FOREWORD

Thank you for your purchasing this motorcycle.

This manual covers the main specs, basic structure, and main procedures of operation, adjustment, maintenance and
troubleshooting of the motorcycle. It will help you familiarize yourself with allto learn the necessary knowledge so that
you can use your vehicle with fun and enjoyments, and minimized trouble as well, for a long service life.
Products are always subject to further improvement, which will cause some difference between the vehicle and this
manual, without further notice.

CONTENTS
I. Safe Drive ..........1

Adjustment of Throttle Cable16

II. Main Data..3

Adjustment of Carburetor..16

III. Parts and Subassemblies.....5

Check-up & Adjustment of Air Valve Cap................17

IV. OPERATION......9

Adjustment of Clutch.19

Ignition Switch...................9

Brake Checking..19

Fuel Cock...... 9

Adjustment of Front Brake.20

Engine Starting..................10

Adjustment of Rear Brake..21

Switches on Right Handlebar.....11

Adjustment of Chain21

Switches on Left Handlebar..................12

Adjustment of Braking Light Switch22

Gear Shifting.....................12

Battery Checking..23

V. Check-ups, Adjustments and Maintenance........13

Replacement of Fuse.24

Machine Oil Checking....................13

Vehicle Washing.24

Renewal of Machine oil......................13

Maintenance in Non-use Time...25

Cleaning of Machine Oil Tank....................14

Resumption of Service...26

Check-up of Spark Plug..............14

Maintenance Routine Diagram. 27

Check-up Cleaning of Air Filter.....................15

VI. Electrical diagram28

I. SAFE DRIVE
Rules for safe drive
Check must be conducted, before starting the engine, to prevent mishaps and damage to components.
Only the qualified person, who has passed the drive examination and to whom a drive license has been issued, is
permitted to drive the vehicle but not anybody else without a drive license.
Full preoccupation is required during drive, paying attention to the following points to avoid any possible hurt to
you by other motorized vehicles:
Do not drive too close to other vehicles;
Never contend for lane.
Strictly follow the local traffic rules.
As driving at over speed is the cause of many accidents, do not drive at a speed the actual situation does not permit.
Turn on the turnlight when making a turn or changing the lane.
Particular care should be exercised at the level crossing of roads, entrance and exit of parking lot or on the
automobile lane.
During drive, grasp the left handlebar by the left hand and the throttle twist grip by the right one, with feet on the
footrests.
The luggage carrier is designed for carrying light goods, which should be securely fastened to prevent loose
movement that may cause mishaps during drive.

Protective Wear
1.

Protective wear such as helmet with protective mask, dust proof glasses and gloves should be worn during
drive for the sake of personal safety.

2.

The passenger should wear high boots or long clothes to protect legs from hurt by the heated exhaust
silencer during ride.

3.

Loose clothes are not suitable for motorcycle drive or ride as they may get caught on the operating lever,
kick lever, footrest or wheel, resulting in danger.

Modification of the vehicle

Caution:
Any unauthorized modification of the vehicle or replacement of the original parts can not ensure driving safety
and is illicit. The user must observe the regulations of the traffic control authorities. We are not responsible for any
vehicle unauthorized modification.
Loading of goods
Caution:
The design of the motorcycle requires distribution of the carried goods in certain extent of equilibrium and
improper arrangement of goods will adversely affect the performance and stability of the vehicle. The manufacturer
shall not take any responsibility due to the reason mentioned above.

II. MAIN DATA

Overall length

2120mm

Cylinder borestroke

Overall width

840mm

Compression ratio

Overall height

1220mm

Output, max

11.0Kw/7500R/min

Wheelbase

1365mm

Torque, max

14.5N.m/6000r/min

Dry weight

126kg

Idling speed

1500150r/min

Max. load

150kg

Displacement of cylinder

1969ml
CR7SHA

Front wheel

275-18

Spark plug

Rear wheel

410-18

Spark plug gap

Speed, max

100km/h

Brake distance

7m

Climb ability

30

67.065.0
9.0:1

0.6mm-0.7mm
Intake valve:0.030.07mm

Cap of air Valve

Exhaust valve: 0.040.07mm

MAIN DATA
Volume of lubricating oil

1.1L

Capacity of gasoline tank

125L

Transmission ratio

fuse
Battery

15A
12V/6.5Ah

Front light illuminator

12V-35W/35W
12V-5W/21W

1st gear

2.909

Taillight/braking light

2nd gear

1.867

Betraying light

3rd gear

1.316

Turnlight

12V-10W4

4th gear

1.000

Turn indicator

12V-1.7W2

5 th gear

0.833

Meter light

Transmission ratio of sprocket

3230

High beam indicator

Primary transmission ratio

3333

Ignition means

12V-5W

12V-3W2
12V-1.7W
C.D.I

III. PARTS&SUBASSEMBLIES
Right rear view mirror
Left rear view mirror

Meter

Ignition switch & head lock

Clutch lever

Front brake lever

Left handlebar

Throttle twist grip

Horn switches

Engine starter switches

Fuel tank lock

Ser.No

Name

Speedometer

In km/h

Turn indicator

The left indicator is lit up

when the turnlight is to the
left and the right one lit up
as the latter to the right.

Hight beam

indicator
Gear position

display

Description

It is lit up when in the

neutral position.

The gear
displayed.

position

is

Neutral indicator

It is lit up when in the

neutral position.

Tachometer

It shows the speed(rpm)

of the engine.

Trip mileometer

It shows the mileage of

trip.

The ser. No. of frame [Vehicle Identification No.(VIN)]

is on the right side and the brand on the front

Front turnlight

Rear turnlight

Front shockabsorber

Rear wheel

Front wheel

Main stand

Fuel cock

Seat cushion

Exhaust silencer
IV. OPERATION

Ignition Switch

Ignition switch

Position

OFF

ON

LOCK

Function
To stop the
vehicle
(switching off
all circuits )
For starting or
driving the
vehicle (making
all the main
circuits )
To lock the
steering handle

OFF

Remarks
the key can be
removed out
taker
the key can
not be
removed
the key can be
taken out

ON

LOCK
Fuel cock
1.

fuel filling
The capacity of the fuel tank is

12.5L in total including 0.9L of

reserve .Leadless gasoline of
No.93or above or low lead
gasoline is required for the
motorcycle
.To
fuel
the
vehicle ,support it by the main
stand ,open the lock cover of the
fuel tank and fill fuel through the
opening ,and then close the tank by
the cover with the two on them in
good alignment .
2. Operation of the fuel cock (the
valve of fuel tank )
ON:With the handle of the fuel
cock to ON position ,the fuel
circuit is through for fuel supply .
OFF:With the handle of the fuel
cock to OFFposition ,the fuel
circuit is cut off without supply .
RES:With the handle of the fuel
cock to RES position ,the fuel is
supplied from the reserve .

Fuel cock handle (ON\OFF\RES)

(Note:The reserved fuel can only be
used when the normal supply is run
out .)In this case ,refueling should
be carried out as soon as
possible ,for there is only some
1.1L of fuel reserve for use .

Fuel cock handle

Engine starting
Set the key of the ignition switch to ONposition .
Set the emergency stop swithch to position .
Ascertain the neutral position,where it should be
displayed .
Ascertain the amount of fuel in the tank .
Set the fuel cock handle to ON position .
To start a cold engine :
pull up the choke bar of the carburetor (to close the
choke )
Rotate the throttle twist grip by 1/8 to 1/4 turn .
Start the engine by the electric or the kick starting
system .
Slightly turn the throttle twist grip to increase the
speed of the engine so as to warm up the engine .
Turn the carburetor choke bar downward to B, fully
open the choke when the engine is sufficiently warmed
up .

Caution:
The engine can only be started after the neutral
position is ascertained .Otherwise accident will
happen .
Unnecessary idle running (especially at a high
speed )is harmful to the engine .
Procedures of stopping engine :
Release the throttle twist grip to slow down the
engine .
Turn to neutral position .
Set the ignition switch key to OFF position .
Set the fuel cock (the fuel tank valve )handle to
OFF position .

Switches on Right Handlebar

1) Electric start button (no such device for the vehicle
of kick start mode only)
The electric start button is located below the
headlight switch .The engine will be started by
Pressing down this button .
2)

Emergency stop switch

When starting the engine ,set the emergency stop
switch in

Start

button

Thorttle

position to directly stop the engine

by cutting off the electric powe

Switches on Left handlebar

1Headlight switch

twist

grip

The Headlight switch has three positions"

""

Press this button to horn.

" and ""(a white point).

"

":When the switch is in this position,tail the

headlight and meter lights are all lit up.

"

":When the switch is in this position,the

Headlight switch

tail,betraying and meter lights are lit up.

"":When it is in this position,the headlight tail,betraying

Light changing switch

and meter lights are all off.

The headlight and taillight will be lit up only after the
vehicle is started.
2Light changing switch
Position, Headlight is in high beam.
Position, Headlight is in low beam.
3Turnlight switch
Position, Left
Position, Right
4Horn button

Horn button
Turnlight
Gear
shiftingswitch
Warm up the engine for normal running.

When the engine is idling, disengage the clutch and

tread the gear shifting pedal to at the gear to the 1st

Shifting forward

position.
Gradually increase the speed of the engine and slowly
release the clutch lever, with a good coordination
between the two operations to ensure a natural driving
start.
When the motorcycle reaches a balanced state of
running, slow down the engine, disengage the clutch

5
4
3
2
N
1

again and tread the shifting pedal to change the gear to

the 2nd
position. The gear can be shifted to other position in the
same way.

V. Check-ups, Adjustments and Maintenance

Shifting backward 4

Machine Oil Checking

The vehicle should be
checked for machine oil before
drive by supporting it with the main
stand on a flat ground .The oil level
should be between the upper and
lower lines of the oil gauge ,which
is not screwed into the filling
orifice .
High
quality
4-stroke
machine oil ,as Class SE or SD in
API
classification
,of
SAE
15W-40QE in viscosity will help
maintain a long service life of the
engine .In case those are not
available ,a substitute suitable for
the ambient temperature of
application should be selected
according to the table on the right
side .
Cleaning of Machine Oil Tank

Machine oil gauge

Renewal of Machine oil

Machine oil plays a very important
role in the normal operation of the
engine and for that reason ,it is
necessary to check the motorcycle
for machine oil periodically and
renew the oil once every 800-1000
km of drive by the following
procedures .
Remove the screw plug from the
bottom of the hot engine to drain
off all old oil .
Wash the oil filter screen clean and
remount it really to position .Then
fill in 1.1L fresh machine oil and
start the engine for idle running
2-3 minutes .
Let the engine stop for 2-3
minutes ,and check to see whither
the oil livel is in between the upper
and lower line the oil gauge .
Do not use any machine oil of a
different grade than the specified
one to avoid machinery failure .
one to avoid machinery failure.

Drain off all the run-in machine oil from the oil

tank.
Dismount the related parts.
Wash clean all the related parts.
Fill in the required oil.
*This job should not be done by any untrained

Check-up of Spark Plug

Remove the cap of spark plug and

persons but shall be done at an authorized service

center.

screw off the spark by the plug

wrench.
Clean the spark plug all around or
replace it if it is corroded or there is
too much deposit on it.
Regulate the gap of the spark plug
to 0.6-0.7mm.
The spark plug of the designated
type should be used.
CR7HSA

Screw plug for oil draining

Check-up, cleaning of Air Filter

Take out the air filter and check if it is contaminated.

Air filter

Dismounting:
Remove the left side cover screw of the filter, open
the left cover and disassemble the air filter.
Cleaning:
Wash the filter in clean washing oil and wipe it dry
with dry cloth.
Soak the filter element in clean machine oil. Squeeze
it dry and fit it back to position.
Recommended oil:15W/40QE
Caution:
The air filter element for use must be intact or the
engine will suck in dust and dirt, resulting a shorter
service life of the engine.
Watcher should be prevented from interring into

Collar clamp

the filter in washing the vehicle.

The filter shall never be cleaned with gasoline on
any other agent of a low ignition point.

Adjustment of Throttle cable

Make sure that the adjusting nut of the throttle cable

works normally.

Caution:

Check to see if the throttle twist grip is with the

required free operating movement.

The idling speed adjustment of the engine should be

carried out with a hot engine.

The required free operating movement:2-6mm.

If the grip can not be so moved freely, turn the

Set the idling speed to the required value by the help

of the idling speed adjusting screw with the vehicle

adjusting nut to ensure it.

*After adjustment, start the engine and check for

standing on a flat ground.

The required idling speed: 1500r/min.

the free operating movement again, repeat the

adjustment if necessary until it is as required.

Adjusting nut

Locking nut

Adjustment of Carburetor
Check-up & Adjustment of Air Valve Gap

Idling speed adjusting screw

Noise will stem from too big gap of the air valve .However if there is too small gap or even no gap at all , closing
of the valve will be hindered ,which will cause burn of the valve and output drop .Therefore ,the air valve gap must be
checked periodically .
The gap of the air valve should be inspected and adjusted with a cold engine by the following procedures:
1)

Remove the caps of the central hole and the top holed (the ignition timing observation hole )in the left crankcase
cover .

2)

Remove the caps of the two air valves on the cylinder head .

3)

Insert the T key into the central hole of the crankcase cover, jam it against the nut of the flying wheel and then
turn the flying wheel clockwise until the engraved T mark on the flying wheel aligns with the engraved line on
the top of the crankcase cover .Swing the rocking arm slightly .A loose rocking arm (which indicates the existence
of clearance )shows that the

piston is in the lower stop position of the compressing stroke .In this case ,continuously turn the T key colckwise for
360 degrees until the alignment of those engraved marks ,where the valve can be adjusted. Afterwards ,check the valve
gap by inserting a feeler in the valve adjusting screw and the end of the valve .
The specified air valve gap :0.030.07mm for the intake and exhaust valves repectively .

4)

If the adjustment needed ,loosen the locking nut of the valve ,turn the adjusting nut till a slight resistance is felt on

inserting the feeler .

At the end of the adjustment ,tighten the Locking out to prevent
loosening and another check to make sure that the valve gap is OK before all those dismounted caps are refitted on .
central hole cap .

Valve cap

Central hole cap

Adjustment of Clutch

The clutch should be adjusted with the engine in

stopped state .

check for wear of the brake shoes .If the mark

on

There should be a free operating movement of 10-20

the brake drum cover aligns with that on the brake

mm at the end of the clutch lever as shown in the figure

cam ,it means that the brake shoes are already worn to

on the right side .

the limit and have to be .

When adjustment is needed ,loosen the set the clutch

lever

to

the

required

range

of

free

operating

movement .In case of adjustment to be made to a great

2)Replacement should becarried out at a desinated

service center and it is recommended that the parts made
by our company are there in 10-20 mm.

extend ,turn the clutch adjusting screw studon the right

crankcase .
Is tart she engine to ascertain whether the adjusted

10-20mm

clutch works normally .

Readjustment has to be made if there is slipping of
clutch or difficulty in the engaement of gears .

Brake Checking
1)Pull up the front and rear brakes respectively and

Adjustment of front Brake

(1)The front brake lever has a free operating

movement of 10-20mm as shown in the figure on the

10-20mm

right side.
(2)If adjustment is needed, turn the adjusting nut
near the lower side of the front hub, clockwise to reduce
and counterclockwise to increase the free operating
movement of the brake lever.
(3)After adjustment, the groove of the adjusting nut

Disc brake oil hose

should be aligned with the pin of the brake arm.

Caution:
After adjustment, check the front braking
system. The braking light should be lit up on time
when the front brake is applied by gripping the brake
lever.

Plate of disc brake

Lower pump of disc brake
Adjustment of Rear Brake
The vehicle should be

supported by the main stand for

check.

(1)The rear brake pedal has a

free operating movement of

20-30mm as shown in the figure on

the right side.
(2)To make adjustment, turn the
rear brake adjusting nut clockwise
to reduce and counterclockwise to
increase
the
free
operating
movement of the brake pedal
(3)After adjustment, the groove
of the adjusting nut should be
aligned with the pin of the brake
arm.
Caution:
After regulation, check the
rear braking system, The braking
light should be lit on time when
the rear brake is applied by
stepping down the brake pedal.
Rear brake pedal

20-30mm
Adjusting nut
Rear brake arm

Brake cam Brake pull

Brake arm pin

rod

tension and lubrication.

(1)With
the
motorcycle
supported by the main stand, turn
the upper and lower portions of the
chain by hand to check for its
tension to see if the sag is within
the specified range of 10-20mm.
(2)When regulation is needed,
loosen the axle nut and locking nut
of the rear wheel, then set the chain
to the required tension by turning
the adjusting nut.
(3)Apply a little grease to the
chain.
Caution:
At the ad of regulation, the
marks on the chain adjuster should
be in good coordination with the
engraved line on the horizontal fork
al position is concerned.

Adjustment of Chain
Check the chain for wear,
Chain adjuster (with graduations)

Braking light switch

Adjusting nut

Rear wheel axle nut

Bear axle
Braking light switch spring

Adjustment of Braking Light Switch

The braking light should be lit up on time as soon as the rear wheel is braked. If not, regulation shall be made by
turning the adjusting nut.
With the braking light switch in ON position, the braking light should be lit up. If not, check should be carried
out to see shether the braking lamp, circuit and switch work normally, Make replacement if needed.
Caution:
For the adjustment of the braking light switch, the brake needs to be first checked to make sure that the free
operating movement is ensured within the specified range.

Battery Checking

Open the right side cover.

Clean away dust and

corrosive from the surface of the

battery.
Set the vehicle in a vertical
position to see whether the level of
the battery electrolyte is between
the upper and lower mark lines. If it
is below the lower one, distilled
water shall be added to the battery.
Seriously corroded
conductor connectors of the battery
shall be replaced.
Caution:
To dismantle battery,
disconnect the negative()
electrode before the positive(+) one,
and vice versa in installation.
Ensure against any contact of the
positive(+)electrode with the
vehicle body.
Never have the electrolyte
level come over the upper mark line
when adding distilled water.
Otherwise overflow and corrosion
will occur.
The electrolyte contains

Vehicle washing

sulfuric acid and will cause serious

hurt to skin and eyes by contact. In
case of contact with it, wash it off
for 5 minutes and see a doctor
immediately.
Foreign matter should be
prevented from entering into the
battery daring dismounting and
installation.
The breathing pipe must be
kept unblocked.
Negative (-)
Positive (+)
Connector

Connecto

position. The specified fuse tube of

15A should be used for
replacement.
Open the left side cover,
remove the fuse holder on the side
of the battery and replace the fuse
tube.
If the new fuse tube is broken
again as soon as it is fitted on, it
means that there is some trouble
with other electric parts.
Caution:
Do not use any fuse over15A
Be sure not to wash the battery
when washing the vehicle.

Lower electrolyte
Level line

Upper electrolyte
Level line

Replacement of Fuse
Set the ignition switch to OFF

Cleaning the vehicle regularly can slow down the color fading of its body make it easier to check if there is any
damage and any oil leakage with it.
Caution:
Washing the motorcycle with over-pressurized water may cause damage to some of its components. Therefore, do
not jet over-pressurized water directly on to the following parts:
--Wheel hub
--Exhaust pipe
--Fuel tank and lower portion of cushion
--Carburetor
--Head lock and ignition switch
--Meters
(1)After pre-wiping, the vehicle should be washed with clean water to remove dirty residues so as to prevent
corrosion. Plastic subassemblies should be cleaned by wiping with cloth or sponge soaked in neutral detergent solution,
followed by washing with clean water.
(2)After the cleaned vehicle is air dried, grease the chain and run the engine at idling speed for a few minutes.
(3)Prior to driving, carefully check braking system repeatedly and repair of adjust it if necessary.

Maintenance in Non-use Time

Storage and Maintenance

For the motorcycle to be stored for a long period of

time, attention should be paid to the prevention of
moisture, sunshine and rain attack in order to protect it
from unnecessary damage. Special check-ups should be
carried out on those important parts and subassemblies
be for storage.
Change lubricating oil.
Grease the chain.
Drain off fuel from the fuel tank and
carburetor(for the vehicle not to be used for over a
month, the fuel in the latter must be thoroughly drained
away), turn off the fuel cock and fill antirust solution
into the fuel tank, followed by closing the tank with the
cover.
Caution:
As fuel is inflammable, the engine should be
stopped before filling or drain fuel and it is prohibited to
smoke at the fuel storing, filling or draining location.

Take out the spark plug, fill about 15-20ml of

Resumption of Service

clean lubricating oil into the cylinder, step down the kick
lever repetitively for several times and finally fit the
spark plug back on.
Attention:
The ignition switch key must be set to OFF
position before stepping down the kick lever, To protect
the ignition system from damage, the spark plug should
be put on its cap and earthed.
Dismantle the battery and put it in a shady, cool
and well-ventilated place. It is suggested that the battery
be charged once a month.
Clean the vehicle, spray the colored part with
color fastening agent and apply antirust oil to the part
vulnerable to rust.
Inflate the type as required and pad the vehicle
up with the two wheels clear of the ground.
Put the covering over the motorcycle.

Remove the cover and clean the vehicle. Change the lubricating oil if the vehicle has been off service for over
4months.
Charge the battery and remount it.
Drain off the antirust solution from the fuel tank, followed by filling fuel therein to the required level.
Prior to driving, test the vehicle at low speed in a safe place.
Maintenance Routine Diagram
The vehicle should be under good maintenance as specified in the following table, where;
I means: Check, cleaning, adjustment, lubrication and/or replacement are needed.
C means: Cleaning is needed.
R means: Replacement is needed.
A means: Adjustment is needed.
L means: Lubrication is needed.
means: This item of maintenance should be carried out at a service center. It may be also done by the user
himself with reference to this manual provided he has special tools, sprats and is capable of this job.
means: This item can only be carried out by the serviceman at General Accessories Corp. service center in
order to ensure safety.
Notes: 1.Maintenance should be conducted more frequently when the motorcycle drives in dusty areas.
2. When the read-out of the odometer exceeds the maximum figures specified in the table, maintenance
should be still cycled according to the interval of mileage stated herein.

Frequency
Item of maintenance

Item /frequency

Odometer km(Note 2)

1000km

*
*
*
*
*

*
*

**
**
**
**
*
*
*
*
**
**

Circuit of fuel system

Fuel filter
Throttle operating system
Choke of carburetor
Air filter element
Spark plug
Air valve gap
Air valve gap
Engine lubricating oil
Lubricating oil screen
Tension of chain
Idling speed of carburetor
Driving chain
Battery
Wear of brake shoes
Rear braking system
Braking liquid hose
Cup of braking liquid
Braking liquid
Front braking system
Rear braking light switch
Light changing of headlight
Clutch
Side stand
Suspension
Nuts, bolts & other fasteners
Wheel/spokes
Bearing of steering handle

C
I
R-yearly
R-yearly

I
I
I
R

Monthly

R-4year
I
R-2year
I
I

I
I
I
I
I
I
I
I
I

4000km
I
C
I
I
C
I
I

8000km
12000km
I
I
C
C
I
I
I
I
C
C
I
R
I
I
I
I
One replacement every 2000km
C
C
C
A
A
A
I
I
I
IL every 500km
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
One replacement every two year
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I

Remote-Controller s Function Operation And instructions

Function operation:

Set acousto-optic anti-theft:

remark

Also for disc

style

Press the button The horn will sound & the turnlight
flash once. Three seconds later, be in the warning
state of acousto-optic antitheft.
Anti-theft sensing:
In the state of anti-theft, any shock to the
motorcycle makes the system present impedance with
horn sounding once & turnlight flashing once. Incase of
further harassing activities within the following three
seconds, the system is to sound the alarm immediately;
horn ringing, turnlingt flashing and engine being locked
automatically. Remain warning state after the alarm
stopped automatically. In case the motorcycle is stolen,
electrics witch shall flashing and engine being locked
autos \metrically.
Anti-theft relieving:
In the state of anti-theft, press the button and the
horn will sound twice & the light flash twice to relieve
the state of anti-theft.
Remote-control starting:
Press the button to ignite and drive the motorcycle
without start. If difficult, press the button longer till

starting.
Press the button to stop the motorcycle in the state
of remote-control starting.
Anti-rob:
In the state that the engine is working, press the
button to stop the motorcycle in such emergencies as
being robbed of or stolen.
Acousto-optically target-seeking:
Set acousto-optically anti-theft, there seconds later,
press the button for horn and light flash so as to find the
motorcycle at the parking lot.
Instructions to remote-controller use.
The function of remote-control starting only
applies to the motorcycles which is required with
automatic transmission or able to electrically start.
Pay attention to the prevention of soaking, hard
throwing and high temperature to avoid natural loss of
electrical power.
Do not put the keys to the remote-controller into
the lock.

ELECTRICAL DIAGRAM