Haojue HJ110-2 Service Manual
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Haojue HJ110-2 Service Manual

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HJ110-2/2A
95500H51121H000
https://www.motomanuals.net/

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  • Page 1 HJ110-2/2A 95500H51121H000 https://www.motomanuals.net/...
  • Page 2 https://www.motomanuals.net/...
  • Page 3 This manual is for those adequately informed and skilled in the maintenance of HAOJUE motorcycle. If you are not well-informed and skilled in this respect, you should not attempt to effect maintenance and repair only by the help of this manual.
  • Page 4 GENERAL INFORMATION CONTENTS ......WARNING/CAUTION/NOTE ......GENERAL PRECAUTIONS ......SERIAL NUMBER LOCATIONS ..... FUEL AND OIL RECOMMENDATIONS ....... BREAK-IN PROCEDURE ..
  • Page 5 SYMBOLS The following symbols illustrate necessary information of directions and servicing. Symbol Symbol Item Item Controlling torque 1342 THREAD LOCK BOND “1342” Near data indicates specified torque Oil filling Filling or using brake fluid Use engine oil unless otherwise stated Measure the voltage SUPER GREASE “A”...
  • Page 6 After servicing the fuel, oil, muffler or brake system, check all hoses and fittings related to the system for leaks. CAUTION ● If parts replacement is necessary, replace the parts with the HAOJUE GENUINE PARTs or their equivalent. ● When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation.
  • Page 7 GENERAL INFORMATION SERIAL NUMBER LOCATIONS ENGINE OIL ① The V.I.N (Vehicle Identification Number) stamped on the chassis rear under the saddle. ② Be sure that the motorcycle engine oil you use The engine serial number is located on the comes under API classification of SF or SG and its lower of the left crankcase.
  • Page 8 GENERAL INFORMATION SPECIFICATIONS DIMENSIONS AND CURB WEIGHT .......... （ Overall length 1909 mm HJ110-2) 1906 mm(HJ110-2A) ........... Overall width 677 mm(HJ110-2) 676 mm(HJ110-2A) .......... Overall height 1088 mm(HJ110-2) 1085 mm(HJ110-2A) ........... Wheelbase 1218 mm(HJ110-2) 1202 mm(HJ110-2A) ........Ground clearance 120 mm ..........
  • Page 9 ..........Fuse ..........Headlight 12V, 35W/35W ......... Tail/Brake light 12V, 5W/21W ........Turn signal light 12V, 21W (front) 12V,21W(rear) (HJ110-2) ） 12V, 21W (front 12V,16W(rear) (HJ110-2A) ........... Position light 12V, 5W ......Gear position indicator light 12V, 2W×5 ........Dashboard panel light 12V, 2W ........

  • Page 10: Table Of Contents

    PERIODIC MAINTENANCE CONTENTS ......PERIODIC MAINTENANCE ..... . MAINTENANCE PROCEDURES .

  • Page 11: Periodic Maintenance

    PERIODIC MAINTENANCE PERIODIC MAINTENANCE The chart below lists recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at performance and economy. Mileage are expressed in terms of kilometer and times for your convenience. NOTE: More frequent servicing should be considered if the motorcycle is operated under the rough conditions.
  • Page 12 PERIODIC MAINTENANCE LUBRICATION CHART The following is a basic lubrication requirement for a motorcycle operated in an economical manner and based on the mileage displayed by the odometer. INTERVAL Initial and Every 6,000 km Every 12,000 km ITEM month Throttle cable Engine oil Throttle grip Grease...

  • Page 13: Maintenance Procedures

    PERIODIC MAINTENANCE MAINTENANCE PROCEDURES － BATTERY ＋ Inspect at Initial 1,000 km and Every 3,000 km ● Unlock and open the saddle; remove the wires on both the positive and negative poles, Remove the battery. NOTE: When remove the battery, remove the negative wire first.

  • Page 14: Air Cleaner

    ● Remove the front basket (for HJ110-2) and the front panel, ● Remove the front left / right side cover ●...

  • Page 15: Muffler Mounting Nuts & Bolts

    PERIODIC MAINTENANCE MUFFLER MOUNTING NUTS & BOLTS Inspect at Initial 1,000 km and Every 3,000 km ● Tighten the muffler mounting nuts and bolts. CYLINDER HEAD & CYLINDER NUTS & BOLTS Tighten at Initial 1,000 km and Every 3,000 km CYLINDER HEAD LEFT NUT ●...

  • Page 16: Valve Clearance

    PERIODIC MAINTENANCE VALVE CLEARANCE Inspect at Initial 1,000 km and Every 3,000 km NOTE: The valve clearance must be checked and adjusted under cooled engine states. ① , ● Remove spark plug, valve inspecting caps ③ and valve timing inspecting plug . ②...

  • Page 17: Spark Plug

    PERIODIC MAINTENANCE ADJUSTMENT ● Loosen the lock nut, turn the tappet adjusting screw until the gauge feels a slight resistance. ● Fix the tappet adjusting screw and tighten the lock nut to the specified torque. 09917-14910: Tappet adjusting driver TOOL ●...

  • Page 18: Engine Oil

    PERIODIC MAINTENANCE CARBON DEPOSIT Check for the carbon deposit on the plug. If the carbon is deposited, remove it with a spark plug cleaner machine or a needle carefully SPARK PLUG GAP Measure the spark plug gap with a thickness gauge if it is correct.

  • Page 19: Oil Strainer

    1 turn (do not overturn), rotate the adjusting screw Lock nut counterclockwise slowly until feeling a slight resistance. (HJ110-2) (HJ110-2A) ● Rotate the adjusting screw clockwise by 1/18 turn and tighten the lock nut to the specified torque.

  • Page 20: Throttle Cable Play

    PERIODIC MAINTENANCE THROTTLE CABLE PLAY Inspect at Initial 1,000 km and Every 3,000 km. ● Loosen the lock nut . ● Turn the adjuster to adjust the cable play to keep it between 0.5-1.0 mm. ● Adjuster Tighten the lock nut securely after the play adjustment is completed.

  • Page 21: Drive Chain

    PERIODIC MAINTENANCE DRIVE CHAIN Inspect ,clean and lubricate Every 1,000 km CHAIN SAG WARNING It is prohibited to check and adjust the chain sag when the engine is running. ● Turn-off the engine; support the motorcycle with the main stand; shift the gear to neutral. ●...
  • Page 22 PERIODIC MAINTENANCE ② ● Tighten the two adjusting nuts ● Check the chain sag and free rotation of rear wheel. ● Check the free travel of the rear brake pedal (refer to page.2-14). Adjust if necessary. INSPECTION/CLEAN & LUBRICATION Bolt ●...
  • Page 23 PERIODIC MAINTENANCE ● Check the drive chain for damage or wear. 1 2 3 20 21 22 If damaged, loose or twisted defects are found on the chain, replace it immediately. ● Stretch the chain to measure its length. Drive chain 20pitch 259.0 mm length service limit 09900-20103 vernier caliper...

  • Page 24: Brakes

    PERIODIC MAINTENANCE BRAKES Inspect at Initial 1,000 km and Every 3,000 km FREE TRAVEL OF THE BRAKE LEVER ● Measure the free travel of the front brake lever at the end of it. ～ 10 20 mm Free travel 10-20 mm ●...

  • Page 25: Tires

    PERIODIC MAINTENANCE BRAKE SHOES WEAR-OFF FRONT BRAKE SHOES Wear-off limit ● If, when applying the brakes, the arrow on the Print △ indication plate aligns to the " ” mark on the wheel hub panel, check the brake shoes and wheel hub panel and replace the brake shoes if necessary.

  • Page 26: Steering

    PERIODIC MAINTENANCE Check the tire pressure, and examine the calve for evidence of air leakage. TIRE PRESSURE SOLD RIDING DUAL RIDING kg/cm kg/cm 1.75 2.00 FRONT 175KPa 200KPa 2.00 kg/cm 2.25 kg/cm REAR 200KPa 225KPa STEERING Inspect at Initial 1,000 km and Every 3,000 km ●...

  • Page 27: Lights And Signal Lights

    PERIODIC MAINTENANCE LIGHTS AND SIGNAL LIGHTS Inspect at Initial 1,000 km and Every 3,000 km Check all the lights and signal lights that must be correct. Refer to page 6-8 and page 6-9. CHASSIS AND ENGINE MOUNTING BOLTS AND NUTS Inspect at Initial 1,000 km and Every 3,000 km Check the tightening torque of the bolts and nuts for the motorcycle according to the table below: Kg m...

  • Page 28: Compression Press

    PERIODIC MAINTENANCE COMPRESSION PRESSURE INSPECTION NOTE: Before testing the compression pressure of the engine, be sure that the nuts and bolts of the cylinder head are securely tightened to the specified torque, and the valve clearance is correct. Keep the engine running idle for several minutes before carrying-out the test. ●...
  • Page 29 ENGINE CONTENTS ..REMOVE ENGINE PARTS WITH ENGINE UNREMOVED ....ENGINE REMOVAL AND REMOUNTING ......CYLINDER HERD AND VALVE ......CYLINDER AND PISTON 3-21 ......CLUTCH AND GEAR SHIFT 3-27...

  • Page 30: Remove Engine Parts With Engine Unremoved

    ENGINE REMOVE ENGINE PARTS WITH ENGINE UNREMOVED The following parts can be dismounted and remounted without removing the engine. Refer to sections about parts dismounting and remounting. ENGINE PARTS ....... CYLINDER HEAD COVER ......CYLINDER HEAD ......... CAMSHAFT ......

  • Page 31: Engine Removal And Remounting

    ENGINE ENGINE REMOVAL AND REMOUNTING ENGINE REMOVAL Before take the engine out of the chassis, clean the engine with a suitable cleaner completely. ● Support the motorcycle with the main stand. ● Drain out the engine oil. ● Remove the front panel, the front left / right side covers, the central guard, the suffer cover, the saddle, the rear bracket ,the tail cover, and the left / right side cover.
  • Page 32 ENGINE ● Disconnect the plug terminal of the starting motor. Terminal ① ② ● Loosen the rear wheel axle nut ; lock nut ③ and the sprocket adjusting nut ● Push the rear wheel axle forward to enable the chain to be loose enough. ●...
  • Page 33 ENGINE ● Remove the bolts and the front footrest bar. ● Remove the bolts and the engine sprocket cover. ● Remove the sprocket bolts, the gasket and the Engine mounting sprocket. bolts/nuts ● Loose the engine mounting nuts. ● Support the engine with a jack or wooden block to facilitate removing the lower mounting bolt.
  • Page 34 ENGINE ENGINE REMOUNTING The engine can be mounted in the reverse order of removal. ● Support the engine with a jack or wooden block; place the engine onto the chassis; mount the engine mounting bolts from the right to the left. CAUTION Be careful not to damage the chassis.
  • Page 35 ENGINE ● Mount the new O-ring into the groove of the Bolt intake pipe, and tighten the bolts of the intake pipe to the specified torque. Specified torque: 8~12 N m • Tighten the bolts of the front footrest bar to the ●...

  • Page 36: Cylinder Herd And Valve

    ENGINE CYLINDER HEAD AND VALVE CYLINDER HEAD REMOVAL ① ● Remove valve inspecting caps and spark plug. ● Loosen the cylinder head side cover bolts. ● Tap on the bolt to remove the left cover from the cylinder head. ● Remove the bolt, gasket and cylinder head left cover.
  • Page 37 ENGINE ● Remove the nut, sealing washer and copper washer as well as the cylinder head cover and sealing gasket. Copper washer ● Remove the side bolt and the cylinder head. ● Remove the sealing gasket and pin of the cylinder head.
  • Page 38 ENGINE ● Screw a bolt M8 into the hole of the rocker arm axle temporarily, draw the rocker arm axle out, remove the rocker arm and the locating plate. ● Remove the camshaft from the cylinder head. ● Remove the valve spring clamp by using the special tool.
  • Page 39 ENGINE INSPECTION CAMSHAFT Rotate the outer loop of the camshaft bearing by hand. The rotation must be smooth and without noise. Check if the inner ring of the bearing fits tightly with the camshaft. If they do not match tightly, replace the camshaft with a new one. Worn-down cams are often the cause of mistimed valve operation resulting in reduced output power.
  • Page 40 ENGINE CYLINDER HEAD ● Remove accumulated carbon in the combustion chamber. ● Check for fractures at the spark plug hole and valve seat. NOTE: Avoid damaging the surface of the sealing gasket. ● Check the evenness of the cylinder head plane with ruler and thickness gauge.
  • Page 41 ENGINE VALVE SPRING ● Measure the length of internal/external valve spring. If the length is less than the utility limit, replace with a new valve spring. 09900-20101 : Vernier calipers (150mm) TOOL INNER 31.47mm Service limit OUTER 34.13mm VALVE ● Check if the valve is bent, burnt or abnormally worn.
  • Page 42 ENGINE VALVE SEAT INSPECTION AND SERVICING ● Clean the intake/exhaust valve completely to remove carbon. Apply a thin layer of Prussian blue on the surface of the valve seat, rotate the valve with rubber stick or other handle. ● Remove and inspect the valve. CAUTION The valve must not grind.
  • Page 43 ENGINE ● Grind the uneven or irregular surface with 45 ° tooling. NOTE: Finish the valve seat surface with 45 tooling ° after the valve is replaced. ● Grind the top surface of the original valve seat by 1/4 of its width with 30 tooling. °...
  • Page 44 3-15 ENGINE ENGINE ● Apply a thin layer of Prussian blue on the surface of the valve seat; insert the valve into the tube and squeeze it, leaving a clear. dent on the valve seat. NOTE: The seat position is significant to the performance of the valve.
  • Page 45 ENGINE ENGINE 3-16 CYLINDER HEAD REASSEMBLY Lock nip Valve seat Inner spring Outer spring Gasket Left side cover Rocker arm Locating plate Exh. Valve Inlet. Valve Rocker arm shaft Camshaft Lock nut Valve adjust screw ● Clean the cylinder head with detergent and blow the tube with compressed air.
  • Page 46 ENGINE ● Mount the valve clamp with special tool . 09916-14510 : Valve spring compressor TOOL CAUTION Do not over-press the spring to prevent from loss of elasticity. ● Tap on the sleeve with plastic hammer to let the clamp fall into exact place. CAUTION Place the cylinder head on the surface of oper- ation table to prevent from valve damage.
  • Page 47 ENGINE ● Install the rocker arm. NOTE: Align the threaded end toward outside. ● Mount a new seal gasket on the right side cover and install the right side cover onto the cylinder head. ● Install and tighten the nut of right side cover to the specified torque.
  • Page 48 ENGINE ● Install the cylinder head and put a new sealing gasket on it. Then, mount the head cover. N O T E : P u t t h e c o v e r o n t h e c y l i n d e r h e a d w i t h t h e a r r o w p o i n t i n g d o w n w a r d s .
  • Page 49 ENGINE ● Assemble the new sealing gasket and the left cover on the cylinder head. NOTE: Rest the plane boss of the cover at the side of the top dead center of the cylinder head. ● Mount the M6 bolt with new sealing gasket on the right side cover and tighten it.

  • Page 50: Cylinder And Piston

    ENGINE CYLINDER AND PISTON Guide wheel bolt/washer CYLINDER DISASSEMBLY ● Remove the cylinder head (refer to page 3-7 ). ● Remove the bolt for timing chain guide wheel, washer and guide wheel. Cylinder mounting bolt ● Remove the cylinder mounting bolt and the cylinder.
  • Page 51 ENGINE CYLINDER AND PISTON INSPECTION ● Check for damage or wearing of the cylinder. ● Measure the cylinder I.D. both in "X" and "Y" directions on three levels, and determine the cylinder wear with the maximum value. Service limit 52.535 mm 09900-20508 : ylinder gauge set TOOL ●...
  • Page 52 ENGINE ● Check for damage or wearing of the piston. ● Measure the piston O.D. at 15 mm along the vertical direction of the piston pin. TOOL 09900-20202 : Micrometer (25~50mm) 15 mm Service limit 52.25 mm ● Measure the hole inner diameter of the piston pin.
  • Page 53 ENGINE ● Put the piston ring horizontally on the cylinder bottom to measure the opening clearance. Piston ring Service limit 0.5 mm 0.5 mm PISTON RING ASSEMBLY ● Clean the piston ring slot completely and assemble the piston ring. Engine oil Top ring NOTE: Apply engine oil on all piston rings.
  • Page 54 ENGINE Apply clean engine oil on the outer surface of ● the piston pin. ● Install the piston with the "IN" mark aligned to the valve. ● Install the piston pin and click the new pin circlip securely. NOTE: Do not leave the pin circlip opening aligned to the piston gap.
  • Page 55 ENGINE ● Tighten guide pin bolt of the timing chain to the specified torque. Specified torque: 7~10 N•m Install cylinder bolt, leave it untighten first. ● Install the cylinder head and tighten the bolts and nuts. ● Tighten the cylinder bolt to the specified torque.

  • Page 56: Clutch And Gear Shift

    Remove right crankcase cover after unscrew the bolts. RIGHT CRANKCASE COVER ● Remove the clutch lock nut, washer, O-ring and clutch adjusting bolt (HJ110-2). Lock nut adjusting bolt ● Remove the clutch lock nut, washer, O-ring and clutch adjusting bolt (HJ110-2A).
  • Page 57 ENGINE ● Check if the oil seal of the kick starter lever is in normal condition, replace it if necessary. CLUTCH DISASSEMBLY DOUBLE CLUTCHING (HJ110-2) Push ● Remove the clutch manipulating rod and push pedal Manipulating rod pedal. ● Remove the screws and oil filter rotor cover.
  • Page 58 ENGINE ● Remove the lock nut with special tool. 09930-40113 : Rotor and sprocket holder TOOL 09940-14921 : 4-jaw socket wrench Specified torque: 35~38 N•m ● Remove the lock spacer, lock washer and primary clutch drive disc/clutch shoe assy. ● Remove the clutch bearing.
  • Page 59 ENGINE Remove the lock nut, lock washer and gasket. ● ● Remove the bolt for oil separating cover. ● Remove the primary clutch enclosure, clutch and oil separating cover as a whole. ● Remove the washer from crankshaft. 3-30 https://www.motomanuals.net/...
  • Page 60 ENGINE Remove the bush from main shaft. ● SINGLE CLUTCHING (HJ110-2A) ● Remove the oil pipe and pipe spring. Remove the separating arm and separating ● cam of the clutch. ● Dismantle the washer and end cover screws. ● Remove the end cover of the clutch. 3-31 https://www.motomanuals.net/...
  • Page 61 Dismantle the lock washer and the clutch lock nut. ● Remove the clutch. ● Remove the driven gear and its circlip. PRIMARY CLUTCH (HJ110-2) DISASSEMBLY AND INSPECTION ONE-WAY LUTCH ● Rotate the driving disc and inspect the operation conditions of the one-way clutch.
  • Page 62 ENGINE ● Remove the hole circlip and washer. TOOL 09900-06108 : Snap ring pliers (closing type) ● Remove the roller and starting clutch spring. ● Remove the inner cover of the starting clutch. ● Check for damage or wearing on the roller and spring, replace it if necessary.
  • Page 63 ENGINE ● Check for damage or wearing on the inner and outer slide surface of the starting clutch, replace it if necessary. CLUTCH CENTRIFUGAL SHOE ● Check for wearing of the clutch centrifugal shoe. ● Measure the thickness of every clutch centrifugal shoe.
  • Page 64 ENGINE ● Check for damage or wearing of the pin axle of for the driving disc. ● Check for damage or wearing of the clutch centrifugal shoe. ENCLOSURE ● Check for scratch or wear-off on the inner surface of the clutch enclosure. ●...
  • Page 65 ENGINE CRANKCASE ● Measure the crankshaft O.D. Service limit 18.92 mm 09900-20205 : Micrometer (0~25mm) TOOL CLUTCH CENTRIFUGAL SHOE REASSEMBLY ● Apply engine oil on the surface of pin axle of for the driving disc. ● Install the circlip. STARTING CLUTCH REASSEMBLY ●...
  • Page 66 ENGINE ● Install the hole circlip and washer. CLUTCH DIAASSEMBLY ● Fix the clutch exterior with the generator rotor clamp, then loosen and remove the bolt, push pedal and spring. TOOL 09930-44400 : Rotor holder NOTE: Loosen the bolts of clutch push pedal in diagonal sequence.
  • Page 67 ENGINE SPRING ● Check for fatigue or damage on the spring, and measure the free length of the spring. 09900-20101 : Vernier caliper TOOL 34.5 mm Service limit DRIVEN HUB ● Check for damage or wearing of the driven hub, replace it if necessary.
  • Page 68 Install the clutch spring, push pedal and bolt. NOTE: Fix the clutch jacket with rotor clamp, then tighten the push pedal bolt in diagonal sequence. TOOL 09930-44400 : Rotor holder CLUTCH REMOUNTING ( HJ110-2A) (HJ110-2) ● Mount the separating washer onto the main shaft. 3-39 https://www.motomanuals.net/...
  • Page 69 ENGINE GEAR SHAFT ROD DISASSEMBLY ① ② ● Remove the bolt , stop arm and return ③ spring ④ ● Pull down the shift arm , remove the shift ⑤ shaft ⑥ ⑦ ● Remove the bolt and the shift shaft guard ⑧...
  • Page 70 ENGINE INSPECTION ● Check of bend, damage or wearing of the shift shaft. Check of damage or wearing of the shift arm ● spring as well as the return spring. REASSEMBLY ● Mount the pins of the shift camshaft and the pins of the shift shaft guard into the holes on the shift amshaft drum.
  • Page 71 ENGINE ● Install the return spring and stop arm, then tighten to the specified torque. Specified torque: 8~12 N•m ● Install the clutch and the primary clutch as a whole (refer to page 3-41). ● Install the shaft and tighten the bolt. RIGHT CRANKCASE COVER ASSY CLUTCH ROD ●...
  • Page 72 ENGINE ● Install the dowel pin and new sealing gasket onto the crankcase. Install the right crankcase cover. ● CAUTION Do not damage the lip of the oil seal of the kick starter shaft. ● Install a new oil seal of the kick starter shaft and apply engine oil on the lip of the oil seal.

  • Page 73: Generator, Starting Clutch And Timing Chain Tensioner

    ENGINE GENERATOR, STARTING CLUTCH AND TIMING CHAIN TENSIONER LEFT CRANKCASE COVER DIS- ASSEMBLY ● Remove the left crankcase cover and the bolt. CAUTION The left crankcase cover is likely to be affect- ed by the magnetic force of the generator rotor, so please be careful during dis- assembly.
  • Page 74 ENGINE GENERATOR ROTOR DISASSEMBLY ● Fix the rotor with the special tool, then remove the rotor nut and washer. 09930-44400 : Rotor holder TOOL ● Remove the rotor with the special tool. 09930-30102 : Slide shaft TOOL 09930-34951 : Rotor remover ●...
  • Page 75 ENGINE ● Remove the shaft snap ring from the starting motor shaft. ● R e m o v e t h e s t a r t i n g d r i v e a n d d r i v e n sprockets as a whole.
  • Page 76 ENGINE ● Check for damage or wearing of the starting clutch. ASSEMBLY Sping Roller 10 N•m(1.0kgf•m, 7 lbf•ft) Rotor Side plate Thimble Starting clutch cover ● Install the side plate; align the hole to the pin. Side plate 3-47 https://www.motomanuals.net/...
  • Page 77 ENGINE ● Apply engine oil on the surface of the start clutch enclosure. ● Install the sta ti r ng clutch enclosure; align the hole on the enclosure to the dowel pin. Engine oil Clutch cover ● Apply THREAD LOCK BOND “1342” on the screw thread and tighten it to the specified torque.
  • Page 78 ENGINE ● Apply engine oil on the surface of starting driven sprocket and needle bearing. ● Mount the starting driven sprocket onto the starting clutch, rotate the starting driven sprocket; check the operation of the starting clutch. ● The starting driven sprocket should be able to revolve clockwise and not counter-clockwise.
  • Page 79 ENGINE Remove the oil separating cover. ● ① ② ● Remove the seal ring/bolt , tension spring ③ and rod ④ ● Remove the tension arm bolt , tension arm ⑤ ⑥ and tension roller INSPECTION ● Check the free length of tension spring. 3-50 https://www.motomanuals.net/...
  • Page 80 ENGINE ● Check for damage or wear-off of the tension rod. REASSEMBLY ● Install the tension wheel, arm and bolt after applying engine oil on the inner surface of the spprocket wheel, and tighten the bolt of the tension arm to the specified torque. Engine oil Specified torque: 15~17 N•m ●...
  • Page 81 ENGINE ● Check for damage on oil separating cover, replace it if necessary. After applying engine oil on the O-ring, ● assemble it onto the crankcase and oil separating cover. Engine oil ● Install the oil separating cover and tighten the screws.

  • Page 82: Crankshaft, Transmission And Kick Starter

    ENGINE CRANKSHAFT, TRANSMISSION AND KICK STARTER CRANKCASE DISASSEMBLY ● Remove the starting motor. ● Remove the shaft snap ring from the kick starter shaft. Loosen the return spring, remove the spring ● and the seat. ● Remove the bolt and the gear position switch. 3-53 https://www.motomanuals.net/...
  • Page 83 ENGINE ● L o o s e n t h e c r a n k c a s e b o l t i n d i a g o n a l sequence. ● D i s m a n t l e t h e c r a n k c a s e w i t h t h e l e f t crankcase facing downwards.
  • Page 84 ENGINE ● Remove the oil pump sprocket and shaft if necessary. INSPECTION ● Measure the clearance at the larger end of the connecting rod with thickness gauge. TOOL 09900-20803 : Thickness gauge Service limit 0.6 mm ● Measure the radial clearance at the larger end of the connecting rod at the symmetrical points as shown in the figure.
  • Page 85 ENGINE ● Place the crankshaft on a V-shaped block and measure the radial run-out with a dial gauge. TOOL 09900-20606 : Dial gauge 09900-21304 : V-block 09900-20701 : magnetic stand Service limit 0.05 mm 30 mm 30 mm REASSEMBLY ● Install the oil pump sprocket and shaft after applying engine oil on the inner surface of the sprocket.
  • Page 86 ENGINE TRANSMISSION DISASSEMBLY ● Remove the kick starter lever. ● Remove the main shaft, counter-shaft and shift hub as a whole. Disassembling the main shaft, counter-shaft ● and shift hub. Shift hub Main shaft Counter-shaft INSPECTION ● Check the gear engaging flange, flange hole or gear teeth of abnormal wear-off or insufficient lubrication.
  • Page 87 ENGINE REASSEMBLY ● Reassembly in the reversed order of dis-assembly. NOTE: Apply the engine oil on the rotating / sliding area and the side of the shaft and gear. Engine oil C1 gear 34T) Counter-shaft Main shaft M1 gear 12T C2 gear 29T M2 gear 17T C3 gear 26T...
  • Page 88 ENGINE SHAFTING HUB DISASSEMBLY ● Remove the clamp of the guide pin. Remove the guide pin, then the fork. ● ● Check for damage or wearing of the shift hub. ● Measure the inner diameter of the shift hub. 34.14 mm Service limit TOOL 09900-20101 : Vernier calipers...
  • Page 89 ENGINE SHAFTING HUB REASSEMBLY Fork Lock-up Fork pin Shafting hub ● Applying engine oil on the shift hub and the ring slot of the fork pin, mount the fork on the shift hub. ● Install the guiding pin and clamp. Engine oil BEARING REPLACEMENT ●...
  • Page 90 ENGINE Remove the oil seal of the counter-shaft. ● ● Remove the bearings of left/right crankcase with special tool. TOOL 09923-73210 : Bearing puller 09930-30102 : Rotor remove slide shaft ● Mount new bearings with special tool. TOOL 09940-53311 : Bearing installer 09924-84510 : Bearing installer 09913-75820 : Bearing installer 09913-80112 Bearing installer...
  • Page 91 ENGINE REASSEMBLY ● Coat a layer of SUPER GREASE "A" on the new counter-shaft. ● Assembling the main shaft, counter-shaft and shift hub as shown in the figure. 99000-25010 : SUPER GREASE “A” ● Install the main shaft, counter-shaft and shift hub into the left crankcase as a whole, rotate the shift hub, check the operation of the shaft.
  • Page 92 ENGINE ● Remove the snap ring, washer and starting gear. INSPECTION ● Check if the start shaft is bent. ● Check if the spring is defective. ● Check for damage or wear-off on each part, replace if necessary. ASSEMBLY ● Assembly in the reversed order of dis- assembly.
  • Page 93 ENGINE ● Align the spring to the slot on crankcase cover; install the kick starter shaft. CRANKCASE REASSEMBLY ● Clean the contact area of the crankcase before installation. NOTE: Grind the tiny rough or uneven plane with whet- stone if necessary. Lubricate the camshaft bearing and other con- tact area with engine oil.

  • Page 94: Secondary Air System

    ENGINE SECONDARY AIR SYSTEM When the engine is started, fresh air will flow through the air filter, intake pipe, secondary air valve and secondary intake tube to blend with the exhaust gas generated by in-engine combustion of secondary combustion, and the exhaust gas will be expelled through the muffler. 3-65 https://www.motomanuals.net/...
  • Page 95 ENGINE SCHEMATIC PLAN Secondary air valve Air cleaner Negative Carburetor Intake Exhaust Second burning HJ110 ENGINE Exhaust Negative Exhaust gas Mix gas REMOVAL AND INSPECTION ● Remove the fixing bolt of the secondary air valve. ● Unplug the intake tube, negative-pressure tube and intermediate tube;...
  • Page 96 ENGINE ② ● Remove the reed valve , check the reed valve and gasket, replace it if it has damnification. ● Reed valve Check the reed valve and the valve seat face, replace the reed valve, if reed distortion. Valve seat REMOUNTING ●...
  • Page 97 FUEL AND LUBRICATION CONTENTS ........AIR CLEANER ........CARBURETOR ........FUEL TANK LUBRICATION SYSTEM ......https://www.motomanuals.net/...

  • Page 98: Air Cleaner

    FUEL AND LUBRICATION AIR CLEANER REMOVAL Aerate pipe Air cleaner rear cover ● Remove the front panel and the front left & Bolt right covers. ● Disconnect the air cleaner pipe and crankcase air pipe at the rear cover of the air cleaner. Gasket ●...

  • Page 99: Carburetor

    FUEL AND LUBRICATION CARBURETOR CARBURETOR CONSTRUCTION 1. Fuel needle 2. Idle air screw 3. Idle screw 4. Idle jet 5. Needle valve 6. Float 7. Main jet 8. Bubbler 9. Main fuel jet SPECIFICATION SPECIFICATION ITEM ITEM Bubbler Φ Carburetor type Pz19 2.6 mm Bore size...
  • Page 100 FUEL AND LUBRICATION CARBURETOR REMOVAL CARBURETOR THROTTLE VALVE Carburetor cover ● Remove the front panel and the front left & right covers. ● Loosen the carburetor cover. Throttle valve Remove the carburetor cover and the throttle ● valve from the carburetor. ●...
  • Page 101 FUEL AND LUBRICATION CARBURETOR DISASSEMBLY Float chamber body ● Remove the screws and the float chamber body. ① ② ● Remove the pin , float and needle valve ③. ● Check for damage or deformation of the float. ● Check for dents, scratch, block or damage of the float needle valve seat.
  • Page 102 FUEL AND LUBRICATION CARBURETOR REASSEMBLY ● Reassembly in the reserved order of the dis- assembly. NOTE: Before reassembly, blow through all the air- channels and fuel-channels on the carburetor body with the compressed air. ● Install the idle air screw; turn it to the original position recorded before disassembly.
  • Page 103 FUEL AND LUBRICATION ● Tighten the drain screw. ● Install the fuel release hose and fuel hose. ● Turn the fuel cock to “ON". “ON” ● Check the engine idle speed as follow steps. Fuel cock IDLE SPEED ADJUSTMENT WARNING Be sure to start the engine at a place well ventilated or equipped with a ventilation system.

  • Page 104: Fuel Tank

    FUEL AND LUBRICATION FUEL TANK REMOVAL WARNING Fuel hose Fuel is flammable and explosive, so please handle with extreme care. ● Remove the front left/right cover. Remove the fuel hoses. ● Drain the fuel into a proper container. ● Dismantle the following parts: * Saddle * Protective covers Disconnect the fuel level sensor connector.

  • Page 105: Lubrication System

    FUEL AND LUBRICATION LUBRICATION SYSTEM Rocker arm Rocker arm shaft Camshaft Piston Oil pump Crankshaft Filter rotor Principal axis Oil strainer Countershaft Start shaft https://www.motomanuals.net/...
  • Page 106 CHASSIS CONTENTS ..EXTERIOR PARTS REMOVAL AND REMOUNTING .......... HANDLEBAR ........FRONT WHEEL ........FRONT BRAKE ........FRONT ABSORBER 5-11 ..........STEERING 5-15 ......... REAR WHEEL 5-19 ..........REAR HUB 5-21 ........REAR SWING ARM 5-28 ........
  • Page 107 CHASSIS https://www.motomanuals.net/...

  • Page 108: Handlebar

    CHASSIS HANDLEBAR REMOVAL ● Remove left and right rearview mirrors. ● Remove the mounting screws, and remove the handlebar front hood and dashboard cover. ● Disconnect the brake switch connector, and starting switch connector ● Remove the screws and the dashboard. ●...
  • Page 109 CHASSIS ● Remove the bolts of the throttle cover. ● Disconnect the throttle cable and remove the throttle grip. ● Remove the bolt and nut of the handlebar. REMOUNTING ● The handlebar can be mounted in the reverse order of removal. ●...

  • Page 110: Front Wheel

    CHASSIS FRONT WHEEL REMOVAL ● Support the motorcycle with a jack or wooden block. ● Remove the bolt for the flexible cable of odometer and disconnect it. ① ② ● Remove the adjustment nut , brake cable ③ and brake arm pin of the front brake.
  • Page 111 CHASSIS ● Place the wheel hub on a revolving bracket, rotate the wheel manually and measure the radial movement with a micrometer, examine radial run-out of the hub. Actual run-out should be 1/2 of the reading. ● Axial 2.0mm Service limit Radial 2.0mm ●...
  • Page 112 CHASSIS CAST WHEEL Bush Gasket Bearing Bearing ● Fill the bearing cavity with SUPPER GREASE “A” ● Tap the new bearing evenly into the right side of the hub with the sealing side facing outwards, mount the bushing, then tap another new bearing into the left side with the sealing side facing outwards.
  • Page 113 CHASSIS REMOUNTING ● Install the bushing. ● Align the boss of the counter wheel with the hub slot, and mount the brake drum cover onto the left side of the wheel hub. ● Align the slot on the brake drum cover to the boss of the absorber bottom, then mount the front wheel between the bottom of the two absorbers.

  • Page 114: Front Brake

    CHASSIS FRONT BRAKE REMOVAL ● Remove the brake drum cover from the wheel hub (refer to page 5-4 ). INSPECTION ● Measure the inner diameter of the wheel hub. Service limit 111.0mm DISASSEMBLY ● Remove the brake shoes and the springs. ●...
  • Page 115 CHASSIS REASSEMBLY Spring Gear Brake shoe Gasket Gasket Spring Brake cam Indicator ～ N•m Wheel hub cover Bolt Brake arm ● Apply SUPPER GREASE “A” on the lip of the new dust-proof seal ring, and then install it into the brake drum cover. ●...
  • Page 116 CHASSIS ● Apply grease on the seal ring, and then install it into the brake drum cover. Install the return ring and press the spring end ● into the hole of the brake drum cover. ● Install the indication plate on the brake cam, with the wider tooth aligned to the wider slot on the brake cam.

  • Page 117: Front Absorber

    CHASSIS FRONT ABSORBER REMOVAL ● Remove the following parts: * Front panel * Front fender * Front wheel ● Disassemble the clamping bolt of the front absorber, then loosen the bolt of the front absorber and remove the front absorber. DISASSEMBLY ●...
  • Page 118 CHASSIS ● Remove the seal spacer, piston rod and buffer spring. Remove the inner tube from the outer tube. ● ● Remove the retaining ring. ● Remove the oil seal with special tool . TOOL 09913-50121 : Oil seal remover CAUTION Removed oil seals must not be reused.
  • Page 119 CHASSIS INNER TUBE AND OUTER TUBE ● Inspect the inner tube and outer tube sliding surfaces for any scuffing or flaws. ABSORBER SPRING ● Measure the absorber spring free length. If it is shorter than the service limit, replace it. Service limit 329.4mm REASSEMBLY...
  • Page 120 CHASSIS OIL SEAL ● Install the oil seal to the outer tube by using the special tool as shown. TOOL 09940-50112 : absorber oil seal installer ABSORBER OIL ● For the absorber oil, be sure to use the front absorber oil whose viscosity rating meets specifications below.

  • Page 121: Steering

    CHASSIS STEERING REMOVAL Remove the following parts: * handlebar * front absorbers ● Remove the screws, nuts, bush and seat of the steering handlebar. ① ② ● Remove the nut and washer ③ ● Remove the lock-up nut Removal the following parts: * upper circlip * upper steel ball (23) * steering stem...
  • Page 122 CHASSIS BEARING REPLACEMENT Note: Bearing and guard bowl should be replaced in pairs. ● Remove the upper and lower bearing guard bowl. ● Remove the lower bearing guard bowl with a professional tool kit or similar. ● Do not damage the steering stem when disassembling the guard bowl.
  • Page 123 CHASSIS REASSEMBLY Assemble the steering stem in the reversed order of disassembly. Apply grease on the upper and lower guard bowl. 99000-25010 : SUPPER GREASE Upper Number of balls Lower ● Insert the steering stem into the vertical tube, pay attention to not leave the steel balls out. ●...
  • Page 124 CHASSIS ● Rotate the steering stem right and left to ensure it moves smoothly without gap and bending. ● Tighten the steering stem nut. ● Install the steering handlebar seat on the steering stem. Align the thread hole, bolt, sleeve, nut and ●...

  • Page 125: Rear Wheel

    CHASSIS REAR WHEEL REMOVAL ● Support the motorcycle by the main stand. Dismantle the following parts: ① * Dowel pin ② ③ * Nut , washer ④ * Stop bolt ⑤ * Adjus ing nut ⑥ ⑦ * Spring , pin ⑧...
  • Page 126 CHASSIS REAR WHEEL ● Place the rear wheel on a revolving bracket, check the radial run-out of wheel rim and measure with dial gauge. Radial 2.0mm Service limit Axial 2.0mm BEARING ● Rotate the inner loop of the bearing by hand; t h e r o t a t i o n s h o u l d b e s m o o t h w i t h o u t abnormal noise.
  • Page 127 CHASSIS Remove the left/right bearing of the rear wheel ● hub. Note: Replace with new bearings once they are removed. REASSEMBLY ● Install the right/left bearings after filling the bearing cavity with grease. 99000-25010 : SUPPER GREASE 5-21 https://www.motomanuals.net/...
  • Page 128 CHASSIS ● Check the radial run-out of the wheel rim when installing new spokes. ● Mount the wheel buffer block into the hub. Apply grease on the new O-ring and mount it in the slot of the hub. CAUTION Do not let the grease move into the hub, or brake performance may be affected.
  • Page 129 CHASSIS ● Install the left drive chain adjuster and the nut of the rear wheel axle. Install the following parts: ⑥, ⑦ * Spring ⑤ * Adjusting nut ④ * Stop screw ③ * Rubber gasket, washer ② ● Tighten the stop nut ①...
  • Page 130 CHASSIS SPROCKET HUB REMOVAL ● Remove the bolts and the sprocket cover. ● Remove the nuts of sprocket bushing, remove the chain from the wheel, left chain adjuster and sprocket hub. ● Remove the rear wheel. DISASSEMBLY ● Install the sprocket hub into the wheel hub temporarily, and remove the driven sprocket and the nut.
  • Page 131 CHASSIS BEARING Rotate the inner loop of the bearing by hand; the rotation should be smooth without abnormal noise. In the meantime, check if the outer ring of the bearing fits tightly with the chain hub. If the rotation of the inner and outer rings is not smooth, noisy or in loose fit with the wheel hub, remove and replace the bearing.
  • Page 132 CHASSIS REAR BRAKE REMOVAL ● Remove the rear wheel. Remove the rear brake drum cover from the ● rear wheel. INSPECTION ● Measure the inner diameter of the rear brake hub. Service limit 111mm DISASSEMBLY Spring ● Remove the brake shoe and the spring. CAUTION Replace the brake shoe in pairs.
  • Page 133 CHASSIS ASSEMBLY ● Install the brake cam onto the rear brake drum cover after applying grease on the dowel pin and brake cam. Brake cam 99000-25010 : SUPPER GREASE ● Apply engine oil on the oil seal and install it onto the rear brake drum cover.

  • Page 134: Rear Swing Arm

    CHASSIS ● Install the rear brake arm, aligning it with the mark on the cam. ● Mount the bolt of brake arm, tighten the nut to specified torque. Specified torque: 7~10 N•m ● Install the brake shoe and the spring. ●...

  • Page 135: Rear Absorber

    CHASSIS Remove the bolts, washer, and left footrest ● support. ● Remove the nuts and washers of the lower part of rear absorbers. ● Remove the rear rocker arm as well as the nut and axle. DISASSEMBLY Dismantle the following parts: * Dowel pin * Nut, washer * Stop bolt...
  • Page 136 CHASSIS ● Remove the chain guide. INSPECTION ● Check for damage or wearing of lining. Check for damage or wear of the rear rocker ● arm. Lining REASSEMBLY ● Install the chain guide. ● Install the anchor rod, stop bolt, washer and nut, then tighten the nut.
  • Page 137 CHASSIS REMOUNTING Remounted in the reverse order of removal. ● Tighten the nut to the specified torque. Specified torque: 25~35 N•m ● Tighten the rear absorber nuts to the specified torque. Specified torque: 20~30 N•m ① ● Tighten the bushing nut to the specified torque.
  • Page 138 ELECTRICAL CONTENTS ....... . IGNITION SYSTEM ....... CHARGING SYSTEM .
  • Page 139 ELECTRICAL IGNITION SYSTEM DESCRIPTION DC-CDI ignition system charges the capacitor with the electric output from the ignition source to battery boosted by a converter. The electrical current supplied by the battery is first boosted through a converter, and then used to charge the capacitor.
  • Page 140 ELECTRICAL INSPECTION IGNITION COIL ● Remove the front panel and the left/right cover. ● Remove the ignition coil. ● The conductivity of the primary or secondary coil can be examined with a pocket tester. ● Precise result is not necessary. If the winding is normal, take a record about the approximate values.
  • Page 141 ELECTRICAL CHARGING SYSTEM CHARGING OUTPUT CHECK Start the engine and keep it running at 5000 r/min. Using the pocket tester, measure the DC voltage between the battery terminal If the tester reads under 14.0 V or over 15.0 V, check the AC generator no-load performance and regulator/rectifier.
  • Page 142 ELECTRICAL STARTING SYSTEM DESCRIPTION The starting system is shown in the diagram below: namely, the starting motor, the starting relay, engine stop switch, IG switch, starting button and battery. Depressing the starting button (on the right handlebar switch box) energizes the relay, causing the contact points to close which connects the starting motor to the battery.
  • Page 143 ELECTRICAL STARTING MOTOR INSPECTION CARBON BRUSHES When the brushes are worn, the motor will be Brushes unable to produce sufficient torque, and the engine will be difficult to turn over. To prevent this, periodically, inspect the length of the brushes, replacing them when they are too short or chipping.
  • Page 144 ELECTRICAL STARTING MOTOR REMOUNTING BRUSH HOLDER AND HOUSING END ● Fix the carbon brush bracket on the starting motor cover. SECURING SCREW Apply THREAD LOCK “1342” to starting motor securing screw. 1342 09900-32050 : THREAD LOCK “1342” Specified torque: 9~14 N m •...
  • Page 145 ELECTRICAL DASHBOARD ● Remove the dashboard. Disassembly the dashboard as follows. ● INSPECTION Using the pocket tester, check the continuity between lead wires in the following diagram. If the continuity measured is incorrect, replace the respective part. 09900-25002 : Pocket tester TOOL NOTE: When making this test, it is not necessary to...
  • Page 146 ELECTRICAL LIGHTS HEADLIGHT TAIL/BRAKE LIGHT TURN SIGNAL (FRONT) TURN SIGNAL (REAR) https://www.motomanuals.net/...
  • Page 147 ELECTRICAL SWITCHES Inspect each switch for continuity with the pocket tester referring to the chart. If it is found any abnormality, replace the respective switch assembly with new one. 09900-25002 : Pocket tester TOOL IGNITION SWITCH Bl/Y ○ ○ LOCK ○...
  • Page 148 ELECTRICAL DIMMER SWITCH ○ ○ ○ ○ TURN SIGNAL LIGHT SWITCH ○ ○ ● ○ ○ HORN SWITCH ○ ○ REAR BRAKE LIGHT SWITCH ○ ○ GEAR POSITION INDICATOR LIGHT SWITCH Y/Bl G/Bl Ground ○ ○ ○ ○ ○ ○ ○...
  • Page 149 ELECTRICAL BATTERY SPECIFICATIONS Type designation 12N6-3B Battery Breather Capacity 12V 5Ah pipe 1.28±0.01 20℃ Standard electrolyte S.G. In fitting the battery to the motorcycle, connect the breather tube to the battery vent. INITIAL CHARGING Filling electrolyte R e m o v e s h o r t s e a l e d t u b e b e f o r e f i l l i n g electrolyte.
  • Page 150 ELECTRICAL Check the electrolyte level and refill distilled water, as necessary, to raise the electrolyte to each cell upper level. Check the battery for proper charge by taking an electrolyte S.G. reading. If the reading is 1.22 or battery is still in a run-down condition and needs recharging. NOTE: First, remove the lead wire.
  • Page 151 SERVICING INFORMATION CONTENTS ......TROUBLESHOOTING ........SPECIAL TOOLS ......7-10 TIGHTENING TORQUE ........7-12 SERVICE DATA ......7-16 WIRE AND CABLE ROUTING ........ 7-18 WIRING DIAGRAM https://www.motomanuals.net/...

  • Page 152: Troubleshooting

    SERVICING INFORMATION TROUBLESHOOTING ENGINE Symptom and possible causes Complaint Remedy Engine will not start Compression too low or is hard to start. 1. Valve clearance out of limit. Adjust. 2. Worn valve guides or poor seating of valves. Repair or replace. 3.
  • Page 153 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Trouble with starting. Clean. 1.Starter jet is clogged. 2.Starter pipe is clogged. Clean. 3. Air leaking from a joint between choke body Check choke body and and carburetor. carburetor for tightness, adjust and replace gasket. 4.Choke is not operating properly.
  • Page 154 SERVICING INFORMATION Symptom and possible causes Complaint Remedy Slipping clutch. 1. Clutch control out of limit or loss of play. Adjust. 2. Weakened clutch springs. Replace. Replace. 3. Worn or distorted pressure plate. 4. Distorted clutch plates, driven and drive. Replace.
  • Page 155 SERVICING INFORMATION CARBURETOR Complaint Symptom and possible causes Remedy Trouble with 1.Starter jet is clogged. Clean. starting. 2.Starter pipe is clogged. Clean. 3. Air leaking from a joint between choke body and Check choke body and carburetor carburetor. for tightness, adjust and replace gasket.
  • Page 156 SERVICING INFORMATION ELECTRICAL Complaint Symptom and possible causes Remedy No sparking or 1. Defective ignition coil. Replace. 2. Defective spark plug. Replace. poor sparking. 3. Defective trigger coil or ignitor unit. Replace. Spark plug soon 1. Mixture too rich. Adjust carburetor. 2.
  • Page 157 SERVICING INFORMATION BATTERY Complaint Symptom and possible causes Remedy “Sulfation”, acidic 1. Not enough electrolyte. Pour distilled water, if the battery has not been damaged and white powdery "sulfation" has not advanced substance or spots on too far, and recharge. surface of cell plates.

  • Page 158: Special Tools

    SERVICING INFORMATION SPECIAL TOOLS Note: The tools list below is partical tools, and only for reference, check the actual tools listed in previous section. 09900-20101 09900-20103 09900-20202 vernier caliper vernier caliper micrometer 09900-06107 09900-06108 (1/50mm,150mm) (1/50mm,300mm) (1/100mm,25~50mm) snapring pliers snapring pliers 09900-20605 09900-20606 09900-20203...
  • Page 159 SERVICING INFORMATION 11F14-001 11F14-002 11F14-010 11F14-011 11F14-018 rotor holder front absorber tool rotor separator four claw wrench valve spring tool https://www.motomanuals.net/...

  • Page 160: Tightening Torque

    SERVICING INFORMATION TIGHTENING TORQUE ENGINE Kg•m ITEM • 25~35 Engine oil drain plug 2.5~3.5 1.0~1.5 10~15 Crankcase mounting bolt 0.8~1.2 8~12 Cylinder right cover bolt 3.5~3.8 35~38 Primary drive gear/oil pump drive gear nut 1.0~1.5 10~15 Clutch cover bolt 15~18 1.5~1.8 Clutch adjusting nut 1.1~1.5...
  • Page 161 SERVICING INFORMATION TIGHTENING TORQUE CHART For other bolt and nuts who's torque is not listed, refer to this chart: Conventional or "4" marked bolt "7" marked bolt Bolt Diameter Kg•m (mm) Kg•m • • 0.1-0.2 1.0-2.0 0.15-0.3 1.5-3.0 0.2-0.4 2.0-4.0 0.3-0.6 3.0-6.0 0.4-0.7...

  • Page 162: Service Data

    SERVICING INFORMATION SERVICE DATA VALVE + GUIDE Unit: mm ITEM STANDARD LIMIT ～ 19.9 20.1 Valve diam 22.9 23.1 0.35 Valve stem deflection 0.35 IN. or EX. 0.03 0.07 Valve clearance (cold) 0.015 0.042 0.08 Valve guide to valve stem clearance 0.030 0.057 0.10 Valve guide I.D.
  • Page 163 SERVICING INFORMATION CONROD + CRANKSHAFT Unit: mm ITEM STANDARD LIMIT 13.016~13.034 Conrod small end I.D. 13.10 Conrod big end side clearance 0.10~0.35 Conrod big end oil clearance 0.08 0.05 Crankshaft runout Crank pin O.D. 18.92 CLUTCH Unit: mm ITEM STANDARD LIMIT 104.3 Clutch cover I.D.
  • Page 164 ITEM Neutral indication light 12V,35W 12V,2W Headlight Tachometer light 12V,35W 12V,2W Tail/brake light High beam indicator light 12V,5W/21W 12V,2W HJ110-2 Turn signal indicator light 12V,21W 12V,2W HJ110-2A(F) Turn signal light Speedometer light HJ110-2A(R) 12V,16W 12V,2W Parking or position light 12V,2W...
  • Page 165 SERVICING INFORMATION BRAKE + WHEEL Unit: mm ITEM STANDARD LIMIT Rear brake pedal free travel 20~30 Brake drum I.D. 111.0 Front Wheel rim runout Rear 0.25 Front Wheel axle runout Rear 0.25 Front 2.50-17 4PR Tire size Rear 2.75-17 4PR Front Tire tread depth Rear...

  • Page 166: Wire And Cable Routing

    SERVICING INFORMATION WIRE AND CABLE ROUTING 7-16 https://www.motomanuals.net/...
  • Page 167 SERVICING INFORMATION 7-17 https://www.motomanuals.net/...

  • Page 168: Wiring Diagram

    SERVICING INFORMATION WIRING DIAGRAM 7-18 https://www.motomanuals.net/...
  • Page 169 JIANGMEN DACHANGJIANG GROUP CO.,LTD. October 2008 Printed in China https://www.motomanuals.net/...
  • Page 170 JIANGMEN DACHANGJIANG GROUP CO., LTD. Address: No.5, Jiandabei Road, Jiangmen City, Guangdong Province P.R.C Address: No.5, Jiandabei Road, Jiangmen City, Guangdong Province P.R.C Telephone: 86-750-3288999 Telephone: 86-750-3288999 Fax: 86-750-3288333 Fax: 86-750-3288333 Postcode: 529000 Postcode: 529000 https://www.motomanuals.net/...

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