Professional Documents
Culture Documents
SHI N ERAY
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FOREWORD
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I Thank you for your purchasing this motorcycle.
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This manual covers the main data, basic structure, and main procedUJ'es of operation,
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adjustment, maintenance and troubleshooting of this motorcycle. It will hel p you familiari ze
yourself with all the necessary skills so that you will bring your vehicle into full, best play with
minimized trouble for a long service life.
Products are always subject to further improvement, which will cause some difference
between the vehicle and this manual,without further notici.
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CONTENTS
I. Safe Drive . ... . .. .... ... .. .... .. .... ...... .. .... .. .. .. .... . . '" .. ...... . . 1 Adjustment of Throttle Ca ble .. .. ... . ............ ..... ... .... ·17
II. Main Data .. .... . ... .... .. .... ... .. . .... .. .. .... .... .. .. .. . . .. . .... ... ... 3 Adjustment of Carburetor ..... .. ..... .. ... ..... .... .......... 17
ill . Parts and Subassemblies .. ... " . .... .. ..... ...... ... ... . .... ... ... . .. 5 Check - up & Adjustment of Air Valve Gap·· · · · ·· · · ·· 18
N . Operati6n ·· ···· · ··· · ·· ··· ····· · .. · ···· ·· .. ·· ··· .. ··· ········· ······ ·······9 Adjustment of Clutch .. ... .. .... .. . ... .... ... ...... ... .. .. . .... 20
Ignition Switch ·· ··· .. . ... .. .. ...... ... .. .... .. .. . .. .... .. ... ..... .. ... -9 Brake Checking .. ...... .... . . .... ... ... . .. .. .... . . .. .... ... ... . 20
Fuel Cock . ....... ... .. .. ... ....... .. ........ .... .. ..... ... . ........ . . 9 Adjustment of Front Brake ·· ·.... .... ·.. ·· .. .. .. ...... · .. .... ·2 1
Engine Starling .. · .. ·· .. ···· · ···· ·· · .. ·· ···· ··· ·· · ····· · ···· ·· ··· ·· .. 10 Adjustment of Rear Brake ..... ..... .. .............. .. ... . .... 22
Switche<l on Right Handlebar ...... ....... . .. ... ...... .. .. ... ... . II Adjustme nt of Chai n ....... . .. ...... .. .... ...... ... .. .... . .... 22
Swicthe<l on Left Handlebar . ... ... .... .. . ........ ... .... .. ... ... .. 12 Adjustment of Braking Li ght Switch . .... ...... ........ .... . 23
Gear ShIti ng .. ....... .... .... .. .. . .. ... .... . ... ... ... ... .. . .. ... . ... . 13 Battery Checking .... . ............... .... ......... .. .......... 24
V. Check - ups , Adjustment and Maintenance .. .. ... .... .. . ..... . .. "14 Re placement of Fuse ...... .. ..... ... .. .. ... .. . .... ..... .. . .. .. 24
Machine Oil Chec ki ng .. .... . . ... .. . ..... . .... ....... . .. ..... ... ... 14 Vehicle Washing ·· ······ .. ..· .... ··· ··· ·· · .. · .. ··· · ··· ·· .. ·· ·· ··25
Renewal of Machine Oil .... . .. . ... ......... .. . .... . ... ......... .. 14 Mai ntenance in Non· use Time· .... ·· ... ... . .. .... .. .... .. .. ·· ·26
Cleaning of Mac hine Oil Tank ... ..... ... .... ............. .... ... . 15 Resumption of Service . ... .... ..... . ... .. .... ... .. . ... ... .. . .. . ·27
Check· up of spark plug . ...... ... ....... ..... .. ... ..... ... ... .. .. 15 Maintenance Routine Di agram ····· ...... .. .......... ........ ··28
Check· up & Cleaning of Air Filter ·· ·· · ····· ··· · ··· ··· ·· ··· · ···· 16 VI . Eletric Di agram . . .. . ...... ... ... ... .. ..... ... .... .. ..... .. .... ... . 29
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SAFE DRIVE
Rules for Safe Drive
Check must be conducted, before starting the engine, to prevent mishaps and damage to components.
Only the qualified person, who has passed the drive examination and to whom a dri ve license h~
been issued, is permitted to drive the vehicle but not anybody else without a drive license.
Full preoccupation is required during drive, paying attention to the following points to avoid any
possible hurt to you by other motorized vehicles:
Do not drive too close to other vehicles;
Never contend for lane.
Strictly observe the local traffic mles.
As dri ving at overspeed is the cause of many accidents, do not drive at a speed the actual situation
does not permit.
Turn on the tumlight when making a tum or changing the lane.
Particular care should be exercised at the level crossing of road s , entrance and exit of parking lot or
on the automobile lane.
During drive, grasp the left handlebar by the left hand and the throttle twist grip by the right one ,
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with feet on the footrests.
The luggage carrier is designed for carrying light goods, which should be securely fastened /to
prevent loose movement that may cause mishaps during drive.
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Prote ti ve Wear
1. Protective wear such as helmet \vith protec tiv e mask, d ustproof glasses and gloves should b e worn
durin g drive for the sake of personal safety.
2. T he passe nge r should wear hi gh t boots or long clothes to protect legs from hu rt by the heated exhaust
s ilencer during ride.
3. Loose clothes are not suitable for motorcycle drive or ride as they may get caught on the oi-le ra ting
lever, ki c k lev er, footres t or whe el, result to dan ger.
Modifi ca tion of the vehicle
Caution:
An y'unauthorized modifica tion of the veh icle or replacement of the original parts ca n not ensure driv ing
safe ty and is illicit. The user must observe the regulations of the traffic cont rol authori ties . We are not re
sponsible for any vehicle with unauthorized modification.
Loading of goods
Caution:
The design of the mot orcycle requires distribution of the carried goo ds in certain extent of equilibrium
an d improper a rra ngement of goods will adversely affec t the performa nce and s tability of the vehicle. The
ma nufacturer ~hall not take any responsibility due to t he reason men tioned above.
MAIN DATA
Overall widlh 830mm Cylinder hore x slroke 56.5 x 49.5rnm (')2.0 x 49.5mm 03.5 x ti2. 2m lll
Overall height 1240mm Compression ratio 9.0:1
Wheelhase 1320mm Output,max. 8.2kW/9<XXnfmin 8.5kW/9(XX)rlmin 11.5kW/8500rlmin
Dead weinght 117kg TorfJue,rnax 8.5N-mI7S00rlmir II.ON"rnI7S00dmin 15.0N"ITl/'X)OOJ/miJ
Payload 150kg IrIling speed 1500rlmin 1420rlmin ISOOr/(IJil l
Front whed 2.75- 2l1200 Displacement of cylinder 124.0rnl I49.4i'n1 196.9"d
Rearwlwd 4. 10-1 8/225 Spark plllg D7TC n~nc
Speed, Max ~ 90km/h Spark plllg gap O.n - 0 .8mm 0.6 - 0.7""11
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MAIN DATA
II
II
Ser.No Name Description
CD Speedometer lnkmfh
~ Turn indicator The left indicator is lit up when the tumlight is to the left and the right one lit up as the latter to the righl
® Neutral indicator It is lit up when in the neutral position.
@ Odometer It shows the total accumulated mileage already covered by the vehicle.
(5) Tachometer It shows the speed (rpm) of the engine.
@ Trip mileometer It shows the mileage of trip.
CD
Front wheel
Front
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Seat cushion
Kick lever
Fuel Cock to "OFF" position. the fuel circuit is
N. OPERATION CD Fuel filling cut off without supply,
Ignition Switch The capacity of the fuel tank is 18L in RES: With the handle of the fuel
*Ignition swicth total including L I L of reserve, Leadless cock to RES position. the fuel is sup
gasoline of No. 90 or above or lowJead plied from the reserve.
Posiloin Function Remarks gasoline is required for the motorcycle, To ( Note: The reserved fuel can only
To , SlOp the vehicle Theke",anbtte fuel the vehicle. support it by the main
OFF be used when the normal supply is run
(switching off all circuits) mcved.outtaker
stand. open th e lock cover of the fuel tank out. ) In this case. refueling should be
For lIartin« or drivi"« lh~ \'dU. The key can nol
ON
ck{ makins all (be main cirtuill ) be removed and fill fuel through the opening. and then carried out as soon as possible, for
LOCK Tolock the steering handle The key ca n
close the tank by the cover with the two on
be taken out there is only some O. 8L of fuel re
them in good alignment. serve fo r use.
(2) Operation of the fuel cock ( the valve
Off of fuel tank )
ON: With the handle of the fuel cock to OFF
ON
"ON" position. the fuel circuit is through for
ON
LOCK fuel supply.
OFF: With the handle of the fuel coc k RES
III
@ Turnlight switch
+-Position, Left
-Position, Right
@ Horn button
press this button to horn.
@
CD
Gear Shifting
Wann up the engine !"lr nonnal runing.
CD When the engine is idling, disengage the
Shifting forward
clutch and tread the geacshifting pedal to et the
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gear to the 1st position.
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@ Gradually increase the speed of the engine 3
and slowly release the clutch lever, with a good 2
coordination between the two operations to ensure a N
natural driving start. 1
Shifting backwardS
® When the motorcycle reaches a balanced
state of runniing, slow down the engine, disengage
the clutch again and tread the shifting pedal to
change the gear to the 2nd position. The gear can
be shifted to other positions in the same way.
cosity will help maintain a long ser oil and start the engine for idle running 2 - 3 min
are not available, a substitute suitable Let the engine stop for 2 - 3 minutes, and
for the ambient temperature of appli check to see whether the oil level is in between the
cation should be selected according 10 upper and lower lines of the oil gauge.
the table on the right side. Do not use any machine Iii of a different grade
Machine oil gauge
than the specified one to avoid machinery failure.
Cleaning of Machine Oil Tank
CD Drain off all the run in machine oil 0.6 -0. 7mm
from the oil tank. t
(2) Dismount the related parts. Check_up of Spark Plug
@ Wash clean all the related parts. CD Remove the cap of spark plug and
@ Fill in the required oil. screw off the spark plug by the plug
Dismounting:
Remove the left side cover screw of the filter, open the left Air filter
Valve cap
When adjustment IS needed. loosen brakes respectively and check for wear
the locking nut on the clutch operating of the brake shoes. (f the mark "6 "on
cable and set the clutch lever to the re ~--=~-- the brake drum cover aligns with that
quired range of free operating movement. In u 6 .. on the brake cam, it means that
case of adjustment to be made to a great --~~ the brake shoes are already worn to the
10 - 20mm
extent, turn the clutch adjusting screw stud limit and have to be (2 ) Replacement
on the right crankcase. should becamed out at a designated
Is tart the engine to ascertain whether service center and it is recommended
that the parts made by our company are
used therein. 10 - 20mm
Adjustment of f ro nt ,Brake
10 - 20mm
( 1)The front brake lever has a free opera ting
movement of 10 - 20 mm as shown in the figure I
on th e right side.
(2) If adjustment is needed , turn th e adjust
Il1g nut near the lower side of the front hub.
clockwise to reduce and count erclock wise to in
crease the free operating movement of the bra ke
lever.
(3) After adjustment, the groove of the ad
justing nut should be aligred with the pin of the
brake arm .
Caution:
After adjustment, chec k the front bra king
system. The braking li ght should be lit up on time
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Chai n adjuster(with graduations) . Braking light switch Adjusting nut
Rear wheel axle nut Bear axle Braking light switch spring
mi nutes.
Ne ver have the elec
trolyte leve l co me over thp Upper electrolyte level line
vver L1l e
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llation. Vehicle Washing
II be kept
Cleaning the vehicle regularly can slow down the color fading of its bod y make it easier to check if
there is any damage and an y oil leakage with it.
~ "OFF"
Caution:
. tube of
lCement. Washing the motorcycle with over - pressurized water may cause damage to so me of its compo
I remove nents. Therefore. do not jet over - press urized water directly on to-the following parts:
~e battery -Wheel hub
-Exhaust pipe
lroken a -Fuel tank a nd lower portion of cushion
it means
-Carburetor
ilh other
-Head lock and ignition switch
-Meters
lOA ( 1) After pre - wiping, the vehicle should be washed with clean water to remove dirty residues so as to
e battery prevent cOITosion. Plastic subassemblies should be cl eaned by wi ping with colth or s ponge soa ked in ne utral
detergent solution, followed by washing with clean wate r.
(2) After the cleaned ve hicle is air dried, grease the chain and run the engin e at idling ;;pee d for a few
minutes.
( 3)Prior to driving, carefully check braking sys tem repeatedly and repair or adjust it if ner:essary .
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Maint e n a nce in Non - use Time Resumptio
Stora ge and Maintenance
For the motorcycle to be stored for a long period of time, attention s hould be paid to the prevention of moi sture, CD Remov
su nshine and rain attack in order to protect it from unnecessary damage. Special check - ups should be carried out on ewer 4months.
those import an t parts and subassemblies before sto~age.
(2) Charge
<D Change lubri cating oil.
® Grease the chain. ® Drain 0
® Drain off fuel from the fuel tank and carburetorC for the vehicle not to be used for over a montf;} , the fuel in the latter @ Prior to
mu st be thoroughly drain ed away) , turn off the fuel coc k and fi 11 antiru st solution into the fuel tank, followed by dos ing the Maintenan
ta nk with the cove r. "(' means:
Caution : "c" means
As fu el is inflammable, the engine s hould be stopped before filling or drain fuel a nd it is prohibited to smoke at the "R"means
fuel s torin g ,filling or draining location.
"A" means
@ Take out the s park plug, fill about J 5 - 20ml of clean lubricatin g oil int~ the cyliQder, s tep down the kick lever
"L"means·
rep etitivel y for sev E' ral times and finally fit the spark plug back on.
Attention:
., * "mean
The igniti on s witch key must be set to "OFF" position before stepping down the ki ck lever. To protect th e ignition user himself wit
system from damage, the spark plug should be put on its cap and earthed. "* * "
@ Dismantle the battery and put it in a shady, cool and well - ventilat ed p lace. It is suggested that the battery be ensure safety.
c harged once a month. Notes: l.
@ Clean the vehicle, s pray the colored pa rt with co lor fastening agen t and apply antitu st oil to the part vulnerable to 2. When t
rust.
s hou ld be still
(J) Inflate the tyre as required and pad the vehicle up with th e two wheels clear of the ground.
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Resumption of Service
CD Remove the cover and clean the vehicle. Change the lubricating oil if the vehicle has been off service for
over 4months.
(2) Charge the battery and remount it.
® Drain off the antirust solution from the fuel tank, followed by filling fu el therein to the required level.
@ Prior to dri ving, test the vehicle at low speed in a safe place.
"r" means: Check, cleaning, adjustment, lubrication and / or replacemnet are needed .
" * "means: This item of maintennace should be carried out at a service center. It may be also done by the
user himself with reference to this manual provided he has special tools, sparts and is capable of this job.
"* *" menas: This item can only be carried out by the serviceman at Kington service cenler in order to
ensure safety.
Notes; 1. Maintenance should be conducted more frequently when the motorcycle drives in dusty areas.
2. When the read - out of the odometer exceeds the maximum figures specified in the table, maintenance
should be still cycled according to the interval of mileage stated herein.
. ~~cv.
Item of Maintenance
item / fn ~ qI H·hc}'
Odometer km (Note 2)
Remark B-Black
lOOOkm 4000km 8000km 12000km
Circuit of fuel system I Y-Yellow
* Fuel filter
I I
W-White
* Thrott le operat;ng sysern
C C C
[
C
[
BI-Blue
* Choke of rarburetor
I 1
I I
R-Red
* Air fi ller e l ~menl R - yearly C
[
C C
G-Grey
O-Orange
Spark plug R 'co rlv I I I R Br-Brown
Air valve gap I I LG-Light Green
* Air valve gap
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[
[
[ I LB-Light Blue
f.lIgine lubricating oil R One replaceme nt every 2000km
J.uhricating oil sc reen Monthl C I c c
* Te n ~ion of chaiu A A I A A
* tcUing !5peed of carbu retor I I I [
Oriv ing chain R -4 'ear I ,L every 500km
Battery [ I I I
Wear of brake shoes r - 2v ear I I I
n ea r braking system [ I [ I
Braking liquid hose also for di sc styl e
** Cup of braking tiquid [
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[
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** Braking liquid
J I I
** tront braking system I
One replacement every two year
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*
,**r- Wheel! spokes [ [ I I
Btari ng of steerill!!: handle I
** I
ELECTRICAL DIAGRAM
B-Black
Y-YelJow
W-White
BI-Blue
R-Red
G-Grey
O-Orange
Br-Brown
LG-LightGreen
LB-Lighl Blue
·yle