American Lifan 250-B User manual

i.,,1rr'.1{
-=€E ==

PREFACE
Thankyou for choosingthemotorcycle.May you enjoyriding all time.
The manualcontainsthenecessaryinstructionsand
guidance
with respectto the operationandmaintenanceof the motorcycle,andBE SURETO
READ IT CAREFULLY BEFOREYOU RIDE THE MOTORCYCLE. Properoperationandmaintenancecan
guarantee
asaferidingtominimizetroubles
of themotorcycleandkeepit in a soundcondilion,whichcanextendtheengineservicelife.
All rightsreserved.No partof thispublicationmaybereproduced
withoutour prior written permission.
IMPORTANTNOTICES
a OperatorandPassenger
Thismotorcycleisdesignedtocarrytheoperatorandone
passenger.
Themaximumloadweightofthemotorcyclemustnotexceedl50kg.
O On.road
Thismotorcycleisdesignedforon-roaduse.
Payspecial
attentiontostatementspreceded bythe
followingwords:
AWARNING: Irdicdtesastrong
possibilil! ofsevere personal
injury ordeathif insbuctionsarcnot
follo$,ed.
z\CAUTION: lzdicatesa possibilit!of equipmentdo .ageif instructionsarenot
folloved.
NOTE: Giveshelpfulinformation.
EnylronmentalProtectton
(EP): Indicatesspecial
precautions
that mustbetakento meetenvironment
protectionlaws
and regulations.
lmproperuseof amotorcyclemaycauseenvironment
pollution.
If theoperatorfailstofollowsafeoperatingandmaintenancepractices,the
Co.
will nottakeanyresponsibility
toany
injury
ordamageoccured.
Thismanualshouldbeconsideredasa
permanentpan
ofthemotorcycleandshouldremainwiththemotorcyclewhenresold.

CONTENTS
MOTORCYCLE SAFERIDING
SafeRidingRules
Protective Cloths
Refining
GENERALINT'ORMATION
Pafis l,ocation
VIN Record
EngineOiI9.........
ClearawayCarbonDeposit
f ...........................
i',lAlll3,f::::::::::::::::::::::::::::::::::::
FuelandEngine
Oilm
CONTROLLING PARTS
ValveClearance
CamChainAdjustment
MufflerI
Electroniildlrated
AerationSysrem
1...........
ODerationof Thronle
ri- c---,r ^rr---r,,-r^- E
;.t fi ::,.":::_"":::-:.H
L"cr^ Lcds d,u,,5 4,, ruPP,rI.......................
Clu1ch.......................
DriveChain
FrcntBrake
R€arBrake
BrakeLight.................
How to UseBrakeWearlndicator
Front/RearShockAbsorberandSusoension..........
Tyre
Front Wheel
RearWheel
RemovalfromStorase
Anti-theftDevice
(Optional)
ELECTRICDIAGRAM
l0
l0
l0
l0
ll
ll
ll
ll
12
l3
l3
l5
l5
l5
l5
Meter
and
Indicators
Ignirion
SwitchandSte€ringlrck ..................,.......
RiehlHandlebar Controls
t eft Handlebar
Controls
Choke
t-ever
Refuelingand
Cap
FuelCock
Gearshift
Pedal
RearBrakePedal
Rear
Shock
Absorber
ll
t2
t2
t2
l3
t4
t4
t4
Stand,............,....,...................
OPERATIONGIJIDE
Pre-rideInspection
SbningtheEngine
Breaking-in
tuding
BrakingandParking.,.............,....,...,,.........,....,....,..
8
MAINIENANCE
ToolKit
Fuse
Battery!
IROUBLFSHOOTING,
STOMGE ANDOPTIONAL
PARTS
Troubleshooting
CleaningandStorage l6 l6
l6
l6
t'1
9
9
Maintenance
Schedule SPECIFICATIONS l8

MOTORCYCLE
SAFE
RIDING
SAFERIDINGRULES
AWARNING Motorcycle riding requires specialefforts on your part
to ensure safety. Know theserequirements before you ride.
I Alwaysmake
apre-ride inspectionbefore
youstantheengine.You muy
prevent
accidentor equipment
damage
O Mostcountriesrequirea specialmotorcycleridingteslor Iicensc.Makc
sureyou are qualified
before
youride.NEVER lend yourmolorcycletoan
inexperiencedrider.
OMakc yourself
conspicuoustohelpavoidtheaccidentthatwasn't
your
fault:
OWear brightor reflectiveclothing.
a Don't ride in another
motorist's"blind spot".
ODon'l speedilycrossanother'sway.
Oobey all nationalandlocallawsandregulations.
aobey thesp€edlimits,andNEVER travelfaster
thanconditions
warrant.
OSignal beforeyou makea tum or lanechangeto draw other motorists'
altention.
OUse extracautionatintersections,
parking
lot entrancesandexits.
OAlways rememberto ridewith bothhandsandkeepbothfeetontherider
footrestwhile thepassengergrasps thehandrailwith bothfeetontherear
footr€st.
PROTECTIVECLOTHS
O Forthesafetysake,alwayswearahelmet,afaceshield,dust
glasses
and
protective
clothing.Youl passengerneedsthesame
protection.
O Theexhaustsystembecomeshotduringoperation,andit rcmainshotfor
awhile afterstoppingtheengine.Takecarenotto touchtheexhaust
systemwhile it is hot.Wear
clothingthatfully covers
your legs.
ODo notwearlooseclothingthatcouldcatchonthecontrcllevers,wheels,
etc.
REFITTING
original parts may make riding unsafe, and is illegal also.The user
must obey all national and local la$s and regulations in relation to
vehicleand traffic, Ifyou havea good proposal concerning refitting of
the motorcycle, please write us, The relitment can be done with per-
mission of the Co, Otherwis€, the user will take the consequences.
LOADING
AWARNING Addition of accessoriesand cargo may reduce (he
motorcycle's stability, performance and safeoperating speed.
OKeep cargoandaccessoryweightlowerandcloseto thecenterof the
motorcycle.Loadweight equallyon bothsidesto minimizeimbalance.As
weight
islocatedtunherf.om themotorcycle'scenterofgravity, handling
is proponionallyaffccted.
aAdjust tyre pressure
andrearsuspension to suit load weight andriding
conditions.
OMake surethatcargois faslenedon thevehicle.
ODo notattachitemstothehandlebars.fork or fender.Otherwise.unstable
handlingor slowsteering response
mayoccur.
OThe maximumloadweightof themotorcycleis l50kg.Please
do not
overload.
ACCESSORIES
Genuineaccessoriesof theMotorshavebeenspecificallydesignedand
testedonthemotorcycle.Beacusethefactorycannottestallotheraccessories,
you arepersonallyre-sponsiblefor selection,installationanduseof acces
sories
notproduced by theCo. Al-waysfollow SafeRidingRulesandthese
below:
Ocaretully inspecttheaccessoryto makesurethatit doesnotobscureany
lights,reduce
ground
clearanceorbankingangle,orlimit suspensionbavel,
steering
travelorcontroloperation.
aDo notinstallothercoolingequipmentfor theengine.
aDo not
addelecricalequipmentthat
will exceedthe motorcycle's
electri-
AWARNING Arbitrarily refitting themotorcycleor removing
th€O calsystemcapaciry.

GENERALINT'ORMATION
PARTSLOCATION
cie.
r-zr
Fig. I (Left-view)
O Meter @Fr.winker @Headlight @
cearshift
pedal
lDl
)roestanq to, Kr.snocKaDsoroer
Fig.2 (Right-view)
O Rearviewminor OFueltank@Taillight@Exhaust
muffler
@Pillion
fbotrest @Driverfootrest @Rr.brake
pedal
@Fr.shockabsorber
o

VIN RECORD (fig. 3-S) Engineoilmustbeselectedinaccordancewithrulesbelowandotheroils,
such
asordinaryengineoil.gearoilandvegetablc oil.areforbiddentobeused.
l-'ig 3 VIN Fig 4 Enginecode Fig' 5 Namephte n.ti\'c nluslbetechnicalryequivalentin every
VIN: il f flll l flTf Tl]l l l rcspecl.
viscosily varieswirh regions
and
Enginecodc: lT- -- lcmperarurcs.
so
thclubricanthasto besc-
Pleascfill thcVIN and
cnginc
codcof your motorcyclein theblanl bclow. lectedacc(n.dingtoourrccommendalion.
Theywill helpordc.spare
parts
andfind outthevehiclewhenslolcn. ll lhercisnogasoline
engineoil SAEl5W40-
NOTES SE.thc
engineoil No.HQB-10
(or
HQB-6in
(D The VIN is slamped
ontherightoi thesteering
stem
(Fig.3
). rcgionswhercthelemperalureislowerthan
@ Theenginecodcisstampedon thebottom-leftolihe crankcase
(Fig.4). l0 c )canbeusedinstead.
@ Thevchiclc nameplateis fixedonthe
leftofthe steeringstem
(Fig.5).
FUELANDENGINEOILGP) CONTROLLING PARTS
Fuel Selection METER AND
Fuel isa key factor in decidingtheexhaustemissionsfrom theengine,
so JNDICATORS ifig. zl
selectionoffuel mustlirllow thcrulcsbelow.
Selected
fuelrnuslbeunl.rd"d lr-)
Sp""d,r."l".
gasoline
withoctaneNo.RQ-93or higher.Usingimpropcr
lucl could rcducc (l Odonletef
performancc,sho(cn thccnginc's scrvicelife. (3)
Rightturnsignalindicator "+"
EngineOil Selection
(Fig.6) @
Leftturn
signalindicator
"+"
The
quality
ol theengineoilplays avilal roleindeciding$e cnginc
pcrtirmrutcc '3)
Fli-beam
indicator " "
and
service. _ (6)
Ncutralindicator
"N '
s
tII E 'E--'
'- !E- I E| - -: Thc
vchicle
hr. heenfilleduithengineoilSAEI5\\'/40-SEhclbrc
beins
il w vFil ::;:::Ji::::Tiil'it::11n";
I I \ othermotoroilis to beusedinstead.thealter- ---l-I---J

IGNITION SWITCHANDSTEERING
LOCKtpie.
sr
Isnition Switch
Theswitchisequipped
wilh 2 keys
including
aspareone.
''O" OFF:
Engineand
lighlscannotbc
operatedandthekeycdnbc rcmoved.
'Q" ON:Engine
andlightscan
beoperated.
neutral
light is lit and the key cannot
be
Ignition
sw
removed.
Parking
Insenthekey intothelockcore.and
prcssit whilc turnin-q
counlerck)ckwise
to
"P" position.lhen renrcvelhekey.In thiscase.thetailliShl
and
purkinS
lightwill glow,andengineand
otherlightscannot
beoperulcd.
Toci.ncelthc
contlition.turn
lheley Llockwtse
luother
po\lll(rn.
NOTE when thcvehicleisnol keptin use.ulways
sctlhc switcht() OFF"
andremovethekey-
Steering Lock
To lock the steering
head.turn leti thesteering
baras
farasit willgo,lum clockwisethc
ignition
keyuntil lockingthe
steedngbar.atlasl
rcnlove
the
key.To unlockthe
steeringhead.turn
lhe
keycounterclockwise.
RIGTIT
IIANDLEBARCONTROI,S
(Fig.
9)
StarterButton
Depresithebutton
- ..' tostanup
lheengine.
Lighting Switch
Thc3-position
swilchlunctions
aslbllows:
:Thchc:dlight,taillighl andmeter
lightsarebright.
p: :Thc parking
light.tailightandmcter
lightsarebright.
a :(OFF) Theheadlight.
taillighl.
pitrkingIightandmeler
Iighlsareotl.
Emcrgency Switch
Inunemergency.
dcprcssing
theswilch
to': '' will stall the
engineatonce.
Innormal
ridingcascs,
alwayssctthe
switchat 'O".
Throttle Grip
The
gripisusedtocontrol
engine
power.Tumingin the
gripwill incrcase
fuel
supply,
while
turning
outit willdecreasefuel
supPly.
LEFT HANDLEBAR CONTROTS Oi&
IO)
Headlight
Dimmer Switch
Pushtheswilch to " to select
hiSh
hlam.
Pushthcswitchlo ' ' to selcctlowcr
bcam.
T[rn Signal
Switch
Movc theswitchto '+" lo signal
a left
lurn-
1()
"+" lo signaldrightlurn.
Horn Button
Prcss
thebullon " )r=" ' to soundlhe
horn.
Passing
SignalSwitch ',,D" (Fig.
ll)
Whenpassing,pressandrclcase
the
switch,lheheadlight
will wink
lo wamthe
vehicles.
CHOKE
LEVERtnie.
tt)
The choke lcver is located
on the left
handlebarcontrols.
Pushtheleverto open
thethrottlc.
Fig.8 Slccringbck
O Shner bulton
@
LiShtingsw.
O Emergency
sw.
O Throltle grip
Fig.
9
!?, Fig.
l0 O Dimmer sw.
O Turnsignalsw.
O Hombutton
Passingsignal
sw.
Fig.ll Choke
lever

REFUELINGANDFUELFILLER
CAP
(r'rg.
rz)
lOpen thelocklid andinscrt
thc
ignitionkcy:
aTurn theke)'clockwiseby90'' :
O Rc'novc
thccap.
Toreinstalltlrecap,.just
dcprcss
it ontothetank
inlet.Thefueltankcapacilyis l,l L including
thcrcscrvcssupply
ol 2 L.
AWARNINC
a Do not overfill the tank (thcrc should be no luel in the filler neck).
After refueling, make sure the fuel filler cap is closedsecurely.
O Gasolineis extremelyflammable and is explosiveunder certain
conditions. Refuel in a well-ventilated ar€a with the enginc stopped.
Do not smoke or allow flames or sparks in the area where the fuel
tank is refueled.
a Before refueling, make sure to filter fuel first. Spilled fuel vapor
may ignite. If any fuel is spilled, make sure the area is dry before
starting the engine.
FUELCOCKrnig. rrl
a Thciucicocki\ hcatcdat
thc
Icti-bottom
ol-thetank.
With
thlrfucl
cock
in 'OFF" posilion.
lirelcannolllow fr(xn thetanktothe
carburetor.Tum
thccock1()OFFwhcncvcr
thc
nrotorcvclc
isnotkeptin uslr.
alWith thclirclcockin ON" positron.
fuelwill tlowfromthemainluel
syppl)tothecarburelor.Withthccockin "RES" position,
fuel
will tlow
fromthc rcscrvcfuclsupplv
to thccilrllurelor.UsethereseNefuelonlv
whenthcmainsupp)yisgonc.Rclill thctankattheearlieslopportuniry.
ACAUTION Alierrelueling.makcsurethalthcfuclcockisin " ON"
position.IiiIisin RES position.you
mayrunoutol-fuelwithnoreserve.
Corect useol lheluel cockcanavoid
thcstatc above-mentioned.
GEARSHIFTPEDALrrie. rar rsr
Thc motorcycleisequippedwilh a 5-speedmeshtransmission.
Thcgcar
indicatorshowsthcgcarposition
atpresent.
Fig. l5 showsagearpatlern.
Internaitiona5-speed
Fig.15
Lock lid Fuellillcr cap
Fig.
12
[;j,',,'..'f*15ffi
Fig.l4

REAR
BRAKEPEDAL
rnie.rrr
Therearbrakewill functionaDdthcrciLrslop
lightwill glow whcntreadingthcpcdal.
Fig.16 Rr.
brake
pedal
REAR SHOCKABSORBER oig. rzi
Theshockabso|berhas
5iLd.juslrncntposilionsld dilltrentIoiLdsoIriding
conditions.PosilionI istbrlighl
loadsitndslnoothK)iLdconditions.Positions
Il ltt
V increasespfinll plcloadlirl a stiffcl rcarsuspcnsion.
andcanbe
usedwhenthcmoiorcyclcis
heuvilyloadedorriddeninruggcdroads.
Usc
:r
fiin
{pann(r
lolurnlhe.rJju.lerr,,
fri,fcr
pi,\lr,,n.
NOTE Besuletoadjustshockrbsorhcrs
hoth
lcti andright10thesaDte
posllron.
SIDESTAND rntg. ttt
Whenparking
lhe
vehicle.
turnthesidesrandclockwiscalong
thc
fianrc
to
position.
Belbrcclrivingthevehicle,sctthestandtothcinitialposition.
CAUTION Besure to setthe stand to position beforedriving the
motorcycle. Otherwise, it may fall over.
Fig.l8
Fig.
l7

OPERATIONGUIDE
PRE-RIDEINSPECTION
Inspect
your motorcycleeverytimebefore yourideil. Theitemslisledhere
will only takea few minutesto inspecl,andin the long run they cansave
time. expense,and
possiblyyour life.
L Engineoil level
- addengineoil ifrequired.Checkfor leaks.
2.Fuellevel- refuelwhennecessary.
Check
for leaks.
3.Frontand
rear
brakes checkoperation,and
adjustfreeplayif necessary.
4.Tyres - checkconditionandpressure.
5. Batteryelectrolyte
- checkthattheelectrolyteis suitable.
6.Throttle
-checkforsmoothopeningandfullclosinginallsteering
positions.
Adjust or replaceit if necessary.
7. Lights andhorn - checkthatheadlight,
tail/stopli8ht, winkers,parking
light, indicatorsandhom functionproperly.
8.Drivechain
-checkconditionandslack.Adjustandlubricateifnecessary.
9.Fasteners
- checkthatall nuts,screwsandboltsarcmountedsecurely.
10.Steeringsystem
- checkfor its smoothnessandreliability.
STARTINGTIIE ENGINE
CAUTION Do notstarttheenginein anarrowareato prevent
accidents.
Attempting to starttheenginewith thetransmissionin gearmayresultin
damagetoequipment.
Beforestarting,confirmthefollowing:
OMake surethefuelin thetankisenough.Setfuelcockto "ON" position.
a Move lhe gearshitipedalinto NEUTRAL to light up theindicator "N"
(green).
a Setthechokelevertothefully closed
position
if theengineiscold.
a With thethrottleslightlyopen(less
than l/8 of its entireopening),oper
atethestartersoasto slan theengine.Then push chokeleverto half-open
posruon,
I Warm up theengineentirelyatanidle speedof 1300r/minuntil it works
normally,andthenpushthechokeleverto its fully openposition.
NOTE
Do not use the electric starter for more than 5 seconds at a time.
R€leasethe starter button for approximately l0 secondsbefore press
ing it again,
BREAKING-IN
Helpassure
your motorcycle'sfuturereliability and performance
by paying
extraattentionto how you ride the first l000km. During this periodavoid
full throttleriding,besuretodriveataspeednomorethan807,ofeachgear I
andto continually changingspeed.After the break-in period,be sureto
conduct
maintenancesoas to makecompensationfor initial wear.The ser-
vicelite will beextendedobviouslythroughsuch
maintenance.
RIDING
a Starttheengineand
warmup it.
I While theengineidling, pull in theclutchleverand
push
downthe gear
shift pedal to shift into low (lst) gear.
a Slowly releasetheclutch leverandatthesametime graduallyincrease
enginespeedby openingthethrottle.
a lnserttheignitionswitchandtumit to "Q" position. fO When
the
motorcydeattlinlsa:t:adyspeed,closethe
throttl"l
ryI,h"

clutchleverandshiftto 2nd
gear
byaeadingthegearshiftpedal.
Thissequenceis repeatedtoprcgrcssively shifttohigher
gea$.
O Coordinatethethrottlewith brakesfor smoothdeceleration.
aBoft frontandrearbrakesshouldbeusedatthesametimeandshouldnot
beappliedsronglyenoughtolockth€wheel,orbrakingeffectiveness
will be
reducedandcontrolofthemotorcyclebedifficult.
CAUTION
It isforbiddentogearshift upordownwhenthethrotdeisstill notdecreased
andtheclutchisin. Otherwise,damageto theengine,chainandother
parts
mayoccur.Makesurethe
gearshiftpedal
isoperated
gently
andexactly.
Ridingwithyour footrestingonthebrake
pedal
maysuddenlychangea
speedand/ordamagethedrivingmechanism.
BRAKING AND PARKING
To stopthe motorcycle, close thethrottle anddisengagethecluich by pulling
in the clutch lever, then smoothly operatethe front andrearbrakesuntil
stoppingthe motorcycle.
Shift the transmission into neutral, tum the emergencyswitch to "m"
position.Then setthe fuel cock to "OFF" position, supportthe motor-
cycle with the centcr or side stand,After parking, turn the ignition switch to
"X" position andlock thesteeringlock,followed by removingthekey.

MAINTENANCE
TOOLKIT 1rig.
rry
Someroadsiderepairs,minor adjustmentsandpartsreplacementcanbe
performacedwith thetoolsavailablein thekil.
O Screwdrivergrip
@Double-end
screwdriverstem
@Spark
plugwrench
@SIip-jointed
pliers
O Open-endedspanner, 8 ' lOmnl
@Open-endedspanner, 12 ' l4mm
O Open-endedspanner,
13 x lSmm
@Open-endedspanner, 17 ' lgrnn Fig.l9
O Allenkey,
i5
@
Allenkey,i6
O Allenkey,
#8
@Toolbag
MAINTENANCE SCHEDTJLE
Maintenancework shouldbeperformed
in light of MaintenanceSchedule.
Lettersin thetableindicateasfollows:
l: INSPECT
AND CLEAN, ADJUST.LUBRICATE OR REPLACElF
NECESSARY
C: CLEAN R: REPLACE A: ADJUST L: LUBRICATE
* The item shouldbe servicedby your dealer,unlesstheownerhasthe
proper
toolsandismechanically
qualified.
Referto themanual.
)t<:t<In theinterestof safety,werecommend
theseitemsshouldbeserviecd
only by your dealer.
NOTES: OClean more ftequentlywhen riding in unusual wet or dusty
aieas.
@At higherodometerreadings,still follow theirequencyintervalsestab-
lished
in thismanual.
o@@@@@@@@@
rlrf
iillrr
;S{--- ODOMETERREADING.
km(Note
@)
.000kn4.000knl.000krl2,000tir
!'uelline
svstem I
Fuelfilrcr C C c c
Throtlle oper.rtion II
Carburetor choke I
Airclcrncrelemenl
\ule Oc c C
Sp.rl pluS II
II
Ensinc
oil fearly REvery2,000km-R
Engineoil strainerYeari).R C
C.rn chainsl ck
Engineidlespeed I I
Drivc chain t.L I.L I.L I,L
Bartery Monlhl) I I
Brulc shuevprdwe I
Brake syslem II
Brrlc lighrswit(.h I
Hcadlightadjusrmenl II
Clulch II
Sidc
stand I
Suspcnsion I I
Nuls.bolts.fasteners II
II
Steeringbearings I

ENGINEOIL (EP)
Check of Engine Oil (Fig. 20)
Check
theengineoil level beforeevery
use.
aPlace themotorcycleonalevelground
andkeepit in venical position. Then
startthe engineand run at idle for a
few minutes.
O Stop
theenginesoas
to letthe
oil
levelbestable. Checktheoil level
throughtthesight
glass
locatedatthe
lowerof therightcrankshaftcase.
O The level mustbe maintainedbe-
tweentheupperandlowerlevelmarks.
Add theengineoil if necessary
CAUTION Running the engine with insufficient oil can causeseri-
ous damage to the engine.
Change
of Engine
Oil (Fig.
2f)
OIt isbetterto drainwhen
theengineis still warmed.
OPIace
anemptycontainerundertheengine,
unscrewthedrainplug.
OTread thekick-stanerpedalseveral
timessoastohelpemptytheoil thoroughly.
!Reinstall thedrain
plug.andtightcnit up.
X Pour
approx.
lLof SAEl5W40-SEinto
thccrankcase.Restantheengine,keepit idle
for a few minutes,andthenstallit. Recheck
theoil level,andaddoil if necessary. Fig.2l
Fig.20
0 Oil tillercap
O Uppcrlcvcl nrark
{t Lowerlcvcl mark
running in very dustyconditions,oil chalges
more frequentlythan specifed in themainte-
CLEAR
AWAY CARBON DEPOSIT
(EP)
Clcarawaycarbondepositaroundthe
sparkplug
and
pistonring,
onthe
piston
top,inthcpistonring slotandcombustionchamberregularly.
SPARKPLUG
(EP)
rnie.zzt
SparkPlugType: ATTC
Check
andReplace
ODisconncct
thespark
plug
capfromthespark
plug.Cleanany dirt from aroundthespark
plugbasc.Removethespark plug by the
specialwrench.
alnspect thcclcctrodcsandcenter
porcelain
lbrdeposits,andcleanwithawirebrush.If
thcsparkplugisdamaged,
replaceit.
acheck thespark
pluggap
whichshouldbe0.
7r 0.lmm. andadjustby bendingthe
side
elcclrodeif necessary.
AIR CLEANER
(EP)
rrie.
z:r
Theaircleanermuslbecleanedandthensoakedin cleanoilal leaslonceevery
,l(XX)knr's
drive.Ridingin verydustyarea.the
job shouldbedonemoreoften.
Sec
yourdcalcr tbr funherinformation.
I Rcmovethe right sidccover. Loosen off
screws.Removelheair cleanercover.Take
thcelcmcnt
outof the housing.
I Wush
thcelcmcntin cleansing
solvent
and
ory [.
O Soaktheelementin gasoline
engineoil
SAEl5W40-SE untilsalurated.andsqueeze
outthcexccssoil.
a Reinslallalltheremoved
parts
well in the Fig.23 Air cleaner
CAUTION When
shouldbe performed
nance
schedule.
C=0.7
i 0.1mm
Drainplug
rcvcrseorderof removal.

VALVECLEARANCE
Excessive
valve
clearance
will causenoiseandeventualenginedamage.
Littlc
or nocleamncewill prevent thevalvetiom closingandcausethedamageto
valve
and
lossofpower. Checkvalveclearance
when
theengine
iscoldat the
\pecified
intervals.See
your
dealerforlhis
\crvicc.
EXHASUTMUFFLER(EP)
Clearawayregularlycarbondepositin theexhausl
pipe;
check
theexhaust
pipe
insidefor crackand
washer
damage,
andreparior replaceif necessary
ELECTROMC-CONTROLLH)AEMIION SYSTEM
(P)
wORKING PRINCIPLE
(Fig.24)
Basedon advanced
thin combustionin thegrsolineengineandelectronic-
controlledtheory,adjustthedutycycleofEGR valvcatrcaltimebycollecting
rotatorysignal
with ECU andcontroltheair tlow throughEGR valve, asa
result,achievingdynamicadjustionof aeration.controllingair/fuelmixlure
from thecarburetorandimprovingfuel supplyd carburctor.
FEATURES
l. By adoptingelcctronic-controlled
technology,theenginecanrunal an
optimalairlfuel mixturesoas1()makeit notonly more
powerful,
lowcr f'ucl
(on:\umption.
butrlsolowcr exhaust
emissionr.
2.The electronic-controlled systemconsistsol anECU, anEGR valveand
SCHEMATICDRAWINGOFJL CORE
TECHNICALSYSTEM
Fig.24
OPERATION OF THROTTLE lrig.xy
a Che(kforsmoothrolxrion
ol lhelhroflle
grrpliom tie fully opentothefullyclosed
position
atbothtull stccring
position.
I Merrurethethroltle
gripfree play
at
thethrottle
gripflange.Thestandardfree
pluyshouldbeapprox.2 6rnm.To adjust
lhefree
play.
looscnthelocknut. tum the
adjuster.Adjustmentover. fastenthe
locknut.
oo
Fig.25
O Throttlegrip
O)
Locknut
(DAdjuster
linesetc,ischaracterizedby easyinstallationandrcliable
pertbrmance. O

IDLE SPEEDOFCARBURETOR
(EP)
rrt zer
O Thecarburctoris mountedbctweentheenginc
andtheaircleaner.
NOTE
The
carburetorhasbeensellccur{telyin titctory.
Theuser
()nly
needsto
adjustidle speedaftertheengincis warmcd
up.
! AdjustidlcspeedwithIhcthrottlestopscrcw
() sel
idlc
spced
utaboul
lJ00r/min.
TumthescrewinrlirectionA will incrcose
idlcspccd.indirection
B decreaseidlcspeed.
Owhen theenginehasnoidlespccdorruns
al
adecreasedspeed.
selthethfi)ttlestopscrew
in themiddle
hctweenthctr'rolimit pLlsi-
tionsto helpmix lrirand firel.
O Make atrial. andreadjustlhc throttlestop
screw,if necessary.
CHECKLEAKSALONG
AIR SUPPLYLINE (EP)
Checkregularly
airsupplyIine.speciallysuch
asthe
joint betweenthc
muffler
andengine.the
jointbetweentheaircleaner.
carburetorandinlet
pipc,
etc.for leakage,andrcpairorreplace
damaged
parts
oncetherearesome
lroublesto assurea normalair supply.
ADJUSTMENT
OFCLUTCH
(ris.
27)
OMeasuretheclutchleverfreeplay
attheclutchleverflange.Thefree
play
should
be l0..'20mm.Adjustmentof the
clutchshouldbedonewith the
engine
stalled.
OTum loosethelocknutatthe
clutchcabieholderlocatedon thecrankcase.
andthenmakeadjustmenlby scrcwingin or outtheconespondingadjusting
(f Locknui
12
Clulchcablcholder
'l Ilool
Fi,j.21
DRIVE
CHAIN
rrig.
zo
Chrck
Checkthedrivcchainlbr wear
and
slack.Lubricate
thechainif it seemstobc
dry.
Slackshouldbe I0-20mm.Supporlthemolorcyclewilh lhecentersland.
chcckslackin thclowerchainrunn1idwaybetweenthesprockets.
o@oo Fig.28
afChain al Rear
axlelocknut
@
Nut @Adjusting
bolt
O Indexmark @
Chainclip
Throltlc stopscrew
Fig.26
nut.After adjustment.tightenup thelocknut.

Adjustment
l-oosentherearaxlenut
and
locknut,
tum bothadjustingbo]tsuntilthechain
slack
meetsthestandard,andmakesureleftandrightadjustersalignwith the
sameindexmarks.After checking,
tightenupthe
rear
axlenutwith atorque
of 50
- 60N.m.
NOTE Tuming theadjustingnut indirectionA will increasc
thechainslack,
andin directionB decreasetheslack.
X Checkthechainfor slack
X If slackofchain ischanged.it is necessarytorelocatetherearwheel,for
adjustmentwill affecttherearbrakepedalf'reeplay.
Lubrication
Pullout thechainclip with pliers, removethejoint andchain.Wash
thechain
in cleansingsolution
anddry it in theair.Checkthechainincludinglink
plates,
bushings,androllenfordamage,
cracks,
wear-out.
Replaceifnecessary.
Lubricate
thechain.thenreinstallandadjustit.
CAUTION The chainclip should beso installed asto makesurethatits
closedendfacesthedirectionof wheelrotution.
FRONT
BRAKE (rie. zqr:o)
Check
Thefrontbrakecylinder islocatedontheright
handlebar.
When operatingthe brakelever,the pads
equippedwithcaliperwill clampthe
brakedisc.
If any padis worn to its limit deplh,replace
bolh
pxds
a\ a\el on lhefir\t opporlunity.
Fig.29
Placethemotorcycleonthelevelground.
Checkthebrakefluid level through
the sight glass. lf thefluid levelisbelowtheLOWER, Ioosenthecylinder
cover screws,remove the thecover,addbrakefluid uptothe
UPPER
level
m;rk.
AWARNING Brake fluid may causeirritation. Avoid contact with
skin or eyes,In caseofcontact, flush thoroughly with water and call a
doctor if your eyes wereexposed.Apply specifredbrake fluid, or brak-
ing effectivenessand riding safety will be affected adversely. Do not
allow contaminants such asdirt or water to enter the brake fluid tank.
Adjustment
The free
play shouldbe l0-20mm. Adjust it asfollows if necessary:
Pumpthebrakelever,
then
gentlyloosenthebleedvalvewhile holding the
lever.Takecaretotightenupthebleedvalveassoon
asflowing fluid. Repeat
above
prccedure
until thesystemiscompletelybled.
Apply thebrakeseveraltimesandcheckfor freewheelrotationafterthe
brake
lever
isreleased.
REAR BRAKElrig.:ty
al
Fig.3l
C)
Rr.brake
pedal
O Adjusting
nut
affi::
gfl
.
fl
-******.,ru*g***$;uw
Fr.brakelever

ADJUSTMENT
OFBRAKELIGHT SWITCH
rrie.:zi
Thc rear
brakelight switchis lo-
catedon the right of thevehicle.If
theswitchoperates1oolale.turn
thenutin directionBr ifthe switch
FRONT/REAR
SHOCK
ABSORBER
ANDSUSPENSiON
Supponthemotorcycle
onthecenterstand,
pull in thefront brakeleverto
lookthef.ont wheel.pump
the
fronthear
shockabsorberup anddown
several
times
tosee
thatit functionswell withoutnoiseor lealiage.
Checkthe
rearfbrk bushingfbr properplay by pressing
the sideof the rearwheel.
Makesurethalall of thefastenersaretightened
securely.
TYRE
Properairpressure will provide naximum stability,ridingcomfbrtand pro-
lonstvrelife.
WARNING Operation with excessivelyworn tyres is hazardous and
will adversely affect traction and handling.
NOTE Tyrepressure shouldbecheckedbefore
youridewhile thetyresare
"cold". Checkthe tyres for cuts,embeddednails, or other sharpobjects.
Checkthe
rimsfordentsordeformation.See your
delerforchangeordamaged
tyresor punctured innertubes.
CAUTION Impropertyre inflation will causeabnormaltread wear and
createasafetyhazard.Thetyrepresseless thantheratedvaluemayresultin
slippingwheelonthe
ground
orcomingoff from therim.
When thetreaddepthin themiddle sectionof tyres reachedlimits below,
please
replacethem.
TREADDEPTHLIMITS
Front tyre l.6mm Rear
tyre 2.0mm
brakelightsw.
Adjustingnut
operatestco soon.lurn the nul in
directionA.
HOWTOUSEBRAEKWEARINDICATOR6ig.r * rar
Shouldeither pads of tiont brakebeworn to lhe limit depth,replaceboth
pads
asa setassoonas
possible.
Therearbrakeisequippedwith abrakewearindicator.IIthe indicatoraligns
with the referencemarkson full applicationoJthebrake,the brakeshoes
must
bereDlaced.
S.giiii**;".*-"1
Rider
& passenger
(kPa)
a

FRONTWHEEL
rrie.:sl
Supportlhu
nr,rtorclclcl-irrnlybeforere-
movingthcfront whccl.
Loosentheliont axlenut.extract
thefroDt
axle.andrcnrolc thcfrcnt wheel.
ACAUTION Thc supportshouldbeso
heighnndlastustorvoidthe vehicletuming
over.
REARWHEEL
rnig.:rl
Suppoft
then()torrycle. unscrewthcrcarbr kc rdiustingnut, taketheIink
out
of thcbr[kcxrln.Loosenthelocknutsulbothsidcsofthereafwheel.
thenlooscnthcrcuraxlcnul andadjuslingboll.
Takeoulthechuinclipby
pliers.removethcchainandrcaraxlenul.rclract
thercaraxlc,atlast.rcnlovethercarwhccl.
NOTES
Installationshallbedoneintherevcrsc
or-
derof rcmoval.
Tighteningtorqucol rearaxle
nut:
5(160N.
m Adjustmcntol realrbrakeandchainrreter
to
relnteditenrsinthcnranual.
ACAUTION Thcsupportshouldbeso
heighandlast{s touvoidthe
vehicle
tuming
over,
FUSE
rnrg.
.rzr
Thefuseis
positioncdbchindtheleflcover
nearthebattery
stay.
The tuse
will blow lo
protect
thecircuitautomatically
inthecasc
oftroublessuchusashoncircuitoranovcr-
loadtrouhlc.Alicrthclrouble\houlinF.
llt
newfuseavailablein thefusebox.
BATTERY
(EP)
trie.:nr
Thc battcry is locatedbchindthc letl coverol-
vchiclc.Maintainit inaccorduncdewith theMain-
tcnilnccSchedule
in themnnual.Thc batteryelec-
lrdytc levelshouldbebetwecntheUPPERlevel
nrork and
LOWER levelrnark.
Should
battery
clectrolytelevelbebelowtheLOWERlcvclmark.
add
proper
distilled
watcr
to thcUPPER
levcl
mark. Becarcfulnot to exccedthe UPPERmark
whcn ddingdislilledwutcr,otherwise.overflow-
ingclcctrolytemaycuuseco(osion.
Fr.irxlc
Lowerlevelmark
Fig.38
Fig.36
Locknul
Brakc
link
AATTENTION Bc sutcnot
todiscard
thebatleryelcctrolytc
or used
batlery.Handlc
inaccord{ncc with nationalor krcalenvironnrcnlalprotection
rules.Avoidentering
walcr
oroundthebattery
whcnwashing
the
vehicle.
AWARNING If thebattcryisto beremoved.disconncctthenegalivelead
'' '' tiom thebatterylemlinu,llrst. andthentheposition
lead +". Connec-
tionshouldbedonein thercvcrscordcrof removal.Do nottouchthepositive
lcadrviththevehiclebodytoprevcntshoncircuiting.Thcleadsshouldbe
tightencd
sccurely,or sparknrayoccurtocauseafire.Makcsurc
thattheduct
ol battery
keepsunblockcd.orthc battcrymaybe
explosivcundercertain
conditions.Thcbattery,
in addition, should
beequipped
wilh anexhaust
pipc.
otherwise,overtlowingclectrolyte
(sulfuric
acid)muyerodethevehicle
body,maincable,evenoausingr fire by short-circuiting.
ACAUTION The balterycontninssulfuricacid(electrolylc).
Contacting
wilh skin
oreyes
may
causc
scvcrc
burns.
lf such
cascoccurs.flush
with
water
tbr at least 5 minutcs andcallaphysicianimmcdiately. Please
protec-
Fusc tiveclothingandaface
shicld.
Keepoutof reachof children.Donotuseanew
batteryuntiltakinga30-minute
waitafteradding liquid.If theenginefailsto
Fig.37 besunedwiththeelectricstarterandtheneutrallightisdim.usethekick-
st[rtertostarttheengine.For prolonging theseNice.
please
start
theengine
usingthe
kick-starterwhen
thcair tcmperature
islower.
Chargethebatteryat
aratelessthan lA for l0- l5 hours
if necessary. Foriurtherdetails.referto
Upperlevelmark
OOperating
InstructionsofBatlcry.

TROUBLESHOOTING,
STORAGE
ANDOPTIONALPARTS
TROTIBLESHOOTING Preventlhe
muffler from getting
in water,
rhesparkplug from beingwetred
If the
enginefails to start,
dochecks
asfollows: downwhen
washing
thev;hicle:
l. Isthere
enoughfuelin the
tank? Storatse
2 ls fuelreaching
thecarburetor
from thetank
cock? Takesome
measures
asfollowing whensubjecting
thevehicleto60-day
or
3. Disconnect
thefuel line from thecarburetor,
set
thetankcock to ,,1
t," more
stonge.
position.and
see
if fuelflows
oul? " L Empty
fuetinside
theluel
tanl.carburelor
andotherpipes.
4 f.os-check theignitionsystem 2. Driveoffthe sparkplug,pourabirof engine
oilSAE15W40-SE intothe
ACAUTION Do not allow fuel to IIow at will. Fuel should becollect€d engine.Tum off ihe emeigency
switch
and"operate
thestarter
button
several
in the retainer.Do not smoke or allow flames or sparks iD the area times
to scatter
evenlythJoil inside
thecylinder.
where the engine is subjected to the check. 3.Remove
thedrive
chain.clean
andoil it.
5. Removethe spark
plug from thecylinder head,andconnecrit with the 4. Lubricate
all ofthe controllinc
cables.
spark
Plugcap. 5. Block upthevehicle
liamesJ thatboththewheels
cleartheground.
6 Fix thesparkplugonthevehicle
body.Turn theignitionswitch
on,selthe 6. Sealthemuffler outlet with a plasticbagto prevent
the foimer against
emergency
switch
to " a) " position.
Press
thestart
button,
andseeif there moisture.
are
sparks
attheelectrodegap
ofthesparkplug.
If there
areno
sparks,see 7.Coal allsurfaces
ofbarc
metalwith
athinlayer
ofrust-resisting
oilif the
yorrr
dealer
forhelp. motorcycle
isstored
inmoistand
saltyregions.
aCAUTIoN 8.Dismantle
the
batteryandstore
ini dry,cool
andwell-venrilated
place.
Donotconduct
the
saidcheck
by lixing lhesparknear
tolhecyliner qh_arge_rle
b4rlerl4olihly incourse
ofsrorage.
head.
Oth€rwise.
gas
in thecytinder
mayignire
bysparks. REMOVAL FROM STORAGE '
!'orsafety's
sake,it isbetter
toconnect
lhe m€tal
portion
ofspark
plug Afterlong-term
storing
the
motorcycle,
check,
adjustand
serviceitaccording
outer
housinewiah
baremetalof vehicle
body. - torequirements
stated
inthemanual
tomakesuie
themotorcycl"
iun"tioni
CLEANING AND STORAGE ;rqpg4y.fq,1[e vshlcte
artowspeed
inasate
ridinparea
awavlrom
rraffic.
creaning ANTI-TITEFT
DEVICE
(optionalt -
l- Checkif thesparkplugandinlets
areinstalled
or pluged
sccurely
before L Before usingthe
remore-controllir,
6esurethat
thevehicle
isin neutraland
cleaning
thevehicle. theignirions;irch isrumed
off.
2' Hose
thevehicle
completely 2.EGctricstafting
by theremole-controller
only warmsuptheengine,
and
3.Dry themotorcycle
using
asoftclothor sponge. the
enginewill stJpiutomatically in 2.5minutes.
4.Lubricate
thedrivechain
immediately
after
washing
anddryingto prevent 3.Do;'t applybotir
thciiont andrearbrakes
afterstaning
theengine
by the
su.faces
from Settins
rusty. remote-controller
andbefore
turningon theignition swiich,othirwisJ, the
t slart the€ngine,
and
allow it to run for several
minutes. starting
motorwill runonce
more.
CAUTION High-pressure
watercan
damage
cenain
parts
suchaswheel 4. Don't ride without the key to insure that the function of anti-theft is
..
bearinC:,
frolllfork,
brakes,seal
ofrransmi:..11
:l".rl:.quill1, etc- O reliabte
enough.

ELECTRICDIAGRAM
SPEED UGHTNG EMERGFNCY
sENSOR 5W. sraRrER SW.
SUNON
GNT|oN
ldo-l
TT
t: qilTOENGINECASE
GNINON
IGNI ON COIL 2
coll l
if_-]if_-]
lt t| |
'crF'cF
:tr tl
RR.BRA(E STARTNG SATTERY
GNITION SW RELAY
CONTROILER
12VJ0Ah
FR.WNKER,RH
fRWNKERIH
NEIJIRAI
NOIC.
TURN
SGNAL
IND
C, RN
HEAOLGI]I
t2v-35/35W
POSnONr Gfr
l2v-sw
t2y-2tt5w
l2v r0w
UCENSELGHl
t2v.5ul
wBu
j Grosb g!Bl BLo ll ll
d*TffiltErffirl | | | | t{. Fr+
ild+r EFtfl toroltofot
\/ Ll
PASSNG
DMVrp .p\ \GN^r -
glat FoFr., trr'9Fr\G
s!,v sw rw. BUTToN REtaY
tl
-rI
totol 6
SIDESTAND DIODE
arjxLraRYFRepere [w cLLrtctt
REATY SW. SW MAGNFTO RECTIFIER
lxu
tl