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CABLE AND ELECTRIC APPLIANCE SYSTEM

187

The troubleshooting

Check steps:

1. Fuse

2. Battery

Flasher, brake lamp / or indicator lamp fail to come on. The horn doesn

t work

3. Main switch

4. Wiring connection

Discharge the following parts before troubleshooting

Side cover

Seats

Use the following special tools for trouble shooting:

Note

Pocket tester

continuity

No continuity

The fuse tube is broken replace it.

Incorrect

2. Battery

Check the battery condition

Eletrolyte specific gravity: 1.280 20

1. Fuse

Tale off the fuse

Check the fuse tuber (

1) to the fuse tube for

Replenish destilled water

Clean battery terminal

Charge or replace it

Incorrect

The main switch is failure, replace it

Poor connection

Correct

3. Main switch

Discharge the main switch coupler form wire harness

Check the continuity between

red and brown

main switch

Repair it

Check each circuit condition of signal system

Refer to

signal system check

section.

4. Wiring connections

Check the entire signal system coupler

Refer to

Circuit Diagram

section

Correct

Содержание JS125-6B

Страница 1: ......

Страница 2: ...P P...

Страница 3: ...orwarded to all authorized Jianshe Group dealers and will appear in future editions of this manual where applicable IMPORTANT INFORMATION Particularly important information is distinguished in this ma...

Страница 4: ...ly engine oil 8 Apply gear oil 9 Apply molybdenum disulfide oil 10 Apply wheel bearing grease 11 Apply lightweight lithium soap base grease 12 Apply molybdenum disulfide grease 13 Apply fluid locking...

Страница 5: ...dtypeoflubricants 21 Enginelubricationflow 23 CHAPTER 3 PERIODIC INSPECTION AND ADJUSTMENT Introduction 26 Periodicmaintenance lubrication 26 Disassemble and install the seat cushion oil tank and cove...

Страница 6: ...brake 45 Check the rear brake shoes 45 Check the rear brake switch 45 Check and adjust the drive chain 46 Check front fork 47 Adjust rear shock absorber 47 CheckTire 48 Checksteeringdevice 49 Check b...

Страница 7: ...64 Valve 65 Check and repair 66 Cylinderhead 66 Valveseat 67 Valveandvalveguide 69 Valve spring 70 Camshaft 70 Rocker arm and rocker arm shaft 71 Timingchain sprocket chainguideplateandchaintensioner...

Страница 8: ...shaft kick starter axle and kick starter idle gear 94 Clutch oilpump 97 Timingsystem 102 Cylinderandpiston 106 Cylinderhead 107 Cam shaft and dowel pin 108 Intake and exhaust system 109 Carburetor 10...

Страница 9: ...ctricdeviceprinciple 158 Electricappliance 159 Componentsofelectricappliance 161 Ignitionsystemdiagram 165 Starting motor 174 Chargingsystem 178 Lighting system 181 Signalsystem 186 CHAPTER 7 TROUBLES...

Страница 10: ...P P...

Страница 11: ...CHAPTER 1 GENERAL INFORMATION...

Страница 12: ...f 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 VIS Engine Ser No The N...

Страница 13: ...the use of inappropriate tools or improvised techniques Use appropriate tools and metro logic instrument for replacement Use double offset ring spanner and socket key in stead of non adjustable wrenc...

Страница 14: ...er to prevent mix and loss The parts of the engine transmission must be cleaned by oil and dried by compressed air after knocked down 8 Defer to each part to confirm while assembling Screw down from i...

Страница 15: ...bolt or nut has been tightened to specification Bearings and oil seals Install bearings and oil seals so that the manufactures marks of numbers are visible When in stalling oil seals apply a light coa...

Страница 16: ...niques Slide hammer bolt Weight Drawing Special tools name Crankcase separating tool Crankshaft installer set Crankshaft installer bolt Joint of different diameter tide Spacer Crankshaft installer too...

Страница 17: ...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 check...

Страница 18: ...P P...

Страница 19: ...CHAPTER 2 SPECIFICATIONS...

Страница 20: ...10 SPECIFICATIONS General specifications SAE 20W 40 SAE 10W 30...

Страница 21: ...SPECIFICATIONS 11...

Страница 22: ...12 SPECIFICATIONS...

Страница 23: ...SPECIFICATIONS 13 Check the Specification...

Страница 24: ...14 SPECIFICATIONS...

Страница 25: ...SPECIFICATIONS 15...

Страница 26: ...16 SPECIFICATIONS...

Страница 27: ...SPECIFICATIONS 17...

Страница 28: ...18 SPECIFICATIONS Lock torque Engine...

Страница 29: ...SPECIFICATIONS 19 Body frame...

Страница 30: ...ial number 5 Then a special gasket of the nut serial number is assembled a retaining pawl should be jammed in the furrows of the nuts serial number and in the meantime If the furrows are not aligned t...

Страница 31: ...SPECIFICATIONS 21 Lubrication point and type of lubricants Engine...

Страница 32: ...22 SPECIFICATIONS Body YAMAHA 4 Stroke engine oil Light lithium base grease Special grease...

Страница 33: ...SPECIFICATIONS 23 Engine lubrication flow Valve arm intake Rocker shaft Valve arm exhaust Cam shaft Fine oil filter Oil pump Push rod Filter net...

Страница 34: ...24 SPECIFICATIONS Cam shaft Filter net assy Crankshaft assy Main axle Drive axle Clutch assy...

Страница 35: ...CHAPTER 3 PERIODIC INSPECTION AND ADJUSTMENT...

Страница 36: ...aintenance 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 machin...

Страница 37: ...Lithium soap base grease 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 2 The oil se...

Страница 38: ...serial number Take out the side cover on the direction of the arrow serial number points 2 Disassemble the side cover right Take out the bolt serial number with screw driver Pull out the fixed pin of...

Страница 39: ...l This installment steps is the reverse of disassembling steps 2 Install Seat cushion Note Bolt torque see above figure 2 kgf m 20 N m Bolt torque see the left figure 1 kgf m 10 N m The parts of lobes...

Страница 40: ...D C Note 1 Disassemble the parts as fellows Side cover left and right Seat cushion Fuel tank Refer to disassembling and installment of the seat cushion fuel tank and cover types 2 Disassemble the par...

Страница 41: ...he adjuster to a standard value In order to avoid it turn round together the fixed screw cap is fixed with the adjusting tool and then locked Confirm the valve clearance if it is not in line with the...

Страница 42: ...just Turnover number of standard idle speed 1300 1500rpm Note Start engine Turn the adjusting screw from left to right until standard number of turns Turn in Engine speed is increase Turn out Engine s...

Страница 43: ...standard value Adjust P S adjusting screw work in with adjustment of the idle speed screw Standard CO consistency value 1 5 4 5 Out of specification Adjust Free play of extent part of the throttle han...

Страница 44: ...t of specification Adjust side the electric pole The clearance between the electric poles 0 6 0 7mm Standard spark plug A6RTC CR6HSA Check the spark plug 1 Check Check electrode insulation pollution b...

Страница 45: ...device or the electric starter when the throttle is opened fully until the reading of the pressure indicator reaches a maxi mum value and then read it Check the reading by the specification 7 Install...

Страница 46: ...he fuel gauge Engine oil capacity recommendatory lubricationoil Must be in a level place and maintain the body in vertical position Check the oil level of the fuel gauge to make sure it is between and...

Страница 47: ...Disassemble pour oil into the cock Outage cock Gasket be fixed on the outage cock 4 Oil drain 5 Charge oil from the place where oil is poured into the cock 6 Install Pour oil into the cock Gasket be f...

Страница 48: ...horoughly 2 Loosen the locknut 3 Turn in or turn back adjusting nut until it reaches given free play 4 Tighten the locknut If a free play is incorrect using the adjustor one of the part of the clutch...

Страница 49: ...cushion Air cleaner housing cover 2 Disassemble Filter element Starting the engine is strictly forbidden when the air cleaner has been disassembled or unfiltered air may be enters into the engine resu...

Страница 50: ...with neutral solution after finishing it must be dried by blowing Be mustn t add oil onto the filter element 2 Be should confirm the filter element has been fixed in the air cleaner housing If the fi...

Страница 51: ...en the locknut Turn in or turn out the adjusting nut until it reaches the defined free play Check front brake shoes 1 Check Clock hand wear indicating panel Clock hand has reached limited scale mark o...

Страница 52: ...ake lining When the wear indicator almost touches the brake disc Replace the whole group of brake linings Check the amount of brake fluid 1 Check Brake fluid level Make the brake fluid in a level plac...

Страница 53: ...of the oil drain screw and put an oil tray in front of the front end of the rubber hose 4 After braking several times the brake handle is held tightened loosening the oil drain screw about one half c...

Страница 54: ...eel rim 4 Disassemble the brake fluid cylinder diaphragm 5 Pour brake fluid into the above of the lower limit position Oil drain screw 0 6kg m 6N m Don t mix different brand brake fluids 6 Pull the br...

Страница 55: ...d has reached a wear limit reticle of indicator board Replace the brake shoes Must replace the tension spring when replace the brake shoes Turn in Decrease Turn out Increase Note Check the rear brake...

Страница 56: ...eck Put the motorcycle on the main stand Check drive chain slack Axle locknut 9 1kgf m 91N m Transmissionchainlubrication The drive chain includes lot of parts to jointly work If maintain improperly t...

Страница 57: ...fork in chapter 6 Adjust rear shock absorber Warning Caution Must adjust each absorber s preloaded values to uniform set value to avoid worsening operability and reducing stability Support the machine...

Страница 58: ...th a worn out tire When a tire is out of specification replace the tire immediately Pay attention not to pick the tubed tire when repair Front tire specification Rear tire specification 2 75 18 42P 90...

Страница 59: ...roughly Adjust the steering column screw cap 2 Steering nut Steering screw cap Adjusting steps double ring locknut Disassemble the steering handle Refer to Steering handle in Chapter 6 Disassemble th...

Страница 60: ...te level The level must be kept between upper level and lower level marks Lower Fill Refill with distilled water only Tap water contains minerals harmful to a battery Caution Ring locknut Install the...

Страница 61: ...indicate one cell to be lover than the rest Warpage or buckling of plates or insulators is evident Caution After cleaning the terminals apply grease lightly to the terminals 4 Check Breather hose Obs...

Страница 62: ...res Charge batteries in a well ventilated area Keep batteries away from fire spark or open flames e g welding equipment lighted cigarettes etc Do not smoke when charging or handling batteries Keep bat...

Страница 63: ...CHAPTER 4 ENGINE...

Страница 64: ...semble 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 Disassemble the carburetor Carburetor 5 Disassembl...

Страница 65: ...emble the engine 1 Place proper a bracket underneath the engine and the frame or place the main stand in a level position make it steady 2 Disassemble Install the bolt front side lower support and the...

Страница 66: ...t the fixed needle pointer on the crankcase cover Timing adjustment steps Turn the crankcase anticlockwise with spanner Aim mark on the rotor at the fixed needle pointer on the crankcase When mark is...

Страница 67: ...le to avoid dropping into the crankcase 10 Disassemble Bolt Cylinder head Each blot is loosened quarter turn in advance and is twisted off when all of them is loose Loosen them from the minimum number...

Страница 68: ...ic circlip of piston pin Piston pin Piston 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...

Страница 69: ...ate Friction lining Clutch lining Push rod 1 Steel ball First loosen each bolt quarter turn by the order of across corners and then turn off all the bolts Note First loosen each bolt quarter turn by t...

Страница 70: ...an not be put into the place between the driven gear and the primary driven gear Should use the sleeve to fix the nut at the place where the rotor fixes the nut and then disassemble the primary driven...

Страница 71: ...iven gear nut Key Oil filter Oilpump 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...

Страница 72: ...guide plate Timing chain Shift shaft 1 Disassemble Shifting lever Torsion spring Bolt Stopper Rotor 1 Disassemble Nut Fix the rotor with a rotor clamp and then loosen the nut 2 Disassemble Rotor Wood...

Страница 73: ...ce of the crankcase Balancing device transmission and shifting rod 1 Disassemble Shifting fork guide rod short Shifting fork guide rod long Shifting fork C Shifting fork R Shifting fork L Shifting cam...

Страница 74: ...er 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...

Страница 75: ...intenance Note 2 Disassemble Valve lock When disassemble the valve lock use the valve spring compression tool to compress the compression valve spring Note 3 Disassemble Valve spring upper seat Valve...

Страница 76: ...shape surface steps Place a piece of wet sandpaper of 400 600 onto a platform and use it to grind the cylinder head by fig ure eight Skewness less than 0 03mm 2 Check Cylinder head Scratches or damage...

Страница 77: ...e valve seat through the valve guide and then got a clear trace Measure the width of the trace that is the width of the valve seat No matter how the valve seat and valve face contact anywhere the blue...

Страница 78: ...ace and the valve seat are polished evenly and then eliminate all grinding agents For good effective knock the valve seat lightly while turning the valve back and forth with two hands Smear fine grind...

Страница 79: ...stem diameter 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 3 Check Valve face Pit corrosion or wear Polish surface Valve ste...

Страница 80: ...ipheral region is horizontal con tact Replace Side angle limit 1 2 mm Camshaft 1 Cam heave Pit corrosion scratching bluing Replace 2 Measurement Cam heave A and B Valve spring 1 Measurement Free lengt...

Страница 81: ...on 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 Replace and then check lubrication sys...

Страница 82: ...timing chain and sprocket completely Quarter gear Correct combination Rotor Sprocket 3 Check Chain guide plate exhaust side Chain guide plate intake side Wear or damage Replace Checking steps Press th...

Страница 83: ...tions one parallels to the crankcase one squares to the crankcase and then demand an average value Measuring steps 1 Measure the cylinder bore C with a bore gauge The position of D3 D4 40mm distance f...

Страница 84: ...arance Out of specification Replace Cylinder inside diameter piston outside diameter clearance Standard piston to cylinder clearance 0 020 0 034mm Piston pin outsidediameter 14 991 15 000mmLimit 14 96...

Страница 85: ...e Note 3 Measurement End gap Note End gap 1 ring 0 15 0 30mm Used limit 0 4mm 2 ring 0 30 0 45mm Used limit 0 55mm Oil ring 0 2 0 7mm Use the piston top to push the piston ring to make the ring vertic...

Страница 86: ...table rotation loose Replace 5 Check Crankshaft oil way Blockage Clean it through compressed air Standard width 46 95 47 00mm Crankshaft 1 Check Crankshaft swing tolerance Out of limit Replace Turn th...

Страница 87: ...eck Driving gear Driven gear Wear damage Replace 2 gears 2 Check Friction lining High noise when operating Replace friction lining completely 3 Measurement Friction lining thick Friction lining thick...

Страница 88: ...ure plate Wear damage Replace 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...

Страница 89: ...ting fork action Unfavorable action Replace shifting fork or guide rod Be mustn t straighten the curving guide rod Warning Transmission and shift lever 1 Check Cam follower of shifter fork Shift fork...

Страница 90: ...rter collar tension Kick starter collar tension 0 2 1 2kg 6 Check Gear tooth Bluing pit corrosion wear Replace mating gear End land become round crack and disalignment Replace 7 Check Shifting shaft D...

Страница 91: ...ng Clearance C between inside and outside rotor and pump housing Thickness difference of inside rotor outside rotor and pump housing Gear tip clearance A 0 15mm Side clearance B 0 06 0 10 mm Thickness...

Страница 92: ...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 Ci...

Страница 93: ...nd cam shaft Valve lock Valve spring upper seat Valve stem oil seal Valve spring Valve spring seat Valve stem exhaust Valve stem intake Lock nut Adjusting bolt Rocker arm Rocker arm pin intake Rocker...

Страница 94: ...justment 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...

Страница 95: ...ide 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 Note Note 3 Install Cam shaft 4 Install Pressure plate...

Страница 96: ...86 ENGINE Crankshaft and bala nce device Crank pin Crank Connecting rod Big end needle bearing Crankshaft bearing Woodruff key Balancer Balancer bearing...

Страница 97: ...pper dead center when installing do not touch the crankcase Do not ham the crankshaft with a hammer 2 Install Balance shaft Align the mark on the crank driving gear with the mark on the balance shaft...

Страница 98: ...sprocket Oil seal Bearing 5th wheel gear Driving shaft 2nd wheel gear 3rd wheel gear 4th wheel gear 1st wheel gear Bearing Bearing 5th pinion gear 2nd pinion gear 3rd pinion gear 4th pinion gear Main...

Страница 99: ...ENGINE 89 Gear shift cam and fork Fork guide rod 1 Fork 3 Fork 1 Cam Star gear Fork guide rod 2 short...

Страница 100: ...lled in main shaft inside hole Then install the main shaft 3 Check The installing width of the main shaft gear 4 Install Washer O ring Install the O ring in the mounting groove of the fixed bracket of...

Страница 101: ...L One side marked L towards the clutch Gear shift fork R One side marked R towards the clutch Gear shift fork C One side marked C towards the clutch Gear shift fork guide rod 2 Gear shift fork guide...

Страница 102: ...92 ENGINE Crankcase Left crankcase Dowel pin Air pipe Right crankcase Clutch fixing clip Tightening order Yamaha bond No 1215...

Страница 103: ...the minimum number 5 Smear Four stroke engine oil Smear on the crankshaft pin bearing and crank hole 6 Check Crankshaft and transmission actions Tough operation Repair Sealant Yamaha bond No 1215 Not...

Страница 104: ...94 ENGINE Shift shaft kick starter axle and kick starter idle gear Shift shaft Return spring Stopper Torsion spring Star gear Starting shaft assy Circlip Washer Idle gear Washer Circlip...

Страница 105: ...gear and the pin hole on the cam must be installed on the right position 3 Install Stopper Spring Make the stopper mesh with the shift star gear 4 Install Shift shaft When install the shift shaft the...

Страница 106: ...starter idle gear 1 Install Starting shaft Clamp Spring 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 Install Circlip W...

Страница 107: ...te Push plate Push rod 1 Friction lining Clutch lining Clutch hub Stop washer Main driven gear Steel ball Push rod Push rod assy Driving gear Oil filter Dowel pin Oil pump transmission gear Oil pump d...

Страница 108: ...entrifugal filter Install the dowel pin of the centrifugal filter in the stop groove of the crankshaft Main driving gear 1 Install Main driving gear Dowel pin Washer Nut When lock the nut the rotor mu...

Страница 109: ...ing the lock washer 3 Install Four friction linings Three clutch plate Smear the clutch plates with four stroke engine oil and then install it Install the clutch plate and friction lining on the clutc...

Страница 110: ...ghly confirming whether the objection of the push rod aligns with the one of the alignment mark of the crankcase or not Unaligned Adjust 4 Install Steel ball 5 Install Push rod Push plate Washer Nut 6...

Страница 111: ...e thoroughly Turn the push rod right and left for adjusting until aligns with Lock the nut after adjusting 9 Install Gasket new Right case cover 10 Install Kick starting rod Lock torque of the nut 0 8...

Страница 112: ...102 ENGINE Timing system Timing chain Chain guide plate Dowel shaft Idle starting gear 1 Pressure plate Washer Starting gear 2 Woodruff key Rotor Stator Gasket Dowel pin Left case cover...

Страница 113: ...ed and then the guide plate is fixed Mounting torque 1 0kgf m 10 N m Note Mounting torque 0 7kgf m 7N m 2 Install Starting idle gear Pressure plate Check steps Install the starter gear in the clutch o...

Страница 114: ...g tool lock the rotor with the nut with the washer Note Locking torque 7 0kgf m 70 N m Note 7 Install Dowel pin Gasket Left case cover Sliding stopping tool The left case cover must be installed after...

Страница 115: ...be installed first and then install the Oil bearing baffle finally install the scraper baffle After assembling make sure that the piston ring can turn smoothly The connecting place among each ring sho...

Страница 116: ...106 ENGINE Cylinder and piston Cylinder O ring Gasket Dowel pin Piston ring Piston pin circlip Piston Piston pin...

Страница 117: ...ENGINE 107 Cylinder head Bolt Copper washer Inner hexagon bolt Valve cover intake O ring Valve cover exhaust Cylinder head Dowel pin Steel gasket O ring Cylinder head side cover spark plug...

Страница 118: ...108 ENGINE Cam shaft and dowel pin Gasket Tensioner Chain guide plate intake Timing sprocket Timing chain Chain guide plate exhaust...

Страница 119: ...stic clamp ring Needle washer Fuel needle Throttle valve Carburetor body Idle screw Spring Washer Rubber washer Choke lever Wave washer Screw Rubber cap Guide holder Choke valve Spring piece Fixed pla...

Страница 120: ...oater Needle valve Needle valve seating Disassemble 1 Disassemble Guide tube of throttle cable Carburetor body 3 Disassemble Choke lever Choke valve Disconnect 1 Loosen Drain screw 2 Disassemble Throt...

Страница 121: ...ble 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...

Страница 122: ...lace the motorcycle in the position of level and made sure that the carburetor maintain in verticality Connect the fuel liquidometer to the drain oil tube Note 4 Check Main nozzle Main jet O ring Idle...

Страница 123: ...ber Measure the fuel level with fuel liquidometer The readings on the pipeline of the two sides of the carburetor are equal Note 2 If the fuel level is not correct adjusting Disassemble the carburetor...

Страница 124: ...gative pressure pipe Wire clip Complementary gas valve Circlip Complementary gas 1 pipe Syphon assy Washer plate Muffler assy Engine assy wire clip Exhaust gas cycle tube Air filter assy Complementary...

Страница 125: ...CHAPTER 5 CHASSIS...

Страница 126: ...116 CHASSIS Front wheel Lock nut Instrument gears Front wheel axle Spacer Front wheel assy Spacer assy Front wheel assy...

Страница 127: ...CHASSIS 117 Front brake Brake shoes assy Oil seal Speedometer clutch Drive gear Cam shaft lever Indicator plate Cam shaft Spacer Washer Meter gear O ring Oil seal...

Страница 128: ...4 Remove Front wheel axle Front brake assy Spacer Front wheel assy Place the machine on a level place Place the machine on main stand Elevate the front wheels by placing suitable stand under the frame...

Страница 129: ...ng Warning Crook limit 0 25mm Be sure not to straighten the crooked front wheel shaft 3 Measure Wheel runout 4 Inspection Wheel bearing The bearing moving in the hub or rotating unstably Replace Oil s...

Страница 130: ...eter cable Instrumentationclutch 1 Inspection Instrumentation clutch Wear Damage Replace Frontbrake 1 Inspection Brake shoe lining surface Smooth side Grinding Sand with coarse sand paper Note Instrum...

Страница 131: ...Brake shoe thickness 4mm Limited 2mm Brake drum inside diameter standard 130mm limit 131mm Over specified limit Replace 4 Inspect Brake drum inner surface Oil scratched Remove Oil use a rag soaked in...

Страница 132: ...ft Aim the needle at the wear indicator 2 Install Camshaft rod 3 Install Brake shoe Brake shoe spring Don t use plier when installing which may cause disshape and damage of hooks and rings of spring D...

Страница 133: ...brake shoe Note Install 1 Install Front brake cable Speedometer cable Front wheel axle nut The convex seat of the left front shock absorber must bite with the locating slot of gear assy correctly Not...

Страница 134: ...124 CHASSIS Rear wheel Adjusting nut pin Compression spring split pin Tension rod Lock nut Chain adjuster assy Sprocket shaft Rear wheel Rear brake Damper Oil seal Spacer Bearing...

Страница 135: ...CHASSIS 125 Brake shoes Camshaft lever Rear brake Indicator plate Brake camshaft...

Страница 136: ...uster Tension rod Nut Compressing spring Brake rod Rear wheel shaft nut 2 Remove Rear wheel shaft Spacer When removing the wheel shaft Spacer will drop down Be careful not to lose it 3 Remove Rear whe...

Страница 137: ...n 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 R...

Страница 138: ...128 CHASSIS Divingchain Sprocket cover Slave sprocket Link plate Chain adapter Chain connect Main drive sprocket Adjuster Circlip Stop washer...

Страница 139: ...ng chain driving sprocket The clearance that is pressed to right side must not excess 1 2 of the gear Overran Replace Stand the motorcycle firmly and avoid turning 1 Put the motorcycle on the main sta...

Страница 140: ...nts in differ ent sections two or three times The max length of 10 chain elements 119 5mm Note Warning Screw up the bolts following the cross curve Nut 2 6kgf m 26N m Note Excess the stipulated scope...

Страница 141: ...Assembly Chain connect work carrier Pay attention to eh assembling direction of the work carrier of the carrier of the chain connect 3 Adjustment Loose degree of driving chain Please refer to the sec...

Страница 142: ...132 CHASSIS Front fork Front fender Plug Bolt O ring Collar Spring seat Spring Dust preventative cap Circlip Bolt Washer Button valve Resistance device Inner tube Spring Oil seal Outer tube...

Страница 143: ...e Collar Spring seat Spring 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...

Страница 144: ...gularity limit 0 2mm Warning 4 Disassemble Dust preventative cap Circlip Be careful not to damage the surface of inner tube Note 5 Remove Bolt Hold the shock absorber rod and loosen the bolt shock abs...

Страница 145: ...d clean all oil hole with compressed air Don t try to straighten crocked resistance device rod otherwise it will be damaged seriously Note Free length of front fork spring 339 9mm Min free length 330m...

Страница 146: ...istance device rod 2 3kgf m 23N m Note T spanner Shock absorber rod fixture 3 Install Resistance device Button valve Inner tube of front fork Outer tube of front fork Front fork oil 10w or equal subst...

Страница 147: ...t Measuring cup 10 Move the front fork up and down slowly after infection to make the oil all over the tube Every front fork tube 156ml 10W shock absorber oil 11 Install Front fork spring Make the end...

Страница 148: ...k Tighten the bolt temporary 2 Tighten Bolt Bolt Cap bolt Note Bolt 2 8kgf m 28N m Bolt 2 3kgf m 23N m Cap bolt 2 3lgf 23N m 12 Install Cap bolt O ring Be careful not to damage the outer surface of in...

Страница 149: ...andlebar clamp Handlebar Right holder lever assy Handlebar seat Thimble Ring Nut Ring washer Ring nut Dust preventative cap Steering seat Upper ball bearing race upper Upper Steel ball Lower steel bal...

Страница 150: ...ap nut Handlebar clamp Handlebar Right holder lever assy Handlebar seat Dust preventative cap nut Steering seat Upper ball bearing race upper Upper Steel ball Lower steel ball Upper ball bearing race...

Страница 151: ...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...

Страница 152: ...ring nut wench Warning 6 Remove Ball bearing race cover Upper ball bearing race upper Steering seat Steel ball lower 7 Remove Ball bearing race cover Upper ball bearing race upper Steel ball upper Ste...

Страница 153: ...ace step Shown as illustration the ball bearing race with a long rod and hand hammer and take it out of the convex slot of frame tube Shown as illustration remove the ball bearing race of steering of...

Страница 154: ...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 1 Lubrication Steel ball Bearing race 2 Ins...

Страница 155: ...to flexible the front face bolt Note Make the difference handlebar clamp from front to rear to assemble the front face 2 Assembly Front brake lever Clutch holder lever Tighten torque 2 3kgf m 23 N m...

Страница 156: ...146 CHASSIS Rear shock absorber and rear arm Rear shock absorber Nut Rear arm Connection rod Chain cover...

Страница 157: ...to downward of rear arm If the vertical shift is found too tight clipped or unstable then replace Stand the motorcycle firmly avoid turning over 1 Rear shock absorber 2 Disassembly Left and right and...

Страница 158: ...P P...

Страница 159: ...CHAPTER 6 CABLE AND ELECTRIC APPLIANCE SYSTEM...

Страница 160: ...the back hole of front headlight and connect in the inside front headlight C Tighten the white mark of wire by the frame wire clamp D Insert the carburetor vent pipe in the storage battery box clamp...

Страница 161: ...uretor overflow pipe Battery vent pipe Complementary gas pipe 2 Complementary gas valve Negative pressure pipe Complementary gas pipe1 Syphon assy Washer A Tighten the ground wire and ignition coil to...

Страница 162: ...gh the guide frame A Trottle cable brake cable and handbar switch lead wire must pass through the guide frame B Clutch cable handlebar switch wire and clutch switch wire must pass through the guide fr...

Страница 163: ...t 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 Tight...

Страница 164: ...e 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 Front brake switch wire Brake cable Right flasher wire Throttle cab...

Страница 165: ...s leads must passed through the back hole of front light and connect in the inside front headlight C Tighten the white mark of wire by the frame wire clamp D Insert the carburetor vent pipe in the sto...

Страница 166: ...brake switch lead wire Carburetor vent pipe Exhaust gas circulation pipe Carburetor overflow pipe Storage battery vent pipe A Tighten the ground wire and ignition coil together B Carburetor overflow...

Страница 167: ...hrough the guide frame B Clutch cable handlebar switch wire and clutch switch wire must pass through the guide frame C Be sure to tighten left handlebar switch and clutch switch wire with shell ring D...

Страница 168: ...CABLE AND ELECTRIC APPLIANCE SYSTEM 158 Electric device principle...

Страница 169: ...159 Electric appliance...

Страница 170: ...CABLE AND ELECTRIC APPLIANCE SYSTEM 160...

Страница 171: ...CABLE AND ELECTRIC APPLIANCE SYSTEM 161 Components of electric appliance Storage battery Rear brake switch Starting relay safety assy Rectifier regulator Oil sensor Key sets Harness wire...

Страница 172: ...CABLE AND ELECTRIC APPLIANCE SYSTEM 162 Ignition coil Spark plug cap Shift switch Flasher relay CDI Horn Components of electric appliance...

Страница 173: ...s disconnected 5 If the binding post is drawn out the pin should be crankled Insert the binding post into the socket connectors 6 Connection Socket connectors 7 Check if the socket connectors are powe...

Страница 174: ...the multi meter to inspecting Adjust the multi meter to O before when inspect ing the circuit Note The manual explains how to inspect the switch The left figure indicate the wire and position of switc...

Страница 175: ...CABLE AND ELECTRIC APPLIANCE SYSTEM 165 Ignition system diagram...

Страница 176: ...ial tools should be used to obviate the fault Note Small size multitester Abnormal Code of standard spark plug model CR6HSA Spark plug gap 0 6 0 7mm 0 02 0 03in Normal Replace or adjust Spark arc run...

Страница 177: ...esistance 0 3 10 20 Multimeter lead Orange spark plug wire Multimeter lead Ground wire Multimeter lead Side of spark plug Multimeter lead High tension wire 3 Spark plug cap resistance Disassemble the...

Страница 178: ...o coils work normally Multimeter lead Orange spark plug wire Multimeter lead Ground wire Abnormal The ignition coil is faulty and should replaced Out of stipulation Regulation resistance 310K 20 20 Re...

Страница 179: ...CABLE AND ELECTRIC APPLIANCE SYSTEM 169 Electric start system...

Страница 180: ...uld be used to trouble shoot Note Small size multimeter No electrification 1 Protecting Device Disassemble the protecting device Connect a small size multimeter 1 to the protecting pipe Check if the p...

Страница 181: ...r motor is faulty and should be checked or replaced Run The starter relay is fault and should be replaced starter relay 4 Starter relay Disassemble the socket connectors of the start Connect the stora...

Страница 182: ...e harness Check if the switch can connect to Red Brown Normal The main switch is faulty and should be replaced Abnormal Normal The neutral switch is faulty and should be replaced 6 Neutral switch Disa...

Страница 183: ...h switch is faulty and should be replaced Adjust or replace 8 Wire connection condition Please refer to the section of Electric circuit 7 Clutch switch Disassemble the socket connectors of the clutch...

Страница 184: ...CABLE AND ELECTRIC APPLIANCE SYSTEM 174 Starting motor Starting motor assy Rear bracket Brush spring Brush assy O ring Magnetic yoke Armature Adjusting washer Front bracket O ring...

Страница 185: ...ercut In order to ensure the normal work of commutator the isolation mica sheet of commutator must have undercut Depth of mica sheet undercut 1 5mm Note Discharge 1 Before discharge sign some marks on...

Страница 186: ...resistance is incorrect replace the starting motor Armature coil resistance Continuitychecking 0 017 0 021 20 Insulation checking More than 1M 20 When replacing brush pay attention to its side which...

Страница 187: ...agnetic yoke Aimed the marks to the rear brocket s matching mark and then install 5 Install Washer Front brocket Aimed the boss of washer to the groove of front brocket and then install Make the marks...

Страница 188: ...CABLE AND ELECTRIC APPLIANCE SYSTEM 178 Charging system...

Страница 189: ...ponents should be taken off Side cover Seats Whentroubleshooting thefollowingspecialtoolshould be used Note No continuity 1 Fuse Check if the fuse tube is electrified The fuse tube is broken replace i...

Страница 190: ...ler form the wire harness Connect the pocket tester 1 to the charging coil Measure the charging coil resistance Tester lead White terminal Tester lead Green terminal Out of specification Charging coil...

Страница 191: ...CABLE AND ELECTRIC APPLIANCE SYSTEM 181 Lighting system...

Страница 192: ...o continuity 1 Bulb and bulb socket Check the bulb and bulb socket for continuity continuity Bulb and or bulb socket is fail replace it No continuity The fuse tube is broken replace it Incorrect 3 Bat...

Страница 193: ...right coupler form wire harness Connect the pocket tester 1 to handlebar switch right terminal Check switch continuity between blue black and blue Lighting switch is failure replace the handle bar swi...

Страница 194: ...continuity Replace the bulb and or bulb socket Meets specification 12V continuity 2 Voltage Connect the pocket tester DC20V to the coupler of headlamp and high beam indicator lamp Headlamp Tester lead...

Страница 195: ...faulty repair 3 If the tail lamp fails to come on This circuit is not faulty No Continuity 1 Bulb and bulb socket Check the bulb and the bulb socket for continuity Replace bulb and or bulb socket Out...

Страница 196: ...CABLE AND ELECTRIC APPLIANCE SYSTEM 186 Signal system...

Страница 197: ...Battery Check the battery condition Eletrolyte specific gravity 1 280 20 1 Fuse Tale off the fuse Check the fuse tuber 1 to the fuse tube for Replenish destilled water Clean battery terminal Charge o...

Страница 198: ...main switch to ON Check the horn brown green terminal Check if the voltage is 12V by pressing the horn button The circuit connection from main switch to the horn terminal is poor repair it The horn d...

Страница 199: ...from wire harness Check the continuity between yellow and brown on the switch Incorrect 3 Voltage Connect the pocket tester DC20V to the bulb socket coupler Tester lead Yellow terminal Tester lead Bl...

Страница 200: ...ing relay Tester lead Brown terminal Tester lead Ground wire of frame Turn the main switch to ON Check the voltage 12V of black terminal on flashing relay terminal 2 Flasher switch Discharge handlebar...

Страница 201: ...utral Check the continuity between light blue and ground wire on the shift switch If the neutral switch is failure replace it continuity Normal Out of specification Signal system is correct 5 Turn lam...

Страница 202: ...al on bulb socket The circuit from the main switch to the bulb socket coupler is poor repair it Out of specification 1 Fuel sensor Discharge the fuel from the fuel tank Connect the fuel sensor 10 to f...

Страница 203: ...e on the fuel gauge terminal Check all couplers of signal system 3 Fuel gauge Connect the fuel sensor to wire connecter Move the float from to Turn on the main switch to ON Move the float to check if...

Страница 204: ...P P...

Страница 205: ...CHAPTER 7 TROUBLESHOOTING...

Страница 206: ...ifier adjuster Rectifier regulator damaged Check entire wire coupler Ignition coil Primary coil or secondary coil is damaged or shortened Failure of high pressure wire Faulty spark plug cap Ignition c...

Страница 207: ...ression System Damage Wear clog damage Accumulative carbon Damage Wear clog damage Lack of tighten moment Buckle Accumulative carbon Wear clog damage Wear clog damage Wear clog Damage Damage Buckle we...

Страница 208: ...clogged Fuel pipe Clogged scratched or bent Air filter Contaminated or clogged Silencer clogged Outlet pipe Scratched or damaged Accumulate carbon Jet needle valve Improperly adjusted Incorrect of cla...

Страница 209: ...P P...

Страница 210: ......

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