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SERVICE MANUAL

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2. 15 Bent front axle incorrect wheel mounting Roundness error of wheel rim Refer to Front Wheel Service Deformation of wheel rim Inadequate tire pressure Deformed wheel rim Loose front wheel bearing Refer to Front Wheel RR DEDE oor tire Service Poor axle locking Refer to Front Shock Soft front shock absorber Spring fatigue Absorber Service Deformed wheel rim Refer to Rear Wheel Rear wheel oscillation o Refer to Rear Shock Soft rear shock absorber Spring fatigue Absorber Service SECTION TWO DETAILED DESCRIPTION OF BODY PARTS TROUBLES Precautions in Operation Forced mounting or dismounting of body cover parts will cause damage to claws and slots of corresponding hoods When mounting body cover parts be sure to align the corresponding parts of hoods When mounting body cover parts avoid pressing wires cables or pipes I FRONT WHEEL SERVICE Front Wheel Dismounting Support the body bottom to lift front wheel front shock absorber front axle 16 front axle nut Remove front axle nut brake calipers front absorbers connecting bolt and remove brake calipers front shock absorber transmission gear box front axle bush and the small bush remove front axle front wheel front shock Remove front wheel Ane Remove brake disc mounting bolts Remove brake disc small front axle bush front axle bush
3. Axle Bending Inspection Place axle on a V seat and measure with a dial gauge The dial gauge indicates a 1 2 bending value Limit of use Replace if gt 0 2mm Wheel Rim Oscillation Inspection Measure oscillation value on a correcting bench Limit of use Replace if gt 2 0mm Traverse direction Replace if gt 2 0mm 17 dust cover front axle bush 2d Front Wheel Bearing Inspection Remove front wheel bearing and dust cover Turn bearing inner race to inspect sliding Replace it w new one in case of no sliding or damage or loosening race Front Wheel Bearing Replacement Dismounting Remove front wheel bearing by means oi a bearing remover take out spacer Mounting Apply grease to the bearing Drive in left bearings Mount spacer Drive in right bearings Bearings must be driven in parallel Dust cover must be driven in with the face out Apply grease to new dust cover lip Mount front axle bush Front Wheel Mounting Mount brake disc tighten brake disc mounting bolts Torque 27N m Spread front axle with a thin film of grease Mount front axle from left side Mount in order small bush left front shock absorber bush front wheel transmission gear box right front shock absorber front axle nut and fasten it 18 Torque 60N m Mount brake caliper as specified II FRONT BRAKE SERVICE DISK BRAKE Brake Oil Replacing Pre
4. Mount head cover front part and rear part Replenish brake oil and exhaust air in brake system III FRONT SHOCK ABSORBER SERVICE Dismounting Remove body covering parts Remove front wheel front whee Remove 4 pieces of bolts on the upper part of fron absorber Remove shock absorber bod coverin I arts g Inspection Inspect if there is oil leakage in front shock absorber if there is deformation of shock absorber arm and if there is damage or loosening of any part Mounting Mount front shock absorber on front fork and mount 4 bolts Torque upper bolt 35N m Mount front wheel 21 IV FRONT FORK SERVICE Dismounting Remove motorcycle body covering parts bady cerig Remove nut and blot from handlebar Remove handlebar Remove steering stem setting nut Remove upper bearing cup upper bearing top and bear Remove front axle nut Remove front wheel front fender Remove front shock absorber front fender the m screws 1s inside the fender etc SCrews shock absorber Remove steering stem from head tube The removing of the bottom bearing cup bearing top bearing set is the same as the removing of the upper se Do not damage steering stem when removing E cup and bearing top Clean opening parts of motorcycle body covert with cloth upper bearing to Inspection il di Inspect if there is
5. Brake Disc Inspection Inspect brake disc thickness Limit of use 3 0mm Inspect brake disc angularity Limit of use 0 3mm 2 Rear Brake Inspect rear brake lever free travel Free travel 10 20mm Turn adjusting nut to effect adjustment when free t exceeds limit adjusting nut VIII FRONT AND REAR SHOCK ABSORBER INSPECTION 1 Front Shock Absorber Tighten front brake lever press front shock absorbe and down and inspect actuation Inspect front shock absorber to see if there is leaka and if there is damage or loosening 2 Rear Shock Absorber Press rear shock absorber to inspect actuation Insp shock absorber to see if there is oil leakage and if 1 damage or loosening in machine parts Lift rear wheel press rear wheel right and left to in engine suspension lug buffer bush is loose IX FRONT WHEEL AND REAR WHEEL INSPE Wheel Rim Inspection front brake lever Inspect wheel rim remove rust stains and rubber chips Deformation and fissures are causes of air leakage Do not use wheel rims in the following cases Bruise of wheel rim face contacting tire bead ring exceeds 0 5mm in depth and 1 0mm in width Tire Inspection Inspect if there is fissure or iron nail in the tire In one of the following conditions tires must be replaced instead of repair Puncture of tire by a foreigner matter 6mm in diameter or tire
6. part of brake cam Do not apply grease to parts not specified Superfluous grease flows into brake friction linings of brake drum shall reduce braking effect Mount brake cam Mount brake swing arm on brake cam Notch on brake swing arm should be aligned with the cut off of brake cam Mount brake swing arm setting bolt and fasten it Torque 10N m Mount brake block assembled with spring Mount rear wheel Mount exhaust muffler adjusting nut rear brake cable return spring 26 Mount brake swing arm pin and rear brake cable Mount return spring of brake cable with the spring aligned with the recess hole of left crankcase cover Mount adjusting nut Adjust brake system VIII REAR SHOCK ABSORBER SERVICE Dismounting Remove motorcycle body covering parts Remove 2 mounting bolts of air filter air filter s mounting bolts Remove mounting bolt connecting rear shock absorber ana motorcycle frame bolt connecting rear shock absorber engine Withdraw air filter Remove rear shock absorber Inspection Inspect rear shock absorber oil seal for oil leakage ins buffer bar and spring for deformation and other parts f damage and loosening Mounting Mount rear shock absorber Torque upper mounting bolt 40N m bottom mounting bolt 25N m Mount air filter Mount motorcycle body covering parts 27
7. slot or pit in bearing cup and bearing upper bearing cup jj there is effect replacement bottom bearing top 3 bottom beari ottom bearing cup Q Pase 8 ball set Inspect for completeness of bearing balls and if there is effect replacement with new ones Inspect for proper tightness of steering stem and if not effect adjustment and fasten it Inspect for correct position of bearing cup and bearing top and if not effect correct mounting Bearing Cup and Bearing Top Replacement Remove bearing cup and bearing top with special bearing cup and bearing top removers Mounting Apply grease to bearing cup and bearing top at the bottom Mount in order bottom bearing cup bearing ball set bottom bearing top on the bottom of steering stem Pass steering stem through head tube Mount front fender on steering stem Mount front wheel Mount front shock absorber and other parts Apply grease to top bearing cup and bearing top Mount in order upper bearing cup bearing ball set and upper bearing top on the upper part of steering stem and fasten them Torque 15 N m Turn front fork right and left to effect close contact of bearing balls Loosen upper bearing top to torque 0 and fasten it Torque 2 5N m Fix upper bearing top and tighten steering stem setting nut Torque 70N m Turn front fork and confirm easy rotation without loosening Mount handlebar V HANDLEBAR SERVICE Dismounting left handlebar
8. BT49QT 7 amp BT49QT 8 SERVICE MANUAL JIANGMEN SINO HONGKONG BAOTIAN MOTORCYCLE INDUSTRIAL CO LTD CONTENTS CHAPTER ONE MAINTENANCE OF THE MOTORCYCLE ITEMS OF MAINTENANCE 1 PERIODIC MAINTENANCE SCHEDULE AND MAINTENANCE LOCATIONS 1 MAINTENANCE SPECIFICATIONS 4 THROTTLE ACTUATION INSPECTION 5 AIR FILTER INSPECTION AND CLEANING 6 REAR BRAKE FRICITION LINING INSPECTION 6 BRAKE SYSTEM INSPECTION ADJUSTMENT AND REPLACEMENT 7 FRONT AND REAR SHOCK ABSORBER INSPECTION 8 FRONT WHEEL AND REAR WHEEL INSPECTION 9 STEERING STEM INSPECTION 10 CHAPTER TWO MAINTENANCE INFORMATION FRAME NUMBER AND ENGINE NUMBER LOCATION 11 PRECAUTIONS IN OPERATION 11 SPECIFIED TORQUES 12 CHAPTER THREE BODY TROUBLESHOOTING SECTION ONE BODY COMMON TROUBLES AND TROUBLE DETECTION 14 SECTION TWO DETAILED DESCRIPTIONS OF BODY PARTS TROUBLES FRONT WHEEL SERVICE 17 FRONT BRAKE SERVICE DISK BRAKE 19 FRONT SHOCK ABSORBER SERVICE 2 FRONT FORK SERVICE 22 HANDLEBAR SERVICE 24 REAR WHEEL SERVICE 25 REAR BRAKE SERVICE 26 REAR SHOCK ABSORBER SERVICE 28 CHAPTER FOUR ELECTRIC PART TROUBLESHOOTING SECTION ONE ELECTRIC PART COMMON TROUBLES AND TROUBLE DETECTION 29 SECTION TWO DETAILED DESCRIPTIONS OF ELECTRIC ASSEMBLIES AND PARTS SERVICE PRECAUTIONS IN ELECTRIC CIRCUIT SERVICE 32 POWER CHARGING SYSTEM SERVICE 32 IGNITION SYSTEM SERVICE 38 ELECTRIC STARTING SYSTEM SERVICE 44 LIGHTING AND SIGNAL SYSTEM SERVICE 45 CHAPTER ONE MAINTENANCE OF THE MOTORCYCLE ITEMS OF MAINTENAN
9. CE When the motorcycle is used loosening of parts and mechanical wear inevitably occur to varied extents Neglect of timely maintenance not only reduces its mechanical function economic performance stability and durability but also threatens the safety of the motorcycle and the rider Correct and timely maintenance of the motorcycle is a must Items of maintenance refer to the parts and positions for maintenance Different items of maintenance are effected at different intervals and in different manners 1 Running in Maintenance This is the maintenance at the end of the first 1000km and is an all round inspection of the motorcycle A newly bought motorcycle or a motorcycle fresh from an overhaul might be severely overheated as a result of severe friction between the moving parts which might be imperfect in finishing or fitting Neglect in use might lead to damage of the friction surfaces and might threaten the performance and the service life of the motorcycle Please observe the following points Restrict the speed in speed range specified in the instruction manual Restrict the load to 2 3 of the maximum load and ride in fairly good road conditions Restrict the length of riding time to avoid long time running of the engine Replace engine oil at short intervals so that metal chips caused in the running in period can be discharged It is recommended to replace engine oil for 3 times during the running in period 2 Routine
10. Maintenance Routine maintenance is the basis of all kinds of maintenances It refers to the daily maintenance including cleaning inspection and common troubleshooting 3 Periodic Maintenance This maintenance is to restore normal performance of the motorcycle The maintenance is classified into first grade periodic technical maintenance and second grade periodic technical maintenance also known as items of maintenance according to different mileages Generally speaking a first grade maintenance is effected after the initial 4000km and a second grade maintenance is effected every 8000km As the service time extends maintenance intervals should be shortened accordingly PERIODIC MAINTENANCE SCHEDULE AND MAINTENANCE LOCATIONS After a period of use one day one month or half a year for example or a certain mileage 1000km 4000km 8000km for example an all round maintenance operation should be effected including comprehensive inspection adjustment tightening lubrication cleaning or replacement The specific regulation made according to time intervals or mileages is known as maintenance interval The motorcycle maintenance schedule is as follows 1 Maintenance Schedule Maintenance Schedule Mileage 1000km 10 2000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 C strainer Gasoline strainer New R Gear oil Note 4 300km Carburetor Note 3 Air filter S Sparkplug lu Clean e
11. ake Leakage in hydraulic Inspection Adjustment lever device and Replacement Front Brake Service Disk brake failure Clogged hydraulic passage Chart continued Disk brake failure Feeble brake Inadequate liquid Refer to Brake System lever Contaminated brake Inspection Adjustment block and brake disc and Replacement Bent or deformed brake Eon Brake Sr disc Contaminated brake caliper Worn seal ring of brake caliper piston Viscous or worn brake caliper piston 14 Inability of brake caliper normal sliding Worn main cylinder piston seal ring Viscous or worn main cylinder piston Contaminated main cylinder Clogged narrow brake system Clogged narrow liquid passage Viscous worn brake Stiff brake lever Caup Inability of brake caliper normal sliding caliper piston cylinder piston block and brake disc Bent or deformed brake Resisted disc braking Inability of brake caliper normal sliding Wheel not adjusted straight Chart continued Hardened brake block surface or dusty block l Refer to Rear Brake Abnormal braking sound Uneven or slotted brake block surface Service ervice Serious wear of brake block lining Serious slots inside brake drum Deviation of motorcycle Refer to Front Fork ees heed Steering stem rotation not easy oa direction inclining to Service roadside Bent shock absorber Refer to Front Shock Shock absorber oil leakage Absorber Service
12. and rear head cover Remove front part and rear part of head cover Exhaust brake oil from front brake system Pull out brake switch plug from main cable Remove bracket bolts from handlebar Remove main cylinder Remove brake oil pipe from main cylinder Prevent brake oil from splashing to rubber pla painted surfaces Cover the above mentioned p with a cloth Remove brake light switch and brake lever Remove retaining ring from main cylinder Use special retaining ring remover when remo retaining ring Remove piston cover piston and spring Clean oil reservoir and piston with pure brake oil Do not effect cleaning with gasoline as it is cor to rubber parts Inspection head cover front part head cover rear part bracket bolts oil pipe bolt brake oil pipe Inspect for wear or ageing of main and auxiliary cups on pistons Inspect for scratches and other damages on main cylinder and piston Measure main cylinder bore Measure outside diameter of piston at the end of auxiliary cup Mounting Apply pure brake oil to piston main cup and auxiliary cup 20 Mount spring piston retaining ring and piston cap Piston cup cannot be used inside out Apply grease to brake lever axis pin Mount brake lever and brake switch Mount main cylinder main cylinder bracket and lock them Mount brake oil pipe Connect brake light switch cable with switch
13. e wires are not loose Confirm that connectors plastic sleeves completely cover the connectors without fail Before connecting the connectors confirm that their sleeves are free from breakage and their terminals are not oversized Connector plugs must be fully inserted Confirm that plastic sleeves completely cover the terminals Plastic sleeves should not be placed with the open side up Wire bunch bands should be fixed at the specified position of motorcycle frame Wire clamps must correctly keep wires in place Avoid welding stains of welded clamps when clamping wires 11 Wire bunches must be fixed away from turning or moving parts Do not damage the covering of wire bunches In case of wire bunch defects remedy it with insulating bands Wire bunches must not be covered with mounted parts amp Do not twist or bend cables by force Deformed or damaged cables would result in poor rotation or damage III SPECIFIED TORQUES Torques at important positions and standard torques of other positions are as follows SPECIFIED TORQUES Frame Deseret of tightening positions Thread specification magnae ue moaia 1 wo 4 Engine mounting nut Front axle nut Rear shock absorber upper mounting bolt Rear shock absorber lower mounting bolt Front shock absorber upper lock bolt EE NE Steering stem lock nut 12 Handlebar mounting nut M10 Upper bearing top M25 Exhaust muffler connector nu Exhaust muf
14. fissure Layered tire Chunking of tread Damaged tire bead Broken tire bead or other tire bead damages Broken tire cord Damage due to forced dismounting Fissure extending to frame Abnormal inner lining Tire groove wear front wheel lt 0 8mm rear wheel lt 0 8mm Punctured or otherwise damaged tire flank Inspect tire pressure by means of a tire pressure gauge Tire pressure should be inspected when the motorcycle is in a cold state Specified pressure Unit kPa Front wheel Tire Specifications Front wheel 120 70 56J Rear wheel 3 50 10 51J Inspect if front wheel nut is loose Inspect if rear wheel nut is loose If loose tighten them to specified torques Torques front wheel nut 60N m rear wheel nut 120N m X STEERING STEM INSPECTION Swing handlebar right and left to see if there is interference such as wire or other things Turn front wheel to see that handlebar is easy in op In case of any difficulty in operation inspect steerir bearing assembly CHAPTER TWO MAINTENANCE INFORMATION I FRAME NUMBER AND ENGINE NUMBER LOCATION 10 II PRECAUTIONS IN OPERATION Removed washers O rings elastic retaining rings and split pins must be replaced with new ones When mounting bolts nuts and screws proceed from trial tightening from larger diameters to smaller diameters and inner ones to outer ones in a diagonally order Tighten them to spec
15. fler mounting bol Standard Torques BelmMS 0000000 0 0 Bem ee SeewM 9 CHAPTER THREE BODY TROUBLESHOOTING SECTION ONE BODY COMMON TROUBLES AND TROUBLE DETECTION Body part common troubles and possible causes are as follows Handlebar rotation not Over tightening of handlebar adjusting nut l F E J 8 Refer to Front Fork easy strenuous turning us Steering stem over worn Service or unstable tightness Incorrect mounting of brake cable or Refer to Handlebar Service Front Fork Service Remarkable deformation of steering stem Refer to Front Fork due to outside impact Service 13 Heavy steering stem turning tachometer cable Over tightening of steering stem top ball he retainer Damaged or broken ball bearing or broken ball bearing Refer to Front Wheel Reduced tire air Service Rear Wheel Service Refer to Front Shock Absorber Service Refer to Front Fork Service Refer to Front Wheel Service Imbalance of right and left shock absorbers Deflected steering stem Bent front fork Bent front tire deflected tire Normal wear of brake lining Hardened brake block or dusty block Excessive front brake and rear brake Refer to Brake System Drum brake failure Damaged brake cable peepee on Austone and Replacement Worn brake block Worn or slotted brake drum bore Bent brake lever Air in hydraulic device Refer to Brake System Feeble br
16. ific torques Parts and greases must be those made by our factory or recommended by our factory Special operations must be effected with special tools or specified universal tools Removed parts must be rubbed or cleaned before they are inspected or measured They must be coated on the sliding faces before mounting They must be greased at the specified positions with designated or equivalent greases Parts must be tightened and their performances inspected at their positions when mounted The battery s negative terminal must be disconnected before operation Make sure that tools such as wrenches are not in contact with the frame At the completion of operations reconfirm correct connections and fastenings The positive terminal must be connected first in case of a removed battery Connected terminals must be coated with lubricant The terminals must be completely covered with caps When a fuse is burnt inspect the cause and replace the fuse with a fuse of equivalent capacity At the completion of operation completely cover terminals with caps When removing connectors with locks they must be unlocked before operation When removing connectors the connectors proper must be held instead of pulling their wires Before connecting connectors confirm that they are free from breakage bending over length or loosening Connectors must be inserted home When connecting connectors with locks confirm that their locks are fastened Confirm that th
17. ny conditions strainer must be cleaned or replaced earlier Remove 5 tightening bolts of air filter Remove strainer cover Take out the foam strainer Immerse foam strainer in gasoline and wash it tore dust and impurities by gripping and pressing Press gasoline out of the foam Soak the cleaned foam with engine oil press out or out engine oil to leave it moist with oil Mount VI REAR BRAKE FRICTION LINING INSPEC If the arrow on brake swing arm is aligned with the on gear case when brake lever is drawn to the stopping position friction linings must be replaced with new on arrow scotch VII BRAKE SYSTEM INSPECTION ADJUSTMENT AND REPLACEMENT 1 Front brake disk brake Remove the bolts linking brake caliper and front sho absorber Remove brake caliper Do not pull brake lever when brake caliper is remo as to prevent jamming of brake block If brake block is jammed pry it with screwdriver anc piston back into caliper Brake Block Replacement Brake block must be replaced when it is worn to the use It is not necessary to remove brake oil pipe when replacing brake block Brake block must be replaced as a set Remove two pieces of brake block pins by mear hexagon wrench Effect mounting in an order reversed to that of dismo After effecting first tighten the brake caliper and hole right to the hole of brake caliper and then put thi block pin in and tighten it
18. s to reduce scuffing abrasion deformation and to reduce friction it is necessary to coat or spray these parts with a lubricant Different lubricants and lubricating methods are required for different machine parts with different functions Application of lubricants to machine parts is known as lubrication Replenishing supplement and replacement These operations refer to addition of oil lubricants cooling water electrolyte fuel and replacement of damaged parts with new ones and replacement of denatured oils with new oils IV THROTTLE ACTUATION INSPECTION Inspect throttle grip for easy and smooth movement f d 1 2 6 Inspect throttle free travel ree ravel 2 6mm Free travel 2 6mm The main adjusting position is beside the carbureto Remove rear store case cover Adjust by loosening the fastening nut and turn adjusting nut Fine adjustment is effected on the side of the thrott Effected adjustment is by removing the dust loosening the tightening nut and turning the adjusting 1 m tightening nut adjusting nut dust cover AIR FILTER INSPECTION AND CLEANING After a certain mileage dust and impurities will gather in air filter case and strainer which will clog strainer pores and reduce inlet of air and thus lead to excessive concentration of mixed gas and reduce the performance of engine That s why the strainer must be cleaned every 2000 3000km and in dusty or rai
19. switch left grip Remove covering parts of front part and rear part Remove connectors of left handlebar switch handle bar 2 23 laft handlahar ewiteh wira Remove 2 screws of left handlebar switch Remove left handlebar switch Remove left grip from handlebar Remove front brake main cylinder Remove connectors of right handlebar switch E P T EE aces Remove 2 screws of right handlebar switch destino Remove right handlebar switch Remove throttle cable from throttle grip Remove throttle grip from handlebar Remove handlebar bolt and nut from handlebar r throttle cable Remove handlebar When removing left handlebar and throttle grip remove contamination and grease from contacting face Mounting Mount handlebar on steering stem guide tube setting t nut Torque 45 N m Mount left handlebar switch and fasten screws Torque 9 N m Mount front brake main cylinder and fasten bolts Mount right handlebar switch and fasten screws Torque 9 N m Apply grease to throttle cable Mount throttle grip and connect throttle cable Mount left grip Mount covering parts of front head cover and rear head cover amp Confirm easy rotation of throttle grip When mounting handlebar rubber apply a thin film of adhesive to contacting face and then mount grip in a turning manner VI REAR WHEEL SERVICE Dismounting 24 Remove 2 connecting nu
20. torcycle maintenance include inspection adjustment tightening lubrication cleaning supplementing and replacement which constitute the main elements of maintenance 1 Inspection Inspection refers to basic inspecting operations in accordance with items and requirements specified in the user s manual including inspection with instruments or with eyes for abnormalities in machine parts directly comparing related data and aligning with tools and gauges Adjustment Adjustment refers to inspection based adjustment and rectification of some specified machine parts including adjustment of machine part plays and rectification of misfittings and deformations so as to restore correct positions forms and plays Tightening Tightening refers tightening of bolts screws and nuts of machine parts with tools so as to avoid loosening of machine parts and to obtain specified tightening torques Cleaning Cleaning is needed by machine parts and positions which call for cleanliness and tidiness Cleaning operations include all the means and measures taken to remove dust contamination metal chips oily stains and carbon deposits that might lead to pipe clogging or reduction in motorcycle performance Cleaning measures are washing carbon deposit removing rubbing cleaning and clearing Lubrication In order to facilitate smooth and easy running of moving machine parts including swinging parts reciprocating parts sliding parts and vibrating part
21. ts and 2 mounting bolts of exhaust muffler Remove exhaust muffler Remove rear axle nut and rear axle Rear Wheel Oscillation Inspection Measure oscillation value on a correcting bench Limit of use Longitudinal gt 2 0 mm Traverse gt 2 0 mm Mounting Mount rear wheel and fasten rear axle nut Torque 120N m Mount exhaust muffler Fasten exhaust muffler connecting nuts and bolts Torque Exhaust muffler connecting nut 12N m Exhaust muffler mounting bolt 35N m VIT REAR BRAKE SERVICE Remove exhaust muffler Remove rear wheel Inspect rear brake drum Measure rear brake drum bore 25 rear axle nut exhaust muffler Limit of use l I Imm effect replacement if the limit is exceeded Rear Brake Block Replacement Remove rear brake block and return spring as a whole replace them with new ones set pin See that no grease is with brake block friction s NR cum spring brake block return spring brake block brake cam Rear Brake Disassembling Remove rear brake adjusting nut remove rear brake ca from brake swing arm Remove brake block assembly brake cam Remove brake swing arm setting bolt and swing arm set bolt Remove brake cam brake swing arm adjusting nut rear brake cable Rear Brake Device Assembling Apply grease to setting pin brake cam and brake block friction surface Apply grease to moving
22. vent dust or water from entering brake system Do not use brake oils of different specifications or impure brake oils Prevent brake oil from dripping onto rubber plastic or painted parts Brake Oil Exhausting oil reservoir cover Place main cylinder at a level place remove oil reserv cover and diaphragm Connect a hose to oil exhaust valve loosen exhaust va grip and release brake lever till oil is exhausted Brake Oil Replenishing Lock exhaust valve Replenish oil reservoir with specified brake oil tis not necessary to fill the oil reservoir to its 1 capacity Brake oil for replenishing should be the same a original The specification of brake oil is indicated on the reserv Cover Place diaphragm Connect a transparent hose to exhaust valve D Grip brake lever fast and open exhaust valve 1 2 turn to t air and lock exhaust valve Repeat this operation till no a NG 7 releasing bubbles are exhausted from brake oil passage brake lever Do not release brake lever before exhaust valve closed At the completion of adjustment replenish brake oil ti over the lower limit line of the oil reservoir Mount diaphragm set and oil reservoir cover R lower limit line Tighten oil reservoir cover bolt 19 Main Brake Oil Tank Dismounting and Mounting Dismounting Remove each 2 bolts and screws of front part
23. very 3000km replace when necessary park plug ME rent we PENN 95e TT R Y a J fa me M 10 Steering rod I I I bearing Screws and I I bolts of parts Rear brake C cam Notes 1 I Inspect and when necessary clean lubricate supplement modify or replace A adjust C clean R replace T tighten Effect periodic maintenance according to the instructions in the user s manual When the mileage exceeds the range specified in the schedule repeat the maintenance In dusty or rainy conditions inspection and replacement should be effected earlier C bo ecu In heavy load long distance or rainy conditions replacement should be effected earlier 2 Maintenance locations Spark plug Throttle grip Oil tank Frontshock absorber damage contamination e actuation play brake oillevel damage loosening Rear tire Rearrim Frontrim Fronttire Y wear damage tire pressure damage oscillation Y damage oscillation amp wear damage tire pressure Headlight Rear brake rod Rear shock absorber Air filter Y beam adjustment free play Y damage loosening contamination 4 Front brake disc Frontbrake caliper Rear brake gearcase Y damage wear wear of friction lining wear of brake drum Y engine oil quantity damage wear of friction lining oil replacement MAINTENANCE SPECIFICATIONS The basic methods of mo

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