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Haojue HJ110-2, Service Manual

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FOREWORD

This manual contains an introductory description
on

HJ110-2/2A and procedures for their

inspection/maintenance and overhaul of their
main components. Other information considered
as generally known is not included.
A p p r e n t i c e m e c h a n i c s a n d d o i t y o u r s e l f
mechanics will also find this an extremely useful
repair guide.

HAOJUE

JIANGMEN DACHANGJIANG GROUP CO.,LTD.

October, 2008

This manual provides you with more informa-
tion about your motorcycle and ensures users
best and quickest service.
This manual is for those adequately informed
and skilled in the maintenance of HAOJUE
motorcycle. If you are not well-informed and
skilled in this respect, you should not attempt
to effect maintenance and repair only by the
help of this manual.
This manual contain up-to-date information at
the time of its issue. There might be minor
discrepancies between your motorcycle and
this manual as a result of modifications made
after the publication of this manual.
P l e a s e c o n t a c t y o u r n e a r e s t a u t h o r i z e d
HAOJUE motorcycle dealer.

*

*

*

https://www.motomanuals.net/

Summary of Contents for HJ110-2

Page 1: ...HJ110 2 2A 95500H51121H000 https www motomanuals net...

Page 2: ...https www motomanuals net...

Page 3: ...ma tion about your motorcycle and ensures users best and quickest service This manual is for those adequately informed and skilled in the maintenance of HAOJUE motorcycle If you are not well informed...

Page 4: ...1 1 1 2 1 2 1 2 1 3 GENERAL INFORMATION CONTENTS WARNING CAUTION NOTE GENERAL PRECAUTIONS SERIAL NUMBER LOCATIONS FUEL AND OIL RECOMMENDATIONS BREAK IN PROCEDURE SPECIFICATIONS 1 https www motomanual...

Page 5: ...SILICONE GREASE SYMBOLS The following symbols illustrate necessary information of directions and servicing Symbol Item Symbol Item SUPER GREASE A MOLY PASTE BOND No 4 THREAD LOCK BOND 1322 THREAD LOCK...

Page 6: ...rts replacement is necessary replace the parts with the HAOJUE GENUINE PARTs or their equivalent When removing parts that are to be reused keep them arranged in an orderly manner so that they may be r...

Page 7: ...e as follows p materials it is still necessary to before The future performance and reliability of the engine depend on 1 2 The break in mileage is 500 km The throttle must not be opened to the full d...

Page 8: ...ocal shift driving cyclic shift parking 4 speed gear transmission 4 059 2 571 2 833 1 705 1 238 0 958 428 100 links SPECIFICATIONS DIMENSIONS AND CURB WEIGHT Overall length Overall width Overall heigh...

Page 9: ...Dashboard panel light High beam indicator light Turn signal indicator light CHASSIS Front suspension Rear suspension Steering angle Caster Trail Turning diameter Front brake Rear brake Front tire siz...

Page 10: ...VE CHAIN BRAKES TIRES STEERING FRONT REAR LIGHTS AND SIGNAL LIGHTS CHASSIS AND ENGINE MOUNTING BOLTS AND NUTS COMPRESSION PRESS AIR CLEANER ENGINE OIL OIL STRAINER CLUTCH CARBURETOR ABSORBER MUFFLER M...

Page 11: ...spect Inspect Tighten Clean The first change at Initial 500 km the second change at 1 000km total mileage while further change Every 3 000 km Clean Every 12 000 km Replace Every 12 000 km Throttle cab...

Page 12: ...ars or 24 000 km Grease Grease Grease Throttle cable Throttle grip Odometer cable Speedometer gear box Drive chain Brake pedal axle Brake cam Steering bearing Rear rocker arm bearing bush PERIODIC MAI...

Page 13: ...R LOWER Once the battery is put into use no more diluted sulfuric acid should be poured Do not bend clog the exhaust pipe of the battery or alter its path Make sure that one end of the pipe is securel...

Page 14: ...ment to avoid breaking it Dip the element into the engine oil again squeeze out excessive oil to keep the element slightly wet Look carefully for fractures on the element before and during cleaning In...

Page 15: ...der head to the specified torque CYLINDER HEAD SIDE BOLT Specified torque 15 18 N m Specified torque 8 12 N m CYLINDER MOUNTING BOLT Tighten the cylinder connecting bolt to the specified torque Tighte...

Page 16: ...ed clockwise due to negligence it must then be rotated counterclockwise by two or more turns The adjusted valve can only be ensured to be correct when the T mark on the rotor is aligned with the mark...

Page 17: ...cap valve timing inspection plug and the generator cover cap SPARK PLUG Inspect at I Every 3 000 km nitial 1 000 km and Replace Every 12 000 km TORCH NHSP LD A6RC or A6RTC TYPE KIND O ring PERIODIC MA...

Page 18: ...ew motorcycle is 900 ml engine oil into the filling hole screw the filling hole cover properly to avoid over tightening Start the engine keep it at idle speed for several minutes Shut down the engine...

Page 19: ...1 turn do not overturn rotate the adjusting screw counterclockwise slowly until feeling a slight resistance Rotate the adjusting screw clockwise by 1 18 turn and tighten the lock nut to the specified...

Page 20: ...r Inspect at Initial 1 000 km and Every 3 000 km Replace Every four years FUEL HOSE AND SECONDARY AIR HOSE Check for damage fracture or fuel leakage on the fuel hose and secondary air hose as well as...

Page 21: ...inspection hole Chain sag Excessive chain sag may result in an accident caused by the chain falling off as well as severe engine damage ADJUSTMENT Loosen the rear axle nut and Rotate the adjusting nut...

Page 22: ...e upper lower chain guard Bolt Upper Lower If the chain is too dirty remove the chain and wash it before lubrication Disassemble the chain and chain board after removing the chain lock plate carefully...

Page 23: ...ural Check the bolts and nuts of drive and driven sprockets Tighten the bolts and nuts if they were loosed Install the chain onto the sprocket mount the connecting plate and the chain plate Install th...

Page 24: ...Note After adjusted check whether the arc slot of the nut is al igned with the round pin of the brake swinging arm FREE STROKE OF THE BRAKE PEDAL Free stroke Measure the free stoke of the top end of...

Page 25: ...at the lower right of the chassis To adjust it turn the nut and move it up and down Enable the brake light on when feeling a bit pressure by stepping down on the pedal TIRES Wear off limit Print Print...

Page 26: ...d Make sure the steering handlebar can move flexibly while the brake cables do not obstruct If the steering handlebar cannot move smoothly or shows radial run out check the steering column bearing car...

Page 27: ...and nuts for the motorcycle according to the table below CHASSIS AND ENGINE MOUNTING BOLTS AND NUTS Kick starter bolt Rear sprocket nut Torque link bolt nut Hub assy nut Brake cam lever bolt nut F R...

Page 28: ...e the connec tion absolutely tight Twist the throttle grip into wide open position Crank the engine several times with the starting motor and read the highest gauge indication as the compression of th...

Page 29: ...E PARTS WITH ENGINE UNREMOVED ENGINE REMOVAL AND REMOUNTING CYLINDER HERD AND VALVE CYLINDER AND PISTON CLUTCH AND GENERATOR STARTING CLUTCH AND TIMING CHAIN TENSIONER CRANKSHAFT TRANSMISSION AND KICK...

Page 30: ...ing the engine Refer to sections about parts dismounting and remounting LIFT SIDE OF ENGINE RIGHT SIDE OF ENGINE ENGINE PARTS CYLINDER HEAD COVER CYLINDER HEAD CAMSHAFT CYLINDER PISTON RIGHT CRANKCASE...

Page 31: ...oil Remove the front panel the front left right side covers the central guard the suffer cover the saddle the rear bracket the tail cover and the left right side cover Remove the muffler mounting nuts...

Page 32: ...he starting motor Loosen the rear wheel axle nut lock nut and the sprocket adjusting nut Terminal Push the rear wheel axle forward to enable the chain to be loose enough Remove the gear rod and the bo...

Page 33: ...procket bolts the gasket and the sprocket Loose the engine mounting nuts Support the engine with a jack or wooden block to facilitate removing the lower mounting bolt Remove the mounting bolts and the...

Page 34: ...35 45 N m Mount the chain on shaft put on the gasket and sprocket bolts and tighten them to the specified torque Specified torque 8 12 N m ENGINE 3 5 CAUTION Engine mounting bolts nuts Sprocket bolts...

Page 35: ...er to page 2 14 ENGINE 3 6 Mount the new O ring into the groove of the intake pipe and tighten the bolts of the intake pipe to the specified torque Bolt Specified torque 8 12 N m Specified torque 18 2...

Page 36: ...crank hole cover and timing hole cover Rotate the crankshaft counterclockwise align the T mark on the generator rotor to the mark on the left crankcase Make sure that the mark on the camshaft sprocket...

Page 37: ...r head cover and sealing gasket Copper washer Remove the side bolt and the cylinder head Remove the sealing gasket and pin of the cylinder head Gasket Pin CYLINDER DISASSEMLY Remove the bolts and righ...

Page 38: ...ate Remove the camshaft from the cylinder head Remove the valve spring clamp by using the special tool Do not over press the spring to avoid loss of elasticity Remove the following parts Valve seat In...

Page 39: ...d output power The limit of cam wear is specified for both intake and exhaust cams in terms of cam height which is to be measured with a micrometer Replace the camshaft if fount it worn down to the li...

Page 40: ...eck the evenness of the cylinder head plane with ruler and thickness gauge Service limit ROCKER ARM Check for damage or wearing on the sliding surface of the rocker arm Check whether the oil hole is c...

Page 41: ...NER OUTER VALVE Check if the valve is bent burnt or abnormally worn Check for valve motion in the valve tube measure the O D of the valve Standard IN EX Remove carbon first before examine the valve tu...

Page 42: ...grind If the surface of the valve is severely burnt damaged or shows an uneven seat surface replace the valve Measure the width of every valve seat plane Standard Valve seat width VALVE SEAT SERVICIN...

Page 43: ...p surface of the original valve seat by 1 4 of its width with 30 tooling Grind the bottom of the original valve seat by 1 4 of its width with 60 tooling Process the valve seat surface to standard heig...

Page 44: ...oo high finish it with 30 tooling to reduce the height If the contact face of valve is too low finish it with 60 tooling to increase the height Finish the valve seat surface again to standard range wi...

Page 45: ...t Valve spring Clean the cylinder head with detergent and blow the tube with compressed air Install the valve spring seat ring and new oil seal Lubricate the valve stem with Moly Paste then insert it...

Page 46: ...he surface of oper ation table to prevent from valve damage After applying engine oil on the camshaft and bearing install the camshaft into the cylinder head aligning the camshaft toward the combustio...

Page 47: ...and install the right side cover onto the cylinder head Install and tighten the nut of right side cover to the specified torque Specified torque 8 12 N m CYLINDER REMOUNTING Remove the used sealing g...

Page 48: ...en the cylinder head nut to the specified torque Rotate the crankshaft counterclockwise align the T mark on the generator rotor to the dent on the left crankcase Specified torque 8 12 N m Specified to...

Page 49: ...enter of the cylinder head Mount the M6 bolt with new sealing gasket on the right side cover and tighten it Adjust the valve clearance refer to page 2 6 Apply engine oil on the thread of watch hole pl...

Page 50: ...PISTON DISASSEMBLY Remove the piston pin circlip with circlip pliers NOTE Insert a piece of clean cloth into the contact face between the crankcase and the cylinder case to prevent the piston pin circ...

Page 51: ...Y directions on three levels and determine the cylinder wear with the maximum value Service limit Service limit Examine the evenness of the cylinder top as shown in the right figure Remove the carbon...

Page 52: ...Check for damage or wearing of the piston Measure the piston O D at 15 mm along the vertical direction of the piston pin Service limit Service limit Service limit Service limit Measure the hole inner...

Page 53: ...Align the mark on the piston ring upward during assembly pay attention to distinguish the marks of the top ring and the second ring Keep the opening of each ring cross at 120 do not leave the oil rin...

Page 54: ...Y Install the dowel pin and new sealing gasket Apply engine oil on the outer surface of the piston as well as on the ring slot and inner cylinder wall Compress the cylinder installed with piston rings...

Page 55: ...leave it untighten first Install the cylinder head and tighten the bolts and nuts Tighten the cylinder bolt to the specified torque Assemble the removed parts in the reversed order of disassembly Spe...

Page 56: ...kick starter lever Remove right crankcase cover after unscrew the bolts RIGHT CRANKCASE COVER Remove the clutch lock nut washer O ring and clutch adjusting bolt HJ110 2 Lock nut adjusting bolt Lock n...

Page 57: ...condition replace it if necessary CLUTCH DISASSEMBLY DOUBLE CLUTCHING HJ110 2 Remove the clutch manipulating rod and push pedal Push pedal Manipulating rod Remove the screws and oil filter rotor cove...

Page 58: ...k nut with special tool Remove the lock spacer lock washer and primary clutch drive disc clutch shoe assy Remove the clutch bearing Fix the drive and driven gears loose the lock nut of shift clutch Sp...

Page 59: ...ut lock washer and gasket Remove the bolt for oil separating cover Remove the primary clutch enclosure clutch and oil separating cover as a whole Remove the washer from crankshaft ENGINE 3 30 https ww...

Page 60: ...move the oil pipe and pipe spring Remove the separating arm and separating cam of the clutch Dismantle the washer and end cover screws Remove the end cover of the clutch SINGLE CLUTCHING HJ110 2A ENGI...

Page 61: ...gear and its circlip Rotate the driving disc and inspect the operation conditions of the one way clutch Confirm that the driving disc can only rotate clockwise and not counterclockwise PRIMARY CLUTCH...

Page 62: ...rclip and washer Remove the roller and starting clutch spring Remove the inner cover of the starting clutch Check for damage or wearing on the roller and spring replace it if necessary Check for damag...

Page 63: ...HOE Check for wearing of the clutch centrifugal shoe Measure the thickness of every clutch centrifugal shoe Service limit Remove the shaft circlip and washer Lift the clutch centrifugal shoe remove th...

Page 64: ...aring of the clutch centrifugal shoe Check for scratch or wear off on the inner surface of the clutch enclosure Measure the clutch enclosure O D Rotate the pinion to check for wearing Measure the I D...

Page 65: ...EMBLY Apply engine oil on the surface of pin axle of for the driving disc Install the circlip STARTING CLUTCH REASSEMBLY Apply clean engine oil on the sliding surface of starting clutch Install the in...

Page 66: ...clutch driven hub friction plate and driven plate Remove the pressing disc Rotate the inner loop of the push pedal bearing by hand The bearing must revolve smoothly without excessive clearance If nece...

Page 67: ...for damage or wearing of the driven hub replace it if necessary Replace the friction plate which is burnt or whose color is changed Measure the thickness of the friction plate Examine the evenness of...

Page 68: ...clutch enclosure Remove the driven hub friction plate and driven plate onto the clutch jacket Install the clutch spring push pedal and bolt NOTE Fix the clutch jacket with rotor clamp then tighten the...

Page 69: ...and return spring DISASSEMBLY GEAR SHAFT ROD Pull down the shift arm remove the shift shaft Remove the bolt and the shift shaft guard Remove the pins of the shift rod and the pins of the shift shaft g...

Page 70: ...e shift camshaft drum then install the guard the pins of the shift and the pins of the shift shaft guard c Tighten the bolt to the specified torque Apply engine oil at the oil seal of the starting sha...

Page 71: ...torque Install the clutch and the primary clutch as a whole refer to page 3 41 Install the shaft and tighten the bolt Install the clutch rod align the boss to the hole on crankcase cover Put the new O...

Page 72: ...mage the lip of the oil seal of the kick starter shaft Install a new oil seal of the kick starter shaft and apply engine oil on the lip of the oil seal Install and tighten the bolts of the right crank...

Page 73: ...assembly Remove the bolt and plate loosen the wire clip of the generator at the left crankcase cover Remove the bolt and the generator assy from the left crankcase cover Install the generator assy on...

Page 74: ...her Remove the rotor with the special tool Remove the semi circular key from crankshaft Remove the generator rotor Remove the guide plate and the protector of the starting sprocket Remove the bolt and...

Page 75: ...enclosure Remove the 3 screws on the starting clutch enclosure with an impact screwdriver Remove the starting clutch enclosure side board and dowel pin Check of damage or wearing of the starting drive...

Page 76: ...eck for damage or wearing of the starting clutch ASSEMBLY Pin Rotor Side plate Sping Roller Starting clutch cover Thimble Pin Side plate Install the side plate align the hole to the pin ENGINE 3 47 OI...

Page 77: ...Apply THREAD LOCK BOND 1342 on the screw thread and tighten it to the specified torque Install the roller spring cover and roller of the starting clutch Push the spring as shown in the figure install...

Page 78: ...r clockwise Install the starting drive and driven sprockets as a whole Put the shaft snap ring into the slot on the starting motor shaft Apply engine oil on the starting chain protector guiding plate...

Page 79: ...he oil separating cover Remove the seal ring bolt tension spring and rod Remove the tension arm bolt tension arm and tension roller Check the free length of tension spring INSPECTION ENGINE 3 50 https...

Page 80: ...arm to the specified torque Install tension rod and spring Check that the seal ring is undamaged install the seal ring bolt and tighten to the specified torque Remove the sealing bolt and washer of t...

Page 81: ...cket Clean the grease on the crankshaft and rotor install the semi circular key Install the washer and rotor nut fix the rotor with special too kit then tighten the lock up nut to the specified torque...

Page 82: ...CRANKCASE DISASSEMBLY Remove the starting motor Remove the shaft snap ring from the kick starter shaft Loosen the return spring remove the spring and the seat Remove the bolt and the gear position swi...

Page 83: ...diagonal sequence Dismantle the crankcase with the left crankcase facing downwards Remove the sealing gasket and dowel pin CRANKSHAFT DISASSEMBLY Remove the crankshaft from the left crankcase ENGINE 3...

Page 84: ...of the connecting rod with thickness gauge Service limit Measure the radial clearance at the larger end of the connecting rod at the symmetrical points as shown in the figure Service limit Rotate the...

Page 85: ...un out with a dial gauge Service limit REASSEMBLY Install the oil pump sprocket and shaft after applying engine oil on the inner surface of the sprocket Pour a little engine oil into the crankshaft be...

Page 86: ...a whole Disassembling the main shaft counter shaft and shift hub INSPECTION Check the gear engaging flange flange hole or gear teeth of abnormal wear off or insufficient lubrication Check the gear sha...

Page 87: ...T M1 gear 12T REASSEMBLY Reassembly in the reversed order of dis assembly NOTE Apply the engine oil on the rotating sliding area and the side of the shaft and gear Counter shaft Main shaft ENGINE 3 58...

Page 88: ...Remove the clamp of the guide pin Remove the guide pin then the fork Check for damage or wearing of the shift hub Measure the inner diameter of the shift hub Service limit Measure the thickness of the...

Page 89: ...f the fork pin mount the fork on the shift hub Install the guiding pin and clamp Rotate every bearing by hand Check for rotation smoothness as well as the movement of the outer ring in the crankcase r...

Page 90: ...er 09924 84510 Bearing installer 09913 75820 Bearing installer 09913 80112 Bearing installer TOOL Remove the oil seal of the counter shaft Remove the bearings of left right crankcase with special tool...

Page 91: ...ft counter shaft and shift hub into the left crankcase as a whole rotate the shift hub check the operation of the shaft KICK STARTER DISASSEMBLY Remove the kick starter assembly from the left crankcas...

Page 92: ...defective Check for damage or wear off on each part replace if necessary Assembly in the reversed order of dis assembly NOTE Direction of the snap ring Apply engine oil on the rotating sliding sectio...

Page 93: ...ny rough or uneven plane with whet stone if necessary Lubricate the camshaft bearing and other con tact area with engine oil Install the return spring and spring seat on the start shaft NOTE Install t...

Page 94: ...he air filter intake pipe secondary air valve and secondary intake tube to blend with the exhaust gas generated by in engine combustion of secondary combustion and the exhaust gas will be expelled thr...

Page 95: ...Air REMOVAL AND INSPECTION Remove the fixing bolt of the secondary air valve Unplug the intake tube negative pressure tube and intermediate tube remove the secondary air valve Check for damage or twi...

Page 96: ...lace it if it has damnification Check the reed valve and the valve seat face replace the reed valve if reed distortion REMOUNTING Remount the secondary air valve in the reversed order of disassembly V...

Page 97: ...1 4 1 4 2 4 7 4 8 4 FUEL AND LUBRICATION CONTENTS AIR CLEANER CARBURETOR FUEL TANK LUBRICATION SYSTEM https www motomanuals net...

Page 98: ...wire clip and rear cover assy Remounting in the reversed order of removal DISASSEMBLY AND REASSEMBLY Remove the screws and upper cover of the air cleaner Remove the screws front cover and air cleaner...

Page 99: ...0 5 1 0 mm Carburetor type Bore size I D No Idle Main fuel jet Bubbler Idle jet Idle screw Fuel needle Throttle cable play CARBURETOR FUEL AND LUBRICATION 4 2 WARNING Fuel is flammable and explosive...

Page 100: ...s the carburetor and the thermal insulation pad FUEL AND LUBRICATION Carburetor cover Throttle valve CARBURETOR THROTTLE VALVE Remove the front panel and the front left right covers Compress the throt...

Page 101: ...uel jet Bubbler Idle jet FUEL AND LUBRICATION Check for damage or wearing of each jet replace it if necessary Main jet 4 4 CARBURETOR DISASSEMBLY Remove the screws and the float chamber body Float cha...

Page 102: ...tall the new O ring into the slot on the thermal insulation pad and carburetor body Install the throttle valve on the carburetor body align the idle screw Remount in the reserved order of the removal...

Page 103: ...screw lightly to the end clockwise and then return to the specified turns Turns The idle air screw seat may be damaged if it is over tightened CAUTION Idle air screw Idle screw ON Tighten the drain sc...

Page 104: ...LUBRICATION 4 7 WARNING Dismantle the following parts Saddle Protective covers Disconnect the fuel level sensor connector Remove the 4 bolts of fuel tank Lift the fuel tank remove it after disconnect...

Page 105: ...LUBRICATION SYSTEM Rocker arm Rocker arm shaft Piston Camshaft Crankshaft Filter rotor Start shaft Countershaft Principal axis Oil strainer Oil pump FUEL AND LUBRICATION 4 8 https www motomanuals net...

Page 106: ...5 15 5 19 5 21 5 28 5 31 5 5 5 CHASSIS CONTENTS EXTERIOR PARTS REMOVAL AND REMOUNTING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT ABSORBER STEERING REAR WHEEL REAR HUB REAR SWING ARM REAR ABSORBER https w...

Page 107: ...nt right side cover Front right turn light Right side cover V I N cover Battery box Tail light Tail cover Rear fender upper part Fuel tank Handlebar front hood Headlight Handlebar Dashboard Dashboard...

Page 108: ...ing screws and remove the and dashboard cover handlebar front hood Disconnect the brake switch connector and starting switch Remove the screws and the dashboard connector Remove the screws washer and...

Page 109: ...and remove the throttle grip Remove the bolt and nut of the handlebar The handlebar can be mounted in the reverse order of removal REMOUNTING CHASSIS 5 3 Specified torque 45 55 N m Tighten bolt and nu...

Page 110: ...ve the brake drum cover from the left Place the wheel axle on a V shaped block and measure the radial run out Actual run out should be 1 2 of the reading Service limit Rotate the inner ring of each be...

Page 111: ...ment with a micrometer examine radial run out of the hub Actual run out should be 1 2 of the reading Service limit Axial Radial Remove the oil seal bearing or bush from the right of the hub and check...

Page 112: ...he bushing then tap another new bearing into the left side with the sealing side facing outwards SUPPER GREASE A Do not reuse used bearings Replace with new bearings once they are removed Check the ra...

Page 113: ...front wheel between the bottom of the two absorbers Install the front wheel axle from the right side after applying a bit of grease Install and tighten the nut for the wheel axle to the specified tor...

Page 114: ...vice limit Measure the inner diameter of the wheel hub Remove the brake shoes and the springs Remove the counter wheel and dust proof sealing gasket Remove the nut bolt and brake arm Remove the indica...

Page 115: ...9000 25010 SUPPER GREASE A Apply on the lip of the new dust proof seal ring and then install it into the brake drum cover Apply on the counter wheel and then install it into the brake drum cover SUPPE...

Page 116: ...e brake cam with the wider tooth aligned to the wider slot on the brake cam Install the brake arm with its mark aligned to that on the brake cam Mount the bolt of the brake arm then tighten the bolt t...

Page 117: ...loosen the bolt of the front absorber and remove the front absorber DISASSEMBLY Take off the bush of the front absorber spring and spring seat Incline the front absorber push it several times and drai...

Page 118: ...Remove the inner tube from the outer tube Remove the retaining ring Remove the oil seal with special tool Removed oil seals must not be reused New oil seals must be used INSPECTION PISTON RING Check f...

Page 119: ...eplace it Service limit Reassemble and remount the front absorber in the reverse order of disassembly and removal and also carry out the following steps DAMPER ROD BOLT Apply BOND No 4 and THREAD LOCK...

Page 120: ...g meets specifications below Special absorber oil Capacity each leg Upside ABSORBER SPRING When installing the front absorber spring the close pitch end should toward upside REMOUNTING When installing...

Page 121: ...ove the screws nuts bush and seat of the steering handlebar Remove the nut and washer Remove the lock up nut Removal the following parts upper circlip upper steel ball 23 steering stem lower steel bal...

Page 122: ...tool kit or similar Do not damage the steering stem when disassembling the guard bowl Remove dust proof sealing gasket and washer Install washer of steering stem apply grease on the lip of the new dus...

Page 123: ...ease on the upper and lower guard bowl 99000 25010 SUPPER GREASE Number of balls Upper Lower Insert the steering stem into the vertical tube pay attention to not leave the steel balls out Install the...

Page 124: ...ut Install the steering handlebar seat on the steering stem Align the thread hole bolt sleeve nut and lock up screw and tighten the nut to the specified torque Install the following components Steerin...

Page 125: ...ear wheel axle nut and the chain adjuster Remove the rear wheel axle and bushing from the left Move the rear wheel to the right remove it from the sprocket hub Remove the rear wheel by pulling it back...

Page 126: ...the inner loop of the bearing by hand the rotation should be smooth without abnormal noise Check if the outer ring of the bearing fits tightly with the hub If not replace the bearing immediately Note...

Page 127: ...ring of the rear wheel hub Note Replace with new bearings once they are removed REASSEMBLY Install the right left bearings after filling the bearing cavity with grease 99000 25010 SUPPER GREASE CHASSI...

Page 128: ...he slot of the hub Do not let the grease move into the hub or brake performance may be affected Mount the brake drum cover on the right side of the wheel hub REMOUNTING Put the rear wheel into the cha...

Page 129: ...r and the nut of the rear wheel axle Install the following parts Spring pin Adjusting nut Stop screw Rubber gasket washer Tighten the stop nut Install a new dowel pin Adjust the rear brake refer to pa...

Page 130: ...porarily and remove the driven sprocket and the nut Remove the left bushing and sealing gasket INSPECTION Check for damage or wear of the sprocket and replace with a new sprocket immediately if damage...

Page 131: ...place the used with new ne once they were removed bearing o REASSEMBLY Apply grease on the lip of the seal ring then install it into the sprocket hub Install the left sleeve apply engine oil on the th...

Page 132: ...of the rear brake hub Service limit DISASSEMBLY Remove the brake shoe and the spring Replace the brake shoe in pairs If the shoe skin is removed make a mark for correct reassembly Spring Brake shoe R...

Page 133: ...ng grease on the dowel pin and brake cam Apply engine oil on the oil seal and install it onto the rear brake drum cover Install the indication plate on the brake cam with the wider tooth aligned to th...

Page 134: ...rear brake drum cover on the rear wheel hub Install the rear wheel Specified torque 7 10 N m REAR SWING ARM REMOVAL Dismantle the following components Muffler Sprocket hub Release the return spring of...

Page 135: ...nd washers of the lower part of rear absorbers Remove the rear rocker arm as well as the nut and axle Dismantle the following parts Dowel pin Nut washer Stop bolt Anchor rod DISASSEMBLY Dowel pin Anch...

Page 136: ...ge or wear of the rear rocker arm INSPECTION REASSEMBLY Install the chain guide Install the anchor rod stop bolt washer and nut then tighten the nut Install new dowel pin to lock the nut Dowel pin Anc...

Page 137: ...torque Tighten the bushing nut to the specified torque Tighten the rear wheel axle nut to the specified torque Check the free travel of the rear brake pedal refer to page 2 14 Specified torque 40 50...

Page 138: ...1 6 1 6 3 6 4 6 7 6 8 6 8 6 10 6 ELECTRICAL CONTENTS IGNITION SYSTEM CHARGING SYSTEM STARTING SYSTEM DASHBOARD LIGHTS SWITCHES BATTERY https www motomanuals net...

Page 139: ...generated by the signal generator flows to the SCR through the ignition time testing circuit to activate the SCR Thus a high voltage current is generated between the spark plug and the electrode by t...

Page 140: ...result is not necessary If the winding is normal take a record about the approximate values Ignition coil resistance Primary Secondary 0 24 0 36 3 15 3 85 k ELECTRICAL 6 2 SPARK PLUG Unplug the spark...

Page 141: ...test be sure that the battery is full charged condition 5000 r min 14 0 15 0 V Standard charging output 09900 25002 Pocket tester AC GENERATOR NO LOAD PERFORMANCE Disconnect the three lead wires from...

Page 142: ...dlebar switch box energizes the relay causing the contact points to close which connects the starting motor to the battery The starting motor draws about 80 amperes to start the engine Starting relay...

Page 143: ...ith 400 or similar fine emery paper when it is dirty After polishing it wipe the commutator with a clean dry cloth Check the commutator under cut ARMATURE COIL Using a pocket tester check the coil for...

Page 144: ...ION Disconnect lead wire of the starting motor at starting relay Turn on the ignition switch inspect continuity between the terminals positive and negative when pushing the starting button If the star...

Page 145: ...pocket tester check the continuity between lead wires in the following diagram If the continuity measured is incorrect replace the respective part NOTE When making this test it is not necessary to rem...

Page 146: ...LIGHTS HEADLIGHT TAIL BRAKE LIGHT TURN SIGNAL REAR TURN SIGNAL FRONT ELECTRICAL 6 8 https www motomanuals net...

Page 147: ...et tester referring to the chart If it is found any abnormality replace the respective switch assembly with new one TOOL 09900 25002 Pocket tester IGNITION SWITCH LIGHTING SWITCH STARTING SWITCH FRONT...

Page 148: ...Lbl Lg G O W B O Y Bl G Bl R B W Y Bl GEAR POSITION INDICATOR LIGHT SWITCH DIMMER SWITCH TURN SIGNAL LIGHT SWITCH HORN SWITCH Ground Neutral Low 2nd 3rd 4th REAR BRAKE LIGHT SWITCH ELECTRICAL 6 10 htt...

Page 149: ...harging current Charging time The charging time for a new battery is determined by the number of months that have elapsed since the date of manufacture Confirmation for date of manufacture The manufac...

Page 150: ...ery Be careful not to permit the electrolyte temperature to exceeded 45 at any time during the recharging operation Interrupt the operation as necessary to let the electrolyte cool down Recharge the b...

Page 151: ...1 7 1 7 8 7 10 7 12 7 16 7 18 7 SERVICING INFORMATION CONTENTS TROUBLESHOOTING SPECIAL TOOLS TIGHTENING TORQUE SERVICE DATA WIRE AND CABLE ROUTING WIRING DIAGRAM https www motomanuals net...

Page 152: ...arburetor 1 Clogged hole in the fuel tank cap 2 Clogged or defective fuel cock 3 Defective carburetor needle valve 4 Clogged fuel hose 5 Clogged fuel filter Excessive valve chatter 1 Valve clearance t...

Page 153: ...lls easily Clean Replace Replace Clean Clean Adjust Clean or replace 1 Fouled spark plug 2 Defective trigger coil 3 Defective ignitor unit 4 Clogged fuel hose 5 Clogged jets in carburetor 6 Valve clea...

Page 154: ...lean 1 Clutch control out of limit or loss of play 2 Weakened clutch springs 3 Worn or distorted pressure plate 4 Distorted clutch plates driven and drive Adjust Replace Replace Replace Slipping clutc...

Page 155: ...ke lever Replenish fluid to specified lever bleed air Replace with correct fluid 1 Insufficlent tightening of connection joints 2 Cracked hose 3 Worn piston and or cup Tighten to specified torque Repl...

Page 156: ...Tune up Adjust Retighten Adjust carburetor 1 Open or short in lead wires or loose lead connections 2 Shorted grounded or open generator coils 3 Shorted or destroyed regulator rectifler Repair or repl...

Page 157: ...ation Replace the battery and correct the charging system Replace the battery Recharge the battery fully and adjust electrolyte S G Replace the electrolyte recharge the battery and adjust the S G Repl...

Page 158: ...mm 09900 20101 vernier caliper 1 50mm 150mm 09900 21304 V block set 100mm 09900 20605 dial calipers 1 100mm 10 34mm 09900 20103 vernier caliper 1 50mm 300mm 09900 25002 pocket tester 09915 64512 cylin...

Page 159: ...SERVICING INFORMATION 11F14 001 rotor holder 11F14 002 rotor separator 11F14 010 front absorber tool 11F14 011 four claw wrench 11F14 018 valve spring tool 7 9 https www motomanuals net...

Page 160: ...cover bolt Primary drive gear oil pump drive gear nut SERVICING INFORMATION 4 5 5 5 3 5 5 5 2 5 3 5 4 8 5 76 1 5 2 0 3 5 4 5 2 5 3 5 2 0 3 0 1 8 2 8 4 8 5 8 0 6 0 8 0 7 1 0 4 0 5 0 1 0 1 6 1 8 2 8 1...

Page 161: ...6 0 7 0 10 0 11 0 16 0 17 0 25 0 20 0 28 0 0 1 0 2 0 2 0 4 0 4 0 7 1 0 1 6 2 2 3 5 3 5 5 5 5 0 8 0 8 0 13 0 13 0 19 0 1 0 2 0 2 0 4 0 4 0 7 0 10 0 16 0 22 0 35 0 35 0 55 0 50 0 80 0 80 0 130 0 130 0 1...

Page 162: ...m Valve clearance cold Unit mm Valve stem deflection Valve guide to valve stem clearance Valve guide I D Valve stem O D Valve stem runout Valve seat width Valve spring free length IN or EX IN EX IN IN...

Page 163: ...d big end oil clearance Crankshaft runout Crank pin O D Clutch cover I D Primary drive gear I D Drive plate thickness Driven plate distortion Clutch spring free length Primary reduction ratio Final re...

Page 164: ...SPENSION ITEM STANDARD LIMIT NOTE Front absorber stroke TORCH A7RC or T NHSP LD A7R C 0 6 0 8 mm 0 24 0 36 3 15 3 85 k 12N5 3B 12V 5AH 1 280 0 01 20 15 A ITEM STANDARD LIMIT Ignition timing Spark plug...

Page 165: ...Front Rear Tire tread depth Tire size Wheel axle runout Wheel rim runout Brake drum I D Rear brake pedal free travel COLD INFLATION TIRE PRESSURE SOLO RIDING DUAL RIDING FRONT REAR ITEM SPECIFICATION...

Page 166: ...or wire Gear position switch wire 1 clamp PVC pipe 2 starting motor wire more length clamp front Rear brake switch wire outside Engine right suspension plate Starting motor connector Clamp wire bunch...

Page 167: ...clamp PVC pipe 2 starting motor wire more length clamp front Rear brake switch wire outside Engine right suspension plate Starting motor connector Clamp wire bunch sign Adhibit sponge Battery pipe Wi...

Page 168: ...IGNITION COIL REG REC IGNITER R BRAKE SW FUEL LEVEL GAUGE FUSE BATTERY GEAR POSITION SW GENERATOR STARTING MOTOR STARTING RELAY IGNITION SW HORN TURN RELAY HORN SW TURN SIGNAL SW DIMMER SW WB BW Gr B...

Page 169: ...Printed in China October 2008 JIANGMEN DACHANGJIANG GROUP CO LTD https www motomanuals net...

Page 170: ...nce P R C Telephone 86 750 3288999 Fax 86 750 3288333 Postcode 529000 Address No 5 Jiandabei Road Jiangmen City Guangdong Province P R C Telephone 86 750 3288999 Fax 86 750 3288333 Postcode 529000 JIA...

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