Two-wheel Motorcycle QJ125GY-16A

Two-wheel Motorcycle QJ125GY-16A

Instruction and Maintenance Manual

 

 

ZHEJIANG QIANJIANG MOTORCYCLE CO., LTD.

Contents

PrefaceЎ¤ - 1 -

Preparatory DataЎ¤ - 2 -

Inspection/Adjustment - 15 -

Check and Maintenance of Body Ў¤ - 32 -

I Braking System Ў¤Ў¤ - 34 -

1.1 Maintenance InstructionЎ¤ - 34 -

1.2 Fault diagnosis - 35 -

1.3 Front Hydraulic BrakeЎ¤ - 36 -

1.4 Back liquid brakeЎ¤ - 38 -

II Vehicle Housing Ў¤ - 42 -

III Front Wheel/Front Suspension Ў¤ - 45 -

3.1 Preparatory DataЎ¤ - 45 -

3.2 Fault diagnosis - 45 -

3.3 Front wheel - 47 -

3.4 Direction handleЎ¤ - 49 -

3.5 Front forkЎ¤ - 49 -

IV Rear Wheel/Rear Suspension Ў¤ - 54 -

4.1 Preparatory DataЎ¤ - 54 -

4.2 Fault Diagnosis - 55 -

4.3 Rear wheel - 56 -

4.4 Rear Shock Absorber - 57 -

4.5 Rear Swing ArmЎ¤Ў¤ - 58 -

4.6 Drive ChainЎ¤ - 59 -

V Storage Battery/Charging System Ў¤Ў¤ - 62 -

5.1 Preparatory DataЎ¤ - 62 -

5.2 Fault Diagnosis - 63 -

5.3 Storage BatteryЎ¤ - 64 -

5.4 Charging SystemЎ¤Ў¤ - 65 -

5.5 Voltage-current Regulator - 66 -

5.6 Alternator Charging Coil - 67 -

5.7 alternator light coil - 67 -

5.8 disassembly of alternator - 68 -

VI Ignition System Ў¤Ў¤ - 71 -

6.1 Preparatory DataЎ¤ - 71 -

6.2 Fault Diagnosis - 72 -

6.3 Ignition System InspectionЎ¤ - 73 -

6.4 CDI AssemblyЎ¤ - 75 -

6.5 Ignition Coil - 75 -

6.6 Trigger - 76 -

VIIStarting System Ў¤Ў¤ - 78 -

7.1 Preparatory DataЎ¤ - 78 -

7.2 Fault Diagnosis - 79 -

7.3 Starting Motor - 79 -

7.4 Starting RelayЎ¤ - 81 -

VIIIBulbs/Switches/Instruments - 82 -

8.1 Preparatory DataЎ¤ - 82 -

8.2 Fault Diagnosis - 82 -

8.3 Headlamp Bulb Replacement - 83 -

8.4 Front Turn Signal Lamp Bulb Replacement - 84 -

8.5 Taillight/license plate lamp/rear turn-lamp bulb replacement - 84 -

8.6 Instrument - 85 -

8.7 Main SwitchЎ¤ - 85 -

8.8 HornЎ¤ - 86 -

8.9 Handle switchЎ¤ - 86 -

Engine Inspection and Maintenance Ў¤ - 87 -

IX Lubricating System Ў¤Ў¤ - 89 -

9.1 Preparatory DataЎ¤ - 89 -

9.2 Fault Diagnosis - 89 -

9.3 Oil PumpЎ¤ - 90 -

X Cooling system Ў¤Ў¤ - 93 -

10.1 Preparatory dataЎ¤ - 93 -

10.2 Fault diagnosis - 93 -

10.3 Water pumpЎ¤ - 94 -

XI Cylinder Head Ў¤ - 97 -

11.1 Preparatory DataЎ¤ - 97 -

11.2 Fault Diagnosis - 98 -

11.3 Cylinder HeadЎ¤ - 98 -

XII Cylinder Block and Piston Ў¤ - 107 -

12.1 Preparatory DataЎ¤ - 107 -

12.2 Fault Diagnosis - 108 -

12.3 Cylinder HeadЎ¤ - 108 -

XIII Crankcase Ў¤ - 113 -

13.1 Preparatory DataЎ¤ - 113 -

13.2 Fault Diagnosis - 114 -

13.3 CrankcaseЎ¤ - 115 -

13.4 ClutchЎ¤ - 116 -

13.5 Gearshift mechanismЎ¤Ў¤ - 121 -

13.6 Crankcase connecting rod combinationЎ¤ - 122 -

13.7 Variable speed chamber - 125 -

Exhaust System Inspection and Maintenance Ў¤ - 128 -

XV Emission Control System Ў¤Ў¤ - 129 -

15.1 Emission Control System GuaranteeЎ¤ - 129 -

15.2 Regular maintenance guidelines - 129 -

15.3 Emission Control System Mechanical Functions - 130 -

15.4 Catalyst conversion systemЎ¤Ў¤ - 131 -

15.5 Solutions to Idle Exhaust Exceeding Specified ValueЎ¤ - 132 -

Inspection and Maintenance of EFI System Ў¤Ў¤ - 133 -

XVIEFI System Description Ў¤ - 134 -

16.1 Introduction to EFI System of finished enginecycleЎ¤ - 134 -

16.2 EFI system parts - 134 -

16.3 Troubleshooting diagnosis - 146 -

16.4 Common troubleshootingЎ¤ - 153 -

16.4.3 Concise troubleshootingЎ¤ - 154 -

QJ125GY-16A circuit diagram Ў¤Ў¤ i

 

Preface

 

The Instruction and Maintenance Manual contains an introductory description of maintenance on QJ125GY-16A motorcycle.

Preparatory data include attentions that shall be paid on all the maintenance operations in the Instruction and Maintenance Manual. Please read the manual carefully before operation.

Check and adjustment contains main aspects for inspection and adjustment, safety of the vehicle, performance and maintenance of each component. This shall be started from the time of periodical inspection.

The parts following Chapter One demonstrate the main point of disassembly, installation and check of electrics parts, finished vehicle, engine and other components.

System diagrams, breakdown drawings, fault diagnosis, maintenance and other explanatory contents are presented before each part.

Note:

The parts which are not explained separately in the manual apply to both of the motorcycles.

For any pattern and structure change of the motorcycle, or any difference between the product and pictures, drawings and instructions in the manual, the product shall prevail. The product is subject to changes without prior personal notice.

 

ZHEJIANG QIANJIANG MOTORCYCLE CO., LTD.

Finished Automobile Institute

Preparatory Data

General Safety Maintenance Rules

Specification Table Fault Diagnosis

General Safety

Carbon monoxide (CO)

When it is necessary to start the engine, please make sure the operation area is well ventilated. Never run the engine in an enclosed place.

Attention

Gas exhausted from the motorcycle contains harmful carbon monoxide, which may lead to loss of consciousness and death.

It is necessary to run the engine in an open area. To run the engine in an enclosed site, ventilation system shall be used.

Gasoline

Operate in well-ventilated site. No fire or smoking is allowed in operation site and gasoline storage place.

Storage Battery

Electrolyte in the storage battery has sulfuric acid, so leave eyesЎўskin and clothes away from it. Once got electrolyte on our skin or clothes, you will have to wash them by fresh water thoroughly; once into our eyes, to see a doctor immediately is necessary.

Special Tool

When disassembly and installation is in process, general tools and special tools should be selected correctly. When it is time to use the special, the general can not be substitution. Besides, appropriate power is welcomed to avoid the damage of components.

High Temperature Burn

Tips: Do not be burned by engine, exhaust pipe,silencer and other components with high temperature. When operating together with others, youЎЇd better look after each other and keep a way for safety.

Maintenance Rules

While repairing and servicing, use tools of metric system as possible. Incorrect tools may damage the motorcycle.

Before taking down or opening protecting plate for repair work, please clean the dirt on the external surfaces of components or combination parts and prevent the dirt from falling into engine, chassis or braking system

After disassembly and before measuring friction, please clean the components and blow them with compressed air.

 

 

ЎЄBending or Warping are forbidden in operation, otherwise tough operation or advanced damage will be caused.

 

Plastic parts may age and deteriorate, which are apt to be damaged by solvent or oil. Check before re-installation and replace if necessary.

 

To loose component with many assembling units, it shall start from external to internal and loosen smaller assemblies first.

The complicated assemblies such as transmission case shall be put in proper assembling order for easy assembly in the future.

 

Pay special attention to the key fitting position before disassembly. The components that are not used any more shall be replaced on time before disassembly.

 

Length of bolts and screws are different for assembly components and protecting plates. They shall be installed at correct positions. If confused, just put the bolt in the hole and see if it matches.

 

 

Fill lubricating grease into the groove during oil seal installation. Check if the oil seal is smooth and if there is any damage to it.

 

 

Installation of rubber hose (fuel, vacuum, or coolant): insert its end into bottom of connector so that there is enough room for the hose clamp to grip the connector. Install the rubber or plastic dust cover back to its originally designed position

 

 

Disassembly of ball bearing: use a tool to push against one or two (internal and external) bearing races. If the force works only on one bearing race (whatever internal or external), it may be damaged when the bearing is disassembled, in which case, it must be replaced

Specifications (QJ125GY-16A)

Model	QJ125GY-16A	Engine	Engine type	QJ160MI-A
Overall Length (mm)		Fuel type	92# or 95# unleaded gasoline
Overall Width (mm)		Number of cylinders
Overall height (mm)		Bore*stroke	§¶60 mm *44 mm
Wheelbase (mm)		Displacement	124.4
Vehicle Weight (kg)	Front axle	63kg	Starting mode	Electric
Rear axle	76kg	Cooling mode	Water cooled
Total	139kg	Lubricating mode	Force-feed and splash lubrication
Wheel Specification	Front (External)	Fuel tank capacity	1.2L(Oil change1L)
100/80-17
RearЈЁExternalЈ©	Air cleaner	Filter sponge
130/80-17
Drive Train	Clutch type	Wet multi-plate friction type	Fuel tank capacity	7.5L ЎА 0.2L
Performance	Top speed	110 km/h
Gear shift pattern	Manual 6 gear	Slope climbing force	Maximum climbing angle is not less than 20 degrees
Idle speed	1700ЎА 100rpm/min
Drive Train	Clutch type
Max. torque	12.18NЎ¤m/7500r/min
Electrical	Battery capacity/type	12V-6AH/YUASA TT27SL	Max. power	11 Kw/ 9000 r/min
Generator type	Alternating current permanent magnetic motor	Compression ratio	12.0: 1
Spark plug	NGK CR8E	Pressure of cylinder	8.5Mpa
Spark plug clearance	0.7~0.8mm	Braking system	Diameter of front brake disc	¦Х280mm
Ignition type	CDI	Diameter of rear brake disc	¦Х240mm

QJ125GY-16A

Fault Diagnosis

Preparatory Standard

General

Warning!

• Before running the engine, please make sure the area you are working in is well ventilated. You shall never run the engine in an enclosed site. Gas exhausted from the motorcycle contains carbon monoxide, which may lead to loss of consciousness and result in death. • Under certain conditions, gasoline is highly volatile. Work in well-ventilated site. Fire and smoking are forbidden in working site or gasoline storage place.

 

 

Specifications

Engine

Idle speed	1,700ЎА100rpm/min
Spark plug clearance	0.7~0.8mm	engine oil volume	1.2L(oil change1L)
Spark plug type	NGK CR8E
Cylinder compression pressure	1.1~1.3Mpa
Ignition time	BTDC12 degrees (+/-)1degree 1,700ЎА100rpm

 

Frame

Clearance of front brake handle	10-20mm
Clearance of rear brake pedal	10-20mm
Pneumatic pressure unit of tyre: Kpa	Specification	Tyre pressure
QJ125GY-16A	Front wheel	100/80-17	225kpa
Rear wheel	130/80-17	225kpa
Torque	Front shaft locknut	75-88 NЎ¤m
Rear shaft locknut	100-113 NЎ¤m

Engine Oil/Filter

Engine oil level

*Attention

• Motorcycle shall stand on the flat ground while checking engine oil level. •Inspect engine oil level when the engine has run for 2~3mintues or stopped for 2~3minutes.

Check engine oil level

When the engine oil level sensor alarms, refill engine oil to its upper limit.

Engine oil replacement

* Attention

When the engine is warmed up, replace engine oil. The oil can flow out easily.

Shut down engine.

Screw off the drain plug at the bottom of crankcase to drain engine oil.

When the engine oil is completely drained, put back cleaned drain plug and sealing ring.

Refill engine oil to specified level.

Engine oil volume: 1.0-1.2L

Check if there is engine oil leakage. Start the engine and run the engine on idle for a few minutes.

Check engine oil level again.

Gasoline filter

Check of degradation and damage of fuel pipe.

If there is any degradation, damage or fuel leakage, new products should replace the old ones.

 

 

Warning!

No open flames.

Free stroke: 2-6mm

Side of the restrictor is the main parts which should be adjusted.

Loosen the hold-down nut and rotate to adjust nuts.

Air filter

Change of air filter

Disassemble seat cushion

 

 

 

Disassemble backplate of the right fuel tank

Disassemble right knee board.

Disassemble backplate of the left fuel tank

Disassemble left knee board.

 

Disassemble gusset plate of right and left fuel tank backplate

 

Disassemble air filter cover; fix bolts; take down the cover.

Disassemble bolts; take down air filter.

Disassemble filter sponge from air filter.

 

 

Check whether the filter sponge is polluted or damaged.

If there is pollution or damage, please replace a new one.

If there is pollution, please replace and wash.

How to wash the filter sponge:

a) Wash it in the clean washing oil.

b) Make it fully dry.

c) Soak it in the clean gear oil until soaking well.

d) Squeeze out the extra oil in sponge.

 

 

Replacing Time

If driving under dusty condition or in rainy days frequently, replace the air cleaner earlier.

*Attention

• When installing air filter cover, please make sure that it is finished well.

Spark plug

Pull out head of spark plug.

 

Disassemble spark plug with spark plug sleeve.

Check the burning, pollution and carbon deposit of spark plug.

If the conditions above happen, please clear with spark plug scavenger or steel brush.

 

Clearance inspection of spark plug

Gap: 0.7-0.8mm

Spark plug type: CR8E (NGK)

*Attention

When installing spark plug, youЎЇd better install with hands and then use spark plug sleeve to tighten.

Storage battery

Disassembly of storage battery

Open seat cushion

Disassemble gusset plate of right and left fuel tank backplate.

Disassemble air filter cover

Disassemble negative wire first and then the positive one.

Take out storage battery.

Warning!

During positive lead wire disconnection, be sure to prevent the tools being used from touching the frame; or it will result in short circuit sparks, which may ignite gasoline and damage battery. It is dangerous!

Install the battery in reverse order of removal.

Warning!

To avoid short circuit, please connect positive (+) lead wire first, then the negative (-) lead wire.

 

Check of the charging state (closed circuit voltage)

Open seat cushion

Open roof cover of air filter; disassemble joint wire of storage battery.

Measure the battery voltage using a voltmeter.

Fully charged: 13.1V

Undercharge: 12.3V

* Attention

Voltmeter shall be used for charging inspection.

Charging

Connection method: Positive pole of battery charger is connected to battery positive lead wire;
Negative pole of battery charger is connected to battery negative lead wire.

Warning!

• Battery shall be away from fire. • Shut off charger switch first before or after charging in case sparks may be generated at connection parts, which may result in explosion. • During charging, please take the current time labeled on the battery as basic time.

 

* Attention

• Battery quick recharging is not recommended except in case of emergency. • After recharging, wait at least 30minutes and then measure the battery voltage.

 

Quick recharging: 4.0A

Recharging time: Standard: 10-15hours

Quick recharging: 30minutes

Restrictor

Idle speed adjustment

* Attention

Perform idle speed adjustment when the engine is warm.

 

Warm up the engine and then adjust idle speed.

Run the engine and connect engine tachometer.

Adjust the throttle cable lock-screw to specified RPM.

Idle speed RPM: 1,700ЎА100rpm/min

If idle speed RPM is unsteady, or idle speed is not smooth when gently raise engine speed, adjust idle speed adjusting screw again.

Cylinder pressure

Operation when engine is warming.

Disassemble spark plug.

Install roof cylinder pressure gage.

Fully open accelerator; start engine to measure cylinder pressure.

Drive Chain Slackness

Service life of drive chain relies on proper lubrication and adjustment. If not maintained in a proper way, advanced abrasion will come out in drive chain or chain wheel. In the harsh using conditions, maintain frequently is necessary.

 

Stand vertically the motorcycle on the flat ground and check drive chain slackness a.

Lubrication of drive chain

Use drive chain grease first; buy drive chain grease or engine oil or other lubricating oil. Soak every chain joint to make grease through link plateЎўmeltЎўlining and rolling.

*Attention

DonЎЇt install new chain on the damaged chain wheel or install damaged chain on new chain wheel. Chain and chain wheel should be in good condition, or the changed chain or chain wheel will be damaged soon.

Clearance: 10-20mm

Please adjust free travel of front brake handle in the following way:

(1) Loose mandrill to lock nut1.

(2) Twist in or out the mandril2 to adjust free travel of front brake handle, after adjusting free travel to 10-20mm.

(3) Install mandril1 tight and lock nut1

 

Rear brake clearance

Measure the clearance of rear brake at the tip of front brake handle.

Clearance: 10-20mm

Please adjust free travel of back brake footstep in the following way:

(1) Loose mandrill to lock nut1.

(2) Twist in or out the mandril2 to adjust free travel of front brake handle, after adjusting free travel to 10-20mm.

(3) Install mandril1 tight and lock nut1

Front/back brake shoeЎЇs abrasive wear

Front brake shoeЎЇs abrasive wear

When braking exactly, check oil level from oil immersion lens. If liquid level of brake fluid is below the arrow position in the right picture, brake shoe should be replaced immediately by a new one.

 

 

Back brake shoeЎЇs abrasive wear

When braking exactly, look oil cup to check oil level of brake fluid. If the level is below MIN, brake shoe should be replaced as soon as possible.

 

Headlight

Adjustment

Optical axis adjustment of headlight is loosening headlight spinning adjusting bolt and then rotating.

 

 

Clutch

Start engine and increase rotation speed gradually to check running condition of clutch. If motorcycle can not walk or engine shuts down, check clutch block. Replace a new one when necessary.

Bolt/Nut/Fastening Part

Inspect bolts, nuts and fastening parts at every part of the motorcycle for looseness.

If it is loose, tighten it to specified torque.

 

Wheel Rim/Tyre

Check if there is crack, nails and similar sharp objects, and other injuries on the tyres.

 

 

Inspect pneumatic pressure of tyres.

 

 

* Attention

Measure cold inflation tyre pressure

Front liquid brake block

A Thickness of brake shoe: 7.8mm Use limits: 3.8mm B Torsion force to Install Bolt 1: 22-34NЎ¤m C Torsion force to Install Bolt 7: 30-35NЎ¤m D Torsion force to Install Bolt 14: 5-10NЎ¤m E Torsion force to Install Bolt 16: 2-5NЎ¤m F Torsion force to Install Bolt 18: 5-10NЎ¤m

ўЕ Inner hexagon screw M8*35 ўЖ Gasket 8 ўЗ Front liquid brake block units ўИ Brake cylinder units

ўЙ Brake shoe units ўК Sealing gasket ўЛ Erection bolt in oil tube ўМ Brake house units ўН Oil pump units

ўО Handle ўП Thin nut M6 ўР Handle screw ўС Fixed cover ўТ Bolt M6*25 ўУ Brake switch units

ўФ Countersunk flat Phillips heads for exposed screws M4*12 ўХ Mandrill ўЦ Self-locking nut M6
Back liquid brake block

A Thickness of brake shoe: 7.0mm Use limits: 3.7mm B Torsion force to Install Bolt 3: 5-10NЎ¤m C Torsion force to Install Bolt 4: 5-10 NЎ¤m D Torsion force to Install Bolt 7: 30-35 NЎ¤m E Torsion force to Install Bolt 12: 22-34NЎ¤m F Torsion force to Install Bolt 23: 30-35 NЎ¤m

ўЕ Rear liquid brake block units ўЖ Gasket 6 ўЗ Inner hexagon screw M6*16 ўИ Inner hexagon screw M6*16 ўЙ Gasket 6 ўК Oil pump assembly ўЛ Brake switch assembly ўМ Seal ring ўН Lining I ўОLining II ўП Connecting plate ўРInner hexagon screw M8*20 ўСGasket 8 ўТ Brake cylinder B ўУ Friction plate units ўФ Nut M6 ўХ Draw bar ўЦ Draw handle ўЧ Brake hose unit ўШ Oil tube (21) Hoop (22) Oil cup units (23) Hexagon flange head tapping screw (24) Protecting spring

I Braking System

Maintenance instruction--------------------1.1

Fault diagnosis-------------------------------1.2

Front hydraulic disc brake----------------- 1.3

Rear drum brake-----------------------------1.4

1.1 Maintenance Instruction

Precautions on operation

* Attention

• Please do not contaminate braking assembly with oil while assembly or disassembly. • Please use specified detergent to clean the braking assembly, or it may reduce braking performance.

* Please check braking system before driving your motorcycle.*

1.1.1 Specifications

project	Standard value	Available limits	project	Standard value	Available limits
front	Dedicated brake fluid	DOT4	-	back	Dedicated brake fluid	DOT4	-
thickness of liquid brake block	4.0	3.0	thickness of liquid brake block	5.0	4.0
thickness of brake shoe	9mm	4.5mm	thickness of brake shoe	9mm	4.5mm
diameter of liquid brake block	¦Х280mm	-	diameter of liquid brake block	¦Х240mm	-
Jump of liquid brake block	0.1mm	-	Jump of liquid brake block	0.1mm	-
Inner diameter of mercury oil cylinder	§¶12.7+0.027 0mm	-	Inner diameter of mercury oil cylinder	§¶14+0.027 0mm	-
Outer diameter of mercury oil piston	§¶12.7-0.050 -0.077mm	-	Outer diameter of mercury oil piston	§¶14-0.050 -0.077mm	-
Inner diameter caliper cylinder	§¶25+0.05 0mm	-	Inner diameter caliper cylinder	§¶30+0.05 0mm	-
Outer diameter of caliper piston	§¶25-0.07 -0.10mm	-	Outer diameter of caliper piston	§¶25-0.07 -0.10mm	-

1.1.2 Torsion force

Former brake disc retaining bolt 5-10NЎ¤m

Under the brake fluid before pump installation bolt 22-34NЎ¤m

Liquid brake oil pump before installation bolt 5-10NЎ¤m

Front wheel spindle 100-113NЎ¤m

Front wheel head bolt 5-10NЎ¤m

The brake disc retaining bolt 5-10NЎ¤m

Liquid brake pump installation after the bolt 22-34NЎ¤m

Back oil pump installing bolts liquid brake 5-10NЎ¤m

Back wheel spindle 100-113NЎ¤m

1.2 Fault diagnosis

1.2.1Brake in ill performing services

l Brake without adjustment well

l Abrasive wear of brake shoe units and liquid brake plate

l Improper installment of brake shoe units

l Pollution of liquid brake plate of brake shoe units

1.2.2 Brake reaction slowly or handle is tight

l Brake without adjustment well

l Abrasive wear of brake shoe units and liquid brake plate

Improper installment of brake shoe units

1.2.2 Brake with abnormal sound

l Abrasive wear of brake shoe units and liquid brake plate

l Pollution of liquid brake plate of brake shoe units

1.2.4 Braking handle/footstep is soft or light

l Air in hydraulic system

l Leakage of hydraulic system

l Braking footstep/plate is dirty

l Sealing abrasive wear of caliper piston

l Abrasive wear of braking footstep/plate

l Caliper is dirty

l Caliper can not slide well

l Lack of brake fluid

l Block of brake fluid pipe

l Bending/incompletion of caliper piston

l Bending/incompletion of master cylinder piston

l Master cylinder piston is dirty

l Braking handle/footstep is curving

1.2.5 Brake gets stuck or is pulled to one side

l Braking footstep/plate is dirty

l Deviation of wheels

l Block or restriction in brake hose joints

l Bending/incompletion of braking plate

l Caliper slides abnormally

1.2.6 Brake drag

l Braking footstep/plate is dirty

l Deviation of wheels

l Abrasive wear of braking footstep/plate

l Bending/incompletion of braking plate

l Caliper slides abnormally

1.2.7Brake handle/footstep is hard

l Block or restriction of brake system

l Adhere/abrasive wear of caliper piston

l Caliper slides abnormally

l Block/restriction of brake fluid pipe

l Sealing gasket abrasive wear of caliper piston

l Adhere/abrasive wear of master cylinder piston

l Braking handle/footstep is curving

1.3 Front Hydraulic Brake

1.3.1 Removal

 

* Attention

• Replace braking shoe assembly. • If a braking shoe assembly will be used again, please mark it on the side before removal so as to re-install it to its original place.

Loosen brake cylinder units and fix bolts.

Disassemble brake cylinder units from front damper

Disassemble the following units from front damper:

 

Front liquid brake block

1. Braking shoe

2. Front brake block oil pipe

3. Brake cylinder units

* Attention

•Please do not contaminate braking shoe assembly with oil while assembly or disassembly •Please use specified detergent to clean the braking assembly, or it may reduce braking performance.

Disassemble front axle

Take down front axle

Disassemble front liquid brake block from front wheel

 

1.3.2 Check

Check the abrasive wear condition of brake shoe. Replace it when necessary.

Measure brake shoeЎўbrake plate and then write down the maximum number.

Measure the thickness of brake shoe.

Specification

Diameter of front liquid brake plate: ¦Х280mm

*Attention

• Wipe brake plate with #120abrasive paper if it rusts • Micrometer is the only choice for measurement.

If the thickness of brake plate and brake shoe are less than maintenance value or polluted by grease, please replace them.

 

* Attention

• Micrometer and vernier caliper are the only choices for measurement.

 

1.3.3 Installment

Install front wheel

Install front liquid brake oil pipe and brake cylinder units

Do not get grease on brake shoe

* Attention

If there is grease on brake shoe, brake ability will reduce and cause brake failure

 

Fasten bolts to the setting torsion force

Torsion force:

Former brake disc retaining bolt 5-10NЎ¤m

Under the brake fluid before pump installation bolt 22-34NЎ¤m

Liquid brake oil pump before installation bolt 5-10NЎ¤m

Front wheel spindle 100-113NЎ¤m

Front wheel head bolt 5-10NЎ¤m

1.4 Back liquid brake

1.4.1 Disassembly

Disassemble back brake oil pump units

Disassemble back brake cylinder units

Disassemble back wheel

Disassemble bake disc from back wheel hub

 

NoteЈє

Specification

Diameter of front liquid brake plate: ¦Х280mm

*Attention

• Wipe brake plate with #120abrasive paper if it rusts • Micrometer is the only choice for measurement.

If the thickness of brake plate and brake shoe are less than maintenance value or polluted by grease, please replace them.

 

 

* Attention

• Micrometer and vernier caliper are the only choices for measurement.

 

1.4.3 Installment

Install front wheel

Install front liquid brake oil pipe and brake cylinder units

Do not get grease on brake shoe

* Attention

If there is grease on brake shoe, brake ability will reduce and cause brake failure

 

Fasten bolts to the setting torsion force

Torsion force:

Former brake disc retaining bolt 5-10NЎ¤m

Under the brake fluid before pump installation bolt 22-34NЎ¤m

Liquid brake oil pump before installation bolt 5-10NЎ¤m

Front wheel spindle 100-113NЎ¤m

Front wheel head bolt 5-10NЎ¤m

No oil stain shall be on brake shoe and brake disk.

If any, use brake cleaner fluid.

*Attention

Oil stain on brake shoe will eliminate braking performance.

Body outer panels

1 Front and right turn light 2 Front and left turn light 3 Front night-light fixed position 4 Pod

5 Right mounting plate of pod 6 Left mounting plate of pod 7 Headlight 8 Instrument assembly

9 Front splash guard 10 Right and left oil tank guard plate gusset piece 11 Right back plate 12 Left back plate 13 Right and left back plate 14 Left dale 15 Back plate of left oil tank 16 Front of back splash guard 17 Right and left guard plate gusset piece 18 Seat cushion 19 Left kneelet 20 Right kneelet 21 Back plate of right oil tank 22 Right decorative plate 23 Back license plate lamp 24 Back and left turn light 25 Back and right turn light 26 Back splash guard 27 Back splash guardўт 28 Back taillight 29 Back of back splash guard

II Vehicle Housing

Disassemble body as the following order:

 

rearview mirror Ўъfront pod Ўъinstrument support Ўъinstrument Ўъback pod Ўъfront splash guard Ўъseat cushion Ўъdecorating plate of left and right front back plate Ўъleft and right front back plateЎъ front and back junction plate of right and left back plateЎъ bottom coverЎъ left and right back plate of oil tank Ўъ right and left back guard board Ўъright and left step tread ЎъtaillightЎъ back splash plate Ўъ back license tag support

* Attention

Do not damage exterior parts during assembly and disassembly.

Do not damage the jaws on the exterior parts of the vehicle during assembly or disassembly.

Align built-in panel and cover plate to their grooves respectively.

Correctly install paw of each part during combination.

Do not damage the fittings during exterior part installation.
Front wheel/front suspension

Front wheel

1 Front wheel axleM14*1.5*219 2 Odometer wheel gear units 3 Front wheel sealed units 4 Front wheel middle shaft sleeve 5 Cycle valve6 vacuum tyre 100/80-17 7 Front wheel ring 8 Liquid brake plate erection bolt

9 Front wheel left shaft sleeve 10 Antifriction bearing 6202-2RS 11 Front brake plate

Tightening torque Tools

Direction handle fixed screw 22-29 NЎ¤m Bearing disassembly pole

Front axle 37-44 NЎ¤m

3.2 Fault diagnosis

3.2.1 Direction handle moves hard

l Direction handle is out of order or damaged

l Bearing failure of direction handle

l Faucet bearing rating nut is too tight

l Tire pressure is not enough

3.2.2 Wobbly Direction Handle

l Damaged handle bearing

l Not enough tyre pressure.

l Front fork bent, front wheel shaft bent.

l Distorted and crooked front wheel tyre.

3.2.3 Wobbly Front Wheel

l Distorted wheel rim

l Worn front wheel bearing

l Defective front tyre

l Unbalance of tyre or wheel

3.2.4 Difficult Rotation of Wheel

l Breakdown of front wheel bearing

l Braking breakdown of brake

l Breakdown of wheel and axle

l Bending of front wheel

3.2.5 Noisy Front Shock Absorber

l Lack of liquid in shock absorber

l Friction sound of shock absorber protecting plate.

l Loosened bolts on the shock absorber.

3.2.6 Operated to one side only or walking not in straight line

l unbalance of both crossesЎЇ adjustment

l bending of shock absorber

l bending of wheels

l inaccuracy of wheelsЎЇ installment

l bending of car frame

l illness of axle

l illness of swing arm central shaft units

3.2.7 Front shock absorber is soft

l lack of liquid in shock absorber

l insecure of spring in shock absorber

l tyre pressure is too low

3.2.8 Front shock absorber is hard

l inadequacy of liquid weight

l block of shock absorber liquid pipe

Front wheel

3.3.1 Disassembly

Support the bottom of body to float front wheel

Disassemble bolt and take down front splash guard and odometer guide line.

Disassemble front brake hose

Disassemble front axle jam nut

Disassemble front axle

Disassemble front wheel

Disassemble oil seal with oil seal stripping attachment and bearing with bearing stripping attachment.

*Note: dismounting picture is on page 41 of this manual

3.3.2 Inspection

3.3.2.1 Shaft Bow Inspection

Place the shaft onto a V block and measure its eccentricity with a dial gauge.

 

 

Attention

Without folding and locking odometer wheel gear units to front axle, odometer wheel gear units will be out of shape After installment of axle, rotate it to make sure the rotation condition of autometer drive shaft.

Install front axle and then lock tight.

* Note: the dismounting picture is on page 41 of this manual

Torsion force

Front axle: 37-44 NЎ¤m

3.4 Direction handle

3.4.1 Disassembly

Disassemble direction handle sheath and rearview mirror units

Disassemble front brake handle and left handle units

Take down accelerator seats units and right grip units

Take down accelerator cable units

Take down left direction handle cover

Take down clutch line units and ventilation door line units

Take down handle fixed bolt and handle.

3.4.2 Installment

Install in the order which is against disassembly

Fixed bolt

Torsion forceЈє22-29NЎ¤m

3.5 Front fork

3.5.1 Disassembly

Disassemble front splash guard

Disassemble front wheel

Disassemble brake hose and autometer wire

Disassemble front shock absorber

Disassemble diversion fixed nut

Disassemble direction handle

Tools:

Direction handle fixed bolt wrench

Fixed nut wrench

* Attention:

• Clean the opening part of protecting plate of motorcycle block with a cloth.

 

3.5.3 Installation

Tools:

Locknut wrench

 

Rotate the front fork left and right to be sure of its smoothness and there shall be no looseness.

 

Steps:

Install direction handle.

Install front shock absorber.

Install front wheel.

Rear wheel

4.3.1 Disassembly

Loosen rear axle nut

Disassemble rear axle nut and take down chain from chain wheel seat

Disassemble rear axle

Disassemble rear wheel

 

4.3.2 Inspection

4.3.2.1 Check the bending of axle

Put axle on V-style seat and measure its eccentricity ratio with dial indicator

Rear wheel shaft locknut

Tightening torque: 100-113NЎ¤m

4.4 Rear Shock Absorber

4.4.1 Disassemble rear shock absorber

Disassemble body guard board

Disassemble rear splash guard

Disassemble tool box

Disassemble air filter

Disassemble rear wheel shock absorber fixed bolt

Take down rear shock absorber

 

4.4.2 Rear Shock Absorber Inspection

Visual inspection of shock absorber to check whether there is damage

 

Check the following items:

ЎЄbending or damage of shock absorber pipe

ЎЄout of shape or oil leakage of shock absorber

ЎЄabrasive wear or damage of block rubber

ЎЄdamage of spring

 

Check damage or abrasive wear of other parts

Replace shock absorber if necessary

 

4.4.3 Install Rear Shock Absorber

Install the rear shock absorber in the reverse order of removal.

Install upper locknut and lower mounting bolt on the rear shock absorber

Tighten them to specified torque.

 

Torsion force:

Upper hold-down nut: 37-44NЎ¤m

Bottom hold-down nut: 37-44NЎ¤m

4.5 Rear Swing Arm

4.5.1 Remove Rear Swing Arm

Disassemble chain guard board

Disassemble chain tension wheel and rear axle

Disassemble rear wheel and rear shock absorber

Disassemble rear swing arm installment axle

Take down rear swing arm weld assembly

 

4.5.2 Rear Swing Arm Inspection

Check rear swing arm installation shaft. Rotate the shaft on a flat surface or measure it with a dial gauge. If it is bent, replace it.

* Attention

DonЎЇt attempt to straighten bent shaft.

 

 

Wash in solvent the components for rear swing arm installation shaft.

Check sleeve assembly and intermediate sleeve of rear swing arm.

If they are damaged, replace them.

 

4.6 Drive Chain

4.6.1Ј® Disassembly

Lay motorcycle on the flat ground and fasten

Disassemble shift lever swing arm, left rear cover and drive chain

Disassemble rear wheelЎўchain shield and drive chain

 

4.5.2Ј® Inspection

Wash drive chain and put it into kerosene. Brush dust and then take it out from kerosene and dry it out.

 

Check rattleer1and side panel2. replace drive chain when damaged or abrased.

 

Lubricate drive chain. Buy it from store

Check drive chain. Wash, lubricate and replace it if it is hard.

 

 

 

 

Check drive chain and driven chain wheel. Replace chain wheel when 1/4 gear teeth are worn. Replace it when gear teeth is bending.

 

Check wheel axle. Replace when there is bearing gap in hub or unbalance of rotation. Check oil seal and replace when there is abrasive wear or damage.

Attention

Make sure the rotation cylinder number of adjusting device is the same to install axle correctly

At last, screw down locking nut

4.5.4 Installment

Do the verse steps as disassembly

Install drive, hull, rear shock absorber(left), rear wheel and drive chain sleeve

Adjust slackness of drive chain and free travel of brake footstep. If the slackness is too small, engine and other important parts will overload. Make sure the slackness in the scope of limit value.
Check and maintenance of electrical equipment

Charging system

Testing device

Multimeter

5.2 Fault Diagnosis

No power unstable power

Battery over discharged Lead wire of battery is poorly contacted.

Lead wire of battery is not connected. Discharging system is of poor contact.

Fuse is broken. Lighting system is of poor contact or short circuit.

Power switch is poorly contacted.

Low voltage Poor charging system

Battery is poorly recharged. Wire connector is of poor contact, short circuit or short line.

Poor contact. Defective voltage and current adjuster

Poor charging system Magneto does not work well.

Bad voltage and current adjuster

 

Storage Battery

5.3.1 Battery Removal

Open seat cushion

Disassemble left guard board

Disassemble negative guide line first and then the positive guide line

Take out storage battery

 

Warning!

During positive lead wire disconnection, be sure to prevent the tools being used from touching the frame; or it will result in short circuit sparks, which may ignite gasoline and damage battery. It is dangerous!

 

Install the battery in the reverse order of removal.

 

*Attention

To avoid short circuit, please connect positive (+) lead wire first, then the negative (-) lead wire.

Check of charging situation (open-circuit voltage)

Open sear cushion

Open air filterЎЇs cover and disassemble storage battery joint guide line

 

Measure voltage between terminals of the battery

Fully charged: 13.1V

Quick charging: 4.0A

Quick recharging: 30minutes

VI Ignition System

Preparatory data ----------------6.1 Ignition coil ------------6.5

Fault diagnosis -----------------6.2 Trigger -----------------6.6

Ignition system inspection ---- 6.3 Charging coil---------- 6.7

CDI assembly ------------------6.4

Preparatory Data

Precautions on operation

1. Ignition system inspection: please perform inspection in the sequence listed in the fault diagnosis table.

2. Ignition system uses electronic-type automatic timing device, which is solidified in the CDI assembly, so it is unnecessary to adjust the ignition time.

3. Ignition system inspection: please perform inspection in accordance with the sequence listed in the fault diagnosis table.

4. Ignition system CDI shall not be dropped and hung, or heavily knocked (this is also the main reason for its failure). Pay special attention to this while removing it.

5. Most of the ignition system problem due to poor contact of sockets. Please check first if parts of the connector are well contacted.

6. Check if heat value of spark plug is proper. Improper spark plug may result in unsmooth engine running or burn of spark plug.

7. The maximum voltage is taken to introduce inspection items in this Part. Inspection methods for impedance value of ignition coil are also recorded and judged.

8. Check ignition switch according to the continuity test table.

9. Remove alternator and stator on operation instructions.

Preparatory data

Item	Standard Value
Recommending spark plug	Standard	C5HSA(NGK)
Hot type	C6HSA(NGK)
Cold type	C7HSA(NGK)
Spark plug gap	0.5-0.7mm
Ignition coil impedance value (20Ўж)	Primary coil	0.4¦ёЈЁ+/-Ј©10%
Secondary coil	With spark plug cap	8-11K¦ё
Without spark plug cap	4.5-5.5K¦ё
Impedance value of trigger (20Ўж)	100-200¦ё
Ignition coil primary peak voltage	95-400V
Trigger voltage	Above 1.7V

Tools

Multimeter

 

Fault Diagnosis

Spark plug not sparking

Ignition coil	Symptom	Possible causes (Determine the cause from 1 in sequence)
When the high voltage power is too low.	ўЩ Inner impedance is too small. Use appointed tester to test. ўЪCrankshaft rpm is too low. ўЫTester is disturbed (it is normal when more than one timeЎЇs measured voltage is above the basic). ўЬWiring of ignition system is poorly contacted. ўЭIgnition coil is no good. ўЮCharging coil is bad. (Peak voltage measurement)
Secondary side voltage	While no high-voltage power supply, high voltage power is sporadic.	ўЩTester is wrongly connected. ўЪPoor ignition switch. ўЫConnector of CDI assembly is poorly contacted. ўЬGround wire for CDI assembly is shorted or poorly contacted. ўЭ Poor charging coil (Peak voltage measurement). ўЮ Defective trigger (Peak voltage measurement). ўЯ Connector of high voltage wire is not good. ўа Inferior CDI assembly (after items ўЩ-ўЯ are tested and proved abnormal or spark plug no sparking)
High-voltage power is normal, spark plug no sparking.	ўЩInferior spark plug or secondary leakage of the ignition coil. ўЪ Bad ignition coil.
Charging coil	No high-voltage power supply	ўЩInner impedance is too small. Use appointed tester to test. ўЪCrankshaft rpm is too low. ўЫTester is disturbed (it is normal when more than one timeЎЇs measured voltage is above the basic). ўЬCharging coil is bad. (when items ўЩ-ўЫ are proved normal)
No high-voltage power supply or high voltage power is sporadic.	ўЩDefective ignition coil. ўЪDefective charging coil.
Trigger	When high-voltage power supply is too low.	ўЩInner impedance is too small. Use appointed tester to test. ўЪCrankshaft rpm is too low. ўЫTester is disturbed (it is normal when more than one timeЎЇs measured voltage is above the basic). ўЬTrigger is bad. (when items ўЩ-ўЫ are proved normal)
No high-voltage power supply or high voltage power is sporadic.	ўЩBad ignition coil. ўЪBad trigger.

 

6.3 Ignition System Inspection

* Attention

• When the spark plug is not sparking, check if components of wiring are loosened or badly contacted and make sure if all the voltage values are normal. • There are many brands of multimeters with different interior impedance. The values they measured are not the same.

 

Connect a high-voltage shunt or an ammeter with input impedance higher than 10M¦ё 10CV to the multimeter.

6.3.1 Primary voltage of ignition coil

If an old spark plug is removed and replaced with a good one, ground it with engine.

* Attention

Test when wirings of all the circuits are correct. Normal cylinder compression pressure means to test with spark plug installed on the cylinder head.

 

Disassemble central cover

Connect lead wire of ignition coil; a shunt is connected between the terminal (black/white) of primary coil and the grounding vehicle block.

Press starting motor button or kick starting pedal to measure primary peak voltage of ignition coil.

Min. voltage: over 95V.

 

*Attention

Please do not touch the metal parts of testing probe with your fingers while measuring the voltage, or you will be shocked. Please take care.

 

6.3.2 Charging coil

* Attention

Install spark plug on the head of cylinder. Check in the condition of normal compression pressure