Ⅰ.SAFE DRIVE
Contents
1. 3 3 gear 1 Points for Attention during Drive gear shifting 1 Avoid unnecessary idling of the engine and it is not allowed In particuiar to nave at a mgn speed Other wise it will damage components seriously 2 Shift to the low speed gear when feeliing that the power is not strong enoush on climbing 3 It is forbidden to use the front brake only or to coast by the neutral gear especially when descending or driving at high speed 4 On braking Narrow the throttle and then apply the brake V Checking Adjustm ent and Maintenance 11 Machine Oil Checking The vehicle should be checked for machine oil before drive by sup porting it with the Main stand on a flat ground The oil livel should be between the upper and lower Lines of the oil gauge Which is not screwed into the filling orifice High quality 4 stroke machine oil Class SE or SD in classifi cation of SAEI5W 40 in viscosity will help maintain a long service life or the engine In case those are not available a substitute suitable for the ambient temperature of application should be selected according to the table on the right side Kenewal of Machine Oil Machine oil plays a very important role in the normal operation of the po anua Machine oil gauge 12 engine and for this reason it is necessary to check the motorcycle for machine oil periodically and renew the oi2. water may cause damage to some of its components Therefore do not jet over pressurized water directly on to the follow ing parts Wheel hub Exhaust pipe Fuel tank and lower portion of cushion Carburetor Head lock and ignition switch Meters 1 After pre wiping the vehicle should be washed with clean water to remove dirty residues so as to prevent corrosion Plastic subassemblies should be cleaned by wiping with cloth or foam soaked in neutral detergent solution followed by washing with clean water 2 After the cleaned vehicle is air dried grease the chain and run the engine at idling speed for a few minutes 3 Prior to driving carefully check the braking system repeatedly and repair or adjust it if necessary 20 Instructions Storage For the motorcycle not to be used for a long period of time for example in wintertime some steps should be taken t pervent malfunction and damage to its components which might be caused by long storage Besides before the long storage proper maintenance has to be carride out for fear that it might be forgotten when the vehicle is put bak into use after storage Change engine oil and oil filter 2 Drain off fuel from the fuel tank and carburetor spray atomized anti rust oil noto the inside wall of the tank and then close the tank Attention If the storage will last for more than one month feul in the carburetor must be fully dratined of
3. I SAFE DRIVE Rules for Safe Drive Check must be conducted bef ore starting the engine to prevent mishaps damage to components Only the qualified person who has passed the drive examination with a drive license is permitted to drive the vehicle but not anybody else without a drive license Full preoccupation is required during drive paying attention to the following points to avoid any possible hurt to you by other motorizd vehicles Do not drive too close to other vehicles Never contend for lane Strictly observe the local traffic rules As driving at overspeed is the cause of many accidents Do not drive at a speed that the actual situation does not permit Particular care should be exercised at the level crossing of roads entrance and exit of parking lot or on the autonobile lane During drive grasp the left handlebar by the left hand and the throttle twist grip by the right hand with feet on the footrests Protective wear 1 Protective wear such as helmet with protective mask dustproof glasses and gloves should be worn during drive for the sake of personal safety 2 Loose clothes are not suitable for motorcycle drive or ride as they may get caught on the operating lever Kick footrest or wheel resulting in danger Modification of the vehicle Caution Any unauthorized modification of the vehicle or replacement of the original parts can not ensure driving safety and is illicit The user must observe the regulatio
4. LIGHT GREEN LG RED R GREY GR BLUE BU WHITE BROWN BR ORANGE 0
5. atomizd antirust oil from the fuel tank followed by filling it with fresh gasoline therein 3 Prior to driving all the required check ups must be made It is better to drive it ata low speed in a place of traffic safety to test its performance before normal drive Table of Torque for Fasteners 3 Nut for tightening upper joining plate of front fork with vertical ube 4050 3 Ls A I oor AA s o Ps eating forest Resumption of Service 22 Remove the covering and clean the vehicle Change the lubricating oil if the vehicle has been off service for over 4 months 2 Charge the battery and remount it 3 Drain off the antirust solution from the fuel tank followed by filling fuel therein to the required level 4 Prior to driving test the vehicle at low speed in a safe place Maintenance Routine Diagram The vehicle should be under good maintenance as specified in the follow ing table where means Check cleaning adjustment lubrication and or replacement are needed C means Cleaning is needed R means Replacement is needed A menas Adjust ment is needed L means Lubrication is needed means This item of maintenance should be carried out at a service centre It may be also done by the user himself with reference to this manual provided he has special tools spare parts and is capable of this job means This item can only be carried out by the serviceman at professional
6. e 2 To make adjustment turn the rear brake adjusting nut clockwise to reduce snd counter clock wise to increase the free operating movement of the brake pedal Adjustment of Chain When regulation is needed Ioosen the rearaxle nut 2 Turn the chail adjusting nuts djusting nut Rear brake arm Rear braking pedal Brake arm pin Brake pull rod on the left and right sides to adjust the tension of the chain and to align tne marking or the chain adjuster with the engraved lines in the similar position on both sides 3 Tighten the lock nut and rear axke nut by a torque of 35 50Nm 4 Repetitively check the tension of the chain 5 When the rear wheel is changed in position and the chain adjusted the free operating movement of the rear brake pedal will be affected which therefore should be checked thereafter and also regulated if necessary 18 Greasing procedures to the driving chain 1 Shut off the engine 2 Add some machine oil or chain grease to the driving chain Attention When the rear wheel axil has moved to the back adjusting limit if excess loose be cause of wearing to the driving chain please change with a new one 15720mm Rear wheel axle nut Rear wheel axle 19 Vehicle Washing Cleaning the vehicle reularly can slow down the color fading of its body and make it easier to check if there is any damage and oil leakage with if Caution Washing the motorcycle with over pressurized
7. e valve adjusting screw and the end of the valve The specified air valve gap 0 05mm for the intake and exhaust valves respecively Brake Checking 1 pull up the front and rear brakes respectively and check for wear of the brake shoes If the mark A on the brake drum cover aligns with that A on the brake cam it means that the brake shoes are already worn to the limit and have to be replaced 2 Replacement should be carried out at a designated service center and it is recommended that the parts made by our company are used therein 16 Adjustment of Front Brake conducted sumultaneously despite only one of them 1 The front brake has a free operating movement of 10 20mm as shown in the figure on the right side 2 inspect the reseivoir capacity and refill if necessary in order to maintain proper level in the reservior This should be the major project of your regular inspection 3 check the front brake lining for its worm Rd depth if its worn depth is up to the limited mark d ine ake assy replace the brake lining if the lining doesn t have limited mark but a concave slot as the figure replace the lining while its worn depth up to the bottom of concave slot replacement of a pair of linings shall be is worn 17 Adjustment of Rear Brake The vehicle should be supported the main stand for check 1 The rear brake pedal has a free operating movement of 20 30mm as shown in the figure on the right sid
8. f which is very important because it will help ensure that the Carburetor maintains its normal performance after the storage Warning Gasoline is inflammable and may cause fire and even explosion under certain conditions Therefore do not smoke make fire or have any fire left behind on Resumption of Servise after storage 21 draining off fuel 3 Take out the spark plug pour about 15 20ml of clean engine oil into the cylinder step down the kick lever repectitively for several step down the kick lever repetitively for several times so as to have machine oil distributed all over the engine and finally fit the spark plug back on Attention The ignition switch must be set to 12 off plsition before stepping down the kick lever To protect the ignition system from damage the spark plug should be inserted in its cap and earthed 4 Wash the vehicle clean wipe it dry and apply an even coat of wax to the painted surface and a coat of antirust oil the chrome plated surface 5 Inflate the tyre asrequired and pad the vehicle up by wooden blocks with the two wheels clear of the ground 6 Put the vehicle in a shady and cool place free from humidity and direct sunshine and cover it properlly but not with plastic or other painted materials If there is garage store it therein Remoe the covering and clean the vehicle Change the lubricating oil if the vehicle has been off service for over 4 months 2 Drain off the remaining
9. l once every800 1 000km of driving by the following procedures Remove the screw plug from the bottom of the hot engine to drain off all old oil Wash the oil filter screen clean and remount it really to position T hen fill in 0 81 fresh machine oil and start the engine for idle running2 3 minutes Let the engine stop for 1 2 minutes and check to see whether the oil level is in between the upper and lower lines of the oil gauge Do not use any machine oil of a different grade than the specified one to avoid machinery failure Cleaning of machine oil tank 1 Drain off all the run machine oil from the oil tank 2 Dismount the related parts 3 Wash clean all the related parts 4 Fill in the required oil This job should not be done by untrained persons but shall be done at an authorized service center 13 Check up of Spark Plug Remove the cap of spark plug and screw off the spark plug by the plug wrench 2 Clean the spark plug all aroud or replace it if it is corroded or there is too much deposit on it 3 Regulate the gap of the spark plug to 0 6 0 7mm 4 The spark plug of the designated type should be used The applicable type of spark plug NGK CR6HAS Check up amp Cleaning of Air Filter Take out the air filter and check if it is contaminated Dismou nting Remove the right side cover take out the screw and disassemble the air filter C
10. leaning Wash the filter in clean washing oil and wipe it dry with dry cloth Soak it in clean machine oil squeez it dry and fit it back to position Recommended oil 15W 40QE Caution The air filter element for use must be intact or the enine will suck in dust and dirt resulting in a shorter service life of the engine Water should be prevented from entering into the filter in washing the vehicle The filter shall never be cleaned with gasoline or any other agent of a low ignition point 14 Adjustment of Throttle Cable Make sure that the adjusting nut of the throttle cable and locking nut work normally Check to see if the throttle twist grip is with the required free operating movement The required free operating movement 2 6m m If the grip can not be so moved freely turn the adjusting nut to ensure it After adjustment start the engine and check for the free operating movenent again Repeat the adjustment if necessary until it is as required Adjustment of Carburetor Caution The adjusting procedures of idling speed Support the vehicle by a stand 2 Adjust the idling speed by the throttle stop screw 1 to 1300 100rpm 15 Caution Do not try to cover up any trouble of other parts of the carburetor by adjusting the idling speed In case of any abnormality with the carburetor it has to removed by your dealer Adjust ment of idling speed shall be made only when the cold engine is warmed up or 10 minutes af
11. ns of the traffic conrtol authorities We are not responsible for any vehic le with unauthorized mod ification MAIN DATA Rear wheel 0 6 0 8mm Speed max 120km h Gap of air valve Inlake valve 0 03 0 05mm Braking distance lt 7m 30km h Exhaust valve 0 05 0 08mm Climbabi lit Ground clearance 130mm Capacity f 14L Ignition means CDI Transmission ratio Primary ratio 369 d I st gear 2 846 3thd gear 1333 Sth gear 0 913 Final drive ratio IILPARTS amp SUBASSEMBLIES Rearview mirror Meter 4 ignition lock Throttle grip Clutch lever N Left switch ass y Fuel cock Gear shifting Center stand Side stand Rear fork Seat cushion Fuel tank Rear wheel Exhaust silencer Rear braking pedal Front wheel IV OPERATION Fuel Cock 1 Fuel filling The capacity of the fuel tank is 4 5L Leadless gasoline of No 90or above or low lead gasoline is required for the motorcycle To fuel the vehicle support it by the main stand open the lock cover of the fuel tank and fill fuel through the opening Operation of the fuel cock ON With the handle of the fuel cock to ON position he fuel circuit is through for fuel supply OFE With the handle of the fuel cock fo OFF position the fuel circuit is cut off without supply RES With the handle of the fuel cock to RES position the fuel is supplide from the reserve Note T he reserved fuel can only be used when the normal suppl
12. service center in order to ensure safety Notes 1 Maintenance should be conducted more frequently when the motorcycod dreves in dusty areas 2 When the read out of the odometer exceeds the maximum figures specified in the table maintenance should bestill cycled according to the intreval of mileage stated herein Table of Maintenance 23 Odometer km Note Item frequency Frequency Items of Maintenance Circurt of fuel system Fue filter Throttleoperating system Choke of car buretor Airfilter element Soark olug Airvalve gap Airvalve gap Enginelutricating oil One replacement every 300km 600km 1000km 2000km amp 1 Also for disc style Lubriating oil screen Tension of chain Ldling speed of carbureor Driving chain Baliery Monthty Wear ofbrake shoers Rear braking systems Brakint liquid hose ofbraking liquic Braking licud Front braking system One replacement every two year Rear braking lightswrtch Lightchanging of front illuminator Clutch Sidestand Suspension Nuts bolts amp osher fastene s Lightehanpingoffrontiluminatr Bearing of steering handne S 24 V ELECTRICAL DIAGRAM RR B BATTERY FOR BEC ert ge EH EL ME E Mi Ree GEAR DISPLAY MAGNOTO SE PT tT REECE LTT RIGHT a GREEN G BLACK B LIGHT BLUE LBU YELLOW Y PINK P
13. tart button The electric start button is located below the right handlebar When the ignition switch is set in position and the engine is in the neutral position push the button to start the engine Light switch The front light switch has three positions O 5002 And a white point 5 4 When the switch is in this position front head Y light button tail and meter lights are all lit up 00 When the switch is in this position the tail betraying and meter lights are lit up When it is in this position The front illuminator tail betraying and meter lights are all off Switches Left Handle bar 1 Headlights dimmer button Positi z Don Headligh is in high beam Positi Z Headligt is in low beam 2 turning light switch aposition Left r position Right 3 Horn button press this button for horn overtaking button Headlight dimmer button Turning light Switch Horn button 10 Gear Shifting 4 4 gear 5 57 non cycling mode of gear shifting is employed of this motorcycle gear The throttle must be clossed befor the gear shifting every time Shifing the gear before closing the condition of backing it for four times The speed shifting pedal must be operated suitably Ga Stepping on the gear shifting pedal is forbided when driving to prevent damaging the clutch when changing the gear abruptly o O 9 NOTE N Neutral gear 1 18 gear x 2 2
14. ter the motorcycle is stopped from driving Idling speed adjusting screw Check up amp Adjustment of Air Valve Gap Noise will stem from too big gap of the air valve However if there is too small gap or even no gap at all closing of the valve will be hindered which will cause burn of the valve and output drop Therefore the air valve gap must be checked periodically The gap of the air valve should be inspected and adjusted with a cold engine by the follow ing procedures Remove the caps of the central hole and the top hole the ignition timing observation hole in the left crankcase cover 2 Remove the caps of the two air valves on the cylinder head 3 Insert the key into the central hole of the crankcase cover jam it against the nut of the flying wheel and then turm the flying wheel clockwise nutil the engraved mark on the flying wheel alin gns with the engraved line on the top of the crankcase cover Swing the rocking arm slightly A loose rocking arm which indicates the existence of clearance shows that the piston is in the upper stop position of the compressing t stroke where the valve can be adjusted A tight rocking arm means thar the piston is in the lower stop position of the compressing stroke In this case continuously turn the key clock wise for 360 degrees until the alignment of those engravd marks where the valve can be adjustd Afterwards check the valve gap by inserting feeler in between th
15. y is run out In this case refueling should be carried out as soon as possible for there is only somelOL of fuel reserve for use E Fuel Cock Handle RES Engine Starting Warning Never start the engine in a closed place or warehouse or warehouse as the exhausted gas from the vehicle contains toxic carbon monox ide 1 5 the key of the ignition switch to ON position 2 Ascertain the neutral position where it should be displayed 3 Ascertain the amount of fuel in the tank 4 Set the fuel cock handle to ON position To start cold engine Pull up the choke bar of the carburetor to close the choke 2 Rotate the throttle twist grip by 1 8to Aturn 3 Start the engine by the electric starting system 4 Slightly turn the throttle twist grip to increase the speed of the engine so as to warm up the engine Switches on Right Handle bar 8 5 Turn the carburetor choke bar downward to fully open the choke when the engine is sufficiently warmed up Caution The engine can only be started after the neutral position is ascertained Otherwise accident will happen Unnecessary idle running especially at a high speed is harmful to the engine Procedures for stopping the engine Release the throttle twist grip to slow down the engine 2 Turn to the neutral position 3 Set the ignition switch key to OFF position 4 Set the fuel cockhandle to OFF position Electric s
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