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- KAVIR Motor

1. BRAKE 133 TENSIONING THE REAR BRAKE 133 PEDAL CHANGING 134 CARBURETTOR 134 TVAE NI NES ES I9 129 NAKED VENE MOTORCYCLES ADJUSTMENT TRANSMISSION CHAIN TENSION To adjust the tension of the transmission chain the steps described below must be carried out on both sides Loosen the two nuts A securing the rear wheel Loosen the securing nut B e Using the bolt C adjust the tension of the chain e The chain D should have a tolerance of some 30mm e Set the position using the securing bolt B e Tighten the wheel shaft nuts TVAE NI NES ES I9 131 7 72 ADJUSTMENT CLUTCH TENSION To increase or decrease the clutch tension e Hemove the protective rubber A oosen the locking wheel e Turn the wheel C to tighten or loosen the cable e Use the locking wheel B to set the position THROTTLE CONTROL To increase or decrease the throttle twist grip tension e Hemove the protective rubber A oosen the locking wheel e Turn the wheel C to tighten or loosen the cable e Use the locking wheel B to set the position NAKED VERE MOTORCYCLES ADJUSTMENT TENSIONING THE FRONT BRAKE To increase or decrease the tension of the front brake e Loosen the securing nut e With a No 4 Allen key B increase or decrease the action of the front brake e Use the
2. Incorrect valve clearance Air filter element obstructed FUEL SYSTEM Incorrectly adjusted engine idling Incorrect throttle cable clearance Flooded throttle body Faulty air intake system ELECTRICAL SYSTEMS Flat battery Faulty battery Fuse blown damaged or incorrect Fuse fitted incorrectly Incorrect spark plug gap Oiled up spark plug Electrode worn or damaged Insulation worn or damaged Faulty spark plug cap Primary or secondary coils broken or short circuited Faulty spark plug cable FAULTY GEAR CHANGE DIFFICULTY CHANGING GEAR See The clutch is dragging in this section THE GEAR PEDAL DOES NOT MOVE Bent gear change shaft Foreign object in the selection drum slot Seized gear change fork Bent gear change fork guide bar Seized gearbox gearing Foreign object between the gearbox gears Incorrectly fitted gearbox THE GEARS JUMP Incorrect gear change pedal position Incorrect stop lever return Worn gear selector fork Worn selection drum slot Worn gear securing device NAKED S N MOTORCYCLES TROUBLESHOOTING FAULTY CLUTCH THE CLUTCH SLIPS Glutch incorrectly fitted Clutch cable incorrectly adjusted Loose or fatigued clutch spring Worn friction plate Worn clutch plate Incorrect oil level Incorrect oil viscosity low Oil altered THE
3. 5 9 RPM The value of rpm is shown by the analogic quadrant Overboost between 10 000 and 12 000 rpm The number of rpm pulses are settable between 1 and 8 68000 rhy km h 0864 6 ALARMS MANAGEMENT 6 1 Battery voltage alarm Every time that found out voltage value goes down 9 5V the system starts alarm routine to signal the possibility that after switching ON of the vehicle the Speedometer can loose its settled data The signal is the graphic bar visualization regardless Picture 6 1 battery voltage alarm the current function by blinking the first segment of the bar and battery symbol as shown in picture 6 1 This indication does not change the operation of the speedometer that normally continues its activity with the only difference that when there is this alarm the previous logo is shown When the voltage goes over 9 5V the alarm status turn off NAKED METE MOTORCYCLES ELECTRICAL SYSTEM 6 2 Fuel Level Alarm Every time that fuel level sensor closes on earth the icon is visualized on the displa fuel reserve symbol as shown in picture 6 2 PE At the same time the microcontroller will turn on the related light on the dial see paragraph 7 4 The icon disappears and the light turned on when the sensor opens again the contact ee n km h 7 BACKLIGHT AND INDICATORS LIGHTS FUNCTION 7 1 High Beam light The system has to switch on the led when the input No 12 of
4. MEAN AKES CHASSIS INSTRUMENT PANEL u REMOVAL Disconnect from the general wiring e Unscrew the 3 support bracket bolts B e Hemove the instrument panel ASSEMBLY o assemble carry out the operations in reverse order IGNITION SWITCH REMOVAL e Disconnect from the general wiring N B Unscrew the 2 headlight housing bolts e Remove the headlight housing e Unscrew the 2 bolts C Remove the switch ASSEMBLY To assemble carry out the operations in reverse order MH7 NAKED MT 125cc MOTORCYCLES CHASSIS EXHAUST PIPE Set spanner REMOVAL e Unscrew the 2 bolts A e Remove the central nut B located at the bottom of the engine e Remove the pipe and the gasket WARNING ASSEMBLY e To assemble carry out the operations in reverse order MinVZAINANE BS Phillips screwdriver 7 7 CHASSIS AIR FILTER REMOVAL Remove the seat see section Remove the 6 bolts A securing the filter cover e Remove the cover B by pulling upwards Remove the filter C by pulling upwards e Check that the filter is soaked in oll ASSEMBLY e To assemble carry out the operations in reverse order SHOCK ABSORBER REMOVAL e Remove the seat see section e Remove the tank see section He
5. Hemove the right and left hand rear cowling see section e Remove the turn indicators see section e Remove the rear light see section e Unscrew the 3 Allen bolts e Hemove the number plate ASSEMBLY e To assemble carry out the operations in reverse order Llave Torck MH7 NAKED MAATE CHASSIS REMOVAL e Remove the cap e Unscrew the 5 Allen bolts e Hemove the support orifice C e Unscrew the 3 screws D from the cover e Remove the top tank cover E Hemove the joining seal F e Unscrew the 6 Allen bolts Remove the tank filler hole e Remove the tank filler hole rubber seal ASSEMBLY e To assemble carry out the operations in reverse order MOTORCYCLES MEAN AKES cHassis REMOVAL e Remove the seat see section e Remove the front covers see section Remove the cap e Unscrew the 5 Allen bolts e Remove the support orifice C e Unscrew the 3 bolts D from the central cover e Remove the cover E e Unscrew the 4 bolts F from the side cover e Hemove the covers ASSEMBLY e To assemble carry out the operations in reverse order CAUTION VENE MOTORCYCLES CHASSIS REMOVAL e Remove the seat see section e Remove the front covers see section Remove the fuel cap see section e Remove the tank covers s
6. WORKSHOP MANUAL vM Y 20 g MEZANAKEB NAKED VERE MOTORCYCLES IMPORTANT e READ THIS MANUAL AND FOLLOW THE INSTRUCTIONS CAREFULLY THE ESPECIALLY IMPORTANT INFORMATION HAS BEEN INDICATED WITH THE WORDS WARNING CAUTION AND N B WHICH HAVE VERY PRECISE MEANINGS WARNING CAUTION N B FOREWORD This manual describes the procedures for the diagnosis maintenance adjustments basic service work chan ging of parts and the dismantling and assembly of the main parts Model applicable MH7 NAKED with the following and subsequent VIN numbers VTVNKOA1ES307XXXXXX This text is classified into sections each of which has a section number as can be seen in the Contents on the following page and on the first page of every individual section there is a contents list for that section Keep this manual to hand so that it can be consulted quickly when carrying out service work The specified points must be carefully observed to ensure that the machine functions perfectly in accordance with the specification When changing parts or carrying out service work that involves dismantling it is recommended to use genuine G H E MOTORHISPANIA S L spare parts tools and service materials as specified in the corresponding des criptions All the information figures and specifications in this manual are based on the latest approved product informa tion available at
7. 10 e Remove the chain tensioner slipper Remove the timing chain and notice its direction of ro tation Remove the 2 screws of the starter pinionholder plate 11 e Remove the starter drive pinion MEAN AKES 7 ENGINE Remove the 10 screws from the LH crankcase 2 of which are located on the RH crankcase Remove the nuts that secure the engine to the fixture Remove the RH half crankcase and the 2 centering pins e Fit the 2 nuts that secure the engine to the fixture e Remove the balance shaft 12 e Remove the 2 pins 13 of the shift forks e Remove the selector cylinder 14 e Hemove the shift forks Hemove at the same time the input shaft 15 and se condary shaft 16 assembly e Remove the clutch push rod of the input shaft REMOVAL OF THE CRANKSHAFT Fit protective cap P N 69098 to the end of the crank assembly MH7 NAKED Ly MT 125cc MOTORCYCLES 2363 ENGINE e Fit to casing with tool P N 647068 fitted with plate P N 758466 e Fix the assembly to the casing using 4 bolts 1 e Tighten the tool centre screw holding the crank with one hand on the other side until it is fully extracted e Hemoving the the cranshaft and conrod assembly 113 ENGINE CHECKING THE CRANKSHAFT AND CONROD ASSEMBLY e Using set of shims check the big end side play e The maximum side play the conrod end must not e
8. MH7NAKED MITE MOTORCYCLES SPECIFICATIONS GENERAL SPECIFICATIONS ELEMENT SPECIFICATIONS MODEL CODE NAKED 125cc DIMENSIONS Total length 1980 mm Total width 750 mm Height without rear view mirrors 795 mm Distance between axles 1310 mm WEIGHT 120 kg 13 23 SPECIFICATIONS CHASSIS SPECIFICATIONS WHEELS Front wheel Front tyre Front pressure Hear wheel Hear tyre Hear pressure FRONT BRAKE Type brake pistons of disk Thickness of disk main piston cylinder REAR BRAKE Type brake pistons of disk Thickness of disk main piston cylinder FRONT SUSPENSION Type of suspension Type of front forks Forks capacity Travel REAR SUSPENSION Type of suspension Central hydraulic single shock absorber travel STEERING Tipo 9 0x17 Continental 100 80 17 1 5 bar Continental 130 70 17 2 bar Hydraulic disk radial calliper eomm 300mm 4 1 11mm Hydraulic disk 25mm 220mm 4 1 mm 12mm Hydraulic telescopic forks 41 mm inverted advanced shaft 360 4 cc 90 mm owinging arm with single central shock absorber 45 2 mm Column mounted on ball bearings ELEMENT ENGINE Type of engine Make Cubic capacity Diameter x stroke Maximum power Maximum torque ratio FUEL Recommended fuel Total capacity of fuel tank including reserve LUBRICACION Recommended o
9. Remove the electrolyte container from the PVC wrapping and remove the top cover by sliding sideways FILLING THE BATTERY WITH ELECTROLYTE Fit the electrolyte container vertically into the battery filling orifice and push in with a single movement This will cause the seal to break and allow the liquid filling to begin N B The electrolyte container needs to be correctly inserted otherwise the battery may fall over or the sul phuric acid may spill out PLEASE CHECK THE FOLLOWING That bubbles are emerging from the 6 reservoirs That the liquid level is falling gradually Allow to stand for 10 minutes no more than 12 hours N B If there are places where no bubbles are emerging the liquid can be encouraged to enter by tapping this part with the finger without removing the electrolyte container REMOVING THE ELECTROLYTE CONTAINER Check once again that no electrolyte is remaining If there is electrolyte remaining tap the container gently Remove the electrolyte container carefully Clean off any electrolyte that may have splashed onto the battery FITTING THE HERMETIC PLUG Hemove the hermetic plug fitted to the battery and position it gently horizontally lined up with the liquid filling orifice Push down several times with both hands on the 6 parts until it is at the same level as the top of the battery N B Do not adopt the method of pushing each hermetic plug once PRECAUTIONS FOR HANDLING Take care that the electrolyt
10. e Fit the fluid reservoir with the 2 bolts B e Fit the banjo bolt C REAR BRAKE LEVER Set spanner REMOVAL e Remove the 2 bolts A securing the fluid reservoir to the support e Remove the bolt and the nut B e Remove the spring C e Unscrew the bolt D and the nut E securing the lever to the support and remove it N B ASSEMBLY e o assemble carry out the operations in reverse order MEAN AKES 39 7 7 CHASSIS REAR SPROCKET REMOVAL e Remove the rear wheel see section e Unscrew the 5 bolts e Hemove the rear sprocket ASSEMBLY o assemble carry out the operations in reverse order PROP STAND REMOVAL e Remove the spring e Unscrew the bolt B securing the nut on the inside e Hemove the prop stand ASSEMBLY e o assemble carry out the operations in reverse order NAKED VERE MOTORCYCLES 77721 cHassis FRONT BRAKE LEVER REMOVAL e Unscrew the bolt A the securing nut e Remove the lever ASSEMBLY e o assemble carry out the operations in reverse order FRONT BRAKE FLUID RESERVOIR e Hemove the rear view mirror e Unscrew the brake cable B e Hemove the rear brake switch C e Remove the lever see section e Unscrew the banjo bolt D e rain the brake fluid e Unscrew the 2 Allen bolts E from the clamp e Hemove the brake reservoir N B ASSEMBLY e To
11. 1 000mm to 2 500mm with step of 1mm Setting a value over 2 500mm will cause the circumference set to default value 1 845mm Obs 8 4 Once inside the regulation menu f 20 sec will pass without the button mode is pushed or e f the vehicle is turned on speed gt OQ or f the key is turned OFF The system will be automatically taken to the stan dard operating mode and the modifications possibly pro duced will be lost 8 3 2 Modification wheel revolution impulses This parameter expresses the number of impulses that the speed sensor sends to the instrumentation for every wheel revolution The selected value is shown blinking as in picture 8 4 f21Hz Duty 50 Pressure of Set button allows the unit increase im pulses from a minimum of 1 to a maximum of 12 Pressure of Mode button allows the value confir mation and the passage to the following screen The information concerning the number of im pulses which the instrumentation receives from the speed sensor is saved memory Obs 8 5 Impulses can also have the same dis tance Obs 8 6 Once inside the regulation menu f 20 sec will pass without the button mode is pushed or e f the vehicle is turned on speed gt OQ e f the key is turned OFF The system will be automatically taken to the stan dard operating mode and the modifications possibly produced will be lost 8 3 3 Modification engine revolution impulses his pa
12. 1 1 Obs 5 6 If there is no feeding the AVE value is ho peless lost Picture 5 11 average speed out of 5 7 Max speed function MAX range This function describes the correct working visualization of maximum speed function The information is visualized by using digit 14 16 logo MAX pic 5 1 1 The parameter identifies the maximum speed achieved by the vehicle expressed in km h or mph depen ding on the selected unit of measurement Its possible to set to zero the counter related to this parameter in correspondence of MAX func tion by pushing Set button till value OO appears Picture 5 11 Maximum Speed The setting to zero of MAX function is possible both when the vehicle is running or stopped Changing measurement unit will cause conversion of MAX value The data isnt memorized in a permanent mode Obs 5 7 If there is no feeding the MAX value is hopeless lost MEAN AKES 7 ELECTRICAL SYSTEM 5 8 Battery charge level function The information is visualized on the bottom left part by using the graphic bar accompanied by the battery symbol ignition as shown in picture 5 12 The graphic bar updated every O 5 seconds is mana ged by the following table Picture 5 12 battery level From 9 50V to 9 99V_ From 10 00V to 1049V 3 From 10 50Vto 10 99V 14 From 11 00 to 11 49V 5 From 11 50Vto 11 929SV 8 Ovri amp SOV 8
13. 1 500 km Every 6 000 km Every 3 000 km Every 10 000 km Every 10 000 km Every 10 000 km 1 The need to decarbonise can be estimated by checking the quantity of carbonisation present in the cylinder exhaust outlet CHECKING AND GREASING MAINTENANCE OPERATIONS REINFORCED MAINTENANCE 500 km or 3 months Every 3 000 km Every 1 500 km Every 6 000 km Every 3 000 km Chain tension and condition X X X CHECKING AND ADJUSTING MAINTENANCE OPERATIONS REINFORCED MAINTENANCE Clutch cable Oil pump control opark plug Tension of the wheel spokes 500 km or 3 months lt Kx Every 3 000 km Every 1 500 km Every 6 000 km Every 3 000 km X X X X CHECKING AND ADJUSTING MAINTENANCE OPERATIONS REINFORCED MAINTENANCE 500 km or 3 months Every 3 000 km Every 1 500 km Every 6 000 km Every 3 000 km Carburettor X X MH7NAKED MOTORCYCLES TROUBLESHOOTING INDICE FAILURE TO START 145 INCORRECT IDLING SPEED 146 FAULTY GEAR CHANGE 146 FAULTY CLUTCH 147 OVERHEATING 147 POOR BRAKING 147 FAULTY FRONT FORK ARMS 148 UNSTABLE HANDLING 148 FAULTY LIGHTS OR TURN INDICATOR SYSTEM 149 MH7 NAKED EE 125cc MOTORCYCLES TROUBLESHOOTING N B The following troubleshooting guide does not cover all the possible causes of faults I
14. 7 ELECTRICAL SYSTEM Picture 5 4 Partial covered distance 90998 0864 jii t3 Picture 5 5 clock NAKED MOTORCYCLES ELECTRICAL SYSTEM Clock regulation can be done by pushing Mode button until when only segments related to TIME function are active about 5sec while all the others are off see picture 5 6 It s possible to modify in series first the hours then the minutes this depends by the selected data that will be shown blinking with f 1Hz Duty 5056 By pushing the Set button the selected parameter Picture 5 6 clock regulation will add one unit while by pushing the Mode button it will be possible to select the chosen parameter minutes or hours and to exit from regulation phase Time parameter will be shown in O 24 format if unit of measurement chosen is km h while it will be shown in 0 12 format if unit of measurement is mph In this case on the display You will see on 5 and feo 3 6 digits the logo AM or PM during regulation e N phase see picture 5 7 Lr ii Obs 5 3 Entered the regulation menu if bu ttons have been pushed the system will automa tically return to standard method of operation saving possible modifications Picture 5 7 clock regulation format O 12 Obs 5 4 Entered the regulation menu if the vehicle starts gt 0 the system will au tomatically return to standard method
15. N Partial covered distance LAP 5 Time on turn AVE Q Average speed MAX N Max speed MHZNAKED MITE MOTORCYCLES ELECTRICAL SYSTEM 10 START UP At the start up key from OFF to the system gives to the user some information which are shown in following screens or pages First page visualization of the release date and software s version for about 2 seconds This information is shown only during the first ins tallation of the instrumentation picture 10 1 Second page display check All the display segments are ON for about 2 seconds picture 10 2 Third page visualization of the wheel circumference of the measurement unit selected for the distance of the impulses number for every turn of the wheel and of the engine visualization of symbols associated to graphic bars picture 10 3 e n correspondence of screens over described the system start the lights check backlighting check all lights led are active and at display check end they are off After all the check the system will show the normal visualization Sw version release Sw week release ow year release Picture 10 1 first page 8885 km h TOTAL LAP AVE MAX BEBE BEBE Picture 10 2 second page MEAN ACES 3 ELECTRICAL SYSTEM Selected wheel circumference mag FK C Distance measurement unit B Wheel turn impulses Graphic
16. Remove one of the spring clips 11 using pliers P N 732000 Remove the gudgeon pin e Remove the piston MinVZAINANE BS 91 ENGINE CHECKING THE CYLINDER he oylinder should show no traces of scoring Or seizure e Cylinder diameter 54 000 to 54 018 mm CHECKING THE PISTON e he piston should show no traces of scoring or seizure e The rings must be free in their grooves Measure the piston diameter at 4 5 mm from the piston skirt Piston diameter 53 977 to 53 8996 mm e Cylinder amp piston set 0 020 to 0 028 mm e Utilisation limit O 15 mm CHECKING THE PISTON RINGS Carefully remove the piston rings e Place a ring in the bore parallel to it and measure the gap using a feeler gauge Piston ring gap 0 15 to O 30 mm e Utilisation limit O 4 mm NAKED MOTORCYCLES ENGINE INSTALLING THE PISTON RINGS ON THE PISTON Proceed in the following order in order to install the oil control rings e Install the spring 1 no special direction e Install the 2 piston rings 2 on each side of the spring by offsetting the gap of each ring no special direction e Install the compression ring 3 by placing the TOP mark upwards e Install the compression ring 4 by placing the mark upwards FITTING THE PISTON e Install the piston with its arrow stamped into the piston crown pointing at the exhaust e Fit the gudgeon
17. SPECIFICATIONS TIGHTENING TORQUES TIGHTENING TORGUE 0 1 daN m 1 0 1 daN m 1 0 8 0 1 daN m 8 1 N m 0 8 0 1 daN m 8 1 N m 4 5 daN m 45 N m 1 2 daN m 12 6 5 daN m 65 N m 6 5 daN m 65 N m 2 8 daN m 28 N m 4 3 daN m 43 Nem 4 3 daN m 43 N m 1 5 daN m 15 2 0 daN m 25 N m 2 0 daN m 85 1 daN m 10 N m 1 daN m 10 N m 1 9 daN m 19 N m 0 6 daN m 6 0 5 daN m 5 1 daN m 10 N m 2 2 daN m 22 3 9 daN m 35 9 9 daN m 55 NAKED MOTORCYCLES 77751 COMMISSIONING CONTENTS COMMISSIONING Battery preparation except maintenance free batteries 19 Checking levels 20 Commissioning the fuel and oil circuits 20 Checks before delivery to customer 20 MEAN AKES 17 NAKED VERE MOTORCYCLES NPE COMMISSIONING PREPARING THE BATTERY EXCEPT MAINTENANCE FREE BATTERIES Regarding use of electrolyte please read this manual carefully and fill the electrolyte liquid correctly making sure not to spill any WARNING Check to make sure the electrolyte is the same type as in the battery The electrolyte must always be filled with the battery removed from the machine The fitting of bolts and nuts must be carried out after filling with electrolyte PREPARING THE BATTERY Place the battery on a flat surface and remove the filling orifice seal PREPARING THE ELECTROLYTE
18. The information is always visualized on digits 5 7 see mn picture 9 1 nagu If measurement unit is km h default value the corresponding digit is visualized if You push the button iili entering the Set Up it is possible to select mph unit of measurement pic 5 2 Picture 5 1 Speed indication Km h The system has got following parameters oelected by end user oelected by end user 200 km h 676 constant all 1 km h Min 1 000 Max 2 500 Min 1 Max 12 184 mph over the scale 1 mph 5 2 Totalizer function TOTAL c j The information is visualized on digit 8 12 and accompa nied by TOTAL logo as shown in pic 5 3 The data is permanently memorized in a non volatile me He d ag OH mory E2prom refresh every km n di uiii 23 If the memory is empty Youll see numbers visualised Picture 5 2 Speed indication mph This information is always calculated in km Anyway it must be expressed in km or mph You can select the chosen information by entering the Set Up menu During normal using of the instrumentation it is not possible to set the information to zero Picture 5 3 Total covered distance MEAN AKES 5 3 Trip function TD This function describes the correct working visualiza tion of the board automatic partial totalizer This function is always represented on digit 13 16 and by logo TD pic 5 4 he visualized data
19. assemble carry out the operations in reverse order e Refill the fluid reservoir see section CHASSIS THROTTLE CONTROL o REMOVAL e Remove the protective rubber e Loosen the throttle cable tensioner B e Remove the cover C e Disconnect the cable D e Unscrew the 2 Allen bolts E from the clamp e Remove the throttle control ASSEMBLY e Fit the cable terminal F e Fit the cable through the cover guide C e Fit the cable through the tensioner cut out H eves z REMOVAL e Remove the rubber e oosen the cable tensioner B e Remove the cable C Unscrew the bolt and the nut D from the securing bracket e Hemove the lever ASSEMBLY e To assemble carry out the operations in reverse order M MOTORCYCLES CHASSIS COMMUTATOR REMOVAL e emove the rear view mirror e Remove the choke cable B e Remove the clutch lever see section e Unscrew the 2 bolts C e Remove the commutator ASSEMBLY e To assemble carry out the operations reverse order HANDLEBARS screwdriver EE e Remove the front brake reservoir see section e Hemove the commutator see section e Remove the electric start button Unscrew the 4 securing clamp bolts e Hemove the handlebars ASSEMBLY o assemble carry out the operations in reverse order
20. dusty regions or an ambient temperature of above 30 C CHECK MAINTENANCE OPERATIONS 900 km or 3 months Every 3 000 km Every 6 000 km REINFORCED MAINTENANCE Every 1 500 km Every 3 000 gt lt Adjust idling speed Throttle cable and oil pump Front and rear brake cables X X X Functioning of the front and rear brakes gt X lt X 2 X Functioning of the electrical equipment Fuel circuit Oil circuit gt lt lt lt x X Front and rear brake fluid piping 0X X Coolant circuit X lt x X gt X lt Carburettor heating circuit Tyre pressures X Condition pressure and wear of tyres X X Front and rear brake fluid level X Coolant level X X X X X Battery electrolyte level X X 7X 0X X Tightening nuts and bolts gt X lt Charging the battery MEAN AKES MAINTENANCE OPERATIONS REINFORCED MAINTENANCE Intake filter element Front and rear brake pads where appropriate Gearbox oil Chain sprocket crown wheel where appropriate Clutch disks where appropriate 500 km or 3 months Every 3 000 km Every 1 500 km X X MAINTENANCE E RENEWING Every 6 000 km Every 3 000 km X X X X X CHECKING AND DECARBONISING MAINTENANCE OPERATIONS REINFORCED MAINTENANCE Piston Gylinder head Exhaust port 500 km or 3 months Every 3 000 km Every
21. e Turn wheel impulses 6 e Turn engine impulses 4 To modify one of these parameters You have to follow the procedure as in Setup menu paragraph During first installation of device the display always shows the updated software version and date MEAN AKES 13 TEST MENU ATTENTION DO NOT USE Foreseen menu function and do not disclose the content of this chapter to final end user Entry in test menu is allowed only during installation phase of device on the vehicle by placing at earth the test wire 5 usually without cable and keeping pushed Mode and Set button together In these conditions the system will place itself on Test menu and following operations will be possible Operator check of the device COLL MAN e Check of the device by using an automatic and optical test system television camera COLL AUTO Erasing of the E2prom E2PROM e Calibrating pointer position on the dial IND To well operate inside the Test Menu some inputs of the speedometer are set up again as follows Function Up button Md button Down button 13 1 Manual Test procedure COLL_MAN This is a procedure very useful for an operator to briefly check in a safe way the instrumentation s input the pointers movement To enter the procedure the Md button must be pressed inside the correspondent screen in Test Menu by using Up and Down buttons the selection will occur pic 1 ELECTRICAL SYSTEM Pictu
22. horn and the brake light are functioning correctly 6 Check the functioning of the different indicator lights 7 Carry out a road test MH7NAKED VERE MOTORCYCLES 7 7 CHASSIS CONTENTS FRONT COVERS 23 CENTRAL COVERS 23 SEAT 24 PILLION PASSENGER SEAT 29 REAR COWLING 29 GRILL 26 NUMBER PLATE 26 FUEL CAP 27 TANK COVERS 28 FUEL TANK 29 BATTERY SUPPORT 30 FRONT MUDGUARDS 30 FRONT FOOTRESTS 31 REAR FOOTRESTS 31 CHAIN 3e CHAIN PROTECTOR 33 GEAR CHANGE PEDAL 33 FRONT WHEEL 34 FRONT BRAKE CALLIPER 35 FRONT BRAKE DISK 35 WHEEL 36 REAR BRAKE CALLIPER 38 BRAKE DISK 38 HEAR BRAKE FLUID RESERVOIR 39 BRAKE LEVER 39 HEAR SPROCKET 40 PROP STAND 40 BRAKE LEVER 41 FRONT BRAKE FLUID RESERVOIR 41 THROTTLE CONTROL 42 CLUTCH LEVER 42 COMMUTATOR 43 HANDLEBARS 43 INSTRUMENT PANEL 44 IGNITION SWITCH 44 EXHAUST 45 AIR FILTER 46 SHOCK ABSORBER 46 SWINGING ARM 47 FORKS 48 CARBURETTOR 50 MEAN AKES 21 NAKED VERE MOTORCYCLES CHASSIS FRONT COVERS REMOVAL e Unscrew the 3 Allen bolts on each end of the cover Remove the front cover ASSEMBLY e To assemble carry out the operations in reverse or der CAUTION Allen key CENTRAL COVERS REMOVAL e Remove the seat see section e Unscrew the 3 Allen bolts on each end of the cover e Remove the central cover ASSE
23. pin and circlips e The circlip gaps 1 must face upwards or downwards but under no circumstances to the side wv The circlips must be changed every time they are removed MEAN AKES ENGINE e Position the piston ring gap as follows 1 Top compression ring gap 2 Compression ring gap 3 Upper oil control ring gap 4 Lower oil control ring gap FITTING THE CYLINDER e Install the cylinder base gasket and the 2 guiding pillars on the crankcase e Fit a new O ring 1 on the cylinder skirt e Fit the cylinder over the piston by compressing the pis ton rings by hand e Fit the chain and the chain guide tensioner into the timing chain tunnel NAKED MOTORCYCLES 29363 ENGINE FITTING THE CYLINDER HEAD e Fit the 2 guiding pillars 1 and the metal gasket 2 on the cylinder e Fit the chain pad 3 e Install the cylinder head Slightly lubricate the thread of the 6 screws that secure the cylinder head e Fit the 6 screws e Tighten in 2 or 3 sequences the 6 screws that secure the cylinder head in the indicated direction Tightening torque e 6 mm diameter screw 1 m daN e 8 mm diameter screw 2 2 m daN FITTING THE CAMSHAFT GEAR SETTING THE TIMING Pivot the engine to the right e Hotate the conrod and crankshaft assembly so as to align the marks of flywheel magneto with the mark A of the cover Remove the wire that holds the timing cha
24. represents the vehicle covered distance expressed in miles or km depending on the selected measurement unit with resolution 0 1 miles or km This counter is automatic in fact it automatically starts with the first pulse arriving from speed sensor The data isnt memorized in a permanent mode It is possible setting the counter of this parameter to zero by pushing the Set button for about O3 sec in correspon dence of the TD function till the value OOO O appears It is possible setting to zero the TD function both when the vehicle is stopped and when it is running this causes also the setting to zero of LAP and AVE functions If the data gets over 999 9 the system automatically sets to zero TD LAP and AVE functions and then starts again the counting Obs 5 1 So If there is no feeding the TD value is hopeless lost 5 4 Time Function TIME This function describes the correct working visualization of the current hour This function is always shown in the format hh mm by using digit 1 4 pic 5 5 Clock is active also when the microcontroller is in sleep mode phase and regulation of the hour can be done only when the vehicle 15 stopped This information 15 not saved the memory Visualized Series from 0 00 to 23 59 for method 0 24 from 0 00 to 12 59 for method 0 12 am from 1 00 to 11 59 for method O 12 pm Clock precision 2 5 sec day Obs 5 2 If there is no feeding the TIME value is ho peless lost
25. spacer C and the spring D Drain the hydraulic fluid into a container e Unscrew the bolt E and the seal F Remove the dust guard the locking ring the airtight seal I and the ring J e Hydraulic fluid L TYPE SAE 15 9 MEAN AKES 48 CHASSIS CARBURETTOR REMOVAL e Remove the seat see section e Remove the fuel tank see section e Disconnect the carburettor air intake A e Disconnect the throttle cable B e Disconnect the fuel intake C e Disconnect the choke cable D e Disconnect the gas outlet pipe E e Disconnect the inlet manifold F e Disconnect the cables e Remove the carburettor ASSEMBLY e To assemble carry out the operations in reverse order MHZNAKED Vee MOTORCYCLES ELECTRICAL SYSTEM CONTENTS HEADLIGHT MAIN BEAM DIPPED BEAM BULB 93 FRONT HEADLIGHT SIDELIGHT 94 HEAR LIGHT 99 FRONT AND TURN INDICATORS 96 NUMBER PLATE LIGHT 27 HELAY 98 E C U 98 COIL 99 HEGULATOR 99 FUSE 99 BATTERY 60 INSTRUMENT PANEL 61 MEAN AKES 51 M MOTORCYCLES ELECTRICAL SYSTEM FRONT HEADLIGHT MAIN BEAM DIPPED BEAM BULB e Remove the two bolts A one on each side securing the headlight housing e Tilt the headlight housing B downwards to be able to access the headlight Loosen the two bolts C one on each side securing th
26. the clock e Set to zero the TD AVE LAP and MAX values e Entering the Set up menu to modify the wheel circumfe rence value the measurement unit value of distance the number of impulses for every turn of the wheel and of the engine and finally to associate the graphic bar to the selected information The function scrolling is always possible it means the passage from function to the following one with the vehicle stopped or not To update the instrumentation with the new function it s enough briefly pushing the button tmin 1 sec when it will be left the display will show the new function The setting to zero of TD of the chronometer of the average and max speed can be done both with the vehi cle stopped or in movement as described in the previous paragraphs Clock regulation is possible only when vehicle is stop ped The entering in the Set up menu is possible only when the vehicle is stopped by pushing at the same time the two buttons for about 4 seconds the back up of all data will be done only when the Mode and Set buttons it depends on selected set up chosen will allow the exit from the Set up menu Buttons inhibited Function allowed gt ocrolling Set to zero of selected function All functions are allowed 9 1 Sequence of represented functions The function scrolling is always possible with the vehicle stopped or not by using the button as follows Mode Button p TD
27. the connector is high at the same time of High Beam ignition Picture 6 2 Fuel level alarm 7 2 Indicators lights function The system has to switch on the led when the inputs No 2 or No 13 of the connector are high at the same time of Indicators lights ignition N B 7 3 Neutral light function The system has to switch on the led when the input No 6 of the connector is low at the same time of placing of gear lever in neutral position 7 4 Fuel light function The system has to switch on the led when the input No 15 of the connector is low at the same time of mi nimum level of fuel tank 7 5 Backlighting and dial lights function LCD and dial backlight is orange and is always ON when the key is turned on MEAN AKES 8 SET UP MENU The entry in the set up menu is only possible when the vehicle is stopped by pushing at the same time the Mode and the Set button for about O4 seconds regardless the visualized function On the display the SET Par logo will appear fixed as in the picture 8 1 for the entry in the set up menu of parameters Obs 8 1 If the input 5 settings on the connector Is connected to ground it is possible to change every parameter If the input 5 settings on the connector is not con nected to ground default condition it is only possi ble to change measurement unit 8 1 Parameters SET UP menu This menu allows to modify the following parameters e Wheel circumfer
28. the time of publication The main model used for the description throughout this manual is the model with basic specifications The figures may therefore appear slightly different from the model in the workshop G H E MOTORHISPANIA S L reserves the right to make changes without prior warning G H E MOTORHISPANIA S L SERVICE DEPARTMENT Copyright G H E MOTORHISPANIA S L 2007 MHZ NAKED 125cc GENERAL CONTENTS GENERAL INFORMATION SPECIFICATIONS COMMISSIONING CHASSIS ELECTRICAL SYSTEM ENGINE ADJUSTMENT MAINTENANCE TROUBLESHOOTING 5 MHZ NAKED 125cc mm GENERAL INFORMATION CONTENTS IDENTIFICATION Machine identification 9 Engine identification 9 7 JN e MOTORCYCLES GENERAL INFORMATION IDENTIFICATION CHASSIS IDENTIFICATION NUMBER The chassis identification number is located at the front right hand side of the machine The chassis number is required when requesting any motorcycle part ENGINE IDENTIFICATION NUMBER The engine identification number is located at the top right hand side of the engine The engine number is required when requesting any engine part MH7 NAKED aVE EE 125cc MOTORCYCLES SPECIFICATIONS CONTENTS GENERAL SPECIFICATIONS 13 CHASSIS SPECIFICATIONS 14 ENGINE SPECIFICATIONS 15 TIGHTENING TORQUES 16 MEAN AKES 1
29. the wheel e Insert the shaft through to the other side of the wheel e Fit the chain B on the sprocket e Fit the other separator Insert the shaft through to the other side of the swin ging arm e Fit the tensioner e Tighten the chain tension see section e Fit the 2 wheel shaft nuts C 7 7 CHASSIS REAR BRAKE CALLIPER REMOVAL e Unscrew the banjo bolt A from the bottom end of the brake hose e rain the brake fluid e Remove the rear wheel see section e Unscrew the 2 bolts B securing the support e Hemove the calliper N B 0 S T SC ASSEMBLY J 2 e Fit the banjo bolt SQ e Fit the calliper on the support e Fit the calliper support on the swinging arm using the bolts B e Fit the rear wheel see section e Refill the fluid reservoir see section REAR BRAKE DISK REMOVAL e Remove the front wheel see section e Unscrew the 6 bolts A e Remove the disk ASSEMBLY e To assemble carry out the operations in reverse order NAKED MOTORCYCLES 77721 cHassis REAR BRAKE FLUID RESERVOIR e Open the reservoir cover e Drain the fluid e Unscrew the banjo bolt C e Unscrew the 2 bolts B e Remove the reservoir N B ASSEMBLY e Refill the fluid reservoir see section
30. 14 2541002000227 opening 2541002000214 large model plate New or modified twmh MH7NAKED MTE MOTORCYCLES 7 ENGINE PUTTING THE ENGINE THE STAND e Fit the engine to adapter P N 758464 e Put the assembly on stand P N 64765 clamped in the jaws of a vice e Remove the bolt 1 in order to drain off the gearbox Tightening torque 2 m daN REMOVAL OF THE CYLINDER HEAD Removal of the camshaft gear cover 1 Hemoval of the timing mark plug 2 Removal of the central plug 3 MEAN AKES 89 e Using wrench turn the crankshaft counterclockwise so as to align the crankshaft gear mark I with the cylin der head mark A e mmobilize the conrod and crankshaft assembly by means of the flywheel magneto nut e Remove the camshaft gear bolt e Removal of the chain tensioner 5 plug 4 e Removal of the chain tensioner e Remove the camshaft gear i Tie a wire to the timing chain in order to pre V vent it from falling into the crankcase NAKED VERE MOTORCYCLES 3 ENGINE e Slacken off the cylinder head cylinder 6 mounting bolts in the order shown in 2 or 3 stages e Hemove the oylinder head REMOVAL OF THE CYLINDER PISTON Removal of the metal gasket 6 and the 2 centring pillars 7 e Remove the chain guide pad 8 Hemoval of the oylinder and its O ring Hemove the base gasket 9 and the 2 centring pillars 10
31. B e Turn the bulb C to the left and remove it ASSEMBLY e To assemble carry out the operations in reverse order WARNING NAKED VENE MOTORCYCLES 7772 ELECTRICAL SYSTEM Allen key NUMBER PLATE LIGHT REMOVAL e Remove the bolt A holding the screen e Then pull out the bulb B while holding the bulb holder C with the other hand ASSEMBLY e To assemble carry out the operations in reverse order 57 7772 ELECTRICAL SYSTEM RELAY REMOVAL e Remove the seat see section Disconnect the relay ASSEMBLY o assemble carry out the operations in reverse order E C U REMOVAL e Remove the seat see section e Remove the fuel tank see section e Disconnect the ECU ASSEMBLY e To assemble carry out the operations in reverse order NAKED MOTORCYCLES NE ELECTRICAL SYSTEM COIL REMOVAL e Remove the seat see section e Remove the fuel tank see section e Remove the 2 bolts e Hemove the coil B ASSEMBLY e To assemble carry out the operations in reverse order REGULATOR REMOVAL e Remove the seat see section e Remove the fuel tank see section e Remove the 2 bolts e Remove the regulator ASSEMBLY o assemble carry out the operations in reverse order FUSE REMOVAL e Remove the seat see section Remov
32. Blown rear light bulb Brake light bulb BLOWN REAR LIGHT BULB BRAKE LIGHT BULB Incorrect rear light brake light bulb Battery faulty Incorrectly adjusted rear brake light switch Hear light brake light bulb reached end of life THE TURN INDICATORS DO NOT COME ON Faulty turn indicator switch Blown turn indicator bulb Incorrect connection Damaged or faulty wiring loom Battery faulty Fuse blown damaged or incorrect THE TURN INDICATORS BLINK SLOWLY Faulty turn indicator switch Incorrect turn indicator bulb THE TURN INDICATORS BLINK RAPIDLY Incorrect turn indicator bulb Blown turn indicator bulb THE HORN DOES NOT SOUND Horn incorrectly adjusted Horn damaged or faulty Faulty horn switch Battery faulty Fault in wiring loom TVAE NI NES ES I9 149 MOTORCYCLES www motorhispania es Created by www ciandisseny com FACTORY Parque Sevilla Industrial calle 3 41016 Sevilla Espa a T 34 954 47 56 87 Este manual corresponde a las especificaciones y equipamiento del veh culo MH comercializado a trav s de la Red de Distribuidores de MOTORHISPANIA El constante inter s por mejorar las especificaciones dise o y producci n de nuestros veh culos puede dar lugar a diversas modificaciones Incluso habiendo tomado todas las medidas posibles para asegurar la exactitud del manual ste puede tener errores y no debe considerarse como un docum
33. CLUTCH DRAGS Uneven clutch spring tension Bent pressure plate Bent clutch plate Distorted friction plate Bent clutch push bar Broken clutch lobe Marks not aligned Incorrect oil level Incorrect oil viscosity high Oil altered OVERHEATING ENGINE Coolant passages blocked Large accumulation of carbon deposits Incorrect oil level Incorrect oil viscosity Inferior oil quality CHASSIS Brakes activated ELECTRICAL SYSTEMS Incorrect spark plug electrode gap POOR BRAKING Worn brake pads Worn brake disk Air in the hydraulic brake system Leaking brake fluid Damaged brake calliper seal Damaged brake pipe Oil or grease on the brake disk Uil or grease on the brake pad Incorrect brake fluid level TVAE NINE ES I9 7 TROUBLESHOOTING DAMAGED FRONT FORK ARMS LEAKING OIL Inner tube bent damaged or rusted Outer tube cracked or damaged Uil seal fitted incorrectly Damaged oil seal lip Incorrect fluid level high Loose shock absorber bar assembly bolt Damaged shock absorber bar assembly copper washer INCORRECT FUNCTIONING Inner tube bent or damaged Duter tube bent or damaged Damaged forks spring Outer tube hose worn or damaged Shock absorber bar bent or damaged Incorrect oil viscosity Incorrect oil level UNSTABLE HANDLING Handlebars b
34. IL FILTERS 103 ADJUSTING THE CLUTCH CONTROL LEVER 107 MAGNETO FLYWHEEL 108 CHECKING THE OVERRUNNING CLUTCH 109 GEARBOX CONROD AND GRANKSHAFT ASSEMBLY 110 CHECKING THE CRANKSHAFT AND CONROD ASSEMBLY 114 CHECKING THE GEARBOX 115 MISCELLANEOUS OPERATIONS 122 CHECKING THE VALVE CLEARANCE 124 CARBURETTOR 125 83 METE MOTORCYCLES ENGINE CHARACTERISTICS ENGINE Type 4 stroke single cylinder Cooling By natural air circulation Bore x stroke 54 x 54 mm Cubic capacity CG By chain Distribution Single overhead camshaft 2 valves Oil bath multi disc clutch with manual control 4 smooth discs Clutch 5 lining discs Gearbox speed Fuel supply Carburettor Mikuni VM20 Lubrication Trochoidal pump Spark plug CR ZHSA Starter motor Electric 400 VW Exhaust Non catalytic CAPACITIES TE 10W30 ENGINE MARKING AR Engine type E336E MEAN AKES 85 ENGINE SPECIAL IMPORTANT POINTS OIL AND FUEL This engine is designed to run 95 98 un V leaded fuel only Fuel pipes must absolutely be changed if there are any wear marks cracks etc If they have to be changed install genuine pi pes Petrol is highly inflammable do not smoke in the working area and avoid proximity to flames or sparks Work in a clear and well ventilated area Before carrying out any work
35. KED VERE MOTORCYCLES ENGINE REMOVAL OF THE ENGINE SPEED ADJUSTER SCREW AND MIXTURE CONTROL SCREW e Turn clockwise the engine speed adjuster screw 1 and mixture control screw 2 while counting the number of turns until they are screwed home e When re fitting this operation allows you to put them back to their initial adjutment position e Hemove the idle screw and the mixture control screw with their spring NOTE e Clean the body of the carburettor and its components with a cleanser e Blow into every jet and duct of the carburettor body with compressed air NOTE Y 127 ENGINE RE FITTING THE JETS FLOAT AND NEEDLE VALVE e Fit the jet spray nozzle 1 e Fit the main Jet 2 e Fit the idle adjuster screw 3 e Install the float on the carburettor body while fitting the needle valve into its recess e Fit the pin 6 into the float e Fit the paper gasket e Fit teh float chamber e Fit and tighten the 4 screws of teh float chamber e Position the needle valve 4 on the tongue of the float 5 Re install all the other components and if necessary when starting the engine readjust according to the va lues indicated on the technical data card NAKED MOTORCYCLES ADJUSTMENT CONTENTS TRANSMISSION CHAIN TENSION 131 LUTCH TENSION 132 THROTTLE CONTROL 132 TENSIONING THE
36. MBLY o assemble carry out the operations in reverse order MEAN AKES 7 7 CHASSIS SEAT REMOVAL Insert the key in the lock and turn 90 to the left e Pull the seat upwards and backwards ASSEMBLY e Fit the central tab A under the flange B e At the same time fit the two anchorages C located on both sides of the seat onto the chassis securing flanges e ower the back of the seat Turn the key 90 to the right and remove tt o MOTORCYCLES 77721 cHassis EFI PILLION PASSENGER SEAT REMOVAL e Remove the seat see section e Unscrew the 4 Allen bolts e Hemove the pillion passenger seat ASSEMBLY e Fit the pilllon passenger seat in its position e Screw on the 4 Allen bolts and 4 washers e Fit the seat see section REAR COWLING REMOVAL e Remove the seat see section e Remove the pillion passenger seat see section e Unscrew the 4 Allen bolts e Hemove the cowling ASSEMBLY e o assemble carry out the operations in reverse order CAUTION L CHASSIS GRILL REMOVAL Remove the front covers see section e Hemove the grill by pulling upwards ASSEMBLY o assemble carry out the operations in reverse order NUMBER PLATE REMOVAL e Remove the seat see section e Remove the pillion passenger seat see section
37. RCYCLES ELECTRICAL SYSTEM 14 ELECTRICAL FEATURES Maximum working features Param No Feature Simb Mim Max Units Lua a 20 m Pw Max current applicable wo inputs 20 m AF 20 mA PM5 Max current applicable to outputs Normal working features Um Eme e 08 Current absorption during On with all the light switched on Vbatt 1 3 0 Current absorption during On with all the light switched off lon Sele i tbd tbd mA Vbatt 1 3 0 Current absorption during Sleep to be determined MEAN AKES 81 ELECTRICAL SYSTEM 15 CONNECTOR PINOUT CONFIGURATION The connector is directly placed on the bottom side of the board Producer MOLEX Part Number 43045 1818 Meaning Meaning Not connected 14 GND SS 7 TATAE Male figure Female insertion side NAKED VERE MOTORCYCLES ENGINE TABLE OF CONTENTS CHARACTERISTICS ENGINE 85 CAPACITIES 85 ENGINE MARKING 85 SPECIAL IMPORTANT POINTS OIL AND FUEL 86 TIGHTENING TORQUES 87 SPECIAL TOOLS 88 CYLINDER HEAD CYLINDER PISTON 89 CHECKING THE CYLINDER 92 CHECKING THE PISTON 92 CHECKING THE PISTON RINGS 92 INSTALLING THE PISTON RINGS ON THE PISTON 93 SETTING THE TIMING 95 CLUTCH 99 CHECKING THE CLUTCH 102 CHECKING AND CLEANING THE O
38. VIP e Hemove the starter motor e Remove the transmission cover 9 fixing bolts e Hemove the transmission cover Tightening torque 1 m daN Hemove the paper gasket 1 and the 2 locating pins 2 Hemove the 4 bolts and spring 3 from the pressure plate 4 e Remove the set of 5 lined discs and the 4 smooth discs e Hemove the ball from the transmission input shaft MEAN AKES 99 ENGINE e Fold down the clutch nut 6 lockwasher tab 5 e ock the clutch main shaft 7 with tool P N 753731 e Remove the nut and the washer Immobilize the gears by fitting a copper washer bet ween the gears e oosen and remove the nut 8 from the conrod and crankshaft assembly and the washer e Hemove e he clutch main shaft 7 e splined bush 9 e clutch housing 10 e The plain washer 11 e he tapered washer 12 MH7 NAKED Ly MS 125cc MOTORCYCLES ENGINE e Remove the pinion 13 e Remove the key 14 from the crank e Remove the centrifugal filter 15 e Remove the drive gear from the oil pump 16 e Remove washer 1 7 e Remove the circlip e Remove the pinion 18 e Remove the tapered washer Remove the oil pump 2 fixing bolts 20 e Remove the oil pump and its gasket MinVZAINANE BS ENGINE CHECKING THE CLUTCH e Measure the thickness of the lined discs e Disc thickness 3 mm e Utilisation li
39. bar information Picture 10 3 third page Obs 10 1 If during the Start up phase the vehicle starts speed O the instrumentation will interrupt the check and will return to the standard operation mode Obs 10 2 If during the Start up phase the key will be turned off the instrumentation will interrupt the check and will return to sleep mode MH7NAKED VERE MOTORCYCLES ELECTRICAL SYSTEM 11 SLEEP MODE AND WAKE UP 11 1 Sleep mode The microcontroller enters the sleep mode phase with low current absorption when the key is turned off To reach this aim during sleep mode phase every activi ty will be interrupted the display and its backlighting will be off only the update of current hour is on Sleep mode phase can always be reached regardless from selected function 11 2 Wake Up Awakening from Sleep mode phase occurs when the key is turned ON Immediately after the microcontroller awakening follo wing activities happen e Check of the display and of lights for about 2 seconds e Visualization of selected wheel circumference of wheel turns impulses of unit of measurement and of graphic bars for about 2 seconds see picture 10 3 e Starting of last visualized function before sleep mode status and qualification of all functions 42 FIRST INSTALLATION OF DEVICE Default values of the device e Circumference 1 845mm Measurement unit of distance km h for speed and km for distance
40. daN 7 ENGINE e nstall the starter pinion 7 e nstall the starter pinion holder plate 8 Tightening torque 0 8 m daN e Install the timing chain e Install the the chain tensioner slipper Tightening torque 1 m daN e Fit e The circlip 9 e The washer 10 e The starter drive pinion 11 The kick starter pinion is on the engine but it is not used e The plain washer 12 e The circlip 13 MHZ NAKED 125cc ENGINE Install the star locking lever 10 and its spring 11 Tightening torque 1 m daN Install the star 12 and its 2 centering pins NOTE Tightening torque 0 8 m daN e Install the shift shaft 13 MEAN AKES 121 ENGINE MISCELLANEOUS OPERATIONS REMOVAL OF THE CAMSHAFT AND OR ROCKERS e Hemove the oylinder head e Remove the stopper plate e Remove the camshaft 1 e Using the intertia extractor e Remove the cam follower shafts Remove the inlet 3 and exhaust rockers REMOVAL OF THE VALVES OR VALVE STEM SEALS e Compress the spring of one of the valves using the valve lifter P N 754035 e Remove the 2 half cones e Uncompress the spring and remove the tool NAKED MAATE MOTORCYCLES ENGINE e Hemove e upper cup 1 e he spring 2 e he valve 3 Hemove the 2nd valve the same way NOTE NOTE e n case
41. described standard OFF J tall ON For 10 times consecutively before returning to the oU test menu During the succession of the screening it is possible e Turning on all the indicators lights and the backlight by pushing Up button e Turning off all the indicators lights and the backlight by pushing Down button e Viewing the velocity without increasing the kilometers arriving from the SENS IN 10 e Moving the pointer only during standard screen turn off the RPM signal before changing screen Due to this HPM 8 is set up so that the system de termine the shifting of the pointer of equal number Picture 19 2 entering automatic of steps to the incoming number of impluses test The direction of the shifting is determined by the Set button button which is not pressed shows an clock di rection while pressed button determines a direction of shifting of the index in anticlockwise direction N B 4 MEAN AKES 13 3 Erasing procedure E prom E PROM During the tests and the controls of the instrumen tation its useful erasing the E2prom memory To enter the procedure the Md button must be pres sed inside the correspondent screen in Test Menu by using Up and Down buttons the selection will occur 13 3 Now the display shows warning message Heset shown blinking picture 13 4 this operation IS IRRE VERSIBLE and deleted data can t be recovered By using Up or Down b
42. e does not come into contact with the skin or eyes when filling the battery In the event of electrolyte coming into contact with clothing or skin the affected part must be washed immedia tely with plenty of water and then washed with soap and water In the event of electrolyte coming into contact with the eyes the effected eye must be washed immediately with running water and the nearest medical personnel contacted Before disposing of the container it should be made safe by diluting the contents in water or neutralising it and then washing the contents with water oulphuric acid 41 opecific weight 1 32 MEAN AKES ERF COMMISSIONING WARNING CHECKING LEVELS 1 Check the gearbox oil level 2 Check the coolant level 3 Check the brake fluid level COMMISSIONING THE FUEL AND OIL CIRCUITS 1 Start up the engine and check that it is running correctly e Fill the tank up with 95 or 98 octane lead free petrol 1 Check the tightness of the wheel nuts Front wheel shaft nut tightening torque 1 2 daN m 12 N m Rear wheel shaft nut tightening torque 6 5 daN m 65 N m 2 Check tightness of nuts and bolts see Tightening torques 3 Check the adjustment and effectiveness of the brakes 4 Check the inflation pressure of the tyres when cold Front tyre inflation pressure 1 9 bars Rear tyre inflation pressure 2 bars 5 Check that the lights the turn indicators the
43. e headlight to the chassis e Tilt the headlight D forwards to make working easier e Remove the bulb connector E hen remove the dust guard F covering the bulb To remove the bulb e Press the securing clips e Remove the bulb H ASSEMBLY e o assemble carry out the operations in reverse order HEADLIGHT SIDELIGHT Hemove the front headlight main beam dipped beam bulb see section oosen the two bolts A securing the headlight e Tilt the headlight B forwards e Pull down the headlight housing C to extract the hea dlight e Then pull out the bulb D while holding the headlight housing with the other hand ASSEMBLY e o assemble carry out the operations in reverse order WARNING CAUTION NAKED VENE MOTORCYCLES ELECTRICAL SYSTEM REAR LIGHT REMOVAL To replace the rear light these operations must be ca rried out by way of the step for the rear wheel Disconnect the light from the wiring Hold the light with one hand e Remove the two nuts B securing the light to the num ber plate bracket ASSEMBLY e o assemble carry out the operations in reverse order MEAN AKES 7 ELECTRICAL SYSTEM Phillips screwdriver FRONT AND REAR TURN INDICATOR LIGHTS REMOVAL e Loosen the bolt A holding the screen e Remove the screen
44. e the pillion passenger seat see section e Remove the rear right hand cowling see section e Remove the right hand central cover see section e Disconnect and remove the fuse ASSEMBLY e To assemble carry out the operations in reverse order MEAN AKES 7 ELECTRICAL SYSTEM REMOVAL e Remove the seat see section e Disconnect the two connecting cables Negative A Positive B ASSEMBLY e To assemble carry out the operations in reverse order WARNING WARNING CAUTION NAKED VENE MOTORCYCLES ELECTRICAL SYSTEM DASHBOARD CONFIGURATION OR ADJUSTMENT e he instrument panel has two adjustment buttons SET 1 button and MODE 2 button Aim of the buttons is Allow functions scrolling Hegulation of the clock Set to zero the TD AVE LAP and MAX values Entering the Set up menu to modify the wheel cir cumference value the measurement unit value of dis tance the number of impulses for every turn of the wheel and of the engine and finally to associate the graphic bar to the selected information The function scrolling is always possible it means the passage from one function to the following one with the vehicle stopped or not update the instrumentation with the new function it s enough briefly pushing the bu tton tmin 1 sec when it will be left the display will show the new function The setting to ze
45. e the rotor 1 using the flywheel clamp P N 68570 e Hemove the nut 2 Tightening torque 7 m daN e By means of the 3 screws secure the flywheel extrac tor P N 758465 to the flywheel magneto ock the flywheel extractor and turn the thrust bolt until the rotor is released e Hemove the rotor and the overrunning clutch e Hemove the washer under the rotor NAKED MAITE MOTORCYCLES ENGINE CHECKING THE OVERRUNNING CLUTCH Hotate the overrunning clutch by hand e t must rotate in direction e t must be block in direction B e f it doesnt replace the overrunning clutch MEAN AKES 109 GEARBOX CONROD AND CRANKSHAFT ASSEMBLY REMOVAL OF THE GEARBOX REMOVAL OF THE CRANKSHAFT e Remove the cylinder head Remove the cylinder and the piston e Remove the primary drive Remove the flywheel magneto rotor e Remove the gear shift shaft 1 e Remove the screw that secures the star locking lever 2 Remove the lever and Its spring e Remove the star clamping screw 3 Remove the star and its 2 centering pins NAKED VERE MOTORCYCLES ENGINE e Hemove e circlip 4 e The washer 5 e The starter drive pinion 6 e The plain washer 7 e The circlip 8 The kick starter pinion is on the engine but it is not used Remove the screw which secures 9 the chain tensio ner slipper
46. ee section Disconnect the tap from the general wiring e Remove the pipe B from the tap e Remove the tank C e Unscrew the clamp D and remove the tap N B ASSEMBLY e To assemble carry out the operations in reverse order 7 71 CHASSIS REMOVAL e Remove the seat see section e Remove the pillion passenger seat see section Hemove the right and left hand rear cowlings see section e Hemove the number plate see section e Remove the battery see section e Unscrew the 7 bolts e Hemove the support ASSEMBLY o assemble carry out the operations in reverse order FRONT MUDGUARD REMOVAL e Unscrew the 4 bolts e Remove the front mudguard ASSEMBLY e To assemble carry out the operations in reverse order CAUTION VENE MOTORCYCLES CHASSIS FRONT FOOTRESTS REMOVAL e Unscrew the nut e Remove the bolt Allen Remove the footrests ASSEMBLY e o assemble carry out the operations in reverse order EDU REAR FOOTRESTS REMOVAL e Remove the clip and the washer Remove the key B and the washer e Remove the spring C e Remove the footrest N B WARNING ASSEMBLY e To assemble carry out the operations in reverse order 31 CHASSIS CHAIN REMOVAL e Situate the securing clip de A
47. en the gears e Tighten the nut 15 Tightening torque 7 m daN e Lock the clutch main shaft 16 with tool P N 753731 e Tighten the nut 17 Tightening torque 6 m daN e Fold over the clutch nut washer locking tab e Fit the ball into the input shaft e Fit the clutch discs starting with a lined disc 18 and then alternate smooth and lined discs 19 MEAN AKES 105 ENGINE e When re assembling ensure that the marks B on the smooth discs are offset by 90 from the others e Fit the pressure plate 20 lining up the arrow C on the plate with the round imprint D on the clutch main shaft Tightening torque 0 6 m daN e Fit the pressure plate springs 21 and the 4 bolts and washers 22 MH7 NAKED Ly MS 125cc MOTORCYCLES ENGINE ADJUSTING THE CLUTCH CONTROL LEVER e Slacken the pressure plate locknut 1 e Bring the lever into contact with the control rod e Check that the mark A of the lever is lined up with the notch B of the crankcase e t is isn t adjust with the screw 2 e Tighten the locknut without altering the adjustment Tightening torque 0 8 m daN 107 7 ENGINE MAGNETO FLYWHEEL TO REMOVE THE MAGNETO FLYWHEEL e Hemove the bolts that secure the cover Remove the flywheel magneto cover e Remove the paper gasket and the two 2 centering pins Tightening torque 1 m daN e Immobiliz
48. ence min 1 000mm max 2 500mm e Number of pulses for every turn of the wheel min 1 max 12 e Number of pulses for every turn of the engine min 1 max 8 e Measurement unit of distance km h or mph To save the modifications in the memory it is necessary that the set up procedure is completed using the Mode button by keeping pressed the Mode button in corres pondence of the measurement unit selected When the dashboard is in the set up menu if Velocity becames gt O e The button is not pushed for 20 seconds The dashboard will exit from setup menu without saving any changes and will restore the previous values Only in the case in which the procedure of Set Up is completed in a correct way the system goes on with the saving in permanent memory of all the made selections ELECTRICAL SYSTEM Picture 8 1 parameters set up menu factory factory factory factory user NAKED VERE MOTORCYCLES 7772 ELECTRICAL SYSTEM 8 2 Modifications allowed to user input 5 discon nected 8 2 1 Distance unit measurement regulation The display the symbols km h and mph will be shown the selected value will be shown first blinking f21Hz Duty 50 picture 8 2 Pressure on Set button causes the change in shown blinking unit while the Mode button pressure in corres pondence of blinking unit allows to select the same unit and the passage to following screen or going o
49. ent or incorrectly fitted Top support incorrectly fitted Bottom support fitted incorrectly badly tightened lock nut Bent steering shaft Damaged ball bearings or bearing guide ring Uneven fluid levels in the two front fork arms Uneven fork spring tension in the two front fork arms Broken fork spring Inner tube bent or damaged Duter tube bent or damaged Worn bearing or hose Swinging arm bent or damaged Faulty rear shock absorber spring Oil or gas leak Uneven tire pressures front and rear Incorrect tyre pressure Uneven tyre wear Incorrect wheel balancing Broken or loose spokes Damaged wheel bearing Bent or loose wheel shaft Excessive decentring of the wheel Bent frame Damaged steering column tube Incorrectly fitted bearing guide ring MH7 NAKED Ly MT 125cc MOTORCYCLES TROUBLESHOOTING FAULTY LIGHTS OR TURN INDICATOR SYSTEM THE HEADLIGHT DOES NOT COME ON Incorrect headlight bulb many electrical accessories Excessive load Incorrect connection Circuit incorrectly connected to earth Faulty contacts main switch Blown headlight bulb BLOWN HEADLIGHT BULB Incorrect headlight bulb Battery faulty Headlight bulb blown THE REAR LIGHT BRAKE LIGHT DOES NOT COME ON Blown rear light bulb Brake light bulb Too many electrical accessories Incorrect connection
50. ento vinculante en cuanto a las especificaciones actuales ni constitutivo de oferta de venta por este veh culo 2007 G H E MOTORHISPANIA S L Todos los derechos reservados Ninguna parte de esta publicaci n puede ser reproducida transmitida de ninguna forma ni por ning n medio electr nico mec nico para ning n uso sin la autorizaci n por escrito de MOTORHISPANIA S L This catalogue shows the specifications and equipment of MH vehicles sold through the MOTORHISPANIA official dealer network in country desire to improve the design specifications and production of our vehicles may end up in modifications of what is shown here Even though we undertake all possible measures to ensure that the information in this catalogue is exact and precise it may have errors and it should not be considered as entail able to the shown specs This catalogue is not intended to act as a sales tool for the vehicles ontinen fal rplus EMPRESA CEATIFIC DA ISO 9001 EC 0000 00 ACREDITADO POR ENAC
51. il Oil tank capacity COOLING Type IGNITION Type Spark plug CARBURETTOR Type Main jet Idling jet Needle Position Float height Air screw position TRANSMISSION Type Primary transmission Secondary transmission Gearbox Gearbox capacity Clutch MAGNETO STARTER MOTOR MHZ NAKED 125cc YAMAHA 123 7 12 5 litres 10W30 1 Litre Air Electric NGK CR6HSA MIKUNI 3D6 10 95 15 oQ6J3 2 18 9 mm 1 1 8 turns Final by chain Gears 68 x 20 Chain 52 x 14 O speed Te MORIC 3D9 SPECIFICATIONS Single cylinder 4 stroke 54 mm X 54 mm 7 5 Kw a 9000 min 1 9 4 Nm a 6500 min 1 95 98 octane lead free petrol Primary by gears Electric Kick start lever VE a MOTORCYCLES SPECIFICATIONS ENGINE SPECIFICATIONS Multidisk multidisks bathed in oil with manual control MEAN AKES BODYWORK Side covers Front mudguards Hear mudguards okirting CHASSIS Front wheel shaft Front wheel shaft clamp Hear wheel shaft nut Suspension arm nut Engine chassis mounting Shock absorber top mounting Shock absorber base mount Forks I sections Front brake calliper Rear brake calliper Front brake disk Rear brake disk Support on chassis steering lock STANDARD 5 mm diameter bolt and nut 6 mm diameter bolt and nut 8 mm diameter bolt and nut 10 mm diameter bolt and nut 12 mm diameter bolt and nut
52. in MEAN AKES g5 ENGINE e Fit the gear in the chain on one of the sides e Using a tool with a small diameter finish fitting the chain around the gear e Fit the gear on the camshaft Make sure the mark I of the camshaft gear isaligned with the mark B of the cylinder head e f necessary dislodge the gear from the camshaft without removing it and move the chain around the gear on the required side e Install the camshaft gear e mmobilize the flywheel magneto using a wrench pre tighten the camshaft gear Tightening torque 2 m daN MH7 NAKED EE 125cc MOTORCYCLES 2563 ENGINE e oosen the chain tensioner as indicated e Fit the chain tensioner seal respect the position of ins tallation e Install the chain tensioner and the 2 attachment screws Tightening torque 1 m daN e Install the tensioner cap Tightening torque 0 8 m daN Check the alignment of the timing marks of the flywheel magneto with the mark A of the cover and of the cams haft gear with the mark B of the cylinder head e In case of misalignment start the operation again from the beginning MEAN AKES 97 Install the timing gear 1 cover Tightening torque 1 m daN e Install the timing mark cap 2 e Fit the central cap 3 MH7 NAKED Ly MT 125cc MOTORCYCLES ENGINE CLUTCH REMOVAL OF THE CLUTCH REMOVAL OF THE OIL PUI
53. leave the engine to cool for at least 2 hours MHZNAKED SVETE MOTORCYCLES 7772 ENGINE TIGHTENING TORGUES Cylinder head 1 m daN 2 2 m daN Cylinder casings 1 m daN Transmission cover 1 m daN Inlet manifold 1 m daN Camshaft gear e m daN Camshaft gear cover 1 m daN Chain tensioner 4 m daN Chain tensioner 1 m daN Conrod and crankshaft assembly gear m daN Clutch housing 6 m daN Clutch pressure plate 0 6 m daN Oil pump 0 7 m daN Gearshift star 0 8 m daN Gearshift lock 1 m daN Clutch thrust bearing locknut 0 8 m daN Starter motor 1 m daN Rotor 7 m daN Flywheel magneto cover 1 m daN Gearbox drain plug e m daN Spark plug 1 2 m daN MEAN AKES 87 Designation Used Designation with Casing Casing extractor opening Pin nut and plate 2541002000221 2541002000216 opening twl pin 2541002000214 Shouldered Clutch lever 2941002000215 centering 2941002000214 2041002000222 lip seal fitting tool tool Pin 12 2541002000216 Pitch 125 2541002000221 2541002000223 Fixed flange pite locking tml Engine mount adapter 2541002000217 2541002000224 Valve lifter Flywheel E ME 2041002000218 2941002000225 mount 2941002000215 clamp adapter Externa 2541002000213 circlips pliers 2541002000226 1 Protective Casing 2541002000220 end piece 29410020002
54. mileometer take off C e Fit the nut A and tighten it e Fit the shaft with the bolt D e Fit the front mudguards see section NZ cnassis NAKED VERE MOTORCYCLES cHassis FRONT BRAKE CALLIPER remova e Unscrew the banjo bolt A from the bottom end of the brake hose e rain the brake fluid e Unscrew the 2 bolts and washers e Hemove the calliper N B ASSEMBLY e Fit the calliper e Secure with the 2 bolts and washers e Fit the banjo bolt A e Refill the fluid reservoir see section FRONT BRAKE DISK REMOVAL e Remove the front wheel see section e Unscrew the 6 bolts e Remove the disk ASSEMBLY e To assemble carry out the operations in reverse order MEAN AKES 35 IZ cHAssis REAR WHEEL oosen the tensioner locking nut e Tighten the bolt B right down e Remove the 2 nuts C from the shaft e Remove the 2 tensioners D e Push the wheel forwards e Remove the chain E e Pull the shaft to free the brake calliper support e Pull the shaft to free the separator the wheel and the other separator WARNING N B NAKED VERE MOTORCYCLES 77721 cuassis REAR WHEEL aee N B e Fit the tensioner A on the swinging arm e nsert the shaft in the tensioner e Fit the brake calliper support e Fit the separator e Fit
55. mit 2 8 mm e Measure the length of the springs e Spring length 33 mm e Utilisation limit 31 mm e Check the condition of the notches of the clutch housing and the condition of the splines of the clutch gear e n case of severe wear replace the parts MH7 NAKED Ly MS 125cc MOTORCYCLES ENGINE CHECKING AND CLEANING THE OIL FILTERS e Clean the centrifugal filter by dipping it into a cleanser Blow through the holes of the centrifugal filter with compressed air e Check and clean the strainer 1 MinVZAINANE BS ENGINE FITTING THE OIL PUIVIP e Install the oil pump and a new gasket 1 Tightening torque 0 7 m daN e nstall the tapered washer 2 the humped side to the oil pump e nstall the pinion 3 e nstall the circlips 4 FITTING THE CLUTCH e Install the conrod and crankshaft assembly e he washer 1 e pinion 2 e The centrifugal filter 3 the F mark outwards e he key 4 e The pinion 5 the C mark outwards e he washer 6 and the nut 7 e Fit to the primary shaft e tapered washer 8 with the round endtowards the bearing e The plain washer 9 e he clutch housing 10 e The splined bush 11 e The clutch main shaft 12 e tab washer 13 and the nut 14 MH7 NAKED Ly EE 125cc MOTORCYCLES ENGINE e mmobilize the gears by fitting a copper washer bet we
56. move the 2 bolts and the 2 securing nuts e Hemove the shock absorber N B ASSEMBLY e o assemble carry out the operations in reverse order NAKED VERE MOTORCYCLES cHassis SWINGING ARM REMOVAL e Remove the chain protector see section e Remove the chain see section e Remove the rear wheel see section e Remove the shock absorber the bottom part see section e Remove the rear brake cable clamp located at the bottom of the swinging arm e Remove the trim B Remove chain roller e Unscrew the nut A on both sides e Remove the swinging arm shaft e Remove the swinging arm CAUTION ASSEMBLY e o assemble carry out the operations in reverse order 7 7 CHASSIS REMOVAL e Hemove the handlebars see section e Hemove the front wheel see section Remove the headlight see section e Hemove the instrument panel see section e Remove the ignition switch see section Remove the front mudguards see section e Remove the mudguard brackets A e Remove the nut and washer B e Loosen the 2 bolts C from the top plate e Remove the fork tubes from the bottom e Remove the top plate CAUTION ASSEMBLY e To assemble carry out the operations in reverse order MH7 NAKED Ly MS 125cc MOTORCYCLES CHASSIS Unscrew the plug e Remove the O ring B the
57. of operation saving possible modifications MEAN AKES 5 5 Automatic Chronometer Function LAP This function describes the correct working visualization of the chronometer related to TD and AVE This information is visualized by using digit 13 16 and logo LAP The data represents the effective route time of the vehi cle in the form mm ss if hours O pic 5 8 and in the form hh mm if hours O pic 5 9 It is automatically activated by the first pulse coming from the speed sensor and it stops after 3 seconds from receiving of the last pulse which arrives from the speed sensor If hours gt when LAP is operative the digit that separates the hours from the minutes is shown blinking while it is shown fixed when LAP is not opera tive If hours when LAP is operative the digit and that separates the minutes from the se conds is shown blinking while it is shown fixed when LAP Is not operative The data isn t memorized in a permanent mode It is possible to set to zero the counter of this parame ter by pushing the Set button for about 2 seconds in correspondence of the function LAP till when the value OO OO appears The setting to zero of LAP which is possible both when the vehicle is stopped or when the vehicle is running produces the setting to zero of TD and AVE too If the data gets over the value 23 59 which means e3h59 59 the system provides to set to zero LAP TD and AVE then it s
58. of the lining of the pads e Service limit lining 1mm CLEANING THE AIR FILTER Remove the air filter sponge e Wash with FILTER CLEAN Hinse and dry the filter Impregnate with AGIP FILTE oil e Eliminate the excess by pressure TYRES Tyre pressure HEAH 1 5 bar bar Minimum tread depth O 8 mm 139 MAINTENANCE STEERING REMOVAL Loosen the bolts on the 2 plates Hemove the front calliper see section Free the wheel forks assembly from the top plate e Remove the plug B the washer Remove the top plate handlebars assembly C CAUTION The inside of the steering e Remove the oil seal D e Remove the spacer pipe E e Remove the oil seal F ASSEMBLY e To assemble carry out the operations in reverse order MH7NAKED VERE MOTORCYCLES WME O This section includes all the information needed for forming all the recommended maintenance and com missioning operations Observing these procedures will ensure the machine functions more reliably and has a longer useful life while reducing the need for costly repair work REINFORCED MAINTENANCE PLAN Heinforced maintenance is aimed at machines used in severe conditions driver mood short journeys with a cold engine
59. om the cover C e Remove the cover C and the rubber D up with fluid if necessary Hecommended fluid DOT 3 DOT 4 REAR BRAKE FLUID screwdriver Allen key The brake fluid reservoir is located behind the lever e There is an inspection window A in the reservoir to view the fluid level e Check that the level is correct If not carry out the following steps Remove the two bolts B and place the reservoir in a horizontal position e oosen the two bolts C on the cover D Remove the cover D and the rubber e Top up with fluid if necessary Fluid DOT 3 DOT 4 TVAE NINE ES I9 OIL LEVEL Before carrying out this operation turn off the engine and remove the oil cap located on the right hand side of the engine e he cap incorporates a dipstick A that will indicate the level of the oil e Hemove the cap e Wipe the dipstick dry A e Refit the cap e Hemove the cap again and check the level marked on the dipstick Recommended oil SAE 10W30 SPARK PLUG ATTENTION e Standard spark plug CH6HSA Abnormal colour Henew The normal colour is light brown e Inspect Electrode A Insulator B e Measure Gap between electrodes C 0 6 mm O 7 mm MAINTENANCE MH7 NAKED aVE EE 125cc MOTORCYCLES MAINTENANCE BRAKE PADS e Measure the thickness A
60. rameter expresses the number of impul ses that the vehicle sends to the instrumentation for every engine tree revolution The chosen value is shown blinking with f 1Hz Duty 5094 Visualization on the display picture 8 5 has RPM on digit 10 12 Pressure of Set button allows the unit increase of engine turns impulses from a minimum of 1 to a maximum of 8 Pressure of Mode button allows the value confirmation and the exit from Set up menu 7 ELECTRICAL SYSTEM Picture 8 4 wheel turns regulation Picture 8 5 engine turns regulation MHZNAKED SVETE MOTORCYCLES ELECTRICAL SYSTEM The information concerning the number of impulses of the engine is saved in memory Obs 8 7 Once inside the regulation menu f 20 sec will pass without the button mode is pushed or e f the vehicle is turned on speed gt Q e if the key is turned OFF The system will be automatically taken to the standard operating mode and the modifications possibly produced will be lost 8 3 4 Distance unit measurement regulation oee paragraph 8 2 1 8 4 Regulations sequence Input 11 disconnected X RU WHEEL ENGINE Input 11 connected to 55 WHEEL REVOLUTION REVOLUTION MEASUREMENT CIRCUMFERENCE PULSES UNIT PULSES 13 ELECTRICAL SYSTEM 9 MODE AND SET BUTTONS FUNCTION Aim of the buttons is e Allow functions scrolling Regulation of
61. re 13 1 entering manual test NAKED MOTORCYCLES E ELECTRICAL SYSTEM Now the system starts the display check by lighting all segments in series at the end of the check screen in picture 5 2 will be visualized the total distance covered from the vehicle appears unit of measurement km e Every time Mode button is pressed the system starts pointer s check that follows the movement of all the route foreseen on the dial from zero to end of the scale and return e By using Up button it is possible to turn on all the in dicators lights and backlighting only of the dial because display backlighting is always By using Down button it is possible to turn off all in dicators lights and backlighting only of the dial because display backlighting is always In this function is also possible to show the velocity without improving TOTAL or TD By using button it is possible to exit from Manual Test and come back to Test Menu 13 2 Automatic test procedure COLL AUTO Its an useful procedure to verify the instrumentation through an automatic equipment To enter the pro cedure button must be pressed inside the corres pondent screen in Test menu by using Up and Down buttons the selection will occur pic 13 2 Now the system wil show the standard screen except for the battery charge graphic bar By pushing the Mode button it is possible to change the screen as
62. ro of TD of the chronometer of the average and max speed can be done both with the vehi cle stopped or in movement as described in the previous paragraphs Clock regulation is possible only when vehicle Is stopped The entering in the Set up menu is possible only when the vehicle is stopped by pushing at the same time the two buttons for about 4 seconds the back up of all data will be done only when the Mode and Set buttons it depends on selected set up chosen will allow the exit from the oet up menu MinVZAINANEB ELECTRICAL SYSTEM ATTENTION 1 AIM This document constitutes the technical manual with functional specifications for speedometer 2 REFERENCES M A E electronic devices general contract 3 SYSTEM GENERAL DESCRIPTION Display LCD driver Stepper motor Microcontroller Depas pas eae a gg BI 197812121511 BBI p button Connector MODE button Vehicle feeding MH7NAKED MOTORCYCLES ELECTRICAL SYSTEM 4 COMPONENTS DEFINITION 4 1 LCD Display 4 2 Mode Set buttons Picture 4 1 lcd display The device has got two buttons normally OPEN that close on a NEGATIVE Button 1 MODE Button 2 SET Functions and use of buttons is described in following pa ragraphs of the technical manual 9 FUNCTIONAL CHARACTERISTICS 9 1 Instant speed function Nm
63. securing nut A to set the position TENSIONING THE REAR BRAKE To increase or decrease the tension of the rear brake e Loosen the securing nut e Turn the threaded wheel B to increase or decrease the action of the rear brake e Use the securing nut A to set the position ADJUSTMENT GEAR CHANGE PEDAL Adjust the position of the gear change pedal to adapt the position to your requirements e Put the gear change pedal in neutral position e Unscrew the bolt e Place in the desired position e oosen the nuts B Adjust the tension using the bar C e Set the position with the nuts B e Set the position with the bolt CARBURETTOR e Adjust the carburettor idling speed using the screws Idling speed 1 e Mixture 2 MH7NAKED MOTORCYCLES MAINTENANCE CONTENTS FRONT BRAKE FLUID 137 REAR BRAKE FLUID 137 FLUID LEVEL 138 SPARK PLUG 138 AIR FILTER CLEANING 139 BRAKE PADS 139 TYRES 139 STEERING 140 MAINTENANCE PLAN 141 135 NAKED VENE MOTORCYCLES MAINTENANCE FRONT BRAKE FLUID The brake fluid reservoir is next to the right hand lever e There is an inspection window A in the reservoir to view the fluid level e Check that the level is correct If not carry out the following steps e oosen the two bolts B fr
64. t may however prove useful as a guide for basic fault findingUse this manual to consult the corresponding checking adjusting and part renewal procedures FAILURE TO START ENGINE Loose park plug Cylinder or cylinder head damaged Damaged cylinder head gasket Damaged cylinder gasket Cylinder worn or damaged Incorrect valve clearance Seized valve Wrongly fitted piston ring Damaged worn or fatigued piston ring Seized piston ring seized or damaged piston Air filter incorrectly fitted Air filter element obstructed Crankcase fitted incorrectly seized crankshaft Cylinder head gasket damaged FUEL SYSTEM Fuel tank empty Fuel tank drain pipe blocked Altered or contaminated fuel Carburettor air suction blocked ELECTRICAL SYSTEMS Flat battery Faulty battery Fuse blown damaged or incorrect Fuse fitted incorrectly Incorrect spark plug gap Oiled up spark plug Electrode worn or damaged Insulation worn or damaged Faulty spark plug cap Primary or secondary coils broken or short circuited Faulty spark plug cable Faulty main switch Faulty engine stop switch Broken or short circuited wiring Faulty neutral light switch Faulty starter switch Loose connections Faulty starter motor TROUBLESHOOTING INCORRECT IDLING SPEED ENGINE
65. tarts again the counting Obs 5 5 If there is no feeding the LAP value 15 hopeless lost 5 6 Average speed function AVE This function describes the correct working visualization of average speed function related to TD and LAP The information is visualized by using digit 13 16 and logo AVE pic 5 10 The data represents the average speed of the vehicle expressed in Km h or in Mph depending on the selec ted measurement unit that is calculated as ratio bet ween covered distance TD and the time used to cover this distance LAP The average speed is updated every O 1 Km O 1 Miles depending by measurement unit selected 7 ELECTRICAL SYSTEM Picture 5 8 lap in format mm ss Picture 5 9 lap in format hh mm MH7NAKED VERE MOTORCYCLES ELECTRICAL SYSTEM The data isnt memorized in a permanent mode Its possible to set to zero the counter of this parameter pushing the Set button for about 2 se conds in correspondence of the function AVE till when the value O O appears The setting to zero of AVE which is possible both when the vehicle is stopped or when the vehicle is run ning produces the setting to zero of TD and LAP too Picture 5 10 Average speed indi cation AVE setting to zero is foreseen when LAP function arrives to 23 59 59 value or when TD function rises 999 9 value If the data is out of range it will be visualized as shown in picture 5
66. the end of the crank ass embly e Fit to casing with tool P N 64706 fitted with plate P N 758466 e Centre the assembly to the casing with 4 bolts 1 e Fit centring tool P N 64710 to tool P N 64706 e Tighten pin nut P N 69104 on pin P N 64712 in order to bring the crankshat assembly into contact with the bearing ensuring that the crank is pointing towards the oylinder side FITTING THE GEARBOX 1 EN JOT e Put the clutch pushrod 1 in the input shaft A m DP e Install at the same time the input shaft ans secondary E TM IT 1 shaft assembly the crankcase e m m MEAN AKES 117 7 ENGINE e nstall the shift fork as shown Marking A is upwards Install the selector cylinder 2 e Fit the shift fork guides into the grooves of the oylinder e nstall the shift fork pins 3 e Install the balance shaft 4 by lining up the mark of the balance shaft pinion with the mark of the conrod and crankshaft assembly MH7 NAKED aVE EE 125cc MOTORCYCLES ENGINE e Make sure the gasket seat of the RH and LH crankca ses is perfectly clean e Fit the 2 centring pins 5 e Put gasket seal paste on the LH crankcase gasket seat Place the RH casing over the LH casing assembly No tools are necessary for assembling the Y casings which shall be carried out without effort e Fit and tighten the 10 fixing bolts 6 Tightening torque 1 m
67. ut from regulation depending on 5 input Picture 8 e distance unit misure regulation The information concerning the selected measurement unit is saved in memory Obs 8 1 Changing measurement unit will cause the conversion of TOTAL and will set to OOO O TD Obs 8 2 Once inside the regulation menu f 20 sec will pass without the button mode is pushed or e f the vehicle is turned on speed gt Q or e f the key is turned OFF The system will be automatically taken to the sta dard operating mode and the modifications possibly produced will be lost 8 3 Modifications allowed to the factory input 5 connected to gnd 8 3 1 Wheel circumference modification The display is introduced as shown in picture 8 3 where the information of wheel circumference is visualized on digit 13 16 preceded by the letter crf on digit 10 12 Picture 8 3 wheel circumference regulation Its possible modifying the various digits which constitute the value of the wheel circumference leaving from the most significant digit and moving in series towards the least significant digit otarting from the selected data that will be shown blin king with f 1 Hz Duty 50 a short pressure of the Set button will allow unitary increase while a long pressure of Mode button will allow to select a different digit The selected circumference of the wheel is saved in me mory MEAN AKES Obs 8 3 Regulation from
68. utton it is possible to fail this operation and come back to Test menu By using button it is possible to go on with the ope ration and completely erase the whole memory A confirmation message fixed logo Reset will remem ber the operator the possible need to make pointer ca libration The return to Test menu will be possible by using whate ver of the three buttons Up or Down 13 4 Pointer s procedure of calibration IND The calibration is useful to correct eventual mis takes of position made during the phase of setting out of the pointer enter this procedure the Md button must be pres sed inside the correspondent screen in Test menu by using Up and Down buttons the selection will occur pic 13 5 Now the display will ask to the operator to put in micro step numbers necessary to allow the pointer to reach the zero on silk screen printing By using Up button it is possible to start movement of the pointer in clockwise direction By using the Down button it is possible to start movement of the pointer in anticlockwise direction By using button it is possible to exit from Auto matic test procedure and come back to previous The selected value will be saved in a permanent me mory ELECTRICAL SYSTEM Picture 13 3 entering E prom erasing Picture 13 4 Erasing procedure warning ind ePi Picture 13 5 Entering pointer calibration NAKED S N MOTO
69. where it can be seen e Hemove the securing clip e Hemove the chain by pulling it out N B ASSEMBLY oosen the tensioner locking nut e Tighten the bolt B right to the end e oosen the 2 shaft nuts C e Push the wheel forwards e Remove the sprocket protector D e Fit the chain onto the front sprocket and the rear sprocket e Fit the securing clip e Adjust the tensioners e Fit the 2 wheel shaft nuts NAKED VERE MOTORCYCLES CHASSIS REMOVAL e Unscrew the 4 bolts e Hemove the protector ASSEMBLY o assemble carry out the operations in reverse order GEAR CHANGE PEDAL REMOVAL e Unscrew the 2 bolts Hemove the gear change pedal ASSEMBLY e o assemble carry out the operations in reverse order 33 FRONT WHEEL e Remove the front mudguards see section Remove the A left hand side wheel shaft nut e Remove the mileometer take off C Loosen the bolt D on the right hand fork arm securing the shaft B e Extract the wheel B until the separator E the wheel and the separator F are freed WARNING N B ASSEMBLY e Insert the shaft B into the right hand fork arm e nsert the separator F on the shaft e Fit the wheel and insert the shaft B e Insert the separator E e nsert the shaft B into the left hand fork arm e Fit the
70. xceed O 45 mm e he out of round values measured on the ends of the crank should not exceed 0 03 mm and must be measu red e 30 mm from the transmission side end e 60 mm from the flywheel magneto end e Check the condition of the bearing and timing pinion 1 f there is too much play in the bearing or if the ti ming pinion is excessively worn replace the conrod and crankshaft assembly NAKED VERE MOTORCYCLES ENGINE CHECKING THE GEARBOX e Check the condition of the ends A and the guide B of the shift forks e Check the condition of the grooves C of the selector oylinder Check the condition of every gear e Check that every gear slides and rotates on the corre ponding shaft Check the condition of the sliding gear and idler gear driving dogs If a component has to be changed replace also V the component which is associated ENGINE FITTING THE CRANK ASSEMBLY RH BEARING The bearing is positioned into the casing by means of a press FITTING THE SEALS AND GASKETS e Using tool P N 753729 fit the clutch lever seal The gearbox output and gear shift shaft seals are to be positioned flush with the crankcase NAKED MOTORCYCLES ENGINE FITTING THE CONROD AND CRANKSHAFT ASSEMBLY e Fit the conrod and crankshaft assembly into the LH crankcase Tighten pin P N 64712 at
71. you remove the seal of a valve stem 5 replace it with a new seal after removing all the carbon residues which could remain inside the cylinder head MEAN AKES 123 7 ENGINE CHECKING THE VALVE CLEARANCE Removal of the camshaft gear cover 1 e Removal of the central plug 2 e Using a wrench turn the crankshaft counterclockwise so as to align the crankshaft gear mark 1 with the oylin der head mark e Using the set of feeler gauges measure the clearance of each valve Clearances e 10 100 at the intake e 15 100 at the exhaust e f the clearance is not correct adjust by means of the cam follower screw MH7 NAKED Ly EE 125cc MOTORCYCLES 2563 ENGINE CARBURETTOR REMOVAL OF THE THROTTLE VALVE e Unscrew the carburettor chamber 1 Dismantle the valve equipped with its needle spring and carburettor chamber cap e Dismantle the needle 2 by pushing it out in order to remove the clips 3 REMOVAL OF THE FLOAT NEEDLE VALVE AND JETS e Remove the 4 screws that secure the float chamber 1 e Hemove the chamber MEAN AKES 125 ENGINE e Remove the paper gasket Hemove the float 3 pin 2 e Remove the float and the needle valve e Hemove the idle jet 4 e Remove the main jet 5 Hemove the jet spray nozzle 6 e Check the condition of the needle valve and the needle valve seat NA

- KAVIR Motor

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