PREFACE
PREFACE
This shop manual describes the technical feature and
servicing procedures for the SANYANG NCA250.
All information, illustrations, directions and
specifications included in this publication are base on
SANYANG NCA250.
SANYANG reserves the right to make changes at any
time without notice and without incurring any
obligation whatever.
SANYANG INDUSTRY CO.,LTD.
SERVICE DIVISION
CONTENTS
CONTENTS
GENERAL INFORMATION ..........................................................................1
INSPECTION/ADJUSTMENT.......................................................................2
LUBRICATION SYSTEM..............................................................................3
ENGINE REMOVAL/INSTALLATION ..........................................................4
CYLINDER HEAD/VALVE............................................................................5
CYLINDER/PISTON......................................................................................6
CLUTCH/OIL PUMP/GEAR SHIFT ..............................................................7
A.C. GENERATOR.......................................................................................8
CRANK SHAFT/CRANK CASE/TRANSMISSION.......................................9
CARBURETOR.............................................................................................10
HEADLIGHT/STEERING/FRONT WHEEL/FRONT FORK ..........................11
REAR WHEEL/REAR SUSPENSION ..........................................................12
BATTERY/CHARGING SYSTEM.................................................................13
IGNITION SYSTEM.......................................................................................14
SWITCHES/HORN........................................................................................15
WIRING DIAGRAM.......................................................................................16
1.GENERAL INFORMATION
1-1
SERVICE RULES...............................1-1
SPECIFICATIONS..............................1-2
TORQUE VALUES.............................1-3
TROUBLE SHOOTING ......................1-4
SERVICE RULES:
(1)Use new packings, gaskets,O-rings and cotter
pins space and clipes whenever reassembling.
(5)Clean all removed parts in or with solvent, and
lubricate their sliding surfaces upon disassembly.
(2)When tightening bolts or nuts, begin on center or
larger diameter bolts and tighten them in criss-
cross pattern in two or more steps if necessary.
(6)Coat or fill parts with specified grease where
specified.
(3)Use genuine SANYANG parts and lubricants or
those equivalent. When parts are to be reused,
they must be inspected carefully to make sure they
are not damaged or deteriorated and in good
usable condition.
(7)Upon assembling, check every possible part for
proper installation and movement or operation.
(4)Use special tool when use of such a tool is
specified.
(8)Work safely and give your work your undivided
attention. Exchange signals as frequently as possi ble when a work involves two or more workers. Do
not run the engine unless the shop or working a re a
is well ventilated.
Symbol Marks:
:Apply engine oil.
NOTE: Things must be noticed.
CAUTION: Things that could cause damage to the
engine parts.
:Apply grease.
WARNING: Things that could cause damage to
the person or partner.
1.GENERAL INFORMATION
1-2
SPECIFICATIONS
ITEM NCA250
DIMENSIONS
Overall length
Overall width
Overall height
Wheel base
Ground clearance
Dry weight
2180mm
960mm
1130mm
1480mm
160mm
175kg
FRAME
Type
Front suspension and travel
Rear suspension and travel
Front tire size and tire pressure
Rear tire size and tire pressure
Front brake
Rear brake
Fuel capacity
Fuel reserve capacity
Caster angle
Front fork oil capacity
Double pipe
Telescope 165mm
Swing arm 63mm
90/90-18 2.25Kg/C ㎡
130/90-15 2.50Kg/C ㎡
Disk
Drum
14 liter
2.0 liter
26 °
160c.c
ENGINE
Type
Cylinder arrangement
Bore & stroke
Displacement
Compression ratio
Oil capacity
Intake valve opens
closes
Exhaust valve opens
closes
Valve clearance IN.
EX.
Idle speed
Air cooled 4 stroke O.H.C. engine
Double cylinders 15~ inclinde from vertical
53 x53mm
233.9c.c.
9.5:1
1.1 ~1.5 liter (1.3 liter for change)
0° BTDC
30 ° ABDC
35° BBDC
-5 ° ATDC
0.08mm
0.10mm
1500 rpm
DRIVE TRAIN
Clutch
Transmission
Primary reduction ratio
Gear ratio I
II
III
IV
V
Final reduction ratio
Gearshift pattern
Wet muti-plate type
5-speed internationl
3.83
2.46
1.777
1.333
1.083
0.913
2.285
1→N→2→3→4→5
ELECTRICAL
Ignition system
Ignition timing "F" mark
Full advance
Starting system
Alternator
Battery capacity
Fuse
Spark plug
Spark plug gap
C.D.I. unit
BTDC 15°±20° /1500rpm
BTDC 29.5°±2° /4000rpm
Electrical motor starter
A.C. generator
12V 9AH
20A×2/15A×2/10A×4
A6RTC
0.6~0.7mm
1.GENERAL INFORMATION
1-3
ENGINE
TIGHTEN LOCATION Q'TY THREAD DIA(mm) TORQUE(kgf·cm)
Oil plate pan screw
Crank shaft bolt
Crank shaft nut
Cylinder head nut
Cylinder head cover
Cam shaft sprocket bolt
Crank case bolt
L crank case cover bolt
Fly wheel bolt
A.C.G. scocket bolt
Start motor bolt
R crank case cove bolt
Cam shaft holder nut
Primary drive gear nut
Oil pump flat bolt
Clutch lock nut
Shift durm stopper
Shift cam bolt
Cam chain adjuster screw
Drain oil bolt
Gear shift spindle bolt
3
5
1
3
2
2
10
7
1
3
4
10
8
1
3
1
1
1
1
1
1
6
8
7
6
6
7
6
6
10
5
6
6
8
16
6
16
6
6
6
12
8
80~120
180~220
70~110
80~120
80~120
80~120
80~120
80~120
400~500
50~70
80~120
80~120
180~220
400~500
80~120
400~500
80~120
80~120
80~120
150~250
100~150
FRAME
TIGHTEN LOCATION Q'TY THREAD DIA(mm) TORQUE(kgf·cm)
Front wheel nut
Rear wheel nut
Rear fork pivot nut
Engine hanger nut
Handle pipe upper holder bolt
Steering stem nut
Front fork nut
Rear shock absorber
Rear brake torque link
Front fork top bridge
Rear fork bottom bridge
Final drive sprocket
Seat bolt
Drive sprocket bolt
1
1
1
3
4
1
1
4
1
2
2
4
2
2
14
14
14
10
8
22
22
10
8
7
8
10
8
6
600~800
1000~1200
800~1000
450~550
180~ 250
600~900
400~500
300~400
150~200
100~140
240~300
270~330
200~250
100~140
STANDARD TORQUE
TYPE TORQUE(kgf·cm) TYPE TORQUE(kgf·cm)
5 mm bolt, nut
6 mm bolt, nut
8 mm bolt, nut
10 mm bolt, nut
12 mm bolt, nut
45~60
80~120
180~250
300~400
500~600
5 mm bolt
6 mm bolt
6 mm flange bolt, nut
8 mm flange bolt, nut
10 mm flange bolt, nut
35~50
70~110
100~140
240~300
350~450
1.GENERAL INFORMATION
1-4
Torque specifications listed below for respective locations.
TROUBLE SHOOTING
A. HARD START OR CANNOT START
start engine with choke closed
engine knocks, but no
starting
follow the starter
keypoints to re-start
inspection adjustment
cause
loosen carburetor drain
screw, check inner side for
gasoline
enough gasoline supplied
for carbuertor
remove spark plug,insert it
into plug cap, check the
spark by touching engine
grid
test cylinder
compression
spark plug jump
spark weak or no spark
normal compression
pressure too low or no
pressure
engine dose not fire
spark plug dry
no gasoline in the tank
fuel tube between gasoline tank and
carburetor clogged.
float chamber fuel tube clogged
gasoline cover air hole clogged
fuel filter clogged
fuel filter screen clogged
gasoline auto fuel cup faulty
spark plug faulty
fouled spark plug
CDI unit fualty
pulse coil faulty
high voltage coil cable open or
short
high voltage coil open or short
main switch faulty
A.C.G. faulty
Battery faulty
valve too tight, no gap
valve seat faulty
cylinder, piston, piston ring
faulty
cylinder gasket leak
valve burnt out
valve timing faulty
crankcase leak when wmpress
Fuel tube clogged
muffler clogged
auto air cut poor action
inlet duct has air in
ignition timing incorrect
carburetor fuel adjusting
screw set faulty
air cleaner clogged
symptom
no gasoline supplied
for carburetor
remove and check the
spark plug again
spark plug wet
carburetor fuel level too high
auto air cut poor action
throttle excessively
1.GENERAL INFORMATION
1-5
B. ROTATION ROUGH (LACKS POWER)
symptom
inspection adjustment
cause
start engine and slightly
apply fuel
engine speed up
engine speed can't up
adjust ignition timing use
timing tester
valve adjusterpoor
ignition timing
correct
ignition timing
incorrect
valve clearance
correct
valve coearance
incorrect
compression pressure check
compression normal pressure to low
carburetor block check
remove spark plug
no clogged
block
air cleaner clogged
fuel tube clogged
air hole on the fuel tank cap blocked
exhaust tube clogged
auto air cut faulty
carburetor vacuum diaphragm worn
auto fuel cup faulty
faulty CDI unit
faulty A.C.Generator
fualty valve seat
cylinder, piston worn
gasket leak
valve timing incorrect
piston ring worn
remove and clean
remove dirt
spark plug improper heat range
spark plug clearance misadjustment
no fouled
discolored
dirt and color change
valve clearance misadjustment
valve seat worn
check crankcase oil level
for too much or dirt
oil lever normal
oil too much
too much oil
too little oil
oil no replacement
check cylinder head
lubrication
normal
abnormal
oil tube clogged
lean projection from oil pump
engine too hot
no overheating overheated
piston, cylinder worn
lean mixture
poor gasoline
carbon in burning chamber too much
ignition timing too early (C.D.I. faulty)
clutch slip
high speed
continue working
no knock shock knocks
carbon in burning chamber too much
poor gasoline
clutch slip
lean mixture
ignition timing too early(C.D.I.faulty)
1.GENERAL INFORMATION
1-6
C. ROTATION ROUGH (ESPECIALLY IN THE LOW SPEED AND IDLE SPEED)
symptom
inspection adjustment
cause
ignition timing
adjustment
faulty CDI unit
faulty A.C.Generator
valve gap adjust faulty
normal abnormal
adjust carburetor fuel
adjusting screw
adjust OK
adjust faulty
lean mixture(loosen screw)
rich mixture(tighten screw)
no air inlet
has air inlet
carburetor gasket
has air inlet
insulator plate gasket poor
carburetor locking nut loose
insulator plate gasket torn
vacuum tube crack
remove spark plug,
insert to the plug
cap, check spark by
toucning engine iron
g
rid.
sparking well poor sparking
poor or dirty spark plug
faulty CDI unit
faulty A.C.Genertor
poor ignition coil
spark plug cable open or short
poor main switch
good no good
vacuum tube damaged
air inlet duct clogged, damaged
1.GENERAL INFORMATION
1-7
D. ROTATION ROUGH (HIGH SPEED)
symptom
inspection adjustment
cause
ignition timing
adjustment
faulty CDI unit
faulty pulse generator
normal abnormal
valve clearance
adjustment
normal
abnormal
poor adjustment
valve seat faulty
normal abnormal
check auto fuel
cup for fuel
su
pp
lied.
too little fuel in the fuel tank
fuel tube, fuel filter clogged
air hole on the fuel tank colgs
auto fuel cup faulty
no blocked blocked
valve timing
adjusting
ins
p
ection
timing correct
timing incorrect
cam sprocket aligning marks incorrect
carburetor blocked
check valve spring
clean
good
spring broken
loose elasticit
y
faulty spring
1.GENERAL INFORMATION
1-8
E. POOR CHARGE (BATTERY OVER DISCHARGE OR OVER CHARGE)
symptom
inspection adjustment
cause
measure battery voltage.
and then start engine
reach battery life
faulty battery
battery voltage
can't rise
battery voltage rise to
normal value,after
engine stops, the voltage
return to original.
check voltage regulator
rectifier coupler
normal
abnormal
coupler poor contact
red wire open
hsa voltage no voltage
check the voltage between
voltage red wire
and frame body(grounding)
with mult-meter(+).(-)
terminals.
normal
abnormal
after engine starter, measure the
voltage between voltage regulaton
/rectifier red (+) wire and
green (-) wire connected with
frame body.
voltage over
normal
voltage normal
measure the resistance of
AC generator coil
check voltage regulator/
rectifier coupler for poor
contact.
coil faulty
connector.poor contact
AC generator white wire open
normal poor contact
voltage adjuster
white wire open
faulty battery
poor charge (over charge)
measure the resistance of
voltage adjuster unit
can't meet
s
p
ecification
faulty voltage
regulator/rectifier
Coupler poor contact.
green wire poor
grounding
1.GENERAL INFORMATION
1-9
F.SPARK PLUG NO SPARK
symptom
Inspection adjustment
cause
replace with new spark plug
and test again.
spark wear of
no spark
spark strong
original spark
plug faulty
Check spark cap and high
voltage cable for slack
no slack slack
spark plug cap
slack
check CDI unit plug for slack
normal abnormal
plug poor contact
Check the resistance
between the wires.
terminals of CDI unit.
normal abnormal
Check related portions
normal
abnormal
use CDI tester for CDI unit
normal
abnormal
use CDI tester to check
ignition voltage coil
abnormal
fualty main switch.
faulty trigger
magntic coil
faulty CDI unit
faulty IGN coil
control cable open
connector.socket
poor contact
poor pulse coil
poor IGN coil
2.INSPECTION/ADJUSTMENT
2-1
ENGINE
MAINTENANCE SCHEDULE.............2-2
SERVICE INFORMATION..................2-3
ENGINE OIL/OIL FILTER...................2-4
SPARK PLUG.....................................2-5
COMPRESSION TEST.......................2-6
VALVE CLEARANCE .........................2-7
IGNITION TIMING..............................2-8
CAM CHAIN TENSION ADJUSTMENT .......2-9
THROTTLE GRIP ADJUSTMENT......2-10
IDLING SPEED ADJUSTMENT..........2-11
FRAME
AIR CLEANER................................... 2-12
CLUTCH ADJUSTMENT................... 2-12
BRAKE ADJUSTMENT ..................... 2-13
DRIVE CHAIN ADJUSTMENT .......... 2-14
WHEELS/RIM .................................... 2-15
SUSPENSION................................... 2-16
STEERING........................................ 2-17
BATTERY.......................................... 2-17
HEAD LIGHT AIM.............................. 2-18
STOPLIGHT SWITCH....................... 2-18
2.INSPECTION/ADJUSTMENT
2-2
MAINTENANCE SCHEDULE
Maintenance
kilometer
300KM
Every
1000KM
Every
3000KM
Every
6000KM
Every
12000KM
Item
Check Items
Maintenance
Interval
NEW 1 Month 3 Months 6 Months 1 Year
1
Air cleaner I C R
2
Gasoline filter I C R
3
Oil filter C Replacement for every 5000KM R
4
Oil filter screen C Cleaning for every 5000km C
5
Engine Oil R Replacement for every 1000KM R
6
Wheels tires I I
7
Battery I I
8
Brake and operation free play I I
9 Steering stem bearing
I
10
FR./RR. Cushion I I
11
Screws/nuts I I
12
Spark plug I R
13
Clutch I I
14
Frame of lubrication L
15
Exhaust muffler I I
16
Carburetor I I
17
Ignition timing I I
18
Emission I I
19
Idle speed I I
20 Gasoline system
I I
21 Throttle cable
I I
22 Engine bolt torque
I I
23 Deposit of exhaust outlet
I
24
Cylinder head/cylinder
Piston exhaust system deposit
I
25 Cam chain
I I
26 Valve clearance
I I
27 Light/electrical appliance/Meter
I I
28 Side stand﹠Spring
I I
The table is refered to the driving distance about 1000km per month
I-inspection, cleaning, adjustment or replacement (if necessary)R-replacement C-leaning L-lubrication
REMARK: Ridden in unusually dusty areas, require more frequently air filter element cleaning.
2.INSPECTION/ADJUSTMENT
2-3
SERVICE INFORMATION
SPECIFICATLON
ENGINE
Oil capacity 1.1～1.5 liter
Spark plug gap A6RTC
Spark plug gap 0.6-0.7mm
Valve clearance IN 0.08mm
EX 0.10mm
Cylinder compression 12.5kg/c ㎡±2kg/c ㎡
FRAME
Clutch lever free play 10-20mm
Drive chain stack 10-20mm
Front brake lever free play 10-20mm
Rear brake pedal free play 20-30mm
Throttle grip free play 2-6mm
SPECIAL TOOL
Valve clearance adjuster
TORQUE VALVES
Right crankcase cover 80-120 kgf·cm
Front fork top bridge bolt 100-140 kgf
·cm
Front fork bottom bridge bolt 200-250 kgf
·cm
Rear wheel axle nut 400-550 kgf
·cm
Rear shock absorber nut 300-400 kgf
·cm
Rear fork pivot bolt 350-450 kgf
·cm
2.INSPECTION/ADJUSTMENT
2-4
OIL/OIL FILTER
OIL LEVEL CHECK
Start and warm up the engine for few minutes,then
stop the engine.
Check the oil level with oil level gauge after a few
minutes.
If the oil level is near the lower mark,fill the
crankcase to the upper level mark with the
recommended grade oil.
OIL REPLACEMENT
NOTE:
Remove the drain bolt, and drain the engine oil.
NOTE :
Fill the crankcase up to the upper level mark on the
oil level gauge with the recommended oil:15W-40
API:SH/CD
Drain the engine oil while the engine is warm.
Make sure that the drain bolt washer is in good
condition.
DRAIN BOLT
2.INSPECTION/ADJUSTMENT
2-5
OIL FILTER SCREEN CLEANING
Remove the drain bolt, and drain the engine oil.
Remove the right crankcase cover.
Remove the pump.
Clean the oil filter screen with compressed air.
Assemble the filter screen in reverse order of
disassemble.
SPARK PLUG
Disconnect the spark plug cap and remove the spark
plug .
Visually inspect the spark plug electrodes for wear.
The center electrode should have square edges and
side electrode should have a constant thickness.
Discard the spark plug if there is apparent wear or if
the insulator is cracked and/or chipped .If the spark
plug deposits can be removed by sandblasting or wire
brushing,the spark plug can be reused.
Inspect the gap with a feeler gauge and adjust by
bending the side electrode.
Standard gap:0.6-0.7mm
NOTE:
To install turn finger tight then tighten with a spark
plug wrench.
OIL FILTER
2.INSPECTION/ADJUSTMENT
2-6
COMPRESSION TEST
Warm up the engine.
Stop the engine .Remove spark plug .Insert the
compression gauge.
Push in the choke lever .Open the throttle grip fully.
Electrical start engine several times.
NOTE:
Compression:9.5kg/c ㎡±1kg/c ㎡
Low compression can be caused by:
Improper calve adjustment.
Valve leakage .
Blown cylinder head gasket.
Worn piston rings or cylinder.
Worn piston.
High compression can be caused by:
Carbon deposits in combustion chamber or on
piston head.
Watch for compression leaking at the gauge
connection.
Crank the engine until the gauge reading stops
rising .The maximum reading is usually reached
in several times.
ELECTRICAL
START ENGINE
2.INSPECTION/ADJUSTMENT
2-7
VALVE CLEARANCE
NOTE:
Remove the timing inspection hole cap and crankshaft
hole cap.
Rotate the generator rotor counterclockwise and align
the “T”mark on the generator rotor with the index mark
in the left crankcase
(piston must be at T.D.C.of the compression
stroke).
Inspect the intake and exhaust valve clearance by
inserting a feeler gauge between the adjusting screw
and valve stem,valve clearance:
Intake: 0.08mm
Exhaust: 0.10mm
Adjust by loosening the lock nut and turning the
adjusting screw until there is a slight drag in the feeler
gauge.
NOTE:
Inspect and adjust the valve clearance while the
engine is cold.
Inspect the valve clearance again after tightened the
lock nut.
ALIGN
MARK
ALIGN
MARK
ADJUSTING
SCREW
LOCK NUT
2.INSPECTION/ADJUSTMENT
2-8
Install the valve adjuster caps and generator cap.
NOTE:
IGNITION TIMING
Use the standard tester to check the ignition timing.
Spark plug inspection and adjustment.
Replace the coil if there is no sparks at plug.
IGNITION TIMING INSPECTION
Remove the generator cover and check the ignition
timing with a timing light.
Timing is correct if the index mark aligns with the
“F”mark within ±3°at 1500rpm.
Ignition timing :10°BTDC/1500rpm.
Ignition coil continuity test :
Check the resistance of the primary coil
and secondary coil.
1.Primary coil 0.31±0.03Ω
2.Secondary coil 4.0±0.4kΩ
Check the O-ring for damage and spread oil before
installing the caps.
The C.D.I.ignition timing is not adjustable.
If the ignition timing is not correct ,check the C.D.I.unit
and A.C.generator and replace any faulty parts.
O-RING
2.INSPECTION/ADJUSTMENT
2-9
Inspect the C.D.I unit with C.D.I tester.
Replace the faulty C.D.I unit.
SWITCH C.D.I. normal C.D.I faulty
1. OFF
2. P
3. EXT
4. ONI
5. ONZ
no sparks
no sparks
no sparks
sparks
sparks
-------
------sparks
no sparks
no sparks
CAM CHAIN TENSIONER
ADJUESTER
The cam chain tension is kept by the tensioner
push rod that is compressed by the spring.
CAUTION:
If remove any parts that is related with the cam
chain ,remove the cam chain tensioner adjuester
first.
CAM CHAIN TENSIONER ADJUESTER
2.INSPECTION/ADJUSTMENT
2-10
CARBURETOR
THROTTLE GRIP FREE PLAY
Check throttle grip free play.
Free play:2-6mm
THROTTLE GRIP ADJUSTMENT
Loosen the lock nut and turn the adjuster to adjust.
ADJUSTER NUT
2.INSPECTION/ADJUSTMENT
2-11
IDLING SPEED ADJUSTMENT
Warm up the engine.
Turn the stop screw to obtain the idling speed of
1100rpm.
Turn the air screw to the maximum speed,then turn
the stop screw to obtain the specified idling speed.
Idling speed:1500±100 rpm
NOTE:
Turn the air screw clockwise for making fuel –air
mixture lean.
Turn counterclockwise for rich.
STOP
SCREW
AIR SCREW
2.INSPECTION/ADJUSTMENT
2-12
AIR CLEANER
Remove the left side cover.
Remove the air cleaner cover.
Remove the air cleaner element.
NOTE:
Clean the cleaner element periodically.(Refer to
maintenance schedule.)
Assemble air cleaner element in reverse order of
disassemble.
CLUTCH ADJUSTMENT
CLUTCH LEVER FREE PLAY
Measure the clutch free play at the tip of the clutch
lever.
Free play :10-20mm
SCREWS
AIR CLEANER ELEMENT
2.INSPECTION/ADJUSTMENT
2-13
FREE PLAY ADJUSTMENT
Loosen the lock nut and turn the adjuster.
Turn the adjuster ,clockwise for decreasing the free
play ,counterclockwise for increasing the free play.
.
Or adjust clutch lever adjuster nut.
BRAKE ADJUSTMENT
FRONT BRAKE LEVER FREE PLAY
Measure the brake free play at the tip of the brake
lever.
Free play:10-20mm
BRAKE PAD WEAR INSPECTION
Check for brake pad wear by operating the bake lever.
Check the brake pads for wear by looking through the
slot indicated by the arrow cast on the caliper
assembly.
Replace the brake pads if the wear line on the pads
reaches the edge of the brake disc.
ADJUSTER
NUT
LOCK
NUT
LEVER ADJUSTER NUT
10~20mm
2.INSPECTION/ADJUSTMENT
2-14
REAR BRAKE PEDAL FREE PLAY
Measure the brake pedal free play before the brake
start to engage.
Free play :20-30mm
REAR BRAKE PEDAL ADJUSTMENT
Turn the adjuster clockwise for decreasing the
clearance ,counterclockwise for increasing the
clearance.
CAUTION:
Keep the adjuster at the right position.
DRIVE CHAIN ADJUSTMENT
Place the motorcycle on its side stand and shift the
transmission into neutral.
Remove chain cap and check the drive chain slack by
moving up and down with the fingers.
Chain slack:10-20mm
20~30mm
A
DJUSTER NUT
10~20mm
2.INSPECTION/ADJUSTMENT
2-15
Loose the rear wheel axle nut for adjusting.
Turn the adjusting nuts on both adjusters as
necessary.
CAUTION:
Tighten the axle nut.
TORQUE:1000-1200 kgf·cm
Recheck the drive chain slack and free wheel rotation.
Lubricate the drive chain with chain lubricant.
WHEEL/RIM
Stand the motorcycle,check the tires for
cuts,imbedded nails,or other sharp objects.
Check the tire pressure.
One rider
Front 2.25 kg/c ㎡
Rear 2.50 kg/c ㎡
Cold tire
Two riders
pressure
Front 2.50 kg/c ㎡
Rear 2.50 kg/c ㎡
Max.load 120kg
Tire size
Front 90/90-18
Rear 130/90-15
Min. depth of tread
Front 1.5mm
Rear 2.0mm
A
DJUSTING NUTS
2.INSPECTION/ADJUSTMENT
2-16
SUSPENSION
FRONT SUSPENSION
Check the action of the front forks by compressing
them several times with the front brake applied .
If there are abnormal noises or rattles ,check all the
fasteners and tighten them to the specified torque.
TORQUE:
Front fork top bridge bolt :100-140 kgf
·cm
Frint fork bottom bridge bolt :240-300 kgf
·cm
Axle nut:600-800 kgf
·cm
REAR SUSPENSION
Check for abnormal noises and leaks by compressing
the rear suspension several times.
Check the rear suspension nut for loosing
Torque:300-400 kgf
·cm
Move the rear wheel side ways with force to see if the
swing arm bushings are worn.
Rear fork torque:800-1000 kgf
·cm
2.INSPECTION/ADJUSTMENT
2-17
STEERING
Raise the front wheel off the ground and check that
the handlebar rotates freely.If the handlebar moves
unevenly ,binds or has vertical movement,adjust the
steering head nut.
BATTERY
Inspect the battery fluid level ,if the fluid level nears
the lower level mark,fill with distilled water to the upper
level mark .
Clean the battery terminals with warm water.
Check the specific gravity of the battery
electrolyte.(13-3)
NOTE :
Do not overfill. Add only distilled water.
Tap water will shorten the service life of the
battery.
WARNING:
Keep the electrolyte away from eyes ,skin and
clothes. If touched it ,wash them with clean
water quickly.
2.INSPECTION/ADJUSTMENT
2-18
HEADLIGHT AIM
Adjust vertically by turning headlight up and down with
the headlight bolts loosening.
Fasten the bolts after adjustment.
STOPLIGHT SWITCH
The stoplight should come on when the brake pedal is
depressed 20mm from the standard pedal position.If
the action is abmormal, adjust by turning the stoplight
switch adjusting nut.
NUTS
STOPLIGHT SWITCH
A
DJUSTING NUT
3.LUBRICATION SYSTEM
3-0
CAM SHAFT
OIL LINE OF
CAM SHAFT
PISTON
OIL FILTER
OIL ORIFICE OF
CRANKSHAFT
OIL PUMP
MAIN SHAFT
COUNTER SHAFT
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