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Moto3 User Manual

Gulp valvel

Functional introduction for secondary gulp valve of emission use with State III standard:
Connect air filter with air inlet tube, and then, connect air outlet tube to metal tube on the cylinder head. Connect the
negative pressure tube of the gulp valve with the air inlet tube on engine, control the entry of air into the exhaust pipe
through changing negative pressure in air inlet tube on the engine, decrease CO, HC, and Nox.

1.  Negative pressure tube on gulp valve
2.  Air inlet tube
3.  Air outlet tube

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Summary of Contents for Moto3

Page 1: ...1 Moto3 User Manual moto3Usermanual ...

Page 2: ...98 2007 Limitation of fuel evaporative pollutants for motorcycle trail bike and their measurement method all the standards above has been reached when the products left factory We may make structural improvements to the motorcycle in the future The pictures and contents of this service manual may be slightly different to current products Products herein are subject to change without notice at any ...

Page 3: ...3 Moto3 User Manual ...

Page 4: ... Checking the spark plug 23 Checking and replacing the air filter 24 Adjusting the throttle cable 25 Fine Tuning the Carburetor 25 Checking and adjusting the valve cap 26 Adjusting the clutch 27 Adjusting the brake pedal 27 Kick stand 27 Front and rear disc brake maintenance 28 ChainAdjustment 30 Adjusting the braking switch 30 Checking the battery 31 Replacing the fuse 31 Tires 32 Tire pressure 3...

Page 5: ...egree hin dering mechanical systems such as shock absorber steering and controlling parts are not allowed 3 Accessories installation on handle bar or front fork may lead to serious imbalance Extra weight on front end may de crease sensitivity of turning shock on front wheel and instability during driving Minimum the weight of accessories to be installed on handle bar and front fork 4 Windshield ba...

Page 6: ... riding a motorcycle please put both hands on the handlebars and both feet on the pedals The passenger should hug the driver with both hands and put both feet on the back pedals Protective Article Please select and wear a new helmet that adheres to Australia s standards Before riding please unsure that you have a safe helmet leather boots and appropriate clothing Please unsure that any passengers ...

Page 7: ...ell 4 Max loading capacity of luggage is 5kg 5 Certification should be moisture proof Our company is not responsible for the motorcycle damages caused from the above actions Checking before driving Before driving Check as following details Items to check Content of checking Steering stem Flexible turning no clearance and loosening Brake The brake light should be shining when the brakes are applied...

Page 8: ...n the handlebars is very dangerous make sure both of your hands and feet are in the correct riding position at all times 3 Do not brake through a corner Reduce to appropriate speed before taking the corner 4 When the roads are wet or icy please allow for extra time to slow down before the corner 5 Proceed with extra caution when exiting a tunnel in a valley passing a truck or when it is generally ...

Page 9: ... speed 13kw 8000r min Load capacity I50kg With driver Maximum torque Rotational speed 17N m 6000r min Allowed maximum weight 303kg Idling rotational speed 1500 150 r min Load capacity of front axle 107kg Working volume of Cylinder 250ml Load capacity of rear axle 196kg Spark plug D8EA Size of front tyre 110 70 17 Clarence of spark plug 0 6 0 7 mm Size of rear tyre 140 70 17 Air inlet valve 0 04 0 ...

Page 10: ...rminal transmission ratio Primary transitional ratio Data 2 91L 100km 1 2L 15 5L 3 083 2 063 1 450 1 130 0 957 0 815 3 231 3 091 Model Fuse Headlight Taillight Brake light Front position light Front turning signal Rear position light Battery Rear turning signal Ignition mode Data 15A 15W 12V 35Wx2 55W 12V 0 34W 1 4W 12V 2W 12V 1 2Wx2 12V 0 34W 12V7Ah 12V 0 25Wx2 CDI electronic ignition ...

Page 11: ...otorcycle Parts name 1 Clutch lever 2 LH rear mirror 3 Speedometer 4 Power switch 5 RH rear mirror 6 Front brake lever 7 LH handlebar 8 LH handlebar switch 9 Fuel tank lock 10 RH handlebar switch 11 Throttle grip 2 3 4 5 1 6 7 8 9 10 11 ...

Page 12: ...light 1 2 3 4 5 2 Rear view mirror 3 Fuel tank lock 4 Fuel switch 5 Rear indicators 6 Rear wheel 7 Rear shock absorber 8 Engine type and factory number 9 Gearshift pedal 10 Front shock absorber 11 Front disc brake 12 Front wheel 12 11 10 8 9 7 6 ...

Page 13: ...r Manual 1 Muffler 2 Rear disc brake 3 Seat assy 4 Rear braking pedal 5 Position of brand plate Name plate right side of frame 6 Identification No VIN Position Right side of standing tube 7 Gulp valve 7 1 2 3 4 5 6 ...

Page 14: ...ank is low 4 Gear indicator This Indicates which gear the motorcycle is currently in 5 Tachometer Indicates the rotational speed of engine r min 6 Right turning signal Indicator light flashes when turning right 7 High beam This light flashes when you turn on the high beam 8 Neutral indicator This light flashes when you are in neutral gear 9 Left turning signal Indicator light flashes when turning ...

Page 15: ...nd then connect air outlet tube to metal tube on the cylinder head Connect the negative pressure tube of the gulp valve with the air inlet tube on engine control the entry of air into the exhaust pipe through changing negative pressure in air inlet tube on the engine decrease CO HC and Nox 1 Negative pressure tube on gulp valve 2 Air inlet tube 3 Air outlet tube ...

Page 16: ...fuel tank cap by aligning the mark on the cap with that on the fuel tank Caution Use unleaded or low lead gasoline fuel graded 90 or higher 2 Use of the fuel valve switch on fuel tank 1 open 2 closed 3 reserve Caution if the fuel tank valve lever is in the open position quite often excessive fuel will enter the carburetor and may even flow into the engine If the engine is started in this condition...

Page 17: ... or without ventilating device because carbon monoxide is very toxic Do not get off the motorcycle with the engine running if noone is around to guard it Engine Start UP 1 Put key in ignition switch in the position of 2 Put the emergency stop switch in the position of 3 Confirm neutral position make sure the neutral indicator light is on 4 Check the amount of fuel 5 Turn the fuel valve cock to Ope...

Page 18: ...the emergency off switch is set to the position and the engine is in neutral gear Push this button to start the engine 3 Emergency shut off switch When engine is started the emergency shut off switch is normally set to the position In emergency situations the emergency off switch should be set to the position so as to shut off the power supply to the engine Warning When engaging the electric start...

Page 19: ...on indicates that the left indicator is on Position indicates that the right indicator is on 3 Horn Push this button to get a loud sound from the horn 4 High beam signal switch Used for cutting in Warning Use the indicators to change lanes and make turns Be sure to turn the indicator off once you have made the turn 1 Beam Switch 2 Indicator switch 3 Horn 4 High beam signal switch 1 2 3 4 ...

Page 20: ...position 2 Gradually Increase the rotation speed of the engine while slowly releasing the clutch lever so that the bike starts to slowly move forward 3 Once the bike has reached a balanced running state reduce the rotation speed of the engine then engage the clutch then raise the gear shift pedal to the 2nd gear position The same method can be used for the rest of the gears International Six speed...

Page 21: ...wn the engine meanwhile cut off clutch and then brake Warning 1 Higher speed longer braking distance Please ensure that you maintain a safe distance from the vehicle in front of you 2 An inexperienced driver usually uses the rear brake which speeds up the wear of the tire and lengthens braking distance 3 Lonely use of front or rear brake is dangerous which causes slip and runaway out of control Ca...

Page 22: ...larly Change the oil after the first 500kms After this change the oil every 2000kms however it is recommended to check the oil every 1000km While the engine is warm hot carefully remove the drain plug to drain the old oil Wash the oil screen Once properly re installed then pour 1 2L of new oil into the engine When finished start the engine and let it idle for 2 3mins After this time check to see i...

Page 23: ...w plugs out 2 Clean the surface of the spark plug If there is corrosion or excessive grit on the spark plug then replace them 0 6 0 7mm 3 Adjust the spark plug gap to 0 6 0 7mm 4 Please use specified spark plug Caution 1 Do not tighten spark plug to much or thread the rings to avoid damaging the cylinder cap While the spark plug is out please ensure that no dust or contaminants get into the spark ...

Page 24: ...ild up on the air filter If there is replace the air filter Caution Be sure that the air filter is installed correctly If it is install incorrectly dirt and other materials will do series damage to the engine Also when 1 Air in Nozzle washing the bike make sure that no water leaks down into the engine 2 Clip If you often ride the motorcycle in a dust area be sure to replace the air filter regularl...

Page 25: ... adjust Locknut Adjusting nut Warning After adjustment check the throttle grip Do not increase the idle speed of engine and make sure the throttle grip turns automatically to the Close position Fine tuning the carburetor 1 This motorcycle has passed the state III standard It is already finely tuned to this standard 2 Make sure the engine is hot when you tune the carburetor 3 Ensure that the motorc...

Page 26: ...t means the piston is on the top dead center of the compression stroke The valve can be adjusted If the rocker arm is tight it means the piston is on the bottom dead center of the exhaust stroke In this case continue turning the T wrench clockwise by 360 degrees until the line marks are aligned and then adjust the valve Check the valve gap by inserting a feeler gauge into the valve adjusting screw...

Page 27: ...n the right crankcase cover After adjustment start engine confirm clutch is working normally if it is skipping or is hard to put into gear than readjust Adjusting the brake pedal When checking the disc brake system hold the motorcycle upright with the side stand 1 The free moving distance of the rear brake pedal should be 15 25mm 2 After making the adjustment tighten the adjustment nut Caution Bra...

Page 28: ...ut the bleeder nozzle in the lowest position 3 Unscrew the bleeder nozzle to make the brake oil flow out freely 4 Add 30 50ml of new brake oil into the oil cylinder and empty the oil cylinder after old oil cylinder does not flow out 5 Screw down the bleeder nozzle wipe the brake oil off the brake caliper and mount the brake caliper on the motorcycle Secondly add new special brake oil into the oil ...

Page 29: ...nd push down and up on the rear brake pedal several times to let the brake lining fully fit to resume normal grasping force and to make the brake oil circulate all the way through 4 Steps and method of bleeding the brake system 1 Master pump bleeding Turn front wheel with RH master pump to left contrarily for LH master pump open the oil well cover and washer Move front brake lever repeatedly to ob...

Page 30: ...lubricating oil on chain Marks on left and right chain adjuster are at same position with scale mark on rear fork Warning Excessively loosening the chain may lead to the chain dropping off and may cause an accident It may also seriously damage the engine Adjustment for brake switch After the rear wheel has braked make sure the brake light is working in case it is not lighting up adjust regulating ...

Page 31: ...le 3 The battery contains sulfuric acid which will cause serious physical damage if it gets onto the skin or into the eyes In the case of contamination wash the contaminated part with water for five minutes and then call or go to the doctor immediately 4 Be sure that any foreign matters are kept from getting into the battery when removing or installing it 5 Make sure the battery vent tube is alway...

Page 32: ...e tire pressure within specified limit Front tire pressure 225kPa Rare tire pressure 250kPa Replacement of headlight Rated power of each lamp is as shown in the table Replace the blown lamp by the one with the same rated power If a lamp with different rated power is used The circuit system may be overloaded and the lamp may be blown Headlight 12v 35w x 2 55w Tail Brake light 12v 0 34w 1 4w Front l...

Page 33: ...65 75 M25X1 21 26 6 Specification M6X1 25 10 14 M8X1 25 22 32 7 Specification M12X1 25 55 61 8 Specification M10X1 25 35 45 9 Specification M8X1 25 17 23 10 Specification M14X1 25 65 75 Maintenance periodic table Maintenance should follow stipulated period Refer to table next page Means done by maintenance station If you have the specialized tools spare parts and know how maintenance could be done...

Page 34: ...g chain Each year R I I I I Idling speed of carburetor I L I L I L I L Driving chain I I I I Battery I I I Wear loss of brake pads Each month I I I I Rear brake system I I I Soft tube of brake fluid I I I I Cup of brake fluid 4 years R I I I I Brake fluid Front brake system 2 years R Light switch of rear brake Replace each 2 years Headlight dimmer I I I I Clutch 1 I I I I Side stand I I I Suspensi...

Page 35: ...r part of fuel tank and seat Carburetor Steering lock and ignition switch Speedometer 1 Flush the vehicle with clean water after washing it to remove remaining dirt and prevent rusting The plastic parts should be cleaned with cloth or sponge soaked with neutral cleaning detergent and then flushed with clean water 2 Lubricate the drive chain and run the engine at idle speed after the vehicle is cle...

Page 36: ...l oil is combustible therefore stop the engine on oiling and discharging and do not smoke near oil storage or other position in which the fuel oil is added NOTE Screw the key to OFF position before pushing the start arm in addition install the spark plug on the cap and ground it to prevent the ignition system from damage 4 Remove the battery keep it in a shady cool and ventilated area and recharge...

Page 37: ...on Motorcycle with electric start is on the basis of recoil starting partly improved electrical parts and then produced new type of motorcycle Starting by electricity only selected battery of 12V7Ah Clutch lever switch for starting is installed on left hand grip and equipped electric button on right hand grip for starting engine When starting turn the key to the position of ON tightly hold clutch ...

Page 38: ...38 Moto3 User Manual X Electrical schematic diagram ...

Page 39: ...39 Moto3 User Manual ...

Page 40: ...40 Moto3 User Manual ...

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