CONTENTS 1. INFORMATION............................................................2 2. MAINTENANCE..........................................................6 3. ENGINE REMOVAL AND INSTALLATION......................12 4. ENGINE FUEL SYSTEM.............................................14 5. ENGINE LUBRICATION AND COOLING SYSTEM...........18 6. ENGINE COMBUSTION SYSTEM.................................21 7. TRANSMISSION SYSTEM..........................................25 8. FRONT WHEEL AND STEERING SYSTEM....................29 9. REAR WHEEL SYSTEM.............................................42 10. FENDERS AND EXHAUST PIPE.................................45 11. HYDRAULIC DISC SYSTEM......................................48 12. ELECTRICAL SYSTEM.............................................53 13.TROUBLE SHOOTING.............................................57 1 1. INFORMATION 1.1 SAFETY 1.2 NOTES 1.3 SERIAL NUMBER 1.4 SPECIFICATION 1.5 TORQUE VALUES 1.1 SAFETY Gasoline is extremely flammable and is explosive under certain condition. Do not smoke or allow sparks or flames in your work area. Never run the engine in a closed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death. The battery electrolyte contains sulfuric acid. Protect your eyes, skin and clothing. If you contact it, flush thoroughly with water and call a doctor if electrolyte gets in your eyes. 1.2 NOTES All information, illustrations, directions and specifications included in this publication are base on the latest product information available at the time of approval for printing. JI-EE Industry Co., Ltd. reserves the right to make changes at any time without notice and without incurring any obligation whatever. No part of this publication may be reproduced without written permission. 2 1.3 SERIAL NUMBER The frame serial number is stamped on the right side of the frame. The engine serial number is stamped on the left side of the crankcase. Frame serial number Engine serial number 3 1.4 SPECIFICATION ENGINE Type Displacement Bore and Stroke Compression Maximum Torque Carburetor Ignition Starting Lubrication Oil Capacity Transmission Forced Air-Cooling 2-Stroke 49.3cc/95.6cc 40.0*39.2mm/52.0*45.0mm 6.8:1/7.8:1 4.8 N-m@6500rpm/8.0N-m@4500rpm Mikuni VM16 Capacitor Discharge Ignition Electric/Kick Starter Oil Pump Separate Supply 1. 0 liter Automatic (C.V.T V-belt) CHASSIS Overall Length Overall Width Overall Height Seat Height Wheel base Ground Clearance Dry Weight Fuel Tank Capacity 1600mm(62.9inch) 795mm(31.2inch) 1020mm(40.1inch) 700mm(27.5inch) 1020mm(40.1inch) 120mm(4.7inch) 141kg 6.5±0.2liter SUSPENSION Front Rear Dual Absorber& Swing arm Single Absorber& Swing arm BRAKES Front Rear Drum Hydraulic Disc TIRIES Front Rear 19"*7"-8" 19"*8"-8" Red / Blue / Silver COLORING Specifications subject to change without notice. 4 1.5 TORQUE VALUES ENGINE Item Cylinder head nut park plug Cylinder head bolt Alternator bolt N·m 28-30 12-19 20-30 8-12 Lbf-ft 20.7-22.1 8.9-14.0 14.8-22.1 5.9- 8.9 FRAME Item Handlebar upper holder bolt Steering shaft nut Steering shaft bushing holder nut Wheel rim bolt Tie rod lock nut King pin nut Handlebar lower holder nut Front wheel bolt Front axle castle nut Front brake arm nut Rear brake arm nut Rear axle castle nut Rear wheel bolt Exhaust muffler mounting bolt Engine hanger bolt N·m 24-30 50-60 24-30 18-25 35-43 30-40 40-48 24-30 40-60 4-7 7-12 40-60 24-30 30-35 24-30 Lbf-ft 17.7-22.1 36.9-44.3 17.7-22.1 13.3-18.4 25.8-31.7 22.1-29.5 29.5-35.4 17.7-22.1 30-45 3.0- 5.2 5.2- 8.9 30-45 17.7-22.1 22.1-25.8 17.7-22.1 5 2. MAINTENANCE 2.1 MAINTENANCE DATA 2.2 MAINTENANCE SCHEDULE 2.3 FUEL TUBE 2.4 THROTTLE OPERATION 2.5 THROTTLE CABLE ADJUSTMENT 2.6 AIR CLEANER 2.7 SPARK PLUG 2.1 MAINTENANCE DATA 2.8 IDLE SPEED 2.9 DRIVE CHAIN 2.10 BRAKE SYSTEM 2.11 WHEELS AND TIRES 2.12 STEERING SYSTEM 2.13 TOE-IN 2.14 GEAR OIL SPECIFICATION SPARK PLUG GAP: RECOMMENDED SPARK PLUGS: THROTTLE LEVER FREE PLAY: IDLE SPEED: BRAKE LEVER FREE PLAY: DRIVE CHAIN SLACK FRONT/REAR TIRE SIZE FRONT/REAR TIRE PRESSURE TOE-IN 0.6-0.7 mm NGK BPR7HS 5-10 mm 1800±100 rpm 15-25 mm 10-25 mm 19X7-8/19X8-8 12 psi (0.8 kgf/cm2) 5±10 mm TORQUE VALUES SPARK PLUG TIE-ROD LOCK NUT 25-30 N.m 35-43 N.m ENGINE OIL GEAR LUBRICATION OIL 2.2 MAINTENANCE SCHEDULE JASO FC Grade or same degree oil SAE 90 The maintenance internals in the follow table is based upon average riding, conditions. Riding in unusually dusty areas, require more frequent servicing INITIAL REGULAR SERVICE SERVICE EVERY YEAR (Every 30 (First week) operating days) FUEL LINE I THROTTLE OPERATION I I AIR CLEANER C SPARK PLUG I CARBURETOR IDLE SPEED I I DRIVE CHAIN I, L I, L BRAKE SHOE WEAR I BRAKE SYSTEM I I NUT, BOLT, FASTENER I I WHEEL I I STEERING SYSTEM I SUSPENSION SYSTEM I C.V.T. AIR FILTER C GEAR OIL R Note ­ I: Inspect and Clean, Adjust, Lubricate or Replace, if necessary C: Clean L: Lubricate R: Replace 6 2.3 FUEL TUBE Inspect the fuel lines for deterioration, damage or leakage and replace any parts if necessary. 2.4 THROTTLE OPERATION Inspect throttle lever for smooth full opening and automatic full closing in all steering positions. Inspect if there is no deterioration, damage or kinking in the throttle cable, replace it if occur any damage. Check the throttle lever, free play is 5-10 mm at the tip of the throttle lever. Disconnect the throttle cable at the upper end. Lubricate the cable with commercially lubricant to prevent from premature wear. 2.5 THROTTLE CABLE ADJUSTMENT Slide the rubber cap of the adjuster off the throttle Housing, loosen the lock nut and adjust the free play of the throttle lever by turning the adjuster on the throttle housing. Inspect the free play of the throttle lever. 2.6 AIR CLEANER Unscrew the air cleaner cover screws. Pull out the air filter element from the air cleaner case. Wash the element in non-flammable solvent, squeeze out the solvent thoroughly. Let it dry. Soak the filter element in gear oil and then squeeze out the excess oil. Install the element into air cleaner carefully. 7 2.7 SPARK PLUG This spark plug located at the front of the engine. Disconnect the spark plug cap and unscrew the spark plug. Inspect the spark plug electrodes for wear. Change a new spark plug if the electrodes and insulator tip appear unusually fouled or burned. Discard the spark plug if there is apparent wear or if the insulator is cracked or chipped. The spark plug gap shall keep in 0.6-0.7mm. With the sealing washer attached, thread the spark plug in by hand to prevent cross threading. Tighten the spark plug with 25-30 N.m 2.8 IDLE SPEED Connect an engine speedometer. Warm up the engine, 10 minutes are enough. Turn the idle-speed adjust screw on the carburetor to obtain the idle speed. "Turn in" (clockwise) will get higher speed. "Turn out" (counter clockwise) will get lower speed. IDLE SPEED: 1800±100 rpm ADJUST SCREW 2.9 DRIVE CHAIN Inspect the chain slack. The standard is 10-25mm. Adjust the chain slack. Loose the lock bolts (4 pcs) then adjust the drive chain slack by turn the adjusting nut. Tighten the four lock bolts. 8 When the drive chain becomes very dirty, it should be removed, cleaned and lubricated by specify lubricator. Using commercial chain lubricant to lubricate the drive chain. Clean the drive chain with kerosene and wipe it dry. Inspect the drive chain for possible wear or damage. Replace the chain, if it is worn excessively or damaged. Inspect the sprocket teeth, if it is excessive wear or damage, replace it. 2.10 BRAKE SYSTEM Inspect the front brake lever and cable for excessive play or other damage. Replace or repair if necessary. Measure the free play of the brake lever at the end of the brake lever. The standard of free play is 15-25 mm. Inspect the rear brake lever and cable for excessive play or other damage. Replace or repair if necessary. Measure the free play of the rear brake lever at the end of the lever. The standard is 10-20 mm. 2.11 WHEELS AND TIRES Inspect the tire surfaces for cuts, nails or other sharp objects. Check the tire surfaces at cold tire condition. The standard of tire pressure is 12 psi (0.8 kgf/cm2). 9 2.12 STEERING SYSTEM Check the free play of the steering shaft with the front wheels, turned straight ahead. When there is excessive play, inspect the tie-rod, kingpin bushing and ball joint. 2.13 TOE-IN Let the vehicle on level ground and the front wheels facing straight ahead. Mark the centers of the tires to indicate the axle center height. Measure the distance between the marks. Carefully move the vehicle back, let the wheels have turned 180 °, so the marks on the tires are aligned with the axle center height. Measure the distance between the marks. Calculate the difference in the front and rear measurements. Toe-in: 5±10mm If the toe-in is out of standard, adjust it by changing the length of the tie-rods equally by turning the tie-rod while holding the ball joint. Tighten the lock nuts. Torque: 35-43 N.m 10 2.14 GEAR OIL Gear oil needs to be changed every year. There is a gear oil release bolt at the rear of engine. Unscrew this release bolt and can let the dirty oil flow out. The re-add oil hole is on the engine case beside gearbox. OIL DRAIN BOLT FILL OIL 11 3. ENGINE REMOVALS AND INSTALLATION 3.1 SERVICE INFORMATION 3.2 ENGINE REMOVAL 3.3 ENGINE INSTALLATION 3.1 SERVICE INFORMATION Engine shall be removed in the conditions of necessary repairment or adjustment in the transmission and combustion system only. 3.2 ENGINE REMOVAL Remove the seat and rear fender. (Chapter 10) Remove the spark plug cap from the spark plug. Remove the rear tires first, and than disassemble the exhaust pipe. Caution: When remove the tailpipe before, be careful the temperature. Please wear the gloves to avoid the heat from tailpipe. 2.REMOVE TAILPIPE 1.REMOVE REAR TIRE Remove the drive chain cover. This is under the chain. Remove the drive chain retaining clip and master link, than remove the drive chain. 12 Remove the three engine hanger nuts and bolts. Two hanger nuts are outside and one is inside. Remove the engine from the left side of frame. ENGINE HANGER NUTS 3.3 ENGINE INSTALLATION Engine installation is essentially the reverse order of removal. The torque of engine hanger bolt is 24-30 Nm Route the wires and cable in reverse order properly. 13 4. ENGINE FUEL SYSTEM 4.1 TROUBLESHOOTING 4.2 FUEL TANK 4.3 CARBURETOR 4.4 ASSEMBLY 4.1 TROUBLESHOOTING ENGINE CAN NOT START NO FUEL IN TANK NO FUEL TO CARBURETOR TOO MUCH FUEL INTO CYLINDER NO SPARK AT PLUG AIR CLEANER CLOGGED ENGINE IDLES UNSTEADY, STALLS OR RUNS POORLY UNPROPER ADJUSTMENT TO THE IDLE SPEED SCREW IGNITION MALFUNCTION FUEL/AIR MIXTURE RATIO NOT GOOD AIR CLEANER DIRTY INSULATOR LEAKAGE FUEL TANK CAP BREATHING HOLE CLOGGED LEAN MIXTURE FUEL JET OF CARBURETOR CLOGGED FUEL TANK CAP BREATHING HOLE CLOGGED FUEL FILTER CLOGGED FUEL FLOWS IN THE TUBE UNSMOOTHLY FLOAT LEVEL IN CARBURETOR TOO LOW RICH MIXTURE FLOAT NEEDLE VALVE IN CARBURETOR FAULTY FLOAT LEVEL TOO HIGH AIR DUCT IN CARBURETOR IS CLOGGED AIR CLEANER DIRTY 14 4.2 FUEL TANK REMOVAL Remove the seat and rear fender. Disconnect the fuel line from the carburetor. Remove the fuel tank cap and front fender. Unscrew the fuel tank fixed bolts. Note: Keep gasoline away from flames or sparks. Wipe up spilled gasoline at once. 4.3 CARBURETOR REMOVAL Remove the air cleaner. Disconnect the fuel line and auto-choke electric wire. Unscrew the intake pipe mounting bolts at the carburetor then remove the carburetor. Note: Turn off the fuel pipe by turn the fuel cup (below fuel tank) to "off" position. DISASSEMBLY Remove the carburetor cap. Remove the throttle cable from the throttle valve while depressing the throttle valve spring. Remove the needle clip retainer, the jet needle and needle clip. Inspect the throttle valve and jet needle surface for wearness, scratches or dirt. 15 Unscrew the float chamber screws and remove the float chamber. Disassembly the float arm pin, float and float needle valve. Inspect the seat of the float needle valve for wear or damage. Disassembly the idle jet, main jet, idle speed adjust screw and idle mixtures adjust screw. Inspect all the jets and screws for wear or damage. Clean the passages and jets with compressed air. 16 4.4 ASSEMBLY Clean all parts in solvent and blow it dry with clean compressed air. Assembly is essentially the reverse order of disassembly. THROTTLE VALVE ASSEMBLY Install the needle clip on the jet needle. Install the jet needle into the throttle valve. Assemble the throttle cable, spring and the throttle valve. Align the throttle valve groove with the idle speed adjust screw and install the carburetor cap to the carburetor. 17 5. ENGINE LUBRICATION AND COOLING SYSTEM 5.1 ENGINE LUBRICATION SYSTEM 5.2 CAUTION 5.3 OIL PUMP 5.4 COOLING SYSTEM 5.5 TROUBLESHOOTING 5.1 ENGINE LUBRICA ...