Aeon Overland 125180 Manual de Repara
Aeon Overland 125180 Manual de Repara
Aeon Overland 125180 Manual de Repara
,LTD
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CONTENTS
1. INFORMATION………………………………………... 2
2. MAINTENANCE…………………….………………… 6
7. TRANSMISSION SYSTEM…………………………… 46
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1. INFORMATION
1.1 Safety
1.2 Notes
1.3 Specifications
1.4 Serial number
Torque valve
1.1 Safety
GASOLINE
Gasoline is extremely flammable and is explosive under certain condition. Do not smoke or
allow sparks or flames in your work area.
CARBON MONOXIDE
Never run the engine in a closed area. The exhaust contains poisonous carbon monoxide gas that
may cause loss of consciousness and lead to death.
BATTERY ELECTROLYTE
The battery electrolyte contains sulfuric acid. Protect your eyes, skin and clothing. If you come
into contact with the electrolyte, flush the area thoroughly with water. If you get the electrolyte
in your eyes, flush with water and contact a doctor immediately.
HOT PARTS
Engine and exhaust pipe become very hot and remain hot for one hour after the engine is run.
Wear insulated gloves before handling these parts.
1.2 NOTES
All information, illustrations, directions and specifications included in this publication are base
on the latest product information available at the time of approval for printing.
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1.3 SPECIFICATION
ENGINE 180
Type Air-Cooled 4-syroke
with Oil Cooler
Displacement 169 cc
Bore and Stroke 61×57.8mm
Compression 9.1:1
Maximum Power 6.2 Nm@6300 min-1
Carburetor MIKUNI 180
Ignition C.D.I Electronic
Starting Electrical & Kick-Start
Lubrication Wet crankcase with lobes
pump
Air Cleaner AE-9
Transmission Automatic(C.V.T. system)
CHASSIS
Overall Length 1790mm
Overall Width 970mm
Overall Height 1200mm
Wheel Base 1050mm
Dry Weight 156kg
Fuel Tank Capacity 8.0 liter
SUSPENSION
Front Double wishbone
Rear Swing Arm
BRAKES
Front Drum
Rear Disc
TIRES
Front 21” × 7” - 10”
Rear 22” × 10” - 8”
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1.4 SERIAL NUMBER
The frame serial number is stamped on the front frame.
And stick a bar code paper to cover it.
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1.5 TORQUE VALUES
STANDARD
5mm bolt and nut 5 N.m (3.5 lbs.ft)
6mm bolt and nut 10 N.m (7.2 lbs.ft)
8mm bolt and nut 22 N.m (16 lbs.ft)
10mm bolt and nut 35 N.m (25 lbs.ft)
12mm bolt and nut 55 N.m (40 lbs.ft)
ENGINE
Cylinder head nut 28 N.m (20.7 lbs.ft)
Spark plug 12 N.m (8.9 lbs.ft)
Cylinder head bolt 20 N.m (14.8 lbs.ft)
Alternator bolt 8 N.m (5.9 lbs.ft)
FRAME
Handlebar upper holder bolt 24 N.m (17.7 lbs.ft)
Throttle housing cover screw 4 N.m (2.9 lbs.ft)
Steering shaft nut 50 N.m (36.9 lbs.ft)
Steering shaft holder bolt 33 N.m (24 lbs.ft)
Wheel rim bolt 18 N.m (13.3 lbs.ft)
Tie rod lock nut 35 N.m (25.8 lbs.ft)
King pin nut 40 N.m (29 lbs.ft)
Handlebar lower holder nut 40 N.m (29.5 lbs.ft)
Front wheel bolt 24 N.m (17.7 lbs.ft)
Front axle nut 60 N.m (44 lbs.ft)
Front brake arm nut 4 N.m (3.0 lbs.ft)
Rear brake arm nut 7 N.m (5.2 lbs.ft)
Rear axle nut 60 N.m (44.3 lbs.ft)
Rear wheel bolt 24 N.m (17.7 lbs.ft)
Exhaust muffler mounting bolt 30 N.m (22.1 lbs.ft)
Engine hanger bolt 30 N.m (22 lbs.ft)
Rear axle holder bolt 90 N.m (65 lbs.ft)
Swingarm pivot nut 90 N.m (65 lbs.ft)
Rear shock absorber mounting nut 45 N.m (33 lbs.ft)
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2. Maintenance
2.1 Maintenance data
2.2 Maintenance schedule
2.3 Fuel tube
2.4 Throttle operation
2.5 Throttle cable adjustment
2.6 Air cleaner
2.7 Spark plug
2.8 Idle speed
2.9 Drive chain
2.10 Brake system
2.11 Wheels and tires
2.12 Steering system
2.13 Toe-in
2.14 Gear oil
2.1 MAINTENANCE DATA
SPECIFICATION
SPARK PLUG
Spark plug cap 0.6-0.7mm
Recommended spark plugs NGK C7HSA or CR7HSA
Throttle lever free play: 5-10mm
Idle speed 1800rpm
Brake lever free play: 10~20mm
Drive chain slack 15-25mm
Front/rear tire size 21×7-10 / 22×10-8
Front/rear tire pressure 3±0.3psi (0.15 kgf/cm2)
Toe-in 5±10mm
TORQUE VALUES
SPARK PLUG 12-19 N.m
TIE-ROD LOCK NUT 35-43 N.m
ENGINE OIL
Viscosity: SAE 15W-40
GEAR LUBRICATION OIL
Viscosity: SAE 85W-140
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2.2 MAINTENANCE SCHEDULE
The maintenance intervals in the follow table is based upon average riding, condition. Riding
in usually dusty areas, require more frequent servicing.
Service Item Initial Service Every 100 hours Every 200 hours Every 300 hours
(First 30 hours)
ENGINE OIL R R
GEAR OIL R R
FUEL FILTER R
AIR VLEAN
R
FILTER
ENGINE OIL
C
FILTER
CARBURETOR I
SPARK PLUG C
VALVE GAP A
IGNITION
A
TIMING
CHAIN A
BATTERY I
DRIVE
I
BATTERY
CLUTCH I
THROTTLE
I
OPERATE
TIRE
Check before riding each time
PRESSURE
BRAKE
Check before riding each time
SYSTEM
NUTS/BOLTS T
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2.3 FUEL TUBE
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2.5 THROTTLE CABLE ADJUSTMENT
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2.7 SPARK PLUG
The spark plug is located at the front of the
engine.
(1) Disconnect the spark plug cap and remove
the spark plug
(2) Visually inspect the spark plug electrode
for wear or cranks in insulator. Replace if
needed.
(3) The center electrode should have square
edges and the side electrode should have a
constant thickness.
(4) Discard the spark plug if there is apparent
wear or if the insulator is cracked or
chipped.
(5) Measure the gap with a wire-type feeler
gauge and adjust if necessary by carefully
bending the side electrode.
SPARK PLUG GAP: 0.6~0.7 mm
RECOMMENDED REPLACEMENT PLUG:
NGK CR7HSA
(6) Check the sealing washer and replace with a
new one if damaged.
(7) With the sealing washer attached thread the
spark plug in by hand to prevent cross
threading. Tighten the spark plug. TORQUE:
12-19 N-m
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2.9 DRIVE CHAIN ADJUSTMENT
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2.10 BRAKE SYSTEM ADJUSTMENT
Inspect the front brake lever and cable for
excessive play or other damage.
Replace or repair if necessary.
Measure the free play of the brake lever at the
end of the lever. The standard is 10~20 mm.
Adjust the free play of the front brake lever by
turning the adjuster on the brake lever assembly.
Front Brake
Release the front wheel and inspect the brake
lining thickness. Service Limit: 2.0mm (0.08
inch), if either lining is worn beyond the service
limit, replace both brakes shoes.
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Inspect the tire surface for cuts, nails or other
sharp objects.
2.13 TOE-IN
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Park the vehicle on level ground with the front
wheels facing straight ahead.
Mark the centers of the tires to indicate the axle
center height.
Toe-in: 5±10 mm
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Gear oil needs to be changed every 200 hours.
There is a gear oil drain hole bolt at the rear of
the engine.
(STEP1)
Unscrew this drain hole bolt and let the dirty oil
flow out, catching the oil in a proper container
for later disposal.
(STEP2)
Reinstall the drain hole bolt an tightness.
(STEP3)
Fill with new gear oil through the oil fill hole
located on the engine case beside the gear box.
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ENGINE SHOULD ONLY BE REMOVED IN THE CONDITIONS OF NECESSARY
REPAIRS OR ADJUSTMENT TO THE TRANSMISSION AND COMBUSTION SYSTEM
ONLY!
4. LUBRICATION
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4.1 Service Information
4.2 Trouble Shooting
4.3 Engine Oil Level
4.4 Engine Oil & Filter Change
4.5 Oil Pump Removal /Installation
GENERAL
This section describes inspection and replacement of the engine oil, oil filter screen and
assembly of the oil pump.
Fill the oil pump with clean oil when reassembling the pump.
SPECIFICATIONS
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Cover-to-rotor clearance --------- 0.12
Rotor tip clearance -------- 0.12
End clearance 0.01-0.10 0.2
TORQUE VALUE
Oil contamination
Worn piston rings.
Faulty heat gasket.
Oil or filter not changed often enough.
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Add the recommended oil up to the upper
level if the oil level is below or near lower
level line on the gauge.
Remove the oil filter cap and the oil drain bolt.
OIL DRAIN
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TORQUE: 20~30 N.m (14.8~22.1 lbs.ft)
Stop the engine and check that the oil level at the
OIL FILTER
upper line on the gauge. Make sure there are no CAP
oil leaks.
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Remove the left crankcase cover.
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sprocket.
INSPECTION
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rotor tip clearance.
SERVICE LIMMIT: 0.12 mm.
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chain.
Install the new gasket, dowel pins and right crankcase cover.
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Install the A.C.G generator ass’y
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5.1 SERVICE INFORMATION
5.2 TROUBLESHOOTING
5.3 CAMSHAFT ASS’Y REMOVAL
5.4 CYLINDER HEAD REMOVAL
5.5 CYLINDER HEAD INSTALLATION
GENERAL
This section describes the maintenance of cylinder head, valves, camshaft and the other parts.
The engine must be removed from the frame to service cylinder head.
Camshaft lubrication oil is fed to the cylinder head through an oil orifice in the engine case.
Before installing the cylinder head be sure the orifice is not clogged and the gasket, O-ring and
dowel pins are in place.
SPECIFICATIONS
TORQUE VALUES
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Engine top-end problems usually affect engine performance. These problems can be diagnosed
by a compression test, or by tracing engine noise to the top end with a sounding rod or
stethoscope.
Cylinder head
Leaking or damaged head gasket.
Warped or cracked cylinder head.
Faulty cylinder or piston
Excessive noise
Incorrect valve adjustment
Sticking valve or broken valve spring.
Worn or damaged rocker arm or camshaft.
Worn or damaged cam chain.
Worn or damaged cam chain tensioner.
Worn cam sprocket teeth.
Excessive smoke
Damaged valve stem seal.
Faulty cylinder or piston rings.
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Remove the rubber tube of gas waste recovery.
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chain-adjusting bolt with clockwise direction.
Relax the camshaft gear from cam chain and remove the
camshaft.
INSPECTION
Inspect the cam lobes surface and height of cam lobes for
wear or damage.
SERVICE LIMIT: IN 25.57/26.18 mm
EX 25.41/26.02 mm
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Screw a 5 mm bolt into the rocker arm shaft threaded end.
Pull on the bolt to remove the shafts and rocker arms.
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Remove the cylinder head gasket and dowel pins.
INSPECTION
Clean off all carbon deposits from the com- bustion and
check the spark plug hole and valve area for cracks.
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Measure the cylinder head diagonally for warp with a
straight edge and feeler gauge.
Measure the free length of the inner and outer valve springs.
SERVICE LIMITS: Inner 31.2 mm
Outer 34.1 mm
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Calculate the stem-to-guide clearance.
SERVICE LIMITS: IN 0.08 mm
EX 0.10 mm
INSTALLATION
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Install the cylinder head.
Install the rocker arms and rocker arm shafts into the
camshaft holder.
Align the “T” mark on the flywheel with the index mark on
the alternator cover by turning the flywheel
counter-clockwise.
Position the camshaft gear with cam chain so that its “I”
mark aligns with the cylinder head surface and the circle
hole towards the front.
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Install the dowel pins and camshaft holder.
Tighten the washers and nuts.
Torque: 20 N.m (14.8 lbs.ft)
Adjust the clearance between the rocker arm and valve stem
by applying a feeler gauge.
STANDARD VALVE: 0.08 mm
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6. CYLINDER AND PISTON
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GENERAL
Camshaft lubrication oil is fed to the cylinder head through an oil orifice in the cylinder head
and engine case. Before installing the cylinder head be sure the orifice is not clogged and the
gasket, O-ring and dowel pins are in place.
SPECIFICATION
ITEM STANDARD SERVICE LIMIT
Cylinder I.D. 52,400-52,410/ 52.50/
61,730-61,740 61.830
Taper ---------- 0.10
Out of round ---------- 0.10
Warp across top ---------- 0.10
Piston Piston O.D. 52,370-52,390 52,3/
61,700-61,720 61,63
Piston pin Piston pin bore 15.002-15.008 15.04
Piston rings Piston pin O.D. 14.994-15.000 14.960
Piston-to-pin clearance 0.002-0.014 0.02
Piston ring TOP 0.015-0.050 0.12
SECOND 0.015-0.050 0.12
Groove Clearance TOP/SEC 0.10-0.25 0.5
Piston ring end gap OIL 0.2-0.7 ----------
Cylinder-to-piston clearance 0.0005-0.1025 0.1
Connecting rod small end I.D. 15.010-15.028 15.06
TORQUE VALUES
Overheating
Excessive carbon build-up on piston or combustion chamber wall.
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Knocking or abnormal noise
Worn piston and cylinder.
Excessive carbon build-up.
Excessive smoke
Worn cylinder, piston, or piston rings.
Improper installation of piston rings
Scored or scratched piston or cylinder wall.
Damaged valve stem seal.
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Remove the cylinder gasket and dowel pins.
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Spread each piston ring and remove it by lifting up at a point
opposite the gap.
INSPECTION
Inspect the cylinder walls for scratches or wear.
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Inspect the top of the cylinder for warp.
SERVICE LIMITS: 0.10 mm
Insert each piston ring into the cylinder and measure the ring
end gap.
NOTE: Push the rings into the cylinder with the top of the
piston to be sure they are squarely set in the cylinder,
SERVICE LIMITS: TOP 0.5 mm
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SECOND 0.5 mm
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6.5 PISTON &
PISTON RING INSTALLATION
Clean the piston ring grooves thoroughly and install the
piston ring with the marks facing up.
PISTON INSTALLATION
Install the piston with it’s “IN” mark on the intake valve.
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Clean any gasket material from the crankcase surface.
Coat the cylinder bore and piston rings with engine oil and
install the cylinder.
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7. TRANSMISSION & KICK STARTER
7.1 SERVUCE INFORMATION
7.2 TROUBLE SHOOTING
7.3 C.V.T DISASSEMBLY
7.4 KICK STARTER DISASSEMBLY
7.5 KICK STARTER ASSEMBLY
7.6 C.V.T ASSEMBLY
If the drain tube ass’y fills with water, the tube should be drained.
SPECIFICATIONS
ITEM STANDARD (mm) SERVICE LIMIT (mm)
Driven the width 19.8-20.2 19.0
Weight roller O.D. 15.0-15.02/17.0-17.02 14.6/16.6
Movable drive face I.D. 27.98-28.0 28.03
Drive face collar I.D. 24.06-24.09 24.098
Drive face boss O.D. 23.96-23.98 23.92
Clutch outer I.D. 124.8-125.2 125.5
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Clutch weight lining thickness -------------- 1.5
Driven face spring length 168.4-169.4 164.0
TORQUE VALUES
Clutch outer nut 55 N.m (40.6 lbs.ft)
Drive face nut 55 N.m (40.6 lbs.ft)
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7.3 C.V.T DISASSEMBLY LH CRANKCASE COVER C.V.T INLET DUCT
REMOVAL
Relax the band screw and remove the C.V.T inlet duct.
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Remove the bolts and LH crankcase cover.
LH CRANKCASE COVER
FLANGE NUT
LH CRANKCASE SURFACE
C.V.T REMOVAL
Relax the flange nut, and remove the drive face.
DRIVE FACE
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FLANGE BELT DRIVE PULLEY
Remove the drive face boss and movable driven face ass’y.
DRIVE FACE BOSS
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Inspect the weight roller for wear or damage
and replace them if necessary.
Measure the O.D. of weight rollers.
SERVICE LIMIT:14.6/16.6 mm
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Inspect the clutch weight set for wear or
damage.
Measure the thickness of clutch weight lining.
SERVICE LIMIT:1.5mm
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Remove the ex. Circle-clip and washer from
kick starter spindle composition.
EX. CIRCLIP
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Inspect the kick driven gear and spring for
wear or damage.
KICK STARTER
7.6 C.V.T ASSEMBLY
Assemble the driven face ass’y, spring and
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driven plate.
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DRIVE FACE
DOWEL PIN
GASKET
LH CRANKCASE COVER
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8. FRONT WHEEL, SUPENSION AND STEERING
8.1 PARTS DRAWING
8.2 TROUBLESHOOTING
8.3 HANDLEBAR
8.4 THROTTLE HOUSING
8.5 FRONT WHEEL
8.6 FRONT BRAKES
8.7 STEERING SYSTEM
8.8 FRONT SUSPENSION
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8.2 TROUBLESHOOTING
HARD STEERING Faulty tire
Steering shaft holder too tight
Insufficient tire pressure
Faulty steering shaft bushing
Damaged steering shaft bushing
FRONT WHEEL WOBBLING Faulty tire
Worn front brake drum bearing
Bent rim
Axle nut not tightened properly
BRAKE DRAG Incorrect brake adjustment
Sticking brake cable
STEERS TO ONE SIDE Bent tie rods
Wheel installed incorrectly
Unequal tire pressure
Bent frame
Worn swing arm pivot bushing
Incorrect wheel alignment
POOR BRAKE PERFORMANCE Brake shoes worn
Worn brake drum
Brake lining oily, greasy or dirty
Improper brake adjustment
FRONT SUSPENSION Loose front suspension fastener
Binding suspension link
HARD SUSPENSION Faulty front swing arm bushing
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Improperly installed front swing arms
Bent front shock absorber swing rod
SOFT SUSPENSION Wear front shock absorber springs
Worn or damage front swing arm bushing
Removal
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Remove the bolts attaching the handlebar upper
holder. Remove the handlebar.
Installation
Install the switch housing. Tighten two screws
securely.
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8.4 THROTTLE HOUSING
Disassembly
Unscrew the screws on the throttle housing
cover.
Remove throttle housing cover and gasket.
Disconnect throttle cable from the throttle arm
and remove from the throttle housing.
Assembly is in the reverse order of disassembly.
8.5 FRONT WHEEL
Remove
Raise the front wheels off the ground by placing
a jack or other support under the frame.
Remove the front wheel nuts, washer and
wheels.
Installation
Install and tighten the four-wheel nuts torque:
60 N.m (44 lbs.ft ) Remember put a cotter pin in
the castle nut.
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Measure the brake lining thickness. The
minimum limit: 1.5 mm
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Remove brake arm and cam.
Remove return spring.
Remove indicator plate and felt seal.
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Install the brake panel on the knuckle.
Connect the brake cable to the brake arm.
Tie-rod inspection
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The ball joints should turn smoothly and quietly.
Kingpin inspection
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Inspect the steering shaft for damage or cracks.
Installation of Tie-rod
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9. REAR WHEEL SYSTEM
9.1 PARTS DRAWING
9.2 TROUBLESHOOTING
9.3 REMOVE REAR WHEEL AND REAR BRAKE
9.4 DRIVE MECHNISM
9.5 REAR BRAKE AND WHEEL INSTALLATION
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9.2 Troubleshooting
Bad Brake Performance Brake shoes are worn
Bad brake adjustment
Brake lining are oily, greasy or dirty
Brake drums are worn
Brake arm setting is improperly engage
Vibration or wobble Axle is not tightened well
Bent rim
Axle bearings are worn
Faulty tires
Rear axle bearing holder is faulty
Brake Drag Incorrect brake adjustment
Sticking brake cam
Sticking brake cable
Hard Suspension Bent damper rod
Faulty swing arm pivot bushing
Soft Suspension Wear shock absorber damper
Wear shock absorber spring
Handlebar
Rear Brake Cable
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The cable connectsto
the left side brake
lever.
The cable connects
to wire connector
for front brake
function.
Hydraulic Cylinder
Driving Rod
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Left Side Right Side
Brake Lever
Brake Lever
Wire Connector
Rear Brake
Caliper
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The Brake Adjustment
Pan
Phillips Bolts (93100-05016-K), Plain Washer(94101-0514010-K), Nylon Lock Nut(90350-05000-K) ×
10 sets
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STEP.1) Take off the right side footwell for adjustment.
Fixing Set
STEP.2) Take off the rear brake fixing set and the bolt of brake pump.
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Hydraulic Clyinder Driving Rod
Adjusting Bolt
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STEP.4) Drain the air in the brake oil tube in order to prevent the brake pump
malfunction in power delivering.
1).Open the brake oil tank, lose the drain screw of the brake caliper without braking
motion. It functions normal if the brake oil could drain automatically, please try this for
couple times for confirmation. If it doesn’t work, please be back to STEP 3. and
decrease the distance until the oil could run out normally.
2). Press on the brake pedal or the brake lever for several times then hold press,
release the drain screw and lock it on immediately until no air bubble in the brake oil.
Be careful for the splashing oil when operating.
Adjusting
Screw
Brake Cable
Gap Adjuster
Rear Brake
Cable Fixing Set
Gap(2~3mm)
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STEP.5) Install the rear brake cable fixing set & adjust the brake cable.
1).Spin the gap adjuster on the left lever till the shortest position.
2).Adjust the adjusting screw and keep the gap being 2-3 mm.
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Left / Right Front Brake
Balance Adjuster.
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Removal and inspection.
Remove the rear wheel and the rear brake.
Remove the skid plate under swing arm.
Remove the drive chain cover.
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Also check that the bearing outer race fits tightly
in the axle holder. Replace if necessary.
Installation
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10.1 REAR FENDER REMOVAL
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Remove the mounting bolts and nuts from the
front fender and footrest plate.
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11. ELECTRICAL SYSTEM
11.1 TROUBLESHOOTING
11.2 IGNITION COIL
11.3 IGNITION TIMING
11.4 ALTERNATOR EXCITER COIL
11.5 BATTERY CAUTION
11.6 BATTERY VOLTAGE
11.7 CHARGING
11.8 ELECTRIC STARTER
11.9 LIGHT BULBS REPLACEMENT
11.10 WIRING DIAGRAMS
11.1 Troubleshooting
ENGINE STARTS BUT STOPS IMPROPER IGNITION TIMING
FAULTY SPARK PLUG
NO SPARK AT PLUG ENGINE STOP SWITCH AT LEFT OR
RIGHT POSITION
GEARSHIFT BAR IS NOT AT NEUTRAL
POSITION
FAULTY IGNITION COIL
FAULTY GENERATOR
FAULTY CDI UNIT
POORLY CONNECTED:
Between CDI and ignition coil
Between alternator and CDI unit
Between CDI and engine stop switch
Between ignition coil and spark plug
Between generator and CDI unit
ENGINE STARTS BUT RUNS IGNITION PRIMARY CIRCUIT
POORLY Faulty generator
Faulty CDI unit
Faulty alternator
Loosen contacted terminals
Faulty ignition coil
IGNITION SECONDARY CIRCUIT
Faulty plug
Loosen contacted spark plug wire
IMPROPER IGNITION TIMING
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Faulty generator
Faulty CDI unit
CHARGING SYSTEM FAILURE LOOSE, BROKEN OR SHORTED WIRE.
FAULTY ALTERNATOR
FAULTY IGNITION SWITCH
STANDARD: 0.1-0.30
STANDARD: 7.4-11 K
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11.4 ALTERNATOR EXCITER COIL
Remove the seat/ rear fender and front fender. (see page 72) disconnect the exciter coil wire.
Measure the resistance between the yellow or white or green wire and ground.
STANDARD : 467-700
Electrolyte is poisonous. Drink large quantities of water or milk and call a physician if
swallowed.
The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide
adequate ventilation when charging or using the battery in an open area. The battery contains
sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective
clothing and a face shield. Electrolyte is poisonous. Drink large quantities of water or milk
and call a physician if swallowed.
BATTERY REMOVAL
BATTERY INSTALLATION
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11.7 CHARGING
Information
A weak battery may be unable run the starter
motor quickly enough.
Troubleshooting
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11.9 LIGHT BULBS REPLACEMENT
Remove inside two bolts on both sides of the
head light cover.
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Change a new bulb and reinstall.
TAIL
LIGHT
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11.10 WIRING DIAGRAMS
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12.TROUBLE SHOOTING
12.1 Engine does not start
12.2 Poor Performance at low and idle speed
12.3 Poor Performance at high speed
12.4 Loss of power
12.5 Poor handling
N.G
Spark Test Faulty Spark Plug
Weak or No Spark
Fouled spark Plug
Faulty CDI unit
Faulty Alternator
OK Faulty engine stop switch
Poor connection / Broken or shorted wires
Broken or shorted ignition coil
OK
Carburetor flooded
N.G Improper adjustment of air screw
Remove spark Plug
Fuel/Air mixture ratio to rich
And Inspect Wet plug
Auto choke stuck or damaged
Air cleaner dirty
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12.2 Poor Performance at Low / Idle Speed
Possible Causes
Check Ignition Timing N.G Faulty CDI Unit or Pulse generator
OK
OK
OK
N.G
Preform Spark Loose or disconnected ignition system wires
Weak or Intermittent Faulty spark plug, carbon fouled or wet
Plug Test Faulty alternator
Spark
Faulty CDI unit
Faulty ignition switch
Faulty ignition coil
Faulty pulse generator
Broken or shorted spark plug wire
Faulty engine stop switch
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12.3 Poor performance at high speed
OK
OK
N.G
Check Air
Dirty Clean or Replace air clean element
Clean Element
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12.4 Loose of power
N.G
Check Tire Pressure Low tire pressure Punctured tire
Faulty tire pressure value
OK
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12.5 Poor Handing
Possible Causes
Steering feels heavy N.G Damaged steering bearing
Damaged steering shaft bushing
Bent steering shaft
OK
Bent tie-rod
N.G Incorrect tie-rod adjustment
Vehicle pulls to one side Rear tire pressure incorrect
Improper wheel alignment
Bent frame
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