Keeway Focus /matrix Service Manual
Keeway Focus /matrix Service Manual
Keeway Focus /matrix Service Manual
Model: Focus/Matrix
COPY RIGHT:
FEB.2006
1
If you have any problems can not fnd the solution in this manual, please
fell free to contact with:
Our engineer are very glad to give you the necessary assistance
and help.
2
Index 前
The service manual has been
specially prepared to provide all the
necessary information for the proper
maintenance and servicing of
FOCUS/MATRIX.
The FOCUS/MATRIX is a new type of
scooter that has many techinal features
such as:
V-belt drive automatic transmission
Forced air-cooling system
CDI ignition system
Electric starter system
The FOCUS/MATRIX fits the needs of
a wide variety of scooter user. Those who
will be servicing the scooter should
carefully review the manual before
performing any repair or services. Major
modifications and changes incorporated later
will be advised to QIANJIANG product
distributor in each market. Therefore, if
newest information is requested in the future,
please contact the local QIANJIANG
distributor.
The FOCUS/MATRIX scooters
distributed in your country mignt differ in
minor respects from the standard
specification and, if they do, it is because
some minor modifications had to be made to
comply with the statutory requirements of
your country.
3
Index
General principles 1
Engine 3
Electrical system 5
Frame 6
Maintenance information 7
4
5
GENERAL PRINCIPLES
CONTENTS
6
1-1 GENERAL PRINCIPLES
TYPE IDENTIFICATION
ENGINE NUMBER
ENGINE NUMBER① is carved on rear crankcase as
Shown in figure.
FUEL
Unleaded, the minimum octane number is 90 or more.
ENGINE OIL
For QIANJIANG CCI SYSTEM, we recommend special engine oil, you can choose high quality two-stroke
engine oil (without being diluted) if without special oil.
GEAR OIL
Use high quality, all-purpose SAE90 engine oil for scooter.
BREAK-IN TIME
General requirements are as follows:
Limit break-in speed:
At the first 1000KMS(600 miles)mileage,play throttle less than 4/5 throttle;
After mileage exceeds 1000KMS(600 miles) ,play full throttle;
Don’t run engine too long during break-in time, and try to change throttle position.
7
1-2 GENERAL PRINCIPLES
PRECAUTIONS AND GENERAL INSTRUCTIONS
Correctly abide by the following items when disassembling and assembling scooter:
□ Don’t run engine indoors with little or no ventilation;
□ Be sure to replace new bushings, circlips, O-rings and cotter pins with new ones;
CAUTION
It is forbidden to use the circlip removed from shaft, only use new one;
Be very carefull to install new circlip for fear that the end hatch of circlip exceeds required sliding surface for
shaft;
After installing circlip, inspect whether it has been completely clipped into the groove.
□ Fix bigger diameter bolt first when tightening cylinder head or cylinder, and tighten to specified torque
gradually from inside to outside at diagonal order.
□ Use special tools for some special requrements;
□ Use original components and recommended engine oil;
□ Keep each other’s safety when several persons do;
□ Inspect looseness and operating state of components after reassembling them.;
□ Take high care of gasoline, which is explosive, and never use gasoline as lotion.
The words like warning, notice, note may turn out incessantly in the manual, which means:
WARNING——The personal safety of the rider may be involved. Disregarding the information could
result in injury to the rider.
CAUTION—These instructions point out special service procedures or precautions that must be followed to
avoid damaging the machine.
NOTE——it provides some special information, which keeps maintanance easier and important instructions
clearer..
REPLACEMENT COMPONENTS
Be sure to use genuine QIANJIANG components or their equivalent.. Genuine QIANJIANG components are
high quality parts which are designed specially for QIANJIANG vehicle.
CAUTION
Damage to the scooter may result from use of replacement components which are not
Equivalent in quality to genuine QIANJIANG parts, and it can lead to performance problems.
8
1-3 GENERAL PRINCIPLES
SPECIFICATIONS Turning signal indicator light…12V/3W
DIMENSION AND NET WEIGHT
OVERALL LENGTH……1830mm CAPACITY
OVERALL LENGTH………695mm FUEL TANK……………5.2L
OVERALL HEIGHT………1160 mm ENGINE OIL TANK……………1L
WHEELBASE………………1295mm GEAR OIL……………0.1L
NET WEIGHT………………92kg Transmission system
Clutch system . ......dry auto acentric
CHASSIS Gearshift mechanism....
.CVT stepless
Operating mode of gears shift mechanism...Automatic acentric
Front shock absorber……spring, without damp
Stepless shift range..
...0.86~2.64
Rear shock absorber……spring, oil damp
Turning angle … … … … … 48 º (toward the
left\toward the right)
Front wheel…………120/70-12
Rear wheel…………130/70-12
Front brake…………Discφ190
Rear brake…………Drumφ110 *the above data may be modified without
any notification.
ENGINE
Type………two-stroke, forcible wind cooling
Intake system…………piston-reed valve
Cylinder QTY.…………1
Bore………………40.0mm
Stroke………………39.6mm
Discharge ………………49.8mL
Compression ratio……………6.9:1
Carburetor……………flat inhale stopper style
Air cleaner……………dry
Starting system…electricity start and kicking start
Lubricating system………pressure lubricating
ELECTRIC
Ignition mode…………CDI
Ignition timing…………150 at 1500RPM
Spark plug……………BP8HS
Storage battery…………YTX5L-BS
Generator……………AC magneto
Fuse……………8A
Headlight ……………12V—35/35W
Turning light……………12V/10W
Taillight ………………12V—21/5W
Meter light……………12V/1.7W
Oil level signal indicator light…12V/3W
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TERMLY MAINTENANCE AND REPAIR
CONTENT
Periodic maintenance and service schedule……………………… 2-1
Maintenance and service procedures…………………………… 2-2
Storage battery………………………………………………… 2-2
Spark plug………………………………………………………… 2-3
Cylinder head nut and exhaust pipe bolt……………………… 2-3
Cylinder head and cylinder…………………………………………2-4
Fuel level line………………………………………………………2-4
Air cleaner……………………………………………………………2-5
Throttle cable…………………………………………………………2-5
Engine idle speed……………………………………………………2-5
Oil pump………………………………………………………………2-6
Gear oil………………………………………………………………2-7
Braking…………………………………………………………2-7
Tire …………………………………………………………………2-10
Steering………………………………………………………………2-10
Front shock absorber…………………………………………………2-11
Rear shock absorber…………………………………………………2-11
Vehicle bolts and nuts…………………………………………………2-11
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Periodic maintenance and service schedule
The following table lists all required intervals for maintenance and service,following which, you are assred to
have your scooter perform in the best way.
Note
Do more frequent maintenance when often riding on bad road
Tire I I I I I
Vehicle body bot
T T T T T
andnut
Note
I=inspect,clean,adjust,lubricate,or replace if necessary;
A=adjust; C=clean; R=replace; T=tighten
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Maintenance and adjustment procedures
The section describes the servicing procedures for each item of the Periodic Maintenance requirements.
Storage battery
,
Inspect at initially 1000KM(600 miles,2 months)
andevery 6000KM(4000 miles,12 months)thereafter
□ Uncover seat, and then remove the battery box cap in the
Middle of helmet barrel.
□ Disconnect negative pole line end, positive end, and then remove battery;
12
Cylinder head nuts and exhaust pipe bolts
:
Tithtening torque:
:15-18N.m
Cylinder head nut:
:15-18N.m
Exhaust pipe bolt:
13
SPARK PLUG
14
AIR CLEANER
CAUTION:
Before and during the cleaning operation, inspect the core for tears. A tore core must be
replaced
Be sure to position the filter core,so that no
incoming air will bypass it. remember, rapid wear
of piston rings and cylinder bore is ofter caused by
defective or poorly fitted filter core.
А Non-flammable cleaning solvent
БCCI or CCI SUPER oil
THROTTLE CABLE
Adjust at initially 1000KM(600 miles,2 months),
and every 6000 km(4000 miles,12 months)
Loosen locknut ①,and adjust throttle cable play by
turning adjuster ② in or out to obtain the
following cable play. After adjusting the calbe
play,tighten the locknut.
Cable play:0.5-1.0MM(0.02.-0.040 inch)
Engine idle speed
Adjust at initially 1000KM(600 miles,2 months) and
every 6000 km(4000 miles,12 months)thereafter.
② ①
Adjust the throttle cable play.
warm up the engine.
Note:
Note:
Warm up engine for 10 minutes.
15
Connect an electric tachometer to the connecting protiion of the magneto lead wire as shown I nthe
illustration. Use the selector key “C’ position.
Tachometer
Adjust the throttle stop screw to obtain the idle r/min as follows:
Idle speed:1400±100r/min
OIL PUMP
Inspect at initially 1000KM (600 miles ,2 months )
andevery 6000 km(4000 miles,12 months)thereafter.
The engine oil is fed by the oil pump to the engine. The amount of oil fed to
it is regulated by engine speed and oil pump control lever which is controlled
by amount of throttle opening.
Check the oil pump in the following manner to confirm correct operation for
Throttle valve full opening position.
16
GEAR OIL
BRAKES
Inspect at initially 1000 km((600 miles, ,2 months) ) and
every 6000 km( (4000 miles, ,12 months) )thereafter, replace
brake fluid every 2 years, replace brake hose every 4 years.
WARNING: :
The brake system of the scooter is filled with a glycol-based brake the lowest line
Fluid. Do not use or mix different types of fluid such as silicone-based and petroleum-based. Do not use any
brake fluid taken from old, used or unsealed containers. Never reuse the brake fluid left over from the
last servicing and stored for long periods.
17
:
WARNING:
Brake fluid, if it leaks, will interfere with safe running and immediately discolor painted surfaces.
Check the brake hoses for cracks and hose joints for leakage before riding.
Brake pads
Wearing condition of brake pads can be checked by observing the limit
Line ① marked on the pad. When the wear exceeds the limit mark, replace
The pads with new ones.
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NOTE::when bleeding the brakign system, replenish the brake fluid reservoir if necessary.
Make sure that there is always some fluid visible in the reservoir.
Close the bleeder vavle, disconnect the pipe. Fill the reservoir with brake fluid to the upper end of the
inspection window.
BLEEDER VALVE
TIGHTENING TORQUE: 6-9N.m(0.6-0.9kg-m,4.5-6.5lb-ft)
CAUTION:
Handle brake fluid with care: the fluid reacts
chemically with paint, plastics, rubber materials, etc.
Rear brake
Turn adjusting nut ① so that the the play ② of
Brake lever is 15-25MM as shown in the illustration.
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Tire
Inspect at initially 1000KM(600 miles,2 months) and every
6000KM(4000 miles,12 months)thereafter
Tire pressure:
If the pressure is too high, the scooter will tend to rede stiffly
and have poor traction. Conversely, if tire pressure is too low,
stability will be adversely affected. Thereafter, maintain the
correct tire pressure for good roadability and to prolong tire life.
CAUTION:
Caution:
The standard air pressure of tires is 175/196Kpa, The use of other
Than standard may cause handling instability. It is highly
recommended to use a QIANJIANG genuine tire.
Steering
20
Front shock absorber
Inspect the front shock absorber for oil leakage or other damage, and replace the defective parts, if necessary.
Inspect front shock absorber for oil leakage and other damage, and replace the defective parts if necessary.
21
③
①
④
⑥
⑤
⑨
⑧
14
22
LUBRICATION
Proper lubrication is important for smooth operation and long life of each working part of the scooter. The
major lubrication points are indicated below:
NOTE:
1. Lubricate exposed parts which aare subject to ruse with engine oil.
2. Before lubricating each part, clean off any rusty spots and wipe off any grease, oil dirt of grime.
WARNING:Be careful not to apply too much grease to the rear brake camshaft, otherwise brake slippage will
result from the presence of grease in brake drum.
Αlubrication
①A
②⑦A ④A
⑥A
⑤⑧A
③A
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ENGINE
CONTENS
Engine components removal with the engine in place
Engine removal and remounting
Engine removal
Engine remounting
Engine disassembly
Engine components inspection and servicing
Bearings
Oil seals
crankshaft
automatic clutch inspection
cylinder head
cylinder
piston
reed valve
engine remounting
oil seals
bearings
bushings
crankshaft
crankcase
rear axle shaft
transmission
starter pinion and starter gear
Movable driven and clutch
Movable drive
Kicking starter
Piston
Oil pump and oil pump driven gear
Intake pipe
Magneto
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Engine components removable with the engine in place
The parts listed below can be removed and reinstalled without removing the engine
from the frame.
Engine left side
Kicking starter lever
Clutch brake pad kit
Driver left face
V-belt
Driver belt right face
Electric starter gear
Super clutch
Driven face
Engine center
Carburetor
Intake pipe
Reed valve
Oil pump
Worm wheel
Cylinder head
Cylinder
Piston
engine right side
cooling fan
Magneto
Starter motor
25
ENGINE ASSY.
Remove the muffler
Remove cooling fan cover
Remove cylinder cover
Remove cooling fan
26
Remove worm wheel and oil seal press board
27
Remove starting driven ratchet wheel by removing the nuts.
28
Remove the clutch housing with the
special tool.
29
remove spring④
remove cotter pin⑤ and shaft⑥
remove main stand⑦
remove carburetor
30
Remove crankcase fixing shaft
31
Unscrew clutch shoe nut with special tools.
①nut
②clutch shoe
③spring
CAUTION: :
Do not attempt to disassemble the clutch
shoe assy. Otherwise the clutch shoe may be
damaged.
32
Remove circlip
Remove bearing with special tool.
Remove the oil seal from the gearcase cover with the speical tool.
33
Remove gearcase cover bearing
with special tool
34
Remove right crankcase oil seal with special tool
:use a new oil seal
Warning:
35
ENGINE COMPONENTS INSPECTION AND SERVICING
BEARINGS
Turn the inner ring and check to see that the inner
rieng turns smoothly. If it does not turn lightly, quietly
and smoothly, or if noise is heard, the bearing is
defective and must be replaced with a new one.
36
OIL SEAL
Damage to the lip of the oil seal may result in leakage of the fuel-air mixture or oil. Inspect for damage and be sure to replace the
CRANKSHAFT
CRANKSHAFT RUNOUT
:0.05mm(0.002in)
Service limit:
life.
Turn the crankshaft with the connecting rod to feel the smoothness of
rotary motion in the big end. Move the rod up and down while holding
the crankshaft rigidly to be sure that there is no rattle in the big end.
checking the movement of the small end of the rod. The method can
also check the extent of wear on the parts of the connecting rod ‘s big
end. If wear exceeds the limit, replace connecting rod, crank pin
:3.0mm(0.12in)
Service limit:
37
and centrifugal mechanism located in the clutch.
To insure proper performance and long lifespan of the clutch, it is essentiall that the
clutch engages smoothly and gradually. Two inspection checks must be performed to
thoroughly check the operation of the drivetrain. Follow the procedures listed.
1.Inspect initial engagement
Warm up the scooter to normal operating
temperature.
Remove the right frame side cover.
Connect an electric tachmeter to the connecting portion
of the magneto lead wire (black with red tracer).
Seated on the scooter with the scooter on level ground,
increase the engine RPMs slowly and note the RPM at
which the scooter begins to move forward.
Tachometer
Standard 2900r/min
tolerance ±300r/min
LOCK-UP R/MIN
Standard 5800r/min
Tolerance ±400r/min
38
If the engine R/MIN doesn’t coincide with the specified r/min range, then disassemble the clutch.
Clutch shoe---inspect the shoes visually for chips, cracking, uneven wear and burning, and check the
thickness of the shoes with vernier calipers. If the thickness is less than the following service limit, replace them
as a set.
Clutch springs -----visually inspect the clutch springs for strectched coils or broken coils.
Service limit::2.0mm(0.08in)
CAUTION : clutch shoes or springs must
bechanged as a set and never individually.
Clutch wheel—inspect visually the condition of
the inner clutch wheel surface for scrolling, cracks, or
uneven wear. Measure inside diameter of the clutch wheel
with inside calipers. Measure the diameter at several
points to check for an out-of-round condition as well as
wear.
Service limit:110.50mm(4.350in)
DRIVE BELT
Remove the drive belt and check for cracks, wear and
separation. Measure the drive belt width with a vernier calipers.
Replace it if the belt width is less than the service limit or and defect
has been found.
Service limit:16.0mm(0.630in)
CAUTION;Always keep the drive belt away from any
geasy matter.
Drive face
Inspect the belt contact surface of the dirve faces for wear,
39
Roller and sliding surface
Cylinder head
Decarbon the combusion chamber.
Check the surface of the clinder head as shown in
the illustration for distortion with a straightedge and
thickness gauge, taking a clearance reading at several
places.
:0.05mm(0.002in)
service limit:
40
If the largest reading at any portion of the staightedge excees the limit, rework the surface by
rubbing it against emery paper laid flat on the surface plate in a lapping manner. The surface must
ge smooth and perfectly falt in order to secure a tight join: a
leaky joint can be the cause of reduced power output and
increased fuel consumption.
CYLINER
Decarbon exhaust port and upper part of the cylinder, taking care not to
damage the cylinder wall surface. The wear of the cylinder wall is determined from
diameter reading taken at 20mm from the top of the cylinder with a cylinder
gauge. If the wear thus determined exceeds the limit indicated below, rework the
bore to the next oversize by using a boring machine or replace the cylinder with a
new one. Oversize pistions are available in two sizes: 0.5mm and 1.0mm.
(cylinder gauge)
:40.075mm(1.5778in)
service limit:
after reworking the bore to an oversize, be sure to chamfer the edges of
ports and smooth the chamfered edges with emery paper. To chamfer,
NOTE:
NOTE:
Minor surface flaws on the cylinder wall durto seizure or
similar abnormalities can be corrected by grinding the flaws
off with fine-grain emery paper. If the flaws are deep grooves
or otherwise persist, the cyliner must be reworked with a
boring machine to the next oversize.
PISTON
cylinder and piston clearance
cylinder bore diameter. Be sure to take the maked diameter at right angles to the
end.
(micrometer)
:39.885mm(1.5703in)
service limit:
exceeds the following limit, overhaul the cylinder and use an oversize piston,
replace both cylinder and piston. The measurement for the bore diameter should
41
be taken in the intake-to-exhaust port direction and at 20mm from the cylinder top
surface.
Unit:mm
Decarboning
cleaning the grooves, fit the rings and rotate them in their respective
to cause the piston ring to get stuck in the groove, and the condition
will lead to reduce engine power output. G rind piston surface evenly with emery paper
Use a caliper gauge to measure the piston pin bore inside diameter,.
If reading exceeds the following service limit, replace it with a new one.
(Dial caliper)
positions.
(Micrometer(0-25mm))
service limit:11.980mm(0.4717in)
Piston rings
Check each ring for end gap, reading the gap with a thickness gauge shown in the
illustration. If the end gap is found to exceed the limit, indicated below, replace it
42
with a new one.
The end gap of each ring is to be measued with the ring fitted squarely into the cylidner bore and
held at the least worn part near the cylidner bottom, as shown in the illustration.
Service limit:0.75mm(0.030in)
As the piston ring wears, its end gap increases reducing
reducing engine power output becaust of the resultant blow
by through the enlarged gap. Here lies the importance of
using piston rings with end gaps with the limit. Measure the
piston ring free end gap to check the spring tension.
service limit:3.6mm(0.14in)
Fix the piston ring in the piston ring groove, measure
the ring side clearance with the thicknes gauge while matching
the sliding surface of piston and ring.
Standard clearance
:0.04-0.06mm(0.0016-0.0024in)
1st:
2nd:0.02-0.04mm(0.0008-0.0016in)
Reed vakve
Check the clearance A between reed valve and its seat
and the dimension B. If the clearance A is noted to exceed
0.2mm, replace the reed valve assembly. The dimension B is at
least 1mm.
43
ENGINE Reassembly
Oil seals
fit the oil seals to the crankcase following the
procedure below. Replace removed oil seals with new
ones.
Bearing
Install new bearing with special tool
Install bearing
44
shock absorber bushing
positon
Install crankshaft
45
Decide th length between the webs referring to the figure at
:38±0.1mm(1.496±0.004in)
Standard width between webs::
necessaryto pull its left end into the crankcase with the
special tool.
CAUTION: Never fit the crankshaft into the the crankcase by driving it
with a plastic hammer. Always use the special tool, otherwise crankshaft
46
CRANKCASE
47
install output axle
gearshift
install middle gear, position pin by installing middle gear
axle①, gasket② and thrust gasket③
48
install the bearing② in the fixed driven face①
with the special tool.
49
Install the bearing ① with special tool
NOTE:
When reinstalling the movable face to the fixed
face, make sure that the oil seal is positoned
properly.
50
Install the movable driven face seat①.
:40-60 N.M
tightening torque:
(4.0-6.0kg.m 29.0-43.5Ib-ft)
Torque::40-60 N.M
(4.0-6.0kg.m 29.0-43.5Ib-ft)
51
Apply grease to all the sliding and rolling
surfaces for six roller weights. For each weight,
approximately 1.5g of grease should be used.
QIANJIANG supre grease
52
Insert the spacer④
Position the movable drive face subassembly
on the crankshaft as shown in illustration.
NOTE:
Thoroughly clean the belt contact to be free
from oil.
53
fill the final gear box with engine oil
up to the level hole.
Oil capacity: 90ml
tighten the oil level bolt to the
specified torque.
Tightening torque:9-15M.M
Starter assy.
54
Install the dowel pins①
install the new gaskets(② and ③)
55
apply oil for the piston and install the piston to
the connecting rod.
NOTE:
The arrow mark ① on the piston head should point
the exhaust side.
The circlip should be mounted in such a
position that the mating ends of the circlip do
not coincide with the grovve portion of the
piston.
apply oil on the position and cyoinder wall
surfaces and install the cylinder over the piston
carefully.
OUTSIDE
Oil pump
install oil pump into crankcase
:3-5N.m
torque:
(0.3-0.5kg-m, 2.3-3.7Ib-ft)
56
Reed valve
Instake pipe
install intake pipe
Magneto
clear crankshaft and magneto rotor
install half circle key
install paper gasket and stator coil, and then fix
them
:35-45N.m
specified torque:
(3.5-4.5kg.m,25.5-31.0Ib-ft)
57
install cooling fan
58
CHAPTER 4 FUEL AND LUBRICATION SYSTEM
CONTENTS
FUEL SWITCH
CARBURETOR
OIL PUMP
59
FUEL SWITCH
When the engine has started, a negative pressure(vacuum) is generated at the
intake port. The negative pressure acts upon the diaphragm of the fuel switch and ti
pressed down the spring which supports the diaphragm so that the fuel passageway is
opened and fuel is fed to the carburetor.
When the engine has stopped, the spring presses the valve, the fuel
passagewayos closed, and no fuel flows to the engine.
Fuel switch
60
CARBURETOR
61
CARBURETION
Proper carburetion is determined according to the results of various tests,
mainly concerning engine poer, fuel consumption and cooling effect of feul on
engine, and jet settings ard made so as to satisfy and balance all of these
conditions. Therefore, the jet should not be replaced with a size other than the
original. And the positions of adjustable parts should not be changed except when
compensation for the mixture ratio due to altitude differences or other climatic
conditions. When adjustment is necessary, refer to the following.
OIL PUMP
62
CHAPTER 5 ELECTRICAL SYSTEM
CONTENS
IGNITION SYSTEM
STARTER SYSTEM
FUEL GAUGE
SWITCHS
BARTERY
63
IGNITION SYSTEM
Spark plug
The ignition system consists of a flywheel magneto, a CDI&Ignition coil unit and a spark plug.
①As the rotor tatates, an AC current is induced in the coil. Then current induced in the ○
A
current causes a voltage applied through the ground to the gate of SCR.
③As the SCR conducts, the energy which has been charged in the capacitor is instantaneously
discharged through the primary winding of the ignition coil.
CDI UNIT AND IGNITION COIL INSPECTION
CHECKING WITH ELECTRO TESTER
Connect the CDI test lead to the coil”s primary
connector.
Switch Black
+ lead to the
Connect the high tension leads, red○
red
— lead to the black
spark plug cord and the black○ CDI test lead
64
●Note the spark in the spark gap window. It should be
strong and continuous, not intermittent, acrossa preset
8mm(0.32in) gap. Allow the spark to jump the test gap for at
least five minutes continuously. To insure proper operation
under the temperature of actual riding.
Electronic tester
:140-220
Exciting coil restance:
65
CHARGING AND LIGHTING SYSTEM
66
NO-LOAD PERFORMANCE
tracer lead wire and ground. If the tester reading is as follows, magneto is in
good condition.
Standard
resistance
W/R-GROUND 0.6-1.1Q
W/R-GROUND 0.5-0.8 Q R
regulator/rectifier
Disconnect the lead wire couple.
Using the pocket tester(× 1KQ RANGE), measurethe resistance
between the terminals as shown in the following table. If the
resitance checked is incorrect, replace the regulator/rectifier.
UNIT: KQ
:
NOTES:
Including the components such as transistor,capacitance,
regulator diode and so on, so tested resistance may be different
from actual resistance.
67
STARTER SYSTEM
DESCRIPTION
The starter system is shown in the diagram below: namely, the starter motor, relay, starter switch
and battery. depressing the starter button while squeezing the front or rear brake lever energizes the
relay, causing the contact points to close which connects the starter motor to the battery.
68
STARTER MOTOR INSPECITION
CARBON BRUSHES
When the brushes are worn, the motor will be unable to produce
sufficient torque, and the engine will be difficult to turn over. To
prevent the , periodically inspect the length of the brushes and replace
them when they are too short or chipping.
:3.5mm(0.14in)
Service limit:
Commutator
Segment
If the commutator surface is dirty, starting performance will decrease.
Polish the commutator with #400 or similar fine emery paper when it
is dirty.
:0.2mm(0.008in)
Service limit: Mica
Armature coil
using the pocket tester, check the coil for open and ground by
plcing probe pins on each commutator segment and rotor core and on
any two segments at various places. With the brushes lifted off the
commutator surface. If the coil is found to be open-circuited or
grounded, replace the armatrue.
● Disconnect the starter relay lead wire couple. Check the coil for
“open”, “ground” and ohic resistance. The coil is in good condition,
if the resistance is as follows:
STANDARD RESTANCE::80-150Q
69
FUEL LEVEL METER/GAUGE
FUEL METER INSPECTION
To test the Fuel Meter two different checks may be used.
The first,and simplest test will tell if the mete is
operating but will not indicate the meters accuracy throughout CABLE ASSY.
the range.To perform the test,lift the seat and remove the
right frame cover,then disconnect the B/W and Y/B lead
connector of the fuel gauge sending unit.Connect a jumper
wirebetween B/M and Y/B wiers coming from the main wiring
harness.With the ignition switch tuined ON,the fuel meter
should indicate“F”.
70
SIGNAL SYSTEM
The same bulb is used tor both oil level check light and turn signal indicator light.The circuitry
is shown below.When the oil level has fallen to a certain level (the remaining amount of oil
has become approximately 160 ml,the oil level check light turns on and remains lit.When the turn
signal switch is turned on and the turn signal light flashes,the turn signal indicator light
(oil level check light)also flashes,both being not concurrently but alternatively as one being
lit white the other unit.
机油报警指示灯 刹 闪
车 光
开 蜂 整流/稳压器
转向指示灯 关 鸣
油量表 电源锁 器 蓄电池
电子钟
前右转向灯 后右转向灯
刹车灯
后左转向灯
前左转向灯
防盗器喇叭
机 油
喇 喇叭 磁电机 转向开关
油 位
后 叭 开 传
刹 开 关
防盗器 感
车 关
器
开
关
Fig. 7
71
SWITCH
电源锁 灯控开关
开 大灯
关 会车灯
锁定 关
刹车开关 变光开关
红/白 紫 黄/红 蓝 浅蓝
开 远光
关 近光
喇叭开关 转向开关
红/白 棕 橙 绿/黑 绿/白
开 左转
关 右转
启动开关 机油开关
开 开
关 关
72
BATTERY
SPECIFICATIONS
Type designation YB4L-B
Capacity 12V 4Ah
Standard electrolyte 1.28(20℃)
INITIAL CHARGING
FILLNG ELECTROLYTE
·Remove the aluminum tape ① sealing the battery elec-
trolyte filler holes.
73
RECHARGEING OPERATION
·Apply multimeter to measure the voltage of battery. If the reading is below 12.0V,it should be recharged.
NOTE:
When recharging, remove the battery form the vehicle.
NOTE:
When recharging, don’t remove the sealing cap off battery top.
Recharging time::0.4A or for 5 hours or 4.0A for 1 hour.
NOTE:
The current should be not more than 4A at any time.
·After recharging, wait for more than 30 minutes and apply multimeter to measure the battery voltage.
·if the battery voltage is less than12.5V,please rechare the battery again.
·if battery voltage is still less than 12.5V,please replace the battery with a new one.
·when the battery is left for a long term without using, it is subject to discharge. When th scooter is not used for
more than 1 month (especially dring the winter season), recharge the battery once a month at least.
74
CHAPTER 6 CHASSIS
CONTENTS
LEG SHIELD AND FRAME SIDE COVERS·· ·· ·· ·· ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· ·
LEG SHIELD REMOVAL··· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ··
LEG SHIELD REMOUNTING···· ·· ·· ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ··
FARME SIDE COVER REMOVAL···· ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· ··· ·· ·· ·· ·· ··· ·· ·· ···
FARME SIDE COVER REMOUNTING·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ···
HANDLEBAR COVERS· ······ ·· ·· ··· ·· ·· ·· ·· ··· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ··
REMOVAL···· ··········· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ··
REMORNTING···· ········ ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ···
FRONT WHEEL ·· ············ ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· ··
REMORAL·· ·············· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· ··· ·· ·· ·· ·· ··· ·· ·· ·· ·· ··· ·· ·· ·· ·· ···
INSPECTION AND DISASSEMBLY·· ·· ·· ·· ·· ··· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·
REASSEMBLY AND REMOUNTING···· ·· ·· ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ···
FRONT BRAKE··· ············ ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· ··
BRAKE PAD REPLACEMENT··· ·· ·· ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· ··· ·· ·· ·· ·· ··· ·· ·· ··
CALIPER REMOVAL AND DISASSEMBLY··· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ···
CALIPER AND DISC INSPECTION···· ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ···
CALIPER REASSEMBLY··· ·· ·· ·· ·· ··· ·· ·· ·· ·· ··· ·· ·· ·· ·· ··· ·· ·· ·· ·· ··· ·· ·· ·· ·· ··· ·· ···
MASTER CYLINDER REMOVAL AND DISASSEMBLY··· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ···
MASTER CYLINDER INSPECTION··· ·· ·· ·· ·· ·· ··· ·· ·· ·· ·· ··· ·· ·· ·· ·· ··· ·· ·· ·· ·· ····
MASTER CYLINDER REASSEMBLY AND REMOUNTING···· ·· ·· ·· ·· ·· ··· ·· ·· ·· ·· ··· ·· ··
STEERING STEM AND FRONT SUSPENSION···· ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ··
REMOVAL AND DISASSEMBLY··· ·· · ·· ·· ·· ·· ·· ··· ·· ·· ·· ·· ··· ·· ·· ·· ·· ··· ·· ·· ·· ·· ··· ·· ···
INSPECTION·· ········· ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ··
REASSEMBLY AND REMOUNTING···· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ··
IGNITION SWITCH··· ·· ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ···
REAR WHEEL AND BRAKE··· ·· ·· ·· ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· ··· ·· ·· ·· ·· ··· ·· ·· ·· ·· ··· ·· ·· ·· ·· ·
REMOVAL AND DISASSEMBLY··· ·· · ·· ·· ·· ·· ·· ··· ·· ·· ·· ·· ··· ·· ·· ·· ·· ··· ·· ·· ·· ·· ··· ···
INSPECTION·· ········· ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ··
REASSEMBLY AND REMOUNTING···· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ··
75
Side cover removal
1. remove seat and helmet barrel by opening seat and loosing
tightening screw①.
2. loose hexad screw③ and remove decorating cap②,rear
carrier and oil tank lock④,remove side cover ⑥
by loosing side cover screw⑤⑦;
③
②
③
⑦
⑦
④
3. unlock oil pump cap and remove it, two tapping screw are exposed,
remove them; remove tapping screw⑨;then remove side
cover⑩
side installation ⑩
⑩
4. the sequence of installation is the reverse of removal.
76
③
②
②
①
①
② ②
. ①
②
77
LEGSHIELD AND PEDAL REMOVAL
1. Remove power lock housing ② by unscrewing bolt①.
③
Legshield and pedal installation
78
①②
HANDLE COVER REMOVAL
1. Remove front handle cover ② by unscrewing the six
Tapping screws①
①①
①①
2. Remove master cylinder by removing the bolt③;
①①
①③
79
3.Disconnect throttle cable③ and oil pump cable④
①③
①④
①⑤
80
Handle cover removal
5. remove all cables;
81
Front wheel
1. front rim
2. middle bushing
3. oil seal
4. roller bearing GB6201-2RS
5. tire
6. valve mouth
7. nut GB6817
8. front shaft
9. front wheel left bushing
10. gearcase
11. valve mouth cap
remove ① ②
·Remove the front brake caliper① by removing the mounting
bolts.
NOTE:Do not operate the front brake lever while dismounting caliper
③
82
INSPECTION AND DISASSEMBLY
WHEEL BEARING
Inspect the play of bearing inner ring by hand while mounted in the
wheel.
Rotate the inner ring by hand to inspect if any abnormal noise occurs
or rotating smoothly,
Replace the bearing if there is anything ucusual.
·Remove the dust seal.
CAUTION:
The removed dust seal and bearing should be replaced with new ones.
AXLE SHAFT
Check the axle shaft runout with a micrometer and replace it if
the runout exceeds the limit.
Service limit:0.25mm (0.010in)
WHEEL RIM
Make sure that the wheel rim runout does not exceed the service limit when
checked as shown.
An excessive runout is usually due to worn or loose wheel bearings and can
be reduced by replacing the bearings.If bearing replacement fails to reduce
the runout,replace the wheel.
83
Reassembly and remounting
Reassemble and remount this front wheel in the reverse order of removal, and also carry out the following
steps:
.install this wheel bearing with the special tools as shown in this illustration.
When installing this speedometer gear box, align the two driving pawls
with the two recesses of the wheel hub.
Tighten the nut with special tool.
84
FRONT BRAKE SYSTEM
85
·Remove the brake pads.
CAUTION:
Replace the brake pads as a set,otherwise braking performance
Will be adversely affected.
·Place a rag over the piston to prevent popping up.Froce out the
piston with a air gun.
CAUTION:
Do not use high pressure air to prevent piston damage.
86
CALIPER AND DISC INSPECTION
Inspect the calipe cylinder bore wall or micks,scratches or other
damage.
Inspect piston for damage and wear.
With the disc mounted on the wheel, check the dids for face runout
with a dial gauge as shown.
Replace the disc if the runout exceeds the service limit.
Service Limit:0.3 mm(0.012 in)
87
BRAKE CALIPER REASSEMBLY
CAUTION:
Completely wipe off any brake fluid adhering to any part of motorcycle.
The fluid reacts chemically with paint, plastics, rubber materials, etc.
88
Remove the brake lever and brake switch.
89
Inspect the piston surface for scratches or other damage.
Inspect the primary cup and dust boot for wear or damage.
CAUTION:
Wash the master cylinder components with fresh brake fluis before
reassembly. Never use cleaning solvent or gasoline to wash them.
Apply brake fluid to the cylinder bore and all the internals to be inse-
rted into the bore.
CAUTION:
Bleed air after remounting the master cylinder.
90
STEERING STEM AND FRONT SUSPENSION
91
□ remove disc brake system by unscrewing tightening bolt.
NOTE:
Not drop the steering stem balls.
92
INSPECTION
93
Reassembly and remounting
reassemble and remount the steering stem, handlebar and front
fork in the reverse order of disassembly andremoval, and also
carry out the following steps.
Steel ball
Apply grease when installing the upper and lower steel balls.
QTY:upper :21
lower :21
Tighten the steering outer race with special tool, then extrude it
1/8-1/4round.
NOTE:adjustment will vary from scooter to scooter. Be sure that the steering turns smoothly and easily, left to
right.
□ screw locknut with special tool, and adjust front fork bearing to
get smooth turning.
94
① and bolt
install handlebar and tighten the screw①
to the specified torque:37-44N.M
NOTE:
After performing the adjustment and installing the handlebar,
Rock the front wheel forward and backward to ensure that there
Is not play and that the procuder is accomplished correctly. If
Play is noticeable, raadjust the steering outer race nut.
95
REAR WHEEL AND BRAKE
1. Tire 130/70-12
2.rear rim assy.
3. brake pad kit
assy.
4.brake pad kit
spring
5. rear brake
tension
6. rear indicator
7. anti-dust cover
8. rear brake
camshaft
9. bolt M6Χ30
10.valve
11.nut M16Χ1.5
12. rear brake arm
13. valve cap
96
REMOVE
□ Place the scooter on level ground.
□ Remove muffler.
□ Remove rear small fender.
□ Remove locknut and rear wheel.
□ Remove brake shoes.
INSPECTION
REAR RIM
Measure inner diameter of rear rim hub with micrometer, if measured
diameter exceeds 110.7, replace it with a new one.
Brake shoes
Check the brake shoe and decide whether it should be replaced or
not from the thickness of the brake shoe lining.
Service limit:2.5mm(0.09in)
97
REASSEMBLY AND REMOUNTING
Reassemble and remount the rear wheel and brake in
the reverse of removal, and also carry out the following steps:
□ When installing the brake cam shaft, aligh the groove ④ of camshaft
With the slit ⑤ of on cam shaft.
CAUTION:
Be careful not to daub the camshaft with too much grease.
If grease gets on the lining, brake effectiveness will be lost.
98
SERVICING INFORAMTION
CONTENTS
Troubleshooting
Batteru
Vehicle
Wiringd diagram
Wire, cable and brake hose routing
Special tools
Thread parts tightening torque
Service data
99
TROUBLESHOOTING
ENGINE
Complaint Symptom and possible causes Remedy
Engine does not start, Compression too low
or is hard to start. 1. Excessively worn cylinder or piston rings. Replace.
2. Stiff piston ring in place. Repair or replace.
3. Gas leaks from the joint in crankcase, cylinder or cylinder Repair or replace.
head.
4. Damaged reed valve. Replace.
5. Spark plug too loose. Tighten
6. Broken, cracked or otherwise failed piston. Replace.
Plug not sparking
1. Damaged spark plug or spark plug cap. Replace.
2. Dirty or wet spark plug. Clean and dry.
3. Defective CDI & ignition coil unit or stator coil. Replace.
4. Open or short n high-tension cord. Replace.
5. Defective ignition switch. Replace.
No fuel reaching the carburetor
1. Clogged hole in the fuel tank cap. Clean.
2. Clogged or defective fuel cock. Clean or replace.
3. Defective carburetor float valve. Replace.
4. Clogged fuel hose or defective vacuum hose. Clean or replace.
Engine stalls easily. 1. Carbon deposited on the spark plug. Clean.
2. Defective CDI & ignition coil unit. Replace.
3. Clogged fuel hose. Clean.
4. Clogged jets in carburetor. Clean.
5. Clogged exhaust pipe. Clean.
Noisy engine. Noise appears to come from piston
1. Piston or cylinder worn down. Replace.
2. Combustion chamber fouled with carbon. Clean.
3. Piston pin, bearing or piston pin bore worn. Replace.
4. Piston rings or ring grooves worn. Replace.
Noise seems to come from crankshaft
1. Worn or burnt crankshaft bearings. Replace.
2. Worn or burnt conrod big-end bearings. Replace.
100
Complaint Symptom and possible causes Remedy
Engine runs 1. Excessively worn cylinder or piston rings. Replace.
poorly in 2. Stiff piston ring in place. Replace.
high-speed 3. Spark plug gaps to narrow. Adjust.
range. 4. Ignition not advanced sufficiently due to poorly working CDI & ignition coil unit. Replace.
5. Defective magneto stator coil. Replace.
6. Float-chamber fuel level too low. Adjust or replace.
7. Clogged air cleaner element. Clean.
8. Clogged fuel hose, resulting in inadequate fuel supply to carburetor. Clean and prime.
9. Clogged fuel cock vacuum pipe. Clean.
Dirty or heavy 1. Too much engine oil to the engine. Check oil pump.
exhaust smoke. 2. Use of incorrect engine oil. Change.
Engine lacks 1. Excessively worn cylinder or piston rings. Replace.
power. 2. Stiff piston rings in place. Replace.
3. Gas leaks from crankshaft oil seal. Replace.
4. Spark plug gaps incorrect. Adjust or replace.
5. Clogged air cleaner element. Clean.
6. Float-chamber fuel level out of adjustment. Adjust or replace.
7. Clogged air cleaner element. Clean.
8. Fouled spark plug, Clean or replace.
9. Sucking air from intake pipe. Retighten or replace.
10. Slipping or worn V-belt. Replace.
11. Damaged/worn rollers in the movable drive face. Replace.
12. Weakened movable driven face spring. Replace.
13. Too rich fuel/air mixture due to defective starter system. Replace.
Engine 1. Heavy carbon deposit on piston crown. Clean.
overheats. 2. Defective oil pump or clogged oil circuit. Replace and clean.
3. Fuel level too low in float chamber. Adjust or replace.
4. Air leakage from intake pipe. Retighten or replace.
5. Use of incorrect engine oil. Change.
6. Use lf improper spark plug. Change.
7. Clogged exhaust pipe/muffler. Clean or replace.
CARBURETOR
101
Complaint Symptom and possible causes Remedy
Medium- or 1. Main jet or main air jet is clogged. Check and clean.
high-speed 2. Needle jet is clogged. Check and clean.
trouble. 3. Fuel level is improperly set. Check and replace.
4. Throttle valve is not operating Check throttle valve for operation.
properly. Check and clean.
5. Fuel filter is clogged.
Overflow and 1. Needle valve is worn or damaged. Replace.
fuel level 2. Spring in needle valve is broken. Replace.
fluctuations. 3. Float is not working properly. Check and adjust.
4. Foreign matter has adhered to needle Clean.
valve. Adjust and replace.
5. Fuel level is too high or low.
ELECTRICAL
Complaint Symptom and possible causes Remedy
No sparking or 1. Defective CDI & ignition coil unit. Replace.
poor sparking. 2. Defective spark plug. Replace.
3. Defective magneto stator coil. Replace.
4. Loose connection of lead wire. Connect/tighten.
Spark plug soon 1. Mixture too rich. Adjust carburetor.
becomes fouled 2. Idling speed set too high. Adjust carburetor.
with carbon. 3. Incorrect gasoline. Change.
4. Dirty element in air cleaner. Clean.
5. Spark plug loose. Replace by hot type plug.
6. Incorrect engine oil. Replace.
Spark plug 1. Spark plug too hot. Replace by cold type plug,
electrodes 2. The engine overheats. Tune up.
overheat or burn. 3. Spark plug loose. Retighten.
4. Mixture too lean. Adjust carburetor.
5. Not enough engine oil. Check oil pump.
Magneto does not 1. Open or short in lead wires, or loose lead Repair or retighten.
charge. connections.
2. Shorted, grounded or open magneto coil. Replace.
3. Shorted or open regulator/rectifier. Replace.
Magneto charge, 1. Lead wires tend to get shorted or open-circuited or Repair or retighten.
but charging rate loosely connected at terminal.
is below the 2. Grounded or open-circuited stator coils of magneto. Replace.
specifications. 3. Defective regulator/rectifier.
4. Defective cell plates in the battery, Replace.
Replace the battery.
Magneto 1. Internal short-circuit in the battery. Replace the battery.
overcharges. 2. Resistor element in the regulator/rectifier damaged or Replace.
defective.
3. Regulator/rectifier unit poorly grounded. Clean and tighten ground connection.
102
1. Battery run down. Recharge and replace.
Starter button is 2. Defective switch contacts. Replace.
not effective. 3. Brushes not seating properly on commutator Repair or replace.
in starter motor.
4. Defective starter relay. Replace.
5. Defective starter pinion gears Replace.
6. Defective front or rear brake light switch Repair or replace.
circuit.
BATTERY
Complaint
Remedy
Symptom and possible causes
Battery runs 1. The charging method is not correct. Check the magneto and regulator/rectifier circuit
down quickly. connections, and make necessary adjustments to obtain
specified charging operation.
2. Cell plates have lost much of their active Replace the battery, and correct the charging
material as a result of over-charging. system.
3. A short-circuit condition exists within the battery
due to excessive accumulation of sediments Replace the battery.
caused by the incorrect electrolyte.
4. Battery is too old. Replace the battery.
Reversed battery 1. The battery has been connected the wrong Replace the battery and be sure to connect the
polarity. way round in the system, so that it is being battery properly.
charged in the reverse direction.
Battery 1. Dirty container top and sides. Clean.
discharges too 2. Battery is too old. Replace.
rapidly.
CHASSIS
Complaint
Remedy
Symptom and possible causes
103
Noisy front 1. Not enough grease. Refill.
suspension. 2. Loose nuts on suspension. Retighten.
BRAKES
Complaint Symptom and possible causes Remedy
Insufficient 1. Leakage of brake fluid from hydraulic system. Repair or replace.
brake power. 2. Worn pad. Replace.
3. Oil adhesion on engaging surface of pad. Clean disc and pads.
4. Worn disc. Replace.
5. Air entered into hydraulic system. Bleed air.
6. Worn shoe. Replace.
7. Friction surfaces of shoes are dirty with oil. Replace.
8. Excessively worn drum. Replace.
9. Too much brake lever play. Adjust.
Brake 1. Carbon adhesion on pad surface. Repair surface with sandpaper.
squeaking. 2. Tilted pad. Modify and fitting.
3. Damaged wheel bearing. Replace.
4. Worn pad. Replace.
5. Foreign substance entered into brake fluid. Replace brake fluid.
6. Clogged return port of master cylinder. Disassemble and clean master cylinder.
7. Brake shoe surface glazed. Repair surface with sandpaper,
8. Loose front-wheel axle or rear-wheel axle nut. Tighten to specified torque.
9. Worn shoe. Replace.
104
电气原理图
机油报警指示灯 刹 闪
车 光
远光指示灯 蜂
开 整流/稳压器
转向指示灯 鸣 启动继电器 电子点火器 点火线圈 熄火开关
关
WIRING DIAGRAM
电
子
风
门
前右转向灯 后右转向灯
前照灯 尾灯/刹车灯
后左转向灯
夜小灯
前左转向灯
防盗器喇叭
M
机 油
灯控开关 喇 喇叭 磁电机 转向开关
启 油 位 防盗器
变光开关 叭
后 启动电机 动 开 传
刹 开 开 关
关 感
车 关 器
开
关
R
B
L
导 B N Dg LR G/R G/W G/B G/Y R/W
线 红 黑 棕 蓝 墨绿 粉红 绿/红 绿/白 绿/黑 绿/黄 红/白
颜 Y P W O LBL Y/R B/W N/W BL/W B/R
色 黄 紫 白 橙 淡蓝 黄/红 黑/白 棕/白 蓝/白 黑/红
105
WIRE, CABLE AND BRAKE HOSE ROUTING
106
carburetor
107
108
Starting relay
Ignition coil
CDI
HORN
POWER SWITCHH
109
SPECIAL TOOLS LISTED BELOW FOR REMOVAL AND REINSTALLATION
DESCRIPTION
NO. TOOL NUMBER
① ③
110
⑤ ⑥
⑦ ⑧ ⑨
111
TIGHTENTING TORQUE O F SCREW THREAD PARTS
ENGINE
ITEM N.M
Cylinder guide cover tapping screw 1-4
Fan guide cover lock bolt 10-12
Cylinder cover locknut 15-18
Spark plug 15-18
Inlet pipe lock bolt 10-12
Cooling fan impeller lock screw 10-12
Flywheel lock bolt 45-50
Magneto stator coil lock screw 10-12
Magneto exciting lock screw 3-5
Oil pump lock screw 5-9
Right crankcase lock bolt 10-12
Bearing press board lock bolt 10-12
Cylinder double head bolt 15-18
Motor tightening bolt 10-12
Left crankcase cover lock screw 10-12
Left crankcase cover lock bolt 10-12
Main drive wheel face locknut 35-38
Driven wheel face locknut 35-38
Driven wheel face clutch locknut 55-60
Exceeding clutch outside lock screw 10-12
Electrical start idle press board screw 10-12
Gearcase lock bolt 10-12
Left crankcase discharging oil hole lock bolt 22-25
Left crankcase positioning pin shaft locknut 18-22
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SERVICE DATA
CYLINDER+PISTON+PISTON RING
Unit:mm(in)
ITEM STANDARD TOLERANCE
Piston to cylinder 0.06-0.07 0.120
clearance (0.0024-0.0028) (0.0047)
Cylinder bore 40.005-40.020 40.075
(1.5750-1.5756) (1.5778)
Cylinder diameter 39.94-39.955 39.885
(1.5724-1.5746) (1.5703)
Cylinder distortion 0.04
(0.0016)
Cylinder head distortion 0.04
(0.0016)
st
Piston ring free cotter end 1 ring 0.02~0.06mm
clearance 2en ring 0.02~0.06mm
Piston ring close end 0.15-0.35 0.8
clearance (0.0059-0.0138) (0.0315)
Piston ring to groove 1st ring 0.02~0.06(0.0008~0.0024)
clearance 2en ring 0.02~0.06(0.0008~0.0024)
Piston pin bore 10.002-10.008 10.030
(0.3938-0.3940) (0.3949)
Piston pin outside 9.994-10.000 9.98
diameter (0.3935-0.3937) (0.3929)
CONNECTING ROD+CRANKSHAFT
ITEM STANDARD LIMIT
Conrod small end 13.995-14.006(0.5510-0.5514) 14.040(0.5528)
Conrod deflection 3.0(0.12)
Conrod web to web width 38-38.1(1.496-1.500)
Crankshaft runout 0.05(0.002)
OIL PUMP
ITEM SPECIFICATION
Pump reduction ratio 30.000(30/1)
CCI pump discharge 1.1-1.3ml/5min(working pressure is 0.06Mpa and rotating speed
ratio(full open) 118r/min)
113
CLUTCH
Unit: mm(in)
114
WATTAGE
ITEM SPECIFICATION
Headlight high beam/ 12V 35W/35W
Dipped headlight 12V 35W
Taillight 12V 21W/5W
Front turn light 12V 10W
Rear turn light 12V 10W
Turning signal 12V 3W
indicator light
High beam indicator 12V 1.7 W
light
Meter indicator light 12V 1.7 W
Alarm indicator light Light diode
SUSPENSION
Front shock absorber stroke 88 mm Rear shock absorber stroke 45 mm
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