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

8.5.1 Disassembly

Disassemble bolt and taillight shade.

Disassemble bulb from socket

 

8.5.2 Installment

Install bulb back in the verse order of disassemble.

 

8.5.3 Rear turn signal lamp replacement

8.5.3.1 Disassembly

Disassemble bolt and taillight shade.

Disassemble bulb from socket

8.5.3.2 Installment

Install bulb back in the verse order of disassemble.

 

8.6 Instrument

Remove rear mirror.

Take down the handle hood and pull out waterproof connector.

Remove the bolts.

Remove meter housing

Remove the instrument.

Install the instrument orderly in the reverse order of removal.

 

 

Main Switch

8.7.1 Inspection

Disassemble front guard board

Disassemble master switch guide line joint

Break over test of joint side

8.7.2 Master switch replacement

Disassemble body front guard board

Disassemble fixed bolt and take down master switch fixed seat

Disassemble fixed bolt and replace master switch.

Horn

Inspection

Disconnect wire to the electric horn.

Connect lead wire of horn with the battery. When the electric horn sounds, it indicates the horn is in good condition.

 

 

8.9 Handle switch

Remove protecting plate of steering handle.

Screw off mounting bolt on the brake lever and take down the bracket.

Remove bracket for the rear brake lever.

Remove throttle handle and bolts.

Take down throttle handle from the handle and remove the throttle cable.

 

Remove locknut on the handle and take down the handle.

Engine Inspection and Maintenance

Table of tightening torque for fastening parts used in engine

Table of tightening torque for fastening parts
Names of fastening parts and fasteners	Fastening torque (NЎ¤m)
Cylinder head cover screw M6	10-14
Cam cover fastening screw M5
Cylinder head cover screw M6
Cylinder head cover acorn nut M8	25-28
Cylinder stud bolt M8	25-28
Tensioner fastening screw M6
Chains leading fastening screw M8
Oil pipe set bolt M8
Thermostat fastening screw M6
Induction manifold fastening bolt M6
Flywheel locking hexnut M12
Starting engine set bolt M6
Clutch transmission gear jam nut M16
Clutch jam nut M16
Gearshift star-wheel fastening screw M6
Gearshift positioning wheel rocker arm fastening screw M6
Mould assembling screw M6
Left and right crankcase cap bolt M6
Cylinder head cover fastening screw M6
Water pump cover fastening screw M6
Machine oil strainer cover M6
Engine cover fastening screw M6
Machine oil strainer plug screw M20
Oil pump cover fastening screw M6
Coil fastening screw M6
Output sprocket nut M18
Spark plug M10	10-15
Water temperature sensor M12
Magnetic bolts M12

Lubricating System Chart

 

IX Lubricating System

Preparatory data--------9.1

Fault diagnosis---------9.2

Oil engine pump-------9.3

Preparatory Data

Function of lubricating system:

Function of engine lubricating system is to supply lubricating oil to friction surfaces of engine parts so that dry surface friction will turn to liquid friction between plasmids of lubricating oil. It is used to reduce wear of component, cool components of higher heat, absorb impact from bearing and other parts, weaken noise, increase tightness between piston ring and cylinder wall, clean and take away impurities from surface of component, etc.

Precautions on Operation

When engine oil pump is removed, clean carefully all the components and purge them with high-pressure gas.

During engine oil pump removal and installation, pay attention not to drop anything into the crankcase.

Table of standard values of baseline projects and allowable limit

Item	Standard	Service Limit
Engine oil capacity	Oil replacement	1L	-
Engine overhaul	1.2L	-
Oil pump rotor	Radial clearance between inner and external rotors	Oil pressure pump	0.025-0.175	0.23
Oil suction pump	0.025-0.175	0.23
Clearance between external rotor and pump block	Oil pressure pump	0.11-0.163	0.22
Oil suction pump	0.11-0.163	0.22
Clearance of rotor end face	Oil pressure pump	0.05-0.11	0.15
Oil suction pump	0.05-0.11	0.15

Fault Diagnosis

Reducing engine oil

Natural consumption

Oil leakage

Engine burnt

No oil pressure or too low oil pressure

Oil way clogged

Oil Pump

Disassembly

Remove the right cover, the clutch, and the retaining ring, and then remove the oil pump gears and oil pump transition gear;

 

Remove the fixed pin, the screw and the pup cover, and disassemble the oil pump;

 

 

 

Check the radial clearance between the inner
and outer rotor

Allowable limit: 0.15 mm

 

 

Check the clearance between the outer rotor
and pump body

Allowable limit: 0.15 mm

 

 

 

Check the clearance between the rotor ends

Allowable limit: 0.15 mm

 

 

Assemble Engine Oil Pump

As shown in the following figure :

1 Oil suction pump assembly 2 Oil pressure pump assembly 3 Retaining ring 4 Gasket 5 Oil pump gear 6 Fixed pin 7 Oil suction pump shaft 8 Pin 9 Bolt M6x16 10 Oil pump cover 11 Inner rotor 12 Outer rotor 13 Oil pressure pump shaft 14 Oil pump cover 15 Inner rotor 16 Outer rotor 17 Gasket 18 Oil pump transition gear 19 Transition gear shaft

 

* Attention:

After assembly, inner and external rotors shall rotate smoothly and be out of nimbleness.

 

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Installation

Install the oil pump in the reverse order of removal.

X Cooling system

Preparatory data---------------------------10.1

Fault diagnosis-----------------------------10.2

Water pump---------------------------------10.3

Preparatory data

Functions of cooling system:

It can build some channels which can allow liquid circulation inside the cylinder and the inner wall of the cylinder cover; a special radiator is set outside the engine body so that the forced circulation of cooling water can be made through water pump and pipeline, and then the heat of the engine can be released to cool it through air blowing the surface of the cooling fin of the radiator at high speed.

Fault diagnosis

Water leakage

Seal ring damaged

Pimp body broken

Water pipe breakage