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OPERAT/0/YAL JJVSTRUCTIOJV SHINERAY

OPERAT/0/YAL JJVSTRUCTIOJV

SHINERAY

OPERAT/0/YAL JJVSTRUCTIOJV SHINERAY

FOREWORD

Thank you for your purchasing this motorcycle. This manual covers the main data, basic structure, and main procedmes of operation, adjustment, maintenance and troubleshooting of this motorcycle. It will help you familiarize yourself with all the necessary skills so that you will bring your vehicle into full , best play with minimized trouble for a long service life. Products are always subject to further improvement, which will cause some difference between the vehicle and .this manual,without further notici.

CONTENTS

I.

Safe

Drive

1

· ill . Parts and Subassemblies

· · ·· ·· · ·

·

·

·

·

· ··

II.

Main

Data

· ·· · ··

·

·

·· ·

·

·

· ··

· ·· ·

· · · ·· · ·· · · · · ·· · ·· · ·· ·• ·

·

·

· 5

3

N . Operati 6n

·

·

·

 

·

·

·

·

--9

 

Ignition Switch

 

·

·

· ·· ·

 

· ·

·

·

·

·

· ·

· -9

Fuel Cock

 

9

Engine Starting

 

·

·

·

·

·

·

·

-

·

·

·

· I 0

Switc hes

on

Right Handlebar

 

· · ··

 

·· · ··

"

11

Sw ic thes

on

Left Handlebar

 

]2

Gear Shfting

 

13

V . Check - ups, Adjustment

and Mai nt enance

 

·· ·

" 14

 

Machine

Oil Checking

 

14

Rene wal

of Mac hine

Oil

 

· · ·

 

·

· 14

Clea ning

of Mac hine

Oil Tank

 

-- 15

Chec k-up of spark plug

 

15

Check-up & C l ean ing of Ai r Filter

16

Adj ustment of Throttle Cable

 

··

·17

Adjustment

of Carburetor

 

·

·

·

-

17

Chec k- up & Adjustment of Air Valve Gap

 

-- 18

Adj ustment

of

Clutch

20

Brake Check ing

 

· · · ··

· 20

Adjustment

of

Front Brake

 

21

Adjustme nt

of

Rear Brake

 

··

22

Adj ustment

of

Chain

-

· ··

·

· · ·

·

· 22

Adj us tment

of

Brak ing Li ght

Switch

 

· 23

Battery Checking

·

 

·

· 24

Replaceme nt of Fuse

 

·

"

·

··

· 24

Vehicle Washing

 

25

Maintenanc e in Non-use Time ·

 

-- ·

--26

Resu mpti on of Sen•ice

 

·

·

--27

Maintenance Routine Diagram

 

·

·

·

--28

VI . E l e tric Di agr a m

 

·

·

·

·

·

·

29

SAFE DRIVE

Ru les for Safe Drive Check must be conducted, before starting the engine, to prevent mishaps and damage to components. Only th e qualified person, who has passed th e driv e examination and to whom a dri ve license h~ been issued, is permitted to drive the vehicle but not anybody else without a drive license. Full preoccupation is required during drive , paying attention to the following points to av oid any possible hurt to you by other motorized vehicles :

Do not drive too close to other vehicles; Never contend for lane. Strictly observe the local traffic rules. As drivi ng at overspeed is the cause of many accidents, do not drive at a speed the actual situation does not permit.

Tum on the tumlight when making a tum or changing the lane. Particular care should be exercised at the level crossing of roads, entrance and exit of parking lot or on the automobile lane.

During drive,

grasp the left handlebar by the left hand and the throttl e twist grip by th e right one,

with feet cin the footrests.

The luggage carrier is designed for carrying light goods, which should be sec ure ly fastened,to prevent loose movement that may cause mishaps during drive.

D

Prote ti ve Wear

1. Protective wear such as helmet w;th protective mask,

dustproof glasses and gloves should be worn

during drive for the sake of personal safety.

2. The passenger should we ar hight boots or long clo thes to protect legs from hurt by the hea ted exhaust

s ile ncer during ride.

3. Loose clothes are not suitable for motorcycle drive or ride as they may get caught on the O;)erating

lever, kick lev er, footrest or wheel, result to dan ger. Modification of the vehicle Caution:

Any 'u naut horized modification of the vehicle or replac ement of the original parts can not ensure driving safe ty and is illi c it. The user mu s t observe the regulations of the traffic c ontrol authori ti es. We are not re-

spo nsibl e for

any vehicle with unauthorized modificati on .

Loading of goods Caution:

Th design of the motorcycle requires distribution of the canied goods in certain extent of equilibrium and improper arrangement of goods will adversely affec t the performa nce a nd stabili ty of the vehicle . The

manufacturer · ~h a ll not take any responsibility due to the r e ason men tioned abov e.

MAIN DATA

   

125c:r:

   

150r:c:

   

200('('

 

Ove rall lcn~lh

2080mm

Climhnbilitv

   

Overall width

830mm

Cyli nder bon~ x s troke

56.5 x 49.5mm

(i2.0 x 49.5 mm

l'l3 .5 X fi2 .2mm

Overall height

l240nun

Co mpression ra tio

 

9.0:1

 

Wheelhuse

1320mm

 

8.2kW/ CX'f.J

Rfrrri

n

8.5kW/<xXXk/min

11.5kW/8500rlmin

Output,max.

 

Dead wein ghl

I17kg

TorCJue,max

8.5N-m/7500rlrnir

ll.ON·ml7500!1rnin

15.0i\'· rrr/"X100drrri r

Payload

l50kg

 

Idling spP.erl

 

I500rlmin

 

1420r/rnin

 

I500r/ruirr

 
 

Fronlwhed

2.75-21/200

DisplacemP.nt of cylinder

124.0ml

   

196.9 rrrl

 

RP.ar wheel

4. I0- I8/225

Spark plug

 

D7TC

   

D8TC

 

SpeP.d, Max

~ 90km/h

Spn r k plu~ gap

O.(i-

0 .8mrn

   

0.6 - 0.7111111

Bmk C' dist ance( 30km/h )

~ 7m

 

0.05mm

   

O.OCJrrnn

 
   

Cap of air Valve

   

Lrrhncat ing oil

I.IL

0.08mm

   

0.08rnrrr

 

El

MAIN DATA

 

125rr

l

ISO rr·

200 r:r:

 

125r:r: 1

 

150 r:r:

 

200r;c

Cara r: ity of' gasolin e tank

 

9L

Bauyn y

 

! 2V7Ah

 

Transmission ratio

   

Ign itio n mea ns

 

CDI

 

1st gear

         
 

2.769

 

2.545

2nd gr:ar

 

1.R82

 

1.6R8

3rd gear

   

1.400

 

1.2RO

4th gear

 

1.130

 

1.042

   

5rh gear

         
 

0.960

 

0.903

6th gear

 

0. 8 15

Fina l redu ction

   

4.055

 

Cro un rl el r:arane c>.

   
 

250

II

IU.PARTS & SUBASSEMBLIES

Left rear view mirror

Left handlebar

Right rear view mirror Ignition switch & head lock / Throttle twist grip Switches on
Right rear view mirror
Ignition switch & head lock
/
Throttle twist grip
Switches on left handlebar
Switches on right handl bar

Fuel tank lock

Ser.No

 

Name

Description

 

CD

Speedometer

lnkmfh

   

Turn indicator

The left indicator is lit up when the tumlight is to the left and the right one lit up as the latter to the righl

®

Neutral indicator

It is lit up when in the neutral position.

 

@

Odometer

 

It shows the total accumulated mileage already covered by the vehicle.

(5)

Tachometer

 

It shows the speed (rpm) of the engine.

 

@

Trip mileometer

It shows the mileage of trip.

 
  It shows the speed (rpm) of the engine.   @ Trip mileometer It shows the

The ser. No. of frame [Vehicle Identification No.(VIN)) is on tbe left side and the brand on tbe front

Froot tumlight ~

Front

Fuel cock

/; /

Gear shifting pedal

Rear view minor

Tbe No. of engine is on the

left side of the left

Rear turnlight

I

Seat cushion

Fuel Coc k

N. OPERATION

Ignition Switch

*Ignition swicth

total

<D Fu e l filli ng

The capac ity of the fu el tank is 18L i n

reserve. Leadless

lowj ead

including

of

l. 1L

or

of

gasoline

No. 90

a bove

or

Lhe fuel c ircu it is

c ut o ff wilh o ut su pply.

RE S: Wilh the handle of the fuel

cock to RES position , the fuel is sup-

plied from the reserve.

to "OFF" pos it io n,

Positoin

Function

Remarks

 

To . stop

the

vehicle

Theke yc anb -e-

OFF

 

(switching of! all circuits)

moved outtak er

ON

For llartins or driv\111 lh~ vdU-

The key can nol

cit(

malin&aU lhe main circ uits )

be removed

LOCK

Tolock the steering handle

The key can

be taken out

gaso line is required for the motorcycle. To

( Note : The reserved

fuel can only

fuel

the

ve hicle,

s upport

it

by the

main

be used whe n the normal

supply is ru n

stand,

open the lock cover of the fu e l tank

out. ) In thi s case , refu eli ng should be

and fill fue l through the opening ,

a nd the n

ca rried out as soon as possible ,

for

close the tank by the cover wit h the two on

there is

only some

0 . 8L

of fu el

re-

them in good alignment.

serve for use.

8L of fu el re- them in good alignment. serve for use. (2) Operation of the

(2)

Operation of the fu e l cock ( the valve

OFF

of fu el tan k )

ON : With the

handle of the fuel cock to

ON

 

"ON" pos ition, the

fuel circ uit is through for

LOCK

fu el s uppl y.

OFF: With the handle of the fu el cock

OFF ON
OFF
ON

Fuel cock handle

Engine Starting

· CD Set the key of the ignition switch to "ON" po ition. ® Ascertain the neutral position, where it should be displayed.

® Ascertain the amount of fuel in the tank.

@Set the

*To start a cold engine:

Q) Pull up the choke bar of the carburetor to "

A" (fully close) posi tion.

® Rotate the th rottle twist grip by 1/ 8 to 1I 4

fuel cock handle to "ON" posi tion.

" B", full y open the choke when the engine is suffi-

ciently warmed up. *Caution:

The engine can only be started after the neutral

position

happen. Unnecessary idle running( especialy at a high speed) is harmful to the engine.

is ascertained . Otherwise accident will

*Procedures of stopping engine:

CD Release the thro ttle tw ist grip to slow down

turn.

the engine.

stem.

®

Start the engine by the electric starting sy-

® Turn to the neutral position. @ Set the ignition switch key to "OFF" posi-

@

Slightly turn the throttle twist grip to in-

tion.

crease Lhe speed of the engine so as to warm up th e engine.

downw ard to

@ Tum the carburetor choke bar

@Se t the fu el coc k ( the fuel tank valve) han·

dle to "OFF" position.

ard to @ Tum the carburetor choke bar @Se t the fu el coc k (

Switches on Right Handlebar

CD H e adlight sw it ch

The

H e adlight

 

switc h

has

th ree

posi-

tions"

~([_-",

"P

"

a nd

"

"

(a

white

point).

"

09:-

When the sw itc h is in this po-

sition, tail the headlight and meter lights are

all lit up.

"P

~

"

:

When the swi tch is in this po-

s ition, the ail , be traying and meter lights are

lit up.

th e

headlight tail, betraying and me ter lights are

all off. *The headlight a nd tai lli g ht will be li t

up only after the vehicle is started.

® Electric start button ( no such device

Whe n it is in this posi ti on,

for the vehic le of kick start mode only ) The e lectric start bu tton is located below the

headlight switch. The engine will be started by

Pressing down th is button. @Emerge ncy stop swi tc h When starting the engine, set the eme rg ncy

s top switc h in"l5Sl"posi tion

by cu tting off th e electric power.

to di rectly s top the e ngine

Emergency stop switch

h in"l5Sl"posi tion by cu tting off th e electric power. to di rectly s top

Ill

Switches on Left Handle bar

CD

,., ()

L ight changing switch position, Headlight is in high beam. position, Headlight is in low beam.

4- ()

® Turnlight switch t-Position, Left

----+Position, Right @ Horn button press this button to horn.

is in low beam. 4- () ® Turnlight switch t-Position, Left ----+Position, Right @ Horn button

Gear Shifting

Warm up the engine f'>r normal runing.

CD When

the engine is idling, disengage the

clutch and tread the gear_shifting pedal to et the

gear to the lst position.

@ Gradually increase the speed of the engine

and slowly release the clutch lever, with a good

coordination between the t wo ope rations to ensure a

natural driving start.

@ When the motorcycle reaches a balanced

state of runniing, slow down the engine, disengage

the clutch again and tread the shifting pedal to

change the gear to the 2nd position. The gear can

be shifted to other positions in the same way.

Shiftin g forward

5 4 3 2 N l
5
4
3
2
N
l
The gear can be shifted to other positions in the same way. Shiftin g forward 5

Shifting backwardS

V. Chec k_ups, Adjustments and Maintenance

Machine Oil Checking

* The vehicle shou ld be checked

for machine oil before drive by sup- port in g it wi th the mai n sta nd on a fiat

ground. The oil level should be be- tween the upper and lowerrl ines of the oil gauge, whi ch is not screwed into the filling orifice. *High quality 4_stroke machine oil, as Class SE or SO in API classi- fication, of SAE 15W_40QE in VIS-

cosity will help maintain a long ser- vice life of the engine. In case those

are not available, a substitute suitable

for

cat ion s hould be selec ted accord ing to

the table on the right s ide .

the ambien t temperature of appl i-

3: Pl () ::r ::3 (b ~. 't -30 -20 -10010203040 F -22 - 4
3:
Pl
()
::r
::3
(b
~.
't
-30 -20 -10010203040
F
-22
- 4
14
32 50 68 86 104
-30 -20 -10010203040 F -22 - 4 14 32 50 68 86 104 Machine oil gauge

Machine oil gauge

Renewal of Machine oil

Machi~e oil plays a very impo rt ant role in th e

normal opera tion of the engine and for that reason , it

to check the motorcycle for mac hine oil

is necessary

periodically and renew the oil once every 800- 1,

000 km of drive

Remove the svrew plug from the bottom of the

by th e fo ll owing procedures.

hot e ngine to drain off all old oil.

Wash the oil filter screen clean a nd · remou nt it

really to position. Then fill in 0. 9L fresh machine

oil and start the engine for idle running 2 - 3 min·

utes.

and

check to see whether the oil le vel is in between the

Let

the

engine

slop

for

2 -

3

minutes,

upper and lower lines of th.e oil gauge.

Do not use any machine lil of a different grade

than the specified one to avoid machinery failure.

Cleaning of Machine Oil Tank

CD Drain off all the runjn machine oil from the oil tank.

@ Dismount the related parts.

@ Wash clean all the related parts.

@ Fill in the required oil.

* This job should not be done by any untrained persons but shall be done at an

authorized service center.

persons but shall be done at an authorized servi ce center. Screw plug for oil draining

Screw plug for oil draining

t
t

0. 6 -0. 7mm

Check_up of Spark Pl ug

CD Remove the cap of s park pl ug and

screw off the spark plug by the plug

wrench. @ Clean the spark plug all around or

replace it if it is corroded or there is too

much deposit on it. @ Regulate the gap of the spark plug

to 0. 6_0 . 7mm. @The spark plug of the designated

type should be used. The applicable type of spark plug as

falloning:

D8EA(NGK)

Check - up, Cleaning of Air Filter

Take out the air filter and check if it is contaminated. Dismounting:

Re move the left side cover screw of the

cover and disassemble the air

fi lter.

filter ,open the left

Cleaning:

Wash the filter in clean washing oil and wipe it dry with dry cloth.

Soak the filter element in clean machine oil, squeeze it dry and fit it back to position. Recommended oil : 15WI 40QE Caution:

The air filter element for use must be intact or the engine

will suck in du t and dirt,

the engine. W ather should be preve nted from entering into the fil

resulting in a shorter service life of

Air filter

should be preve nted from entering into the fil resulting in a shorter service life of

Co llar cl a mp

·\cljustmeut of Throitle Cable Ma ke s ure that th e adjust : ng nut of th e throttle ca hle works normally .

Check to see if th e throttl e twi s t grip is with the rf'quired free operating movement.

The required free opera ti ng movement : 2_6mm .

if the grip can not be so mo ved freely,

turn the

adjusting nul lo ensure iL

* After adjus tm en t, sla11 th e engine and check fo r the free operating movement again. R peat the adjust-

ment if necessary until it is a s required.

peat the adjust- ment if necessary until it is a s required. Locking nul A d

Locking

nul

Adju s ti ng nut

Auj us tment of Ca rbu r · to r Caution :

The

idling

speed

adju ·t nH•nr

of

tlw ·<'nv;i n e

should be carried out with a l10t <'nv;im•. :.,d th e idli ng spcPt} to th<• r •qu irt.'d 1alue h

he lp of t he idli ng

a fla t gro un d.

hicle sta nd ing

th<·

w i th t fJt: \ ' C -

speed adj u-, ti n v. s<·rf' l\'

oh

The requ ired idling ~pet'd: I . 500 :!: 150r/min

oh The requ ired idling ~pet'd: I . 500 :!: 150r/min Idling sp c t~d <:~djusting

Idling sp c t~d <:~djusting »l' l' <' ll'

Check- up & Adjustment of Au· Valve Gap

Noi se will s t em from too big gap of the air valve. H owever if t h ere is too smal l gap or even no gap at a ll, cl os i ng of the

valve gap must be c hec ked

valve will be hinde red, periodically.

wh ich will ca use burn of

the valve a nd output drop. Therefore,

the air

Th e gap of the air val ve s hould be inspec ted

CD Remove t he caps of th e cen tr al hole and th e t op hole

and adj usted with a cold engine by th e following procedu res:

( th e i gnitio n t iming observation hole)

in the left crankcasf

cove r.

@ Remove the caps

of the two air val ves on the cylinder head.

into th e central hol e of the c ra nk case co ver , jam it agains t the nut of the fl ying wheel and then tu rn

"T" mark on the fl ying wheel aligns with the engraved line o n the lop of the

s hows that

the pis ton is in the upper s top position of the co mpressing stroke, where the valve can be adjusted. A tight rocking arm mea{IS that th e piston is i n the lower stop positi on of t h e compress in g stroke. In thi s case, contin uousl y tum the "T" key clockwise for 360 degrees until the al ignment of those engraved marks, where the valve can be adjusted. Afterward s, c heck the valve gap b] inserting a feeler in between the valve ad ju s ting screw and the e nd of the valve.

cover. Swing th e rocking arm s li ghtly . A loose rocking arm (which indicates the .exis tence of c learance)

the flyin g crankcase

@ In sert the "T" key

whee l clockwise u n ti l the engraved

T he s pecified air valve gap

:0 . 05m m fo r the inta ke and ex haus t valves respectivel y.

@ U the adjustment needed, loosen the locking nut of the valve, tum the adjusting nut till a slight resistance is felt on inserti ng the feeler.

loosening a nd c o nd uct a nother

At the end of the adjustment, tighten the

"Locking nut" to preve nt

check to make sure that the valve gap is OK before all those dismounte d caps are refitted on .

Valve cap

check to make sure that the valve gap is OK before all those dismounte d caps

Central hole cap

Adjuslment of Clutch

*The clutch should be adjusted with the engine in stopped state. There should be a Cree operating movement of 10 - 20mm at the end of the clutch lever as shown in the figure on the right side. When adju tment ts needed, loosen the locking nut on the clutch operating cable and set the clutch lever to the re- quired range of free operating movement. In case of adjustment to be made to a great extent, turn the clutch adjusting screw stud on the right crankcase. ls tart the engine to ascertain whether

the adjusted dutch works normally. * fteadjustment has to be made if there is slipping of clutch or d ifficulty in the engagement of gears.

Brake Checking

( 1 ) Pull up the front and rear brakes respectively and check for wear of the brake shoes. lf the mark "6 "on fp.~ii:~-- the brake drum cover aligns with that

"6 " on the brake cam, it means that

the brake shoes are already worn to the limit and have to be ( 2 ) Replacement

should becarried out at a designated service center and it is recommended that the parts made by our company are

a designated service center and it is recommended that the parts made by our company are

lO - 20mm

used therein. 10 - 20mm

Adj ustment of F_ront ,Brake

( 1)The front brake lever has a free operating mo veme nt of I 0 - 20 mm as shown in the figure on thr right si de. ( 2) If adjustment is needed, turn th e adjus t-

mg

e

c

le1·er.

nut

nea r the

lower side of

the

front

hub,

lockw ise to red uce a nd co unterclockw ise to in- rf'ase the fret> opera ting movemen t of the brake

( 3) After adjustment , the groove of the ad-

justing nu t should be aligred with the pi n of the

brake ann. Cauti on :

Aft e r adjus tmen t , check the fro nt braking sys t m. Tlw braking light s hould be lit up on tim e

wh e n brake

the fron t brake is ap pli ed by grip ping t he leve r.

I

Adjustment of Rear Brake *The vehicle should be supporte'd by the main stand for check. . ( I )The rear brake pedal has a free op-

erating movement of 20

the figure on the right side.

as shown in

)0mrn

rear

brake adjusting nut clockwise to reduce and counterclockwise to increase the free operat- ing movement of the brake pedal.

( 2) To make adjustment, tum the

( 3) After adjustment, the groove of the

adjusting nut should be aligred with the pin of the brake arm.

Caution :

After regulation, check the rear braking system. The braking light should be lit u on

time when the rear brake is applied by stepping down the brake pedal.

Adjustment of Chain

*Check the chain for wear ,tension and lubrication. ( 1) With the motorcycle supported by the main stand, tum the upper and lower illl!!!l portions of the chain by hand to check for its

Rear brake pedal

of the chain by hand to check for its Rear brake pedal tension to see if

tension to see if the sag is within the speci-

fied range of 10

20mm.

Brake cam Brake pull rod ( 2) When regulation is needed , loosen

the axle nut and locking nut of the rear

wheel, then set the chain to the

requj red

nut of the rear wheel, then set the chain to the requj red tension by turning

tension by turning the adjusting nut.

( 3) Apply a little grease to the chain.

Caution:

* At the end of regulation , the marks on the chain adjuster should be in good co- ordination with the engraved li ne on the

horizontal fork as position is concerned .

Rear brake arm Brake arm pin

Adjusting nut

C hai n adjuster( with graduations)

C hai n adjuster( with graduations) R e a r w h e e l a

Rear wheel axle nut

Bear axle

Braking light switch

Adjusting nut

t s w i t c h A d j u s t i n g

Braking light switch spring

Adjustment of Braking Light Switch *The braking light should be lit up on time as soon as the rear wh eel is braked. If not, regulation shall be made by turning the adjusting nut. *With the braking light switch in "ON" position, the braking light should be lit up. If not, che<·k

should be carried out to

ment if needed. Caution:

For the adjustment of the bra king light switch, the brake needs to be first checked to make s ure that

the fre e operating movement is ens ured within the s pec ifi ed range.

see whetheJ· the braking lamp, circuit and switch work normally , Ma ke repl ac -

Battery Checking

CD Open the right side cover.

upper mark line when adding distilled

Otherwise ovetflow and co rro-

wa ter.

duri ng dismo unting and i ns tallati o n.

The breathing pipe must be kept

(2) Clean away dus t and corrosive

sion will occur.

unblocked.

from the surface of the battery.

The electrolyte contains sulfuri-

Replacement of Fuse

® Set the vehicle in a verti ca l

position to see whether the level of the

battery electrolyte is between the upper

a nd lower mark lines. If it is below the

lower o ne, dis ti lled water sha ll be

added to the battery.

® Seriously con·oded conductor

connectors of the battery shall

placed.

be re-

c ~u tion :

To d isma ntle

battery, discon nec t

( - ) electrode before the

the negative

positive ( +)one, and vice versa in in-

stallatio n. Ens ure aga inst a ny co ntact of

the pos iti ve( + ) electrode with the ve-

hicle body.

·

N

I ever

tro lyte

leve l

h

ave

co me

t

h

e

1

e ec-

over

th P

I ever tro lyte leve l h ave co me t h e 1 e ec-

l

'-'1:-'1-'" '

cac id and will ca use se r io us hu rt to skin

a nd eyes by contac t. In case of contac t

with it, wash it off for 5 minutes and see

a d oc tor immediately.

Foreign matter should be pre-

vented from en tering into the battery

Negative( -

)

connector

Positive( + ) connector

I:=-

battery Negative( - ) connector Positive( + ) connector I:=- Set the ignition switc h to

Set the ignition switc h to "O FF "

posi tion. The specified fuse tube of

I OA should be used for repla ceme nt.

Open the left side cover, remove

the fuse holder on the side of the battery

and replace the fuse tube.

If the new fuse tube is broken a-

gain as soon as it is fitted on, it means

with othe r

e lectric parts.

that there is some trouble

:Caution:

Do not use any fuse over lOA

Be sure not to wash the battery

when washing the vehicle.

Lower electrolyte level line

Upp e r "'"''"rutylt teveJ t-Ine

e l ect rol yte level line

Vehicle Washing

Cleaning the vehicle re gularly can slow down the color fading of its body make it easier to check if

there is any damage and any oil leakage with il. Caution:

Washing the motorc ycl e wi th over- pressurized water may cause damage to s ome of its compo-

nents. Therefore, do not jet over- pressurized water direc tly on to-the fo ll ow ing parts :

-Wheel hub

-Exhaust pipe

-Fuel tank and lower portion of cushion

-Carburetor

-Headlock and ignition switch

-Meters

(I) After pre - wiping, the vehicle should be washed with clean water to remove dirty residues so as to,

prevent coiTosion. Plastic s ubasse mblies should be cleaned by wiping with colth or s ponge soak ed in ne ulral

detergent solution, follow ed by wash ing

( 2 ) After the cleaned vehicle is air dried, grease the chain and run the engine at idling :,.peed for a few

minutes.

with clean water.

( 3) Prior to driving, carefully check braking sys tem

repeatedly and repair or adjust it if necessa ry.

Maintenance in Non- use Time

Storage and rvraintenance For the motorcycle lobe stored for a long period of time,

attention s hould be paid to the prevention of moisture,

sunshine and rain attac k in order to protec t it from unnecessary damage. Special check - ups should be carried out on those important parts and subassemblies before sto~age. <D Change lubri c ating oil.

® Grease the chain.

@ Drain off fuel from the fuel ta nk and ca rburetor ( for the vehicle not to be us ed for over a month, th e fuel in the latter

must be thoroughly drained away), turn off the fuel cock and fill an tirust solution i nto the fuel tank, followed b y dosing the tank with the cove r. Caution:

stopped before fill i ng or drain fu e l and it is prohib ited to smoke at th e

As fu el is i nflammable, the engine shou ld be fuel storing ,filling or draining location.

c y l iQde r, s t e p down the kick l eve r

repetitive ly for s ev ("ral times and finall y fit the s park plug ba c k on. Atte ntion:

To pro tect the ign ition

sys tem fro m damage, the spark plug should be put on its cap and earthed.

@ Dis ma ntl e the battery a nd put it in a shady, coo l a nd we ll - ventilated place. It is s ugges ted that the ba tte ry b e

charged once a month. Cleiln the vehic le, s pray the colored

rust.

color fas tening age nt and appl y antimst oil to the part vul nerable to

@ Take out the s park plug, fill a bou t J 5 -20m! of clean lubri c ating

oil i nt~ the

The ig niti o n s witch key mus t be set to "OFF" positio n before steppin g down the k ick lever.

part with

m® Put th e covering over the motorcycle.

(J)

Inflate th e tyre as required and pad

th e vehicle up with the two wheel s c lear of th e ground.

Resumption of Service

CD Remove the cover and clean the v e hicle. Change the lubricating oil if th e vehicle has bee n off s er v i ce for over 4months.

(2) Charge the battery and remount it. @ Drain off the an tiru st solution from the fuel tank, followed by filling fuel therein to th e requ ired level. @ Prior to driving, test the vehicle at low spee d in a safe place. Maintenance Routine Diagram "('means: Check, cleaning, adjustment, lubrication and/ or replacemnet are needed. "C"means: Cleaning is needed.

"R" means:

"A"means: Adjustment is needed.

Replacement is needed.

"L" means: Lubrication is needed. "*"means: This item of maintennace should be carried out at a service center. It may be also done by the user himself with reference to this manual provided he has special tools, sparts and is capable of this job.

at Kington service c enter in order to

ensure safety. Notes : 1. Maintenance should be conducted more frequently when the motorcycle drives in dusty areas.

maintenance

2. When the read -out of the odometer exceeds the maximum figures specified in the table, should be still cycled according to the interval of mileage stated herein.

"* * " menas: This

item can only be carried out by th e serviceman

   

Odometer kmJ.Note 2)

 

hem of Maintenance

   

lOOOkm

 

4000km

8000km

 

12000km

Remark

*

Ci rcu it o f fu e l system

     

I

 

I

 

I

 

*

fuel filter

   

c

 

c

 

c

 

c

 

*

Thrott le operating syse rn

 

I

 

1

 

I

 

I

 

*

Choke of carburetor

     

I

 

1

 

I

 
 

Air filter el,emenl

 

R

 

c

 

c

 

c

 
 

Spark plug

 

R

-_l'corlv

I

 

1

 

1

 

R

 

*

Air Ya!V<: gap

   

I

 

I

 

I

 

I

 
 

Air va lve gap

   

I

   

I

 

I

 
 

r.,1gine lubri ca ti ng oil

   

R

 

One replacement every 2000km

 
 

l.uhricating oil screen

 

Monthl v

   

c

c

c

 

*

Ten~ion of c hain

   

A

 

A

A

 

A

 

*

Idling speeci of r.arburetor

   

1

I

I

 
 

Oriviug chain

 

R-4·ear

   

l, L every 500 km

   
 

Battery

   

I

 

I

 

l

 

I

 
 

Wear of brake shoes

 

r-2 vear

   

I

   

I

 

I

 
 

Hear braking sy•tem

   

I

 

I

 

I

 

I

 

**

Braking liquid hose

     

I

 

I

 

I

also for disc style

* *

Cup ol brakjng liquid

   

J

I

 

I

 

I

 

I

**

Braking liquid

   

One replacement every two year

   

**

Front braking system

   

I

 

I I

 

I

 

*

Rear bmking light switch

 

I

 

I I

 

I

 

*

Lrght changmg ol haadllght

 

I

 

I I

 

I

 
 

Clutch

   

I

 

1 l

 

I

 
 

Side stand

     

I 1

 

I

 

* Suspension

   

I

 

I I

 

I

 

* Nuts, bolts & other fasteners

 

(

 

1 r

 

I

 
 

Wheel/ spokes

   

I

 

I 1

 

I

 

* *

~rui ng of st•erin~~: handl e

 

I

     

1

 

ELECTRICAL DIAGRAM

B- Biack

Y-Ye /Jo w

W-White

BJ-Biue

ELECTRICAL DIAGRAM B- Biack Y-Ye /Jo w W-White BJ-Biue