TGB Service Manual 303R150 (BR9) and Delivery 150 (BK9)

1
TABLE OF CONTENTS
1. GENERAL INFORMATION
PAGE
1-1 SPECIFICATIONS 3
1-2 INSPECTION PRECAUTIONS
1-3 SAFETY PRECAUTIONS
1-4 SPECIAL TOOLS
1-5 TIGHTENING TORQUE
1-6 LUBRICATION POINTS
1-7 PARTS NAME
1-8 TROUBLE SHOOTING
1-8-1 Troubleshooting for Failure in Starting the Engine
1-8-2 Troubleshooting for Poor skip of Spark Plugs
1-8-3 Troubleshooting for No-Skip of Spark Plugs
1-8-4 Troubleshooting for Slow Run (Troubled Engine
1-8-5 Poor Acseleration and Horse Power
10
11
12
14
16
18

19
22
23
24
25
2.INSPECTION AND ADJUSTMENT

2-1 REGULAR MAINTENANCE SCHEDULE
2-2 INSPECTION AND CHANGE OF ENGINE OIL
2-3 FINAL GEAR OIL
2-4 BRAKE SYSTEM
2-5 TIRE AND TIRE PRESSURE
2-6 AIR CLEANER
2-7 BATTERY
2-8 SPARK PLUG
2-9 FUEL FILTER
2-10 CARBURETOR IDLE SPEED
2-11 THROTTLE VALVE
2-12 VALVE
2-13 HEADLIGHT AXLE
2-14 V BELT
2-15 CYLINDER PRESSUR
27
28
29
30
35
35
36
37
37
38
38
39
40
40
42
3. REMOVAL AND INSTALLATION OF ENGINE

3-1 STANDANTD PREPARATION DATA&SIMPLIFIED
TROUBLESHOOTING
3-2 RELEASE THE ENGINE
3-3 INSTALLATION OF THE ENGINE
3-4 CHECK THE ENGINE PARTS
43

45
45
45
2
3-5 FUEL FEED CIRCUIT
3-6 LUBRICATION
3-7 DRIVING PULLY-CLUTCH-DTIVEN PULLEY
3-8 STARTER ARM
54
59
60
67
4. CHASSIS

4-1 REMOVAL OF COVER
4-2 TROUBLESHOOTING OF CHASSIS
4-3 FRONT WHEEL
4-4 REAR WHEEL
4-5 REAR SHOCK ABSORBER
70
72
76
78
80
5. ELECTRICAL SYSTEM

5-1 OPERATING CAUTIONS & TROUBLESHOOTING
5-2 BATTERY
5-3 SHORT CIRCUIT TEST
5-4 RECTIFIER
5-5 STARTER RELAY
5-6 STARTER MOTOR
5-7 A.C. GENERATOR
5-8 RESISTOR
5-9 CDI UNIT
APPENDIX CIRCUIT DIAGRAM FOR BR8
81
86
87
87
88
90
92
94
95
98

3
1. GENERAL INFORMATION
1-1.SPECIFICATIONS
BR8 PRODUCT SPECIFICATION
MODE BR8 AIR CLEANER TYPE PAPER FILTER
TOTAL LENGTH (mm) 1860 FUEL TANK () 6.8
TOTAL WIDTH (mm) 675 TYPE CVK
TOTAL HEIGHT (mm) 1145 THROTTLE VALVE DIA. ( ) 24
D
I
M
E
N
S
I
O
N

WHEEL BASE (mm) 1270 VENTURI DIA. ( ) 22.1
FRONT 43
F
U
E
L

S
Y
S
T
E
M

C
A
R
B
U
R
E
T
O
R

THROTTLE VALVE TYPE BUTTERFLY
REAR 68 TYPE C.D.I.
DRY WEIGHT (kg)
TOTAL 111 SPARK ADVANCE BTDC 13/ 2950rpm
FRONT 72 SPARK PLUG NGK CR7HSA
REAR 114
I
G
N
I
T
I
O
N

SPARK PLUG GAP ( ) 0.6~0.7
W
E
I
G
H
T

TOTAL WEIGHT (kg)
1 PERSON (75kg)
TOTAL 186
E
L
E
C
T
R
I
C

S
Y
S
T
E
M

BATTERY 12V 7AH
PRIMA TRANSM. C.V.T.
TYPE 4T
SECONDARY TRANSM. GEAR
FUEL TYPE
92/95 UNLEADED
GASOLINE
CLUTCH TYPE
CENTRIFUGAL
TYPE
CYLINDER NO. SINGLE PRIMA 1/0.90~2.40
BORE STORKE (mm) 52.4 57.8
T
R
A
N
S
M
I
S
S
I
O
N

REDUCTION RATIO
SECOND 1/9.45 (14/4313/40)
DISPLACEMENT (c.c.) 124 HEAD LAMP (H / L) 12V 35W/35W1
STARTER ELECTRIC KICK REAR LAMP 12V 5W1
BRAKE LAMP 12V 21W1
COOLING
FORCED AIR
COOLING
L
A
M
P

TURN LAMP 12V 10W4
LUBRICATION PUMP SPLASH 130/60-13 130/60-13
INTAKE VALVE GAP (mm) 0.08~0.10 or120/70-12 130/70-12
EXHAUST VALVE GAP (mm) 0.08~0.10
FRONT REAR
or120/70-12 120/70-12
TOP SPEED (km/hr) 90 FRONT 175
IDLING SPEED (rpm) 1800 100
T
I
R
E

TIRE PRESSURE
(kPa)
REAR 210
MAX. TORQUE (N-m/rpm) 7.90 / 7800 LEFT 45
MAX. POWER (kW/rpm) 6.47 /7800
STEERING ANGLE ( )
RIGHT 45
COMPRESSION RATIO 9.2 1 FRONT DISK
BRAKE
REAR DRUM CYLINDER PRESSURE
( /cm
2
rpm)
12.8-570
FRONT TELESCOPE
ENGINE OIL TYPE SAE 10W - 40
SUSPENSION SYSTEM
REAR ROCKER ARM
ENGINE OIL QUANTITY (c.c.) 900 FRAME STEEL TUBE
GEAR OIL TYPE SAE 90#
E
N
G
I
N
E

GEAR OIL QUANTITY (c.c.) 120

4

BF8 PRODUCT SPECIFICATION
MODE BF8 AIR CLEANER TYPE PAPER FILTER
TOTAL LENGTH (mm) 1890 FUEL TANK () 6.8 3.9
D
I
M
E
N
S
I
O
N

FRONT 47
F
U
E
L

S
Y
S
T
E
M

C
A
R
B
U
R
E
T
O
R

REAR 68 TYPE C.D.I.
DRY WEIGHT (kg)
REAR 112
I
G
N
I
I
T
I
O
N

W
E
I
G
H
T

TOTAL WEIGHT (kg)
I PERSON (75kg)
TOTAL 190
E
L
E
C
T
R
I
C

S
Y
S
T
E
M

BATTERY 12V 7AH
TYPE 4T
FUEL TYPE
92/95 UNLEADED
GASOLINE
CLUTCH TYPE
CENTRIFUGAL
TYPE
T
R
A
N
S
M
I
S
S
I
O
N

REDUCTION RATIO
SECOND 1/9.45 (14/4313/40)
BRAKE LAMP 12V 21W1
COOLING
FORCED AIR
COOLING
L
A
M
P

TURN LAMP 12V 10W4
EXAUST VALVE GAP (mm) 0.08~0.10
FRONT REAR
or120/70-12 120/70-12
T
I
R
E

TIRE PRESSURE
(kPa)
REAR 210
STEERING ANGLE ( )
RIGHT 45
BRAKE
REAR DRUM
CYLINDER PRESSURE
( /cm
2
rpm)
12.8-570
FRONT TELESCOPE
SUSPENSION SYSTEM
REAR ROCKER ARM
E
N
G
I
N
E


5
BR9 PRODUCT SPECIFICATION
MODE BR9 AIR CLEANER TYPE PAPER FILTER
D
I
M
E
N
S
I
O
N

WHEEL BASE (mm) 1270 VENTURI DIA. ( ) 23
FRONT 44
F
U
E
L

S
Y
S
T
E
M

C
A
R
B
U
R
E
T
O
R

REAR 74 TYPE C.D.I.
DRY WEIGHT (kg)
REAR 121
I
G
N
I
I
T
I
O
N

W
E
I
G
H
T

TOTAL WEIGHT (kg)
I PERSON (75kg)
TOTAL 193
E
L
E
C
T
R
I
C

S
Y
S
T
E
M

BATTERY 12V 7AH
TYPE

4T
FUEL TYPE
92/95 UNLEADED
GASOLINE
CLUTCH TYPE
CENTRIFUGAL
TYPE
T
R
A
N
S
M
I
S
S
I
O
N

REDUCTION RATIO
SECOND 1/7.8 (15/4214/39)
BRAKE LAMP 12V 21W1
COOLING
FORCED AIR
COOLING
L
A
M
P

TURN LAMP 12V 10W4
FRONT REAR
or120/70-12 120/70-12
T
I
R
E

TIRE PRESSURE
(kPa)
REAR 210
STEERING ANGLE ( )
RIGHT 45
BRAKE
REAR DRUM
CYLINDER PRESSURE
( /cm
2
rpm)
11.7-700
FRONT TELESCOPE
SUSPENSION SYSTEM
REAR ROCKER ARM
GER OIL TYPE SAE 90#
E
N
G
I
N
E


6
BF9 PRODUCT SPECIFICATION
MODE BF9 AIR CLEANER TYPE PAPER FILTER
D
I
M
E
N
S
I
O
N

FRONT 48
F
U
E
L

S
Y
S
T
E
M

C
A
R
B
U
R
E
T
O
R

REAR 76 TYPE C.D.I.
DRY WEIGHT (kg)
REAR 122
I
G
N
I
I
T
I
O
N

W
E
I
G
H
T

TOTAL WEIGHT (kg)
I PERSON (75kg)
TOTAL 199
E
L
E
C
T
R
I
C

S
Y
S
T
E
M

BATTERY 12V 7AH
TYPE

4T
FUEL TYPE
92/95 UNLEADED
GASOLINE
CLUTCH TYPE
CENTRIFUGAL
TYPE
T
R
A
N
S
M
I
S
S
I
O
N

REDUCTION RATIO
SECOND 1/7.8 (15/4214/39)
BRAKE LAMP 12V 21W1
COOLING
FORCED AIR
COOLING
L
A
M
P

TURN LAMP 12V 10W4
FRONT REAR
or120/70-12 120/70-12
T
I
R
E

TIRE PRESSURE
(kPa)
REAR 210
STEERING ANGLE ( )
RIGHT 45
BRAKE
REAR DRUM
CYLINDER PRESSURE
( /cm
2
rpm)
11.7-700
FRONT TELESCOPE
SUSPENSION SYSTEM
REAR ROCKER ARM
E
N
G
I
N
E


7
BH8 PRODUCT SPECIFICATION
MODE BH8 AIR CLEANER TYPE PAPER FILTER
D
I
M
E
N
S
I
O
N

WHEEL BASE (mm 1240 VENTURI DIA. ( ) 22.1
FRONT 35
F
U
E
L

S
Y
S
T
E
M

C
A
R
B
U
R
E
T
O
R

REAR 58 TYPE C.D.I.
DRY WEIGHT (kg)
REAR 105
I
G
N
I
I
T
I
O
N

W
E
I
G
H
T

TOTAL WEIGHT (kg)
I PERSON (75kg)
TOTAL 168
L
E
C
T
R
I
C

S
Y
S
T
E
M

BATTERY 12V 7AH
TYPE 4T
FUEL TYPE
92/95 UNLEADED
GASOLINE
CLUTCH TYPE
CENTRIFUGAL
TYPE
CYLINDER NO. SINGLE PRIMA 1/0.77~1/2.19
T
R
A
N
S
M
I
S
S
I
O
N

REDUCTION RATIO
SECOND 1/8.61 (15/4213/40)
DISPLACEMENT (c.c.) 124 HEAD LAMP (H / L)
12V 35W/35W1
or 18W /18W2
BRAKE LAMP 12V 21W1
COOLING
FORCED AIR
COOLINE
L
A
M
P

TURN LAMP 12V 10W4
LUBRICATION PUMP SPLASH
INTAKE VALVE GAP (mm) 0.08~0.10
FRONT REAR 120/90-10 110/90-10
T
I
R
E

TIRE PRESSURE
(kPa)
REAR 210
STEERING ANGLE ( )
RIGHT 45
BRAKE
REAR DRUM
CYLINDER PRESSURE
( /cm
2
rpm)
12.8-570
FRONT TELESCOPE
SUSPENSION SYSTEM
REAR ROCKER ARM
E
N
G
I
N
E


8

BK8 PRODUCT SPECIFICATION
MODE BK8 AIR CLEANER TYPE PAPER FILTER
D
I
M
E
N
S
I
O
N

FRONT 38
F
U
E
L

S
Y
S
T
E
M

C
A
R
B
U
R
E
T
O
R

REAR 70 TYPE C.D.I.
DRY WEIGHT (kg)
REAR 119
I
G
N
I
I
T
I
O
N

W
E
I
G
H
T

TOTAL WEIGHT (kg)
I PERSON (75kg)
TOTAL 183
E
L
E
C
T
R
I
C

S
Y
S
T
E
M

BATTERY 12V 7AH
TYPE 4T
FUEL TYPE
92/95 UNLEADED
GASOLINE
CLUTCH TYPE
CENTRIFUGAL
TYPE
T
R
A
N
S
M
I
S
S
I
O
N

REDUCTION RATIO
SECOND 1/9.45 (14/4313/40)
STARTER ELECTRIC & KICK REAR LAMP 12V 5W1
BRAKE LAMP 12V 21W1
COOLING
FORCED AIR
COOLING
L
A
M
P

TURN LAMP 12V 10W4
LUBRICATION PUMP & SPLASH 80/80-14 & 110/80-14
INTAKE VALVE GAP (mm) 0.08~0.10 or
FRONT REAR
110/80-14 & 110/80-14
T
I
R
E

TIRE PRESSURE
(kPa)
REAR 210
STEERING ANGLE ( )
RIGHT 45
BRAKE
REAR DRUM
CYLINDER PRESSURE
( /cm
2
rpm)
12.8-570
FRONT TELESCOPE
SUSPENSION SYSTEM
REAR ROCKER ARM
E
N
G
I
N
E


9
BK9 PRODUCT SPECIFICATION
MODE BK9 AIR CLEANER TYPE PAPER FILTER
TOTAL LENGTH (mm) 1880 FUEL TANK () 6.8 & 3.9
D
I
M
E
N
S
I
O
N

FRONT 39
F
U
E
L

S
Y
S
T
E
M

C
A
R
B
U
R
E
T
O
R

REAR 71 TYPE C.D.I.
DRY WEIGHT (kg)
REAR 120
I
G
N
I
I
T
I
O
N

W
E
I
G
H
T

TOTAL WEIGHT (kg)
I PERSON (75kg)
TOTAL 185
E
L
E
C
T
R
I
C

S
Y
S
T
E
M

BATTERY 12V 7AH
TYPE

4T
FUEL TYPE
92/95 UNLEADED
GASOLINE
CLUTCH TYPE
CENTRIFUGAL
TYPE
T
R
A
N
S
M
I
S
S
I
O
N

REDUCTION RATIO
SECOND 1/7.8 (15/4214/39)
BRAKE LAMP 12V 21W1
COOLING
FORCED AIR
COOLING
L
A
M
P

TURN LAMP 12V 10W4
LUBRICATION PUMP SPLASH 80/80-14 & 110/80-14
INTAKE VALVE GAP (mm) 0.08~0.10 or
FRONT REAR
110/80-14 & 110/80-14
T
I
R
E

TIRE PRESSURE
(kPa)
REAR 210
STEERING ANGLE ( )
RIGHT 45
BRAKE
REAR DRUM
CYLINDER PRESSURE
( /cm
2
rpm)
11.7-700
FRONT TELESCOPE
SUSPENSION SYSTEM
REAR ROCKER ARM
E
N
G
I
N
E


10
1-2 INSPECTION PRECAUTIONS

1. The measurements use IS system for bolts and bolt heads. Please do not
use British system for the bolts and nuts, otherwise it can damage the
motorcycle.
2. Please clean parts outside deposits before maintenance. Otherwise, the
deposits may drop into engine and damage engine in operation.
3. Please use kerosene or diesel to clean-up disassembled parts. Check
and measure parts after clean-up. The parts contact and sliding surface
should apply engine oil for lubrication.
4. The packing, metal gasket, O-ring, seal, clamp, and clipper should be
replaced with new ones after disassembly.
5. Please pay attention to the orientation and relative positions of the major
components. Arrange the parts in order during disassembly. Make
marks if necessary to avoid mistakes in re-assembly.
6. Loosing the parts should start from small to big, from outside to inside, and
in alternative parts. Assembly is in reverse order of disassembly
procedures.
7. The oil seals should be replaced with new ones after disassembly. The
contact surface should be cleaned-up. Check if the contact axle has
scratches or burry. Use special tools for assembly to avoid damaging
seal lip area, which may lead to oil leak. The manufacturer logo should
face outward in assembly. Apply grease at seal lip area.
8. Please do not presses, twist, and over scratch the wire cable to avoid bad
wire contact.
9. Disconnect the battery negative (-) terminal before maintenance.
Connect the positive (+) terminal first in assembly. Apply a thin layer of
grease on terminals, and cover with terminal caps.

11

1-3 SAFETY PRECAUTIONS

Warning: Engine Exhaust
Please keep good ventilation during engine operation. Do not operate engine in
closed-room. The toxic carbon-oxygen (CO) in exhaust may lead human to loss
conscious and even death.

Warning: Gasoline
The gasoline is very easy to burn or explode. Forbid any fire during inspection of
gasoline tank or gasoline leak.

Warning: Battery H
2
and Battery Liquid
1. The battery liquid is toxic sodium liquid. Please do not contact the liquid with
skin or eye. If any contact happens, please wash with massive clean water
and contact with doctor.
2. The released H
2
from battery is explosive. Please keep good ventilation
during charging battery and forbid any fire.

Watch: Brake Fluid
The brake fluid can damage the painting on plastic. Please cover the plastic parts
with towel or cloth during maintenance of brake disk. If the brake fluid is split on
plastic component, please remove the fluid and wash the surface with water right
away.

Watch: High Temperature of Engine
The engine cover, cylinder, and exhaust pipe have high temperature after starting
of engine. Please wear glove in maintenance of parts during engine operation, or
maintenance should be waited until engine is cooled.

12
1-4 SPECIAL TOOLS

Universal Wrench 440601

Hold for removing flywheel.
Hold for removing belt driver pulley.
Hold for removing belt driven pulley.
Four Legs Sleeve 440604

Used for removing starter clutch
gear lock nut.

Flywheel Remover 440602

Used for removing flywheel.
Starter Spring Assembly Tool
440605

Used for starter spring assembly.

Gear Remover 440603

Used for removing starter driven
gear.
Crank Shaft & Right Hand Crank
Case 440606

To draw the crank shaft into the
right hand crank case.

13

Inner Chain Wrench 440607

For disassembly the camshaft inner
chain.
Bush Remover 440610

For removing the crankcase
suspension bush.

Socket of Valve Adjusting Bolt
440608

Adjust the clearance of valve stem
and rock arm.
Fixing Nut Socket 440611

Used for removing steering shaft
nut.

Valve Cotter Tool 440609

For assembling valve cotter

14
1-5 TIGHTENING TORQUE
BR8 Representative Figure

*Standard Torque Values of Bolts and Nuts *

Specification Torque (kg-cm) Specification Torque (kg-cm)
5 mm Bolt and Nut 40 8 mm Bolt and Nut 220
5 mm Flange Bolt and Nut 50 8 mm Flange Bolt and Nut 270
6 mm Bolt and Nut 100 10 mm Bolt and Nut 350
6 mm Flange Bolt and Nut 120 10 mm Flange Bolt and Nut 400
6 mm SH Bolt and Nut 90 12 mm Bolt and Nut 550

* Torque Values of Chassis Components *
No. Tightening Location Specification Torque
(kg-cm)
1 Front Wheel Axle Self-lock Nut M12 500~600
2 Brake Disk Hex Bolt M5 180~280
3 Brake Clipper Tightening Bolt M8x35 210~250
4 Speed Meter Cable Nut X 60
5 Front Fork Bearing Tightening Nut M25x1.0 600~650
6 Rear Wheel Axle Self-lock Nut M16x10 600~900
7 Rear Brake Connecting Rod Bolt M16x32 50~80
8 Rear Brake Pin Self-lock Nut M8 250~270
9 Rear Upper Cushion Tightening Bolt M1046 200~300
10 Rear Lower Cushion Tightening Bolt M835 200~300

15
* Torque Values of Engine components *
Tightening Location Specification Torque Quantities
(kg-cm)
Cylinder Head Bolt M6 80~100 4
Cylinder Stud Bolt M8x182.5 500~800 2
M8x195.5 2
Cylinder Intake Pipe Stud Bolt M6x50 500~800 2
Muffler and Exhaust Pipe Tightening Screw M6 100~120 2
Muffler & Right Crankcase Upper Tightening Screw M8x42 300~400 1
Muffler & Right Crankcase Lower Tightening Screw M8x38 300~400 1
Spark Plug M10 100~120 1
Valve Gap Adjust Lock Bolt M5 50~90 2
Fuel Filter Nut Cap M30 150~200 1
Cooler Fan Lock CR M6x18 500~800 4
Wire Assembly Lock Screw M6x20 800~1000 2
Start Clutch Gear ightening Nut M22 (R.T.) 800~1000 1
Driven Belt Pully Assembly M12 400~600 1
Gearbox Cover Tightening Bolt M6x28 100~1200 3
M6x35 3
Gearbox Oil Fill Cover Screw M8 90~150 1
Gearbox Oil Drain Cover Screw M8x12 90~150 1
Clutch Side Cover Screw M6x40 50~80 6
M6x65 2
Starter Arm Tightening Screw M6x22 100~120 1

16
1-6 LUBRICATION POINTS
*BR8 Representative Figure*

* Chassis *
Lubrication Area Lubrication Type
Inner Side of Acceleration Lever Grease
Steering Bearing
Speed Meter Gear
Front Wheel Axle Bearing
Front Wheel Axle
Main and Side Stand Axles
Rear Wheel Bearing
Seat Cover Lock
Speed Meter Cable
Throttle Wire
Rear Brake Cable
Brake Assembly Brake Fluid

17
* Engine *

Lubrication Area Lubrication Type
Piston and Piston Rings
Piston Pin
Big End of Connecting Rod
Rocker Arm Frictional Contact Area
Cam Shaft and Chain
Cylinder Frictional Area
Oil Pump Chain
Gears Contact Surface
Bearing Operation Area
O Rings
Seal Lip Area
Satisfy SAE 10W-40 and API SE,SG Engine Oil

Starter Frictional Surface
Starting Cam Gear
Spring Operation Frictional Area
High Temperature Durable Grease
Generator Connector
Gearbox Ventilation Tube
Adhesives

18
1-7 PARTS NAME AND WIRING DIAGRAM
* Parts Name *

19
1-8 TROUBLE SHOOTING
1-8-1 Troubleshooting for failure in starting the engine

b
a c
Does not work Works
Check if the battery is
properly charged
Check if the starting gear and the
speeding clutch of the starting
motor suffer critical wear, if yes,
replace them
Bright light
Dim light or
light off
Check the
solenoid switch
of the starting
motor for noise
during work
Charge the battery or
replace it. In case of poor
charging, in addition to
recharging, check the
charging system of the
power plant for failure.
No noise Noise
a. Poor
contact of
starting
switch
b. Starting
relay
breaks or
in short
circuit
c. Loose
contact or
wiring
Check the starting
gear and speeding
gear of the starting
motor for abnormal
engagement.
Poor
Fair
Correct the
engagement
of the
starting
motor with
the speeding
clutch.
Replacement
of new
starting motor
and check for
work.
Engine does not start
Analysis of potential causes
Check if the crank shaft works
Does not work works
Check if the starting motor works Check RPM
Poor (too slow) Fair
Check battery charging
and contact of pins
Loosen the carburetor
leakage screw to check
for inlet of fuel.
Fair Poor
Check for existence
of water or other
impurities in the
carburetor buoyant
Check
for fuel
in the
fuel tank
Fair
Poor
Check for fuel
spill in the
carburetor
Clean the
carburetor
and the
fuel filter
Poor Fair
Repair or
replace
new
buoyant
and needle
valve
Check skips
in spark
l
No
skip
Skip
Refer to
1-8-3 No Skip
in Spark
Plugs for
checking
Poor Fair
Recharge the battery
and be sure the pin is
properly secured.(In
case of poor
charging, proceed
with a new charging
and check the
charging system of
the power plant for
failure.)
Check the
starting motor
and the switch
Poor
Fair
Repair
or
replace
with
new
ones
Check
the
engine
inside
(piston,
bearing
and
others)
for
failure
With
fuel
No fuel
Check the fuel
filter and the
tubing
Add in
designated
fuel
Poor Fair
Clean fuel
filter and fuel
tubing or
replacement
Check fuel tank
ventilation
tubing for
obstruction
See page 17
20
a
c
b

Poor Fair
Check engine
pistons,
bearings and
others
Replace the
original
starting motor
or repair it.
Check spark plug for cleanliness,
normal gap, pollution by gasoline. If
yes, check the choke of the
carburetor
Fair Poor
Clean and adjust
spark plug gap or
replace with new
ones
Poor Fair
Refer to
1-8-2 Poor
skip in
Spark
Plugs for
checking
Check if the
adjustment
screws of the
carburetor need to
be regulated
Poor Fair
Test the
compression
Clean or replace the slow
nozzle or correct, replace
with new threshold
Check choke of
the carburetor
for troubles
Readjustment
Poor Fair
Adjust or
replace new
choke parts
Check if the slop
nozzle of the
carburetor is
obstructed or the
threshold fails
Poor
Fair
Check air filter grill
for obstruction
Check cylinder washer for leakage,
check cylinder, piston, piston ring
for wear, with correction,
adjustment or replacement
Poor
skip
Fair
skip
Poor
Fair
Clean
ventilation
tubing
Adjustment or
replacement of
carburetor buoyant
needle valve
21

No fuel
Dirty fuel filter
Obstructed fuel tubing
Obstructed ventilation tubing of the fuel tank
Poor carburetor buoyant needle valve
Carburetor buoyant with impurities
Poor carburetor buoyant
No skip in spark plugs
Poor skip in spark plugs
Dirty spark plugs
Incorrect spark plugs gap
Dirty and wet spark plugs
Loose adjustment screws in the carburetor
Carburetor choke
Obstructed carburetor slow nozzle
Ailing carburetor threshold
Obstructed air filter grill
Leakage in cylinder washer
Seriously damaged cylinder, piston, piston
Dead battery
Poor contact of battery pin and conductors
Starting switch with poor or failure
Starting relay with broken wire or short circuit
Loose contact and wiring
Starting gear and speeding clutch gear seriously worn
Starting gear and speeding clutch gear in poor engagement
Poor starting motor
22
1-8-2 Troubleshooting for poor skip of spark plugs

Poor skip of spark plugs
Check for spark plug cap, ignition coil
Normal Loose
Replacement of new spark plug and
try skip again
Load in the spark plug
cap
Poor skip
Loosen spark plugs
Poor spark plugs
Poor high-voltage wiring
Poor distributor coils
Poor PICK Ups
Poor main switches
Wiring relay
Poor or abnormal
C.D.I. or plugs,
replacement of
C.D.I. and mount
properly the plug
Check high-voltage
coils, main switches,
PICK UP, distributor
coil for normality
High sparks
Check for loose C.D.I.
plugs, terminal
conduction and
resistance values
Replacement of poor
spark plug
Abnormal
Normal
Poor high-voltage
coils, main
switches, PICK
Ups, distributor
coils
Abnormal Normal
Check for
correct main
wiring contacts
and terminals, if
necessary,
correct them
23
1-8-3 Troubleshooting for no-skip of spark plugs

No skip of spark plugs
Check for proper loading of the spark plug cap
Fair Poor
Replacement spark plug and test the
intensity of the spark plugs
Load properly the spark
plug cap
Intense sparks
Loose spark plug cap
Poor spark plug
Loose C.D. adapter
Poor C.D.I.
Poor PICK UP
Poor distributor
high-voltage wiring
Poor main switch
Main wiring broken or in
short circuit
Ignition coil broken or in
short circuit
Poor adapter contact
Load properly the
C.D.I. adapter
Check C.D.I. terminals
passage and testing of
resistance
Weak sparks
Replacement of
poor spark plugs
Check for loose C.D.I.
contacts
Loose
Normal
a. Poor PICK UP
b. Poor main switch
c. Poor contact of
adapter
d. Broken main wiring
of short circuit
Abnormal Normal
Use C.D.I. tester
for checks of
C.D.I.
Replacement of the poor
C.D.I.
Abnormal Normal
Check ignition coil for
breaking or short
circuit, replace when
necessary
24
1-8-4 Troubleshooting for slow run (troubled engine)

Poor slow run
Check for contamination in spark plugs and excessive gap
Fair Poor
Alarming abnormality of ignition timing
Cleaning and
adjustment
Poor
Dirty spark plugs
Incorrect spark plug
gaps
Incorrect ignition
timing
Obstructed air filter
grill
Poor carburetor
buoyant needle valve
Poor carburetor choke
valve
Poor engagement of
carburetor and inlet
tube
Obstructed carburetor
slow injection
Poor engagement of
cylinder head washer
Severe wear of
cylinder, piston, piston
ring
Replacement of
the filter grill
Is the carburetor buoyant
level normal ?
Fair
adjustment
Is the air filter grill
obstructed?
Poor
Fair
Adjustment or
replacement of the
buoyant needle valve
Fair
Poor
Check if the choke
valve fails (valve
does not open) ?
Check of for air between the
carburetor and the air inlet
Fair Poor
Correction
Check for obstruction in the
carburetor slow injection
Fair Poor
Add tightening force or
replacement of the washer
Fair Poor
Cleaning Test the compression
Check for air leakage in the cylinder washer,
check wear of cylinder, piston, piston ring
and other elements with correction,
adjustment or replacement
25
1-8-5 Poor acceleration and horse power

a
Poor acceleration and horse power
Breakdown of potential causes
Check for drag of braking drum by braking plate
Fair
Poor
Check for obstructed air filter
Adjust or replace
braking plate
Braking plate retaining braking
drum
Air filter grill obstructed
Dirty spark plugs
Incorrect gap in spark plugs
Incorrect ignition timing
Poor skip in spark plugs
Incorrect adjustment of
carburetor adjustment screw
Poor choke valve in carburetor
Dirty or obstructed carburetor
injection nozzle
Poor carburetor buoyant needle
valve
Dirty fuel filter
Obstructed fuel circuitry
Poor engagement of cylinder
washer
Serious damage of cylinder,
piston, piston ring
Cleaning,
adjustment of
replacement of
new spark plugs
Check for
normal ignition
timing
Check for burn of spark
plugs and the gap
Replacement of the
filter grill
Intense
sparks
Poor skip
Check for normal
choke valve action
Adjustment
Check carburetor for
proper adjustment
Fair
Poor
Fair Poor
Test of spark plugs,
sparks
Timing
Fair Poor
See 1-8-2 poor
skip of spark
plug for
checking
methods
Fair Poor
Check for
obstructed
injection nozzle
Correction or
replacement
Fair Poor
26

a

Check for leakage in
cylinder washer; check
cylinder, piston, piston
ring for wear. Correct,
adjustment or
replacement when
necessary
Check for normal
fluid level in the
buoyant
Cleaning or
replacement
Fair Poor
Check the
compression
Check of needle
valve and buoyant
Fair
Poor (low level)
Check fuel pipe
and carburetor for
obstruction
Adjustment or
replacement
Fair Poor
Cleaning or
replacement
27
2. INSPECTION AND ADJUSTMENT
2-1 REGULAR MAINTENANCE SCHEDULE
Explanation:
(1) Please follow the regular maintenance schedule to ensure
the motorcycles function and life.
(2) I : Inspection (including clean up, lubrication, refill, or replace parts),
C: Clean, R: Replace, A: Adjust.
km or time 300 km 1000 km 2000 km 3000 km 4000 km 5000 km 6000 km 7000 km 8000 km 9000 km 10000 11000 12000
Maintenance Item (1 mo.) (3 mo.) (6 mo.) (9 mo.) (12 mo.) (15 mo.) (18 mo.) (21 mo.) (24 mo.) (27 mo.) (30 mo.) (33 mo.) (36 mo.)
Engine Oil R R R R R R R R R R R R R
Oil Strainer Screen C C C
Gear Oil R R R
Brake I I I I I I I I I I I I I
Tires I I I
Air Cleaner I R R
Battery I I I
Spark Plug C C C C
Fuel Filter R R
Carburetor I I C
Valve A A A A
V Belt I
Bolts and Nuts T
Note: (1) If ridden on dusty roads or raining days, please shorten the inspection and
replacement schedule for air filter.
(2) If ridden under heavy load, frequent long distance travel, please shorten the
replacement schedule for engine oil.
(3) Please clean the spark plug regularly, and replace the spark plug if necessary.

* Regularly Maintenance and Performance Relationship*

Performance100%

Ridden Time (or Mileage)

Curve A: With regular maintenance, the performance can be improved to optimal condition with
maintenance at scheduled time.
Curve B: Without regular maintenance, the performance drops and engine can be damaged.
Therefore, the engine needs repair to re-gain high performance, and the motorcycles
life can be shorten.
28
2-2 INSPECTION AND
CHANGE OF ENGINE OIL
Watch: Please place main stand to park the
motorcycle for inspection.

Inspection: Stop engine for 2~3 minutes when
it is warmed. Remove the engine oil level and
check if the oil level is bellow the lower limit.
Fill engine oil to the level between upper and
lower limits.

* Change Engine Oil *
Note: Please change engine oil according to
regular maintenance schedule. If ridden
on heavy load or long distance, please
shorten the maintenance schedule for oil
change.

Please put oil tray under the left crankcase
and remove the oil drain plug. Re-install the
drain plug when the engine oil is drained.

* Clean up the oil filter *
Inspection:
(1) If O-ring is damaged, please replace with
new one.
(2) If there is any deposit, please use clean up
before re-assembly.
Note:
(1) Torque of oil strainer screen:
150 ~ 200 kg-cm.
(2) Lubrication Type: SAE 10W-40
Engine oil capacity
* BH8 / BR8 / BF8 *
125c.c. Engine disassembled : 900c.c.
change oil : 750 c.c.
* BR9 / BF9 *
151c.c. Engine disassembled : 1000c.c.
change oil : 900 c.c.
(3) Check if there is any leakage after oil
change. Warn the engine and check the
engine oil level again.

29
2-3 FINAL GEAR OIL

motorcycle for inspection. Clean grease
around the drain plug.
Disassembly:
Oil refill plug.
Oil drain plug.
Note: Put an used oil tray under the gearbox
before removing the drain bolt plug.
Inspection: Check if the oil drain plug washer
is damaged. Please replace with new one if it
is damaged.
Drain gear oil.

Assembly:
Assembly drain plug.
Refill gearbox oil.
Reinstall oil refill plug.
Note:
(1) Torque on drain plug: 90 ~ 150 kg-cm.
(2) Oil type: SAE 90 #
(3) Oil capacity
* BH8 *
Gearbox disassembled : 110 c.c.
Regular Maintenance : 90 c.c.
* BR8 / BF8 / BR9 / BF9 *
Gearbox disassembled : 120 c.c.
Regular Maintenance : 100 c.c.
(4) Please check if there is any leaking after
oil refill.

30

2-4 BRAKE SYSTEM

A. Front Brake Lever Free Play
Note: Front brake lever free play is 10~20 mm.
Adjustment: This motorcycle uses non-adjust
style.

B. Brake Fluid
Inspection: The front brake fluid level should
above MIN. If it is below, refill the brake fluid
and check leakage of the brake system.
Warning: If there is low or no load when the
brake lever is hold, please check if there is air in
the brake system or fluid leakage.

C. Refill Brake Fluid
Watch: Please place main stand to park the motorcycle for inspection.
Disassembly:
2 tightening bolts on fuel cover.
Fuel trap.
Diaphragm.
Refill brake fluid to level between MIN and MAX.
Assembly: Assembly is in reverse order of disassembly procedures.
Warning:
(1) Please refill the same type of brake fluid. Different fluid type may create toxic chemical
ingredient and can damage the brake.
(2) Please do not let water into the master cylinder. Otherwise, the broil temperature may be
reduced and bubble can occur, then brake may not work.
(3) If the brake fluid is splashed on plastic parts or paints. Please wipe it out right away,
otherwise it may affect engine firing.

31
D. Procedure to Release Air
(1) Apply suitable plastic tube on drain plug,
and put a tray under drain hole.
(2) Slowly apply front brake several times.
(3) Hold the front brake lever, and do not
release the brake lever.
(4) Unplug the air release plug, and still hold the
brake lever.
(5) Tighten the air release bolt, then release the
brake lever.
(6) Repeat procedure 1 to 5, and release
air/bubble completely.
Note: Torque of air release bolt: 60 kg-cm.

E. Front Brake Disk
Inspection: If there is scratches, damage, or
wear, please replace with new one.
Note: The minimum disk thickness: 3.0 mm.

32

Brake disk eccentricity.
Note:
A. The max. eccentricity: 0.5 mm.
B. If eccentricity is not within the limit, please
check tire roundness. If wheel rim
roundness is not within the limit, then
change the brake disk

F. Rear Brake Adjustment
Note: The free play of rear brake lever:
10 ~ 20 mm.

Adjustment: Adjust the adjustment nut.

33

G. Inspection of Brake Lining and Wheel
Rim
Inspection: Check the wear indicator plate. If
the index is higher than the limit, please check
the wear of wheel rim and brake lining.

Disassembly:
2 tightening bolts on exhaust pipe
connector.

2 tightening bolts between exhaust pipe
and right crankcase.
Tightening nut on rear wheel axle.
Washer.
Rear wheel.

Inspection: check rear wheel rim inner
diameter. If it is badly worn, please replace
with new one.
Note:
(1) Please use vacuum to clean wheel rim and
lining. Try to reduce the contamination of
asbestos fiber, which may affect the human
breath system or lead to cancer.

(2) Use the Vernier calipers to measure the
diameter of wheel rim. If the diameter is
larger than 111 mm, then replace with new
one.

34

Note: *BH8*
Wear limit 111mm minimum.
*BR8 / BF8 / BK8 / BR9 / BF9 / BK9*
Wear limit 131mm minimum.
Disassemble the brake shoe and brake
shoe spring.

Inspection: Measure the brake lining
thickness with three points of Vernier calipers
(two ends and center). If badly worn, please
replace with new one (brake shoe and brake
shoe spring).
Note:
(1) Useable thickness is 2.0 mm.
(2) If less than useable thickness, please
replace with new parts.
Assembly: Assembly is in reverse order of
disassembly procedures.
Note:
(1) Torque of rear wheel bearing bolt: 600 ~
900 kg-cm.
(2) Torque of 2 bolts on exhaust pipe
connector: 100 ~ 120 kg-cm.
(3) Torque of 2 bolts on exhaust pipe and right
crankcase: 300 ~ 400 kg-cm.

35
2-5 TIRE AND TIRE PRESSURE
Inspection: Check if tire has been cracked,
damage, worn, inclusions (stone, nail, glass,
etc.). If tire is in poor condition, please replace
with new one.
Note: Tire specifications:
See specification table.

* Tire pressure *
Watch: Please measure cool tire pressure.
Note: Tire pressure.
Front tire: 175kPa(1.78 /
2
25.38 PSI)
Rear tire: 210kPa(2.14 /
2
30.45 PSI)

Warning: Dont over-load the motorcycle.
The tire may explode with over-load and it is
d

2-6 AIR FILTER
Disassembly:
Air filter side cover tightening bolt.
Air filter side co ver.

Filter tightening bolt.
Filter.

Inspection: Check if filter is filthy or broken. If
filthy or broken, please replace with new one.
Watch:
(1) If ridden on dusty roads or raining days,
please shorten the replacement schedule
for air filter.

36

(2) Dont start engine when air filter is not installed, otherwise, the piston or cylinder can be
damaged.

Assembly: Assembly is in reverse order of disassembly procedures.

Watch: Please install air filter and side cover closely.

2-7 BATTERY
Disassembly:
Foot mat.
Battery box cover.
Disconnect the battery negative
cable, and then the positive cable.

Warning: Please do not touch tools with
frame buring disconnecting positive + cable.
It can cause short circuit, then it may spark and
damage battery.

Inspection: This motorcycle use wet type
battery. Please fill with distillation water or
lead battery fluid when the electrolysis fluid is
lower than minimum.

Warning: First connect the positive cable,
and then negative cable.

37
2-8 SPARK PLUG
Disassemble:
Spark plug cap.
Note: Please blow away deposits around
spark plug with blower before removing spark
plug. Otherwise, the dust may drop into
cylinder and it can damage engine.

Inspection: Check if spark plug has carbon
deposits, burned, or cracked. Use steel
brush to remove carbon deposits and adjust
spark plug gap. Replace burned or cracked
spark plug with new one.

Note: Spark plug specification:
CR7HAS (NGK).
Spark plug gap: 0.6 ~ 0.7 mm.
Warning: First install the spark plug with
hand, and then tighten it with spark plug
wrench. Please do not over twist the spark
plug.
Note: Torque of spark plug: 100 ~ 120 kg-cm.

2-9 FUEL FILTER
Inspection: Check if it is hardened, damaged,
or leaking. If any above problem exists,
please replace with new one.

38

2-10 CARBURETOR IDLE SPEED
Note:
Please place main stand to park the motorcycle
for inspection.
Start engine and adjust idle speed at warm
engine condition.
* Adjust Procedure *
Connect engine speed meter.
Adjust idle speed to adequate range
with cross screw driver.

Note:
(1) Increase engine speed by rotating the screw clockwise.
(2) Reduce engine speed by rotating the screw counter-clockwise.
(3) Engine idle speed range:
1800100 rpm.

2-11 THROTTLE VALVE
Inspection: Check if the throttle valve
operation is smooth.
Note:
(1) Throttle lever free play: 2 ~ 6 cm.
(2) Micro-adjustment is performed at throttle
lever. Macro-adjustment is performed at
carburetor throttle valve cable.
A. Throttle Lever Gap Adjust
Procedures:

Open dust boot.
Loose lock bolt.
Adjust by rotating adjust nut.
Note:
1. Increase engine speed by rotating nut
clockwise.
2. Reduce engine speed by rotating nut
counter-clockwise.
Tighten adjust nut after adjustment.
Close dust boot.

39

B. Carburetor Throttle Cable Gap
Adjustment Procedure:
Note: First, adjust the throttle lever gap. If it
does not satisfy the standard, then adjust the
carburetor throttle gap.
Loose Tightening bolt.
Rotate the adjust nut.
Note:
1. Increase gap by rotating the screw
clockwise.
2. Reduce gap by rotating the screw
counter-clockwise.
Tighten nut after adjustment.

2-12 VALVE
Disassembly:
Cylinder head bolt.
Cylinder head.

Note:
(1) Inspect and adjust are performed at engine
temperature lower than 35
o
C.
(2) Rotate the cooler fan, such that the mark on
cam shaft gear match the top-dead center
position and the T mark on flywheel match
the mark on crankcase. Then, perform
check and adjustment.

Adjustment: Use valve adjust wrench to loose
tightening bolt, and rotate nut to adjust gap.
Note: Intake valve gap: 0.08 ~ 0.10 mm.
Exhaust valve gap: 0.08 ~ 0.10 mm.
Watch: Check if the gap is correct after bolt is
tightened.

40

2-13 HEADLIGHT AXLE
Use cross screw driver to adjust the nut.
Note:
1. Rotate the nut clockwise for higher light
axle.
2. Rotate the nut counter-clockwise for lower
light axle.

2-14 V BELT
Disassembly:
Loose the cooler tube tightening ring.

Kicker starter arm tightening bolt.
Kicker starter arm.
8 clutch side cover tightening bolts.

Clutch side plate.
Gasket.

41

Use universal wrench to tight the drive
plate, and remove lock nut and gasket.
Drive plate.

V bel t.
Inspection: Check if the V belt has cracked,
threaded, and pilling. If it is in poor condition,
please replace with new V belt.
Note:
(1) Check the belt length.
Wear limit: 18.0 mm or 8000km
(2) Belt specification:
*BH8*
BANDO VS BELT 743 20 30
*BR8 / BF8 / BR9 / BF9*
BANDO VS BELT 846 20 30
Warning: Please do not apply any grease on
pulley and V belt, which can cause belt slip.
Note:
(1) Diver plate screw is left-threaded.
(2) Torque of driver plate nut: 800 ~ 1000
kg-cm.
(3) Torque of clutch side nut: 50 ~ 60 kg-cm.
(4) Torque of kick starter arm screw:
100 ~ 120 kg-cm.

42

2-15 CYLINDER PRESSURE
Note:
(1) Check the cylinder pressure at warm engine
condition.
(2) Use compressed air to blow away deposits
around spark plug before removing spark
plug. Otherwise, deposits may drop into
cylinder and damage engine.
Disassembly:
Spark plug cap.
Spark plug.

Inspection:
(1) Install cylinder pressure gauge.
(2) Full open fuel valve.
(3) Ignite the starter motor by pressing the start
button and measure cylinder pressure.
Note:
(1) Cylinder pressure
*BH8 / BR8 / BF8*
125c.c. engine
12.8 - 570 kg/cm
2
-rpm.
*BR9 / BF9*
151c.c. engine
11.7 - 700 kg/cm
2
-rpm.
(2) Reasons of too high cylinder pressure:
A. Carbon deposits at combustion
chamber.
B. Carbon deposits on piston top surface.
(3) Reasons of too low cylinder pressure:
A. Valve gap too small.
B. Worn valve seat or seat is not
completely closed.
C. Incorrect valve timing.
D. Leakage due to worn cylinder gasket.
E. Worn piston ring.
F. Worn piston and cylinder wall.
(4) Torque on spark plug 100 ~ 120 kg-cm.

43

3. RELEASE AND INSTALLATION OF ENGINE
3-1 Starterd preparation data Simplified troubleshooting
Disassembling of Crankcase :
Before disassembling the crankcase, the engine must at first dismounted and the
following operations must be completed:
Air cleaner, carburettor, and air intake mounted .
Starter motor.
Cylinder head cover, cylinder head.
Cylinder, piston.
Clutch cover, drive pully comp, driven pully comp.
Rear wheel, rear shock absorber.
Cooling fan, flywheel magneto.
Oil pump.

Standard preparation data for crank, cylinder, piston, and piston rings:
Unit: mm
125 c.c. Engine 151 c.c. Engine
Item

Checking part Standard value Allowable limit Standard value Allowable limit
Cylinder inner diameter 52.400-52.410 52.500 57.400-57.410 57.500
Roundness - 0.05 - 0.05
Cylinder
Cylinder degree - 0.05 - 0.05
Piston outer diameter 52.370-52.390 52.300 57.375-57.395 57.300
Inner diameter of piston pin 15.002-15.008 15.040 15.002-15.008 15.040
Gap between cylinder and piston 0.010-0.040 0.100 0.005-0.035 0.100
Top ring 0.015-0.055 0.090 0.015-0.050 0.090 Gap between
Piston and piston
ring
Second ring 0.015-0.055 0.090 0.015-0.050 0.090
Top ring 0.10-0.25 0.50 0.015-0.300 0.50
Second ring 0.10-0.25 0.50 0.015-0.300 0.50
Piston and
piston rings
Gap of piston ring
Lateral track of
oil scraper ring
0.2-0.7 - 0.2-0.9 -
Gap between piston and piston pin 0.002-0.014 0.020 0.002-0.014 0.020
Outer diameter of piston pin 14.994-15.000 14.960 14.994-15.000 14.960
Inner diameter of the hole at connecting rod
small end
15.016-15.034 15.060 15.016-15.034 15.060
Blow with compressed air the parts after cleaning and before measuring.

44

Simplified troubleshooting:
In case of bad ignition, not running smoothly in low speed, check if there is white smoke
issuing from air intake of the crankcase. If it is the case, dismount the cylinder, piston,
piston rings and measure them according to the above table. The causes may be the
wear or break of piston pins.

If there is white smoke issue from muffler, its causes may be:
Wear or break of piston pins.
Serious wear of pistons and cylinders due to friction.
Wear of connecting rod small end holes and piston rings.

Knocking pistons:
Serious damage of cylinders, pistons, and piston rings by friction wear.
Wear of piston pins and piston pin holes.

Low compression rate:
Wear or break of piston rings.
Wear or damage of cylinder walls and pistons.
Too narrow gap or no gap at all of valve.
Gap between valve and its seat.
Valve burnt.
Valve untimely.
Spark plug not tightened.
Gas leak at cylinder head washer.

Too high compression rate:
Piston hea d or combustion chamber unclean.

Abnormal engine noise:
Bearing of the end transmission mechanism loosened.
Bearing of crank loosened.

45

3-2 RELEASE THE ENGINE
-Disconnect the terminals of the battery.
-Disconnect the electric terminals of the various components.
-Disconnect the fuel feed pipe and the vacuum cock control pipe.
-Disconnect the throttle valve control wire of carburettor.
-Release the rear brake cable.
-Release the shock absorber.
-Remove the engine mounting shaft screw.
3-3 INSTALLATION OF THE ENGINE
-Assemble the engine on the chassis by following the steps described for its disassembly in
reverse order.
-Inspect the engine lubricate oil with the oil level indicated.
-Check the operation of the carburetor and accelerator.
-Adjust the rear brake.
3-4 CHECK THE ENGINE PARTS
3-4-1 Air Cleaner
-Remove the seven fixing screw of the air-cleaner cover.
-Inspect the filter is keep clean or not.
-Change a new filter, if it is badly dirty or broken.
3-4-2 Spark Plug
-Unscrew the spark plug with specified tool.
-Examine the spark plug does any dirty, deposit carbon or burn out
-Clean the spark plug if has dirty or deposit carbon with steel brush.
-Measure the clearance of the spark gap.
-The gap standard is 0.6-0.7 mm
3-4-3 Cylinder head and Timing
-Remove the fan cover, cooling fan and shroud set.
-Release the cylinder head cover bolt, remove the cylinder head cover.
-Turn the flywheel with clockwise direction, let the T mark on the flywheel point to the rib
mark on crankcase. Then, the circle hole mark on the cam shaft gear will be upward
position. Such position, the engine at top dead point position.
-Remove the nuts and washers of the camshaft holder.
-Remove the camshaft holder and dowel pins
-Disassembly the chain gear and take the camshaft off.
-Inspect the cam surface and the bearing.
-If cam surfaces are serious abrasived and the bearings are damaged replaced with a new
one.
46
-Pull out the rocker arms shaft and inspect that the rocker arms should not be worn and the oil
hole is not obstructed.
-Pulling cylinder head gently off the cylinder.
-Remove the dowel pins, cylinder head gasket and the chain guide rod.
-Clean the coupling surfaces with carefully not to damage them.
-Clean the combustion chamber, ridding any carbon deposits.
-Check that the valve seats.
-Examine the combustion chamber and shown no sign of cracks or damage.
-Use a calibrated rule, inspect the cylinder head lower surface is perfect flatness.

-Use a thickness gauge, inspect that the
surface wear does not exceed 0.05mm.

-Measure the free length of the valve springs.
The limit of inner spring is 31.2mm.
The limit of outer spring is 34.1mm.

-Examine the valves should not be damaged,
cracked, burnt or bended.
Clean the valve, removing all carbon formation
and measure the diameter of vale axle.
The wear limit is 4.9mm.
Inspect the condition of the seat on the valve
head, damaged or cracked are not allowed.

47
-Inspect the valve seats and show no signs of damages or crack.
Measure the inside diameter of valve stem seal.
Wear limit of inlet valve stem seal is 0.08mm.
Wear limit of exhaust valve stem seal is 0.10mm.
-Measure the width of the impression on the
valve seat.
Wear limit is 1.8mm maximum.

-Lubricate the valve stems and suit them to the guides. Fit the springs, the upper cups and the
lock cones.
-Fit the valves with special tool carefully.
The springs may come off, it is dangerous.

-Gently tap the valve stems with a plastic
nammer to make the cones in their seats.
Be carefully, when doing this work.

-Insert the two rocker arms shaft.
-Fit a new cylinder head gasket and keep the
surfaces of gasket and keep the surfaces of
gasket clean.

48
-Assembly the cylinder head.
-Turn the flywheel, Let the T mark on the flywheel to aim at the rib mark on the crankcase.
The circle hole on the camshaft gear is upward and the two mark line on the camshaft gear
match with surface of the cylinder head.
Fit the camshaft gear and fit the chain on this camshaft gear.

-Fit the dowel pin.
-Fit the camshaft holder.
Fit the nuts on the related studs and tighten
them by diagonal step.
Tightening torque is 200 kg-cm

-Install the chain guide.
Loose the lock by turning the nut with counter-clock direction.
-Adjusting the valves
Should align with rotate the crankshaft by hand until the circle hole marks on camshaft gear
wheel and the other two mark line cylinder head, then adjust the plays of the valves with special
tool and with the aide of a thickness gauge measure the gap between the rocker arm adjusting
bolt abutting end and the valve stem.
Clearance: Inlet valve gap: 0.08 ~ 0.10 mm
Exhaust valve gap: 0.08 ~ 0.10 mm
-Assemble the head cover.
Replace the sealing ring with a new one, install the cover and screw the four bolts.

49
3-4-4 Cylinder and piston
-After removing the cylinder head and gasket,
take out the cylinder.
-Take off the cylinder gasket and clean the
crankcase surface.

-Place a clean cloth under the piston to prevent
any dust from falling inside the crankcase
chamber.
Remove the piston pin circlip and the piston.

-Inspect the cylinder inside surfaces show no
signs of seizure or anomalous wear, then
measure the inside diameter of the cylinder
with a bore meter.
Note: *BH8 / BR8 / BF8*
125c.c. engine
Wear limit 52.5mm.
* BR9 / BF9*
151c.c. engine
Wear limit 57.5mm.
-Take measurements on three planes along the
cylinder axis; for each plane take a
measurement on the circumference.

-Take off the piston rings carefully.
Inspect the piston surface, anomalous wear is
not allowed.

Note: *BH8 /BR8/ BF8 / BK8* 125c.c. engine
Wear limit 52.5mm.
*BR9/ BF9 / BK9* 151c.c. engine
Wear limit 57.5mm.

50

-Measure the clearance between the ring and
the groove.
The max. clearance of top ring is 0.09mm.
The max. clearance of 2nd ring is 0.09mm too.

-Measure the diameter of the piston pin hole.
Wear limit is 15.04 mm.

-Measure the piston pin outside diameter.
Wear limit is 14.96 mm.

-Measure the inside diameter of the piston-rod
small end.
Wear limit is 15.06mm.

51
-Put the piston ring into the cylinder and
measure the clearness of opening by
thickness of opening by thickness gauge.
Replaced if it exceeds 0.5mm.

-Fitting the rings on the piston.
Take care not to damage the rings during the
fitting and position them as shown in the
figure.
Once fitted, the rings must rotate freely in their
grooves.
-The 2nd ring is engraved 2R mark.
The 1st ring is engraved R mark.
The mark should face upwards while installing.

-Assemble the piston, the IN reference mark
is at the inlet valve side.
Insert the piston pin and assembly rings.
Assemble the circlip carefully.
-Fit the cylinder gasket and cylinder.

52

3-4-5 Crankcase-Crankshaft
-Remove the chain and chain guider.
-Remove the oil divider and then remove the
driving sprocket.

-Remove the coupling bolts, gasket and pin.

-Take out the crankshaft from crankcase.

-Check the side play of the piston-rod big end
with a thinness gauge.
Wear limit is 0.5mm.

53

-Measure the offset between the two shafts of crankshaft.
Maximum offset is 0.1mm.
-Bearing
Before removing the bearings, make sure that they rotate freely and have no play in their
respective housings.
-Fit the crankshaft and smear the coupling surfaces with Loctite fixing glue.
-Fasten the flywheel-side crankcase half to the transmission-side crankcase half.
-Fit the crankcase halves coupling screws.
Tightening torques 90 kg-cm.

54

3-5 FUEL REED CIRCUIT
3-5-1 Carburetor
Disassemble all carburetor components, clean
them with solvent, then dry them with
compresses air.
Pay special attention to the ducts in carburetor
body.
Carefully check the condition of all components.
The needle may be worn, replace it.
The throttle must slide free in the carburetor.
If there is excessive play due to wear the
throttle must be replaced.
Using the new gaskets when reassembling the
carburetor.
Inspect if the pressure piston is worn or
presents notches, Inspect the vacuum
membrane carefully.
Damaged or cut are not allowed.

3-5-2 How to take off the carburetor
-Remove the fuel feed pipes.
-Remove the automatic by choke connector.
-Loosen the throttle control cable adjusting nut
and disconnect the throttle control cable from
the carburetor.
-Loosen the air filter fastening strap and
remove the carburetor.

55

3-5-3 Automatic Choke

The needle of automatic choke must keep well.
Notches, signs of wear, scratches or other
damage are not allowed.

3-5-4 Membrane chamber
-Loosen the drain screw and let the fuel flow out
from the float chamber.

-Remove the two screws of the pressure
chamber.

56

-Remove the compression spring and the
pressure piston

-Remove the needle holder and the needle
from the piston.
Inspect the pressure piston and membrane.
Notches, scratches or other damage are not
allowed.
-Fit the needle, the spring and the needle
holder in the pressure piston and fix the
needle holder.
-Fit the pressure piston in the carburetor body.
-Fit the compression spring.
-Fit the pressure chamber cover and fasten it
with two screws.

57

3-5-5 Float/Needle valve/Jets
-Unscrew the four float chamber screws.

-Remove the float pivot, the float and the
needle.

-Inspect the needle valve and its seat.
Notches or deep scratches are not
allowed.

-Remove the main jet, choke jet and idling
jet.
Inspect these jets.

58

-Before fitting the parts again, blow all parts, and in particular the housings of the jets, with
compressed air.
-Clean the main, choke and idling jets with a detergent solvent and blow them with
compressed air.
-Fit the main, choke and idling jets.
-Fit the seat of the needle valve. Fit the needle valve. the float and the float pivot
-Measure the float height while its tongue
touches the needle valve.
Distance between the float and the float
chamber plane is 18.5mm.
Replace the float if the level is not as
indicated.
Fit the float chamber.

3-5-6 Throttle Valve
Loosen the fastening screws and remove
the throttle valve.
Check that the valve rim shows no deep
scratches.
Fix the throttle valve again with Anti-loosen
glue and new screws.
Note: Before tightening the two screws of
throttle valve, carry out the following
ti

(a) Loosen the slow running adjuster completely, so as to enable the throttle to close the
duct completely.
(b) Proceeding with the utmost care, manually position the throttle in completely closed
position.
(c) Tighten the screws while holding the throttle in place.
(d) Make sure the throttle is correctly repositioned.

59

3-6
3-6-1
LUBRICATION
Engine oil level
The engine must be in cold and the scotter
positioned uprightly on its stand flat ways.
Inspect the oil level with the oil meter that
remove
it from the crankcase.
If the level is close to the minimum point and
the oil is not to be renewed, fill up with oil of
the recommended type.

3-6-2 Oil renewal

Renew the oil easily while the engine is in hot
condition.
Place a vessel under the engine, remove the
outlet bolt and the oil lever gauge.
After draining the oil, clean the oil lever gauge
(check the O-ring seal) and fit the oil lever
gauge and outlet bolt again.
Tightening torque: 150 kg-cm
Supply the engine with recommended oil
through the oil filter
Screw the filler plug.
Lubrication Type: SAE 10W-40
Engine oil capacity
*BH8/BR8/BF8*
125c.c. Engine disassembled:900c.c.
Chang oil: 750c.c.
*BR9/BF9*
151c.c. Engine disassembled:1000c.c.
Chang oil: 800c.c.

Note: Run the engine after a few minutes, then recheck the oil level again when the engine
is until cold condition. The oil level should always be kept below the max. lin and
above the min. line.

60

3-7
3-7-1
DRIVING PULLY-CLUTCH-DRIVEN PULLEY
Transmission cover
-Loosen the fixing screw of cooling duct and
remove the cooling duct.
-Remove the kick starter lever
Assy..
-Remove the clutch cover screws by diagonal
step and then remove the clutch cover.
-Take off the knock pins and remove the
gasket.

3-7-2 Driving pulley
-Use the special tool to lock the fixed drive
face
and loosen the central nut with wrench.

-Remove the belt from the spacer and remove
the
drive pulley

Note: Press the movable drive plate and drive
pulley face while removing the drive pulley
face Assy. in order to avoid the roller to stand
up.

61

3-7-3 Driven pulley
-Remove the central nut of clutch housing
with a
compass spanner to hock the housing bell
and loosen the nut with wrench.
-Remove the driven pulley comp and belt.

3-7-4 Checks
*Drive belt
-Be sure that the drive belt should not be
cracked or damaged.
-Measure the belt length.
Wear limit: 18.0mm or 8000km

62

-Remove the movable drive plate guide
blocks and rollers.

Take care to make the mark on the rollers and groove of drive face in order to install rollers
correctly.

*Rollers
Inspection that the rollers should not to be
damaged or worn.
*BH8*
Wear limit 18.0mm minimum.
*BR8/BF8/BR9/BF9*

*Roller Bush
Inspection that the internal bushing of drive
bush should show no signs of anomalous
wear and with bore meter to measure its
inside diameter.
*BH8*
Wear limit 25.0mm maximum.
*BR8/BF8/BR9/BF9*
Wear limit 24.06mm maximum.
Note: Take care to replace the rollers in their
original positions.

63

*Spacer
-Make sure the spacer surface should not be
damaged.
-Measure the outside diameter of the spacer.
*BH8*
*BR8/BF8/BR9/BF9*

3-7-5 Guide shoes
-Inspect the guide blocks should not be worn
and then inlay them into the movable drive
plate.

Assemble the movable drive plate cover.
64

3-7-6 Clutch housing
-Inspect for any unusual damage and color
change.
-Replaced if the inside diameter exceeds
125.5mm.

3-7-7 Driven pulley
-Remove the central nut with compass
spanner to lock the driven pulley.
-Warning: Press tightly the driven pulley while
unscrewing the nut, so that the spring will
not jump out.

3-7-8 Retaining sheet
-Pull out the retaining sheet by hand

-Pull out the guide pins and extract the
movable drive face from the fixed driven face

65

3-7-9 Fixed driven face comp
-Measure the outside diameter of the fixed
driven face bush.
-Wear limit 33.94mm

3-7-10 Movable driven face comp
-Measure the inside diameter of the movable
drive face.
-Wear Limit 34.06mm.

3-7-11 Spring
-Measure the free length of the movable
driven face spring.
-Replaced if the free length of spring is less
than 135mm.

3-7-12 Fixed driven face comp bearings
-Push out the old bearings and install the new one with the tube that has corresponding
length and suitable diameter.

66

3-7-13 Clutch
-Make sure that should not be oil strained,
cracked and unusual damaged from the
appearance.
-Replaced if the thickness of lining is less
than 1.5mm

3-7-14 Fitting

-Install the fixed driven face comp into the movable driven face comp.
Avoid to damage the lip of oil seal.
-Install two O-rings and apply grease to the groove of the cam then fit the guide pins.
-Apply a little grease inside of the spring sheet and manually push the spring sheet in lightly
and the install the spring and screw the central nut.

67

3-8 STARTER ARM
Disassembly:
Loose cooler tube tightening ring.

Starter arm tightening bolt.
Starter arm.
8 clutch side cover tightening bolts.
Clutch side cover.

Gasket.
Pin.

Use universal wrench to hold drive
plate and remove drive belt pulley
assembly.
Belt.

68

Starter arm washer.
Spring stop plate.
Spring.
Starter arm.
Starter cam assembly.

Inspection:
(1) Check if starter arm surface and collar are
worn and damaged.

(2) Check if starter cam gear surface is worn
and damage.

(3) Check if starter cam and starter arm
loaded surface are worn and damaged.

69

Note:
(1) Apply grease on starter arm collar and
cam loaded area for lubrication.
(2) The starter cam locking pin should match
with crankcase fillister for assembly.

(3) The mark on starter axle gear should
match mark on starter cam.

(4) Use special tool for starter arm spring
assembly. Rotate tool clockwise, such
that spring locking pin is positioned under
crank case half-moon location, then
assemble stop plate.

Note:
(1) Torque of starter arm spring plate
tightening bolt: 90 kg-cm.
(2) Torque drive plate tightening nut:
800~1000 kg-cm.
(3) Torque of clutch side cover bolt: 50~80
kg-cm.
(4) Torque of starter arm tightening bolt:
100~120cm.

70

4
4-1.
CHASSIS
REMOVAL OF COVER

71

* Dismount floor panels following the sequence shown in the list:

Helmet Case. Mirror, Rear View.

Carrier.
Cove Handle Bar,
Upper.

Bottom Plate. Leg Shield Front.

Right and Left Side
Cover.

Front Fender.

Cover Set, Leg Shield Fender, Fixed, Front.

Cover
Handle Bar, Under.

Leg Shield Side,
Lower.

Leg Shield, Rear. Leg Shield, Lower.

Cautions:
1. Do not damage cover of body panels while dismounting.
2. Handle with care regarding lugs of to avoid damage dismounting.
3. When remounting, do not scratch or crash wiring.
4. While assembling every lug shall be fixated effectively.
5. While assembling, make matching panels and their slots.

72

4-2. TROUBLESHOOTING OF CHASSIS

STEERING/ SUSPENSION/ FRONT WHEELS/ FRONT BRAKES

Operation Cautions:
1. Leg shield lower must be dismounted before the front wheel is dismounted. Use a
jack to raise the wheel above ground and support the car body firmly.
2. The brake inner cylinder and lining shall be kept free form grease during operation to
avoid driving danger caused by braking effort reduced by grease.

Troubleshooting
Steering too tight (heavy)
1.The bolt of ball bearing fastening at the top of the steering column too tight.
2. Balls of the steering system broken.
3. The conical base for steering ball bearings damaged.
4. Bad curvature of the front fork comp.
5. Bad curvature of the front wheel shaft or deviation of the tire.
6. Insufficient tire pressure.

Straight driving impossible due to deviation of the steering wheel:
1. Deviation of the front fork comp.
2. Unequal working of the left and right shock absorber beside the front fork comp.
3. Running deviation due to the deviation of the front axle.
4. Deformation of the front tires.
5. Deformation of wheel rim.

Front shock absorber too flexible:
1.Shock absorber spring constant too low.
2. Shock absorber spring fatigue.
3. Lack of oil in the shock absorber resulting from leakage.
4. Loose front fork comp axle bolts.

73

Abnormal noise of working front shock absorber:
1.Noise coming from friction between the shock absorber and the outer tube joint.
2. Noise coming from friction between the shock absorber spring and the outer tube.
3. Noise coming from shock absorber deviation due to loosen screws.
4. Deformed moving parts of the absorber.

Too large sway of front wheels:
1. Deformed wheel rim.
2. Insufficiently tightened bolts of front wheel spindle, or although tightened but
becoming loose.
3. Sway caused by too large gap around the front wheel bear or damaged bearing.
4. Bad of worn tires.

Inefficient braking
1. Unclean or oily friction lining surface.
2. Excessive wear of the friction lining.
3. Deviated or deformed brake discs.
4. Inefficient braking due to air resistance caused by air unduly existing in the braking
system.
5. Insufficient brake fluid.
6. Deteriorated brake fluid.
7. Brake fluid pipe clogged.
8. Improper mounting of brake caliper body.
9. Uneven wear of the lining in the brake caliper.
10. Damaged grease seal of the piston of the brake caliper.
11. Bent brake rod.

Difficult to operate the brake rod:
1. Brake fluid pipe clogged.
2. The brake caliper not working well.
3. The piston the main cylinder not working smoothly or seriously damaged.
4. The brake rod bent.

74

Uneven braking effort.
1. Unclean brake lining or brake disc.
2. Bad mounting of wheels causing serious sway.
3. Deformed brake disc.
4. Clogged brake fluid pipe.
5. Serious wear of the brake caliper lining.
6. Serious damage of the grease seal of the brake caliper piston.
7. Deteriorated brake fluid.
8. Resistance due to air existing in the brake system.

75

. REAR WHEELS/ REAR BRAKES/ REAR SUSPENSIONS

Operating Cautions:
Do not leave greasy the surface of the brake lining inside the brake drum.

Troubleshooting:
Serious sway while rear wheel rotates.
1. Distorted wheel rim.
2. Tire in bad state.
3. Defective mounting of wheel propeller shaft pieces.

Inefficient rear brake (Drum type):
1. Bad adjustment of the brake.
2. Serious wear of the brake drum.
3. Serious wear of the brake cam shaft.
4. Serious wear of the friction face between the rear brake lining and the cam shaft.
5. Wear of the rear brake lining.
6. Unmatched parts in the chisel groove of brake arm.

Rear shock absorber too flexible:
1. Absorber spring constant too low.
2. Fatigue of the absorber spring.

76

4-3 FRONT WHEEL
motorcycle for maintenance.
Disassembly:
Speed meter cable nut.

2 tightening bolts on clipper.
Clipper.
Note: Do not apply brake when removing
clipper from brake disk. Otherwise, the lining
can contact.

Front wheel.
Inspection: Check eccentricity and wear
condition.
Note: If eccentricity is higher than 0.2mm,
please replace with new one to ensure driving
safety.

Speed meter gear assembly.

*Inspection of Wheel Rim*
Put wheel rim on rotation stand.
Rotate the wheel slowly and use dial-gauge to
measure eccentricity
Note:
(1) The transverse eccentricity should be
within 3.0 mm. If the condition is poor,
please replace with new one.

77
(2) The lateral eccentricity should be within
3.0mm. If the condition is poor, please
replace with new one.

*Be Careful Items in Assembly*
(1) Speed meter gear assemble fillister and
wheel hub flange should be fully
matched.

(2) The wheel hub flange fillister and front fork
flange should be fully matched.
Note:
(1) Torque of rear wheel axle self-lock nut:
600~ 900 kg-cm.
(2) Torque of brake clipper tightening bolt:
210 ~250 kg-cm.
(3) Torque of speed meter cable nut: 60kg-cm

78

4-4 REAR WHEEL
Disassembly:
Exhaust pipe.

Lock screw nut and washer.
Rear wheel.

Note:
(1) Please use vacuum to clean wheel rim
and lining. Try to reduce the contamination
of asbestos fiber, which may affect the
human breath system or lead to cancer.

(2) The transverse eccentricity should be within 3.0mm. If the condition is poor, please

(3) The lateral eccentricity should be within 3.0 mm. If the condition is poor, please replace
with new one.

Brake lining assembly (brake shoe,
brake shoe spring).
Inspection: Use 3 points of Vernier calipers
(two ends and center) to measure lining
thickness. If lining is badly worn and
thickness less than 2.0 mm. Please replace
with new assembly (brake shoe, brake shoe
spring).
Warning: Please do not apply any grease on
brake lining, which can lead to unsafe drive.

79
Loose rear brake adjusting nut and
remove brake cable.
Brake arm cover.
Brake spring.
Rear brake connecting rod.
Rear brake cam axle.

Watch: Please apply thin layer of grease on
contact area of cam axle, pin and lining. Do
not apply too much grease.
Note:
(1) Torque of rear brake connecting rod bolt:
50 ~80 kg-cm.
(2) Torque of lock pin nut: 250 ~270 kg-cm.
(3) Torque of rear wheel self-locking nut:
600 ~ 900 kg-cm.

80

4-5 REAR SHOCK ABSORBER

Disassembly:
2 attaching bolts on air filter.
Air filter.

Upper and lower attaching bolts on
rear shock absorber.
Shock absorber.
Inspection: Check if the shock absorber is
worn, scratched, leaking, or bent. If its
condition is poor, please replace with new
one.
Note: Torque of shock absorber upper and
lower attaching bolts: 200 ~ 300 kg-cm.

81

5. ELECTRICAL SYSTEM
5-1. Operating Cautions & Troubleshooting
Operating Cautions:
1. Warning:
a. The liquid in the battery is diluted sulfuric acid that is dangerous. If, your skin or eye
unfortunately get contact with it, please wash with water abundantly and consult
immediately a doctor, lest you should lose vision.
b. If your clothes is touched by the electrolyte, your skin would also be touched.
Therefore you should get it off and wash with water abundantly.

2. Check if electrolyte in the battery is sufficient. If not, add distilled water till the liquid level
reach the upper limit line.

3. The battery is rechargeable after discharging. If it is unused after discharge, it may
deteriorate and shorten service life. It will become less efficient. After usage of 2~3 years,
battery capacity will decrease. It can be regained by recharging several times.

4. When there is other loads while igniting, if the voltage will rise again after an abrupt falling,
it is normal.

5. If a battery is unused during a long time, its energy storage will decrease by its
auto-discharge. Therefore, a recharging is necessary around every 3 months.

6. To charge a battery, it shall be removed from the car and its filler plugs removed. To put
the charging current ON or OFF, you must operate at the chargers switch. You shall not
connect or pull off directly on the battery because electric spark may provoke hydrogen
explosion.

7. During battery charging, hydrogen (H
2
) is produced. It is an inflammable gas. Fire must be
forbidden.

82
8. At recharging a battery, the temperature of electrolyte shall be lower than 45 .

9. To test if a battery is fully charged, please use a voltmeter. Never use Spark method.

10. When there is current in an electrical installation, please do not pull off a contact then
connect it again, because resulting over voltage may damage electronic parts in the
commuter. Therefore, this operation must be done after the main switch is put OFF.

11. If fresh electrolyte is poured in a new battery, a voltage will be generated after a certain
lapse of time. If the voltage is not sufficient, then a recharging is necessary. A recharged
new battery has necessarily a longer lifetime.

12. The C.D.I of the ignition system shall not fall swinging and be shocked. It is a cause of
frequent breakdown. Therefore, a special precaution is necessary in its dismounting and
remounting.

13. Bad contact between plug and jack causes often the breakdown of the ignition system.
Therefore, before undertaking repair, the contact is to be checked at first.

14. Spark plugs of a suitable heat value and gap are to be used. Otherwise, engine will not
work smoothly or break.

83

Troubleshooting:
Battery Recharging System:
No voltage:
1. Battery cable fallen or disconnected.
2. Fuse fused.
3. Defective of flywheel magneto.
4. Excessive battery discharging:
a. Electrolyte leaked.
b. Chemical reaction in battery.
c. Short circuit in battery.
d. Defective rectifier.

Low voltage:
1. Insufficient recharging.
2. Leaking of electrolyte.
3. Defective separator causing short circuit between positive and negative plates.
4. Defective battery terminals.
5. Defective recharging system.
6. Defective rectifier.

Excessive specific weight of electrolyte:
2. Leaking of electrolyte.
3. Reaction between sulfuric acid and pole plates.

Too low capacity:
2. Pole plates react with sulfuric acid.
3. Insufficient electrolyte.
4. Active matter fallen from pole plates because of excessive recharging.

84

Inefficient recharging system:
1. Bad contact at connectors, short circuitry, or broken circuit.
2. Defective rectifier.
a. Armature winding short circuited or broken.
b. Magneto coil short circuited or broken.

Bad electric continuity:
1. Bad contact at battery connection.
2. Ignition system short circuit or bad contact at connectors.
3. Lighting system short circuit or bad contact at connections.

Ignition System:
Dysfunctioning of spark plugs:
2. Defective high-tension coil.
3. Defective C.D.I .
4. Defective spark plugs.
5. Defective conductor contact, breaking, or short circuit, for example:
a. Conduction between flywheel magneto and C.D.I .
b. Conduction between C.D.I and the main switch.
c. Conduction between C.D.I and the high-tension coil.
Engine not running smoothly:
1. Defective ignition first circuit:
a. Bad contact in circuitry or cable.
b. Defective of flywheel magneto.
2. Bad ignition secondary circuit.
a. The ignition coil insulation defect causing electric leakage.
b. Defective magneto coil.
I. Short circuit between coil layers.
II. Defective coil.

85

c. Defective spark plug.
I. Spark plug covered by carbon.
II. Electric leakage in ceramic part of spark plug.
d. Electric leakage from spark plug rubber screen.
3. Defective ignition timing.
a. Defective flywheel magneto.
b. Defective C.D.I .
c. Too large gap of spark plug.
d. Too high electric resistance of spark plug.

Starter System
Starter motor unable to run.
1. Damaged battery.
2. Battery circuit broken, bad contact or too large resistance at connections.
3. Fuse fused.
4. Defective main switch.
5. Defective front and rear brake switches.
6. Defective starter motor switch.
7. Defective starter motor relay.
8. Defective starter motor.
9. Circuitry conductor defective or broken.
10. Starter motor drive pinion locked with the over speed clutch gear.

Weak drive of starter motor:
1. Insufficient recharging of battery.
2. Bad contact on circuit conductors.
3. Strange object introduced in the starter motor pinion.
4. Armature shaft bent.
5. Commutator unclean or worn.
6. Brush worn or spring too weak.
7. Starting motor of relay defective.

86

5-2. BATTERY
A. Cautions in battery inspection and
generator charging.
Inspection: Use gravity gauge to measure
electrolyte. White is fully charged, yellow
means charge is required, and red is broken
or almost totally discharged.
Note: Electrolytes specific gravity and
charge level comparison table (20
o
C).

Electrolyte
Specific Gravity
1.280 1.250 1.220 1.190 1.120
Full 3/4 1/2 1/4 Totally
Charge Level
Charged Charged Charged Discharg

B. Charge by generator
Connecting battery and gener terminals by
+ with + and - with -.
Warning: Battery releases explosive gas
during charging or use battery. Therefore,
it is dangerous to do so in concealed
location. Please put battery in good
ventilation location during charging, and
forbid fire.

Note:
(1) Standard charging current: 0.6 A for 5~10 hours.
(2) Quick charging current: 6.0 A for 30 minutes.
(3) Please do not use quick charge except for emergency.
(4) Measure the battery voltage 30 minutes after battery is charged.
The battery voltage should be higher than 12.8 V.

C. Battery manufactured month and charge time comparison.
Manufactue Within After 6 mo. 10 mo. Within Over
Months 3 mo. 3 mo. 1 yr. 1 yr.
Charge Add electrolyte 10 20 30 40 60
Time And wait 30 m. hr. hr . hr . hr . hr .

87

5-3 SHORT CIRCUIT TEST
Disassembly:
Disconnect battery negative terminal
cable.
Measure method:
A. Connect megga meter +
terminal to battery - terminal.
B. Connect megga meter -
terminal to circuit negative
bl

Note: User megga meter A current
position.
Turn main switch to OFF
position.
Inspection: Check if there is electrical
current. If no current, check the main
switch and wire harness for short circuit.

5-4 RECTIFIER
Watch:
(1) Check if wire harness is normal
before checking rectifier and end
resistor. Check if rectifier socket is
well connected.
(2) Keep fingers away from tester probe.
The circuit resistance can be
changed with human body resistance
involved.

Rectifier Terminal Resistance Table.

Meter+
Meter-
White/Red Yellow/Red Red Black
White / Red Infitity 3k-100k Ohm Infitity
Yellow/ Red Infitity Infitity 3k-100k Ohm
Red Infitity Infitity Infitity
Black Infitity 5k-100k Ohm Infitity
88

5-5 STARTER RELAY
A. Operation of starter relay.
Watch: Please place main stand to park
the motorcycle for inspection.
Inspection: Turn the main switch to
ON position and press the starter
button.
Note:
(1) If there is a snap sound, then the
function is normal.
(2) If there is no snap sound, then the
function is abnormal.
Please check:
1. Starter relay ground circuit.
2. Starter relay voltage.

B. Starter relay ground circuit
Disassembly:
Connect the start relay connector and
electric tester by:
A. Megga meters positive terminal with
the relay yellow/red terminal.
B. Connect the negative terminal with
ground circuit and press the starter
button. Then, check the electricity
continuity.

Note:
(1) There should be continuity when pressing the start button.
(2) If there is no continuity when pressing the starter button, then check the continuity
between starter button and connecting cable.

C. Check starter relay voltage.
Watch: Please place main stand to park
the motorcycle for inspection.
Measure method:
A. Connect megga meters positive
terminal with the relay green/yellow
terminal.
B. Connect the negative terminal with
ground circuit and push the starter
button. Then, check the electricity
continuity.

Turn the main switch to ON position and hold the brake lever.
89

Watch: The battery voltage must satisfy
requirement in checking starter voltage
Note:
(1) If there is voltage, then the relay is
normal.
(2) If there is no voltage, then check the
continuity of brake switch and cable.

90

5-6 STARTER MOTOR
Watch:
(1) Please place main stand to park the
(2) Turn the main switch to OFF position
before maintenance. Disconnect the
battery ground circuit. To ensure safety,
turn the main switch to ON position and
check if the motor has operated.
Disassembly:

2 starter motor attaching bolts.
Starter motor.
Roll up the water -proof rubber jacket and
remove connector.

2 motor case attaching bolts.
Motor commutator.
Front cover.

Check Starter Commutator
Inspection:
(1) Check continuity between segments.
Note:
A. If continuity is good, then it is normal.
B. If no continuity, then it is broken.

91

(2) Check continuity between
segments and armature shaft.
Note:
A. If no continuity, then it is normal.
B. If continuity is good, then it is broken.
(3) Clean the commutators if there is
metal powder between segments.
(4) Check the removed parts for
damaging, burning (discoloration),
and wearing. Replace with a new
if necessary.
(5) Check brush length.
Note:
A. Initial standard brush length is 112.5
mm.
B. If brush length is smaller than 8.5 mm,
please replace with new brush.

Inspection: Check continuity of the
brush holder.
Note:
A. If there is no continuity, it is normal.
B. If there is continuity, it is broken.
Please replace with new one.

92

Assembly: Assembly is in reverse order
of disassembly procedures.
Watch:
(1) Apply grease to the ends of armature
shaft.
(2) Apply grease to the dust seal before
assembly front cover.
(3) The flange of front cover should match
the fillister of motor shell.

5-7 A.C. GEMERATOR
(A) A.C. generator coil
Disassembly: Disconnect the A.C.
generators 4P connector.
Measure:
A. Use megga meters positive terminal
to connect the white wire of the 4P
connector.
B. Connect the megga meters
negative terminal with frame ground
and measure the resistance.

Note:
(1) Standard resistance: 0.2~1.0 Ohm
(20
o
C).
(2) If the measured value exceed the
standard, replace with new A.C.
generator charging coil.

(B) A.C. generator lighting coil
Disassembly: Disconnect the A.C.
generators 4P connector.
Measure:
to connect the yellow wire of the 4P
connector.
negative terminal with body ground
and measure the resistance.

Note:
(1) Standard resistance: 0.1~1.0 Ohm (20
o
C).
(2) If the measured value exceeds the standard, replace with new A.C. generator lighting
coil.

93

A.C. generator Disassembly
Disassembly:
The fan cover.

4 tightening bolts.
Fan.

Use universal wrench to hold
flywheel and remove lock nut.

Use the big end of flywheel
remover and rotate
counter-clockwisely into flywheel.
Use universal wrench to hold
flywheel, and rotate the flywheel
remover clockwisely to remove
lock nut. Then the flywheel can
be removed.
Note: The big end of flywheel remover
is left-threaded.

94

Cable connector.
Cable bracket.
Tighten bolt of pick up.
Pick up.
Assembly: Assembly is in reverse
order of disassembly procedures.
Watch:
(1) The inside surface of the flywheel
is magnetic. Be sure that there is
nothing in there before assembly.

(2) The flywheels fillister should
match crankshaft pin.
Note:
(1) Torque of flywheel tightening
bolt: 550 kg-cm.
(2) Torque of fan tightening bolt: 90
kg-cm.

5-8 RESISTOR
Disassembly: Remove front windshield cover.

Measure:
to connect resistor wire.
B. Connect the megga meters negative
terminal with frame ground and
measure the resistance.
Note: Resistor standard:
20 W 5.9 Ohm: 5.0~7.0 Ohm.
5W 5.0 Ohm: 4.0~6.0 Ohm.

95

5-9 CDI UNIT
Use megga meter to check the following
items.

Check Item Measuring Terminals Standard Value (20
o
C)
Main Switch Black/White - Body Ground Continuity , When Main Switch "OFF"
Exciting Coil Black/Red - Body Ground 300 ~ 1000 Ohm
Pulser Coil Blue/Yellow - Body Ground 40 ~ 300 Ohm
Primary Coil Black/White - Green 0.1 ~ 1.0 Ohm
Secondary Coil Green - Spark Plug Cap 7 ~ 12 k Ohm

A. Exciting Coil Inspection
Disassembly: The exciting coil
connector.
Measure:
A. Use megga meters positive
terminal to connect exciting coils
black/red terminal.
negative terminal with frame
ground and measure the

Note:
(1) The standard resistance is: 300~1000
Ohm (20
o
C).
(2) If the resistance is higher than
standard, then it is broken.
Please replace with new one.

96

B. Pulse Coil Inspection
Disassembly: The pulse coil connector.
Measure:
to connect pulse coils blue/yellow
terminal.
B. Connect the megga meters negative
terminal with body ground and
measure the resistance.
Note:
(1) The standard resistance: 40~300
Ohm (20
o
C).
(2) If the resistance is higher than
standard, then it is broken. Please

97

C. Ignition coil Inspection
Disassembly:
Remove spark plug.

Remove ignition coils plastic cover.
Ignition coils p rimary coil.
Ignition coils tightening attaching
bolt.
Ignition Coil.
Assembly: Assembly is in reverse
order of disassembly procedures.
Note: Connect the black/white wire to
black terminal, and green wire to green
terminal.

D. Primary Coil Inspection
Measure: Connect the electric tester as
Fig. and measure the resistance.
Note:
(20
o
C).
(2) If the resistance isInfinity, then the
coil is broken. Replace it with new one.

E. Secondary Coil Inspection
Measure:
Connect the electric tester with spark plug
cable and ignition wire terminal (as shown
in Fig.), and measure the resistance.
Note:
(20
o
C).
(2) If the resistance is Infinity, then the coil
is broken. Replace it with new one.

98

TGB Service Manual 303R150 (BR9) and Delivery 150 (BK9)

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