Secondary Sheave
Secondary Sheave Assembly
Note:
Apply evenly 4~g of lube. Recommended Lube: XOM
XHP222
9-15
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Install seal collar
Clean the overflow lube.
Note:
In case there is any lube or grease on the secondary sheave.
Make sure to clean it.
Installation:
Install clutch and secondary sheave to driving shaft.
Note:
Clean the grease from driving shaft, if any.
Install clutch housing.
Hold clutch housing with clutch holder and tighten nut.
Tightening torque: 5.0~6.0kgf· m
Install:
— Belt(→ 9-4)
— CVT cover (→ 9-3)
— Left speaker cover (→ 2-9)
9-16
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9 Primary Sheave, Clutch, Secondary Sheave
Primary Sheave, Clutch, Secondary Sheave
9-17
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9-18
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10 Gearbox
Chapter 10 Gearbox
Overhaul Information
Overhaul Standard
Recommended Oil: SAE15W-40 or SAE20W-50 for 4-stroke motorcycle.
SE or SF engine oil as per API category (refer to table 3-11, Oil viscosity should adapt
to the outdoor temperature of the area where the motorcycle is operated.)
Oil Capacity: 0.25L (when disassembling)
0.20L (when replacing)
Tightening Torque
Gearbox Bolt 6mm 0.8~1.2kgf· m
8mm 2.0~2.4kgf· m
10mm 1.0~1.4kgf· m
Tools 10
Special Tools
Bearing Remover Set 12mm Drive Shaft Installation Tool
-Bearing remover 12mm Drive Shaft Installer Tool Sleeve (2 pcs)
-Remover weight
Bearing Remover Set 20mm
-Bearing remover 20mm
-Bearing remover handle
-Remover weight
General Purpose Tools
Bearing puller 37× 40mm
Bearing puller 52× 55mm
Driving tool guide 12mm
Troubleshooting
When engine is running, scooter does not run.
• Gearbox damaged
• Gearbox ablated
Abnormal noise during running
• Worn, ablated gear or damaged gear surface
• Worn or loosen bearing
Oil leakage
• Excessive oil
• Worn or damaged oil seal
10-1
Inspection:
Check drive shaft, gear, bearing for damage or wearing.
In case of replacement of drive gear or bearing, strike out
drive shaft together with gear.
Use bearing remover and shaft protection device (available
from market) to remove gear from shaft.
Remove drive shaft oil seal from left crankcase.
Note:
After removal of drive shaft bearing from left crankcase,
replace with a new one.
Check countershaft and gear for wearing or damage.
10-2
Special Tool:
Bearing Remover Set 15mm
-Bearing remover 15mm
-Remover weight
10
Special Tool:
Bearing Remover Set 20mm
-Bearing remover 20mm
-Remover weight
10-3
10-4
Special Tool:
Drive Shaft Installation Tool
Drive Shaft Installation Tool Sleeve (2 pcs)
10-5
10-6
Overhaul Information
Caution:
Removal of right side cover, stator and flywheel should be done when the engine is cold.
Inspection of right side cover and magneto can be done without removing engine from vehicle.
Refer to Chapter 15 for inspection of magneto.
Tightening Torque
11-1
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Right Side Cover Removal
Remove right side cover (→ 2-3)
Drain coolant (→ 6-4)
Drain engine oil (→ 3-11)
Remove 2 oil pipe tightening bolts, 2 pieces of 8mm oil
pipe bolt,1 piece of 12mm oil pipe bolt.
Remove oil pipe.
Remove water hose from water pump and right side cover.
11-2
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11 Right Side Cover,Magneto, Water Pump
Flywheel Removal
Remove oil channel joint from crankshaft.
Hold flywheel with flywheel holder,
Remove flywheel nut and washer.
Remove straight pin for oil channel joint from crankshaft.
Note:
Keep caution not to drop straight pin into crankcase.
General Purpose Tool:Flywheel Holder
11-3
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Water Pump
Note:
Impeller rotates in the left direction.
11-4
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11 Right Side Cover,Magneto, Water Pump
Note:
Water seal and gasket should be replaced by set.
Remove:
— Right side cover (→ 11-2)
— Elastic retainer from right side cover
— Water pump shaft
11
Special Tool
Bearing remover set 15mm
-Bearing remover 15mm
-Remover shaft 15mm
-Remover head 15mm
-Remover weight
11-5
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Drive the new oil seal into right side cover with its mark
outward.
Note:
Apply sealant to the contact part of water seal and right
side cover before driving in the water seal.
11-6
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11 Right Side Cover,Magneto, Water Pump
Tightening Torque: 11
Oil pipe bolt 8mm 0.8~1.2kgf· m
12mm 1.8~2.2kgf· m
11-7
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Flywheel Installation
Install driven gear to crankshaft.
Install fixing plate and tighten bolt.
Note:
Make sure driven gear can turn smoothly.
Note:
Make sure there is no oil stain on the conical part of
crankshaft.
11-8
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11 Right Side Cover,Magneto, Water Pump
Apply moly grease to flywheel nut and screw part of
crankshaft.
Install flywheel nut to crankshaft.
Hold flywheel with flywheel holder and tighten nut.
Tightening Torque: 10.5~11.5kgf· m
General Purpose Tool: Flywheel Holder
11-9
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Keep water pump shaft groove in line with oil pump shaft.
Connect water hose with water pump and right side cover.
11-10
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11 Right Side Cover,Magneto, Water Pump
Make sure there is no impurity in the oil pipe.
Install oil pipe with 2 pcs of 8mm bolts,
1 pcs of 12mm bolt and 2 pcs of cop-
per washers.
Note:
-Use black bolt on the cylinder head cover side.
Use silver bolt on the right side cover.
Install oil pipe tightening bolts on the right side cover and
water pump.
Tightening Torque:
Oil Pipe Bolt 8mm 0.8~1.2kgf· m
12mm 1.8~2.2kgf· m
11
11-11
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Right Side Cover, Magneto
11-12
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11 Right Side Cover,Magneto, Water Pump
Water Pump
11
11-13
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11-14
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12 Crankcase, Crankshaft, Piston
Overhaul information······························12-1 Crankshaft/piston····································12-4
Troubleshooting······································12-2 Crankcase assembly································12-11
Disassembly of crankcase ······················12-3
Overhaul information
Operation caution
• Inspection of crankshaft and crankcase must be done after the crankcase is disassembled.
Inspection of these parts can only be done after removal of engine from vehicle.(→ Chapter 7)
• Following steps are required when disassembling the crankcase. Follow the relevant chapters
for disassembly:
— Engine removal(→ Chapter 7)
— Cylinder cover、 cylinder head、 cylinder (→ Chapter 8)
— CVT cover、 CVT system(→ Chapter 9)
— Right side cover(→ Chapter 11)
— Electric starting system(→ Chapter 17)
— Lubricating system(→ Chapter 4)
• For inspection of piston and piston ring, just remove cylinder cover、 cylinder head and
cylinder (→ Chapter 8)
•Do not damage the crankcase joint face during inspection.
•Do not damage the inner surface of cylinder, piston excircle.
Overhaul standard
12
Item Standard Service limit
Installation direction “IN” mark towards intake valve —
Outer diameter of piston 71.96-71.98mm 71.9mm
Inner diameter of piston pin-bore 17.002-17.008mm 17.04mm
Outer diameter of piston pin 16.99-17mm 16.96mm
Inner diameter of connecting rod 17.006-17.024mm 17.06mm
small end hole
Clearance between cylinder and piston 0.02-0.059mm 0.10mm
Clearance between piston and piston pin 0.002-0.014mm 0.02mm
Piston Clearance between piston pin and 0.006-0.030mm 0.02mm
connecting rod.
Clearance between Piston ring (1) 0.015-0.05mm 0.09mm
piston ring and Piston ring (2) 0.15-0.30mm 0.50mm
piston groove
Piston ring gap Piston ring (1) 0.15-0.30mm 0.50mm
Piston ring (2) 0.10-0.25mm 0.50mm
Oil ring 0.40-0.50mm
Installation direction of piston ring Mark upside —
Cylinder bore 72-72.019mm 72.1mm
Upper distortion 0.05mm
Cylinder
Roundness 0.002mm 0.05mm
Cylindricity 0.005mm 0.05mm
Axial gap, connecting rod big end 0.10-0.35mm 0.5mm
Crankshaft Radial gap, connecting rod big end 0.013-0.025mm 0.05mm
Vibration 0.02mm 0.10mm
12-1
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Tightening torque
Crankcase bolt 0.8-1.2kgf· m
Cylinder Stud 0.7-1.1kgf· m
Troubleshooting
Knocking
• Worn cylinder or piston
• Improper assembly of piston ring
• Damages to outside of piston or inner surface of cylinder
• Worn or damaged crankshaft bearing
12-2
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12 Crankcase, Crankshaft, Piston
Disassembly of Crankcase
Remove:
— Bolt
— Tenioner, timing chain
— Timing Chain
12
Note:
Do not pry surface of crankcase gasket.
12-3
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Remove bolt and remove oil pipe from right crankcase.
Crankshaft
12-4
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12 Crankcase, Crankshaft, Piston
12
12-5
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Disassembly of Piston
12-6
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12 Crankcase, Crankshaft, Piston
Check clearance between piston ring and piston-ring-
groove.
Service Limit:
Top Ring > 0.09mm → Replace
2nd Ring > 0.09mm → Replace
12
Install each piston ring separately to the cylinder bottom.
Press piston ring into cylinder from piston top.
Measure the working clearance of piston ring.
Service Limit:
Top Ring, 2nd Ring: > 0.50mm → Replace
12-7
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Measure piston outer diameter, at 14mm from piston skirt,
in the direction 90° opposite to the piston pin.
Service Limit: <71.90mm → Replace
Inspection of Cylinder
Check cylinder inner side for wearing or scraps.
Measure Cylinder bore from 3 points of upper, middle and
lower,in the right angle direction of piston pin (X-Y
direction).
Take the maximum value as the cylinder bore.
Service Limit: Above 72.10mm → Rebore or Replace
Service Limit:
Roundness: > 0.05mm → Rebore or Replace
Cylindricity:> 0.05mm→ Rebore or Replace
Cylinder Warpage
Service Limit:>0.05mm→ Rebore or Replace
12-8
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12 Crankcase, Crankshaft, Piston
Installation of Piston Ring
Install piston rings to the piston.
Apply oil to each ring.
Note:
Take care not to scrap piston or damage piston rings.
Keep the manufacturer’s marks or numbers on the upper
side of the rings.
Make sure piston rings can turn freely.
12
Installation of Piston
Installation of piston should be done after crankcase is
completed.
Install piston, piston pin and piston pin retainer.
Note:
-The IN mark on the piston must face the intake valve
-Cover the crankcase opening with a clean rag to prevent
piston pin or piston pin retainer from falling into crankcase.
12-9
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Assembly of Crankcase
Note:
Take care not to damage oil seal.
12-10
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12 Crankcase, Crankshaft, Piston
Install new dowel pin and gasket to left crankcase.
12
Assemble crankcase.
Tighten crankcase with 9 bolts.
Tightening Torque: 0.8~1.2kgf· m
12-11
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Crankcase, Crankshaft
12-12
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13 Front Wheel,Front Brake,Suspension,Steering System
Overhaul Information… … … … … … 13-1 Front Shock Absorber … … … … … 13-9
Troubleshooting … … … … … … … … 13-2 Handlebar… … … … … … … … … … … 13-10
Front Wheel… … … … … … … … … … 13-3 Front Fork… … … … … … … … … … … 13-15
Overhaul information
Operating cautions
Notes
•Securely support the scooter when overhauling the front wheel and suspension system.
•Refer to chapter 18 for overhaul and inspection of lighting, instruments and switches.
•Do not overexert on the wheel. Avoid any damage to the wheel.
•When removing tire, use the special tire lever and rim protector.
Overhaul standard
S erv ice
Item Stan d ard
L im it
F ro n t w h eel ax le b en d - 0 .2 m m
R im L o n gitu d in al 0 .8 m m 2 .0 m m
Vib ratio n L ateral 0 .8 m m 2 .0 m m
F ro n t
w h eel
R em ain ed
tire th read
- 1 .6 m m 13
Tire
Tire
2 5 0 k P a ( 2 .5 k g f/ c m 2) -
P ressu re
F ro n t
F ree p lay (b rak e lev er) 10- 20mm -
b rak e
Tightening torque
Mounting nut, Handlebar 55 N· m( 5.6kgf· m)
Nut, front wheel axle 80 N· m( 8.1kgf· m)
Fixing bolt/nut, Front shock absorber 40 N· m( 4.1kgf· m)
13-1
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Special tools
Rod, bearing remover
Head 10mm, bearing remover,
Handle A , Driving Tool
Sleeve, Driving Tool 28× 30
Guide tool 10mm
Locknut spanner
Bearing adjusting spanner, steering column
Bearing remover set,
Rotor puller
Remover shaft
Remover hammer
Bearing race mounting tool A 27× 47mm, steering column
Bearing race mounting tool B 30× 47mm, steering column
Assembling tool shaft
Troubleshooting
Heavy steering Wheel cannot turn freely
·Upper thread is over tightened. ·Faulty.wheel bearing
·Steering bearing is damaged or worn. ·Front wheel axle is bended
·Inner & outer bearing races are damaged,worn or
·Brake drag
stepped.
Front Suspension is too soft
·Steering column is distorted
·Weakened front shock absorber
·Tire pressure is too low.
·Low tire pressure
·Worn tire
Front suspension is too hard.
Loosened Handlebar
·Front shock absorber is bended.
·Steering bearing is damaged, or not well tightened.
·Right and left shock absorbers are not matched. ·Tire pressure too high.
·Front wheel axle is distorted, Abnormal noise with Front absorber
·Frame warpage ·Faulty front shock absorber
·Worn tire ·Loosening of tightening parts of front shock absorber
·Rocking of wheel bearing Poor brake
·Engine fixing part is rocking. (Refer to Chapter 7) ·Improper brake adjustment
·Stained or damaged brake disc.
Front wheel Vibrates
·Worn brake shoe.
·Warped rim
·Faulty wheel bearing
·Faulty tire
·Improper balance of wheel
·Improper tightening of wheel axle
13-2
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13 Front Wheel,Front Brake,Suspension,Steering System
Front wheel
Removal
Support the frame with jack, lift the front wheel, remove
front wheel axle nut.
Remove:
— Front wheel axle
— Brake disk from brake calipers
— Front wheel. 13
Remove counter.
13-3
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Remove collar from front wheel left side
Inspection
Wheel axle
Set axle on a V block, measure axle vibration with
centesimal gauge.
Service Limit: 0.2mm
Rim
Check the rim for damage, warpage or scrapes.
Replace with a new one, if any.
Slowly turn the wheel, measure the rim vibration with a
centesimal meter.
Wheel bearing
Turn the inner ring of the bearing with finger
to check if it can turn smoothly,
Check if there is any looseness when installed on the hub.
Replace with a new one in case
it cannot turn smoothly, or with abnormal noise or any
rocking.
Note:
Replace the bearings as a set (L&R).
13-4
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13 Front Wheel,Front Brake,Suspension,Steering System
Diassembly
Remove oil seal.
Install remover head on the rim
Install the bearing remover shaft on the
remover head from the reserve side,
strike in and remove the bearing
13
Remove spacer.
Special tool:
Shaft, Bearing remover
Head, Bearing remover 12mm
Note:
Replace the bearings in a set. Do not use the disassembled
bearings.
13-5
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Remove five bolts from brake disc, and remove brake disc.
Inspection
Brake disc thickness:<3mm → Replace
Inspection
Brake clipper.
Check brake calipers for cracks.
Check oil leakage from the tightening parts.
Replace, if any.
13-6
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13 Front Wheel,Front Brake,Suspension,Steering System
Assembly
13
Assemble spacer
Special tools:
Handle A , press tool A
Driving tool outer sleeve 28x30
Guide tool 12mm
Note:
Strike in the bearings in parallel.
13-7
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Apply grease to the protruding part of odometer gear
guard ring.
Apply grease to the gearing and sliding parts of
odometer gear
Install with the groove part of odometer gear in line with
the protruding part of guard ring.
Installation
Install front wheel with the brake disk between brake
calipers.
Note
Make sure counter cam is in line with front absorber
stopper.
Install front wheel axle and tighten nut.
Tightening Torque: 50-60N·m (5.0-6.0kgf·m)
13-8
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13 Front Wheel,Front Brake,Suspension,Steering System
Front Shock Absorbers
Disassembly
Remove:
— Front vent panel(→ 2-4)
— Front left and right panel) (→ 2-7)
— Black panels (L&R) (→ 2-8)
— Left and right panels (→ 2-5)
— Front fender (→ 2-2)
— Front wheel (→ 13-3)
— Bolt 1 & Bolt 2
Note
There should be no damage with the seal ring.
13
Remove shock absorbers
Note:
Do not put the shock absorber upside down to prevent oil
leakage from inner tube.
Inspection:
Oil leakage, aged or damaged oil seal → Replace
13-9
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Installation
Installation of shock absorbers
13-10
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13 Front Wheel,Front Brake,Suspension,Steering System
Loosen right handlebar switch.
Remove throttle cable from throttle grip
Installation
Install right handlebar switch (→ 13-14)
Installation
Install left handlebar switch (→ 13-14)
13-11
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Rear View Mirrors
Disassembly
Loosen nut counter clock-wise,
remove left rear view mirror by turning it counter clockwise.
Installation:
Reverse the removal procedure for installation.
Master Cylinders
Removal:
— Rear View Mirror (L&R)
Note:
1.Do not hang the master cylinders with brake hoses.
2. Maintain the master cylinders in the installation posi-
tion and fix them onto the handlebar.Placing the master
cylinders upside down may cause entrance of air into the
hydraulic system.
13-12
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13 Front Wheel,Front Brake,Suspension,Steering System
Handlebar Tube, Handlebar Lower Cover
Remove:
— handlebar Switch (L&R)( → 13-10)
Separate left & right master cylinders from handlebar
tube.
— 4 inner hex screws.
Installation of Handlebar
Installation of handlebar tube
Install 4 inner hex screws. Adjust the height of the
handlebar properly to best fit your driving habit.
Tightening Torque: 50-60N.m (5.0-6.0kgf.m)
Note:
Main cable, throttle cable, brake hose, etc should be
routed properly;
13
13-13
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Installation of Throttle Grip, Throttle
Cable
Apply lubrication grease to inner side of throttle grip
and contact part with handlebar.
Install throttle grip to handlebar.
13-14
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13 Front Wheel,Front Brake,Suspension,Steering System
Installation of Left Grip
Clean off the stains and grease from inner side of left grip
and handlebar contact part.
Apply cementing agent to handlebar contact part and in-
stall left grip.
Note:
Leave the left grip several hours for drying of cementing
agent after installation.
Note:
Main cable, throttle cable, brake hose, etc should be routed
properly;
Front Fork
Remove:
— Front wheel ( → 13-3)
— Handlebar( → 1 3 - 1 0 )
— Front fender( → 2 -2 )
— Locknut and washer, upper joint plate
— Seal cap and gasket, front shock absorber
— fixing screws, upper joint plate
— Upper joint plate
13-15
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Remove head pipe locknut with special tool
Special Tool
Head pipe locknut remover
Remove upper bearing seat, upper steel balls.
Set special tool on head pipe and remove bottom ball race.
Special Tool:
Bearing remover set
Rotor puller
Rod, remover
Hammer remover
Set special tool on head pipe and remove upper ball race.
Special Tool:
Bearing remover set
Rotor puller
Rod, remover
Hammer remover
13-16
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13 Front Wheel,Front Brake,Suspension,Steering System
Installation
Install new bottom ball race with following special tools to
steering stem
Special tools:
Ball race installation tool A
Installation Rod
Ball race installation tool B
Installation Rod
13
Special Tools:
Ball race installation tool A
Installation Rod
Ball race installation tool B
Installation Rod
Hold installation rod, tighten locknut while press bottom
ball race into head pipe.
13-17
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Replacing Bottom Bearing Seat
Remove bearing retainer, press the new bearing retainer
onto front fork with special tools and hydraulic press.
Special Tool:
Front Fork Shield
Installation
Apply lubrication grease to new upper steel balls and in-
stall to head pipe.
Install bottom bearing seat to front fork.
Apply lubrication grease to new bottom steel balls and
install to front fork.
13-18
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13 Front Wheel,Front Brake,Suspension,Steering System
Insert front fork installed with bottom bearing seat,bottom
steel balls into the head pipe installed withupper and bot-
tom ball races, upper steel balls and upper bearing seat.
Tighten head pipe locknut.
Turn front fork left and right to the stoppers several times
to ensure full grinding-in of bearing seat and ball race.
Turn front fork left and right to the stoppers several times
and make sure it can turn freely without vertical swinging.
13-19
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13-20
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14 Rear Wheel,Rear Brake,Suspension
Overhaul Information… … … … … … 14-1 Rear Fork … … … … … … … … … … 14-4
Troubleshooting … … … … … … … … 14-2 Rear Shock Absorber… … … … … 14-5
Rear wheel … … … … … … … … … … 14-3
Overhaul information
Operating notes
Notes
•Securely support the vehicle when overhauling the rear wheel and suspension system.
•Use genuine parts of bolts and nuts for rear shock absorber.
•Do not overexert on the wheels and avoid damage wheel.
•When removing tire from rim, use special tire lever and rim protector to avoid damage to the rim.
Overhaul standard
Item Standard Limit
14
Tightening torque
Rear wheel axle nut 140N•m (14.3kgf•m)
Shock absorber upper mounting bolt 55N•m (5.6kgf•m)
Shock absorber lower mounting bolt 55N•m (5.6kgf•m)
Rear fork mounting bolt 55N•m (5.6kgf•m)
14-1
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Troubleshooting
Rear Wheel wobbles
•rim warpage.
•faulty tire.
• tire pressure too low
•improper wheel balance
•improper tightening of wheel axle nut.
14-2
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14 Rear Wheel,Rear Brake,Suspension
Rear Wheel
Removal:
Securely support the scooter with main stand.
Remove
— Muffler( → 2-16)
— Rear right shock absorber( → 14-5)
— Rear brake caliper( → 14-6)
— Rear fork( → 14-4)
Inspection
Rim
Check rim for damage, warpage or scrapes.
Refer to page 13 - 4, turn rim slowly and
14
measure the rim vibration with centesimal meter。
Replace rim in case of any damage, warpage or scrapes.
Installation
Reverse the removal procedure for installation.
Apply thread glue on the thread and joint face of rear
wheel axle nut.
Tighten according to specified torque.
14-3
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Rear Fork
Securely support the scooter with main stand.
Remove:
— Muffler (→ 2-16)
— Bolt 1, Bolt 2 and rear wheel axle nut
— Rear right shock absorber( → 14-5)
— Rear fork
Inspection:
Check bearing for smooth turning and balls for damage.
Replace with a new one if any.
Installation:
Press in the bearing with special tool;
Install lock ring, Oil seal.
Reverse the removal procedure for installation of rear
fork.
Tighten the bolts and nuts according to the specified
torque.
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14 Rear Wheel,Rear Brake,Suspension
Rear Shock Absorber
14-5
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Inspection
Check shock absorbers for oil leakage and rubber spacer
for aging. Replace with new ones if any.
Installation
Reverse the removal procedure for installation.
Tighten the nuts according to the specified torque.
Torque: 55N•m (5.6kgf•m)
Rear Brake
Rear brake caliper
Removal:
Remove:
— Bolt1
— Bolt2
— Nut
— Rear brake caliper
Inspection
Check rear brake caliper for cracks, oil leakage at tighten-
ing parts.
Replace, if any.
Check brake pad for wearing and damage( → 3-6)
Replacement
Remove:
— Muffler (→ 2-15)
— Rear Right Absorber (→ 14-5)
— Rear Fork (→ 14-4)
Remove fixing screws of rear brake disc. Remove rear brake
disc.
14-6
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15 Battert,Charging System
15
15-1
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Overhaul information
Operation notes
Warning
•Usually no hydrogen will be generated during charging except when overcharged. Do not smoke when charging.
•Electrolyte is highly corrosive, splash to clothes, skin or eyes will cause burn or loss of sight. Wash with plenty of water
if splashed. In case of splash into eyes, wash with plenty of water and consult the doctor.
Warning
•Spark arc may be generated when removing or joining the electrical parts with switch on and will damage the rectifier.
Operation should be done with ignition switch OFF.
•Remove battery from vehicle for charging and do not open the electrolyte cover.
Warning
Replace if the battery service life expired.
•Keep the ignition switch OFF when disassembling electrical parts.
•Disconnect negative connection of battery when battery is stored on the vehicle.
•Fast charging is not recommended as it may reduce the life of battery.
•If battery is repeatedly charged and discharged deeply (fully-charge and fully-discharge), it may cause damage to the
battery or shorten the service life or lower the capacity of battery. In addition, the capacity of battery will also lower in
2~3 years even under normal use. So the battery should also be replaced.
•If the terminal voltage is less than 12.4V, charge the battery normally.
•The inspection of charging system should be done in the procedure of troubleshooting table. (→ 15-3)
•Refer to illustration on page 15-9 for arrangement of charging system parts.
•Refer to chapter 11 for disassembly of AC magneto.
•The inspection of battery should be done following the owner’s manual.
15-2
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15 Battert,Charging System
Overhaul standard
Item Standard
Model Permanent magnet alternator
AC magneto Output 3-phase AC
Resistance of charging coil (20℃ ) 0.2-0.3Ω
3-phase loop rectification, controllable
Rectifier
parallel connection, regulated voltage
Capacity 12V10Ah
Current Leakage Less than1mA
Voltage between Fully-charged 12.8V
Battery
terminals Insufficient charge Less than 11.8V
Charging Standard 0.9A/5-10hours
current/time Fast charge 4A/60minutes
Troubleshooting
Battery overflow
Normal
Disconnect rectifier, and
measure current leakage again.
Measure the current leakage of battery.( → 15-5) Abnormal Current: less than 1mA
Current: below 1mA
Abnormal
Normal Normal
· Short circuit with main cable
Inspect the charging coil of AC magneto. · Faulty ignition switch
Resistance: 0.2-0.3Ω Abnormal · Faulty rectifier
· AC magneto has short or open circuit.
Normal
15
Inspect monomer voltage of battery and record
it.( → 15-4)
Start engine, turn on headlight with high beam.
Inspect battery’s voltage between terminals at Normal · Charging system is normal.
the engine speed of 5000rpm.( → 15-5)
Standard: monomer voltage<charge voltage<15V
Abnormal
Inspect rectifier system( → 15-6) Normal · Main cable has short/open circuit.
· Faulty contact of connectors
Normal
15-3
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Disassembly Battery
Caution:
Turn the ignition switch to OFF before operation.
Remove Vent Panel (→ 2-4)
Loosen belt, put battery on the ground.
Loosen negative terminal bolt and disconnect negative
connection.
Remove positive terminal cap, loosen positive terminal bolt.
Disconnect positive terminal connection.
Installation:
Reverse the removal procedure for installation.
Notes
• Apply clean lubricant grease on the terminal post
after installation.
•Install cover firmly on the positive terminal post
after installation.
Inspection
Measure voltage between battery terminals, and check
test status.
Complete test: 12.8V
Insufficient test: less than 11.8V
Recharge when charge is not sufficient.
Note
When recharging after charge, measure the voltage
between terminals after 30 minutes. Measuring imme
diately after charging will not gain the correct test due
to the sharp voltage changes between the terminals.
Battery
Note
Usually no hydrogen will be generated during charging.
But overcharging may generate hydrogen.
No smoking during charging.
Charge according to the current and time specified on
the label of battery.
Remove battery from vehicle. (Refer to above content)
15-4
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15 Battert,Charging System
Connect charger’s positive wire to battery’s positive
terminal post.
Connect charger’s negative wire to battery’s negative
terminal post.
Charging current/time: Standard: 0.9A/5-10hours
Fast charge: 4.0A/60mins
Notes
•Keep the battery’s liquid temperature under 45℃ .
Reduce current to adjust the temperature if it is too high.
• Fast charge will reduce battery’s life or cause damage
to battery. Do not use fast charge unless in emergency
case.
Notes
•Avoid short circuit when measuring.
•Keep ignition switch at the “ OFF” position.
•Use a fully charged battery for inspection.
Start engine and turn on high beam.
Increase engine speed slowly. Check voltage of
battery’s terminals which is usually between 13.5-15V,
when the engine speed reaches specified speed
(5000r/min).
15
Standard:
Battery’s monomer voltage<charging voltage<15V
(5000rpm)
15-5
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Remove fuse box.
Notes
•If the measured current is higher than the limit, the
multimeter will be burnt. Therefore, measure the current
by shifting from the big to the small range.
•Do not turn on the ignition switch when measuring
the current.
Rectifier
System inspection
Notes
Inspection can be done without removing the AC magneto
from engine.
Remove:
— Seat(→ 2-3)
— Fuel Tank (→ 2-13)
Disconnect rectifier with 2 connectors.
15-6
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15 Battert,Charging System
Check the connection terminals for loosening, bending,
rust or come-off.
Check the following items of the main cable terminals of
the two rectifier connectors:
Item Result
There should be voltage
Battery wire (red) between red terminal(+) and
frame body earthing wire
Green terminal must be
Earthing wire
connected with frame body
(green)
earthing wire
Charging coil Resistance between yellow
(yellow, yellow, terminals is: 0.2-0.3Ω (at 20
yellow) ℃ )
Black lead wire must be
Ignition switch lead
connected with black
wire (black)
terminal.
Disconnect starting enriching device
when carrying out above inspection.
Disassembly
Remove:
— Seat(→ 2-3)
— Fuel Tank (→ 2-13)
— Bolt 1 and Bolt 2
15
Note:
Wires, hoses and cables should be routed properly.
( → 1-20)
15-7
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Inspection of AC magneto
Remove rear right ornament panel ( → 2-5)
Disconnect connectors of AC magneto (yellow, yellow, yellow),
15-8
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15 Battert,Charging System
15
15-9
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15-10
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16 Ignition System
Overhaul information… … … … … … 16-1 Pickup coil… … … … … … … … … … … 16-6
Troubleshooting… … … … … … … … 16-3 Ignition coil … … … … … … … … … … 16-6
Inspection of ignition system… … … 16-4 Ignition system arrangement… … … … 16-7
Overhaul information
Warning
Exhaust gas contains toxicant, DO NOT keep the engine run for a long time in a closed or poorly ventilated place.
16
16-1
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Overhaul standard
Item Standard
Ignition CDI battery DC digital ignition
NGK
Standard DPR7EA-9
Spark plug
Optional DR8EA、 D7RTC
Spark plug gap 0.8- 0.9mm
Ignition Maximum
28° CA
timing advance angle
Ignition coil ≥ 150V
Peak
Impulse
voltage ≥ 0.8V
generator
Special tool
(Use together with digital muitimeter available in the market with input resistance over 10MΩ /DCV)
16-2
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16 Ignition System
Troubleshooting
•Engine cannot be started.
Check fuel and air channels for any faults; If the fuel and air channels are normal, check the ignition system.
•Inspect ignition system for the following items:
1. Spark inspection:
Check in the following steps:
Remove spark plug
Remove spark plug cap
Set high tension flexible cable end to earthing
Check spark arc
It is normal if spark arc is more than 8mm while it is weak if it is less than 5 mm.
If the spark is normal, check the spark plug.
A faulty spark plug may be caused by the following reasons:
(1) Spark plug is too wet and drowned. This is because the gas mixture is too thick. Cut the fuel and start the
engine several times..
(2) Carbon deposit on spark plug— Mixture too thick or oil combustion in the combustion chamber. Clean and
burnish the spark plug.
(3) Cracks with spark plug insulator.
(4) Spark plug electrodes have short circuit or it is obstructed between negative pole and thread or positive pole
and input end.
2. Faulty spark includes: no spark and weak spark.
Inspect the following aspects if there is no spark.
(1). Inspect ignition coil with multimeter or measurement in the following steps.
1) Measure primary bobbin resistance, usually it is about 1Ω .
2) Measure secondary bobbin resistance, usually it is about 4.2K.
3) Measure damp resistance, usually it is about 5K.
(2). Check CDI if it is out of service.
(3). Check ignition circuit. Usually the voltage between blue/black wire and earthing wire (green) should be 12V. If
there is no voltage, check from the battery positive terminal to the end of blue/black wire.
(4). Check the cable: check if there are any faults from the input of trigger signal (output of magneto trigger) to output
(CDI terminal) and ignition output wire (black/yellow). 16
(5). Check stop switch. When switch is at the ignition position, black/white wire should be cut with green wire.
In case of weak spark, check the following:
(1). Check CDI .
(2). Check ignition coil and secondary coil whether there is short circuit, or fault with the damp resistance.
16-3
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Inspection of ignition system
Note
•If the spark plug generates no spark, check first.
If there is come-off, loosening or poor contact with the
wiring, then measure the peak voltage.
•Different multimeter has different input resistance and
shows different readings. Thus it is impossible to obtain
the correct reading. Measure with digital multimeter
with input impedance over10MΩ /DCV ).
Connect peak voltage oscillograph with digital
universal meter.
Special tools
Peak voltage oscillograph 519-922-150000
(Use together with digital multimeter available from the
market with input impedance over 10MΩ /DCV)
16-4
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16 Ignition System
Pickup coil
Notes
• Measurement should be done after all the wires are
correctly connected.
• Inspect with compression pressure in the cylinder,
spark plug and spark plug cap are properly installed. If
the spark plug is removed and then do the measurement,
the peak voltage will rise.
Special tools
Peak voltage oscillograph 07HGJ-0020100
(Use together with digital multimeter available from the
market with input impedance over 10MΩ /DCV)
Connecting terminal: blue/yellow (+) – green (-)
Warning
When measuring the voltage, do not touch the terminal
with finger to avoid electric shock.
If peak voltage obtained from CDI unit connector is
improper, measure again the peak voltage on the AC
magneto 2P connector.
16
16-5
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Pickup
Disassembly
Remove:
— AC magneto connector
— Water pump inlet hose and outlet hose, and drain
coolant. (→ Chapter 6)
— Muffler. (→ Chapter 2)
Warning
Stator is installed on the right side cover and is
attached by the magnet of rotor. Be careful not to
hurt the fingers when removing.
Loosen bolt, remove AC magneto stator and pickup.
Installation
Reverse the removal procedure for installation.
Ignition coil
Disassembly
Installation
Reverse the removal procedure for installation.
Notes
Routing of wires, pipes and cables should pass properly
(→ Chapter 1-20).
16-6
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16 Ignition System
Ignition System Diagram
16
16-7
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16-8
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17 Electrical Start System, Overriding Clutch
Overhaul information
Note:
• Bundle the wires of the same color. Wires of different colors should be connected with
the wires of the their respective colors. Set color sleeve at the connection part.
Connectors should be connected with those of the same colors.
Overhaul Standard
Item Standard Service Limit
Brush length 12.0-12.5mm 11.0mm
Brush Spring Force 680-920g 670g
Driven Gear, Starting Inner Diameter 22.026-22.045 mm 22.10 mm
motor Outer Diameter 42.175-42.2 mm 42.15 mm
Inner diameter of separating device, overriding
58.899-58.925 mm 58.96 mm
clutch
Troubleshooting
Starting motor does not run
•Insufficient charging of battery
•Faulty contact of main switch
•Faulty contact of starting switch
•Faulty the range switch of starting motor
•Faulty starter relay
•Faulty contact of wire harness, couplers and terminal posts, and short circuit or open circuit.
•Faulty starting motor
•Melted fuse
17-1
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Starter relay
Remove right speaker cover. (→ 2-9)
Hold brake lever and turn main switch to ON.
Press start button.
If the clatter sound can be heard, starter relay coil is normal.
Disassembly
Remove 2 screws.
Remove front and rear cover.
Remove thrust washer and spacer.
Note:
Check position and numbers of thrust washer.
17-2
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17 Electrical Start System, Overriding Clutch
Inspection
Measure brush length
Service Limit: < 11.0mm → Replace
17
17-3
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Make sure armature shaft is not conducted with
commutators.
Installation
17-4
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17 Electrical Start System, Overriding Clutch
Install O-ring to motor housing.
Apply a bit of grease to O-ring.
Align the groove of rear cover with brush holder pin and
assemble.
Installation
Notes:
Connect the wire and confirm the rotating.direction before
installing the starter motor on the engine.
17
17-5
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Overriding clutch
Disassembly
Remove dual gear
Inspection
Check driven gear for wearing or damage.
Measure inner and outer diameters of driven gear.
Service Limit:
Inner diameter: > 22.10mm → Replace
Outer Diameter:< 42.15mm → Replace
17-6
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17 Electrical Start System, Overriding Clutch
Install driven gear onto overriding clutch.
Check performance of overriding clutch.
Hold flywheel and make sure driven gear can only turn
clockwise.
Disassembly
17-7
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17-8
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18 Lighting,Instruments,Switches,Sound System
Overhaul information … … … … … … 18-1 Electrical horn… … … … … … … … … 18-8
Troubleshooting… … … … … … … … 18-2 Dashboard … … … … … … … … … … 18-9
Replacing bulbs … … … … … … … … 18-3 Fuel sensor… … … … … … … … … … 18-10
Head light… … … … … … … … … … … 18-5 Water temperature transducer … … 18-12
Ignition switch lock… … … … … … … 18-6 Starting enriching device … … … … 18-13
Handlebar switch… … … … … … … … 18-7 Audio System … … … … … … … … 18-14
Brake light switch… … … … … … … … 18-8
Overhaul information
Operation Instruction
Warning
•Headlight bulb has larger power and the temperature is very high when it is turned on. Do not touch it after it is just
turned off. Operation should be done when the bulb is cooled down.
•Inspection of water temperature alarm may use fire source and liquid of high temperature. Do not put flammable matters
nearby and take care not to get burnt.
•The temperature of headlight is quite high when turned on. Replacing with bare hand or stained glove will cause oil
stains on the glass cover which may form hot spot and cause deformation of glass face and damage to bulb.
•Pay attention to the following points when replacing the bulb.
— Do not replace the bulb when it is turned on. Keep ignition switch in the OFF position, and replace after the bulb is
cooled down.
— Replace the bulb with hands in clean gloves to avoid oil stains on the glass surface.
— Clean the glass with a piece of clean cloth dipped in alcohol or isoamyl acetate in case of any oil stains on the
surface.
If the Inspection has to be done with battery, check if the battery is normal.
•Inspection of switches can be done without removing the switches from the vehicle.
•After the inspecting and overhauling of each part, routing of cables and wires should pass through the proper positions.
Refer to 1-20.
•For removal and installation of taillight and rear turning lights, refer to chapter 2.
Overhaul standard
Item Standard
Main 20A 18
Fuse
Sub-fuse 5A× 2 10A× 2
Headlight (Hi/Lo) 12V-35/35W
Taillight/brake light 12V-5/21W
Light, bulb Turning light 12V-10W× 4
Dashboard indicator 12V-1.7W
Indicators 12V-3.4W
18-1
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Troubleshooting
Head light cannot turn on
• Fuse break
•Open circuit with main cable
•Bulb burnt
•Night switch is damaged
18-2
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18 Lighting,Instruments,Switches,Sound System
Replacing bulb
Disconnect headlight
Inspection of headlight
Turn the ignition switch to ON position, turn light
switch to the illuminating position and check if the
headlight is on.
ON: Normal
Off: Breaking or short circuit of main cable.
18-3
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Brake light/Tail light bulb
Remove 2 tapping screws, tail light cover.
Turn brake light/tail light bulb counter clockwise and
remove it
Replace light/tail light bulb
Bulb Specification:12V-21/5W
Bulb Specification:12V-10W
Repeat above steps for replacing front turning light
bulbs.
Bulb Specification:12V-10W
18-4
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18 Lighting,Instruments,Switches,Sound System
Dashboard, Fuel Gauge , Water Ther-
mometer Illuminating Bulb
Remove fixing bolt 1, fuel gauge and fixing screw 1, fuel
gauge fairing
Remove fixing bolt 2, dashboard and fixing screw 2, dash-
board fairing
Repeat above steps of fuel gauge for replacing
water thermometer Illuminating bulbs.
Note:
Main cable and wires should be routed properly
( → 1-20)
18-5
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Disconnect headlight connector with front indicator light
connector.
Reverse the removal procedure for installation.
Note
Be careful not to damage main cable when assembling.
After replacing, adjust the headlight beam.( → 3-17)。
Note
main cables and wires should be routed properly( →
1-20)
18-6
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18 Lighting,Instruments,Switches,Sound System
Check according to the following table if the connector
terminals are connected.
● - ● means proper connection
Disassembly
Remove fuel tank( → 2-13)
Remove protection panel (RH) (→ 2-5)
Disconnect ignition switch lock 4P connector.
Handlebar Switch
Remove fuel tank (→ 2-13)
Disconnect left and right handlebar switches.
Check according to the following table if the coupler
terminals are connected.
¡ñ - ● means proper connection
Illuminating Switch
18
18-7
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Turning Light Switch
Dim Switch
Horn
Inspection
Remove vent panel (→ 2-4)
Disconnect horn.
Connect with a fully charged 12V battery and check if
the horn sounds.
In case no hooter, replace with a new horn.
18-8
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18 Lighting,Instruments,Switches,Sound System
Removal and Installation
Remove vent panel( → 2-4)
Disconnect horn.
Remove fixing bolt and horn.
Dashboard
Note
Before inspection, make sure if the speedometer cable
comes off or breaks.
Caution:
Main cables and wires should be routed properly.
18-9
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Fuel Sensor
Remove:
— Fuel tank (→ 2-13)
— 4 fixing nuts and sensor from fuel tank
Inspection
Connect 2P connector
18-10
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18 Lighting,Instruments,Switches,Sound System
Remove fuel sensor 2P connector
Installation
18
18-11
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Water Temperature Transducer
Warning
Be careful not to get scalded and do not place
flammables nearby.
Warning
· Coolant must reach the switch thread, and the depth
from vessel bottom to sensor top should be over 40 mm.
· Keep liquid temperature for three minutes before
measuring, and do not raise temperature sharply.
The thermometer should not contact the vessel bottom.
Disassembly
Remove rear right ornament panel( → 2-5)
Disconnect from connector and remove transducer.
Put the transducer into a vessel with coolant, slowly
heat up the liquid and measure the transducer resistance.
Temperature Resistance
50℃ 154 ± 16 Ω
88℃ 52 ± 4 Ω
100℃ 27 ± 4 Ω
120℃ 162 ± 4 Ω
Replace the transducer if the measured readings exceed
the above datas
Install transducer.
Connect with water temperature transducer connector.
18-12
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18 Lighting,Instruments,Switches,Sound System
Starting Enriching Device System
inspection
Warning
Exhaust gas contains toxic contents. Do not run the
engine for a long time in a closed or poorly ventilated
place.
Note
Inspection should be done after the engine is cooled down.
Unit inspection
Inspection of Resistance
Note
The inspection of resistance can be done without
removing the carburetor.
Disconnect 2 connector of starting enriching device.
Measure resistance between connector terminals
Standard value: 19.5 - 21.5 Ω ( 20℃ )
Inspection
Remove carburetor( → 5-3)
18-13
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Audio System
Disassembly
Note
Main cable, wiring should be routed properly.
Remove right speaker cover (→ 2-6)
Disconnect 2P connector.
18-14
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18 Lighting,Instruments,Switches,Sound System
Disassembly of MP3 Player
Note
Main cable, wiring should be routed properly.
18
18-15
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18-16
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19 Electrical Diagram,wiring
19-1
19-2
Operating notice
This chapter is a general explanation of major troubleshooting of the whole engine.
Refer to the relevant chapters for troubleshoo ting not listed in this chapter.
Loosen drain screw, check if fuel has No Fuel No fuel in fuel tank
reached carburetor Clogged fuel hose
Clogged float valve
Reached Clogged fuel filter
Clogged fuel tank cap breather hole
Remove spark plug and mount it to Weak spark or Faulty spark plug
spark plug cap, get it earthed and No spark Stained or damaged spark plug
check spark
20-1
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Unstable engine running or engine stops
Loosen drain screw, and check if fuel No Fuel No fuel in fuel tank
has reached carburetor Clogged fuel hose
Clogged float valve
Reached Clogged fuel filter
Clogged fuel tank cap breather hole
Remove spark plug and mount it to Weak spark or Faulty spark plug or stained spark plug
spark plug cap, get it earthed and No spark Faulty Ignition coil
check spark High tension coil break or short circuit
Faulty ignition switch
Strong spark Faulty pickup coil
Faulty CDI unit
Measure compression pressure with Low or no Worn or damaged Cylinder and piston ring
pressure meter compression Faulty cylinder gasket
pressure
Proper adjustment
Check if there is Air intake Improper tightening of carburetor and intake pipe
secondary air into joint No elasticity of carburetor intake joint pipe
of air intake pipe
No air intake
Disconnect starting
Not conducted Broken cable of starting enriching device
enriching device and
Faulty starting enriching device
check if it is conducted.
Conducted
20-2
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20 Troubleshooting
Connect starting enriching
cable with battery for 5
minutes. Connect ethylene With Air current
pipe with fuel increment Faulty starting enriching device
loop and blow.
No air current
Clogged carburetor
Proper
Measure compression pressure with Low or no Worn or damaged Cylinder and piston ring
pressure meter Compression Faulty cylinder gasket
Pressure
not clogged
No cylinder knock
Clutch skid
20-3
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Unstable idle speed performance
Check ignition time Improper Faulty pulse generator
Faulty CDI unit
Proper
Properly adjusted
Check if secondary air Intake Faulty tightening of carburetor and inlet pipe
intake into air intake Faulty reed valve seal washer
valve No elasticity of inlet pipe joint
No intake
Remove spark plug and mount it to Weak spark or Stained or damaged spark plug
spark plug cap, get it earthed and No spark Faulty Ignition coil
check spark High tension wire break or short circuit
Faulty ignition switch
Strong spark Faulty CDI unit
Conducted
No air current
Clutch skid
20-4
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20 Troubleshooting
Poor engine performance at middle or high speed
Proper
Not clogged
Disconnect starting
Not conducted Broken starting enriching cable
enriching device and
Faulty starting enriching device
check if it is conducted.
Conducted
No Air Current
20
20-5
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