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  • Pgo Bigmax Servicemanual PDF

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    20 visualizações132 páginas

    Pgo Bigmax Servicemanual PDF

    Enviado por

    port23

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    © All Rights Reserved
    Baixe no formato PDF ou leia online no Scribd
    Sinalizar o conteúdo como inadequado
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    SCOOTERS SERVICES MANUAL PREFACE This manual offers all service specialist with the technological procedures of maintenance , repairing for BIG-MAX Detailedly show those whom may concern how to naintain,repair, change parts, troubleshoot and reaseenble,etc. At-any important section we illustrate by assembly, explosion diagraas and photographs, if necessary please check the diagrams already shown. Though we have tried our best ,please kindly instr~ uct us any faults in this manval. TAIWAN P.G.O. CO,LTD. © =1- CONTENTS: Page — >The specification of BIG-MAY. => Service information. (1) The notice for operation (2) Torque valve (3) Lubrication instruction (4) Wiring diagram (5) Troubleshooting... = Checking and Adjustment. (1) Dated checking table. (2) Battery... (3) Cleaning air cleaner... (4) Final reduction mechanism oil (5) Spark plog (6) Compression pressure measurenent (7) Ignition timing eee (8) Throttle cables adjustment. . (9) Idle adjustment..... (10) Frt brake adjustment (11) Rear brake adjustuent. (12) Wheel... : : > Dismant ing, maintaining, repairing and assembling operation. (1) Lubrication system... (2) Plastic parts of chassis (3) Engine dismantling. (4) Drive pulley, starter, clutch, driven pulley (5) Cylinder head, cylinder, piston (6) AC alternator flywheel magneto. (7) Final transmission mechanism. (8) Crankcase, crankshaft. (9) Carburetor (10) Steering column,front wheel,frt brake comp.,front fork (11) Rear wheel,rear brake,rear damper...........-.000. 00005 ' -2— (12) Fuel tank,oil tank. BH» Electric equipment (1) Troubleshoot ing. (2) Battery... (3) Recharge system (4) Ignition systen.. (5) Starting system —3~ — » Specification: Name: BIG-MAX Model: Size: overall Jength:1710nn overall width : 670mm overall height:1110nn overall] base :1195mm Weight: net weight:84kg front :33kg rear :5lkg total :8¢kg carrying capacity: 2 passengers and 110 kg total weight :194kg front :61 kg rear :133kg total :194kg Performance: consumption :45km/L gradient ability :19° Engine: model ; Pl fuel :unlead cooling: forced cool by fan Cylinder: bore: 40am stroke:39. 2mm number :] arrangement :horizo— ntal displacement :49cc compression ratio: 8:1 ignition:CDI start :kickstarter or 1.3 ke/ent electric start. Rear whee! pressure: Lubrication:separated 1.5 kg/emt Lubrication type Chassis:stee] pipe Front absorber:expanding & contracting Rear absorber:unit swing Drive train: Primary reduction: cvT Sceondary reduction: 52/13 X 44/13=13.538 Clutch type:centrifugal type Selector:infinite va- riable speed(CVT) Wheel dimension & layres: rear:130/90-10 front:120/90-10 Front brake:hand brake disk by oil.pressure type Rear brake:hand brake lining expanding by mechanism type Speedometer :80 kn/hr Head lamp :12V 18¥/18¥ License plate lamp: 12¥-154 Brake lamp:12V-10¥ Turn lamp :12¥-10¥ Horn:12¥ DC Silencer:diffusible absorption closed type Moffler location and direction: Chassis lower right s- ide f engine backward Front wheel pressure: = > Service information: Page (1) The notice for operation. 16 (2) Locking torque value... a7 a. For engine bd. For chassis c. Others (3) Lubrication instruction...... a. For engine b. For chassis (4) wiring diagran. (5) Troubleshooting. 7 -Hard starting or no starting b.Bad pick up c.Running not smoothly(slow speed) d.Running not smoothly(high speed) e.Clutch,érive,driven pulley f.Handiebar steering vhen running g.Front and rear damper not even d i j k -Bad braking Oi] gauge -Fuel gavge Starting motor ~5— (LD The operation notice : l.Alwvays replace gasket , oring , cotter , pins and circlip whenever reassembled. Tighten fastener,beginning on center or iarger dia bolts to specs,where sequence is not specifed in an x patter. .Use PGO. or PGO. recommeded parts. After dismantling please wash all parts necessary for checking and grease all contact surface yhen reassembling. .Use grease recommended by P.G.0 -When renoving battery,please dis~ connect the negative pole(-) fir- st vhen assemblying please connect positive pole(+) first. Before installing a new fuse,con- firm the specification is correct or not. After reassemblying,please confi- rm that all connecting point, loc~ king parts,circuits,polar chara- cteristics are good,before selli- ng out. Nw aa ~ ~ ‘senha sn eon rem ne on titi nthnnsinr whiter neta reerrnnene (2)Torque value: 1.Engine Xo locking location Locking torque gis Remarks 1 | cylinder head 1 2 | When the engine is cold 2| flywheel plate 3.2-4.0 3] rear brake lever 6 } 1.0-1.2 4] driving pulley 10 3.2-4.0 5 | clutch outer 10 3.5-4.0 6 | right crankcase 6 1.0-1.2 7 | drive gear box cover 6 | 1.04.2 8 | left crankcase 6 1.0-1.2 9 | draining bolt 8 | 18 When the engine is cold 10 | inlet pipe 6 | 1.0-1.2 11 | flywheel magneto 6 | 1.01.2 12} cooling fan 6 | 1.01.2 13 | muffler nut on cylinder head 6 1.0-1.2 | When the engine is cold 14) starting motor 6 1,0-1.4 | When the engine is cold 15 | brocket between eng. and 6 } 1.0-1.2 rubber pad of central stand 16 | spark plug 14 | 2.5-3.0 iT | fan cover 6 | 1.0-1.2 18 | fixed plate,drive clutch 6.) 20-14 19 | nut of rear vheel axle 14 | 8.0-10.0 | 0 TYPE xUT 20 | kick starter 6 1,0-1.2 7 HEE 2, Chassis 1 | steering stem nut 10m} 3.0-4.0 | lock nut 2] front axle nut 12mm], 5.0-6.0 | (U type nut) 3 | fixed nut fasten eng. and 12mm] 5.0-6.0 | (U type nut) chassis 4} rear shock absorber 10mm} 3.0-4.0 (upper) rear shock absouber nn} 2.0-3.0 (lover) 7 5 | lock nut fasten frt. brake 8me} 2.0-3.0° | lock nut disk and frt. whee] rim 6 | lock bolt between frt. 8mm} 2.0-3.0 | lock bolt brake pump and frt. absorber 7 3.0ther parts please refer the following table: Standard torque valves: Xo Item Torque kef-a 1 5mm bolt and nut 0.45-0.6 2| 6am bolt and mut 0.8 -1.2 3 §nm bolt and nut 1.8 -2.5 4 10mm bolt and nut 3.0 4.0 5 2mm bolt and nut 5.0 -6.0 6 5mm screw | 0.35-0.5 7 6nm screw 0.7 -1.1 8 6mm flange bolt and screv| 1.0 -1.4 9} aon flange bolt and screr| 2.0 -3.0 | 20 | 20m Fange bolt end seror) 3.0 ~4.0 —3— erromroneinnecuneeninenteheninaesonosateinrennisnee ttn eterna et (8)Lubrication instruction: A. Engine Lubrication parts Oil type Renarks a crankcase inner fotating, sliding part. preniun 2 cycle auto-separated lubric~ action 2) cylinder inner rotating, motorcycle oil slinding parts. or SAE=30 3] drive gear box SAE=90 10ce gasket of starter shaft clean grease start idle gear sliding parts clean grease —9- B .Chassis parts ball-clean grease —10- steering coluan steel brake cam pin-clean grease Wheel bearing part Final drive mechanism-oil i speedometer gear - clean grease Frt. whee] bearing ~ clean grease ~1— (4)Wiring diagram " —o — STIPE -12- =e 2 Front chassis cable assembling diagram -13— 3 Rear chassis cable assembling diagram —14— (5)Trouble shooting: l.Hard starting or can’t start: Check and adjust screw check inner side o icarburetor have fuel. The fuel supplies carb- uretor enough or smooth peers Remove spark plug, ins~ ert spark plug cover,a- nd tovch with engine o~ heck there is any spar! No fuel supplies carburetor sparking or weak sparking there is sparking in spark plug Measurement mpression 0 unsufficient or no pressure pressure is normal ngine as the i astruction of startin; engine engine has no knocking engine knock ing| and can’t start [ret Benove spark plu -156— Trouble condition The reason Dcheck there is fuel or not @check inlet or ovtlet of air carburetor or fuel is block @float is blocked @fuel cover air hole is blocked Ospark plug out of ord- er @dirty QCDI unit out of order @A.C. set magneto out of order @lgnition coil discon- nect or short circult ©uain switch out of o- rder Opiston ring dead @reed valve out of order @piston and piston ring over worn @cylinder washer leakage ®conpression part sand hole @crankcase leakage Qcontroller is abnormal @inlet pipe has air @wrong ignition timing @carburetor oi] level too high @controller is abnormal @throttle valve open too largely 2.Weak acceleration;defficient horsepover Check and adjust [Trouble condition | The reason | oO eagine Star p jtarottle gradually, @air cleaner blockded @fuel supply system abnornal @fvel tank cover bl- [ose engine can rotate engine can’t rot~ ap ate up completely ocked ( Running on flat road ) gnition timin~ g,check with igniti- 1 timing is timing is not correct correct, y perssion pressure (use cylinder comp- ression pressure g~ avge) [Poets etre pressure is normal normal check carburetor } is blocked or noty @mufiler blocked Q@CDI unit ovt of ord- er @aAlternator flywheel magneto out of order Ocylinder,piston ring er worn out @cylinder washer lea- pressure is not! kage @compression part sa~ nd hole @spring plate valve out of order blocked f— clean the carburetor Remove spark plug an check it Yo dirty ead no @clean the dirty jana color orange] @specification is color change {aes check engine overhea' 1 [[crerheats not overheat fRunning accelerately or: igh speed continuously not correct @piston and cylin~ Ger, burnity @nixture is too lean @cylinder,bad quality @aixer,too much ca- rbon @ignition timing is too early Qmixer,too much-ca~ No knocking knocking} rbon —16— @fvel,bad quality @ciutch slip @nixture is too lean 3.Engine running unsmoothly(low speed and idling) Check and adjust] Trouble condition | [The reason not correct}—@CDI or Ac magneto is adjust carbureto: ovt or order. air screr r Omixtur too thick good adjus-| [faulty adj (loose the screw) tmeat stment “ @mixture too lean a (tight the screv) check carburetor ¥~ f Coo! plater washer + asher is air, } is dovt of order @Carburetor locking No leakage Teakage} part loose @lniet pipe washer Remove spark plug, inse- faulty rt spark plug cover,t- L @Carburetor oring ouch with engine kick distorted istart,check the sparking - r Ospark plug dirty [ > @CDI out of order Good sparking] [sparking abnora- |__| @AC magneto abnornal al or no sparking} | @ignition coi! faulty [ @H.7. coil disconnect 4.Engine running onsnoothly (high speed) or short circuit L @nain switch abnormal [Check and adjust] Trouble condition] | The reason o heck gai ing heck fuel 1 supply system tion tix correct cock, fi L @AC nagneto f Ofuel is not check inle 2le of car is blocked good t or noz~ buretor blocked cc Xo blocked ~17- @cvI sets faulty not correct abnormal enough + @fuel pipe, fel f- unsmoothly liter blocked “ @fuel tank air inlet blocked }——~ @clean and wash it 5 ° engine can start but can’t move the vehicle clutch,deive, driven pol ley Trouble condition the reason [— Qariving belt worn out distortion engine runs, bot if stops tH climbing is not smoothly and seem to rush out (rear wheel rotates while id] ing) @adriven plate worn out f—— Qdriven plate spring distortion [— @driving lining worn ovt [-— @ériving pulley shaft gear trough cracked L— @final gear damage f— Odriving lining spring cracked or yorn out f—- Qclutch cover and clutch not tight properly L— @shaft worn out — Odriving belt worn out, distortion, slipping [-— @hanmer roller worn out not tight LY Noise,cdor when running can’t reach high speed — [— @sriv L— @driving pu @ériving plate vorn ovt g plate spring distortion f— Qériving belt worn out slipping +— @hanmer roller worn out L— @ériving pulley shaft worn out [— attach grease on driving belt, pulley @ariving beit orn out [-— Gdriven plate spring distortion ‘— @driving pulley shaft worn ovt ~18— ion ogh or ight ion, ght on S.Handlebar steering vhen ronning. |-—{front and rear wheel swings handlebar operates heavily (Ciaticondtte —] (front and rear whee! pressure is normal) r Osteering column lock screw locked too tightly L @steel bal] cracked @front ,rear wheel rin distorted [eter wheel braring swings @front axle nut loosing r Ofront and rear heel center not ali- i— handlebar turning oneside gnnent 7.Pront,rear damper not evenly @front fork curved Trouble condition the reason | (front and rear whee] pressure is normal) r damper spring is too soft @carrying weight too large damper is too soft @damper oi! leakage ——| damper is too heavy 8.Brake disorder. ik front fork guide rod crooked @aanper and damper cover cracked {7 “camper is noise Ly Odanper tube and spring @danper and damper cover cracked 9 [Trouble condition the reason | ~(adjustuent according to standard procedure) brake plate "A" mark points] -- @brake lining worn out to "A" mark [F Q@brake lining cam worn out f+ Qbrake cam vorn out “ @brake shoe worn out f- Obrake lining worn out [1 “Woise when brake L faulty performance @brake lining material attached @brake shoe contacting surface rovgh Obrake cable enlongs or operated badly Qbrake contacting surface not evenly @ water or sand drop into brake mechanisn @sone grease on brake lining surface ~19— 9.0i1 indicator (a) The oi! lamp doesn’t light, (when the main switch is at “ON” position) Trouble condition check and adjust lamp on check wiring fof battery lamp dims, light not flash,not light} Remove the oif Tamp,} contact vith battery heck electric emove oil gauge,c- pheck the lamp light r not with floati~ f potion float upward: lamp exting~ Ye sod] UI vish float downward: lamp torn on the reason fuse burn out @battery no power Qnain switch abnormal @circuit plug drop off ®uain wiring disconnect fignp“Tgnss] @bulb abnornal TOelectric plug ioose or drop off nain wiring disconnect wrong wiring connecting float faulty @oil gauge switch dis- connect or short cir~ cuit (b) Oil is enough but indicator light continuously (when the main switch is "ON") check and adjust Trouble condition the reason icheck all electr: disorder] Remove oi] gange c- heck the lamp with floating motion electric plug loose or drop off Cem wiring disconnect @rrong wire connecting p7Ofloat faulty good] [disorder |@oil gauge switch di- float upward:lamp ex- LJ. sconnect or short c~ tingwish ireuit float downward: lamp Doil tank distorted turnon @sone impure material in ~—20— i | i t | j t : i 10.Foel gauge (a) fuel gauge indicator indicates uncorrect fuel. quantity(shen the main switch is “ON") Teaibe coin on check and ai tira the turn sign a] lawp on, check } wiring of battery @fase burn out }- Obattery no porer Vanp dins, light o-|[}- @main svitch abnorna) ot flash,not light{} @circuit plug drop off L Qnain riring disconnect enove the fuel nk float move up 2 né dova t check t= he. needle, novenent, fneedie no] [needle moves @float notion abnormal lnot ion est,to check the edie movenent needle }-———— 01 gauge abnorna) oves [~ Deiectric plug drop good abnormal off ETL orton comectin Ovire broken or short circuit (b) fuel gauge needle not steady sonetines move up and dorn(when the main switch is " [heck end adjust [Trouble condition the reason f— Ofvse burnt ovt [~ Obattery no power Poet }- Q@nain switch abnormal [fo otion @cirevit plug érop o- if or broken 1 L. @nain wiring disconnect needle’s tr-] [No aovenent}-— Ofvel gavge contact n,check wiring of battery Renore the float I~ nside the tank ,no- ve up and down to check the needle’s : | ack noves PEPE abnormal down guickly(Imove/; second) check the needle needle no lack of absorbed fue needie’s track noves novenent, rie plug connection ¢ ondition good abnornal @electrie plug drop Poe off, loose @vire broken or short circuit, -21- 11.The starting notor (a) starting motor no notion check and adjust P push starting Swi tch check the mov- enent of start relay Starting wotor ef" ectric vire conta~ } Trouble condition brake lanp not light ash not light the reason QOfuse burn out @battery no power - Qaain svitch abnornal I~ Ocircuit plug drop off L_ main viring disconnect Tenp dim, not f1-}—Qbattery no porer no movement [gt battery directly; starting notor rons Starting wotor| no notion (b) starting motor running slorly or idling To Ostart switch contact poorly f- @relay wire broken or short circuit L_ @circuit plug loose Qcarbon brush vorn E @coil broken or sho- rt circuit t~ Ostarting motor wire broken L. @circuit plug loose Grop off nain Firing broken check and adjust Trouble condition the reason on,to check viri eee ing wotor € fectric wire conta- ct battery power lamp ¢ins not Running aks }—@battery no pover flash not light = @electric plug loose Running normally or drop off @start relay contact (c) starting motor running , no stopping check ard adjust main switch stop motor can't Trouble condition poorly heavily}——— Ocylinder sets burn out @vire broken or short circuit the reason motor stop [}— Ostart pinion can’t return —22— @start relay abnormal short circuit t | i i > Checking and Adjustment: (1) Dated checking table (2) Battery (3) cleaning air cleaner (4) The final reducing mechanism oil (5) Spark plug (6) Compression pressure measurement (1) Ignition timing (8) Throttle cables adjustment (9) Idle adjustment (10) Fre brake adjustment (11) 2r brake adjustment (12) Tire -23- (1)Dated checking table: 1.[O] mark indicates periodical checking 2.[#] indicates changing the parts | checking period judgenent check. item 8 Yrirsel Poe pete Renar pa juonth] G6 | 12} 2] 3 | 12 standard ein tubs pthdnt bbe hy A Suspension | loose,swing | O ojo] aojo steering handlebar | performance | O o]o} ojo suspension:turning angle ° ° front fork ja.cracked o]o] a0}o Doshaft fixed Trow Stee condition O49} 99/0 columa c.shaft: loose ° ° iaeare clearance: check ? oO oO} Oo OO; Oo front: 5-7 mm | steerin eae — : rear: 5-7 nn | colum -Movement 0! ee ofololojofo}o ha loose or danage| |O |O| 0/0 |O|O brake hi ieee coe veer 2 years hi brake cam {xorn out ° i rake Gro fears Den ololololo ! and brake deup nd kg @ shoe Bn shoe late worn out] 7 ole rake drum presniare aia att rear:110.0mn vorn and é ° © himit oF ece: mark t | amage rear:111.0nm Wheel Front axle:dany 5 lage or cracked rear axle:vorn 5 check i i lor damage axl: } megane acer sheel pressure ]O |O|O]O ololo ront vheellrear whee) ‘ 1.30 1,50 [ees wheel cracked x denage : ce O}/O/O}O]O ; = i wheel gap an spl TavesTTOaE WERT? | Sonn 7 ° O}fojo}olo nm rear whee) :0.8m0 whee] Surface | lor other netals| © 9910} 0} I. 1 t [front axle screw torque x axle nut scret 3.064. 0kg-@ Nut ' o}ojolojo in ti S ear axle torque jocat | Pin tightness 8.0-10.Okg-m wheel Fin ee I ngness and day O}O) 0} O) O herticed sving:2anbetor | nage condition arizontal + :Zanbelox f —24— checking period _‘| — Check iten EE eirst pete ee a] Judgement standard | Remark fchec-jnonth) § | 2} 1/3. | 32 rk king us jacoths pont hs eopthsfaon . __ front wheel | bearing of axle, O]1O]O}O }O|O looseness. rear O° ° —| | auper rear camper spring cracked O} JOJO} O/o|o 4 ass’y part Toose or_denage 019/010 |0 =mne| connecting part “at Logse ° © 4. bracket Joose or danage 7 ° Tom suspen- | connect ing e sion part loose ° 9 danper [01] leakage ° oO}|o | cracked oO Ojo So ass'y part, ose ° ° ° — [oorer [Chath andy occ o olo =o change T transni-| | speed itnabatal Oo lolo ssion | nechanism 01) leakage | _| — supply [Oma ie PPIY | ving gear O}O;O}O}O] x per 2 year grease oil change fPlectric lclearance:0.6~0. 7m ——-{ |instal]-| Ignition |spark plug OJOJO/O\O NGK:BP7HS ae OR SAME SPEC os | mn cart | SuarelnE notorpinion| oO O|;O wechanisn ; | aeshing + recharge | ving | eit ofofo]o of ae F electroly= evel between" UPPER” I te quantit © [0/0/01 0 bna”*novar™ : battery jelectroly- lwhen 20°C — te S. gra~ ° O|} O |specific gravity: vity 1.270 = 1,290 jon ; wire com wire | ecting & circuit loose or O] 0; OJO;0 cracked —25— checking period judgement check item te ite Renark 6 1124 1 2 standard pnt athe est hs engine] engine perfornance, Het parts | noise low speed, ol ol! of o | o [idling:1900 + 100 acceleration rpn | check & exhaustion | O o}ofo}olo color of haust ing air cleaner o]|ojolojo ylinder, cyl~ flocking toraue in : linder head inlet of ole) ipe, locking 1.0-1.2kg/ inlet pipe:(cold) condition 1.071 2ka/n sing Stating mo- compression 5 obs i pressure Thg/em'(500rpn) : ie Jeet. [oil leakage Oo] ofa ]o}o aon oil quantity a ee oe} ololojo en irty tid oil quantity | 0 i {oil cleaner BIE i o}o vd blocked bd t fuel ; | lf ae fuel quantity | O pad fuel leakage jolojololo | ; carburetor eae Heelige parts dirty | carburetor thi jet ottle and choke ojo }lojolo od performance carburetor fl ; ololo ° oat _ height ® al tC | | carburetor SoS ale adjustment fuel pipe 1 aoe e | 3 per 4 years —26- checking period anal : ae Te e]_howe oifice — Checking item on ver [er | ver | per | oer Remark cki-lnonta} © |] 1 | 3 1 | standard ag Po" oon roth mnths [mets] ants performance |O OC} Of OJo}o the | } lanp systen f ex-| : pair! dirty, cracked |O olosofofo horn turn horn saa signal performance | O o}oj;olojo reflector turn_signl lock performance Ojo}ojo}o rear view | check the O° OJO};oO}o}o 3 uirror illumination blinker Tine dirty — |ense plate nu- ° mber&uark cracked Isntrument performance |O ofo;o}olo board Ass’: art muffler ae ofolofolo loose cracked | sliencer performance ° o|o loose or chassis ° O;O cracked I —|| the earilier |confirm it does abnornal not happen |O condition | again chassis o}jo}olo;o others [_ltrication bE decoking mixer — muffler, ° ° silencer | —21- (2) Battery:Recharge when run out of it 1.Open the cover and remove the rubber cap.*take out the battery. 2.Remove the negative calbe and then the positive cable, take out the battery to recharge. 3.Re-assembling the battery as the opposite procedure of disassembling after recharging. j Note: A, Do not take out the sealed bolt when recharging. B. Vithoot refilling water for the battety. Please recharging(12¥) as the following current. Time standard: 0.44%5-10 hr or rapid: 44X30 min. —28- (3) Cleaning air cleaner :Remove air cleaner cover vith cross type screwdriver, Take out the sponge of air cleaner. Inmersed in neat oi] then pinch it dry Assemble the air cleaner as the opposite above procedure. Note:Do not start the engine before assembling the air cleaner. ge Ee pu 2) EX KE), \ wash pinch dry wet_— pinch dry (4) The final reducing mechanism oil i 1.Change the oi] in the gear box a.Turn off the engine after warm up. Put a bowl onder the engine. -Renove the draining bolt and filler bolt to drain the gear & oil off. s e. 7 a refill 0.7] gear oi] and then jam lock the filler bolt. -Locking torque:1.8 kg.m —29— (5) Spark plug Remove spark plug Check the spark plug electrode Burnt out or not and carbonized or not Clean the electrode,if it is dirty Spark plug specification spark plug NGK: BP7HS or same spec. Gap of spark plug:0.6~0.7m————4- re electrode 2 burn out carbon piled: up Washer is distorted or not procelain is cracked or not =30- (6) Compression pressure measurement: 1.Measure it when the engine is varm. 2.Remove the cover. 3.Remove spark plug then place conpression pre- ssure gauge. Folly open the throttle act on kickstarter 5 times continuously ,mea- sure the compression pressure. Compression pressure: 6 kg/cm*-600rpn. When the compression pressure is too low, check the following: a.cylinder head washer cracked b.piston cylinder worn out. c.piston ring worn out. The comperssion pressure is too high it is due to carbonization of combu- stion chanber and piston tip. (7) Ignition timing: Don’t adjust the ignition timing because of using the CDI sets. lf ignition timing is not correct check the CD] sets AC magneto,change it if it: is abnormal. checking ignition timing: 1.Remove right side cover. 2.Renove the fan cover. —31- 3.Remove fan case. 4.Check with ignition timing lamp. Keep the engin running at 1,900+100r.p.m if the checking mark lay in 3° apart from F,It’s ok. 5. Ignition timing:B.7.D.C. 17° £3° /1900rpn. (8)Throttle cables adjustment: Check the clearance of throttle twist grip. Normal clearance:1.5-3,5nm Adjust it by rotating the adjuster aut,change it if the throttle cables can’t be adjusted. ~30— (9)Idle adjustment: djust it when the engine is warm. Note: Remove left side cover, Use Tachometer Adjust throttle valve sc~ rew in order to set the idle running at 1900-100rpn. If the rpm net steady vh- en slightly open throttle twist grip, adjust accor ding to the following: 1.Screv the air adjuster screw inside,(cx) then loosen it gppositely(ccw) recommended opening:1% X Ye circle from dead point. 2.Rotate the throttle vaive screw to set the idling condition. 3.Rotate air adjuster screw cw and ccw to find the hi- ghest rotation location. 4.then rotate the throttle, valve screw to set the id- ling condition. 5.Gradually open the throttle, adjust it continvously till the idle running rpm is st- eady. If the rpm is unsteady, pl- ease adjust it repeatedly according to procedure 2-4 —33- (10)Front brake adjustment: 1.Check the clearance of front brake lever. clearance:2-5am 2.1f the clearance is beyond standard: check whethere a.The air mix into the pipe/ pump b.The brake oi] pressure syster leaking. Note: Try brake lever to.see if it is loose, check brake oil and air mix~ ture in oil pipe,which reduces or danages brake efficiency Check the brake oil: a-Refill the brake oil vhen the oil surface lover than the “LOFER" : level b.Specification of oil SAEJ-1703F-DOT3&DOT4 Note: a.To, prevent the splitting oil onto the parts and clothing put a piece of cloth on the bottom at refilling. o a oo =) urea Jo avoid letting in water SJ tones | Se or particles to the main cylinder at refilling. Never use oil of different spec. In case that skin,eyes or clothes touch the brake oi] please washed with-large quantity water, then cured by special doctor immediately. i —34— (1)Rear brake adjustment Check the clearance of rear brake lever. Clearance:5-7mm lf the clearance is beyond the above sta~ ndard,adjust it by rotating the adjuster not. a.Lefthanded rotation add the clearance. b.Righthanded rotation reduce the clearance. Note: When the arrow of rear orake indicator lay in the arrow of left crank- case,change the brake lining —35— 1 (12)Wheel: .Check the whee] pressure Notice check the wheel before running 2 Wheel pressure: front wheel:1.30kg/cm? rear wheel:1.50kg/em? .Wheel dimension: front wheel :120/90-10 rear wheel:130/90-10 Check is there any impure object in the wheel gap. Check the depth of heel stripe a.Depth(front & rear): According to mark of tyre “a” indicateing change new tyre eo a Note: 1.Check and adjust the whee! pressure at it is too lov . Adjusting the pressure according to the carrier > driver > passenger > accessories and crvise speed 2.Proper loading is very inportant for handling * riding braking» performance and safety.Can not load any unfasten parcel.Loading the weighties parce} on the central of vehicle, balancing on the both side. Adjust proper load and check the wheel pressure.The total weight of carrier driver > passenger and accessories can not overload than the limit of approved weight Operating the overload vehicle is easy to cavse wheel damage and accident -36~ = pecteenae oni f¥ > Dismantling , maintaining , repairing and assembling operation: (1) Lubrication system (2) Engine dismant] ing (3) Cylinder head;eylinder, piston (4) AC Alternator flywheel magneto (5) Drive pulley,starter,clutch,driven pulley (6) Final transmission nechanism (1) Crankcase,crank shaft (8) Carburetor (9) Chassis cover (10) Steering column, front vheel,front damper, front fork (11) Rear wheel,rear brake, rear damper (12) Fuel tank,oil tank -37- (1) Lubrication system: 1.lubrication system diagram, troubleshoot ing. -removing oi] pomp. checking oi} pump. -assenbl ing oil pump -releasing air in the oil pump. Ooms ~38— 1.Lubrication system diagram ~39- 2. Troubleshoot ing. A.The exhaust with too mush white fume,carbon collected in spark plug: a.the adjustment of oil pump is not proper.(too much oi!) b.the quality of oil is not good. B.Engine overheating: a.the adjustment: of oi] pump is not proper.(lack of oil) b.the quality of lubrication oil is not good. C.Piston seize a.the adjustment of oil pump is not proper,or pipe is blocked. b.there is air in the oil pomp systen. c.oil punp is out of order. D.The cil pipe from oil tank to oil pump is blocked. a.the air hole of oil tank cover is blocked. b.the oil tank filter net is blocked. Notice:1.¥hen removing the oi] pump,do not drop any object unexpected to the oil pipe 2.1 there is air in ofl pipe,release it. 3.011 punp locking torque:0.8-1.2kg-n. —40— 3.Removing oil pump. Removing when the oil pump and crank case outer is clean a.Remove the luggage and rear bracket b.Remove the input/output oil pipe. f c.Remove control cables of oi) pump. Take out’ the oil pump by removing the locking screw on oil pump. 4.Checking oi] pump Removing oi] pump and check: a,0-ring is distorted or not. d.contactpart of crankcase is injored or not. c.0i1 pomp body is injured or not. d.the movement of control lever is free or not. e.the gears are injured or not f.check seal is oi] leakage or part;It won’t work if it is di- vided into part. : i b 1 not. Avoid dividing the oil pump into | } | =41— 5.Assenbling the oi! pump a.Assenble the oi] pump as the opposite above procedure. O-ring of oi] pump should lubricated by grease of oil,then place on crankcase. The contact part of oil pump and crank- case should be assembled firmly avoid shew assenbly The gears of oi pump should be lubri- cated by grease. b.0i] pump screw should be tighten defi- nitely. After assnebling,checking the following: a.the adjustment of control cables. b.Js there air in oil pipe. c.the oil leakage at any location. 6.Releasing air in the oil pump a.lf there is air existed in oil pipe, t will cause engine lubrication tr- ouble. b.releasing air operation is oi} pipe and oil punp releasing air,so firstly release air of oi! pipe. Pour specific amount of oil to oil tank. Place dry cloth under th ofl pump. Renove oil pipe. Use grease injector, pour oil- to oil punp inlet pipe part,let it full of cil,and let oi] pipe full of oil, then put it in oil pump.After assen~ bling, check definitely the air is in oil pipe or not. ~42— error eae trots meine Pe (2)Dismantling & assembling of plastic parts (1)Screwing out the 3 screws of front windshield-—take off the front protector. (2)Screwing out the 5 screwis of vindshield & frontinner cover. take off the windshield. -43~ (3)Screwing out the 4 screws of the rear protector & body cover—take off the rear protector. (4)screwing out the each 2 screws of right & Teft strips. (5)Take off the right & left strips. ™ —44— (6)0pen the seat, screwing out the 4 screws of the lvggage box.->take out the luggage box. (7)Remove the screws of side cover and front cover-*take off the front cover —45— (9)0pen fuel tank, and take out->remove the 2 screws of the side cover. (10)Remove the right & left screws of side cover—take off the side cover. (11)Remove the step floor & the 3 screws of the cover of battery—take off the cover. —46— (12)Remove the battery—rnegative first then positive (B)remove the screws of the fender—take off the fender. (13)Remove the 3 screws of front inner cover. take off the front inner cover. (14)Remove the 2 screws of each side rear lamp cover. (15)Take off the rear lamp cover (17)Take off the step floor, re-assembl ing as the opposite procedure of disassembling. locking torque: M6=0.7-1.1 kgf-m M5=0.35-0.5 kgf-n Note:avoid clamping & scraping the cables or pipes by the plastic holding =48— (3)Dismantling engine: A.dismantling engine B. Installing engine —49— A Dismantling engine. 1.Remove Rear bumper Luggage tank side cover 2.Renove vacuum pipe and fuel pipe and oil pipe 3.Remove the eletric plug of AC magneto starting motor =50— 4.Remove cable of auto choke and carburetor 5.Remove breather pipe 6.Renove cap of spark plug —51— 7.Renove rear damper bolt 8. Remove engine suspension nut 9.Remove nut of rear brake cable —52— 10.Remove the engine B Installing engine. L.Install engine follow the opposite above procedure. 2.Locking torque: M8:2.0~3.Okgf.m M10:3.0~4. Okgf.m W12:5,0~6, Okgf.n After installing, inspect and adjust the following: l.the wire connecting. 2.throttle cable,oil control cable. 8.let out the air in oi} pump. 4.rear brake adjustment, —53— (4)Drive pulley, starter. clutch. driven pulley . troubleshooting . Measurenent data . drive pulley . Starter . Clutch, driven polley moOmE —54— A. Troubleshoot ing: a.Engine starts,but vehicle don’t move. l.driving belt worn out 2.driveh plate worn out 3.clutch lining worn out b.The vehicle stops or tremble when running. l.clutch hanner spring cracked or broken c.Can’t reach high speed,no pick-up l.driving belt worn ovt. 2.driven-plate spring distortion. 3.hanmer roller worn ont. 4.driven plate abnormal. Note: No grease and oi! should be distributed over driving belt and driven plate. B.Measurement data Iten standard valve limit of use eee 20.035~20..085 20.123 slide driving plate driving plate flange 19.960~19.974 19.911 outer dia henner roller outer 15.992~16.008 15.5 dia Pnnenieiet 107~107.2 107.5 driving plate spring ae aa free length ; ; driving plate sets 33,965-~33.985 33.940 ovter dia ere erat rae 34,.000~34..025 34.070 inner dia —55— (C)Driving pulley. 1.Remove the 10 screws of left cover 2.Take off the left cover 3.Remove the fixing nut of clutch. ~56- 4.Take off the ramp plate. 5.Take off the belt & rear clutch 6.Take off the driving plate. 7.Take off the driving gear starter set. 9.Take off the idle gear. 10. Assemble driving pulley follow the opposite procedure of dismantling. Locking torque: M10 nut of driving pulley: 3.2~4.0kg.m ¥10 not of clutch outer: 3.5~4.0kg.m Checking driving belt (check driving belt if cracked, rubber and fiber is loosen, also check if is abnormal or worn out, (2)driving belt width: limit of use:change it as it “below 16.5mn. (3)Renove slide driving plate sets -Disassenbie slide driving plate sets: (Remove bush of slide driving plate. (2)Remove screv,and disassenble the cover of slide driving plate. (3)Remove RAMP plate. (4)Renove hammer roller. Checking. ()Check the wearing degree of hammer roller. limit of use :change it as it is below 15.5mm, —59— (2)Check gasket’ inner dia of slide deiving plate:limit of use:change it as it is over 20. 068mm. (3)Check the driving pulley surface wearing condition, (4)Check the acting surface with driving plate,this part outer dia limit of use:change it as it is below 15.40mm. Assemble the slide driving plate, (1)clean up the inner slide driving plate, then assemble the roller. (2)Assemble plate, driving plate seal cover,and sc- rew orderly,please notice the torque value. (3)Specified torque: 0.25-0. 40kg-m (4)Other procedure refer the opposite procedure of disassembling. | —60— D.Starter dismantle 1.Dismantle left crankcase cover 2.Loose hexagon nut, then remove the starter lever. 3.Loose two screw of space pate 4.Loose stater spring from start returning positioner. 5.Renove driven gear conp.of kick starter. 6.Renove the retaining ring C type. 7.Remove spindle comp. of kick starter. 8.Checking starter { a.Check the wearing degree of 3 outer diameter of spindle comp. inner diameter of bush and gear. ; b.Check the wearing degree of shaft ‘ of driven gear comp. gear sets and ratchet. 9.Assembling the starter Assemble the starter follows the opposite procedure of dismantling. Note: @One side of the torsion sping must be hooked on the trovgh of sector gear certainly another side mst be hooked on the cylinder inside the left crankcase. @Pvt sone grease in every shaft and gear sets before assenbly. -61— E.Clutch driven pulley 1,Remove the clutch a.Remove left crankcase cover. b.Remove driving plate. c.Remove driving belt, Remove 10mm nut,then remove clutch, 2.Assemble the clutch follows the opposite procedure of dismantling. locking torque: ¥10:3.5~4.0kg.n 3.Checking clutch: dismantling tool a.Check clutch driving face Check clutch cover wearing condition. Inner diameter measurement. limit of use: change it as it above 107.5um Check clutch lining wearing condition: lining thickness measurement, limit of use:change it as it is below 2.5mm. —62— Check driving spring free length:standard:87.9mu limit of use:change it as it is below 82.9nm .Check wearing condition of driving plate sets. Outer diameter measurenetn: limit of use :change it as it is above 33.940nn Check wearing condition of slide driven plate. Inner diameter measurenent: limit of use:change it as it is above 34.070an. Check is there any wearing occur to the ditch. Check vearing condition of sea] location,if necessary change a new one. —63— (5)Cylinder head , cylinder , piston : a B. c. D E. FP 6 a. ] J. . troubleshoot ing the operation notice the operation data dismant] ing cylinder head checking cylinder head flatness cleaning ovt the carbon in combustion -chamber dismantling cylinder dismantling piston checking cylinder, piston installing cylinder, piston —64— 4. Troubleshooting. a.compression pressure is too lov difficult to start engine slow running uasmoothly. Cylinder washer cracked. 2.Spark plug not beling locking vell. 3.Piston ring worn ovt or cracked. 4. | Cylinder,piston worn out or injured. Reed valve is out of order. b.compression pressure is too high,engine overheat ing, knocking cylinder head,piston tip too much carbon accumulated c.piston noise l.cylinder piston vorn out 2.piston pin hole,piston pin worn out. 3.connecting rod smal! end,bearing worn out. d.piston,cylinder noise .piston ring worn ovt,cracked .cylinder owrn out, injured. C.The operation notice “clean before operation to avoid other object drop in engine the connecting vasher must be washed cleanly. dismantle cylinder and cylinder head,don’t injure the contact surface. cylinder inner surface and piston outer face can’t be injured the disnat! ing part should be washed cleanly when checking, the contact surface should lubricate by specified oil D.The operation data information } Ttem Standard valut | limit of use i Cylinder head straightness 0.10 z Piston outer diameter from the lower end of piston 12mm above the skirt edge. a an 39-895 Clearance between cylinder and piston 0,050-0.060 0.100 } Piston pin inner dia 10.002-10. 008 10.025 : Piston pin outer dia 9, 994-10.000 9.970 : Clearance between piston pin and pin hole 0.004-0.018 0.030 : Piston ring gap.(ist ring/2nd ring) | 0.15-0.35° 0.70 Connecting rod small end inner dia 13.996-14. 007 14.025 [Cylinder bore 39. 995-40.015 40,050 —65— E.Dimantiing cylinder head: i.Remove the engine 2.Remove the fan cover. 3.Renove the cooling covl. 4.Renove 4 bolts on the cylinder head, then cy] inder. 5.Assemble the cylinder head follow the opposite above procedure. looking torque: ¥6:1.0~1.2 ke-m —67— F.Checking flatness of cylinder head Check the flatness of every contact suface. limit of use: If it exceeds 0.0mm change a new one. G.Cleaning out the carobn in combustion chamber, Clean out the carbon collected in combustion chamber. De not injure the combustion chamber and contact surface of eylinder during cleaning opera tion ~68— H.Dismantling cylinder 1,Loose two nuts of muffier,then remove the muffler after remove the cylinder head. 2.Remove the cylinder. —69—- 1.Dismantling piston: 1.Remove piston pin clip, then remove piston pin and take off the piston. 2.Open the piston ring, remove piston ring from the opposite direction gap. << 3.Remove the Ist ring, then Qnd ring J.Checking cylinder, piston: Check the worn and injure: of contact surface of cylinder and piston. .Clean out the carbon in cy- linder exhausting port Be careful not to injure i- nner surface of cylinder. .Cylinder bore measurement: (1)Measure each point (4)(B)(C) orderly,and in X.Y. direc tion to find the smallest value. (2)Limit of use :change it as above value exceeds 40.050nm. -Piston outer diameter measurement: (1)Measure from the lower end of piston, ]2mm above the skirt edge. (2)Linit of use:change it as above vlave is jess than 39.885mm (3)Calcvlate the clear ance between cylinder and piston. limit of use:change it as it exceeds 0.100m —n- 5.Piston pin hole inner diameter measurenent: limit of use:chang it as it is more than 10,029mm 6.Piston pin outer dianeter measurement: limit of use:change it as it is less than 9.970mm 7.Checking piston ring: measure piston Ting gap: limit of use :ehange new one when the first fing and second ring are over 0.4mm. {Second rin SS A SSS S oes] I With piston and cylinder wall horizontal direction,press the piston ring into cylinder, then measure the gap. 8.Checking connecting rod small end (1)place piston pin,bearing into connect ing rod small end to check the slackness of piston pin, (2)measvre connecting rod small end inner dia.limit of use: change a new one as it is over 14.025nm. —13— K. Installing piston,cylinder: 1,Place the piston ring into second ring ditch, then install the piston ring into first ditch. 2.Piston ring should be evenly forced into piston ring ditch. After the asseublying,confirn that piston ring silding sur- face is at the sane height as piston outer surface. If piston ring can’t put into ditch,please clean out the carbon in piston ring ditch or in piston ring. 3.a.piston ring must be installed to correct poisition. b.after installing the piston ring,it should be rotated free ly. c.when it is necessary to change new piston ring,change the whole set. 4.The clearance of the piston ring gap between the lock pin in ring ditch should be even. a.piston tip — mark ,must face to exhausting side. b.lubricate the piston pin ,then install it. 5. Install cylinder,cylinder head as the opposite procedure of dismant— ling. —14— (6) A.C. Alternator flywheel magneto : A.dismantlimg AC alternator flywheel magneto. B. installing AC alternator flywheel magneto. A:Dismantling AC alternator flywheel magneto. 1.Remove fan cowl 2,Remove fan. =716— eer tanatteinietinte i nebenanknb aie 3.Remove the AC flywheel magneto by special tool. -11- 4.Remove the electric plug of AC flywheel magneto 5.Remove stator screw, and-take off stator. 6.Installing the AC flywheel magneto follows the proce- dure opposite the disman- tling procedure. Locking torque: M6:1.0~1.2kg.0 M10:3.2~4.Okg.m —78- (7Final transmission mechanism . troubleshooting. . disassemble the final transmission mechanism. . check the fina) transmission mechanism assemble the final transmission mechanism. your 4 Troubleshoot ing @ingine can be started, but the vehicle don't nove, l.gear worn out, cracked. 2.gear burnt out. @xoise occur when vrnning. l.gear worn ovt, burned out, gear surface injured, 2.vearing or looseness of bearing. @0il leakage 1.Too mach oil. 2.seal worn out or injured. —19— B.Disassemble the final transmission mechanism: 1.Renove the left crankcase. 2.Renove driving plate 3.Drain the oi] in gear box. —80- einai en ai niebiniih hinges me apnea 4.Remove the bolt in gear box cover take off the gear box. 5.Remove final reduction gear and idle gear shaft. 6.Remove driving shaft fron gear box. —s1— C.Check the final transmission mechanism: 1.Check wearing condition of driving shaft and gears. 2.Check wearing condition of idle gear shaft and idle gears 3.Check wearing condition of final reduction gear, —82— 4.Check wearing condition of oil seal and shaft. D.Assemble the final tran~ snission nechanism,ple- ase refer the opposite procedure of disassenb]~ ing Inject 110ce oil (SAE 90) after locking drain bolt. locking torque:W6 1.0~].2kg.m 10 3.5~4.0kg.m drain bolt M8:1.8kg.m (8)Crankcase , Crankshaft : A.disassembling diagram. B. troubleshooting C.data D.remove crankcase and crankshaft. E.check crankshaft. F.assemble crankcase. —d— A, Disassembling diagram -85— B Troubleshooting. Engine noise: 1.The bearing of final transmission mechanism is slack. 2.Crank pin bearing is slack. 3.The bearing of gear box is slack. iten stardard value limit of use. (mm) Clearance of connecting rod big end axle-direc~ 0.20-0.50 0.71 tion Clearance of connecting rod big end radial dir~ 0.04 ection Swingness of the crank 0.03 0.10 shaft _jovrnal. —66— D. Renove crankcase and crankshaft. renove according to the following proce~ dore: l.remove engine 2.remove left E/G case and air cleaner. 3.remove driving pulley(driving plate). clutch and belt. —87— 4,renove Carburetor. S.remove IXtake and Reed Valve 6.renove spark plug. fan cove fan cowl and fan. —88— T.remove A.C.’ flywheel magneto 8.renove the oil pump and shaft of oil pump. 9.remove the cylinder head cylinder and piston. —a9— 10.remove the left and right crankcase. li.remove the central stand, L/R crankcase and take out the crankshaft . Check crankshaft: measure the clcarance bet~ yeen crank webs and co-rod big end. limit of use : 0.7lnm change it as above 0.71nn —90— . .check the slackness of connecting rod big end in perpendicular X.Y. directions. limit of use 2 0.04mm change it as above 0.04nm 3.measure the swingness of crank shaft journal limit of use | change it as it is above 0.lum change it as it is above 0.1mm check the slackness of crankshaft bearing, if it is slack, change a new one. horizontal direction —91- a FT vertical direction F, Assemble crarkcase: l.assenble crankcase according to the opposite procedure of disassenbl ing. 2.The locking torgue of bolts and nuts are decribed in previous chapter please refer. -92— ommuow . Carburetor: . fuel system diagran. . carburetor disassembling diagram . trovbleshoot ing. . dismant]ing carburetor. . disassembling float, nozzle. . Teed valve . checking fuel cock. A. Puel system diagran, —94— B. Carburetor disassembling C. Troubleshoot ing = a. Dra s Engine can’t be started: no fuel in fuel tank. fuel pipe is blocked. .too much fuel in cylinder. .air cleaner is blocked. Engine idling RPM unsteady, running unsmoothly. .carburetor idle adjusted un~ properly. ignition disorder. compression pressure is too lov. nixture is too thick. nixture is too lean. air cleaner is blocked. air injection is out order. fuel is dirty ne nO Nan ve 3 ~o6— . mixture is too thick main jet is blocked. fuel -tank cover ventilation hole is blocked. .fuel filter is blocked. fuel pipe curved, squeezed or blocked. -float valve is abnornal. soil -air pipe is blocked. . mixture is too lean -float valve is abnornal. -oil level is too high. cair jet is blocked. level is too low. D. Dismantling carburetor: l.remove the rear protector luggage box 2.loose the hose clamp between carburetor and air cleaner,then remove air cleaner. 3.unscrew carburetor fuel draining screw, drain the fuel (in- side the carburetor) off. 4.renove fuel pipe and vacuum pipe which is on carburetor. t uf | i i ov -Temove oi] pipe on carburetor. -97— F. Reed valve. l.dismantling reed valve. (a)remove air cleaner. (b)remove carburetor. (c)remove locking screw. (d)renove air inlet manifold (e)remove reed valve. .checking the reed valve. change a new one when the reed valve -is worn or é- istortion. Also change a new one vhen the base of reed valve is cracked, injured or distorted. G. Checking fuel. cock: j.when engine stop, remove the fuel pipe and check js there fuel flow out. It is normal when the residue fuel (5-10cc) f- jow out from fue! cock and fuel pipe. If it is continue to flow out, t~ he vacuum pipe is block~ ed, please clean it. renove vacuum pipe from carburetor and suck it to produce vacuum, the fuel should flow ovt th~ en from fvel. pipe, vice versa, if fuel don't fl- ow out follow above ope— ration, please check the folling. (a) clean ovt the blockage in vacuur pipe (b) blow air to fuel cock inlet pipe. 3.Note: Use the bowl under the end of fuel pipe to receive the drop. Avoid fire even spark. —~99— (10)Steering column, front wheel, frt disc brake comp, frt drum brake comp, front fork: . troubleshooting . data change speedometer cable steering handlebar front wheel . front brake front fork Samson Se —100— A. Troubleshooting is injured. b. front fork is crooked. 3. front wheel swings a. wheel rim is distorted b. c. whee) rib is distorted d. wheel is not good e 5. noise in front damper. front damper is too soft, i, steering handlebar is abnormal, too tight. a. steering mechanism; vasher of conical buselocked too tightly. b. steering nechanisn;stee! ball is crackded. c. steering neshanisn; steel ball base and washer of conical base d. wheel pressure is too low. 2. steering handlebar is aslant. a. left and right damper is not even. bearing of front axle too free. front whee] axle locked improperly. spring fatigue a. noise cones from damper box. b. locking screw of damper is slackness. c, the axle of front fork is crooked, whee! is aslant. swingness of frt/rr wheel B. Data Item Standard value(nm) | limit of vse(nm) lining of frt brake 4.0 3.0 i disk of frt brake 3.6 3.1 2 —101— C.Changing speedometer cable: 1.Remove the front handle cover. 2.Remove the nut of speedometer cable. 3.Remove the fixed screw of speedometer cable on the front right wheel. 4.Draw out the damage speedometer cable. 5. Assemble the new cable follows the opposite procedure of dismantling. Note: Put the grease onto the inner cable before assembling. —102— | D.Steering handlebar 1.Remove the LH/TH back mirrors 2.Renove the front handle cover 3.Remove the rear handle cover speedometer and plugs of switch. 4.Renove the terminal of rear brake cable and the switch plug of rear brake Jamp. Loose the acceleration pulley comp -Remove the throttle cable and RH grip assy. -Remove the locking bolt of front brake master cylinder on the steering handlebar,then remove front brake master cylinder —103— 8.Remove the bolts and nuts fixed the handlebar on the front damper. 9.Renove the steering handlebar. 10. Assemble the handlebar follows the opposite procedure of dismantling. Locking torque M6:1.0~1.2kg.m — (10:3.0~4.0kg.m 11.Put the grease onto the cables before assembling -104—- E.Front wheel: 1,Remove the lock nut of front wheel on the right side. Draw out the axle of front wheel,remove the separated ring and take off the gear sets of speedometer, 3.Renove the front wheel assy. 4.Assemble the front vheel follows the opposite procedure of dismantling. Locking torque:M10:3.0~4.0 kg.m Note:1.Put the braking block of speedometer gear assy upon the extension of the frt fork. 2.Put the grease onto the gear sets of speedometer before assembling. —105—- 5.Checking front axle a.check the curreness of front axle. b. limit of use:change it as it is above 0.2mm | 6.Checking the bearing of front whee],rotate the wheel,if noise or slack occur in bear— ing,please change @ new one. 7.Frént wheel rim checking (a)check the swingness of front wheel rim (b)limit of vse: horizontal direction:change a’ new one when it is above 2.0mm. vertical direction: change a new one vhen it is above 2.0mm. horizontal direction vertical direction —106— (F)Front brake 1,System diagram of front brake —107- 2.Disassembling and assembling front brake comp. a.remove two bolts fixed the frt. brake comp. on the front fork b.remove the front brake comp. c.assemble the frt brake comp. follows the opposite procedure of dismantling. locking torque: M8:2.0~3.0kg.m Air leakage of front brake comp. The procedure of air leakage a.inject proper brake oil to the storage tank. Don’t let the brake oil overflow from master cylinder or storage tank when assmeble the naster cylinder cover. Pot the spanner vpon the leaking screw for cylinder. Lock and unlock the screw several times fill there is no bubble. Operate slowly the brake lever several tines. Push the brake lever to the end. Loose the leaking screw, then move forvard the lever to the limit. Locking the leaking screw and then loose it when the lever on the end. -Repeat the above procedure until all of the air of brake system was leaked completely. locking torque of leaking screw: 0.6kg.0 a —108— 4.Disassembling and assembling the front brake~disk. a.Remove the front wheel. b.Remove three nuts on the disk. c.Remove the disk d.Assemble the disk follows the disassembling procedure. locking torque M8:2.0~3-0kg.m 5.Checking the front brake-disk. Standard thickness of disk : 3.6mm linit of use:change it as below 3.1mm 6.Checking the front brake-lining. a.Standard thickness:4. 0mm. limit of use:As the thickness’ is below 3.0nm, change it. Note:Prevent grease on the lining —109— (11)Rear wheel, rear brake , rear damper : A. troubleshooting. B. data. . dismantling the rear vheel. . checking the rear wheel. . Tear brake. . Tear damper. amo oO —110- AL Troubleshoot ing 1. Rear wheel swings. a. wheel rim is distorted. b. wheel is abnorral. c. unproperly assemble the wheel axle. 2. Rear damper is too soft a. rear danper spring fatigue. 3. Bad braking . the adjustment of brake is not good. . the brake lining is dirty. . the brake lining is worn out. . the cam of breke lining is worn out . the brake cam lever is worn out. . the brake hub is worn out. . the assembling of brake lever gear trough is not good. | ars aose B. Data Item Standard value(nm) limit of use(nm) The swingness of rear wheel 2.0 Brake bub inner diameter 10. 110.5 Thickness of brake lining 4.0 2.0 -11- Cc. 1 2 3 4 5 Dismantling and assembling the rear wheel. Remove the rear mudgard. . Remove the muffler. Remove the nut on the rear wheel. Renove the rear vheel. Assemble the rear vheel follows the dismant! ing procedure. Locking torque: M6: 0.7-1.1 Kg.m M14; 8,0-10.0 Kg.m . Checking the rear wheel. check the swingness of rear wheel. radial direction: change it as it is above 2.0nm. 7 horizontal direction: change it as it is above 2.0mm. ~112— E.Rear brake: 1, Rear brake disassembling diagram. (1) Checking rear brake hub: a. b. (2) Checking brake. lining: a. . limit of use:As the thickness measure the inner diameter of rear brake hub. limit of use:change it as the diameter is above 110.5ma measure the thickness of rear brake lining. is less than 2nm, change it. -113— F, Rear damper 1 Rear damper disassembling diagram: specified torque:3.0-4.0Kg-r ° specified torque. (ote: specified torque: 2.0-3.0Rg-m —114— (12)Fuel tank, oil tank : AL B. Puel tank disassembling diagram. c. D E Troubleshoot ing. Dismantling and assembling fev) tank. . Oi] tank disassembling diagram. . Dismantling and assembling oi! tank. —1ib— A. Troubleshoot ing: 1, Engine can’t be started: a. No fuel in fuel tank. b, Fuel pipe is blocked. c. Auto cock and fuel filter is blocked. d. The membrane of fuel cock over extended. 2. The mixture is too lean, a. Ventilation hole is blocked. b. Fuel pipe is crooked, squee- zed, or blocked. c. Auto cock and fuel filter is dirty. ~116— -1I- (B) Fuel tank C. Fuel tank dismantling and assembl ing 1, Remove the rear carrier(rear protector) 2. Open the seat. 3. Remove luggage box. 4.Take off the luggage box. 5, Remove the fuel cover and then take off the side cover. 6. Take off the rear lamp cover 7. Remove the vacuum pipe and fueif pipe. from the fuel tank & carburetor, 8. Remove the connecting terminal of fuel gauge. 9. Remove the fixing bolt from the fvel tank. ~119— 10. Take out the fuel tank. 11, Remove the connection terminal of oil gauge. 12, Renove the fixing bolt of oil tank. 13. Take ovt the oil tank. 14. Re-assembling as the opposite procedure of disassembling. locking torque: W6:1.0-1.2 kgf-m D. Oil tank disassembling diagram: E. Dismantling and assembling oi] tank: om ome . drain the oil off. . Temove the cable plug of oil gauge. - Tenove oil tank. . clean the oil cleaner. . assemble oi] tank just in the way oppisite to dismantling. —121- i » Electric equipment: (1) Troubleshooting (2) Battery 1, check specific gravity of eletrolyte 2. recharge (3) Recharge system 1. the wiring diagram of recharge system 2. check A.C. flywheel magneto 3. check regulator/rectifier. (4) Ignition systen 1. the wiring of ignition 2. check spark plug 3. check 3.7, cable and 1.7. coil 4. check C.D.I. set (5) Starting system L. the wiring of starting 2, checking the starter 3. disnantl ing the starting motor 4. checking the starting motor ~122— (1) Troubleshooting: A.Recharge system: a.No power: L.battery over charge @OXo electrolyte in battery. @Battery becomes white. @Short circuit in battery. @Regulator 2.the connecting of wire is drop off. 3.fuse is broken. 4.power supply lock is abnormal b.Voltage is too low: 1.Battery recharges unsufficiently. 2.The connecting is abnormal 3.Recharge system is abnormal. 4 Regulator B. Ignition systen: a.The sparking of spark plug is a- bnormal: 1.Spark plug is abnormal. 2.Wire connects unproperly, br- oken or short circuit. between A.C. flywheel’ magneto and CDI sets. @between CD] sets and H.T. coil. @between CD] sets and main wsitch. @between nain wsitch and spark plvg. 3.Mdin switch is out of order. 4.1.7. coil is abnormal. 5.CDI sets is out of order. 6.A.C. flywheel magneto is abnormal. C.Starting system: a.Starting motor cna’t rotate: -The fuse is broken. Battery recharges unsufficiently.

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