SERVICE MANUAL
Contents
1. 4 Poor ignition and charging coils when O 1 O sare normal Intermittent voltage of O 1 Poor ignition coil 36 ignition and charging O 2 Poor ignition and charging coils coils Causes Inspect and judge from O 1 Trigger coil voltage too O 1 Inner resistance too low measuree with low specified circuit tester 2 Crankshaft speed too low storage battery voltage too low or starting rod too feeble when tread on Circuit tester interfered normal value repeated measurement readings above reference value Poor trigger coil when O 1 0 3 are normal Intermittent voltage of O 1 Poor ignition coil trigger coil gt Poor trigger coil 1 Precautions a Trace ignition system troubles in order specified in trouble detection chart b The ignition system is an automatic electronic angulation device in CDI set so it is not necessary to adjust ignition time c Disconnection drooping or impact of ignition CDI sysstem is the cause of trouble Dismounting should be effected with special care d Most of the causes of trouble are those of connectors and plugs Before service inspect connectors to ensure sound contact e Inspect for the correct heat value of spark plugs Improper spark plugs are the main causes of ill running or burning of engine f Effect inspection of main switch according to the conductivity chart Refer to dismounting instructions for AC generator and trigger coil dismounting2. 2 Ignition System Inspection Note Incase of sparkless spark plug inspect if there 1s any loosening or poor contact d As circuit testers are of many brands and different inner resistances measurement readings might be different Circuit tester output resistance should be aa above 10M HA CAS Connect high voltage distributor with circuit tester 37 Ignition Primary Coil Voltage Remove spark plug as illustrated and mount a faultless spark plug Connect spark plug with engine earthling Note Effect correct connection of wires and their measurements Cylinder compression pressure measurement is effected in normal condition measure with spark plug fitted on cylinder head Remove middle cover Connect ignition coil wire Distributor is connected between primary coil terminal black yellow and motorcycle earthling Start starting motor or tread on starting jy rod and measure ignition coil primary side maximum voltage Connecting method positive terminal connected togreen wire and negative terminal connected to black yellow wire Minimum voltage 95V and above Note When measuring voltage do not touch any metalpart of the test bar so as to prevent electric shock bp UI arv rd 38 Ignition and Charging Coil Note Mount spark plug on cylinder head inspect at normal compression pressure Remove CDI set connector 6P connect distributor between ignition and
3. JM free travel 2 6mm movement Inspect throttle free travel Free travel 2 6mm The main adjusting position is beside the carburetor Remove rear store case inner cover Adjust by loosening the fastening nut and turning the adjusting nut Fine adjustment is effected on the side of the throttle grip Effected adjustment is by removing the dust cover loosening the tightening nut and turning the adjusting nut V AIR FILTER INSPECTION AND CLEANING After a certain mileage dust and impurities will gather in air filter case and strainer which will clog strainer pores and reduce inlet of air and thus lead to excessive concentration of mixed gas and reduce the performance of engine That s why the strainer must be cleaned every 2000 3000km and in dusty or rainy conditions strainer must be cleaned or replaced earlier Remove 7 screws of air filter Remove strainer cover Take out the strainer Immerse foam strainer in gasoline and 3 gt wash it to remove dust and impurities by E gripping and pressing RK 4 Press gasoline out of the foam Soak the cleaned foam with engine oil press out or throw out engine oil to leave it moist with Oll cleaning gripping gasoline soaking gripping Mount VI BRAKE BLOCKS INSPECTION Grip the brake lever and check the wear amp tear indicator on the brake blocks If the indicator nearly touched brake disc the
4. Roundness error of wheel rim Refer to Front Wheel Service Deformation of wheel rim Inadequate tire pressure Deformed wheel rim Loose front wheel bearing R f E Front wheel oscillation efer to Front Whee Poor tire Service Poor axle locking Soft front shock Refer to Front Shock absorber Absorber Service MEE Deformed wheel rim Refer to Rear Wheel Rear wheel oscillation Poor wheel Service Soft rear shock Sprine fati Refer to Rear Shock absorber Ee Absorber Service Spring fatigue 16 SECTION TWO DETAILED DESCRIPTION OF BODY PARTS MALFUNCTION Precautions in Operation Forced mounting or dismounting of body cover parts will cause damage to claws and slots of corresponding hoods When mounting body cover parts be sure to align the corresponding parts of hoods When mounting body cover parts avoid pressing wires cables or pipes I FRONT WHEEL SERVICE Front Wheel Dismounting Support the body bottom to lift front wheel Remove the left and right rubber cap Loosen and remove the front axle nut Take out the front axle and remove transmission gearbox front axle bush and the small axle bush Remove front wheel Remove brake disc mounting bolts Remove brake disc 17 front axle nut transmission gear box left rubber cap small axle bush mounting bolt Axle Bending Inspection Place axle on a V seat
5. charging coil at wire terminal black red terminal and green terminal Actuate starting motor or tread on starting rod measure ignition and charging coil maximum voltage Connecting method Positive terminal connected with black red wire and negative terminal connected with green wire Minimum voltage 95V and above Note When measuring voltage do not touch any metal part of the test bar so as to prevent electric shock In case measured CDI set terminal maximum voltage is abnormal remove motorcycle right cover and AC generator connector Connect ignition and charging coil black red Incase CDI set terminal voltage is abnormal and AC generator terminal voltage 1s normal it indicates poor contact of connector or wire breakage Abnormality at both ends indicates poor ignition and charging coils Please refer to trouble detection chart for inspection Trigger Coil Note Mount spark plug on cylinder head inspect at normal compression pressure Remove CDI connector 6P connect high voltage distributor between trigger coil at wire terminal blue yellow terminal and green terminal Actuate electric starting motor or tread on starting rod measure trigger coil maximum voltage Connecting method Positive terminal connected to blue yellow wire negative terminal connected to green wire Minimum voltage 1 7V and above Note When measuring voltage do not touch any metal part of the test bar so as to prevent electric sh
6. BODY COMMON MALFUNCTION AND TROUBLE DETECTION 40 SECTION TWO DETAILED DESCRIPTIONS OF BODY PARTS MALFUNCTION FRONT WHEEL SERVICE 43 FRONT BRAKE SERVICE DISK BRAKE 45 54 E ES FRONT FORK SERVICE HANDLEBAR SERVICE FRONT SHOCK ABSORBER SERVICE REAR WHEEL SERVICE REAR BRAKE SERVICE DISK BRAKE REAR SHOCK ABSORBER SERVICE COOLANT SYSTEM CHAPTER FIVE ELECTRIC PART TROUBLESHOOTING SECTION ONE ELECTRIC PART COMMON TROUBLES AND TROUBLE DETECTION SECTION TWO DETAILED DESCRIPTIONS OF ELECTRIC ASSEMBLIES AND PARTS SERVICE PRECAUTIONS IN ELECTRIC CIRCUIT SERVICE POWER CHARGING SYSTEM SERVICE ELECTRIC STARTING SYSTEM SERVICE LIGHTING AND SIGNAL SYSTEM SERVICE CIRCUIT DIAGRAM IGNITION SYSTEM SERVICE 48 48 50 5 S 53 53 54 56 56 56 62 68 69 74 SUMMARY This 2 stroke scooter BT49QT 28 is with low weight enough power low oil consumption and good operating performance This manual is for maintenance men to repair and maintain BT49QT 28 and it is also useful when maintain other models This manual holds the latest technical information We reserve the right to amend the data instructions and specifications without advice The technical specifications of BTA9QT 28 Size and weight Lengthxwidthxheight Unloading weight 96kg 250KPa Fueltank capacity 4 5 0 5L kn Engine Max torque 4 9 6500 Starting method Electric kick st
7. adjustment of machine part plays and rectification of misfittings and deformations so as to restore correct positions forms and plays Tightening Tightening refers tightening of bolts screws and nuts of machine parts with tools so as to avoid loosening of machine parts and to obtain specified tightening torques Cleaning Cleaning is needed where call for cleanliness and tidiness Cleaning operations include all the means and measures taken to remove dust contamination metal chips oily stains and carbon deposits that might lead to pipe clogging or reduction in motorcycle performance Cleaning measures are washing carbon deposit removing rubbing cleaning and clearing Lubrication In order to facilitate smooth and easy running of moving machine parts including swinging parts reciprocating parts sliding parts and vibrating parts to reduce scuffing abrasion deformation and to reduce friction it is necessary to coat or spray these parts with a lubricant Different lubricants and lubricating methods are required for different machine parts with different functions Application of lubricants to machine parts is known as lubrication Replenishing supplement and replacement These operations refer to addition of oil lubricants cooling water electrolyte fuel and replacement of damaged parts with new ones and replacement of denatured oils with new oils IV THROTTLE ACTUATION INSPECTION Inspect throttle grip for easy and smooth
8. and measure with a dial gauge The dial gauge indicates a 1 2 bending value Limit of use Replace if gt 0 2mm Wheel Rim Oscillation Inspection Measure oscillation value on a correcting bench Limit of use Replace if gt 2 0mm Traverse direction Replace if gt 2 0mm Front Wheel Bearing Inspection Remove front wheel bearing and dust cover Turn bearing inner race to inspect sliding Replace it with a new one in case of no sliding or damage or loosening of outer race Front Wheel Bearing Replacement Dismounting Remove front wheel bearing by means of a bearing remover take out spacer Mounting Apply grease to the bearing Drive in left bearings Mount spacer Drive in right bearings Bearings must be driven in parallel Dust cover must be driven in with the face out Apply grease to new dust cover lip Mount front axle bush 18 Front Wheel Mounting Mount brake disc tighten brake disc mounting bolts Torque 27N m Spread front axle with a thin film of grease Mount front axle from left side Mount in order small bush left front shock absorber front axle bush front wheel transmission gearbox right front shock absorber front axle nut and fasten it Torque 60N m II FRONT BRAKE SERVICE DISK BRAKE Brake Oil Replacing Prevent dust or water from entering brake system Do not use brake oils of different specifications or impure b
9. black yellow wire connected with black T connector and green wire connected with MRA green connector 40 Primary Coil Inspection Measure resistance between primary terminals Standard value 0 21 9 10 20 C Resistance within standard value indicates good state Resistance infinity indicates open circuit of coil Replace coil Secondary Coil Inspection Measure primary coil resistance between terminals Standard value 7 12k Q 20 C Resistance value co indicates breakage of wire in coil Remove spark plug cover measure resistance between wire at primary ignition coil side and negative terminal Standard value 3 1k 2 10 20 C 5 Trigger Coil Inspection of trigger coil can be effected on a Remove motorcycle cover Remove trigger coil wire connector Measure resistance between engine side wire blue yellow terminal and earthing Standard value 50 200 Q 20 C In case measured value exceeds standard value replace AC generator 6 Ignition and Charging Coil t is not necessary to remove coil while coil inspecting P CMT E gt ON EE Remove ignition and charging coil wire ____ K ri ee connector Remove ignition and charging coil wire Connector Measure resistance between generator si black red wire and motorcycle earthing Standard value 400 800 2 20 C In case measured value exceeds standard value replace AC generator 41 IV ELECTRIC STARTING SYSTEM S
10. is effected in an order reversed to that of dismounting e To prevent short circuit please connect negativeterminal first before connecting positive terminal Charging Condition Open Circuit Voltage Inspection Remove foot rest Open storage battery cover and remove storage battery terminal EA Measure voltage between storage battery sef pepa Fully charged 13 1V Inadequately charged 12 3V e Effect inspection by means of a voltmeter Charging Method P Storage battery charging can be effected IN MC following way but the best charging method is one with preset charging time and charging current The charging method is as follows Charging method Storage battery YTX5L BS Storage terminal voltage 11 5V and below 0 4A 20 hours 11 5 12 8V 0 4A 57 10 hours 12 8V and above Charging not necessary 3l In the following cases effect replenishing charging of new storage battery Case for replenishing Replenishing method Charge for 2 3 hours at the charging T current value standard current indicated 0 C and below in winter on storage battery cover Stored in high temperature and high Standard current current indicated on humidity environment storage battery cover for charging Damaged or unsealed during storage charging for15 20 hours without bo sound when unsealed Manufactured 1 2 years ago date of production indicated on storage battery When storage battery voltage is under 11 5V a state
11. main cylinder Remove brake oil pipe from main cylinder Prevent brake oil from splashing to rubber plastic or painted surfaces Cover the above mentioned parts with a cloth Remove brake light switch and brake lever Remove retaining ring from main cylinder Use special retaining ring remover when removing retaining ring Remove piston cover piston and spring Clean oil reservoir and piston with pure brake oil Do not effect cleaning with gasoline as it is corrosive to rubber parts 20 Inspection Inspect for wear or ageing of main and auxiliary cups on pistons Inspect for scratches and other damages on main cylinder and piston Measure main cylinder bore Measure the outside diameter of piston at the end of auxiliary cup Mounting Apply pure brake oil to piston main cup and auxiliary cup Mount spring piston retaining ring and piston cap Piston cup cannot be used inside out Apply grease to brake lever axis pin Mount brake lever and brake switch Mount main cylinder main cylinder bracket and lock them Mount brake oil pipe Connect brake light switch cable with switch Replenish brake oil and exhaust air in brake system FRONT SHOCK ABSORBER SERVICE Dismounting Remove front brake calliper Remove front fender mounting screws and remove front fender Remove front wheel front fender Screw front shock absorber Remove front bodycovering parts Remov
12. of overdiacharging inner resistance of storage battery might be very high and charging can not be effected at a common charging voltage 16 17V In such a case charging can be effected at a higher voltage by adjusting charging voltage to 25V maximum under the supervision of a ammeter In 5 minutes when current reaches standard value voltage must be adjusted back to standard value for continued charging In case current does not change after 5 minutes replace storage battery Storage battery judging procedure flow chart gt 12 8 V and above 3 Confirm with 1 Charge storage 2 30 minutes after starting motor OK 7 Rejected battery for 5 10 the completion of or horn Continue using hours at fixed charging measure current at 1 10 terminal voltage NG w 4 Repeatl at motor or a horn 12 8 V and below Connecting method Charger positive terminal connected to storage battery positive terminal Charger negative terminal connected to storage battery negative terminal Keep storage battery away from fire Before starting charging or at the completion of charging turn off charger switch first so as to prevent explosion due to spark at connecting positions Charging must be effected on the basis of current time indicated on storage battery Inno case should quick charging be used except in
13. BT49QT 28 MODEL SERVICE MANUAL CONTENTS CHAPTER ONE MAINTENANCE OF THE MOTORCYCLE I ITEMS OF MAINTENANCE 1 PERIODIC MAINTENANCE SCHEDULE AND MAINTENANCE LOCATIONS 1 MAINTENANCE SPECIFICATIONS 4 IV THROTTLE ACTUATION INSPECTION 5 V AIR FILTER INSPECTION AND CLEANING 6 VI BRAKE BLOCKS INSPECTION 6 VI BRAKE SYSTEM INSPECTION ADJUSTMENT AND REPLACEMENT 1 VII FRONT AND REAR SHOCK ABSORBER INSPECTION 8 IX FRONT WHEEL AND REAR WHEEL INSPECTION 9 X STEERING STEM INSPECTION 10 CHAPTER TWO MAINTENANCE INFORMATION 1 FRAME NUMBER AND ENGINE NUMBER LOCATION 11 PRECAUTIONS IN OPERATION 11 SPECIFIED TORQUES 12 IV TOOLS 14 CHAPTER THREE ENGINE TROUBLESHOOTING 1 DISSEMBLING AND INSPECTING AIRINLETHOUSING AIR FOIL 18 DISSEMBLING AND INSPECTING CYLINDER HEAD HOOD 18 DISSEMBLING AND INSPECTING CYLINDER HEAD AND VALVE 18 IV DISSEMBLING AND INSPECTING CYLINDER AND PISTON 20 V DISSEMBLING AND INSPECTING KICK STARTER 22 VI DISSEMBLING AND INSPECTING STEPLESS TRANSMISSION SYSTEM 23 VII DISSEMBLING AND INSPECTING ELECTRIC STARTER 29 DISSEMBLING AND INSPECTING MAGNETO AND ELECTRIC FITTINGS 27 IX DISSEMBLING AND INSPECTING CRANKCASE AND CRANKSHAFT 3 X DISSEMBLING AND INSPECTING CHAMCHAIN AND TENSIONER 33 Xl DISSEMBLING AND INSPECTING LUBRICATING SYSTEM 23 DISSEMBLING AND INSPECTING REAR TRANSIMISSION 39 DISSEMBLING AND INSPECTING CARBURETOR 36 CHAPTER FOUR BODY TROUBLESHOOTING SECTION ONE
14. ERVICE Electric starting failure with normal One way clutch spring fatigue or circuit and normal starting motor rotation breakage Starting relay failure without closing Damaged brake switch sound when started but with other electric Burnt starting relay circuits normal Damaged starting switch Damaged CDI Other circuit failures Starting motor does not rotate with Inadequate storage battery charging closing sound of starting relay when Poor contactor contact of starting relay started and with other circuit systems Damaged motor worn brush normal Circuit failure Starting motor keeps running when Idle speed too low starting switch is released Starting motor speed too low Inadequate storage battery Poor connection of wire Starting Relay Actuation Inspection Remove motorcycle cover Main switch is set at ON Inspect if there is a clicking sound when starting motor button is pressed This sound indicates normality In case there is no sound Inspect starting relay voltage Inspect starting relay earthing loop Inspect starting relay actuation o Starting Relay Voltage Inspection Support the motorcycle with main stand and meassure voltage between starting relay connector green yellow wire and earthing With main switch at position ON pull brake Lever Storage battery voltage should be within the specified range In case there is no voltage at starting relay terminal inspect conductivity of brake switc
15. M range inspect voltage adjusting rectifier 33 3 Voltage Adjusting Rectifier Troubles Causes Inspection troubleshooting parameter method Burnt bulb in Damaged Start engine and Replace Voltage 8 lighting system voltage measure lighting voltage I2V adjusting part coil voltage In adjusting of voltage case voltage rectifier adjusting rises with the rectifier rise of engine speed trouble exists Storage battery Damaged Start engine Voltage overcharging or voltage measure 11 1 16 8V overdischarging adjusting part charging voltage Current of voltage and charging 0 5 0 51A adjusting current rectifier Note 1 Normally voltage does not rise much with the rise of engine speed In case of remarkable risee of voltage with an engine speed of 5000r min and a voltage of 40V it is abnormal Note 2 The voltage and current are closely related to the degree of storage battery charging Meassred at full charging the voltage 1s higher and current lower 34 Main Wire Terminal Loop Inspection Remove front cover Remove voltage adjusting rectifier plug 4 and measure conductivity between main wire terminals Item wire color Between storage red and motorcycle earthing With storage battery voltage Between earthing wire green and motorcycle With conductivity earthing Between lighting wire yellow and motorcycle With AC generator coil resistance earthing remove resistor and automatic sid
16. M SERVICE Causes Inspect and judge from O 1 Ignition coil voltage too low Intermittent voltage in ignition coil Sparkless spark plug with normal voltage of ignition coil Ignition and charging coil voltage too low Inner resistance too low inspect with a specified circuit tester 2 Crankshaft speed too low storage battery voltage too low or starting rod too feeble when tread on Circuit tester interfered normal case repeated measured voltgage readings stay above standard Poor contact in ignition system wire O 5 Poor ignition coil Poor ignition and charging coils measure maximum voltage Poor CDI abnormal O 1 O with sparkless spark plug O 1 Incorrect circuit tester connection 2 Poor main switch Poor CDI connector Breakage or poor contact of CDI earthing wire O 5 Poor ignition and charging coils measure maximum voltage Poor trigger coil measure maximum voltage Poor contact of high voltage wire O s Poor CDI abnormal O 1 with sparkless spark plug O 1 Poor spark plug or leakage in secondary ignition coll O 2 Poor ignition coil Inner resistance too low measure with specified circuit tester O 2 Crankshaft speed too low storage battery voltage too low or starting rod too feeble when tread on Circuit tester interfered normal value repeated measurement values above reference value
17. arting LE PEN UN 3 52 7000 Ienition method CDI kw r min Idling speed r min 1700 3 100 Cooling system Forced air cooled Electric system 12V 6Ah Turning signal light 10W 12V Headlight 35 35W 12V Position light 5W 12V ONE MAINTENANCE OF THE MOTORCYCLE I ITEMS OF MAINTENANCE When the motorcycle is used parts loose and mechanical wear inevitably occur to varied extents Neglecting of timely maintenance not only reduces its mechanical function economic performance stability and durability but also threatens the safety of the motorcycle and the rider Correct and timely maintenance of the motorcycle is necessary Items of maintenance refer to the parts and positions for maintenance Different items of maintenance are affected in different intervals and in different manners Running in Maintenance This is the maintenance at the end of the first 1000km and is an all round inspection of motorcycle A newly bought motorcycle or a motorcycle fresh from an overhaul might be severely overheated as a result of severe friction between the moving parts which might be imperfect in finishing or fitting Neglecting in use might lead to damage of the friction surfaces and might threaten the performance and the service life of the motorcycle Please observe the following points Restrict the speed in speed range specified in the instruction manual Restrict the load to 2 3 of the maximum load and ride in fairly good road
18. brake blocks must be replaced with new ones G wear amp tear indicator brake disc brake blocks VII BRAKE SYSTEM INSPECTION ADJUSTMENT AND REPLACEMENT 1 Front brake disk brake Remove the bolts linking brake caliper and front shock absorber Remove brake caliper Do not pull brake lever when brake caliper is removed so as to prevent jamming of brake blocks If brake blocks are jammed pry it with screwdriver and push piston back into caliper Brake Blocks Replacement Brake blocks must be replaced when it is worn to the limit of use t is not necessary to remove brake oil pipe when replacing brake blocks Brake blocks must be replaced as a set Remove the brake block pins by means of a hexagon wrench Take out the old brake blocks and mount a set of new brake blocks Effect mounting in an order reversed to that of dismounting Brake Disc Inspection Inspect brake disc thickness Limit of use 3 0mm Inspect brake disc angularity Limit of use 0 3mm brake block pins front shock absorber bolts brake caliper brake caliper brake blocks 2 Rear Brake disk brake Remove the exhaust muffler Remove the black dust cover Remove the rear wheel nut Remove the three mounting bolts of the rear wheel mounting base Remove the rear wheel Remove the bolts linking rear brake caliper and engine Remove the rear brake caliper D
19. conditions Restrict the length of riding time to avoid long time running of the engine Replace engine oil at short intervals so that metal chips caused in the running in period can be discharged It is recommended to replace engine oil for 3 times during the running in period 2 Routine Maintenance Routine maintenance is the basis of all kinds of maintenances It refers to the daily maintenance including cleaning inspecting and common troubleshooting 3 Periodic Maintenance This maintenance is to restore normal performance of the motorcycle The maintenance is classified into first grade periodic technical maintenance and second grade periodic technical maintenance also known as items of maintenance according to different mileages Generally speaking a first grade maintenance 1s effected after the initial 4000km and a second grade maintenance 15 effected every 8000km As the service time extends maintenance intervals should be shortened accordingly II PERIODIC MAINTENANCE SCHEDULE AND MAINTENANCE LOCATIONS After a period of using one day one month or half a year for example or a certain mileage 1000km 4000km 8000km for example an all round maintenance operation should be effected including comprehensive inspection adjustment tightening lubrication cleaning or replacement The specific regulation made according to time intervals or mileages is known as maintenance interval The motorcycle maintenance schedule is as fol
20. connected When connectors with locks are disconnected locks must be pressed or lifted Connectors are classified into two kinds connectors with press off locks and connectors with lift off locks They must be distinguished in shape before they are disconnected When disconnecting storage battery the negative terminal must be disconnected first When connecting storage battery the positive terminal must be connected first At the completion of terminal connection they must be greased At the completion of connection every part should be inspected for correct connection fastening and conductivity Wires of the same color are connected together when wires of different colors are to be connected they should be connected with wires with a sleeve of the same color near the terminal Connectors of the same color and the same number of wires should be connected When measuring terminal voltage and resistance with a gauge the probe should be inserted from behind the connector Waterproof connector tester should be inserted from the front of the terminal POWER CHARGING SYSTEM SERVICE Troubles Inadequate battery charging horn Adjusting rectifier failure producing no sound a low sound Brake light is eternally on or an abnormal sound starting Electric leakage of attached electric device or motor does not run circuit Storage battery over discharging due to long term storage Storage battery over discharging due to fr
21. e starter plugs and inspect with lighting switch plate set at OFF Between charging wire white and motorcycle With AC generator coil resistance earthing Voltage Adjusting Rectifier Inspection When main wires are confirmed correct inspect for good contact of voltage adjusting rectifier and measure resistance between voltage adjusting rectifier terminals During inspection do not touch the metal part of circuit tester as human body resistance shall affect the accuracy of measurement readings Inspect with a standard circuit tester Consumption of dry battery in circuit tester shall affect measurement readings In case of abnormality inspect battery capacity In case of abnormal resistance between terminals replace voltage adjusting rectifier 4 AC Generator Charging Coil Inspection of AC generator charging coil can be effected on engine Remove AC generator connector 4P Measure resistance between AC generator white wire and motorcycle earthing Standard value 0 2 1 0 2 20 C In case measured value exceeds standard value replace AC generator coil 6 AC Generator Lighting Coil Inspection of AC generator lighting coil can be effected on engine Inspection Remove AC generator connector 4P Measure resistance between AC generator yellow wire and motorcycle earthing Standard value 0 1 0 8 Q 20 C In case measured value exceeds standard value replace AC coil m pA xe 35 IGNITION SYSTE
22. e 2 pieces of bolts on the upper part of front shock absorber Remove front shock absorber Inspection Inspect if there is oil leakage in front shock absorber if there is deformation of shock 21 absorber arm and if there is damage or loosening of any part Mounting Mount front shock absorber on front fork and mount 2 bolts Torque upper bolt 40N m Mount bodycovering parts Mount front wheel Mount front fender and front brake caliper IV FRONT FORK SERVICE Dismounting Remove front body covering parts Remove bolt bush and nut Remove handlebar Remove steering stem set nut Remove upper bearing cup upper bearing top and bearing set Support the body bottom to lift front wheel Remove front shock absorber together with front wheel Remove steering stem from head tube The removing of the bottom bearing cup bearing top and bearing set is the same as the removing of the upper series Do not damage steering stem when removing bearing cup and bearing top Clean opening parts of motorcycle body covering parts with cloth 22 head ube bottom bearing cup upper bearing cup bearing top and ball set bearing top and ball set Inspection upper bearing top Inspect if there 1s slot or pit in bearing cup upper bearing cup and bearing top If there 15 effect E replacemented MM ANC D Inspect for completeness of bearin
23. ead cover Remove horn wire Connect horn wire with storage battery Horn sound indicates normality 45 6 Handlebar Switch Remove handlebar switch connector Inspect conductivity between connector terminals Headlight Switch fo _ gt 4 opeta o fete EAS EA mp nS Starting Switch Horn Switch 46 Direction Light Switch Lighting Lamps Switching Switch Brake Switch Remove instrument hood Remove brake switch wire There should be conductivity between two wires while brake bar is gripped 47 METRES VI Circuit Diagram OLO RG YW BY WYBOR Y G P P BWBER OBNBYGY 6 N cu am Speed mind cable i I Electrical Circuit Chart 48
24. emergent cases Voltage measurement should be effected only 30 minutes after completion of charging 32 Charging current Standard 0 6A Quick 6 0A Charging time Standard 5 10 hours Quick 30 minutes At completion of charging Open circuit 12 8V and above 2 Charging System Inspection Electric Leakage Inspection Remove earthing wire from storage battery connect voltmeter between storage battery negative terminal N and earthing wire Inspect if there is short circuit A with main switch plate at position OFF Connect circuit tester positive ter storage battery wire and negative terminal to negavi terminal of storage battery In case of abnormality inspect if there 1s short circuit in main switch or main wire Charging Inspection Inspect by means of a circuit tester with storage battery fully charged Mount fully charged storage battery on preheated Engine Connect an ammeter between storage battery terminals Remove main fuse and connect an ammeter between terminals Connect engine to tachometer Start engine gradually raise its speed and measure limiting voltage and current Limiting voltage current 14 15 5000r min In case limiting voltage is not in specific range inspect voltage adjusting rectifier Lighting System Limiting Voltage Inspection Remove front cover Set circuit tester at AC position Limiting voltage 13 1 40 5V 5000r min In case limiting voltage is not in specific M
25. equent starting and short distance riding Storage battery has reached limit of use or poor storage battery excessive self discharging Storage battery overcharging or Damaged rectifying part of voltage adjusting over discharging rectifier Damaged voltage adjusting part of voltage adjusting rectifier 30 1 Storage Battery Precautions in Using Storage Battery O 1Do not effect the first starting of a new motorcycle by electric starter as a new storage battery has only 80 of full capacity The difficulty in starting a new motorcycle often causes overdischarging of storage battery O 2MF storage battery must not be replenished with the seal removed A new MF storage battery should not be replenished with common electrolyte It should be replenished with the electrolyte supplied with the storage battery After a new storage battery is replenished with electrolyte it must be kept still for at least 20 30 minutes before it is used At at the completion of electrolyte replenishing and after 20 30 minutes voltage at the terminal is gt 12 5V recharging is not necessary Battery Dismounting Remove foot rest storage battery cover screw Open the cover and take out storage battery Remove negative wire and then positive wire e When removing positive terminal tools should not contact motorcycle body otherwise short circuit shall occur which causes spark that shall easily ignite gasoline and damage storage battery Mounting
26. er upper lock bolt 2 _ Upper bearing top ooo Upper bearing top Exhaust muffler connector nut Exhaust muffler mounting bolt Engine Torsion Tighten part N du quadrature specification 5 3 putter _ 31 Ww 5 Mamer fang fing wk RSR 5 ws oa Magneto rotor fixing bolt 1 Oil pump driven gear bolt mm 08 4 4 5 3 Standard Torques Bolt nut M12 Screw M6 Flange bolt nut M6 Flange bolt nut M8 Flange bolt nut M10 IV Tools Flywheel disassemble ware Spark plug spring guide CHAPTER FOUR BODY TROUBLESHOOTING SECTION ONE BODY COMMON TROUBLES AND TROUBLE DETECTION Body part common troubles and possible causes are as follows Details reference Handlebar rotation Over tightening of handlebar not easy strenuous adjusting nut Refer to Front Fork turning or unstable Steering stem over worn service tightness Refer to Handlebar Service Front tachometer cable Fork Service Incorrect mounting of brake cable or Remarkable deformation of steering stem due to outside impact Refer to Front Fork Heavy steering stem Service Over tightening of steering stem top turning ball bearing retainer Damaged or broken ball bearing Refer to Front Wheel Service Reduced tire air Rear Wheel Service Refer to Front Shock Absorber absorbers Service Deflected steerin Refer to Front Fork cem Bent front fork Se
27. g balls amp and if there 15 effect replacement with new ones Inspect for proper tightness of steering stem and if not effect adjustment and fasten it Inspect for correct position of bearing cup and bearing top and if not effect correct mounting Bearing Cup and Bearing Top Replacement Remove bearing cup and bearing top with special bearing cup and bearing top remo vers Mounting Apply grease to bearing cup and bearing top at the bottom Mount in order bottom bearing cup bearing ball set bottom bearing top on the bottom of steering stem Pass steering stem through head tube Apply grease to top bearing cup and bearing top Mount in order upper bearing cup bearing ball set and upper bearing top on the upper part of steering stem and fasten them Torque 15 N m Turn front fork right and left to effect close contact of bearing balls Loosen upper bearing top to torque 0 and fasten it Torque 2 5N m Fix upper bearing top and tighten steering stem setting nut Torque 70N m Turn front fork and confirm easy rotation without loosening Lock set nut Mount front shock absorber together with front wheel Mount handlebar bolt bush and nut Mount handlebar Mount front body covering parts 23 V HANDLEBAR SERVICE Dismounting Remove covering parts of front part rear part upper cover and nether cover of handlebar Remove the meter assy Remove two bolts of rear brake main cylinder and rem
28. h and wire 42 Starting Relay Earthing Loop Inspection Remove starting relay connector Inspect conductivity between wire connector terminal yellow red wire and motorcycle earthing Conductivity between terminal yellow red wire and motorcycle earthing when starting button is pressed Inspect conductivity of starting button and wire Connect starting relay with storage battery connect starting motor terminal with three in one meter Connect fully charged storage battery between yellow wire red wire and green wire yellow wire EE When storage battery voltage 15 introduced conductivity between relay storage battery starting motor terminal should be normal V LIGHTING AND SIGNAL SYSTEM SERVICE Causes Burnt bulb in lighting system Partial damage of voltage adjusting rectifier All direction lights are off Inadequate charging Flashing relay failure Damaged direction lights switch Circuit failure One direction light is not on and one does Burnt bulb or poor contact between bulb not flash and bulb seat When braking all lighting lamps and Breakage of earthing wire direction lights are on but headlight Short circuit of taillight Silent horn or horn sound too low Inadequate storage charging Wire failure Horn failure No indication of fuel gauge Fuel gauge failure Damaged oil level float 43 1 Headlight Adjustment and Dismounting Loosen headlight fastening bolt and turn headli Remove head
29. ial tightening from larger diameters to smaller diameters and inner ones to outer ones in a diagonally order Tighten them to specific torques Parts and greases must be those made by our factory or recommended by our factory Special operations must be effected with special tools or specified universal tools Removed parts must be rubbed or cleaned before they are inspected or measured They must be coated on the sliding faces before mounting They must be greased at the specified positions with designated or equivalent greases Parts must be tightened and their performances inspected at their positions when mounted The battery s negative terminal must be disconnected before operation Make sure that tools such as wrenches are not in contact with the frame At the completion of operations reconfirm correct connections and fastenings The positive terminal must be connected first in case of a removed battery Connected terminals must be coated with lubricant The terminals must be completely covered with caps When a fuse 15 burnt inspect the cause and replace the fuse with a fuse of equivalent capacity At the completion of operation completely cover terminals with caps When removing connectors with locks they must be unlocked before operation When removing connectors the connectors proper must be held instead of pulling their wires Before connecting connectors confirm that they are free from breakage bending ove
30. light fastening bolt Remove headlight cover Remove headlight bulb Mounting is effected in an order reversed to that of dismounting CIf want to change healight bulb the bulb should be 12V 18W to adjust un beam P PE F B H R 2 Front Direction Light Bulb Replacement Remove 2 plus screws Remove direction light cover Remove bulb Effect mounting in an order reversed to that of dismounting Mi fs XT AT if 3 Taillight and Rear Direction Light RI Taillight and Rear Direction Light Bulb Replacement Remove motorcycle guard cover Remove taillight hood set screw Removee taillight hood Remove bulbs of taillight and direction light Effect mounting in an order reversed to that of dismounting J Te XT AT i 4 Main Switch Main Switch Conductivity Chart S ON 040 3 3 Remove front head cover Remove main switch wire connector Inspect conductivity between connector terminals 5 Horn Voltage Current Horn condition Location of Troubleshooting supplied supplied trouble 10 0 2A No sound Horn Increase horn current 14 5V turn out adjusting screw counterclockwise at 1 6 turn a time 2 3A No Nosound Replace horn Horn Decrease horn current turn in adjusting screw 1 6 turn a time Inadequate Inspect power supply power when voltage 10V adjust horn in above mentioned manner Remove front h
31. lows 1 1 Maintenance Schedule Maintenance Schedule Eneine oil VES 5 300km Engine oil straine Gasoline straine Throttle play Spark plug 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 r r Z z 7 bearing Steering Suspension Screws and bolts of parts I Inspect and when necessary clean lubricate supplement modify or replace A adjust C clean R replace T tighten Effect periodic maintenance according to the instructions in the user s manual When the mileage exceeds the range specified in the schedule repeat the maintenance In dusty or rainy conditions inspection and replacement should be effected earlier In heavy load long distance or rainy conditions replacement should be effected earlier MAINTENANCE SPECIFICATIONS The basic methods of motorcycle maintenance include inspection adjustment tightening lubrication cleaning supplementing and replacement which constitute the main elements of maintenance 1 Inspection Inspection refers to basic inspecting operations in accordance with items and requirements specified in the user s manual including inspection with instruments or with eyes for abnormalities in machine parts directly comparing related data and aligning with tools and gauges Adjustment Adjustment refers to inspection based adjustment and rectification of some specified machine parts including
32. mounting am h 07777 Remove 2 mounting bolts of rear wheel fender Remove 2 mounting bolts and 2 mounting nuts of exhaust muffler and remove exhaust rear wheel fender j muffler rear wheel fender mounting bolts exhaust muffler muffler mounting bolts Remove the black dust cover Remove the rear wheel nut Remove the three mounting bolts of the rear wheel mounting base Remove rear wheel mounting nuts exhaust muffler 25 Rear Wheel Oscillation Inspection Measure oscillation value on a correcting bench by means of micrometers Limit of use Longitudinal gt 2 0 mm Traverse gt 2 0 mm Mounting Mount rear brake disc and fasten the bolts Torque 27N m Mount rear wheel in an order reversed to that of dismounting Torque 120N m Mount rear shock absorber and fasten lower mounting bolt Mount exhaust muffler Fasten exhaust muffler connecting nuts and bolts Torque Exhaust muffler connecting nut 12N em Exhaust muffler mounting bolt 35N m VI REAR BRAKE SERVICE DISK BRAKE Rear brake service is the same with front brake service Vil REAR SHOCK ABSORBER SERVICE Dismounting Remove motorcycle body covering parts Remove upper mounting bolt connecting rear shock absorber and motorcycle frame lower mounting bolt connecting rear shock absorber and engine Remove the rear shock absorber 26 cyli
33. nder bracket bolts Inspection Inspect rear shock absorber oil seal for oil leakage inspect buffer bar and spring for deformation and other parts for damage and loosening Mounting Mount rear shock absorber Torque upper mounting bolt 40N m lower mounting bolt 25N m Mount motorcycle body covering parts 27 CHAPTER FIVE ELECTRIC PART TROUBLESHOOTING SECTION ONE ELECTRIC PART COMMON TROUBLES AND TROUBLE DETECTION No electrolyte Whitened electrode plate Battery short circuit overdischarging No power Poor adjusting voltage rectifier Disconnection of battery wire Broken fuse Poor power switch main switch Battery discharge Poor battery charging Refer to Low power Poor contact Power Supply voltage Poor charging system System Poor adjusting rectifier Service Breakage of Poor contact of battery wire power current Poor contact in charging system Poor contact or short circuit in ignition system Poor contact or short circuit in light system Poor contact of wire or connector wire breakage Poor power or short circuit supply Poor adjusting rectifier Poor AC generator Poor spark plug eg gemeng Between AC generator en and CDI Refer to Sparkless circuit of wire Ignition spark plug System Service Poor ignition coil switch Poor ignition coil Poor CDI Poor AC generator 28 Generator running not easy Poor starting Feeble starting motor Engi
34. ne refuses to start with starting motor running No switching between high beam and low beam when hightlight HI or LO is operated Gasoline indicator failure Fluctuation of gasolin gauge Poor primary ignition loop Poor secondary ignition loop Poor ignition timing Burnt fuse Poor ignition coil Poor contact of wire or connector Poor main switch Poor ignition coil Poor contact of wire or connector Poor main switch Poor AC generator coil Poor fitting of stator Poor CDI Inadequate battery charging Poor main switch Poor starting motor switch Poor switches of front brake and rear brake Poor electric relay Poor contact or breakage of wire Poor starting motor Inadequate battery charging Poor contact of wire Jamming of starting motor or pinion by foreign matter Poor starting motor pinion Reversed running of starting motor Poor battery Poor or damaged electric bulb Poor switching switch Wire not mounted Breakage of wire Poor actuation of float Poor gasoline gauge Poor instrument Loose wire bunch Poor gasoline gauge Poor instrument 29 Refer to Ignition System Service Refer to Electric Starting System Service Refer to Lighting and Signal System Service SECTION TWO DETAILED DESCRIPTION OF ELECTRIC II ASSEMBLIES AND PARTS SERVICE PRECAUTIONS IN ELECTRIC CIRCUIT SERVICE Main switch must be set at position OFF before wires are connected or dis
35. o not pull brake lever when brake caliper is removed so as to prevent jamming of brake blocks If brake blocks are jammed pry it with screwdriver and push piston back into caliper Brake Blocks Replacement The same as the replacement of the front brake blocks Brake Disc Inspection The same as the inspection of the front brake disc mounting bolt rear wheel nut VIII FRONT AND REAR SHOCK ABSORBER INSPECTION L Front Shock Absorber Tighten front brake lever press front shock absorber up and down and inspect actuation Inspect front shock absorber to see if there is leakage of oil and if there 15 damage or loosening 2 Rear Shock Absorber Press rear shock absorber to inspect actuation Inspect rear shock absorber to see if there is oil leakage and if there is damage or loosening in machine parts Lift rear wheel press rear wheel right and left to inspect if engine suspension lug buffer bush is loose IX FRONT WHEEL AND REAR WHEEL INSPECTION Wheel Rim Inspection Inspect wheel rim remove rust stains and rubber chips Deformation and fissures are causes of air leakage Do not use wheel rims in the following cases Bruise of wheel rim face contacting tire bead ring exceeds 0 5mm in depth and 1 0mm in width Tire Inspection Inspect if there is fissure or iron nail in the tire In one of the following conditions tires must be replaced instead of
36. ock In case measured CDI set terminal maximum voltage is abnormal remove motorcycle right cover and AC generator connector Connect trigger coil blue yellow with distributor Incase CDI set terminal voltage is abnormal and AC generator terminal voltage 1s normal it indicates poor contact of connector or wire breakage Abnormality at both ends indicates poor ignition and charging coils Please refer to trouble detection chart for inspection 39 3 CDI Check Poor contact Damaged terminal poor connecting Absence of high voltage or contact Occasional misfire punctured or damaged diode Poor acceleration punctured or damaged transistor Effective kick starting elctronic punctured or damaged thyristor starting failure integrated circuit damaged capacitor or resistor Open storage battery cover Remove CDI set inspect ignition related parts and wire terminals Remove CDI set inspect if there is connection loosening or corrosion earthing switch at OFF earthing Trigger coil Blue yellow motorcycle earthing Primary ignition coil Black yellow green 0 21 2 10 Secondary ignition coil Green spark plug cover 3 1k2 10 not including spark plug cover 4 Ignition Coil Dismounting Remove motorcycle cover Remove spark plug cover Remove spark plug cover Remove ignition coil set bolt and ignition coil Effect mounting in an order reserved to that of dismounting Connect primary coil with
37. ove brake main cylinder Remove connectors of left handlebar switch Remove 2 screws of left handlebar switch Remove left handlebar switch Remove left grip from handlebar Remove two bolts of front brake maincylinder and remove brake main cylinder Remove connectors of right handlebar switch Remove 2 screws of right handlebar switch Remove right handlebar switch Remove throttle cable from throttle grip Remove throttle grip from handlebar Remove handlebar bolt bush and nut from handlebar Remove handlebar When removing left handlebar and throttle erip remove contamination and grease from contacting face 24 head cover front part meter assy head cover rear part upper cover nether cover front brake right handlebar switch main cylinder Mounting Mount nether cover of handlebar Mount handlebar on steering stem guide tube fit bush setting bolt and nut Torque 45 N m Mount upper cover of handlebar Mount front and rear brake main cylinder Mount left and right handlebar switch Apply grease to throttle cable Mount throttle grip and connect throttle cable Mount left grip Mount covering parts of front head cover and rear head cover Confirm easy rotation of throttle grip When mounting left grip apply a thin film of adhesive to contacting face and then mount grip in a turning manner VI REAR WHEEL SERVICE Dis
38. r length or loosening 10 Connectors must be inserted home When connecting connectors with locks confirm that their locks are fastened Confirm that the wires are not loose Confirm that connectors plastic sleeves completely cover the connectors without fail Before connecting the connectors confirm that their sleeves are free from breakage and their terminals are not oversized Connector plugs must be fully inserted Confirm that plastic sleeves completely cover the terminals Plastic sleeves should not be placed with the open side up Wire bunch bands should be fixed at the specified position of motorcycle frame Wire clamps must correctly keep wires in place Avoid welding stains of welded clamps when clamping wires Wire bunches must be fixed away from turning or moving parts Do not damage the covering of wire bunches In case of wire bunch defects remedy it with insulating bands Wire bunches must not be covered with mounted parts Do not twist or bend cables by force Deformed or damaged cables would result in poor rotation or damage SPECIFIED TORQUES Torques at important positions and standard torques of other positions are as follows SPECIFIED TORQUES Frame W Thread Torques Designations of tightening positions Number MM specification N m 2 mo 45 2 MIO 45 Fromtasemt Il m 0 M16 Rear shock absorber lower mounting bolt 1 Front shock absorb
39. rake oils Prevent brake oil from dripping onto rubber plastic or painted parts Brake Oil Exhausting Place main cylinder at a level place remove oil reservoir cover oil reservoir cover and diaphragm Connect a hose to oil exhaust valve loosen exhaust valve grip and release brake lever till oil is exhausted Brake Oil Replenishing Lock exhaust valve Replenish oil reservoir with specified brake oil It is not necessary to fill the oil reservoir to the full capacity Brake oil for replenishing should be the same as original The specification of brake oil is indicated on exhaust valve the reservoir cover Place diaphragm 19 Connect a transparent hose to exhaust valve Grip brake lever fast and open exhaust valve 1 2 turn to let out air and lock exhaust valve Repeat this operation till no bubbles are exhausted from brake oil passage brake lever valve is closed releasin Do not release brake lever before exhaust At the completion of adjustment replenish brake oil till oil 1s over the lower limit line of the oil reservoir Mount diaphragm set and oil reservoir cover Tighten oil reservoir cover bolt Main Brake Oil Tank Dismounting and Mounting Dismounting Exhaust brake oil from front brake system We Take out brake switch plug from main cable Remove bracket bolts from handlebar Remove
40. repair Puncture of tire by a foreigner matter 6mm in diameter or tire fissure Layered tire Chunking of tread Damaged tire bead Broken tire bead or other tire bead damages Broken tire cord Damage due to forced dismounting Fissure extending to frame Abnormal inner lining Tire groove wear front wheel lt 0 8mm rear wheel lt 0 8mm Punctured or otherwise damaged tire flank Inspect tire pressure by means of a tire pressure gauge Tire pressure should be inspected when the motorcycle is in a cold state Specified pressure Unit KPa Rear tire Tire Specifications Front tire 130 60 13 Rear tire 130 60 13 Inspect if front wheel nut is loose Inspect if rear wheel nut is loose If loose tighten them to specified torques Torques front wheel nut 60N m rear wheel nut 120N m rear wheel nut X STEERING STEM INSPECTION Swing handlebar right and left to see if there 1s interference such as wire or other things Turn front wheel to see that handlebar 1s easy in operation In case of any difficulty in operation inspect steering stem bearing assembly CHAPTER TWO MAINTENANCE INFORMATION I FRAME NUMBER AND ENGINE NUMBER LOCATION frame number A II PRECAUTIONS IN OPERATION Removed washers O rings elastic retaining rings and split pins must be replaced with new ones When mounting bolts nuts and screws proceed from tr
41. rvice Refer to Front Bent front tire deflected tire Wheel Service Bent brake lever Air in hydraulic Refer to Brake device System Inspection Feeble brake Adjustment and Disk brake failure iever Leakage in hydraulic Replacement Front device brake service or rear brake service Imbalance of right and left shock Clogged hydraulic passage 14 Chart continued Details reference Inadequate liquid block and brake disc brake disc caliper brake caliper piston Feeble brake Viscous or worn lever brake caliper piston Inability of brake caliper normal sliding Worn main cylinder piston seal ring main cylinder piston Refer to Brake cylinder System Inspection De Clogged narrow Adjustment and brake system Replacement Front Clogged narrow brake service or rear liquid passage brake service Viscous worn brake caliper Stiff brake lever Inability of brake caliper normal sliding brake caliper piston main cylinder piston block and brake disc Bent or deformed brake disc Inability of brake Resisted braking caliper normal sliding Wheel not adjusted straight 15 Chart continued Details reference Refer to Front Fork Steering stem rotation not easy TEN ervice Bent shock absorber Refer to Front Shock Ne Shock absorber oil leakage Absorber Service motorcycle direction Bent front axle incorrect wheel inclining to roadside mounting
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