Jianshe JS125-6B Maintenance Manual
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Jianshe JS125-6B Maintenance Manual

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Summary of Contents for Jianshe JS125-6B

  • Page 3 MAINTENANCE MANUAL NOTICE This manual was produced by the chongqing Jianshe motorcycle co., Ltd primarily for use by Jianshe Group dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so if is assumed that anyone who uses this book to perform maintenance and repairs on JS125-6B motorcycle has a basic understanding of the mechanical ideas and the procedures of machine repair.Repairs attemped by anyone without this knowledge are likely to render the machine unsafe and...
  • Page 4 ILLUSTRATED SYMBOLS Special tool Tighten Filling electrolyte Wear limit, clearance Engine speed Tester Apply engine oil Apply gear oil Apply molybdenum disulfide oil Apply wheel bearing grease Apply lightweight lithium-soap base grease Apply molybdenum disulfide grease Apply fluid locking agent Install a new part COLOR INDICATIONS...

  • Page 5: Table Of Contents

    CONTENT CHAPTER 1 GENERAL INFORMATION Motorcycle identification ......................2 Important Information ........................3 Special tools ..........................6 CHAPTER 2 SPECIFICATIONS General specifications ........................ 10 Check the Specification ......................13 Lock torque ..........................18 Lubrication point and type of lubricants ..................21 Engine lubrication flow .......................
  • Page 6 Adjust clutch ..........................38 Clean the air cleaner ........................39 Adjust front brake ........................40 Check front brake shoes ......................41 Check front brake (disk) ......................42 Check brake lining ........................42 Check the amount of brake fluid ....................42 Exhaust .............................
  • Page 7 Oil pump ..........................61 Starting shaft and idle gear ..................... 61 Shift shaft ..........................62 Rotor ............................ 62 Crankcase ..........................63 Balancing device, transmission and shifting rod ............... 63 Crankshaft and counterbalance ....................64 Rocker arm and camshaft ...................... 64 Valve .............................
  • Page 8 Bearing and oil seal ........................ 82 Circlip and washer ......................... 82 Engine assembly and adjustment ................... Valve, rocker arm and cam shaft .................... 83 Crankshaft and bala nce device ....................86 Transmission .......................... 88 Gear shift cam and fork ......................89 Crankcase ..........................
  • Page 9 CHAPTER 6 CABLE AND ELECTRIC APPLIANCE SYSTEM Cable /harness wire/tube diagram .................... 150 Electric device principle ......................158 Electric appliance ........................159 Components of electric appliance .................... 161 Ignition system diagram ......................165 Starting motor ........................174 Charging system ........................178 Lighting system ........................

  • Page 11: Chapter 1 General Information

    CHAPTER 1 GENERAL INFORMATION...

  • Page 12: Motorcycle Identification

    GENERAL INFORMATION Motorcycle identification Frame identification The number is stamped on the front tube of frame. The frame number is make up of 3 parts, the first part 3 ones is the code of manufacturer(WMI); The second part (6 ones) is the direction code of motor- cycle (VDS) the third part (8 ones) is the inspecting position.

  • Page 13: Important Information

    (4)Use authentic replacement parts Use only genuine Jianshe Group parts for all re placements. Use oil and grease recommended by Jianshe Group for all lubrication jobs. Do not use Other Brands' re-placement parts. (5)Wearing parts must usually replaced (marked with Replace all gaskets, oil seals , cotter pin ,circlip and O-rings.
  • Page 14 GENERAL INFORMATION (6)Safe operation Be careful in operation to avoid accident or get a burn by the engine, exhaust pipe and silencer.. Always think of the right tools, right ways, right fixture and the right position to ensure body's steady. (7)The operation should be broken down in order and the taken apart parts should be sort out in time.
  • Page 15 GENERAL INFORMATION Gaskets Oil seal and O-rings 1. Replace all gaskets, oil seals and O-rings when overhauling the engine. All gasket surfaces, oil seal lips and o-rings surface must be cleaned. 2. Properly oil all mating parts and bearings during reassembly.

  • Page 16: Special Tools

    GENERAL INFORMATION Special tools The proper special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriates special tools will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools name Drawing Slide hammer bolt Weight...
  • Page 17 GENERAL INFORMATION Special tools name Drawing Turning and exhaust pipe wrench Turning wrench Magneto rotor holder Clearance ruler Cylinder compression gauge Pocket tester Inductive techometer Valve spring compressor Universal clutch holder Ignition checker...

  • Page 19: Chapter 2 Specifications

    CHAPTER 2 SPECIFICATIONS...

  • Page 20: General Specifications

    SPECIFICATIONS General specifications SAE 20W-40 SAE 10W-30...
  • Page 21 SPECIFICATIONS...
  • Page 22 SPECIFICATIONS...

  • Page 23: Check The Specification

    SPECIFICATIONS Check the Specification...
  • Page 24 SPECIFICATIONS...
  • Page 25 SPECIFICATIONS...
  • Page 26 SPECIFICATIONS...
  • Page 27 SPECIFICATIONS...

  • Page 28: Lock Torque

    SPECIFICATIONS Lock torque Engine...
  • Page 29 SPECIFICATIONS Body frame...
  • Page 30 SPECIFICATIONS Screw diameter ( two-face For general locking torque (except appointed locking Lock width) Thread pitch torque), locking torque force is determined by thread 8 m m 0 . 8 3-4N.m(0.3-0.4kg.m) diameter (two-face width) and thread pitch when fas- M6(10mm) 5-8N.m(0.5-0.8kg.m) tening a screw and a screw cap.

  • Page 31: Lubrication Point And Type Of Lubricants

    SPECIFICATIONS Lubrication point and type of lubricants Engine...
  • Page 32 SPECIFICATIONS Body YAMAHA 4-Stroke engine oil Light lithium base grease Special grease...

  • Page 33: Engine Lubrication Flow

    SPECIFICATIONS Engine lubrication flow Valve arm (intake) Fine oil filter Rocker shaft Oil pump Valve arm (exhaust) Push rod Cam shaft Filter net...
  • Page 34 SPECIFICATIONS Cam shaft Main axle Filter net assy Drive axle Crankshaft assy Clutch assy...

  • Page 35: Chapter 3 Periodic Inspection And Adjustment

    CHAPTER 3 PERIODIC INSPECTION AND ADJUSTMENT...

  • Page 36: Introduction

    PERIODIC INSPECTION AND ADJUSTMENT Introduction This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable operation and a longer service life. In addition, the need for costly overhaul work will be greatly reduced. This information applies to machines already in service as well as new machines that are being prepared for sale.
  • Page 37 PERIODIC INSPECTION AND ADJUSTMENT * : It is recommended that these items be serviced by a Jianshe Service station. * *: Heavy-duty or medium truck wheel bearing grease. * * *: Lithium soap base grease. Remark Replace brake fluid: 1. If disassembling brake master cylinder, the brake fluid must be replaced. Check the fluid level under normal condition and refill if necessary.

  • Page 38: Disassemble And Install The Seat Cushion, Oil Tank And Cover Types

    PERIODIC INSPECTION AND ADJUSTMENT Disassemble and install the seat cushion, oil tank and cover types Disassemble 1. Disassemble the side cover (left) Open with a key Pull out the fixed pin of side cover (serial number Take out the side cover on the direction of the arrow (serial number ) points.
  • Page 39 PERIODIC INSPECTION AND ADJUSTMENT 4. Disassemble the fuel cock Close the fuel cock Note First close the fuel cock to a position of , and then the fuel pipe. 5. Disassemble the fuel tank Bolt Spacer Rubber pad Fuel tank Install This installment steps is the reverse of disassembling steps.

  • Page 40: Check And Adjust Valve Clearance

    PERIODIC INSPECTION AND ADJUSTMENT Check and adjust valve clearance Note The valve clearance must not be checked and adjusted until the engine is cool. It can be adjusted when the piston locates T.D.C. 1. Disassemble the parts as fellows Side cover (left and right) Seat cushion Fuel tank (Refer to disassembling and installment of the seat...
  • Page 41 PERIODIC INSPECTION AND ADJUSTMENT 4. Turn around the rotor in counter clockwise direction, and turn the mark of top dead center of the rotor to a place, which is in alignment with the mark of top dead center of the crankcase cover. 5.

  • Page 42: Adjust Idle Speed

    PERIODIC INSPECTION AND ADJUSTMENT Adjust idle speed 1. Start and warm the engine 2. Install the parts as fellows Engine speedometer Install the engine tachometer on a high-pressure wire (park plug). Engine tachometer 3. Confirm items Turnover number of standard idle speed Turnover number of standard idle speed 1300 1500rpm Out of standard value...

  • Page 43: Check/Adjust The Free Play Of The Throttle Cable

    PERIODIC INSPECTION AND ADJUSTMENT Adjust CO content under idle speed condition 1. Install the measuring instrument as fellows The measuring instrument with the measure-normal- temperature probe and the engine tachometer. 2. Start engine to warm until oil temperature up to the specification.

  • Page 44: Check The Spark Plug

    PERIODIC INSPECTION AND ADJUSTMENT Note When unable to adjust the cable on the throttle handle, adjust the adjuster on the carburetor. The second step (carburetor) Loosen the lock screw cap Adjust the adjustor Turn in The clearance is increased Turn out The clearance is decreased Tighten the lock screw cap ******************************************...

  • Page 45: Inspect Compression Pressure

    PERIODIC INSPECTION AND ADJUSTMENT Inspect compression pressure Note Insufficient compressure will bring about perfor- mance degradation. 1. Check Valve clearance Out of specification Adjust clearance Refer to Valve clearance adjustment 2. Start the engine, and pre-warm it for several minutes. 3.

  • Page 46: Check Engine Oil

    PERIODIC INSPECTION AND ADJUSTMENT Check engine oil Note Must be in a level place, and maintain the body in vertical position. 1. Check Engine oil capacity After two-to-three minutes idle running, the engine is stopped from 2 to 3 minutes so as to make the body in vertical position.

  • Page 47: Replace Engine Oil

    PERIODIC INSPECTION AND ADJUSTMENT Replace engine oil Note Must not super-add any chemical additive. Engine oil is able to lubricate a clutch, but the additive might cause clutch slipping. Take care of not to have for- eign matters into the crankcase. 1.

  • Page 48: Adjust Clutch

    PERIODIC INSPECTION AND ADJUSTMENT Adjust clutch 1. Check The free play of the clutch cable Free play:10 15mm Measure at the clutch handle end Exceed specification range Adjust 2. Adjust The free play of the clutch cable ****************************************** Adjusting steps 1.

  • Page 49: Clean The Air Cleaner

    PERIODIC INSPECTION AND ADJUSTMENT Clean the air cleaner Note There is a flexible tube on the air cleaner housing bottom. If dust and water gather in the flexible tube, cleaning the filter element and the housing is need. 1. Disassemble Side cover (right) Seat cushion Air cleaner housing cover...

  • Page 50: Adjust Front Brake

    PERIODIC INSPECTION AND ADJUSTMENT 3. Check Filter element Damage Replace Dust Remove the dust on the filter net with com- pressed air Remove the filter element 1 and 2, blowing wash them with high-pressure air. If the dust on the filter element 2 is excessive, cleaning it with neutral solution, after finishing, it must be dried by blowing.

  • Page 51: Check Front Brake Shoes

    PERIODIC INSPECTION AND ADJUSTMENT Adjusting steps (handle side) Loosen the locknut Turn in or turn out the adjusting nut until it reaches the defined free play. Turn in Free play is increased Turn out Free play is decreased Tighten locknut Note After adjusting, should make sure the brake has no brake drag.

  • Page 52: Check Front Brake (Disk)

    PERIODIC INSPECTION AND ADJUSTMENT Check front brake (disk) Warning If hand feeling is soft in brake, maybe because of oil leak or entry of air, the amount of brake fluid should be checked. Check Right-left steering or vibration under drive, should check whether the brake hose touches the other part or not, if touch Adjust.

  • Page 53: Exhaust

    PERIODIC INSPECTION AND ADJUSTMENT Note Don't mix different brand brake fluids. The brake fluid can erode painting surface or plastic parts. Therefore the leaked fluid must be wiped off immediately. Exhaust Warning When the parts related to the brake fluid are disassembled, must make sure that the other parts is locked and sealed, and then conduct the exhaust operation.

  • Page 54: Replace Brake Fluid

    PERIODIC INSPECTION AND ADJUSTMENT Replace brake fluid 1. Make the master cylinder in a level position, disassemble the brake fluid cover. 2. Fit the front end of the oil drain screw with rubber hose , putting an oil tray in front of the front end of the rubber hose, loosening the oil drain screw, repeat it until the oil drain screw do not drain brake fluid no longer.

  • Page 55: Check And Adjust The Rear Brake

    PERIODIC INSPECTION AND ADJUSTMENT Check and adjust the rear brake 1. Check Check the brake and the free play of the front end of the brake pedal. The brake and the free play of the front end of the brake pedal:20 30mm Out of specification Adjust 2.

  • Page 56: Check And Adjust The Drive Chain

    PERIODIC INSPECTION AND ADJUSTMENT Check and adjust the drive chain 1. Check Put the motorcycle on the main stand. Check drive chain slack Drive chain slack: 20 30 mm 2. Adjust the drive chain ****************************************** Adjust steps Loosen the axle locknut Loosen the locknut of adjustor Turn in or turn back the adjusting advice until...

  • Page 57: Check Front Fork

    PERIODIC INSPECTION AND ADJUSTMENT Check front fork 1. Place the machine in a level place 2. Check Front fork vertical rod Scratch or damage Replace Oil seal Serious leakage Replace 3. Maintain the machine in vertical position, catching the front brake. 4.

  • Page 58: Check Tire

    PERIODIC INSPECTION AND ADJUSTMENT Check Tire 1. Measure the tire pressure Load Front wheel Rear wheel Load below 175KPa 196KPa 0 90kg* 1.75kgf/cm 2.0kgf/cm Maximum 196KPa 245KPa load 100kg * 2.0kgf/cm 2.5kgf/cm * Load includes total weight of cargo, driver, passenger and accessories.

  • Page 59: Check Steering Device

    PERIODIC INSPECTION AND ADJUSTMENT Check steering device 1. Check Set up the front wheel, shaking the lower part of the front fork with hands to check whether the steering column loosen or not. Check whether the direction handle bar can be turn left and right smoothly. Shake to loosen, turn roughly Adjust the steering column screw cap.

  • Page 60: Check Battery

    PERIODIC INSPECTION AND ADJUSTMENT Ring locknut Install the steering handle seat Install the steering handle Dust cap locknut Install the steering handle seat Install the steering handle Check battery 1. Disassemble Side cover Refer to Disassemble side cover 2. Check Electrolyte level The level must be kept between upper level and lower level...
  • Page 61 PERIODIC INSPECTION AND ADJUSTMENT 3. Check Battery terminal Dirty Clean with wire brush Improper connection Correct Caution After cleaning the terminals, apply grease lightly to the terminals. 4. Check Breather hose Obstruction Remove Damage Replace Caution When inspecting the battery, be sure the breather hose in routed correctly.
  • Page 62 PERIODIC INSPECTION AND ADJUSTMENT Warning Battery electrolyte is dangerous: it contains sulfu- ric acid and therefore is poisonous and highly caustic. Always follow these preventive measures. Avoid bodily contact with electrolyte as it can cause sever burns or permanent eye injury. Wear protective your eyes gear when handling or work near batteries.

  • Page 63: Chapter 4 Engine

    CHAPTER 4 ENGINE...

  • Page 64: Disassemble The Engine

    ENGINE Disassemble the engine Ready to disassemble the engine 1. Disassemble Side cover Seat cushion Fuel tank Refer to Disassemble seat cushion, fuel tank and side cover 2. Engine oil Drain oil Refer Replace engine oil 3. Disassemble the exhaust tube Exhaust tube Fixed bolt 4.

  • Page 65: Disassemble The Engine

    ENGINE 6. Disassemble the shifting pedal and drive chain 1) Loosen Rear wheel axle nut Note Loosen the chain adjustor nut, and increase the chain slack. 2) Disassemble Shifting pedal 3) Disassemble Small chain sprocket cover Drive chain 7. Disassemble the kick starting rod N u t Kick starting rod Disassemble the engine...

  • Page 66: Disconnect The Engine

    ENGINE Disconnect the engine Cylinder head, cylinder and piston 1. Disassemble Spark plug 2. Disassemble Intake tube (the connecting hose joint the cylinder and the carburetor) 3. Disassemble Hole cover 4. Disassemble Valve cover (intake) Valve cover (exhaust) 5. Disassemble The side cover of the cylinder head 6.
  • Page 67 ENGINE 7. Loosen Cap bolt (cam chain tensioner) 8. Disassemble Cam chain tensioner 9. Disassemble Bolt Cam chain sprocket Note The timing chain is fixed by a protecting cable avoid dropping into the crankcase. 10. Disassemble Bolt Cylinder head Note Each blot is loosened quarter turn in advance, and is twisted off when all of them is loose.

  • Page 68: Left Crankcase Cover And Starter Motor

    ENGINE 12. Disassemble Dowel pin Gasket 13. Disassemble Elastic circlip of piston pin Piston pin Piston Note Before disassembling the circlip of piston pin, the crankcase should be covered a piece of clean cloth to prevent the circlip from falling into the crankcase. Before disassembling piston, the groove of circlip and the pin hole should be cleaned.

  • Page 69: Clutch And Oil Pump

    ENGINE Clutch and oil pump 1. Disassemble Kick starter rod 2. Disassemble Crankcase cover (right) Gasket Dowel pin Note First, loosen each bolt quarter turn by the order of cross wire, and then turn off all the bolts. 3. Disassemble Bolt Clutch spring Pressure plate...
  • Page 70 ENGINE 4. Straightening Level the tongue of lock washer Loosen Note When loosen nut (clutch scab), the clutch hub is fixed with the clutch clamp. Universal clutch clamp 6. Disassemble Lock washer Clutch hub Spline washer Driven gear Washer Elastic washer 7.

  • Page 71: Oil Pump

    ENGINE 8. Disassemble Primary driven gear nut Oil filter Oil pump 1. Disassemble Bolt Oil pump Gasket Oil pump driven gear Starting shaft and idle gear 1. Disassemble Circlip Flat washer Idle gear Flat washer Circlip 2. Disassemble Torsion spring Starting shaft assy...

  • Page 72: Shift Shaft

    ENGINE Shift shaft 1. Disassemble Shifting lever Torsion spring Bolt Stopper Rotor 1. Disassemble Note Fix the rotor with a rotor clamp, and then loosen the nut. Rotor clamp 2. Disassemble Rotor Woodruff key Note A fly wheel remover pushes the fly wheel back- wards to disassemble the rotor Fly wheel remover 3.

  • Page 73: Crankcase

    ENGINE Crankcase (right) 1. Disassemble Screw (crankcase) 2. Disassemble Star gear Dowel pin Note The crankcase should be separated from the right side. Disassemble the star gear. Be careful not to damage the mating surface of the crankcase. Balancing device, transmission and shifting rod 1.

  • Page 74: Crankshaft And Counterbalance

    ENGINE Crankshaft and counterbalance 1. Disassemble Counterbalance Crankshaft Disassemble them with a crankshaft remover Note Tighten the strutting bolt of the separating tool, but make sure that the tool shell is perpendicular to the crankshaft. If necessary, one screw can be turned back a little to calibrate the state of the stool shell.

  • Page 75: Valve

    ENGINE Valve Note Before disassembling the inner parts of the cylinder head (for example valve, valve spring, valve seat), check the valve seal before hand. 1. Check Valve sealer Leakage at valve seat Check the working face of the valve Valve seat and valve seat width Refer to Valve seat check and maintenance...

  • Page 76: Check And Repair

    ENGINE Check and repair Cylinder head 1. Clean Carbon deposit (Eliminate from combustion chamber) Note Don't use sharp tool to avoid damaging or scoring spark plug thread and valve seat. 2. Check Cylinder head Scratches or damage Replace 3. Measurement Cylinder skew Check whether the 6 directions of the junction surface of the cylinder head is skew or not.

  • Page 77: Valve Seat

    ENGINE Valve seat 1. Clean Carbon deposit (Eliminate from valve face and the valve seat) 2. Check Valve seat Pit corrosion or wear Repair valve seat once more 3. Measurement Valve seat width Valve seat width Intake: 0.9 1.1mm Exhaust: 0.9 1.1mm Out of specification Repair valve seat once more ******************************************...
  • Page 78 ENGINE ****************************************** Grinding steps Smear rough grinding sand on valve face. Note Don't make grinding sand into the gap between the valve stem and the valve guide. Smear molybdenum-bearing disulfide oil on the valve stem surface. Install the valve into the cylinder head Turn the valve till valve face and the valve seat are polished evenly, and then eliminate all grinding agents.

  • Page 79: Valve And Valve Guide

    ENGINE Valve and valve guide 1. Measure Gap between valve stem and guide Gap between valve stem and guide =guide inside diameter-valve stem diameter Out of specification Replace valve guide Gap between valve stem and guide: Intake: 0.01 0.037 mm limit value:0.08mm Exhaust: 0.025 0.052 mm limit value:0.10mm Note After replacing the valve guide, repair the valve seat...

  • Page 80: Valve Spring

    ENGINE Valve spring 1. Measurement Free length (valve spring) Valve spring free length: Standard:32.28mm Limit:31.90mm Out of specification Replace 2. Check Valve spring verticality Side angle limit : 1.2 mm 3. Check Valve spring contact surface More than 2/3 of peripheral region is horizontal con- tact Replace Camshaft...

  • Page 81: Rocker Arm And Rocker Arm Shaft

    ENGINE Cam heave length Intake: A standard: 25.881-25.981mm Limit:25.851mm B standard: 21.195-21.295 Limit:21.165 Exhaust: A standard:25.841-25.941 Limit:25.811 B standard:21.050-21.150 Limit: 21.02 mm Out of specification Replace 3. Check Bearing Clamping stagnation, shake Replace Rocker arm and rocker arm shaft 1. Check Rocker arm and cam heave contact surface Valve adjusting screw face Wear, pit corrosion, scratching, bluing...

  • Page 82: Timing Chain, Sprocket, Chain Guide Plate And Chain Tensioner

    ENGINE Timing chain, sprocket, chain guide plate and chain tensioner 1. Check Timing chain Hardening or crack Replace timing chain and sprocket completely 2. Check Sprocket Hardening or crack Replace timing chain and sprocket completely Quarter gear Correct combination Rotor Sprocket 3.

  • Page 83: Cylinder And Piston

    ENGINE Cylinder and piston 1. Clean Carbon deposit (From the top of piston and ring groove 2. Check Piston side wall Wear, scratching and damage Replace 3. Check Cylinder wall Wear or scuffing Bore cylinder once more or replace 4. Measurement Piston-to-cylinder clearance ****************************************** Measuring steps...

  • Page 84: Piston Pin

    ENGINE 5. Piston-to cylinder clearance Cylinder inside diameter-piston outside diameter = clearance Standard piston-to-cylinder clearance: 0.020 0.034mm Out of specification Replace Piston pin 1. Check Piston pin Bluing or form groove Replace, and then check lubrication system 2. Measurement Piston pin outside diameter Piston pin outsidediameter: 14.991 15.000mmLimit:14.969mm Out of specification...

  • Page 85: Piston Ring

    ENGINE Piston ring 1. Measurement Side clearance Out of specification Replace piston-ring groove and piston ring completely Note During measuring side clearance, carbon deposit on the piston-ring groove and the every ring should be eliminated. Side clearance: 1 ring:0.03 0.07mm Used limit:0.12mm 2 ring:0.02 0.06mm Used limit:0.12mm...

  • Page 86: Crankshaft

    ENGINE Crankshaft 1. Check Crankshaft swing tolerance Crankshaft swing tolerance: 0.03mm Out of limit Replace Note Turn the crankshaft slowly for the measurement. 2. Check Big-end side clearance Standard side clearance:0.15-0.45mm Used limit:0.8mm Out of limit Replace 3. Measurement Crankshaft width (measure it with a vernier caliper) Standard width: 46.95 47.00mm Out of standard...

  • Page 87: Balancing Device

    ENGINE Balancing device 1. Check Crankshaft driving gear Crankshaft driven gear Wear, damage Replace 2. Check Balancer Wear, damage Replace Cultch 1. Check Driving gear Driven gear Wear, damage Replace 2 gears 2. Check Friction lining High noise when operating Replace friction lining completely 3.
  • Page 88 ENGINE 4. Check Clutch lining Damage Replace clutch lining completely 5. Measurement Clutch warp Out of specification Replace clutch lining com- pletely Use plate and caliper gauge Friction limit value: less than 0.05mm 6. Measurement Clutch spring length Damage Replace clutch spring completely Clutch spring length: 33.0mm Limit: 31.0mm 7.

  • Page 89: Transmission And Shift Lever

    ENGINE Transmission and shift lever 1. Check Cam follower of shifter fork Shift fork claw Scuffing, bend, damage Replace 2. Check Shifting cam groove Damage or wear Replac 3. Check Fork guide rod (short left, long right) Shifting cam Distortion, scuffing, bend, damage Replace 4.

  • Page 90: Kick Starter

    ENGINE 6. Check Gear tooth Bluing, pit corrosion, wear Replace mating gear End land become round, crack and disalignment Replace 7. Check Shifting shaft Damage, bend, wear Replace Torsion spring (stopper lever) Return spring (shifting shaft) Damage Replace Kick starter 1.

  • Page 91: Oil Pump And Oil Filter

    ENGINE Oil pump and oil filter 1. Measurement Gear tip clearance A (Between inside rotor and outside rotor Side clearance B (Between outside rotor and pump housing Clearance C between inside-and-outside rotor and pump housing (Thickness difference of inside rotor , outside rotor and pump housing...

  • Page 92: Crankcase

    ENGINE Crankcase 1. Thoroughly wash the contact face of crankcase with a sort of hot solvent. 2. Thoroughly wash the matching faces of sealing gasket and crankcase with a sort of hot solvent. 3. Check Crankcase Crack or damage Replace Oil hole Blockage Blow out with compressed air...

  • Page 93: Engine Assembly And Adjustment

    ENGINE Engine assembly and adjustment Valve, rocker arm and cam shaft Valve lock Valve stem (intake) O-ring Valve spring upper seat Lock nut Valve guide Valve stem oil seal Adjusting bolt Cam shaft Valve spring Rocker arm Pressure plate Valve spring seat Rocker arm pin (intake) Valve stem (exhaust) Rocker arm pin (exhaust)
  • Page 94 ENGINE Engine assembly and valve adjustment 1. Eliminate burr Valve stem end Polish valve stem end with oilstone 2. Smear Molybdenum sulfide base lubricant (Smear it on the valve stem and valve oil seal) Four stroke engine oil (Smear on the valve stem top) 3.
  • Page 95 ENGINE 5. Ham the valve lock with a hammer to fix it on the valve stem. Note Don't ham it too hard to avoid damaging the valve. Rocker arm and cam shaft 1. Lubrication Supramoly sulfide base lubricant (Smear the contact face of the rocker arm hole and the cam shaft) Four stroke engine oil (Smear rocker arm shaft and O-ring seals)

  • Page 96: Crankshaft And Bala Nce Device

    ENGINE Crankshaft and bala nce device Crank pin Crankshaft bearing Crank Woodruff key Connecting rod Balancer Big-end needle bearing Balancer bearing...
  • Page 97 ENGINE Install crankshaft and balancing shaft 1. Install Crankshaft Distance bushing install The crankshaft spanner The crank shaft bolt Reducing coupling Note Maintain the connecting rod in the position of upper dead center, when installing, do not touch the crankcase. Do not ham the crankshaft with a hammer.

  • Page 98: Transmission

    ENGINE Transmission Driving sprocket 2nd wheel gear Bearing Main shaft Oil seal 3rd wheel gear 5th pinion gear Retaining ring Bearing 4th wheel gear 2nd pinion gear Bearing 5th wheel gear 1st wheel gear 3rd pinion gear Driving shaft Bearing 4th pinion gear...

  • Page 99: Gear Shift Cam And Fork

    ENGINE Gear shift cam and fork Fork guide rod 1 Fork 3 Star gear Fork 1 Fork guide rod 2 (short)
  • Page 100 ENGINE Install transmission system, gear-shift cam, gear-shift fork 1. Install Clutch push rod 2 2. Install Main shaft Note First, the clutch inside push rod is installed in main shaft inside hole. Then install the main shaft. 3. Check The installing width of the main shaft gear Standard installing width of the main shaft:82.25-83.45mm 4.
  • Page 101 ENGINE 5. Install Gear shift cam (Align the salient point on the gear shift cam with the contact point of neutral switch on the crankcase) Gear shift fork (One side marked L towards the clutch) Gear shift fork (One side marked R towards the clutch) Gear shift fork (One side marked C towards the clutch) Gear shift fork guide rod 2...

  • Page 102: Crankcase

    ENGINE Crankcase Tightening order Yamaha bond No.1215 Left crankcase Right crankcase Dowel pin Clutch fixing clip Air pipe...
  • Page 103 ENGINE Crankcase (right) 1. Smear Sealant (Smear on the contact surface of left or right crankcase) Sealant (Yamaha bond.No.1215) Note Be must not let any Sealant into lubricating hole. See figure, the place of 2. Install Dowel pin 3. Install Install the right crankcase on the left crankcase.

  • Page 104: Shift Shaft, Kick Starter Axle And Kick Starter Idle Gear

    ENGINE Shift shaft, kick starter axle and kick starter idle gear Shift shaft Circlip Return spring Washer Stopper Idle gear Torsion spring Washer Star gear Circlip Starting shaft assy...
  • Page 105 ENGINE Shifting cam 1. Install Dowel pin 2. Install Star gear Note When install the star gear, the pin hole on the star gear and the pin hole on the cam must be installed on the right position. 3. Install Stopper Spring Bolt (stopper):1.0kgf.m(10 N.m)
  • Page 106 ENGINE Kick starter axle and kick starter idle gear 1. Install Starting shaft Clamp Spring Note The projection of spring must be installed on the place of the case, and the spring can not be fixed till it rotates one lap. 2.

  • Page 107: Clutch, Oil Pump

    ENGINE Clutch, oil pump Spring Clutch lining Push rod Oil pump transmission gear Pressure plate Clutch hub Push rod assy Oil pump driving gear Push plate Stop washer Driving gear Oil pump housing Push rod 1 Main driven gear Oil filter Oil pump gasket Friction lining Steel ball...
  • Page 108 ENGINE Oil pump 1. Oil charge Four stroke engine oil (Charge into the oil holes in the crankcase and the oil pump) 2. Install Oil pump Oil filter 1. Install Oil pump driving gear Centrifugal filter Note Install the dowel pin of the centrifugal filter in the stop groove of the crankshaft.
  • Page 109 ENGINE Clutch 1. Install Main driven gear Thrust washer Clutch hub Lock washer 2. Install Note Fix the clutch hub with a clutch clamp , locking the nut, and bending the lock washer Clutch clamp nut torque: 6.0 kgf.m(60N.m) 3. Install Four friction linings Three clutch plate Note...
  • Page 110 ENGINE 4. Install Steel ball 5. Install Push rod Push plate Washer N u t 6. Install Pressure plate Spring Bolt Mounting torque of the bolt: 0.6kgf.m(6N.m) Note Tighten the bolts by diagonal order. 7. Confirm Alignment mark of the push rod assy and the crankcase Turn the push rod assy anticlockwise thoroughly, confirming whether the objection...
  • Page 111 ENGINE 8. Adjustment Alignment mark of the push rod and the crankcase Loosen the nut , turn the push rod anticlockwise thoroughly Turn the push rod right and left for adjusting until aligns with Lock the nut after adjusting. Lock torque of the nut: 0.8kgf.m(8N.m) 9.

  • Page 112: Timing System

    ENGINE Timing system Timing chain Washer Gasket Chain guide plate Starting gear 2 Dowel pin Dowel shaft Woodruff key Left case cover Idle starting gear 1 Rotor Pressure plate Stator...
  • Page 113 ENGINE Rotor and starting mechanism 1. Check Check the gear condition of starting gear 1 and 2. Burr, Scraps, out-of-flatness, wear Replace 2. Check Starting gear 2 (contact surface) Pit corrosion, wear, damage Replace ****************************************** Check steps Install the starter gear in the clutch of the starter, and hold the clutch.
  • Page 114 ENGINE 3. Smear Four-stroke engine oil (Smear shaft collar and starter drive mechanism) 4. Install Washer Starting gear 5. Install Woodruff key Rotor Note Eliminate foreign materials and the dirt on the rotor, and then fixed it. 6. Lock Locking torque 7.0kgf.m(70 N.m) Note Fix the rotor with sliding stopping tool...
  • Page 115 ENGINE Piston and piston ring 1. Piston installment Oil-bearing baffle Scraper baffle Second ring First ring Note When install the first ring and second ring, dividing top and bottom. The mark toward the top. When install the oil ring, the scraper baffle should be installed first , and then install the Oil-bearing baffle, finally install the scraper baffle.

  • Page 116: Cylinder And Piston

    ENGINE Cylinder and piston Cylinder Piston ring O-ring Piston pin circlip Gasket Piston Dowel pin Piston pin...

  • Page 117: Cylinder Head

    ENGINE Cylinder head Bolt Cylinder head Copper washer Dowel pin Inner hexagon bolt Steel gasket Valve cover (intake) O-ring O-ring Cylinder head side cover Valve cover (exhaust) spark plug...

  • Page 118: Cam Shaft And Dowel Pin

    ENGINE Cam shaft and dowel pin Gasket Timing sprocket Tensioner Timing chain Chain guide plate (intake) Chain guide plate (exhaust)

  • Page 119: Intake And Exhaust System

    ENGINE Intake and exhaust system Carburetor Adjusting screw of throttle cable Carburetor body O-ring Float unit Rubber cover Idle screw Rubber washer Float pin Guide tube of throttle cable Spring Washer Seal shim Rubber washer. Washer Spring Floater cover Top cover cap Rubber washer Ps adjusting screw Bolt...
  • Page 120 ENGINE Disassemble 1. Disassemble Guide tube of throttle cable Carburetor body Disconnect 1. Loosen Drain screw 2. Disassemble Throttle valve 3. Disassemble Choke lever Choke valve 4. Disassemble Float chamber 5. Disassemble Float pin Floater Needle valve Needle valve seating...
  • Page 121 ENGINE 6. Disassemble Main jet Main nozzle O-ring 7. Disassemble Idle fuel jet 8. Disassemble P.S adjusting screw Check 1. Check Carburetor mixing chamber Pollution Clean 2. Check Floater Damage Replace 3. Check Needle valve Needle valve seating O-ring Wear Replace Note The needle and the needle valve seating must be...
  • Page 122 ENGINE 4. Check Main nozzle Main jet O-ring Idle fuel jet Pollution Clean Note Blow down each jet with compress air. Assemble Assemble them contrary to disassemble steps. Note Clean all the parts with clean gasoline before assem- bling once more. Adjust fuel level 1.
  • Page 123 ENGINE Fuel liquidometer Loosen drain-hole screw , warming the engine for several minutes. Maintain the fuel liquidometer in verticality, making it approach the reticle of the float chamber. Measure the fuel level with fuel liquidometer Note The readings on the pipeline of the two sides of the carburetor are equal.

  • Page 124: Intake, Exhaust System

    ENGINE Intake, exhaust system Negative pressure pipe Engine assy Wire clip wire clip Complementary gas valve Exhaust gas cycle tube Circlip Air filter assy Complementary gas 1 pipe Complementary gas 2 pipe Syphon assy Bolt M6 Washer plate Screw M6 Muffler assy...

  • Page 125: Chapter 5 Chassis

    CHAPTER 5 CHASSIS...

  • Page 126: Front Wheel

    CHASSIS Front wheel Lock nut Front wheel assy Instrument gears Spacer assy Front wheel axle Front wheel assy Spacer...

  • Page 127: Front Brake

    CHASSIS Front brake Brake shoes assy Cam shaft Oil seal Spacer Speedometer clutch Washer Drive gear Meter gear Cam shaft lever O-ring Indicator plate Oil seal...
  • Page 128 CHASSIS Removal Warning Place the machine on a level place Place the machine on main stand Elevate the front wheels by placing suitable stand under the frame or engine. 1. Disconnect: Front brake cable Note Be sure to relax the brake before disconnet 2.
  • Page 129 CHASSIS Inspection 1. Inspection: Front wheel shaft (check with dial indicator) Crooked Replace Warning Be sure not to straighten the crooked front wheel shaft Crook limit: 0.25mm 2. Inspection: Tire Wear/Damage Replace Warning Never try to repair the tire by yourself 3.
  • Page 130 CHASSIS Speedometer gear assy 1. Install Speedometer cable Driven gear Do not crooked the speedometer cable Instrumentation clutch 1. Inspection Instrumentation clutch Wear/Damage Replace Instrumentation driven gear Instrumentation meter gear Front brake 1. Inspection Brake shoe lining surface Smooth side Grinding Sand with coarse sand paper Note...
  • Page 131 CHASSIS 2. Measure: Brake shoe lining thickness Brake shoe thickness : 4mm Limited : 2mm Out off specification Replace Note Be sure to replace the whole brake shoes if any one of them is out of specification. 3. Measure Brake drum inside diameter Brake drum inside diameter: standard:130mm limit:131mm Over specified limit...
  • Page 132 CHASSIS Assembly 1.Install Camshaft Indicator Install steps When install the wear indicator , place its convex part into slot of camshaft Aim the needle at the wear indicator. 2.Install Camshaft rod Install torque: 1.0Kgf.m 3.Install Brake shoe Brake shoe spring Note Don t use plier when installing which may cause disshape and damage of hooks and rings of spring.
  • Page 133 CHASSIS 5.Install Brake assy Note Make the slot face the wear indicator when install brake assy. Pull and press braked shoe in direction of arrow, making pivot and brake camshaft rod as fulcrum, when installing brake shoe. Install 1.Install Front brake cable Speedometer cable Front wheel axle nut 2.Install...

  • Page 134: Rear Wheel

    CHASSIS Rear wheel Adjusting nut Sprocket shaft Rear wheel Compression spring Rear brake split pin Damper Tension rod Oil seal Lock nut Spacer Chain adjuster assy Bearing...

  • Page 135: Rear Brake

    CHASSIS Rear brake Brake shoes Indicator plate Camshaft lever Brake camshaft...
  • Page 136 CHASSIS Removal Warning Support the motorcycle firmly to avoid falling over. 1. Remove; Adjuster Tension rod N u t Compressing spring Brake rod Rear wheel shaft nut 2. Remove Rear wheel shaft Spacer Note When removing the wheel shaft, Spacer will drop down.
  • Page 137 CHASSIS 4.Remove Damper Cracks/Damage Replace Rear wheel hub 1.Inspect Brake drum inner surface Oil/Scratches Remove Oil: use a rag soaked in lacquer thinner or a solvent Scratches: use a emery cloth (lightly and evenly polishing) 2. Measure Brake drum inside surface Brake drum inside diameter: Standard: 130mm Limit: 131mm Out of specification...

  • Page 138: Diving Chain

    CHASSIS Diving chain Sprocket cover Main drive sprocket Slave sprocket Adjuster Link plate Circlip Chain adapter Stop washer Chain connect...
  • Page 139 CHASSIS Disassembly Warning Stand the motorcycle firmly and avoid turning. 1.Put the motorcycle on the main stand 2.Disassembly: Sprocket cover 3.Screwing-down Small sprocket 4.Disassembly Chain connect snap ring Link plate Chain connect Driving sprocket Inspection 1.Inspection The driving chain stuck Get stuck Clean and lubricate or replace it 2.
  • Page 140 CHASSIS 3. Measure The length of 10 chain elements (driving chain) The max length of 10 chain elements: 119.5mm Excess the stipulated scope Replace Note Stretch the chain with fingers first, then measure the length. As shown in the figure, measure the length of 10 chain elements from the internal side of the roller to the roller Measure the length of 10 chain elements in differ-...
  • Page 141 CHASSIS 3. Install Install as the illustration shows Stretch the convex tongue of the antiloosen pad straight, screw down the construction bolt, then dis- assemble the driving sprocket. Install 1.Install Driving chain Driving chain cutter Link plate 2.Assembly Chain connect work carrier Note Pay attention to eh assembling direction of the work carrier of the carrier of the chain connect...

  • Page 142: Front Fork

    CHASSIS Front fork Front fender Spring Resistance device Plug Dust-preventative cap Inner tube Bolt Circlip Spring O-ring Bolt Oil seal Collar Washer Outer tube Spring seat Button valve...
  • Page 143 CHASSIS Remove Warning Securely support the machine to avoid falling over. 1.Place the machine on a level place. 2.Elevate the front wheels by placing the suitable stand under the frame and engine. 3.Remove Front wheel Front fender 4.Loose Bolt Cap bolt Note Be sure to loose the two bolts of the front fork before remove.
  • Page 144 CHASSIS 4. Disassemble Dust-preventative cap Circlip Note Be careful not to damage the surface of inner tube 5. Remove Bolt Hold the shock absorber rod, and loosen the bolt shock absorber rod, with spanner shock absorber rod fixture s p a n n e r 6.
  • Page 145 CHASSIS 2. Measure Free length of front fork spring Free length of front fork spring: 339.9mm Min free length: 330mm Out of specification Replace 3. Inspect: Resistance device rod Absorber piston Wear /Cracked /Damage Replace Spring Button valve Wear/Cracks/Damage Replace Dirt Blow and clean all oil hole with compressed Note...
  • Page 146 CHASSIS 1. Install Spring Absorber piston 2. Lubricate: Inner tube of front fork (outer surface) Front fork oil 10w or equal substitute 3. Install Resistance device Button valve Inner tube of front fork Outer tube of front fork 4. Install Washer Bolt (shock absorber rod) 5.
  • Page 147 CHASSIS 6. Install Oil seal 7. Install Circlip Outer tube of front fork 8. Inspect Inner tube extension Re-inspect if can not extension freely. 9. Inject Measuring cup Every front fork tube: 156ml 10W shock absorber oil 10. Move the front fork up and down slowly after infection to make the oil all over the tube.
  • Page 148 CHASSIS 12. Install Cap bolt O-ring Note Be careful not to damage the outer surface of inner tube. Intall Reverse the REMOVE procedure 1. Install Front fork Tighten the bolt temporary Note Be sure to justify the inner tube port and bolt port. 2.

  • Page 149: Steering Seat And Handlebar

    CHASSIS Steering seat and handlebar Circle lock nut Handlebar clamp Dust preventative cap Handlebar Steering seat Right holder lever assy Upper ball bearing race (upper) Handlebar seat Upper Steel ball Thimble Lower steel ball Ring Nut Upper ball bearing race (middle) Ring washer Lower ball bearing race Ring nut...
  • Page 150 CHASSIS Dust-preventative cap nut Handlebar clamp Upper ball bearing race (upper) Handlebar Upper Steel ball Right holder lever assy Lower steel ball Handlebar seat Upper ball bearing race (middle) Dust-preventative cap nut Lower ball bearing race Steering seat...
  • Page 151 CHASSIS Removal 1. Remove Remove the switch of left and right handle 2. Remove Handlebar clamp Handlebar Handlebar throttle seat 3. Remove Front wheel 4. Remove Front fork Ring lock nut 5. Remove Thimble Ring nut Ring washer...
  • Page 152 CHASSIS 6. Remove Ring nut Remove the ring nut with steering nut wrench Steering nut wrench Warning Never remove the nut with any other instruments except steering nut wrench. 7. Remove Ball bearing race cover Upper ball bearing race (upper) Steel ball(upper) Steering seat Steel ball (lower)
  • Page 153 CHASSIS Inspect Inspect handlebar handlebar Bent Cracks Damage Replace Warning Do not attempt to straighten a bent handlebar, this may weaken the strength of handlebar and cause danger Inspect front steering column 1. Clean out the ball bearing race and steel ball 2.
  • Page 154 CHASSIS Install Steering bar Reverse the REMOVAL procedure 1. Lubrication Steel ball (lower, upper) Bearing race Lithium based grease 2. Assembly: Ring-nut (lower) Ring-washer Ring-nut (upper) Thimble After assembly, make adjustment according to the steps of Part III. Dust-preventative cap lock nut Reverse the REMOVAL procedure...
  • Page 155 CHASSIS Handlebar 1. Assembly: Handlebar Handlebar clamp Tighten torque 2.3kgf.m(23 N.m) Note Make sure to flexible the front face bolt Make the difference handlebar clamp from front to rear to assemble the front face. 2. Assembly Front brake lever Clutch holder lever 3.

  • Page 156: Rear Shock Absorber And Rear Arm

    CHASSIS Rear shock absorber and rear arm Rear shock-absorber Connection rod Chain cover Rear arm...
  • Page 157 CHASSIS Disassembly Warning Stand the motorcycle firmly avoid turning over. 1. Rear shock absorber 2. Disassembly Left and right and rear shock absorber 3. Disassembly Rear wheel 4. Disassembly Chain 5. Disassembly N u t Connection rod Chain cover Rear arm Inspect 1.

  • Page 159: Chapter 6 Cable And Electric Appliance System

    CHAPTER 6 CABLE AND ELECTRIC APPLIANCE SYSTEM...

  • Page 160: Cable /Harness Wire/Tube Diagram

    CABLE AND ELECTRIC APPLIANCE SYSTEM Cable /harness wire/tube diagram Drum brake with cowling Clutch cable Fuel sensor Fuse Overflow pipe Left handlebar switch wire Front brake cable Start electric relay Positive wire Wire clamp Speedometer cable Flasher relay Harness wire Fuel pipe Carburetor vent pipe Negative pressure pipe...
  • Page 161 CABLE AND ELECTRIC APPLIANCE SYSTEM Drum with cowling Throttle cable Carburetor vent pipe Negative pressure pipe Ignition coil Exhaust gas cycle tube Complementary gas pipe1 Ignition coil wire Carburetor overflow pipe Syphon assy Clutch cable Battery vent pipe Washer Rear brake switch Complementary gas pipe 2 Rear brake switch lead wire Complementary gas valve...
  • Page 162 CABLE AND ELECTRIC APPLIANCE SYSTEM Drum with cowling Left handlebar switch A. Trottle cable brake cable and handbar switch lead wire,must pass through the Clutch switch guide frame Front brake switch B. Clutch cable, handlebar switch wire and clutch switch wire must pass through Right handlebar switch the guide frame C.
  • Page 163 CABLE AND ELECTRIC APPLIANCE SYSTEM Disk brake with cowling Handlebar switch lead-wire Front brake switch wire Throttle cable Throttle cable guide frame Front brake cable Front brake cable fixture clamp A. Connect with horn Speedometer cable Cable guide frame Harness wire guide frame A.Tighten the handlebar switch and clutch switch wire...
  • Page 164 CABLE AND ELECTRIC APPLIANCE SYSTEM Disk brake with cowling Right flasher wire A. To front headlight Left flasher wire B. After connect the wire, strap it up with shell ring at this place and cut off the rest. C. Harness wire and cowling cover at this place and cut off the rest. Picture A Front brake switch wire Throttle cable...
  • Page 165 CABLE AND ELECTRIC APPLIANCE SYSTEM Drum without cowling Clutch cable Front brake cable Flasher relay Left handlebar switch wire Speedometer cable Carburetor vent pipe Wire clamp Fuel pipe Carburetor overflow pipe Fuse Positive wire Fuel sensor Starter relay Harness wire A.
  • Page 166 CABLE AND ELECTRIC APPLIANCE SYSTEM Drum without cowling Throttle cable Rear brake switch lead wire Ignition coil Carburetor vent pipe Ignition coil wire Exhaust gas circulation pipe Clutch cable Carburetor overflow pipe Rear brake switch Storage battery vent pipe A. Tighten the ground wire and ignition coil together. B.
  • Page 167 CABLE AND ELECTRIC APPLIANCE SYSTEM Drum without cowling Left handlebar switch A. Throttle cable ,brake cable and brake switch lead wire,handlebar switch wire Clutch switch must pass through the guide frame Front brake switch B. Clutch cable, handlebar switch wire and clutch switch wire must pass through Right handlebar switch the guide frame C.

  • Page 168: Electric Device Principle

    CABLE AND ELECTRIC APPLIANCE SYSTEM Electric device principle...

  • Page 169: Electric Appliance

    Electric appliance...
  • Page 170 CABLE AND ELECTRIC APPLIANCE SYSTEM...

  • Page 171: Components Of Electric Appliance

    CABLE AND ELECTRIC APPLIANCE SYSTEM Components of electric appliance Storage battery Rectifier regulator Rear brake switch Oil sensor Starting relay Key sets safety assy Harness wire...
  • Page 172 CABLE AND ELECTRIC APPLIANCE SYSTEM Components of electric appliance Ignition coil Flasher relay Spark plug cap Shift switch Horn...
  • Page 173 CABLE AND ELECTRIC APPLIANCE SYSTEM Socket connector inspection Clean away the dirt, rust and moisture on the socket connectors 1. Disconnect: Socket connectors 2. Dry every binding post with bowing device 3. Connect and disconnect every socket connector 2 3 times 4.
  • Page 174 CABLE AND ELECTRIC APPLIANCE SYSTEM Switch inspection Inspect if the circuit between wire end is on with pocket multi meter. If there is any failure, replace the switch. Pocket tester Note Should turn on and off the switch many times when inspecting.

  • Page 175: Ignition System Diagram

    CABLE AND ELECTRIC APPLIANCE SYSTEM Ignition system diagram...
  • Page 176 CABLE AND ELECTRIC APPLIANCE SYSTEM Fault obviation Ignition system inefficiency (no spark or interrupted spark) Check steps 5. Pulse wire resistance 1. Spark plug 6. Ignition charging resistance 2. Check the spark 7. Main switch 3. Spark plug cap resistance 8.
  • Page 177 CABLE AND ELECTRIC APPLIANCE SYSTEM Multimeter lead Side of spark plug Multimeter lead High tension wire 3. Spark plug cap resistance Disassemble the cap of the spark plug Connect a small-size( 1K) to the spark plug cap Note Do not pull off the spark plug from the high tension wire Disassemble in an anticlockwise way Install in a clockwise way...
  • Page 178 CABLE AND ELECTRIC APPLIANCE SYSTEM Multimeter lead Orange spark plug wire Multimeter lead Ground wire 5. Ignition coil secondary resistance Disassemble the wire of the coil away from the wire harness. Connect a small-size( 1K) to the spark plug cap AC.CDI Ignition primary coil resistance: 3.16K...
  • Page 179 CABLE AND ELECTRIC APPLIANCE SYSTEM Electric start system...
  • Page 180 CABLE AND ELECTRIC APPLIANCE SYSTEM Troubleshooting Starter motor doesn't run Inspection steps 1. Storage battery 5. Starter relay 2. Fuse 6. Starter switch 3. Starter motor 7. Neutral switch 4. Main switch 8 Clutch switch Note The following parts should be disassembled before troubleshooting Side cover Seat...
  • Page 181 CABLE AND ELECTRIC APPLIANCE SYSTEM Warning The cross-bond should have an equel or more capacivity 3. Starter motor than the wire of the storage battery, otherwise the cross-bond will be fused. Connect the binding pole of the battery with the cable Error spark may occur in the inspection, inflame gas of starter motor with crossbond as shown in the or liquid should be kept away from the around area.
  • Page 182 CABLE AND ELECTRIC APPLIANCE SYSTEM 5. Main switch Disassemble the socket connectors of the main switch away from the wire harness. Check if the switch can connect to Red / Brown Abnormal The main switch is faulty, and should be replaced. Normal 6.
  • Page 183 CABLE AND ELECTRIC APPLIANCE SYSTEM 7. Clutch switch Disassemble the socket connectors of the clutch switch away from the lead wire. Check if the switch can connect to red black black Abnormal The clutch switch is faulty, and should be replaced. Normal 8.

  • Page 184: Starting Motor

    CABLE AND ELECTRIC APPLIANCE SYSTEM Starting motor Starting motor assy Magnetic yoke Rear bracket Armature Brush spring Adjusting washer Brush assy Front bracket O-ring O-ring...
  • Page 185 CABLE AND ELECTRIC APPLIANCE SYSTEM Remove 1.Remove Starting motor wire Starting motor assy Discharge 1.Before discharge, sign some marks on the front and rear brockets, so that it can easy to check. 2.Remove Front brocket Washer Rear brocket 3.Remove Armature magnetic yoke Brush Inspection and repairment...
  • Page 186 CABLE AND ELECTRIC APPLIANCE SYSTEM 4.Check Armature coil (insulation/continuity) Defects Replace starting motor ****************************************** Inspection steps: Connect the pocket tester for the continuity checking and insulation checking Measure the armature resistance. Armature coil resistance: Continuitychecking 0.017 0.021 Insulation checking More than:1M If the resistance is incorrect, replace the starting motor.
  • Page 187 CABLE AND ELECTRIC APPLIANCE SYSTEM Mount Mount as the reserves steps as remove 1.Mount: Brush spring Brush Note When mounting brush the brush wire should round over the projection outside of brush spring clip. When mounting brush, make the brush terminal touch slightly the projection of brush spring clip side.

  • Page 188: Charging System

    CABLE AND ELECTRIC APPLIANCE SYSTEM Charging system...
  • Page 189 CABLE AND ELECTRIC APPLIANCE SYSTEM Troubleshooting The battery is not charged 1. Fuse 4. Light switch 2.Stratage battery 5. high and lower beam switch 3. Main switch Note Before troubleshooting, the following components should be taken off Side cover Seats When troubleshooting, the following special tool should be used.
  • Page 190 CABLE AND ELECTRIC APPLIANCE SYSTEM 3. Charging voltage Connect inductive tachometer to spark plug lead. Connect the pocket tester(DC20V) to the battery Tester lead Battery+terminal Tester lead Battery-terminal Start the engine and accelerate to about 5000r/min Check charging voltage Charging voltage: 14.0V 5000r/min Note Meets specification Use a fully charged battery.

  • Page 191: Lighting System

    CABLE AND ELECTRIC APPLIANCE SYSTEM Lighting system...
  • Page 192 CABLE AND ELECTRIC APPLIANCE SYSTEM Troubleshooting The headlamp, indicator light, tail lamp and /pr instrument lamp fail to come on Note Remove the following parts before troubleshooting Side cover Seats Front light cover Use the following special tools for troubleshooting: Pocket tester 1.
  • Page 193 CABLE AND ELECTRIC APPLIANCE SYSTEM 4. Main switch Discharge the main switch coupler from wire harness Check the continuity of switch between red and b r o w n . Incorrect Normal Main switch is failure, replace it. 5.Lighting switch Discharge the handlebar switch( right) coupler form wire harness Connect the pocket tester (...
  • Page 194 CABLE AND ELECTRIC APPLIANCE SYSTEM Lighting system check 1. If the headlamp and high beam indicator lamp fail to come on. 1 Bulb and bulb socket Check the bulb and bulb socket for contimuity. No Conutinuity continuity Replace the bulb and / or bulb socket 2.
  • Page 195 CABLE AND ELECTRIC APPLIANCE SYSTEM 2. Voltage Connect the pocket tester (DC20V) to the bulb socket coupler Tester lead Yellow terminal Tester lead Black terminal Turn the main switch to Turn the lights switch to Check the voltage (12V) of the brown lead on Out of specification...

  • Page 196: Signal System

    CABLE AND ELECTRIC APPLIANCE SYSTEM Signal system...
  • Page 197 CABLE AND ELECTRIC APPLIANCE SYSTEM The troubleshooting Flasher, brake lamp / or indicator lamp fail to come on. The horn doesn t work Check steps: 1. Fuse 3. Main switch 2. Battery 4. Wiring connection Note Discharge the following parts before troubleshooting Use the following special tools for trouble shooting: Side cover Seats...
  • Page 198 CABLE AND ELECTRIC APPLIANCE SYSTEM Inspection of signal system 1. The horn doesn t work 1.Horn switch Discharge the handlebar switch (left) coupler from Incorrect wire harness.Check the continuity between pink The horn switch is failure, replace the handlebar and black on switch switch 2.Voltage...
  • Page 199 CABLE AND ELECTRIC APPLIANCE SYSTEM 2. The brake lamp fails to come on 1. Bulb and bulb socket No continuity Check the continuity of bulb and bulb socket Replace bulb/or bulb socket 2.Brake switch Discharge the braked switch wire from wire harness Incorrect Check the continuity between yellow and brown...
  • Page 200 CABLE AND ELECTRIC APPLIANCE SYSTEM 3. Turn lamp / or Turn signal lamp indicator fails to come on 1.Bulb and bulb socket Check the bulb and the bulb socket for continuity No continuity Continuity Replace bulb / or bulb socket 2.Flasher switch Discharge handlebar switch (left) coupler from wire harness.Check the continuity between...
  • Page 201 CABLE AND ELECTRIC APPLIANCE SYSTEM 5.Turn lamp indicator Connect the pocket tester (DC 20V) to the bulb socket coupler. The connection of left turn lamp: Tester lead Dark Brown terminal Tester lead Ground wire of frame The connection of right turn lamp: Tester lead Dark green terminal Tester...
  • Page 202 CABLE AND ELECTRIC APPLIANCE SYSTEM 3. Voltage Connect the pocket tester (DC20V) to the bulb socket coupler Connect tester lead to brown wire Connect tester lead to light blue wire Turn the main switch to Check the voltage (12V) of brown terminal on Out of specification...
  • Page 203 CABLE AND ELECTRIC APPLIANCE SYSTEM 2.Voltage Connect the pocket tester (DC20V) to fuel gauge terminal Tester lead Green wire Tester lead Ground wire Check the voltage (12V) of brown wire on the fuel gauge terminal Out of specification Meets specification Check all couplers of signal system 3.Fuel gauge Connect the fuel sensor to wire connecter...

  • Page 205: Chapter 7 Troubleshooting

    CHAPTER 7 TROUBLESHOOTING...

  • Page 206: Electric Appliance System

    TROUBLESHOOTING Electric Appliance System Check entire wire coupler Ignition coil Primary coil or secondary coil is damaged or shortened Main switch Failure of high pressure wire Main switch is broken Faulty spark plug cap Wire is broken or shorted CDI device CDI device is damage Spark plug Clogged...

  • Page 207: Compression System

    TROUBLESHOOTING Compression System Lack of tighten moment Buckle / Accumulative carbon Wear/clog/damage Damage Accumulative carbon Damage Damage Buckle/wear/damage Wear/clog/damage Damage Damage Wear/clog Damage Wear/clog/damage Wear/clog/damage...

  • Page 208: Intake \Exhaust System

    TROUBLESHOOTING Intake \Exhaust System Fuel filter Fuel pipe contaminated or clogged Clogged, scratched or bent Valve lash Air filter Improperly adjusted Contaminated or clogged Silencer Outlet pipe clogged Scratched or damaged Accumulate carbon Jet needle-valve Improperly adjusted Incorrect of clamping piece Nozzle Starter nozzle Damaged...

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