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2. inspection and adjustment

1. MODE BK9 AIR CLEANER TYPE PAPER FILTER _ TOTAL LENGTH mm 1880 FUELTANK 0 6 8 amp 3 9 TOTAL WIDTH mm 715 D CVK Z HEIGHT mm 1160 a THROTTLE VALVE DIA 0 26 2 WHEEL BASE mm 1340 VENTURIDIA 0 23 lt FRONT 39 VALVE TYPE BUTTERFLY DRY WEIGHT kg REAR 71 TYPE C D I TomL 110 SPARK ADVANCE BTDC 13 2950rpm o FRONT 65 SPARKPLUG CR7HSA TOTAL WEIGHT kg PERSON TEK REAR 120 T SPARK PLUG GAP 0 0 6 0 7 TomL 185 BATTERY 12V 7AH TYPE m PRIMA TRANSM CMT Z SECONDARY TRANSM GEAR 92 95 UNLEADED 0 CENTRIFUGAL FUEL TYPE GASOLINE 2 CLUTCH CYLINDER NO SINGLE 5 PRIMA 1 0 90 2 40 F REDUCTION RATIO BORE STORKE mm 57 4 58 4 SECOND 1 7 8 15 42x14 39 DISPLACEMENT c c 151 HEAD LAMP H L 12V 35W 35Wx1 STARTER ELECTRIC KICK o REARLAMP 12V 5Wx1 FORCED AIR 5 BRAKE LAMP 12V 21Wx1 COOLING ON TURN LAMP 12V 10Wx4 LUBRICATION PUMP SPLASH 80 80 14 amp 110 80 14 INTAKE VALVE GAP mm 0 08 0 10 FRONT REAR or Z EXAUST VALVE GAP mm 0 08 0 10 x 110 80 14 amp 110 80 14 LLI IDLING SPEED rpm 1800 100 kPa REAR 210 TORQUE N mirpm 111 14 6500 LEFT 5 STEERING ANGLE MAX POWER kW rpm 7 89 7
2. Primary Coil Black White Green 0 1 1 0 Ohm Secondary Coil Green Spark Plug Cap 7 12k Ohm A Exciting Coil Inspection Disassembly The exciting coil TP 20 Ground Measure A Use megga meter s positive terminal to connect exciting coil s black red terminal B Connect the megga meter s Exciting Coi 8 8 negative terminal with frame Black Red Terminals ground and measure the Note 1 The standard resistance is 300 1000 Ohm 20 C 2 If the resistance is higher than standard then it is broken Please replace with new one 95 B Pulse Coil Inspection Disassembly The pulse coil connector Measure A Use megga meter s positive terminal to connect pulse coil s blue yellow terminal B Connect the megga meter s negative Pulse Coil a T erminal terminal with body ground and measure the resistance Note 1 The standard resistance 40 300 Ohm 20 C 2 If the resistance is higher than standard then it is broken Please replace with new one 96 C Ignition coil Inspection Disassembly Remove spark plug Remove ignition coil s plastic cover Ignition coil s primary coil Ignition coil s tightening attaching bolt Ignition Coil Assembly Assembly is in reverse order of disassembly procedures Note Connect the black white wire to black terminal and green wire to green terminal D Primar
3. Inspection Check if the shock absorber is worn scratched leaking or bent If its condition is poor please replace with new one Note Torque of shock absorber upper and lower attaching bolts 200 300 kg cm 80 5 ELECTRICAL SYSTEM 5 1 Operating Cautions amp Troubleshooting Operating Cautions 1 Warning a The liquid in the battery is diluted sulfuric acid that is dangerous If your skin or eye unfortunately get contact with it please wash with water abundantly and consult immediately a doctor lest you should lose vision b If your clothes is touched by the electrolyte your skin would also be touched Therefore you should get it off and wash with water abundantly 2 Check if electrolyte in the battery is sufficient If not add distilled water till the liquid level reach the upper limit line 3 The battery is rechargeable after discharging If it is unused after discharge it may deteriorate and shorten service life It will become less efficient After usage of 2 3 years battery capacity will decrease It can be regained by recharging several times 4 When there is other loads while igniting if the voltage will rise again after an abrupt falling it is normal 5 If a battery is unused during a long time its energy storage will decrease by its auto discharge Therefore a recharging is necessary around every 3 months 6 To charge a battery it shall be removed from the car and its filler plugs removed
4. 12V 21Wx1 COOLING COOLING TURN LAMP 12V 10Wx4 LUBRICATION PUMP SPLASH 130 60 13 130 60 13 INTAKE VALVE GAP mm 0 08 0 10 FRONT REAR 0r120 70 12 130 70 12 EXHAUST VALVE GAP mm 0 08 0 10 ss 0r120 70 12 120 70 12 1 SPEED km hr 90 TIRE PRESSURE FRONT 175 IDLING SPEED rpm 1800 100 kPa REAR 210 MAX TORQUE N m rpm 7 90 7800 LEFT 45 STEERING ANGLE MAX POWER kW rpm 16 47 7800 RIGHT 5 COMPRESSION RATIO 92 1 BRAKE FRONT DISK CYLINDER PRESSURE 8 570 REAR DRUM 0 cm rpm UPAO FRONT TELESCOPE ENGINE OIL TYPE SAE 10W 40 REAR ROCKER ARM ENGINE OIL QUANTITY c c 900 FRAME STEEL TUBE GEAR OIL TYPE SAE 90 GEAR OIL QUANTITY 120 BF8 PRODUCT SPECIFICATION MODE BFS AIR CLEANER TYPE PAPER FILTER TOTAL LENGTH mm 1890 lt FUEL TANK t 6 80 3 9 amp TOTAL WIDTH mm 715 2 CVK 02 2 TOTAL HEIGHT mm 1115 ig THROTTLE VALVE DIA 0 24 gt 2 WHEEL BASE mm 1280 T amp VENTURIDIA 0 22 1 lt FRONT 47 THROTTLE VALVE TYPE BUTTERFLY DRY WEIGHT kg REAR 68 C D I T 1115 SPARK ADVANCE BTDC 13 2950rpm o FRONT 78 2 SPARK PLUG NGK CR7HSA TOTAL WEIGHT kg T x PERSON oka
5. 150 200 1 Cooler Fan Lock CR M6x18 500 800 4 Wire Assembly Lock Screw M6x20 800 1000 2 Start Clutch Gear ightening Nut M22 R T 800 1000 1 Driven Belt Pully Assembly M12 400 600 1 Gearbox Cover Tightening Bolt M6x28 100 1200 3 M6x35 3 Gearbox Oil Fill Cover Screw M8 90 150 1 Gearbox Oil Drain Cover Screw M8x12 90 150 1 Clutch Side Cover Screw M6x40 50 80 6 M6x65 2 Starter Arm Tightening Screw M6x22 100 120 1 1 6 LUBRICATION POINTS BR8 Representative Figure Brake Oil Brake Assembly Grease x Steering Bearing Engine Oil Speed Mater Cable Grease Speed Meter Gear Front Wheel Axle Bearing Chassis Grease Inner Side of Acceleration Lever Dreasa Seat Cover Lock Engine Oil E Rear Brake Cable Grease Rear Wheel Axle Bearing Engine Oil Throttle Cable Grease Main and Side Stand Axles Lubrication Area Lubrication Type Inner Side of Acceleration Lever Steering Bearing Speed Meter Gear Front Wheel Axle Bearing Front Wheel Axle Main and Side Stand Axles Rear Wheel Bearing Seat Cover Lock Speed Meter Cable Throttle Wire Rear Brake Cable Grease Brake Assembly Brake Fluid Engine Lubrication Area Lubrication Type Piston and Piston Rings Piston Pin Big End of Connecting Rod Rocker Arm Frictional Contact Area Shaft and Chain Cylinder Frictional Area Oil Pump Chain Gears Contact Surface Bearing Opera
6. Curve A With regular maintenance the performance can be improved to optimal condition with maintenance at scheduled time Curve B Without regular maintenance the performance drops and engine can be damaged Therefore the engine needs repair to re gain high performance and the motorcycle s life can be shorten 27 2 2 INSPECTION AND CHANGE OF ENGINE OIL Watch Please place main stand to park the motorcycle for inspection Inspection Stop engine for 2 3 minutes when itis warmed Remove the engine oil level and check if the oil level is bellow the lower limit Fill engine oil to the level between upper and lower limits Change Engine Oil Note Please change engine oil according to regular maintenance schedule If ridden on heavy load or long distance please shorten the maintenance schedule for oil change e Please put oil tray under the left crankcase and remove the oil drain plug Re install the drain plug when the engine oil is drained Clean up the oil filter Inspection 1 If O ring is damaged please replace with new one 2 If there is any deposit please use clean up before re assembly Note 1 Torque of oil strainer screen 150 200 kg cm 2 Lubrication Type SAE 10W 40 Engine oil capacity BH8 BR8 BF8 125c c Engine disassembled 900c c change oil 750 c c BR9 BF9 151c c Engine disassembled 1000c c change oil 900 c c 3 Check if there is any leakage after oil
7. OIL QUANTITY c c 1000 FRAME STEEL TUBE GER OIL TYPE SAE 90 GEAR OIL QUANTITY 120 BF9 PRODUCT SPECIFICATION MODE BF9 AIR CLEANER TYPE PAPER FILTER _ TOTAL LENGTH mm 1890 FUELTANK 0 6 8 3 9 LLI TOTAL WIDTH mm 715 P CVK O TOTAL HEIGHT mm 1115 fy THROTTLE VALVE DIA 1 26 ea gt WHEEL BASE mm 1280 VENTURI DIA 0 23 lt FRONT 48 THROTTLE VALVE TYPE BUTTERFLY DRY WEIGHT kg REAR 76 z TYPE C D I z 124 SPARK ADVANCE 13 2950 FRONT 77 SPARK PLUG NGK CR7HSA TOTAL WEIGHT kg 3 PERSON 78k REAR 122 5 SPARK PLUG GAP D 06 07 199 BATTERY 12V T PRIMA TRANSM C VT Zz O SECONDARY TRANSM GEAR 92 95 UNLEADED 2 CENTRIFUGAL FUEL TYPE CA OLINE 3 CLUTCH TYPE CYLINDER NO SINGLE 5 PRIMA 110 90 2 40 F REDUCTION RATIO STORKE mm 57 4 58 4 SECOND 1 7 8 15 42 14 39 DISPLACEMENT c c 151 HEAD LAMP L 12V 35W 35Wx1 STARTER ELECTRICO KICK REARLAMP 12V 5Wx1 FORCED AIR 5 BRAKE LAMP 12V 21Wx1 COOLING COOLING TURN LAMP 12V 10Wx4 LUBRICATION PUMP SPLASH 130 60 13 130 60 13 INTAKE VALVE GAP mm 0 08 0 10 FRONT REAR 0r120 70 12 13
8. REAR 112 5 SPARK PLUG GAP D 06 07 190 BATTERY 12V PRIMA TRANSM C VT TYPE 4T z SECONDARY TRANSM GEAR 92 95 UNLEADED 2 CENTRIFUGAL FUEL TYPE acl INE 2 CLUTCH PE CYLINDER NO SINGLE 5 PRIMA 1 0 90 2 40 F REDUCTION RATIO STORKE mm 52 4 57 8 SECOND 1 9 45 14 43 13 40 DISPLACEMENT c c 124 HEAD LAMP L 12V 35W 35Wx1 STARTER ELECTRICO KICK a REAR LAMP 12V 5Wx1 lt COOLING TURN LAMP 12V 10Wx4 LUBRICATION PUMP SPLASH 130 60 13 130 60 13 uu INTAKE VALVE GAP mm 0 08 0 10 FRONT REAR or120 70 12 130 70 12 Z EXAUST VALVE GAP mm 0 08 0 10 X or120 70 12 120 70 12 TOP SPEED km hr 90 TIRE PRESSURE FRONT 175 IDLING SPEED rpm 1800 100 kPa REAR 210 MAX TORQUE N m rpm 7 90 7800 LEFT 45 STEERING ANGLE 2 MAX POWER kWirpm 6 47 7800 RIGHT 5 COMPRESSIONRATIO 92 1 FRONT DISK BRAKE CYLINDER PRESSURE 42 8570 REARS RUM rpm FRONT TELESCOPE SUSPENSION SYSTEM ENGINE OIL TYPE SAE 10W 40 REAR ROCKER ARM ENGINE OIL QUANTITY 900 FRAME STEEL TUBE GEAR OIL TYPE SAE 90 GEAR OIL QUANTITY cc 120 BR9 PRODUCT SPECIFICATION MODE BR9 AIR CLEANER TYPE PAPER FILTER TOTAL LENGTH mm 1860 FUELTANK 0 6 8 3 9 Z TOTAL WI
9. To put the charging current ON or OFF you must operate at the charger s switch You shall not connect or pull off directly on the battery because electric spark may provoke hydrogen explosion 7 During battery charging hydrogen H2 is produced It is an inflammable gas Fire must be forbidden 81 8 At recharging a battery the temperature of electrolyte shall be lower than 45 C 9 To test if a battery is fully charged please use a voltmeter Never use Spark method 10 When there is current in an electrical installation please do not pull off a contact then connect it again because resulting over voltage may damage electronic parts in the commuter Therefore this operation must be done after the main switch is put OFF 11 If fresh electrolyte is poured in a new battery a voltage will be generated after a certain lapse of time If the voltage is not sufficient then a recharging is necessary A recharged new battery has necessarily a longer lifetime 12 The C D I of the ignition system shall not fall swinging and be shocked It is a cause of frequent breakdown Therefore a special precaution is necessary in its dismounting and remounting 13 Bad contact between plug and jack causes often the breakdown of the ignition system Therefore before undertaking repair the contact is to be checked at first 14 Spark plugs of a suitable heat value and gap are to be used Otherwise engine will not wor
10. assembly to avoid damaging seal lip area which may lead to oil leak The manufacturer logo should face outward in assembly Apply grease at seal lip area 8 Please do not presses twist and over scratch the wire cable to avoid bad wire contact 9 Disconnect the battery negative terminal before maintenance Connect the positive terminal first in assembly Apply a thin layer of grease on terminals and cover with terminal caps 10 1 3 SAFETY PRECAUTIONS Warning Engine Exhaust Please keep good ventilation during engine operation Do not operate engine in closed room The toxic carbon oxygen CO in exhaust may lead human to loss conscious and even death Warning Gasoline The gasoline is very easy to burn or explode Forbid any fire during inspection of gasoline tank or gasoline leak Warning Battery H2 and Battery Liquid 1 The battery liquid is toxic sodium liquid Please do not contact the liquid with skin or eye If any contact happens please wash with massive clean water and contact with doctor 2 The released battery is explosive Please keep good ventilation during charging battery and forbid any fire Watch Brake Fluid The brake fluid can damage the painting on plastic Please cover the plastic parts with towel or cloth during maintenance of brake disk If the brake fluid is split on plastic component please remove the fluid and wash the surface with water right away Watch High Temperature of Eng
11. inside diameter of valve stem seal Wear limit of inlet valve stem seal is 0 08mm Wear limit of exhaust valve stem seal is 0 10mm Measure the width of the impression on the valve seat Wear limit is 1 8mm maximum Lubricate the valve stems and suit them to the guides Fit the springs the upper cups and the lock cones Fit the valves with special tool carefully The springs may come off it is dangerous Gently tap the valve stems with a plastic nammer to make the cones in their seats Be carefully when doing this work Insert the two rocker arms shaft Fit a new cylinder head gasket and keep the surfaces of gasket and keep the surfaces of gasket clean 47 Assembly the cylinder head Turn the flywheel Let the T mark on the flywheel to aim at the rib mark on the crankcase The circle hole on the camshaft gear is upward and the two mark line on the camshaft gear match with surface of the cylinder head Fit the camshaft gear and fit the chain on this camshaft gear Fit the dowel pin Fit the camshaft holder Fit the nuts on the related studs and tighten them by diagonal step Tightening torque is 200 kg cm Install the chain guide Loose the lock by turning the nut with counter clock direction Adjusting the valves Should align with rotate the crankshaft by hand until the circle hole marks on camshaft gear wheel and the other two mark line cylinder head then adjust the plays of the valves with s
12. main stand to park the motorcycle for maintenance Disassembly Speed meter cable nut 2 tightening bolts on clipper Clipper Note Do not apply brake when removing clipper from brake disk Otherwise the lining can contact Front wheel Inspection Check eccentricity and wear condition Note If eccentricity is higher than 0 2mm please replace with new one to ensure driving safety Speed meter gear assembly Inspection of Wheel Rim Put wheel rim on rotation stand Rotate the wheel slowly and use dial gauge to measure eccentricity Note 1 The transverse eccentricity should be within 3 0 mm If the condition is poor please replace with new one 76 2 The lateral eccentricity should be within 3 0mm If the condition is poor please replace with new one Be Careful Items in Assembly 1 Speed meter gear assemble fillister and wheel hub flange should be fully matched 2 The wheel hub flange fillister and front fork flange should be fully matched Note 1 Torque of rear wheel axle self lock nut 600 900 kg cm 2 Torque of brake clipper tightening bolt 210 250 kg cm 3 Torque of speed meter cable nut G0kg cm 77 4 4 REAR WHEEL Watch Please place main stand to park the motorcycle for maintenance Disassembly Exhaust pipe Lock screw nut and washer Rear wheel Note 1 Please use vacuum to clean wheel rim and lining Try to reduce the cont
13. meter to measure its inside diameter BH8 Wear limit 25 0mm maximum BR8 BF8 BR9 BF9 Wear limit 24 06mm maximum Note Take care to replace the rollers in their original positions 62 Spacer Make sure the spacer surface should not be damaged Measure the outside diameter of the spacer BH8 Wear limit 26 0mm minimum BR8 BF8 BR9 BF9 Wear limit 23 94mm minimum 3 7 5 Guide shoes Inspect the guide blocks should not be worn and then inlay them into the movable drive plate Assemble the movable drive plate cover 63 3 7 6 Clutch housing Inspect for any unusual damage and color change Replaced if the inside diameter exceeds 125 5mm 3 7 7 Driven pulley Remove the central nut with compass spanner to lock the driven pulley Warning Press tightly the driven pulley while unscrewing the nut so that the spring will not jump out 3 7 8 Retaining sheet Pull out the retaining sheet by hand Pull out the guide pins and extract the movable drive face from the fixed driven face 64 3 7 9 Fixed driven face comp Measure the outside diameter of the fixed driven face bush Wear limit 33 94mm 3 7 10 Movable driven face comp Measure the inside diameter of the movable drive face Wear Limit 234 06mm 3 7 11 Spring Measure the free length of the movable driven face spring Replaced if the free length of spring is less than 135mm 3 7 12 Fixed driven face comp bearings Pu
14. not within the limit then change the brake disk F Rear Brake Adjustment Note The free play of rear brake lever 10 20 mm Adjustment Adjust the adjustment nut 32 G Inspection of Brake Lining and Wheel Rim Inspection Check the wear indicator plate If the index is higher than the limit please check the wear of wheel rim and brake lining Disassembly 2 tightening bolts on exhaust pipe connector 2 tightening bolts between exhaust pipe and right crankcase Tightening nut on rear wheel axle Washer Rear wheel Inspection check rear wheel rim inner diameter If it is badly worn please replace with new one Note 1 Please use vacuum to clean wheel rim and lining Try to reduce the contamination of asbestos fiber which may affect the human breath system or lead to cancer 2 Use the Vernier calipers to measure the diameter of wheel rim If the diameter is larger than 111 mm then replace with new one 33 Note BH8 Wear limit 111mm minimum BR8 BF8 BK8 9 BF9 BK9 Wear limit 131mm minimum Disassemble the brake shoe and brake shoe spring Inspection Measure the brake lining thickness with three points of Vernier calipers two ends and center If badly worn please replace with new one brake shoe and brake shoe spring Note 1 Useable thickness is 2 0 mm 2 If less than useable thickness please replace with new parts Assembly As
15. the flywheel side crankcase half to the transmission side crankcase half Fit the crankcase halves coupling screws Tightening torques 90 kg cm 53 3 5 FUEL REED CIRCUIT 3 5 1 Carburetor Disassemble all carburetor components clean them with solvent then dry them with compresses air Pay special attention to the ducts in carburetor body Carefully check the condition of all components The needle may be worn replace it The throttle must slide free in the carburetor If there is excessive play due to wear the throttle must be replaced Using the new gaskets when reassembling the carburetor Inspect if the pressure piston is worn or presents notches Inspect the vacuum membrane carefully Damaged or cut are not allowed 3 5 2 How to take off the carburetor Remove the fuel feed pipes Remove the automatic by choke connector Loosen the throttle control cable adjusting nut and disconnect the throttle control cable from the carburetor Loosen the air filter fastening strap and remove the carburetor 54 3 5 3 Automatic Choke The needle of automatic choke must keep well Notches signs of wear scratches or other damage are not allowed 3 5 4 Membrane chamber Loosen the drain screw and let the fuel flow out from the float chamber Remove the two screws of the pressure chamber 55 Remove the compression spring and the pressure piston Remove the needle holder and the needle from
16. 0 70 12 Zz JEXAUST VALVE mm 0 08 0 10 a or120 70 12 120 70 12 LLI TOP SPEED km hr 97 TIRE PRESSURE FRONT 175 IDLING SPEED rpm 1800 100 kPa REAR 210 MAX TORQUE N m rpm 111 14 6500 LEFT 5 STEERING ANGLE MAX POWER kWirpm 7 89 7250 RIGHT 5 COMPRESSION RATIO 110 80 1 FRONT DISK BRAKE CYLINDER PRESSURE 42700 REAR DRUM 0 rpm FRONT TELESCOPE SUSPENSION SYSTEM ENGINE OIL TYPE SAE 10W 40 REAR ROCKER ARM ENGINE OIL QUANTITY 1000 FRAME STEEL TUBE GEAR OIL TYPE SAE 90 GEAR OIL QUANTITY c c 120 BH8 PRODUCT SPECIFICATION GEAR OIL QUANTITY c c 110 MODE BH8 AIR CLEANER TYPE PAPER FILTER TOTAL LENGTH mm 1790 FUEL TANK 0 6 8 Z TOTAL WIDTH mm 675 oe CVK 2 O TOTAL HEIGHT mm 1080 fy THROTTLE VALVE DIA 0 24 ea gt WHEEL BASE mm 1240 VENTURI DIA 0 22 1 lt FRONT 35 THROTTLE VALVE TYPE BUTTERFLY DRY WEIGHT kg REAR 58 C D I TOTAL 93 SPARK ADVANCE BTDC 13 2950rpm gt FRONT 63 2 SPARK PLUG NGK CR7HSA TOTAL WEIGHT kg cg IPERSON fe 106 z SPARK PLUG GAP D 086 07 168 BATTERY 12V 7AH PRIMA TRANSM 4T z SECO
17. 250 RIGHT 5 COMPRESSION RATIO 10 8 1 FRONT DISK BRAKE CYLINDER PRESSURE ion REAR PROM cm rpm FRONT TELESCOPE SUSPENSION SYSTEM ENGINE OIL TYPE SAE 10W 40 REAR ROCKER ARM ENGINE OIL QUANTITY c c 1000 FRAME STEEL TUBE GEAR OIL TYPE SAE 90 GEAR OIL QUANTITY 120 1 2 INSPECTION PRECAUTIONS 1 The measurements use IS system for bolts and bolt heads Please do not use British system for the bolts and nuts otherwise it can damage the motorcycle 2 Please clean parts outside deposits before maintenance Otherwise the deposits may drop into engine and damage engine in operation 3 Please use kerosene or diesel to clean up disassembled parts Check and measure parts after clean up The parts contact and sliding surface should apply engine oil for lubrication 4 The packing metal gasket O ring seal clamp and clipper should be replaced with new ones after disassembly 5 Please pay attention to the orientation and relative positions of the major components Arrange the parts in order during disassembly Make marks if necessary to avoid mistakes in re assembly 6 Loosing the parts should start from small to big from outside to inside and in alternative parts Assembly is in reverse order of disassembly procedures 7 oil seals should be replaced with new ones after disassembly The contact surface should be cleaned up Check if the contact axle has scratches or burry Use special tools for
18. 4 0 020 Outer diameter of piston pin 14 994 15 000 14 960 14 994 15 000 14 960 Inner diameter of the hole at connecting 15 016 15 034 15 060 15 016 15 034 15 060 small end Blow with compressed air the parts after cleaning and before measuring 43 Simplified troubleshooting n case of bad ignition not running smoothly in low speed check if there is white smoke issuing from air intake of the crankcase If it is the case dismount the cylinder piston piston rings and measure them according to the above table The causes may be the wear or break of piston pins If there is white smoke issue from muffler its causes may be Wear or break of piston pins Serious wear of pistons and cylinders due to friction 9 Wear of connecting rod small end holes and piston rings Knocking pistons Serious damage of cylinders pistons and piston rings by friction wear Wear of piston pins and piston pin holes Low compression rate Wear or break of piston rings 9 Wear or damage of cylinder walls and pistons Too narrow gap or no gap at all of valve Gap between valve and its seat Valve burnt Valve untimely Spark plug not tightened Gas leak at cylinder head washer Too high compression rate Piston head or combustion chamber unclean Abnormal engine noise Bearing of the end transmission mechanism loosened Bearing of crank loosened 44 3 2 RELE
19. ASE THE ENGINE 3 Disconnect the terminals of the battery Disconnect the electric terminals of the various components Disconnect the fuel feed pipe and the vacuum cock control pipe Disconnect the throttle valve control wire of carburettor Release the rear brake cable Release the shock absorber Remove the engine mounting shaft screw 3 INSTALLATION OF THE ENGINE Assemble the engine on the chassis by following the steps described for its disassembly in reverse order Inspect the engine lubricate oil with the oil level indicated Check the operation of the carburetor and accelerator Adjust the rear brake 3 4 CHECK THE ENGINE PARTS 3 4 1 Air Cleaner Remove the seven fixing screw of the air cleaner cover Inspect the filter is keep clean or not Change a new filter if it is badly dirty or broken 3 4 2 Spark Plug Unscrew the spark plug with specified tool Examine the spark plug does any dirty deposit carbon or burn out Clean the spark plug if has dirty or deposit carbon with steel brush Measure the clearance of the spark gap The gap standard is 0 6 0 7 mm 3 4 3 Cylinder head and Timing Remove the fan cover cooling fan and shroud set Release the cylinder head cover bolt remove the cylinder head cover Turn the flywheel with clockwise direction let the T mark on the flywheel point to the rib mark on crankcase Then the circle hole mark on the cam shaft gear will be upward positi
20. DTH mm 675 CVK O TOTAL HEIGHT mm 1145 fy THROTTLE VALVE DIA 0 26 gt WHEEL BASE mm 1270 VENTURIDIA 0 23 lt FRONT 44 THROTTLE VALVE TYPE BUTTERFLY DRY WEIGHT kg REAR 74 C D I Tota 118 SPARK ADVANCE BTDC 13 2950rpm FRONT 72 5 SPARKPLUG NGK CR7HSA TOTAL WEIGHT kg E L PERSON 78k REAR 121 g SPARK PLUG GAP D 06 07 193 BATTERY 12V 7AH TYPE i PRIMA TRANSM C VT Zz SECONDARY TRANSM GEAR 92 95 UNLEADED 2 CENTRIFUGAL FUEL TYPE CA OLINE 3 CLUTCH TYPE CYLINDER NO SINGLE 5 PRIMA 1 0 90 2 40 F REDUCTION RATIO BORE STORKE mm 57 4 58 4 SECOND 1 7 8 1542x14 39 DISPLACEMENT c c 151 HEAD LAMP L 12V 35W 35Wx1 STARTER ELECTRICO KICK a REARLAMP 12V 5Wx1 FORCED 3 BRAKE LAMP 12V 21Wx1 COOLING COOLING TURN LAMP 12V 10Wx4 LUBRICATION PUMP SPLASH 130 60 13 130 60 13 INTAKE VALVE GAP mm 0 08 0 10 FRONT REAR 0r120 70 12 130 70 12 Zz EXAUST VALVE mm 0 08 0 10 a or120 70 12 120 70 12 LLI TOP SPEED km hr 97 TIRE PRESSURE FRONT 175 IDLING SPEED rpm 1800 100 kPa REAR 1210 MAX TORQUE N m rpm 111 14 6500 LEFT 5 STEERING ANGLE 2 MAX POWER kWirpm 7 89 7250 RIGHT 5 COMPRESSION RATIO 110 80 1 FRONT DISK BRAKE CYLINDER PRESSURE 42700 REAR 0 rpm FRONT TELESCOPE SUSPENSION SYSTEM ENGINE OIL TYPE SAE 10W 40 REAR ROCKER ARM ENGINE
21. LATION OF ENGINE 3 1 Starterd preparation data Simplified troubleshooting Disassembling of Crankcase Before disassembling the crankcase the engine must at first dismounted and the following operations must be completed Air cleaner carburettor and air intake mounted Starter motor Cylinder head cover cylinder head Cylinder piston Clutch cover drive pully comp driven pully comp Rear wheel rear shock absorber Cooling fan flywheel magneto Oil pump Standard preparation data for crank cylinder piston and piston rings Unit mm 125 c c Engine 151 c c Engine Item Checking part Standard value Allowable limit Standard value Allowable limit Cylinder Cylinder inner diameter 52 400 52 410 52 500 57 400 57 410 57 500 Roundness 0 05 0 05 Cylinder degree 0 05 0 05 Piston and Piston outer diameter 52 370 52 390 52 300 57 375 57 395 57 300 piston rings Inner diameter of piston pin 15 002 15 008 15 040 15 002 15 008 15 040 Gap between cylinder and piston 0 010 0 040 0 100 0 005 0 035 0 100 Gap between Top ring 0 015 0 055 0 090 0 015 0 050 0 090 Piston and piston Second ring 0 015 0 055 0 090 0 015 0 050 0 090 ring Gap of piston ring Top ring 0 10 0 25 0 50 0 015 0 300 0 50 Second ring 0 10 0 25 0 50 0 015 0 300 0 50 Lateral track of 0 2 0 7 0 2 0 9 oil scraper ring Gap between piston and piston pin 0 002 0 014 0 020 0 002 0 01
22. LECTRICAL SYSTEM OPERATING CAUTIONS amp TROUBLESHOOTING BATTERY SHORT CIRCUIT TEST RECTIFIER STARTER RELAY STARTER MOTOR A C GENERATOR RESISTOR CDI UNIT APPENDIX CIRCUIT DIAGRAM FOR BR8 54 59 60 67 70 72 76 78 80 81 86 87 87 88 90 92 94 95 98 1 GENERAL INFORMATION 1 1 SPECIFICATIONS BR8 PRODUCT SPECIFICATION MODE BR8 AIR CLEANER TYPE PAPER FILTER TOTAL LENGTH mm 1860 z FUEL TANK 2 6 8 Z TOTAL WIDTH mm 675 CVK Z HEIGHT mm 1145 M THROTTLE VALVE DIA 0 24 ea WHEEL BASE mm 1270 VENTURI DIA 22 1 FRONT 43 THROTTLE VALVE TYPE BUTTERFLY DRY WEIGHT kg REAR 68 C D I T 111 SPARK ADVANCE BTDC 13 2950rpm z FRONT 72 SPARK PLUG NGK CR7HSA TOTAL WEIGHT kg E 1 PERSON 75kg fe 114 SPARK PLUG GAP 0 6 0 7 LLI TOTAL 186 BATTERY 12V PRIMA TRANSM i n 6 SECONDARY TRANSM GEAR o 92 95 UNLEADED 2 CENTRIFUGAL FUEL TYPE GASOLINE 2 CLUTCH TYPE lt CYLINDER NO SINGLE 2 PRIMA _ 1 0 90 2 40 BORE STORKE mm 152 4 57 8 F REDUCTIONRATIO SECOND 119 45 14 43x13 40 DISPLACEMENT c c 124 HEAD LAMP H L 12V 35W 35Wx1 STARTER ELECTRIC KICK REAR LAMP 12V 5Wx1 gt FORCED AIR lt BRAKE LAMP
23. LVE Disassembly Cylinder head bolt Cylinder head Note 1 Inspect and adjust are performed at engine temperature lower than 35 C 2 Rotate the cooler fan such that the mark on cam shaft gear match the top dead center position and the T mark on flywheel match the mark on crankcase Then perform check and adjustment Adjustment Use valve adjust wrench to loose tightening bolt and rotate nut to adjust gap Note Intake valve gap 0 08 0 10 mm Exhaust valve gap 0 08 0 10 mm Watch Check if the gap is correct after bolt is tightened 39 2 13 HEADLIGHT AXLE Use cross screw driver to adjust the nut Note 1 Rotate the nut clockwise for higher light axle 2 Rotate the nut counter clockwise for lower light axle 2 14 V BELT Watch Please place main stand to park the motorcycle for inspection Disassembly Loose the cooler tube tightening ring Kicker starter arm tightening bolt Kicker starter arm 8 clutch side cover tightening bolts Clutch side plate Gasket 40 Use universal wrench to tight the drive plate and remove lock nut and gasket Drive plate V belt Inspection Check if the V belt has cracked threaded and pilling If it is in poor condition please replace with new V belt TS Note E 1 Check the belt length Wear limit 18 0 mm or 8000km 2 Belt specification BH8 BANDO VS BELT 743 20 30 B
24. NDARY TRANSM GEAR 92 95 UNLEADED 2 CENTRIFUGAL FUEL TYPE GASOLINE 5 CLUTCH TYPE ae CYLINDER NO SINGLE 5 PRIMA 1 0 77 1 2 19 F REDUCTION RATIO BORE STORKE mm 152 4 57 8 SECOND 1 8 61 15 42x13 40 12V 35WI35W DISPLACEMENT cc 124 HEAD LAMP L apr STARTER ELECTRICO KICK REARLAMP 12V 5Wx1 lt 2 BRAKE LAMP 12V 21Wx1 COOLING CODE CA TURN LAMP 12V 10Wx4 LUBRICATION PUMP SPLASH INTAKE VALVE mm 0 08 0 10 FRONT REAR 120 90 10 110 90 10 EXAUSTVALVEGAP mm 0 08 0 10 2 Lu e TOP SPEED km hr 87 TIRE PRESSURE FRONT 175 IDLING SPEED rpm 1800 100 kPa REAR 7210 MAX TORQUE N m rpm 7 90 7800 LEFT 45 STEERING ANGLE 2 POWER kWirpm 6 47 7800 RIGHT 45 COMPRESSIONRATIO 9 20 1 FRONT DISK BRAKE CYLINDER PRESSURE 42 8570 REMIS BRUM rpm FRONT TELESCOPE SUSPENSION SYSTEM ENGINE OIL TYPE SAE 10W 40 REAR ROCKER ARM ENGINE OIL QUANTITY c c 900 FRAME STEEL TUBE GEAR OIL TYPE SAE 90 BK8 PRODUCT SPECIFICATION MODE BK8 AIR CLEANER TYPE PAPERFILTER TOTAL LENGTH mm 1880 FUEL TANK 0 6 8 5 WIDTH mm 715 2 CVK Z HEIGHT mm 1160 ty THROTTLE VALVE DIA 0 24 gt 2 WHEEL BASE mm 1304 T VENTURIDIA 0 22 1 lt FRONT 38 THR
25. OTTLE VALVETYPE BUTTERFLY DRY WEIGHT kg REAR 70 TYPE C D I T 108 SPARK ADVANCE BTDC 13 2950rpm o FRONT 64 SPARK PLUG NGK CR7HSA TOTAL WEIGHT kg PERSON REAR 119 5 SPARK PLUG GAP D 0 6 0 7 183 i BATTERY 12V PRIMA TRANSM C VT TYPE 4T z SECONDARY TRANSM GEAR 92 95 UNLEADED 2 CENTRIFUGAL FUEL TYPE 2 CLUTCH TYPE CYLINDER NO SINGLE 5 PRIMA 1 0 90 2 40 F REDUCTION RATIO BORE STORKE mm 52 4 57 8 SECOND 1 9 45 14 43 13 40 DISPLACEMENT c c 124 HEAD LAMP L 12V 35W 35Wx1 STARTER ELECTRIC amp KICK REAR LAMP 12V 5Wx1 FORCED AIR 5 BRAKE LAMP 12V 21Wx1 e COOLING TURN LAMP 12V 10Wx4 LUBRICATION PUMP amp SPLASH 80 80 14 amp 110 80 14 INTAKE VALVE GAP mm 0 08 0 10 FRONT REAR or Z EXAUST VALVE GAP mm 0 08 0 10 X 110 80 14 amp 110 80 14 TOP SPEED km hr 90 TIRE PRESSURE FRONT 175 IDLING SPEED rpm 1800 100 kPa REAR 210 MAX TORQUE N m rpm 7 90 7800 LEFT 45 STEERING ANGLE MAX POWER kWirpm 16 47 7800 RIGHT 5 COMPRESSION RATIO 92 1 FRONT DISK BRAKE CYLINDER PRESSURE 42 8570 REAR BRUM cm rpm FRONT TELESCOPE SUSPENSION SYSTEM ENGINE OIL TYPE SAE 10W 40 REAR ROCKER ARM ENGINE OIL QUANTITY 900 FRAME STEEL TUBE GEAR OIL TYPE SAE 90 GEAR OIL QUANTITY c c 120 BK9 PRODUCT SPECIFICATION
26. R8 BF8 BR9 BF9 BANDO VS BELT 846 20 30 Assembly Assembly is in reverse order of disassembly procedures Warning Please do not apply any grease on pulley and V belt which can cause belt slip Note 1 Diver plate screw is left threaded 2 Torque of driver plate nut 800 1000 kg cm 3 Torque of clutch side nut 50 60 kg cm 4 Torque of kick starter arm screw 100 120 kg cm 41 2 15 CYLINDER PRESSURE Note 1 Check the cylinder pressure at warm engine condition 2 Use compressed air to blow away deposits around spark plug before removing spark plug Otherwise deposits may drop into cylinder and damage engine Disassembly Spark plug cap Spark plug Inspection 1 Install cylinder pressure gauge 2 Full open fuel valve 3 Ignite the starter motor by pressing the start button and measure cylinder pressure Note 1 Cylinder pressure BH8 BR8 BF8 125c c engine 12 8 570 kg cm rpm BR9 BF9 151c c engine 11 7 700 kg cm rpm 2 Reasons of too high cylinder pressure A Carbon deposits at combustion chamber B Carbon deposits on piston top surface 3 Reasons of too low cylinder pressure A Valve gap too small B Worn valve seat or seat is not completely closed Incorrect valve timing Leakage due to worn cylinder gasket Worn piston ring Worn piston and cylinder wall 4 Tordik on spark plug 100 120 kg cm mono 42 3 RELEASE AND INSTAL
27. TABLE OF CONTENTS 1 GENERAL INFORMATION 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 SPECIFICATIONS INSPECTION PRECAUTIONS SAFETY PRECAUTIONS SPECIAL TOOLS TIGHTENING TORQUE LUBRICATION POINTS PARTS NAME TROUBLE SHOOTING 1 8 1 Troubleshooting for Failure in Starting the Engine 1 8 2 Troubleshooting for Poor skip of Spark Plugs 1 8 3 Troubleshooting for No Skip of Spark Plugs 1 8 4 Troubleshooting for Slow Run Troubled Engine 1 8 5 Poor Acseleration and Horse Power 2 INSPECTION AND ADJUSTMENT 2 1 2 2 2 3 2 4 2 5 2 6 2 7 2 8 2 9 2 10 2 11 2 12 2 13 2 14 2 15 REGULAR MAINTENANCE SCHEDULE INSPECTION AND CHANGE OF ENGINE OIL FINAL GEAR OIL BRAKE SYSTEM TIRE AND TIRE PRESSURE AIR CLEANER BATTERY SPARK PLUG FUEL FILTER CARBURETOR IDLE SPEED THROTTLE VALVE VALVE HEADLIGHT AXLE V BELT CYLINDER PRESSUR 3 REMOVAL AND INSTALLATION OF ENGINE 3 1 3 2 3 3 3 4 STANDANTD PREPARATION DATA amp SIMPLIFIED TROUBLESHOOTING RELEASE THE ENGINE INSTALLATION OF THE ENGINE CHECK THE ENGINE PARTS 1 PAGE 10 11 12 14 16 18 19 22 23 24 25 27 28 29 30 35 35 36 37 37 38 38 39 40 40 42 43 45 45 45 4 1 4 2 4 3 4 4 4 5 5 5 1 5 2 5 3 5 4 5 5 5 6 5 7 5 8 5 9 FUEL FEED CIRCUIT LUBRICATION DRIVING PULLY CLUTCH DTIVEN PULLEY STARTER ARM CHASSIS REMOVAL OF COVER TROUBLESHOOTING OF CHASSIS FRONT WHEEL REAR WHEEL REAR SHOCK ABSORBER E
28. ain stand to park the motorcycle for inspection Disassembly 2 tightening bolts on fuel cover Fuel trap Diaphragm Refill brake fluid to level between MIN and MAX Assembly Assembly is in reverse order of disassembly procedures Warning 1 Please refill the same type of brake fluid Different fluid type may create toxic chemical ingredient and can damage the brake 2 Please do not let water into the master cylinder Otherwise the broil temperature may be reduced and bubble can occur then brake may not work 3 If the brake fluid is splashed on plastic parts or paints Please wipe it out right away otherwise it may affect engine firing 30 D Procedure to Release Air 1 Apply suitable plastic tube on drain plug and put a tray under drain hole 2 Slowly apply front brake several times 3 Hold the front brake lever and do not release the brake lever 4 Unplug the air release plug and still hold the brake lever 5 Tighten the air release bolt then release the brake lever 6 Repeat procedure 1 to 5 and release air bubble completely Note Torque of air release bolt 60 kg cm E Front Brake Disk Inspection If there is scratches damage or wear please replace with new one Note The minimum disk thickness 3 0 mm 31 Brake disk eccentricity Note A The max eccentricity 0 5 mm B If eccentricity is not within the limit please check tire roundness If wheel rim roundness is
29. amination of asbestos fiber which may affect the human breath system or lead to cancer 2 The transverse eccentricity should be within 3 0mm If the condition is poor please replace with new one 3 The lateral eccentricity should be within 3 0 mm If the condition is poor please replace with new one Brake lining assembly brake shoe brake shoe spring Inspection Use 3 points of Vernier calipers two ends and center to measure lining thickness If lining is badly worn and thickness less than 2 0 mm Please replace with new assembly brake shoe brake shoe spring Warning Please do not apply any grease on brake lining which can lead to unsafe drive 78 Loose rear brake adjusting nut and remove brake cable Brake arm cover Brake spring Rear brake connecting rod Rear brake cam axle Assembly Assembly is in reverse order of disassembly procedures Watch Please apply thin layer of grease on contact area of cam axle pin and lining Do not apply too much grease Note 1 Torque of rear brake connecting rod bolt 50 80 kg cm 2 Torque of lock pin nut 250 270 kg cm 3 Torque of rear wheel self locking nut 600 900 kg cm 79 4 5 REAR SHOCK ABSORBER Watch Please place main stand to park the motorcycle for maintenance Disassembly 2 attaching bolts on air filter Air filter Upper and lower attaching bolts on rear shock absorber 9 Shock absorber
30. and cam loaded area for lubrication 2 The starter cam locking pin should match with crankcase fillister for assembly 3 The mark on starter axle gear should match mark on starter cam 4 Use special tool for starter arm spring assembly Rotate tool clockwise such that spring locking pin is positioned under crank case half moon location then assemble stop plate Note 1 Torque of starter arm spring plate tightening bolt 90 kg cm 2 Torque drive plate tightening nut 800 1000 kg cm 3 Torque of clutch side cover bolt 50 80 kg cm 4 Torque of starter arm tightening bolt 100 120cm 69 4 CHASSIS 4 1 REMOVAL OF COVER BR8 Representative Figure i aver Handle im 4 Lu Dm gt a Y amm 6 C isver lamiie Bar hinder hore Leg Shield Frani H Liwi Sed leg Shield r UP CC par ee oe er SA 2 gt i oe 5 d dd tus ane i E Fesser pon a e gt x NU 3 4 UD 2 Sled side wer 70 Dismount floor panels following the sequence shown in the list Helmet Case Carrier Bottom Plate Cover Right and Left Side Mirror Rear View Cove Handle Bar U
31. arison Manufactue Within After 6mo 10 mo Within Over Months 3 mo 3 mo 1 yr 1 yr Charge Add electrolyte 10 20 30 40 60 Time And wait 30 m hr hr hr hr hr 86 5 3 SHORT CIRCUIT TEST Disassembly Disconnect battery negative terminal cable B Measure method A Connect megga meter terminal to battery terminal B Connect megga meter terminal to circuit negative Note User megga meter A current position B Turn main switch to OFF position Inspection Check if there is electrical current If no current check the main switch and wire harness for short circuit 5 4 RECTIFIER Watch 1 Check if wire harness is normal before checking rectifier and end resistor Check if rectifier socket is well connected 2 Keep fingers away from tester probe The circuit resistance can be changed with human body resistance involved Rectifier Terminal Resistance Table White Red Yellow Red Red Black White Red Yellow Red Infitity Red Infitity Infitity Black Infitity 5k 100k Ohm Infitity Infitity 3k 100k Ohm Infitity Infitity 3k 100k Ohm Infitity 87 5 5 STARTER RELAY A Operation of starter relay Watch Please place main stand to park the motorcycle for inspection Inspection Turn the main switch to ON position and press the starter button Note 1 If there is a snap sound th
32. arry out the following a Loosen the slow running adjuster completely so as to enable the throttle to close the duct completely b Proceeding with the utmost care manually position the throttle in completely closed position c Tighten the screws while holding the throttle in place d Make sure the throttle is correctly repositioned 58 3 6 LUBRICATION 3 6 1 Engine oil level The engine must be in cold and the scotter positioned uprightly on its stand flat ways Inspect the oil level with the oil meter that remove it from the crankcase If the level is close to the minimum point and the oil is not to be renewed fill up with oil of the recommended type 3 6 2 Oil renewal Renew the oil easily while the engine is in hot condition Place a vessel under the engine remove the outlet bolt and the oil lever gauge After draining the oil clean the oil lever gauge check the O ring seal and fit the oil lever gauge and outlet bolt again Tightening torque 150 kg cm Supply the engine with recommended oil through the oil filter Screw the filler plug Lubrication Type SAE 10W 40 Engine oil capacity BH8 BR8 BF8 125c c Engine disassembled 900c c Chang oil 750c c BR9 BF9 151c c Engine disassembled 1000c c Chang oil 800c c Note Run the engine after a few minutes then recheck the oil level again when the engine is until cold condition The oil level should always be kept below the max lin and above the m
33. buretor slow injection Poor engagement of cylinder head washer Check if the choke j Severe wear of valve fails valve cylinder piston piston does not open ring Test the compression Check for air leakage in the cylinder washer check wear of cylinder piston piston ring and other elements with correction adjustment or replacement 24 1 8 5 Poor acceleration and horse power Poor acceleration and horse power Check for drag of braking drum by braking plate Breakdown of potential causes Braking plate retaining braking drum Air filter grill obstructed Incorrect gap in spark plugs Check for obstructed air filter Xd Incorrect ignition timing braking plate Poor skip in spark plugs Incorrect adjustment of carburetor adjustment screw Poor choke valve in carburetor Dirty or obstructed carburetor injection nozzle Poor carburetor buoyant needle valve Dirty fuel filter Obstructed fuel circuitry Poor engagement of cylinder washer Serious damage of cylinder piston piston ring See 1 8 2 poor skip of spark plug for proper adjustment checking methods Check carburetor for Check for normal choke valve action Correction or Check for replacement obstructed injection nozzle 25 Check for normal fluid level in the buoyant Check the compression Check for leakage in ylinder washer check ylinder piston piston A
34. change Warn the engine and check the engine oil level again 28 sy oil filter E Spring Oil Strainer Cap ie 2 3 FINAL GEAR OIL Watch Please place main stand to park the motorcycle for inspection Clean grease around the drain plug Disassembly Oil refill plug Oil drain plug Note Put an used oil tray under the gearbox before removing the drain bolt plug Inspection Check if the oil drain plug washer is damaged Please replace with new one if it is damaged Drain gear oil Assembly Assembly drain plug Refill gearbox oil Reinstall oil refill plug Note 1 Torque on drain plug 90 150 kg cm 2 Oil type SAE 90 3 Oil capacity BH8 Gearbox disassembled 110 c c Regular Maintenance 90 c c BR8 BF8 BR9 BF9 Gearbox disassembled 120 c c Regular Maintenance 100 c c 4 Please check if there is any leaking after oil refill 29 2 4 BRAKE SYSTEM A Front Brake Lever Free Play Note Front brake lever free play is 10 20 mm Adjustment This motorcycle uses non adjust style B Brake Fluid Inspection The front brake fluid level should above MIN If it is below refill the brake fluid and check leakage of the brake system Warning If there is low or no load when the brake lever is hold please check if there is air in the brake system or fluid leakage C Refill Brake Fluid Watch Please place m
35. djustment Check fuel pipe ring for wear Correct and carburetor for Adjustment or obstruction replacement when necessary Cleaning or replacement 26 2 INSPECTION AND ADJUSTMENT 2 1 REGULAR MAINTENANCE SCHEDULE Explanation 1 Please follow the regular maintenance schedule to ensure the motorcycle s function and life 2 Inspection including clean up lubrication refill or replace parts C Clean R Replace A Adjust km or time Maintenance Item 3 mo 2000 km 6 mo 3000 km 9 mo 4000 km 12 mo 15 mo 18 mo 7000 km 21 mo 8000 km 24 mo 27 mo 30 mo 33 mo Engine Oil R R R R R R R R R R R Oil Strainer Screen Gear Oil Brake Tires Air Cleaner Battery Spark Plug Fuel Filter Carburetor Valve gt D O V Belt Bolts and Nuts l A l T Note 1 If ridden on dusty roads or raining days please shorten the inspection and replacement schedule for air filter 2 If ridden under heavy load frequent long distance travel please shorten the replacement schedule for engine oil 3 Please clean the spark plug regularly and replace the spark plug if necessary Regularly Maintenance and Performance Relationship Performance100 Ridden Time or Mileage
36. does not gt gt gt gt gt gt gt gt gt gt gt 5 Check if the crank shaft works See page 17 Check if the battery is properly charged speeding clutch of the starting leakage screw to check motor suffer critical wear if tor inlet of fuel Check for fuel charging in addition to recharging check the charging proceed charging system of the E lant for failure and chec e charging system of heck the starting contact gear and speeding spill in the starting gear of the starting carburetor switch motor for abnormal Starting engagement relay breaks or in short circuit Loose contact or wiring ilter and fuel ubing or replacement jobstruction Refer to 1 8 3 No Skip in Spark Plugs for checking Refer to 1 8 2 Poor skip in Spark or repair it Plugs for checking Check spark plug for cleanliness normal gap pollution by gasoline If yes check the choke of the Check if the slop nozzle of the Clean or replace the slow nozzle or correct replace ith new threshold Check air filter grill Check cylinder washer for leakage check cylinder piston piston ring for obstruction k for wear with correction adjustment or replacement 20 Adjustment or replacement of arburetor buoyant needle valve No fuel Dirty fuel filter Obstructed fuel tubing Obstructed ventilation tubing
37. e kg cm 5 mm Bolt and Nut 40 8 mm Bolt and Nut 220 5 mm Flange Bolt and Nut 50 8 mm Flange Bolt and Nut 270 6 mm Bolt and Nut 100 10 mm Bolt and Nut 350 6 mm Flange Bolt and Nut 120 10 mm Flange Bolt and Nut 400 6 mm SH Bolt and Nut 90 12 mm Bolt and Nut 550 Torque Values of Chassis Components No Tightening Location Specification Torque kg cm 1 Front Wheel Axle Self lock Nut M12 500 600 2 Brake Disk Hex Bolt M5 180 280 3 Brake Clipper Tightening Bolt M8x35 210 250 4 Speed Meter Cable Nut X 60 5 Front Fork Bearing Tightening Nut M25x1 0 600 650 6 Rear Wheel Axle Self lock Nut M16x10 600 900 7 Rear Brake Connecting Rod Bolt M16x32 50 80 8 Rear Brake Pin Self lock Nut M8 250 270 9 Rear Upper Cushion Tightening Bolt M10x46 200 300 10 Rear Lower Cushion Tightening Bolt M8x35 200 300 Torque Values of Engine components Tightening Location Specification Torque Quantities kg cm Cylinder Head Bolt M6 80 100 4 Cylinder Stud Bolt M8x182 5 500 800 2 M8x195 5 2 Cylinder Intake Pipe Stud Bolt M6x50 500 800 2 Muffler and Exhaust Pipe Tightening Screw M6 100 120 2 Muffler amp Right Crankcase Upper Tightening Screw M8x42 300 400 1 Muffler amp Right Crankcase Lower Tightening Screw M8x38 300 400 1 Spark Plug M10 100 120 1 Valve Gap Adjust Lock Bolt M5 50 90 2 Fuel Filter Nut Cap M30
38. e of flywheel magneto Defective high tension coil Defective C D I Defective spark plugs OV de or Re Defective conductor contact breaking or short circuit for example a Conduction between flywheel magneto and C D I b Conduction between C D I and the main switch c Conduction between C D I and the high tension coil Engine not running smoothly 1 Defective ignition first circuit a Bad contact in circuitry or cable b Defective of flywheel magneto 2 Badignition secondary circuit a The ignition coil insulation defect causing electric leakage b Defective magneto coil Short circuit between coil layers ll Defective coil 84 c Defective spark plug Spark plug covered by carbon Il Electric leakage in ceramic part of spark plug d Electric leakage from spark plug rubber screen Defective ignition timing a Defective flywheel magneto b Defective C D I Too large gap of spark plug d Too high electric resistance of spark plug Starter System Starter motor unable to run 1 2 3 4 5 6 7 8 9 1 Damaged battery Battery circuit broken bad contact or too large resistance at connections Fuse fused Defective main switch Defective front and rear brake switches Defective starter motor switch Defective starter motor relay Defective starter motor Circuitry conductor defective or broken 0 Starter motor drive pinion locked with the over speed clutch gear Weak drive
39. en the function is normal 2 If there is no snap sound then the function is abnormal Please check 1 Starter relay ground circuit 2 Starter relay voltage B Starter relay ground circuit Disassembly Connect the start relay connector and electric tester by A Megga meter s positive terminal with the relay yellow red terminal B Connect the negative terminal with ground circuit and press the starter button Then check the electricity continuity Note 1 There should be continuity when pressing the start button 2 If there is no continuity when pressing the starter button then check the continuity between starter button and connecting cable C Check starter relay voltage Watch Please place main stand to park the motorcycle for inspection Measure method A Connect megga meter s positive terminal with the relay green yellow terminal B Connect the negative terminal with ground circuit and push the starter button Then check the electricity continuity Turn the main switch to ON position and hold the brake lever 88 Watch The battery voltage must satisfy requirement in checking starter voltage Note 1 If there is voltage then the relay is normal 2 If there is no voltage then check the continuity of brake switch and cable 89 5 6 STARTER MOTOR Watch 1 Please place main stand to park the motorcycle for inspection 2 Turn the main switch to OFF position be
40. er Damaged grease seal of the piston of the brake caliper Bent brake rod Difficult to operate the brake rod 1 2 3 4 Brake fluid pipe clogged The brake caliper not working well The piston the main cylinder not working smoothly or seriously damaged The brake rod bent 73 Uneven braking effort 1 Bad mounting of wheels causing serious sway Deformed brake disc Clogged brake fluid pipe WD Unclean brake lining or brake disc Serious wear of the brake caliper lining Serious damage of the grease seal of the brake caliper piston Deteriorated brake fluid Resistance due to air existing in the brake system 74 REAR WHEELS REAR BRAKES REAR SUSPENSIONS Operating Cautions Do not leave greasy the surface of the brake lining inside the brake drum Troubleshooting Serious sway while rear wheel rotates 1 Distorted wheel rim 2 Tire in bad state 3 Defective mounting of wheel propeller shaft pieces Inefficient rear brake Drum type 1 Bad adjustment of the brake 2 Serious wear of the brake drum 3 Serious wear of the brake cam shaft 4 Serious wear of the friction face between the rear brake lining and the cam shaft 5 Wear of the rear brake lining 6 Unmatched parts in the chisel groove of brake arm Rear shock absorber too flexible 1 Absorber spring constant too low 2 Fatigue of the absorber spring 75 4 3 FRONT WHEEL Watch Please place
41. fore maintenance Disconnect the battery ground circuit To ensure safety turn the main switch to ON position and check if the motor has operated Water proof Rubber Jacket Disassembly 2 starter motor attaching bolts Starter motor 9 Roll up the water proof rubber jacket and remove connector 9 2 motor case attaching bolts Motor commutator Front cover Check Starter Commutator Check Continuity Between Se 7 Inspection ES Se 1 Check continuity between segments Note s A If continuity is good then it is normal B If no continuity then it is broken 90 2 Check continuity between Check Continuity Between Segments and Armature Shaft segments and armature shaft Note A If no continuity then it is normal B If continuity is good then it is broken 3 Clean the commutators if there is metal powder between segments 4 Check the removed parts for damaging burning discoloration and wearing Replace with a new if necessary 5 Check brush length Note A Initial standard brush length is 112 5 mm B If brush length is smaller than 8 5 mm please replace with new brush Inspection Check continuity of the brush holder Note A If there is no continuity it is normal B If there is continuity it is broken Please replace with new one 91 Assembly Assembly is in reverse order of disassembly procedures Watch 1 Apply g
42. gative cable and then the positive cable Warning Please do not touch tools with frame buring disconnecting positive cable It can cause short circuit then it may spark and damage battery Inspection This motorcycle use wet type battery Please fill with distillation water or lead battery fluid when the electrolysis fluid is lower than minimum m p Upper Limit Assembly Assembly is in reverse order of Lower Limit disassembly procedures c n Warning First connect the positive cable 22 cam and then negative cable 36 2 8 SPARK PLUG Disassemble Spark plug cap Note Please blow away deposits around spark plug with blower before removing spark plug Otherwise the dust may drop into wu cylinder and it can damage engine Inspection Check if spark plug has carbon deposits burned or cracked Use steel brush to remove carbon deposits and adjust spark plug gap Replace burned or cracked spark plug with new one Note Spark plug specification Remove Carbon CR7HAS Deposits Spark plug gap 0 6 0 7 mm Adjust Gap Check If Washer Is Damaged Warning First install the spark plug with Check If Cracked hand and then tighten it with spark plug wrench Please do not over twist the spark plug Note Torque of spark plug 100 120 kg cm 2 9 FUEL FILTER Inspection Check if it is hardened damaged or leaking If any above p
43. imit is 615 04 mm Measure the piston pin outside diameter Wear limit is 14 96 mm Measure the inside diameter of the piston rod small end Wear limit is 15 06 50 Put the piston ring into the cylinder and measure the clearness of opening by thickness of opening by thickness gauge Replaced if it exceeds 0 5mm Fitting the rings on the piston Take care not to damage the rings during the fitting and position them as shown in the figure Once fitted the rings must rotate freely in their grooves The 2nd ring is engraved 2R mark The 1st ring is engraved R mark The mark should face upwards while installing Assemble the piston the IN reference mark is at the inlet valve side Insert the piston pin and assembly rings Assemble the circlip carefully Fit the cylinder gasket and cylinder 51 3 4 5 Crankcase Crankshaft Remove the chain and chain guider Remove the oil divider and then remove the driving sprocket Remove the coupling bolts gasket and pin Take out the crankshaft from crankcase Check the side play of the piston rod big end with a thinness gauge Wear limit is 0 5mm 52 Measure the offset between the two shafts of crankshaft Maximum offset is 0 1mm Bearing Before removing the bearings make sure that they rotate freely and have no play in their respective housings Fit the crankshaft and smear the coupling surfaces with Loctite fixing glue Fasten
44. in line 59 3 7 DRIVING PULLY CLUTCH DRIVEN PULLEY 3 7 1 Transmission cover Loosen the fixing screw of cooling duct and remove the cooling duct Remove the kick starter lever Assy Remove the clutch cover screws by diagonal step and then remove the clutch cover Take off the knock pins and remove the gasket 3 7 2 Driving pulley Use the special tool to lock the fixed drive face and loosen the central nut with wrench Remove the belt from the spacer and remove the drive pulley Note Press the movable drive plate and drive pulley face while removing the drive pulley face Assy in order to avoid the roller to stand up 60 3 7 3 Driven pulley Remove the central nut of clutch housing with a compass spanner to hock the housing bell and loosen the nut with wrench Remove the driven pulley comp and belt 3 7 4 Checks Drive belt Be sure that the drive belt should not be cracked or damaged Measure the belt length Ba a ra Wear limit 18 0mm or 8000km o 61 Remove the movable drive plate guide blocks and rollers Take care to make the mark on the rollers and groove of drive face in order to install rollers correctly Rollers Inspection that the rollers should not to be damaged or worn BH8 Wear limit 18 0mm minimum BR8 BF8 BR9 BF9 Wear limit 17 4mm minimum Roller Bush Inspection that the internal bushing of drive bush should show no signs of anomalous wear and with bore
45. ine The engine cover cylinder and exhaust pipe have high temperature after starting of engine Please wear glove in maintenance of parts during engine operation or maintenance should be waited until engine is cooled 11 1 4 SPECIAL TOOLS Universal Wrench 440601 Hold for removing flywheel Hold for removing belt driver pulley Hold for removing belt driven pulley Four Legs Sleeve 440604 Used for removing starter clutch gear lock nut Flywheel Remover 440602 Used for removing flywheel Starter Spring Assembly Tool 440605 Used for starter spring assembly Gear Remover 440603 Used for removing starter driven gear Crank Shaft amp Right Hand Crank Case 440606 To draw the crank shaft into the right hand crank case 12 Inner Chain Wrench 440607 For disassembly the camshaft inner chain Bush Remover 440610 For removing the crankcase suspension bush Socket of Valve Adjusting Bolt 440608 Adjust the clearance of valve stem and rock arm Fixing Nut Socket 440611 Used for removing steering shaft nut Valve Cotter Tool 440609 For assembling valve cotter 13 1 5 TIGHTENING TORQUE BR8 Representative Figure Standard Torque Values of Bolts and Nuts Specification Torque kg cm Specification Torqu
46. k smoothly or break 82 Troubleshooting Battery Recharging System No voltage 1 2 Battery cable fallen or disconnected Fuse fused 3 Defective of flywheel magneto 4 Excessive battery discharging a Electrolyte leaked b Chemical reaction in battery c Short circuit in battery d Defective rectifier Low voltage 1 Leaking of electrolyte Oo 5 ON Insufficient recharging Defective separator causing short circuit between positive and negative plates Defective battery terminals Defective recharging system Defective rectifier Excessive specific weight of electrolyte 1 2 3 Insufficient recharging Leaking of electrolyte Reaction between sulfuric acid and pole plates Too low capacity 1 Insufficient recharging 2 Pole plates react with sulfuric acid 3 4 Active matter fallen from pole plates because of excessive recharging Insufficient electrolyte 83 Inefficient recharging system 1 Bad contact at connectors short circuitry or broken circuit 2 Defective rectifier 3 Defective of flywheel magneto a Armature winding short circuited or broken b Magneto coil short circuited or broken Bad electric continuity 1 Bad contact at battery connection 2 Ignition system short circuit or bad contact at connectors 3 Lighting system short circuit or bad contact at connections Ignition System Dysfunctioning of spark plugs 1 Defectiv
47. lugs Poor spark plugs Poor high voltage wiring Poor distributor coils Poor PICK Ups Poor main switches Wiring relay 1 8 3 Troubleshooting for no skip of spark plugs Analysis of potential causes No skip of spark plugs Check for proper loading of the spark plug cap Loose spark plug cap Poor spark plug Loose C D adapter Poor CD l Poor PICK UP Replacement spark plug and test the Load properly the spark Poor distributor intensity of the spark plugs plug cap high voltage wiring Poor main switch Intense sparks Replacement of poor spark plugs Check for loose C D I Main wiring broken or in short circuit ignition coil broken or in short circuit Poor adapter contact Poor PICK UP Poor main switch Poor contact of adapter Broken main wiring of short circuit breaking or short circuit replace when necessary 23 1 8 4 Troubleshooting for slow run troubled engine Analysis of potential causes 7 Check for contamination spark plugs and excessive gap Dirty spark plugs Incorrect spark plug gaps Incorrect ignition timing Cleaning and Obstructed air filter adjustment grill Poorcarburetor buoyant needle valve Poorcarburetor choke valve Poorengagement of carburetor and inlet Replacement of tube Obstructed car
48. n of the front fork comp 2 Unequal working of the left and right shock absorber beside the front fork comp 3 Running deviation due to the deviation of the front axle 4 Deformation of the front tires 5 Deformation of wheel rim Front shock absorber too flexible 1 Shock absorber spring constant too low 2 Shock absorber spring fatigue 3 Lack of oil in the shock absorber resulting from leakage 4 Loose front fork comp axle bolts 72 Abnormal noise of working front shock absorber 1 Noise coming from friction between the shock absorber and the outer tube joint 2 Noise coming from friction between the shock absorber spring and the outer tube 3 Noise coming from shock absorber deviation due to loosen screws 4 Deformed moving parts of the absorber Too large sway of front wheels 1 2 Deformed wheel rim Insufficiently tightened bolts of front wheel spindle or although tightened but becoming loose Sway caused by too large gap around the front wheel bear or damaged bearing Bad of worn tires Inefficient braking 1 a ed 75 909 Unclean or oily friction lining surface Excessive wear of the friction lining Deviated or deformed brake discs Inefficient braking due to air resistance caused by air unduly existing in the braking system Insufficient brake fluid Deteriorated brake fluid Brake fluid pipe clogged Improper mounting of brake caliper body Uneven wear of the lining in the brake calip
49. of starter motor 1 5260279 Insufficient recharging of battery Bad contact on circuit conductors Strange object introduced in the starter motor pinion Armature shaft bent Commutator unclean or worn Brush worn or spring too weak Starting motor of relay defective 85 5 2 BATTERY A Cautions in battery inspection and generator charging Inspection Use gravity gauge to measure electrolyte White is fully charged yellow means charge is required and red is broken or almost totally discharged Note Electrolyte s specific gravity and charge level comparison table 20 C Electrolyte 1 280 1 250 1 220 1 190 1 120 Specific Gravity Full 3 4 1 2 1 4 Totally Charge Level Charged Charged Charged Discharg B Charge by generator Connecting battery and gener terminals by with and with Warning Battery releases explosive gas during charging or use battery Therefore it is dangerous to do so in concealed location Please put battery in good ventilation location during charging and forbid fire Note 1 Standard charging current 0 6 A for 5 10 hours 2 Quick charging current 6 0 A for 30 minutes 3 Please do not use quick charge except for emergency 4 Measure the battery voltage 30 minutes after battery is charged The battery voltage should be higher than 12 8 V C Battery manufactured month and charge time comp
50. of the fuel tank Poor carburetor buoyant needle valve Carburetor buoyant with impurities Poor carburetor buoyant No skip in spark plugs Poor skip in spark plugs Dirty spark plugs Incorrect spark plugs gap Dirty and wet spark plugs Loose adjustment screws in the carburetor Carburetor choke Obstructed carburetor slow nozzle Ailing carburetor threshold Obstructed air filter grill Leakage in cylinder washer Seriously damaged cylinder piston piston Dead battery Poor contact of battery pin and conductors Starting switch with poor or failure Starting relay with broken wire or short circuit Loose contact and wiring Starting gear and speeding clutch gear seriously worn Starting gear and speeding clutch gear in poor engagement Poor starting motor 21 1 8 2 Troubleshooting for poor skip of spark plugs Analysis of potential causes gt Poor skip of spark plugs Check for spark plug cap ignition coil Replacement of new spark plug and try skip again Check for loose C D I Replacement of poor plugs terminal Loose Load in the spark plug cap park plug conduction and resistance values Abnormal Normal Poor or abnormal Check high voltage coils main switches PICK UP distributor C D I and mount coil for normality properly the plug Normal Abnormal Poor high voltage coils main switches PICK correct them 22 Loosen spark p
51. on Such position the engine at top dead point position Remove the nuts and washers of the camshaft holder Remove the camshaft holder and dowel pins Disassembly the chain gear and take the camshaft off Inspect the cam surface and the bearing If cam surfaces are serious abrasived and the bearings are damaged replaced with a new one 45 Pull out the rocker arms shaft and inspect that the rocker arms should not be worn and the oil hole is not obstructed Pulling cylinder head gently off the cylinder Remove the dowel pins cylinder head gasket and the chain guide rod Clean the coupling surfaces with carefully not to damage them Clean the combustion chamber ridding any carbon deposits Check that the valve seats Examine the combustion chamber and shown no sign of cracks or damage Use a calibrated rule inspect the cylinder head lower surface is perfect flatness Use a thickness gauge inspect that the surface wear does not exceed 0 05mm Measure the free length of the valve springs The limit of inner spring is 31 2mm The limit of outer spring is 34 1mm Examine the valves should not be damaged cracked burnt or bended Clean the valve removing all carbon formation and measure the diameter of vale axle The wear limit is 4 9mm Inspect the condition of the seat on the valve head damaged or cracked are not allowed 46 Inspect the valve seats and show no signs of damages or crack Measure the
52. pecial tool and with the aide of a thickness gauge measure the gap between the rocker arm adjusting bolt abutting end and the valve stem Clearance Inlet valve gap 0 08 0 10 mm Exhaust valve gap 0 08 0 10 mm Assemble the head cover Replace the sealing ring with a new one install the cover and screw the four bolts 48 3 4 4 Cylinder and piston After removing the cylinder head and gasket take out the cylinder Take off the cylinder gasket and clean the crankcase surface Place a clean cloth under the piston to prevent any dust from falling inside the crankcase chamber Remove the piston pin circlip and the piston Inspect the cylinder inside surfaces show no signs of seizure or anomalous wear then measure the inside diameter of the cylinder with a bore meter Note BH8 BR8 BF8 125c c engine Wear limit 52 5 BR9 BF9 151c c engine Wear limit 57 5mm Take measurements on three planes along the cylinder axis for each plane take a measurement on the circumference Take off the piston rings carefully Inspect the piston surface anomalous wear is not allowed Note BH8 BR8 BF8 BK8 125c c engine Wear limit 252 5mm BR9 BF9 BK9 151c c engine Wear limit 257 5mm 49 Measure the clearance between the ring and the groove The max clearance of top ring is 0 09mm The max clearance of 2nd ring is 0 09mm too Measure the diameter of the piston pin hole Wear l
53. pper Leg Shield Front Front Fender Cautions Cover Set Leg Shield Cover Handle Bar Under Leg Shield Rear Fender Fixed Front Leg Shield Side Lower Leg Shield Lower 1 Do not damage cover of body panels while dismounting 2 Handle with care regarding lugs of to avoid damage dismounting 3 When remounting do not scratch or crash wiring 4 While assembling every lug shall be fixated effectively 5 While assembling make matching panels and their slots 71 4 2 TROUBLESHOOTING OF CHASSIS OSTEERING SUSPENSION FRONT WHEELS FRONT BRAKES Operation Cautions 1 Leg shield lower must be dismounted before the front wheel is dismounted Use a jack to raise the wheel above ground and support the car body firmly 2 The brake inner cylinder and lining shall be kept free form grease during operation to avoid driving danger caused by braking effort reduced by grease Troubleshooting Steering too tight heavy 1 The bolt of ball bearing fastening at the top of the steering column too tight 2 Balls of the steering system broken 3 The conical base for steering ball bearings damaged 4 Bad curvature of the front fork comp 5 Bad curvature of the front wheel shaft or deviation of the tire 6 Insufficient tire pressure Straight driving impossible due to deviation of the steering wheel 1 Deviatio
54. rease to the ends of armature shaft 2 Apply grease to the dust seal before assembly front cover 3 The flange of front cover should match the fillister of motor shell 5 7 GEMERATOR generator coil Disassembly Disconnect the generator s 4P connector Measure A Use megga meter s positive terminal to connect the white wire of the 4P connector B Connect the megga meter s negative terminal with frame ground and measure the resistance Note 1 Standard resistance 0 2 1 0 Ohm 20 2 If the measured value exceed the standard replace with new A C generator charging coil B A C generator lighting coil Disassembly Disconnect the A C generator s 4P connector Measure A Use megga meter s positive terminal to connect the yellow wire of the 4P connector B Connect the megga meter s negative terminal with body ground and measure the resistance Note 1 Standard resistance 0 1 1 0 Ohm 20 C Fillister of Mott ra i i fr rame Ground F y A C Generator 32 Se White Wire Connector ae Frame Ground 1 fy gt p i Generator V Yellow Wire Connector 2 If the measured value exceeds the standard replace with new A C generator lighting coil 92 A C generator Disassembly Disassembly The fan cover 94
55. roblem exists please replace with new one 37 2 10 CARBURETOR IDLE SPEED Note Please place main stand to park the motorcycle for inspection Start engine and adjust idle speed at warm engine condition Adjust Procedure Connect engine speed meter Adjust idle speed to adequate range with cross screw driver Note 1 Increase engine speed by rotating the screw clockwise 2 Reduce engine speed by rotating the screw counter clockwise 3 Engine idle speed range 1800 100 rpm 2 11 THROTTLE VALVE Inspection Check if the throttle valve operation is smooth Note 1 Throttle lever free play 2 6 cm 2 Micro adjustment is performed at throttle lever Macro adjustment is performed at carburetor throttle valve cable A Throttle Lever Gap Adjust Procedures 9 Open dust boot Loose lock bolt Adjust by rotating adjust nut Note 1 Increase engine speed by rotating nut clockwise 2 Reduce engine speed by rotating nut counter clockwise Tighten adjust nut after adjustment Close dust boot 38 B Carburetor Throttle Cable Gap Adjustment Procedure Note First adjust the throttle lever gap If it does not satisfy the standard then adjust the carburetor throttle gap Loose Tightening bolt Rotate the adjust nut Note 1 Increase gap by rotating the screw clockwise 2 Reduce gap by rotating the screw counter clockwise Tighten nut after adjustment 2 12 VA
56. sembly is in reverse order of disassembly procedures Note 1 Torque of rear wheel bearing bolt 600 900 kg cm 2 Torque of 2 bolts on exhaust pipe connector 100 120 kg cm 3 Torque of 2 bolts on exhaust pipe and right crankcase 300 400 kg cm 34 2 5 TIRE AND TIRE PRESSURE Inspection Check if tire has been cracked damage worn inclusions stone nail glass etc If tire is in poor condition please replace with new one Note Tire specifications See specification table Tire pressure Watch Please measure cool tire pressure Note Tire pressure Front tire 175kPa 1 78 0 25 38 PSI Rear tire 210kPa 2 14 2 30 45 PSI Warning Don over load the motorcycle The tire may explode with over load and it is 2 6 AIR FILTER Disassembly Air filter side cover tightening bolt Air filter side cover Filter tightening bolt Filter Inspection Check if filter is filthy or broken If filthy or broken please replace with new one Watch 1 If ridden on dusty roads or raining days please shorten the replacement schedule for air filter 35 2 Don t start engine when air filter is not installed otherwise the piston or cylinder can be damaged Assembly Assembly is in reverse order of disassembly procedures Watch Please install air filter and side cover closely 2 7 BATTERY Disassembly Foot mat Battery box cover Disconnect the battery ne
57. sh out the old bearings and install the new one with the tube that has corresponding length and suitable diameter 65 3 7 13 Clutch Make sure that should not be oil strained cracked and unusual damaged from the appearance Replaced if the thickness of lining is less than 1 5mm 3 7 14 Fitting Install the fixed driven face comp into the movable driven face comp Avoid to damage the lip of oil seal Install two O rings and apply grease to the groove of the cam then fit the guide pins Apply a little grease inside of the spring sheet and manually push the spring sheet in lightly and the install the spring and screw the central nut 66 3 8 STARTER ARM Disassembly Loose cooler tube tightening ring 9 Starter arm tightening bolt Starter arm 8 clutch side cover tightening bolts Clutch side cover Gasket Pin Use universal wrench to hold drive plate and remove drive belt pulley assembly Belt 67 Starter arm washer Spring stop plate Spring Starter arm Starter cam assembly Inspection 1 Check if starter arm surface and collar are worn and damaged 2 Check if starter cam gear surface is worn and damage 3 Check if starter cam and starter arm loaded surface are worn and damaged BLoaded Surface of Starten Ji 68 Assembly Assembly is in reverse order of disassembly procedures Note 1 Apply grease on starter arm collar
58. the piston Inspect the pressure piston and membrane Notches scratches or other damage are not allowed Fit the needle the spring and the needle holder in the pressure piston and fix the needle holder Fit the pressure piston in the carburetor body Fit the compression spring Fit the pressure chamber cover and fasten it with two screws 56 3 5 5 Float Needle valve Jets Unscrew the four float chamber screws Remove the float pivot the float and the needle Inspect the needle valve and its seat Notches or deep scratches are not allowed Remove the main jet choke jet and idling jet Inspect these jets 57 Before fitting the parts again blow all parts and in particular the housings of the jets with compressed air Clean the main choke and idling jets with a detergent solvent and blow them with compressed air Fit the main choke and idling jets Fit the seat of the needle valve Fit the needle valve the float and the float pivot Measure the float height while its tongue touches the needle valve Distance between the float and the float chamber plane is 18 5mm Replace the float if the level is not as indicated Fit the float chamber 3 5 6 Throttle Valve Loosen the fastening screws and remove the throttle valve Check that the valve rim shows no deep scratches Fix the throttle valve again with Anti loosen glue and new screws Note Before tightening the two screws of throttle valve c
59. tightening bolts Fan Use universal wrench to hold flywheel and remove lock nut Use the big end of flywheel remover and rotate counter clockwisely into flywheel Use universal wrench to hold flywheel and rotate the flywheel remover clockwisely to remove lock nut Then the flywheel can be removed Note The big end of flywheel remover is left threaded 93 Cable connector Cable bracket Tighten bolt of pick up Pick up Assembly Assembly is in reverse order of disassembly procedures Watch 1 The inside surface of the flywheel is magnetic Be sure that there is nothing in there before assembly 2 The flywheel s fillister should match crankshaft pin Note 1 Torque of flywheel tightening bolt 550 kg cm 2 Torque of fan tightening bolt 90 kg cm 5 8 RESISTOR Disassembly Remove front windshield cover Measure A Use megga meter s positive terminal to connect resistor wire B Connect the megga meter s negative terminal with frame ground and measure the resistance Note Resistor standard 20 W 5 9 Ohm 5 0 7 0 Ohm 5W 5 0 Ohm 4 0 6 0 Ohm 94 5 9 CDI UNIT Use megga meter to check the following items Check Item Measuring Terminals Standard Value 20 C Main Switch Black White Body Ground Continuity When Main Switch OFF Exciting Coil Black Red Body Ground 300 1000 Ohm Pulser Coil Blue Yellow Body Ground 40 300 Ohm
60. tion Area Rings Seal Lip Area Satisfy SAE 10W 40 and API SE SG Engine Oil Starter Frictional Surface Starting Cam Gear Spring Operation Frictional Area High Temperature Durable Grease Generator Connector Gearbox Ventilation Tube Adhesives 1 7 PARTS NAME AND WIRING DIAGRAM Parts Name BR8 Representative Figure BR8 Representative Figure Back Mirrar Steering Lever Switch Speed Meter Luggage Box Seal Central Cover Seat Lock Frame Fuel Tank Cap i Rear Light Brake Light Rear Signal Light Front Signal Light Front Light Front LOGEC 4 Rear Fender Front Fender _ e ime Raar Shock Absorber Front Fork Set i S wu BU MI sat Aur Filter Front Brake Disk gry Rear Wneel Front Wheel Starter Arm Clipper DOA Battery Main Switch Main Stand Back Mirror seat Luggage Frame NN Fuel Tank Cap Front Signal Light rh 24 w Front Light Rear Signal Light Front Legshield Rear Fender A ux Front Fender NO Front Fork Set Speed Meter Cable Front Whael gt li Exhaust Muffler 2 2 ig Rear Wheel 1 Battery Spark plug Fan Cover Main Stand 18 1 8 TROUBLE SHOOTING 1 8 1 Troubleshooting for failure in starting the engine Analysis of potential causes Engine
61. y Coil Inspection Measure Connect the electric tester as Fig and measure the resistance Note 1 Standard resistance 0 1 1 0 Ohm 20 C 2 If the resistance is Infinity then the coil is broken Replace it with new one E Secondary Coil Inspection Measure Connect the electric tester with spark plug cable and ignition wire terminal as shown in Fig and measure the resistance Note 1 Standard resistance 0 1 1 0 Ohm 20 C 2 If the resistance is Infinity then the coil is broken Replace it with new one 97 20 Wyevia Los 2

2. inspection and adjustment

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