Vehicle view 1. Rear light 2. Fuel tank assembly Gear shifting handle 4. Electric lock assembly 5. Spare power 6. Cooling water tank assembly 7. Rear shock absorber assembly 8. Rear brake assembly 9. Front shock absorber assembly 10. Front brake assembly
ITEM ROUTINE INTIAL EVERY Whichever first month 1 3 6 6 12 Km (mi) 320 (200) 1,200 (750) 2,400 (1,500) 2,400 (1,500) 4,800 (3,000) hours 20 75 150 150 300 Brake* ●Check operation/brake pad wear/fluid leakage. ●Brake fluid needs to be above the lowest position. ●Correct if necessary. Replace pads/disk if worn to the limit. O O O O O Accelerator pedal* ●Check operation and free play. O O O O O Wheels* balance/damage/ run out ●Repair if necessary. O O O O Wheel bearings* ●Check bearing assemblies for looseness or damage.. ●Replace if damaged. O O O O Front and rear Suspension* ●Check operation and for leakage. ●Correct if necessary. O O Steering system* ●Check operation and for looseness/Replace if damage. ●Check toe-in/Adjust if necessary. O O O O O Rear knuckle pivots and suspension arms* ●Lubricate with lithium-soap-based grease. O O O Drive shaft universal joint* ●Lubricate with lithium-soap-based grease. O O O Engine mount* ●Check for cracks or damage. ●Correct bolt tightness. O O O Front and rear axle boots* ●Check operation. ●Replace if damage. O O Stabilizer bushings* ●Check for cracks or damage. O O O Fittings and fasteners* ●Check all chassis fittings and fasteners. ●Correct if necessary. O O O O O Battery ●End connection O O O O Lamp and steering indication ●Operation O O O O O
Until marks on magneto flywheel “1” and magneto cover are aligned. Mark “1” on magneto flywheel Notch on magneto cover Location of crankshaft position sensor At TDC ignition, the printed marks on the camshaft timing gear have to be parallel to cylinder head base as per following illustration. TYPICAL Printed marks on camshaft timing gear Cylinder head base Insert the feeler gauge between the valve stem end and adjusting screw on the rocker arm to check the clearance. If the valve clearance is out of specification, adjust valves as follows. Valve clearance Intake 0.05 to 0.09mm Exhaust 0.10 to 0.15mm Use mean valve of exhaust/intake to ensure a proper valve adjustment. Hold the adjustment screw at the proper position and torque the locking nut. Repeat the procedure for each valve. Adjustment screw Adjustment nut Feeler gauge Valve clearance adjuster locknut:12N.m Install the valve cover of both cylinders, spark plug cable and spark plug of both cylinders, the plug screw and of magneto cover and the crankshaft position sensor.
At TDC ignition, the printed marks on the camshaft timing gear have to be parallel to cylinder head base. Printed marks on camshaft timing gear Cylinder head base To lock crankshaft at TDC ignition, proceed as follows. Remove from crankcase plug with sealing ring. Plug Sealing ring Crankcase PTO side, front side Lock crankshaft with crankshaft locking bolt. 1. Crankshaft locking bolt NOTE: Make sure the locking bolt engines in the groove of the crankshaft. Camshaft Timing Cylinder 1 Using a 14 mm Allen key, turn crankshaft 280 °counterclockwise, until marks on magneto flywheel “1” and magneto cover are aligned. Allen key 14mm Turn crankshaft 280°counterclockwise
SPRAG CLUTCH GEAR Sprag Clutch Gear removal Remove rotor . Pull clutch gear from rotor. Sprag clutch gear Sprag Clutch Gear Inspection Inspect gear, especially teeth and sprag clutch collar, for wear and other damage. Check needle bearing condition. Replace sprag clutch gear if necessary. INSPECT Teeth Collar Needle bearing Sprag Clutch Gear Installation The installation is the reverse of the removal procedure. NOTE: Apply engine oil on needle bearing and collar of sprag clutch gear. TRANSMISSION
Front seat Figure 5.1.5 Lift up lock catch at the rear of front seat by the left hand, and pull up and remove front seat ① by the right hand. Available overhaul: replace front seat Rear rack cover plate combination (include rear rack) Figure 5.1.6 Pull the pulling component ② on cover of rear rack plate towards the rear of a vehicle, releasing it from lock-up status. Figure 5.1.7 Pull it along arrow direction and remove upper cover ③ of rear rack cover plate. Available overhaul: replace upper cover of rear rack cover plate. Figure 5.1.8 Remove four fastening screws of rear rack cover plate combination before removing rear rack cover plate combination ②. Tool: 10mm sleeve Available overhaul: replace rear rack and its plate Figure 5.1.5 Figure 5.1.6 Figure 5.1.7 Figure 5.1.8
Front rack cover plate combination (include front rack) Figure 5.1.9 Pull the pulling component ① at upper cover of rear rack cover plate towards the rear of a vehicle, releasing it from lock-up status. Figure 5.1.10 Pull it along arrow direction and remove upper cover ② of rack cover plate. Available overhaul: replace upper cover of front rack cover plate Figure 5.1.11 Remove 4 fastening screws (inside battery box) of front rack cover plate combination with 10mm sleeve before removing front rack cover plate combination ③. Tool: 10mm sleeve Available overhaul: Replace front rack cover plate and front rack Check coolant supplement and level of auxiliary water tank Battery Figure 5.1.12 Remove lock screws of battery positive and negative electrode and wing nuts of battery hook (two pieces for each) and fastening hook bolt ④ and hold-down plate ⑤ of battery before removing battery ⑥. Tool: 10mm sleeve. Available overhaul: replace and test a battery Figure 5.1.13 Remove shock absorber pad at the bottom of a battery. Available overhaul: replace shock absorber of a battery Figure 5.1.9 Figure 5.1.10 Figure 5.1.11 Figure 5.1.12 Figure 5.1.13
Figure 5.1.25 Disconnect plug-in of left and right steering light and that of high beam and low beam in sequence before removing front panel combination ①. Available overhaul: Replace front panel combination Replace and check left and right steering light Replace, check and adjust high beam light and low beam light Figure 5.1.26 Remove four tightening screws at upper part of front plastic piece combination. Tool: screwdriver Figure 5.1.27 Use flat screwdriver to knock limit retainer of electric lock, making it rotate anticlockwise. Figure 5.1.28 Remove limit retainer ② and gasket ③ of electric lock and press along arrow direction, separating electric lock assembly and front plastic piece. Figure 5.1.25 Figure 5.1.26 Figure 5.1.27 Figure 5.1.28
Figure 5.1.39 Remove rear plastic part combination ① and disconnect plug-in of left and steering light, rear brake light and licence plate light before dismantling plastic part combination. Available overhaul: Replace rear plastic part combination Replace and check rear steering light on the left and right Replace and check rear light and licence plate light Rear bumper Figure 5.1.40 Remove four screws and rear bumper ②. Tool: 10mm sleeve Available overhaul: replace rear bumper Rear bumper lining Figure 5.1.41 Remove two fastening screws below rear bumper lining. Tool: 10mm sleeve Figure 5.1.42 Remove four fastening screws, rear bumper lining ③ and rear seat support plate ④. Tool: 10mm sleeve Available overhaul: replace rear bumper lining Storage box combination Figure 5.1.43 Pull storage box pulling component ⑤ along arrow direction, releasing it from lock-up status. Dismantle two fastening screws of storage box. Remove two positioning and support fastening screws behind front seat and positioning and support ⑥ combination behind front seat. Tool: 8mm Figure 5.1.39 Figure 5.1.40 Figure 5.1.41 Figure 5.1.42 Figure 5.1.43
Manual gear shift plate Figure 5.1.48 Loosen lock nut ① of gear shift ball and rotate gear shift ball ② anticlockwise to remove it. Remove one tightening screw of steady clamp of accelerator cable, separating clamp ③ and manual gear shift plate ④. Remove two tightening screws and manual gear shift plate ④ , completing dismantling all appearance components. Tool: cross screwdriver, 13mm open spanner 8mm sleeve, 10mm open spanner (rotary stop) Re-installation Conduct re-installation based on the reversed sequence of dismantling external components of vehicle. Figure 5.1.48
Figure 5.3.3 Use key ① to open and remove fuel tank ②. Remove two fastening screws in the front of fuel tank. Tool: 8mm sleeve Figure 5.3.4 Remove ear clamp ③ of fuel outlet pipe of fuel pump before removing fuel pipe. Remove six screws and fuel pump assembly ④. Remove four screws, support plate ⑤ of rear storage box and fuel tank assembly ⑥. Tool: 8mm sleeve, sharp-nose pliers Note: ear clamp should not be used repeatedly; new clamp should be used upon installation. When pulling out fuel pipe, attention should be paid to pressure inside fuel pipe, splash measures should be taken and vessel should be prepared to discharge fuel inside fuel pipe in advance. Throttle valve combination Figure 5.3.5 Disconnect throttle valve position sensor and air inlet pressure sensor plug-in, separating it from throttle valve. Disconnect cylinder II nozzle and cylinder head temperature sensor wire group plug-in, separating it from cylinder head. Figure 5.3.6 Pull out high voltage cap ⑦ of cylinder I ignition coil, separating it from engine. Loosen two clamps at one side of air inlet pipe of throttle valve and remove throttle valve combination ⑧. Pull out high voltage cap ⑨ of cylinder II ignition coil, separating it from engine. Tool: flat screwdriver Available overhaul: Replace and conduct maintenance of spark plug Figure 5.3.3 Figure 5.3.4 Figure 5.3.5 Figure 5.3.6
Figure 5.3.7 Remove one fastening screw and lateral cover ① of throttle valve. Tool: cross screwdriver Figure 5.3.8 Loosen lock nut ② of accelerator cable regulator, rotate accelerator rocker arm ③ anticlockwise, loosening and rotating accelerator cable to opening before removing it with limit pin ④ . Rotate accelerator cable regulator anticlockwise and remove accelerator cable ⑤, separating it from throttle valve assembly. Tool: 10mm open spanner Available overhaul: Replace and conduct daily maintenance of throttle valve combination and accelerator cable combination Figure 5.3.9 Disconnect cylinder I fuel nozzle , crankshaft position sensor and stepping motor plug-in separately. Fuel pipe combination Figure 5.3.10 Remove two screws, fuel filter support ⑥ and fuel filter ⑦. Tool: 8mm sleeve Note: one end of filter boss faces cylinder head upon installation. Figure 5.3.7 Figure 5.3.8 Figure 5.3.9 Figure 5.3.10
Figure 5.3.11 Remove ear clamp ① of fuel pipe of cylinder I and II nozzle and pull out fuel pipe ② of cylinder I and II separately along arrow direction before removing fuel pipe assembly ③ Tool: pliers Available overhaul: Replace and conduct daily maintenance of fuel pipe Note: ear clamp should not be used repeatedly; new clamp should be used upon installation. After completing dismantling fuel system, check fuel pipe, fuel filter and fuel pump filter element for block and crack. Replace the component with a new one, if necessary. Re-installation Conduct re-installation on reversed sequence of dismantling. Warning: To prevent fuel leakage, seal gasket, O-ring and ear clamp should be replaced upon re-installation. Fuel pipe should be replaced once every two years. Figure 5.3.11
Figure 5.4.6 Remove three screws and front thermal baffle ① and rear thermal baffle ② of cylinder II exhaust pipe. Remove one screw and thermal baffle ③ at inner side of intermediate exhaust pipe. Tool: 8mm sleeve 10mm open spanner (rotary stop) Figure 5.4.7 Loosen tightening bolt of clamp ④ at the rear of muffler. Remove two screws and pull along arrow direction before removing muffler main body ⑤. Tool: 10mm sleeve, 16mm sleeve 17mm open spanner (rotary stop) Available overhaul: Replace and conduct maintenance of muffler main body Throttle valve combination Figure 5.4.8 Remove two lock nuts at exhaust port of cylinder II. Tool: 13mm open spanner Figure 5.4.9 Loosen tightening bolt of intermediate clamp ⑥ of muffler and pull along arrow direction before removing exhaust pipe ⑦ of cylinder II. Tool: 13mm sleeve 13mm open spanner (rotary stop) Figure 5.4.10 Remove two lock nuts at exhaust port of cylinder I Tool: 13mm open spanner Figure 5.4.6 Figure 5.4.7 Figure 5.4.8 Figure 5.4.9 Figure 5.4.10
Dismantling Gear shift handle combination Figure 5.5.2 Remove lock nut of gear handle on the right side of a vehicle. Remove gear shift tension spring ①, separating the upper part of gear shift handle combination from a vehicle. (Refer to relevant contents in section I of the chapter for dismantling vehicle plastic parts) Tool: 10mm open spanner, sharp-nose pliers 13mm open spanner Figure 5.5.3 Remove lock nut of gear shift handle combination at gear shift rocker arm before removing gear shift handle combination ②. Tool: 10mm open spanner 10mm ring spanner Available overhaul: Replace gear shift handle combination Handlebar combination Figure 5.5.4 Remove screws and left handlebar shield combination ② and handlebar shield hold-down block ③. Tool: 8mm sleeve Figure 5.5.5 Remove three screws and right handlebar shield combination ④ and handlebar guard hold-down block ⑤. Tool: 8mm sleeve Figure 5.5.2 Figure 5.5.3 Figure 5.5.4 Figure 5.5.5
5.6 Traction engine and water tank combination I. Dismantling Figure 5.6.1 Disconnect temperature sensor plug-in ① of water tank, separating it from water tank. Remove two screws, separating traction engine wire group and clip ② from water tank ③. (Refer to relevant contents in section I of the chapter for dismantling vehicle plastic parts) Tool: 10mm sleeve Figure 5.6.2 Rotate control handle of traction engine clockwise from point A to point B (stop), releasing lock-up status of cable. Pull out cable for about 30cm along arrow direction. Figure 5.6.3 Remove two screws, separating cable guide combination ④ of traction engine from fixing plate ⑤ of traction engine. Remove four screws from part of traction engine, separating fixing plate ⑤ and main body ⑥ of traction engine from a vehicle. Remove main body ⑥ and fixing ⑤ of traction engine and cable guide combination ④ successively along arrow direction. Tool: 10mm sleeve Fastening bolt torque of cable guide combination of traction engine: 60-65 N.m Available overhaul: Replace traction engine main body and guide combination Figure 5.6.1 Figure 5.6.2 Figure 5.6.3
Engine Figure 5.7.5 Disconnect speed sensor plug-in ① of transmission case, separating it from wire group. Remove screws, separating gear indication line 1, 2 and 3 from engine. Tool: cross screwdriver (Installation should follow position indicated in figure corresponding to gear line tag serial number! Random connection is not allowed to avoid gear indication out of order) Figure 5.7.6 Disconnect pressure sensor plug-in ② of engine oil. Tool: 8mm sleeve and flat pliers Figure 5.7.7 Remove three screws and engine hanging combination ③. Tool: 13mm sleeve 15mm open spanner (rotary stop) Tightening torque of engine hanging bolt: 60-65 N.m Figure 5.7.8 Remove one fixing screw ④ of vehicle in the front of engine. Remove four screws, separating front transmission shaft ⑤ and engine. Tool: 13mm sleeve and 13mm open spanner 15mm open spanner (rotary stop) Tightening screw torque of front transmission shaft: 70-80 N.m Tightening screw torque of engine: 60-65 N.m Figure 5.7.9 Remove one fixing of vehicle behind engine Tool: 13mm sleeve 15mm open spanner (rotary stop) Tightening screw torque of vehicle behind engine: 60-65 N.m Figure 5.7.5 Figure 5.7.6 Figure 5.7.7 Figure 5.7.8 Figure 5.7.9
Figure 5.9.5 Remove split pin ① at the left drive disk. Tool: sharp-nose pliers Figure 5.9.6 Remove two bolts and remove main body combination ② of front brake pump along arrow direction. Tool: 10mm sleeve Tightening torque of main body bolt of brake pump: 24-28 N.m Available overhaul: replace and conduct maintenance of main body of front brake pump Figure 5.9.7 Use torque spanner ③ and dedicated rotary stop tool ④ to remove lock nut of left drive disk before pulling out drive disk combination ⑤ along axial direction. Tool: 30mm sleeve and torque spanner Dedicated rotary stop tool Tightening torque of drive disk lock nut: 280-300 N.m Available overhaul: replace and conduct maintenance of disk combination Figure 5.9.8 Remove three bolts and front disk brake guard plate ⑥. Tool: 8mm sleeve Figure 5.9.9 Remove steering pull bar ⑦ on the left side and split pin and nut of front upper swing arm ⑧ (two pieces for each). Remove lock nut and bolt of front lower swing arm ⑨ (one piece for each), separating left steering pull bar, front lower swing arm from steering knuckle ⑩. Tool: 13mm sleeve and 17mm sleeve 15mm open spanner and flat pliers Bolt tightening torque of front lower swing arm: 60-65 N.m Available overhaul: replace steering pull bar on the left Figure 5.9.5 Figure 5.9.6 Figure 5.9.7 Figure 5.9.8 Figure 5.9.9