Lifan 100-C 2012 User manual

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IMPORTANTNOTICES
Operator and Passenger
100-C motorcycle is designed to carry the operator and one passenger. The maximum load weight of the motorcycle must not exceed 150kg.
On-road
100-C motorcycle is designed for on-road use.
Pay special attention to statements preceded by the following words:
WARNING: Indicates a strong possibility of severe personal injury or death if instructions are not followed.
CAUTION: Indicates a possibility of equipment damage if instructions are not followed.
NOTE: Gives helpful information.
Environmental Protection (EP) : Indicates special precautions that must be taken to meet environment protection laws and regulations.
Improper use of a motorcycle may cause environment pollution.
If the operator fails to follow safe operating and maintenance practices, the Co. will not take any responsibility to any injury or damage occured.
This manual should be considered as a permanent part of the motorcycle and should remain with the motorcycle when resold.
Thank you for choosing the motorcycle. May you enjoy riding all time.
The manual contains the necessary instructions and guidance with respect to the operation and maintenance of the motorcycle, and BE SURE TO
READ IT CAREFULLY BEFORE YOU RIDE THE MOTORCYCLE. Proper operation and maintenance can guarantee a safe riding to minimize
troubles of the motorcycle and keep it in a sound condition, which can extend the engine service life.
All rights reserved. No part of this publication may be reproduced without our prior written permission.
PREFACE
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CONTENTS
MOTORCYCLE SAFE RIDING
Safe Riding Rules .................................................... 1
Protective Cloths .................................................... 1
Refitting .................................................................. 1
Loading ................................................................... 1
Accessories ............................................................. 1
GENERALINFORMATION
Parts Location ........................................................ 2
VIN Record ............................................................ 3
Fuel and Engine Oil (EP) ........................................ 3
CONTROLLING PARTS
Meter and Indicators .............................................. 3
Ignition Switch and Steering Lock .......................... 4
Right Handlebar Controls ....................................... 4
Left Handlebar Controls......................................... 4
Choke Lever ........................................................... 4
Refueling and Cap .................................................. 5
Fuel Cock ............................................................... 5
Gearshift Pedal ....................................................... 5
Rear Brake Pedal .................................................... 6
Stand....................................................................... 6
OPERATIONGUIDE
Pre-ride Inspection ................................................. 7
Starting the Engine .................................................. 7
Breaking-in ............................................................. 7
Riding ..................................................................... 7
Braking and Parking ................................................ 8
MAINTENANCE
Maintenance Schedule ............................................ 9
Engine Oil (EP) ...................................................... 10
Clear away Carbon Deposit (EP) ............................ 10
Spark Plug (EP) ..................................................... 10
Air Cleaner (EP) ..................................................... 10
Valve Clearance ....................................................... 11
Adjustment of Timing Chain .................................. 11
Exhaust Muffler ..................................................... 11
3-Way Catalytic Converter (EP) ......................... 11
Principle of Secondary air inlet system & Crankcase Gas
Recirculation System (EP) ................................. 12
Operation of Throttle............................................. 12
Idle Speed of Carburetor (EP) ............................... 12
Check Leaks along Air Supply (EP) ....................... 13
Clutch ..................................................................... 13
Drive Chain ............................................................ 13
Front Brake ............................................................ 13
Rear Brake .............................................................. 14
How to Check and Replace Brake Pad ................... 14
Front/Rear ShockAbsorber and Suspension .......... 15
Tyre ........................................................................ 15
Front Wheel ............................................................ 15
Rear Wheel ............................................................. 15
Fuse ........................................................................ 16
Battery (EP) ........................................................... 16
TROUBLESHOOTINGAND STORAGE
Troubleshooting ..................................................... 17
Cleaning and Storage ............................................... 17
Removal from Storage ............................................ 17
ELECTRICDIAGRAM .............................................. 18
SPECIFICATIONS .................................................... 19
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MOTORCYCLE SAFE RIDING
SAFE RIDING RULES
WARNING Motorcycle riding requires special efforts on your part
to ensure safety. Know these requirements before you ride.
Always make a pre-ride inspection before you start the engine. You may
prevent accident or equipment damage.
Most countries require a special motorcycle riding test or license. Make
sure you are qualified before you ride. NEVER lend your motorcycle to an
inexperienced rider.
Make yourself conspicuous to help avoid the accident that wasn’t your
fault:
Wear bright or reflective clothing.
Don’t ride in another motorist’s “blind spot”.
Don’t speedily cross another’s way.
Obey all national and local laws and regulations.
Obey the speed limits, and NEVER travel faster than conditions warrant.
Signal before you make a turn or lane change to draw other motorists’
attention.
Use extra caution at intersections, parking lot entrances and exits.
Always remember to ride with both hands and keep both feet on the
rider footrest while the passenger grasps the handrail with both feet on the
rear footrest.
PROTECTIVECLOTHS
For the safety sake, always wear a helmet, a face shield, dust glasses and
protective clothing. Your passenger needs the same protection.
The exhaust system becomes hot during operation, and it remains hot for
a while after stopping the engine. Take care not to touch the exhaust
system while it is hot. Wear clothing that fully covers your legs.
Do not wear loose clothing that could catch on the control levers, wheels,
etc.
REFITTING
WARNING Arbitrarily refitting the motorcycle or removing the
original partsmay make riding unsafe, and is illegal also. The user
must obey all national and local laws and regulations in relation to
vehicle and traffic. If you have a good proposal concerning refitting of
the motorcycle, please write us. The refitment can be done with per-
mission of the Co. Otherwise, the user will take the consequences.
LOADING
WARNING Addition of accessories and cargo may reduce the
motorcycle’s stability, performance and safe operating speed.
Keep cargo and accessory weight lower and close to the center of the
motorcycle. Load weight equally on both sides to minimize imbalance. As
weight is located further from the motorcycle’s center of gravity, handling
is proportionally affected.
Adjust tyre pressure and rear suspension to suit load weight and riding
conditions.
Make sure that cargo is fastened on the vehicle.
Do not attach items to the handlebars, fork or fender. Otherwise, unstable
handling or slow steering response may occur.
The maximum load weight of the motorcycle is 150kg. Please do not
overload.
ACCESSORIES
Genuine accessories of the Motors have been specifically designed and
tested on themotorcycle. Beacuse the factory cannot test all other
accessories, you are personally re-sponsible for selection, installation and
use of accessories not produced by the Co. Al-ways follow Safe Riding
Rules and these below:
Carefully inspect the accessory to make sure that it does not obscure any
lights, reduce ground clearance or banking angle, or limit suspension travel,
steering travel or control operation.
Do not install other cooling equipment for the engine.
Do not add electrical equipment that will exceed the motorcycle’s electri-
cal system capacity.
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Fig. 1 (Left-view) Fig. 2 (Right-view)
GENERAL INFORMATION
Fr. fender Headlight Headlight cowl Fr. winker
Rearview mirror Fuel tank Fuel cock Carburetor Seat
Taillight Rr. rail Rr. fender Rr. winker Chain Chaincase
Side stand Engine code Gearshif pedal Horn Nameplate
Rr. reflector Kick-starter Fuel filler cap Fr. shock absorber
Fr. wheel VIN Exhaust muffler Rr. brake pedal
Main step Pillion step Rr. brake Rr. wheel
PARTS LOCATION(Fig. 1-2)
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VIN RECORD(Fig. 3-5)
VIN:
EngineCode:
Fig. 3 VIN Fig. 4 Engine code Fig. 5 Nameplate
Fig.6
METERAND INDICATORS(Fig. 7)
Speedometer
LH turn signal indicator,
Hi-beam indicator,
RH turn signal indicator,
Please fill the VIN and engine code of your motorcycle in the blank below.
They will help order spare parts and find out the vehicle when stolen.
NOTES
The VIN is stamped on the right of the steering stem (Fig. 3).
The engine code is stamped on the bottom-left of the crankcase (Fig. 4).
The vehicle nameplate is fixed on the front-right plate of frame body (Fig. 5).
FUELAND ENGINE OIL(EP)
Fuel Selection
Fuel is a key factor in deciding the exhaust emissions from the engine, so
selection of fuel must follow the rules below. Selected fuel must be unleaded
gasoline with octane No. RQ-93 or higher. Using improper fuel could reduce
performance, shorten the engine’s service life.
Engine Oil Selection (Fig. 6)
The quality of the engine oil plays a vital role in deciding the engine performance
and service.
Engine oil must be selected in accordance
with rules below and other oils, such as
ordinary engine oil, gear oil and vegetable
oil, are forbidden to be used.
The vehicle has been filled with engine oil
SAE15W/40-SE before being delivered.
The lubricant is only suitable at a tem-
perature range within 10 40 . If
other motor oil is to be used instead, the
alternative must be technically equivalent
in every respect. Viscosity varies with
CONTROLLING PARTS
regions and temperatures, so the lubricant has to be selected according to our
recommendation.
If there is no gasoline engine oil SAE15W/40-SE, the engine oil No. HQB-10
(or HQB-6 in regions where the temperature is lower than 10 ) can be
used instead.
Fig. 7
ODOMETER
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Ignition Switch
The ignition switch is equipped with 2 keys
inclucing a spare one.
OFF Engine and lights cannot be
operated and the key can be removed.
ON: Engine and lights can be operated,
neutral light “N” is lit and the key cannot be
removed.
Steering Lock
To lock the steering head, turn left or right the
steering bar as far as it will go, insert the key
into the ignition switch slot, turn to OFF
postion, then depress and turn
counterclociwise to “LOCK”, at last remove
the key.
To unlock the steering head, turn the key
colckwise.
RIGHT HANDLEBAR
CONTROLS (Fig. 9)
Headlight Switch
The 3-position switch functions as follows:
Fig. 8
Ignition sw. & steering lock
Headlight sw.
Emergency sw.
Throttle grip
Emergency Switch
In an emergency, setting the switch to will stall the engine at onec.
In normal riding cases, always set it at .
Throttle Grip
The grip is used to control the engine power. Turning toward in the grip will
increase fuel supply, while turning toward out it will decrease fuel supply.
Dimmer switch
Turn signal switch
Horn button
Choke lever
Fig. 11
Choke lever
Fig. 9
Fig. 10
The headlight, taillight and meter lights are bright.
The parking light, tailight and meter lights are bright.
(OFF) The headlight, taillight, parking light and meter lights are off.
LEFT HANDLEBAR
CONTROLS(Fig. 10)
Dimmer Switch
Push the switch to to turn
on high beam.
Push the switch to to turn
on low beam.
Turn Signal Switch
Move the switch to to signal
a left turn; and to to signal a
right turn.
Horn Button
Press the button to sound
the horn.
CHOCK LEVER (Fig. 11)
The choke lever is located in the left-
front of the handlebar. The choke
set in position A is fully open, in
position B half-open and in position
C fully closed.
IGNITION SWITCHAND STEERING LOCK
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Fuel filler cap
Opening of Cap (Fig. 12)
The fuel filler cap is located on the front of fuel
tank. Insert the ignition key.
Turn the key clockwise by 90 .
Remove the cap.
To reinstall the cap, depress it onto the tank inlet in
position, then turn and remove the key. The fuel
tank capacity is 5.5L including the reserves supply
of 1.7 L.
The 3-way fuel cock is on the bottom-left side of the fuel tank. With the
fuel cock in the position, fuel cannot flow from the tank to the
carburetor. Turn it OFF whenever the motorcycle is not kept in use.
With the fuel cock in the position, fuel will flow from the main fuel
supply to the carburetor.With the fuel cock in the position, fuel
flow the reserve fuel supply to the carburetor. Use 1.7 L of reserve fuel
only when the main sypply is gone. Refuel at the earliest opportunity.
CAUTION After refueling, return the fuel cock to ON position. Otherwise,
you mayrun out of fuel with no reserve. Learn how to operate the fuel cock
when riding the motorcycle.
GEARSHIFT PEDAL(Fig. 14 & 15)
The motorcycle is equipped with a 4-speed mesh transmission. The gear
indicator shows the gear position at present.
The shifting patterns are as shown in the Fig.15
Fig. 15
Non-cyclic 4-speed
Fig. 12
WARNING
Do not overfill the tank (there should be no fuel in the filler neck).
After refueling, make sure the fuel filler cap is closed securely.
Gasoline is extremely flammable and is explosive under certain
conditions. Refuel in a well-ventilated area with the engine stopped.
Do not smoke or allow flames or sparks in the area where the fuel
tank is refueled.
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.
KEEP OUT OF REACH OF CHILDREN.
FUEL COCK (Fig. 13)
REFUELINGAND FUELFILLERCAP
Fig. 13
OFF ON RES
Itisforbiddentogearshift
up or down when the
throttle is still not
decreasedandclutchis
in.
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SIDE STAND (Fig. 17)
When parking te vehicle, bring the side stand clockwise along the frame to
position. Before driving the vehicle, turn the stand to the initical position.
REAR BRAKE PEDAL(Fig. 16)
The rear brake will function and the rear
stop light will glow when applying the
pedal.
Rear brake
Fig. 16
Fig. 17
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OPERATION GUIDE
PRE-RIDE INSPECTION
Inspect your motorcycle every time before you ride it. The items listed here
will only take a few minutes to inspect, and in the long run they can save
time, expense, and possibly your life.
1. Engine oil level - add engine oil if required. Check for leaks.
2. Fuel level - refuel when necessary. Check for leaks.
3. Front and rear brakes - check operation, and adjust free play if necessary.
4. Tyres - check condition and pressure.
5. Battery electrolyte - check that the electrolyte is suitable.
6. Throttle - check for smooth opening and full closing in all steering positions.
Adjust or replace it if necessary.
7. Lights and horn - check that headlight, tail/brake light, winkers, parking
light, indicators and horn function properly.
8. Drive chain - check condition and slack. Adjust and lubricate if necessary.
9. Fasteners - check that all nuts, screws and bolts are mounted securely.
10. Steering system - check for its smoothness and reliability.
STARTING THE ENGINE
WARNING Do not start the engine in a narrow area to prevent
accidents. The exhaust contains poisonous carbon monoxide (CO) gas
that cause loss of consciousness and lead to death.
Attempting to start the engine with the transmission in gear may result in
damage to equipment.
Before starting, confirm the following:
Make sure the fuel in the tank is enough. Set fuel cock to position.
Insert the ignition switch and turn it to position.
Move the gearshift pedal into NEUTRAL to light up the indicator “N”
(green).
Set the choke lever to the fully closed position if the engine is cold.
With the throttle slightly open (less than 1/8 of its entire opening), oper-
ate the kick-starter so as to start the engine. Then push choke lever to half-
open position.
Warm up the engine entirely at an idle speed of 1200r/min until it works
normally, and then push the choke lever to its fully open position.
NOTE Starting up the engine in regions with especially low air temperature,
tread the kick-starter pedal several times first to revolve the crankshaft a few
turns while the igintion key should be at “”.
BREAKING-IN
Help assure your motorcycle’s future reliability and performance by paying
extra attention to how you ride the first 1000km. During this period avoid
full throttle riding, be sure to drive at a speed no more than 80% of each gear
and to continually changing speed. After the break-in period, be sure to
conduct maintenance on your vehicle to keep it in a sound condition.
RIDING
Start the engine and warm up it.
While the engine idling, pull in the clutch lever and push down the gear-
shift pedal to shift into low (1st) gear.
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Slowly release the clutch lever and at the same time gradually increase
engine speed by opening the throttle.
When the motorcycle attains a steady speed, close the throttle, pull in the
clutch lever and shift to 2nd gear by treading the gearshift pedal.
This sequence is repeated to progressively shift to higher gears.
Coordinate the throttle with brakes for smooth deceleration.
Both front and rear brakes should be used at the same time and should not
be applied strongly enough to lock the wheel, or braking effectiveness will
be reduced and control of the motorcycle be difficult.
CAUTION
It is forbidden to gearshift up or down when the throttle is still not
decreased and the clutch is in. Otherwise, damage to the engine, chain
and other parts may occur. Make sure the gearshift pedal is operated
gently and exactly. Riding with your foot resting on the brake pedal
may suddenly change a speed and/or damage the driving mechanism.
BRAKINGAND PARKING
To stop the motorcycle, close the throttle and disengage the clutch by pulling
in the clutch lever, then smoothly operate the front and rear brakes until
stopping the motorcycle.
Shift the transmission into neutral, turn the emergency switch to
position. Then set the fuel cock to position, support the motorcycle
with the center or side stand. After parking, turn the ignition switch to
position and lock the steeringlock, followed by removing the key.
CAUTION
For parking, gradually apply both the front and rear brakes until stop-
ping the motorcycle, prevent it from side-slipping or falling over. Inde-
pendent use of only the front or rear brake downgrades stopping
performance, and may damage or wear the brake speedily. Be carefuel
to avoid applying an emergency brake when riding on wet surfaces, or
at a high speed. Otherwise a traffic accident may happen.
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MAINTENANCE
MAINTENANCESCHEDULE
Maintenance work should be performed in light of Maintenance Schedule.
Letters in the table indicate as follows:
I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF
NECESSARY
C: CLEAN R: REPLACE A: ADJUST L: LUBRICATE
The item should be serviced by your dealer, unless the owner has the
proper tools and is mechanically qualified. Refer to the manual.
In the interest of safety, we recommend these items should be serviecd
only by your dealer.
NOTES: Clean more frequently when riding in unusual wet or dusty
areas.
At higher odometer readings, still follow the frequency intervals estab-
lished in this manual.
REGULAR
SERVICE
I T E M
ODOMETER READING, km (Note )
First
1,000km
Remarks
Fuel line system I I I
Fuel filter C C C C
Throttle operation I I I I
Carburetor choke I I I
Air cleaner element Note C C C
Spark plug I I I I
Valve clearance I I I I
Engine oil Yearly R Every 2,000km-R
Engine oil strainer Yearly-R C
Time chain slack A A A A
Engine idle speed I I I I
Drive chain I, L I, L I, L I, L
Battery Monthly I I I I
Brake shoes/pad wear I I I
Brake system I I I I
Stop light switch I I I I
Headlight adjustment I I I I
Clutch I I I I
Side stand I I I I
Suspension I I I I
Nuts, bolts, fasteners I I I I
Wheels/spokes I I I I
Steering bearings I I
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Fig. 18
Dipstick Upper mark
Lower mark
ENGINE OIL (EP)
Check of Engine Oil (Fig. 18)
Check the engine oil level every use.
The dipstick is located onto the rear
portion of the right crankcase cover. The
level must be maintained between upper
mark and lower mark .
Place the motorcycle on a level ground
with the center stand. Remove the
dipstick, wipe it clean. Reinsert and
screw in the dipstick, then remove it for
checking.
Add engine oil SAE15W/40-SE to up-
per level mark. Do not overfill.
Insert the dipstick. Check for leaks.
CAUTION Running the engine with
insufficient oil can cause serious dam-
age to the engine. Fig. 19 Drain plug
Change of Engine Oil (Fig. 19)
It is better to drain when the engine is still warmed.
Place an empty container under the engine, unscrew the drain plug.
Shift the transmission into neutral, operate the starter button several times
so as to help empty the oil thoroughly.
Reinstall the drain plug, and tighten it up.
Pour approx. 1L of SAE15W/40-SE into the engine. Restart the engine,
keep it idle for a few minutes, and then stall it. Recheck the oil level, and add
oil if necessary.
CAUTION When running in very dusty conditions, oil changes
should be performed more frequently than specifed in the mainte-
nance schedule.
CLEARAWAY CARBON DEPOSIT (EP)
Clear away carbon deposit around the spark plug and piston ring, on the
Soak the element in gasoline engine
oil SAE15W/40-SE until saturated, and
then squeeze out the excess oil.
Reassemble the air cleaner in the re-
verse order of removal.
CAUTION The spark plug must be securely tightened. Improperly
tightened plug can become very hot and possibly damage the engine.
AIR CLEANER (EP) (Fig. 21)
The air cleaner must be cleaned and then soaked in clean oil at least once
every 4000km’s drive. Riding in very dusty area, the job should be done more
often. See your dealer for further information.
Remove the right side cover. Loosen off the screws, remove the air cleaner
cover and take the filter element out of the air cleaner housing.
Wash the element in cleansing solvent and dry it.
piston top, in the piston ring slot and combustion
chamber regularly.
SPARK PLUG (EP) (Fig. 20)
Spark Plug Type C7HSA
Check and Replace
Disconnect the spark plug cap from the spark plug.
Clean any dirt from around the spark plug base.
Remove the spark plug by the special wrench.
Inspect the electrodes and center porcelain for
deposits, and clean with a wire brush. If the spark
plug is damaged, replace it.
Check the spark plug gap which should be 0.7 0.
1mm, and adjust by bending the side electrode if
necessary.
Sideelectrode
Fig. 20
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VALVE CLEARANCE(Fig. 22)
Adjusting screw
Fig. 23
3-WAYCATALYTICCONVERTER (EP)(Fig. 24)
3-way catalytic converter is mounted on the exhaust system of motorcycle.
It is designedto decrease contaminations such as CO, HC, NOx, etc. by redox
reaction to catalyst when the exhaust gases flow through the device.
Applying the catalyst controls the pollutant emissions from the motorcycle,
i.e. a chemical reaction sets in when exhaust gases pass through the converter
that contains a catalyst. The noble metal catalyst is characterised by good
adhesiveness, and accelerates a chemical reaction without itself being affected.
Its basic principle is as follow: pollutants in the exhaust gases, such as CO,
CH, NOx, etc. spread into micro-holes in the catalyst when gases pass
through the device, an adsorption reaction happens on the surfaces of catalyst,
as a result, converting them into harmless compounds (CO2, H2O, N2, etc.)
and entering the air. The purging efficiency of catalyst varies with tempera-
ture of, density of and speed of gases.
Attention should be drawn to the following points during service:
1. Handle 3-way catalyst with care, don’t knock or squeeze it, and keep
away oil and dirt. It should be stored in dry and well-ventilated place.
2. Never let acid liquid or electrolyte infiltrate into the exhaust muffler.
Otherwise, make the catalyst unefficient.
3. Unleaded gasoline should be used.
3-WAY CATALYTIC 3-WAY CATALYTIC
CONVERTER II CONVERTER
ADJUSTMENT OF TIMING
CHAIN (Fig. 23)
Start the engine and set its idle speed at 1400r/
min.
Turn the adjusting screw so as to apply a proper
tension to the timing chain.
EXHAUSTMUFFLER(EP)
Clear away regularly carbon deposit in the exhaust
pipe; check the exhaust pipe inside for crack and
washer for damage, and repair or replace if neces-
sary
Check valve clearance when the engine is cold at the specified intervals.
Remove the view hole cap on the front-left cover, magneto cap and cylin-
der head cover.
Rotate the flywheel counterclockwise until mark T on the flywheel aligns
with the index mark on the view hole. Check it is in TDC of the compres-
sion stroke by moving the rocker arms. If they are free, it means check can
be done. Otherwise, rotate the flywheel through 360 .
Clearance should be 0.05mm for the intake and exhaust valves.
If it is necessary to make an adjustment, loosen the valve lock nut and turn
the adjusting screw so there is a slight resistance when the feeler gauge is
inserted. Then tighten up the lock nut, and recheck the clearance.
Mark T
Fig. 22
Index mark Adjusting screw
Locknut
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PRINCIPLE OF SECONDARY INLET SYSTEM &
CRANKCASEGASRECIRCULATIONSYSTEM(EP)
Secondary Inlet System (Fig. 25)
WORKING PRINCIPLE Lead the fresh air into the exhaust pipe so as to
increase oxgen, then re-combust unburnt hydrocarbor (HC) and carbon mon-
oxide (CO) by virtue of exhaust temterature before allowing them to enter air,
thus, HC & CO content in the exhaust gas will decrease. The effect of HC &
CO decrease in the secondary inlet system depends upon oxygen concentra-
tion and temperature in the exhaust passage. As a rule, HC & CO content
after re-oxyenated can decrease by 30 - 60 %. So oxidation of HC & CO needs
more oxygen, i. e. supply more fresh air into exhaust passage, and temparature
must achieve up 400 (for combusting HC) to 500 (for combusting CO).
The secondary inlet system functions by means of exhaust pressure impulse
and a gulp valve.
Secondary gas has an effect on HC & CO, but it is related toA/F of the engine.
NOTE The gulp control valve should be checked periodically. It is recom-
mended that the job is done at least once every 3-month service.
Crankcase Gas Recirculation System
WORKING PRINCIPLE A gas/fuel separator is installed between the
crankcase and air cleaner passage. When the engine is running, the separated
Check for smooth ratation of the throttle
grip from the fully open to the fully closed
position at both full steering position.
Measure the throttle grip free play at the
throttle grip flange. The standard free play
should be approx. 2-6mm.To adjust the free
play, loosen the lock nut,turn the adjuster.
Adjustment over, fasten the lock nut.
air enters into the air cleaner and carburetor via the separator, then returns to
the combusting chamber, avoid exhaust gas in the crankcase directly coming
into air, therefore decrease atmospheric pollution.
NOTE The gas/oil separator should be cleaned periodically. It is recom-
mended that the job is done at least once every 3-month service.
OPERATION OF THROTTLE(Fig. 26)
Fig. 25
The carburetor is installed between the engine and air cleaner.
NOTE The carburetor has been set accurately in factory. The user only
needs to adjust idle speed after the engine is warmed up.
Adjust idle speed with the throttle stop screw to set idle speed at about
1500r/min. Turn the screw in direction A will increase idle speed, in direc-
tion B decrease idle speed.
When the engine has no idle speed or runs a a decreased speed, set the
throttle stop screw in the middle between the two limit
positions to help mis air and fuel.
CAUTION Since the carburetor
is a precision apparatus, don’t dis-
assemble it without the profes-
sional knowledge.
Fig. 26
Locknut
Adjuster
IDLE SPEED OF CARBURETOR (EP) (Fig. 27)
Fig. 27
Throttle stop
screw
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CHECKLEAKS ALONGAIR SUPPLYLINE (EP)
Check regularly air supply line, specially such as the joint between the
muffler and engine, the joint between the air cleaner, carburetor and inlet
pipe, etc. for leakage, and repair or replace damaged parts once there are some
troubles to assure a normal air supply, and avoid polluting the environment.
ADJUSTMENT OF CLUTCH (Fig. 28)
The free play should be 10-20mm and the free clearance be 3-4mm. Adjust
as follows: loosen the locknut located at the holder of clutch cable.
Turning in direction A will decrease the free play, in direction B increase
the play. NOTE: Turning adjusting bolt in clockwise will tighten the chain, and turing
it counterclockwise will releas the chain.
After checking, tighten up the rear axle nut with a torque of N.m.
Check the chain for slack.
If slack of chain is changed, recheck and readjustment to rear brake should
be conducted, because such change will influence the free play of rear brake.
Lubrication
Pull out the chain clip with pliers, remove the joint and chain. Wash the chain
in cleansing solution and dry it in the air. Check the chain including link
plates,bushings and rollersfor damage, cracks,wear-out.Replace if necessary.
Lubricate the chain, then reinstall and adjust it.
CAUTION The chain clip shall be so installed as to make sure that its
closed end faces the direction of wheel rotation.
FRONT BRAKE
The front brake lever is located at the right handlebar. The distance the front
brake lever moves before the brake starts to engage is called free play, which
should be 10-20mm (Fig. 30).
DRIVE CHAIN(Fig. 29)
Check
Check the drive chain for wear and slack. Lubricate the chain if it seems to be
dry.
Slack should be 10-20mm. Support the motorcycle with the center stand,
check slack in the lower chain run midway between the sprockets.
Adjustment
Loosen the rear axle nut and lock nut, turn both adjusting bolts until the chain
slack meets the standard, and make sure left and right adjusters align with the
same index marks.
Fig. 28
Locknut
Clutch cable holder
Boot
Fig. 29
Chain Chain clip Locknut
Adjusting nut Adjusting bolt
Driving
direction
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Check (Fig. 30)
The main cylinder is located at the right
handlebar.
When operating the brake lever, the pads
equipped with caliper will clamp the brake
disc. If any pad is worn to its limit depth,
replace both pads as a set in no time.
Place the motorcycle on the level ground. Check the brake fluid level through
the sight glass. If the fluid level is below the LOWER, loosen the cylinder
cover screws, remove
the cover, add brake fluid up to the UPPER level mark.
Air Bleeding
If the brake lever free play becomes excessive and the brake pads are not
worn beyond its minimum depth, there is probably air in the brake system
and bleed it as follows:
Pump the front brake lever, then gently loosen the bleed valve while holding
the lever. Take care to tighten up the bleed valve as soon as flowing fluid.
Repeat above the procedure until the system is completely bled.
Apply the breke several times and check for free wheel rotation after the
brake lever is released.
WARNING Apply only specified brake fluid, or braking effectiveness
and riding safety will be affected adversely. Do not allow contaminants
such as dirt or water to enter the brake fluid tank. Brake fluid may
cause irritation. Avoid contact with skin or eyes. In case of contact,
flush thoroughly with water.
Rr. brake pedal
Rr. brake arm
Adjusting nut
Pin
Fig. 31
REAR BRAKE (Fig. 31)
Support the vehicle on its center stand. Measure the distance the rear brake
pedal moves the brake starts to engage. The free play should be 20 30mm.
To adjust, turn the rear brake adjusting nut. Turning it in A direction will
decrease the free play, and in B direction increase the free play.
Apply the several times and check for free wheel rotation after the brake
pedal is released.
NOTE If any pad is worn to its limit depth, replace both pads as a set in no
time. For adjustment of rear brake, refer to adjustment of front brake.
HOW TO CHECK AND REPLACE BRAKE PAD
(Fig. 32)
Unscrew 2 bolts M8, remove the brake caliper, check the brake pads for
wear. If any pad is worn its limit depth, replace both pads as a set.
10-20mm
Fr. brake lever
Brakemain cylinder
Sight glass
Screw
Cover
Brake calliper
Fig. 30 Wear limit
20-30mm
Wear limit
Fig. 32
Front brake disc
Front brake calliper
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FRONT/REARSHOCKABSORBERANDSUSPENSION
Support the motorcycle on the center stand, pull in the front brake lever to
lock the front wheel, pump the front/rear shock absorber up and down sev-
eral times to see that it functions well without noise or leakage.Check the rear
fork bushing for proper play by pressing the side of the rear wheel. Make
sure that all of the fasteners are tightened securely.
TYRE
Proper air pressure will provide maximum stability, riding comfort and pro-
long tyre life.
FRONT WHEEL(Fig. 33)
To remove the front wheel, support the
motorcycle on the side stand, loosen the
lock screw, remove the odometer cable,
loosen the nut, extract the front axle, and
remove the front wheel.
NOTES
Installation shall be done in the reverse
order of removal.
Tightening torque of front axle nut: 55
65N.m
WARNING Operation with excessively worn tyres is hazardous and
will adversely affect traction and handling.
NOTE Tyre pressure should be checked before you ride while the tyres are
“cold”. Check the tyres for cuts, embedded nails, or other sharp objects.
Check the rims for dents or deformation. See your deler for change or damaged
tyres or punctured inner tubes.
CAUTION Improper tyre inflation will cause abnormal tread wear
and create a safety hazard. The tyre pressure less than the rated value
may result in slipping wheel on the ground or coming off from the rim.
When the tread depth in the middle section of tyres reached limits below,
please replace them.
REAR WHEEL(Fig. 34)
Support the motorcycle on the side stand. Loosen the lock nuts at both sides
of the rear wheel, then loosen the rear axle nut. Take out the chain clip by
pliers, remove the chain and rear axle nut, retract the rear axle, at last, remove
the rear wheel.
NOTES
Installation shall be done in the reverse
order of removal.
Tightening torque of rear axle nut: 55
65N.m
For adjustment of the rear brake and
chain, refer to related items prescribed in
the manual.
Tyre Pressure
Rider (kPa) Front tyre: Rear tyre:
Rider & passenger (kPa) Front tyre: Rear tyre:
Tyre size Front tyre: Rear tyre:
Tread Depth Limits, mm
Front tyre Rear tyre
Fig. 33
Lock screw
Odometer cable
Front axle nut
Fig. 34
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FUSE(Fig. 35)
The fuse is positioned behind the right cover
near the battery stay. The fuse will blow to
protect the circuit automatically in the case of
troubles such as a short circuit or an overload
trouble. After the troubleshooting, fit a new
fuse available in the fuse box.
CAUTION Be sure not to discard the battery electrolyte or used battery.
Handle in accordance with national or local environmental protection rules.
Avoid entering water around the battery when washing the vehicle.
WARNING If the battery is to be removed, disconnect the negative lead
“” from the battery terminal first, and then the position lead “+”. Connec-
tion should be done in the reverse order of removal. Do not touch the positive
lead with the vehicle body to prevent short-circuiting. The leads should be
tightened securely, or spark may occur to cause a fire.Make sure that the
duct of battery keeps unblocked, or the battery may be explosive under
certain conditions. The battery, in addition, should be equipped with an
exhaust pipe, otherwise, overflowing electrolyte (sulfuric acid) may erode
the vehicle body, main cable, even causing a fire by short-circuiting.
CAUTION The battery contains sulfuric acid (electrolyte). Contacting
with skin or eyes may cause severe burns. If such case occurs, flush with
water for at least 5 minutes and call a physician immediately. Please wear
protective clothing and a face shield. Keep out of reach of children. Do not
use a new battery until taking a 30-minute wait after adding liquid. Charge
the battery at a rate less than 1A for 10-15 hours if necessary. For further
details, refer to Operating Instructions of Battery.
CAUTION Specially pay attention to
specification (15A) of fuse when replace it. Never use other material
such as aluminium, iron or copper wire instead. Otherwise the circuit
may be burnt.
BATTERY (EP) (Fig. 36)
The battery is located behind the right cover of vehicle. Maintain it in accor-
dance with the Maintenance Schedule in the manual. The battery electrolyte
level should be between the UPPER level mark and LOWER level mark.
Should the electrolyte be below the LOWER level mark, add proper distilled
water to the UPPER level mark. Be careful not to exceed the UPPER mark
when adding distilled water, otherwise, overflowing electrolyte may cause
corrosion.
Fuse
Fig. 35
Upper level mark
Lower level mark
Fig.36
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TROUBLESHOOTING AND STORAGE
CAUTION High-pressure water can damage certain parts such as wheel
bearings, front fork, brakes, seal of transmission, electric equipment, etc.
Prevent the muffler from getting in water, the spark plug from being wetted
down when washing the vehicle.
Storage
Take some measures as following when subjecting the vehicle to 60-day or
more storage.
1. Empty fuel inside the fuel tank, carburetor and other pipes.
2. Drive off the spark plug, pour a bit of engine oil SAE15W/40-SE into the
engine. Turn off the ignition switch and tread the kick-pedal several times to
scatter evenly the oil inside the cylinder.
3. Remove the drive chain, clean and oil it.
4. Lubricate all of the controlling cables.
5. Rise the vehicle frame so that both the wheels clear the ground.
6. Seal the muffler outlet with a plastic bag to prevent the former against
moisture.
7. Coat all surfaces of bare metal with a thin layer of rust-resisting oil if the
motorcycle is stored in moist and salty regions.
8. Dismantle the battery and store in a dry, cool and well-ventilated place.
Charge the battery monthly in course of storage.
REMOVALFROM STORAGE
After long-term storing the motorcycle, check, adjust and service it according
to requirements stated in the manual to make sure the motorcycle functions
properly. Try the vehicle at low speed in a safe riding area away from traffic.
TROUBLESHOOTING
If the engine fails to start, do checks as follows:
1. Is there enough fuel in the tank?
2. Is fuel reaching the carburetor from the tank cock?
3. Disconnect the fuel line from the carburetor, set the tank cock to
position,and see if fuel flows out?
4. If OK, check the ignition system.
CAUTION Do not allow fuel to flow at will. Fuel should be collected
in the retainer.Do not smoke or allow flames or sparks in the area
where the engine is subjected to the check.
5. Remove the spark plug from the cylinder head, and connect it with the
spark plug cap.
6. Fix the spark plug on the vehicle body. Turn the ignition switch on, set the
emergency switch to position. Press the start button, and see if there
are sparks at the electrode gap of the spark plug. If there are no sparks, see
your dealer for help.
CLEANINGAND STORAGE
Cleaning
1. Check if the spark plug and inlets are installed or pluged securely before
cleaning the vehicle.
2. Hose the vehicle completely.
3. Dry the motorcycle using a soft cloth or sponge.
4. Lubricate the drive chain immediately after washing and drying to prevent
surfaces from getting rusty.
5. Start the engine, and allow it to run for several minutes.
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