TGB BR8, BR9, BF9, BH8, BK8 Service Manual
...
1
TABLE OF CONTENTS
1. GENERAL INFORMATION
PAGE
1-1 SPECIFICATIONS
3
1-2 INSPECTION PRECAUTIONS
1-3 SAFETY PRECAUTIONS
1-4 SPECIAL TOOLS
1-5 TIGHTENING TORQUE
1-6 LUBRICATION POINTS
1-7 PARTS NAME
1-8 TROUBLE SHOOTING
1-8-1 Troubleshooting for Failure in Starting the Engine
1-8-2 Troubleshooting for Poor skip of Spark Plugs
1-8-3 Troubleshooting for No-Skip of Spark Plugs
1-8-4 Troubleshooting for Slow Run (Troubled Engine
1-8-5 Poor Acseleration and Horse Power
10
11
12
14
16
18
19
22
23
24
25
2.INSPECTION AND ADJUSTMENT
2-1 REGULAR MAINTENANCE SCHEDULE
2-2 INSPECTION AND CHANGE OF ENGINE OIL
2-3 FINAL GEAR OIL
2-4 BRAKE SYSTEM
2-5 TIRE AND TIRE PRESSURE
2-6 AIR CLEANER
2-7 BATTERY
2-8 SPARK PLUG
2-9 FUEL FILTER
2-10 CARBURETOR IDLE SPEED
2-11 THROTTLE VALVE
2-12 VALVE
2-13 HEADLIGHT AXLE
2-14 V BELT
2-15 CYLINDER PRESSUR
27
28
29
30
35
35
36
37
37
38
38
39
40
40
42
3. REMOVAL AND INSTALLATION OF ENGINE
3-1 STANDANTD PREPARATION DATA&SIMPLIFIED
TROUBLESHOOTING
3-2 RELEASE THE ENGINE
3-3 INSTALLATION OF THE ENGINE
3-4 CHECK THE ENGINE PARTS
43
45
45
45
2
3-5 FUEL FEED CIRCUIT
3-6 LUBRICATION
3-7 DRIVING PULLY-CLUTCH-DTIVEN PULLEY
3-8 STARTER ARM
54
59
60
67
4. CHASSIS
4-1 REMOVAL OF COVER
4-2 TROUBLESHOOTING OF CHASSIS
4-3 FRONT WHEEL
4-4 REAR WHEEL
4-5 REAR SHOCK ABSORBER
70
72
76
78
80
5. ELECTRICAL SYSTEM
5-1 OPERATING CAUTIONS & TROUBLESHOOTING
5-2 BATTERY
5-3 SHORT CIRCUIT TEST
5-4 RECTIFIER
5-5 STARTER RELAY
5-6 STARTER MOTOR
5-7 A.C. GENERATOR
5-8 RESISTOR
5-9 CDI UNIT
APPENDIX
CIRCUIT DIAGRAM FOR BR8
81
86
87
87
88
90
92
94
95
98
3
1. GENERAL INFORMATION
1-1.SPECIFICATIONS
BR8 PRODUCT SPECIFICATION
MODE BR8 AIR CLEANER TYPE PAPER FILTER
TOTAL LENGTH (mm) 1860 FUEL TANK (ℓ) 6.8
TOTAL WIDTH (mm) 675 TYPE CVK
TOTAL HEIGHT (mm) 1145 THROTTLE VALVE DIA. (㎜) 24
DIMENSION
WHEEL BASE (mm) 1270 VENTURI DIA. (㎜) 22.1
FRONT 43
FUEL SYSTEM
CARBURETOR
THROTTLE VALVE TYPE BUTTERFLY
REAR 68 TYPE C.D.I.
DRY WEIGHT (kg)
TOTAL 111 SPARK ADVANCE BTDC 13°/ 2950rpm
FRONT 72 SPARK PLUG NGK CR7HSA
REAR 114
IGNITION
SPARK PLUG GAP (㎜) 0.6~0.7
WEIGHT
TOTAL WEIGHT (kg)
1 PERSON (75kg)
TOTAL 186
ELECTRIC SYSTEM
BATTERY 12V 7AH
PRIMA TRANSM. C.V.T.
TYPE 4T
SECONDARY TRANSM. GEAR
FUEL TYPE
92/95 UNLEADED
GASOLINE
CLUTCH TYPE
CENTRIFUGAL
TYPE
CYLINDER NO. SINGLE PRIMA 1/0.90~2.40
BORE ∗ STORKE (mm) 52.4 ∗ 57.8
TRANSMISSION
REDUCTION RATIO
SECOND
1/9.45 (14/43×13/40)
DISPLACEMENT (c.c.) 124 HEAD LAMP (H / L) 12V 35W/35W×1
STARTER ELECTRIC＆KICK REAR LAMP 12V 5W×1
BRAKE LAMP 12V 21W×1
COOLING
FORCED AIR
COOLING
LAMP
TURN LAMP 12V 10W×4
LUBRICATION PUMP＆SPLASH 130/60-13＆130/60-13
INTAKE VALVE GAP (mm) 0.08~0.10 or120/70-12＆130/70-12
EXHAUST VALVE GAP (mm) 0.08~0.10
FRONT＆REAR
or120/70-12＆120/70-12
TOP SPEED (km/hr) 90 FRONT 175
IDLING SPEED (rpm) 1800 ±100
TIRE
TIRE PRESSURE
(kPa)
REAR 210
MAX. TORQUE (N-m/rpm) 7.90 / 7800 LEFT 45
MAX. POWER (kW/rpm) 6.47 /7800
STEERING ANGLE ( °)
RIGHT 45
COMPRESSION RATIO 9.2：1 FRONT DISK
BRAKE
REAR DRUM
CYLINDER PRESSURE
(㎏/cm
2
– rpm)
12.8-570
FRONT TELESCOPE
ENGINE OIL TYPE SAE 10W - 40
SUSPENSION SYSTEM
REAR ROCKER ARM
ENGINE OIL QUANTITY (c.c.) 900 FRAME STEEL TUBE
GEAR OIL TYPE SAE 90#
ENGINE
GEAR OIL QUANTITY (c.c.) 120
4
BF8 PRODUCT SPECIFICATION
MODE BF8 AIR CLEANER TYPE PAPER FILTER
TOTAL LENGTH (mm) 1890 FUEL TANK (ℓ) 6.8＆3.9
TOTAL WIDTH (mm) 715 TYPE CVK
TOTAL HEIGHT (mm) 1115 THROTTLE VALVE DIA. (㎜) 24
DIMENSION
WHEEL BASE (mm) 1280 VENTURI DIA. (㎜) 22.1
FRONT 47
FUEL SYSTEM
CARBURETOR
THROTTLE VALVE TYPE BUTTERFLY
REAR 68 TYPE C.D.I.
DRY WEIGHT (kg)
TOTAL 115 SPARK ADVANCE
BTDC 13°/ 2950rpm
FRONT 78 SPARK PLUG NGK CR7HSA
REAR 112
IGNIITION
SPARK PLUG GAP (㎜) 0.6~0.7
WEIGHT
TOTAL WEIGHT (kg)
I PERSON (75kg)
TOTAL 190
ELECTRIC SYSTEM
BATTERY 12V 7AH
PRIMA TRANSM. C.V.T.
TYPE 4T
SECONDARY TRANSM. GEAR
FUEL TYPE
92/95 UNLEADED
GASOLINE
CLUTCH TYPE
CENTRIFUGAL
TYPE
CYLINDER NO. SINGLE PRIMA 1/0.90~2.40
BORE ∗ STORKE (mm) 52.4 ∗ 57.8
TRANSMISSION
REDUCTION RATIO
SECOND
1/9.45 (14/43×13/40)
DISPLACEMENT (c.c.) 124 HEAD LAMP (H / L) 12V 35W/35W×1
STARTER ELECTRIC＆KICK REAR LAMP 12V 5W×1
BRAKE LAMP 12V 21W×1
COOLING
FORCED AIR
COOLING
LAMP
TURN LAMP 12V 10W×4
LUBRICATION PUMP＆SPLASH 130/60-13＆130/60-13
INTAKE VALVE GAP (mm) 0.08~0.10 or120/70-12＆130/70-12
EXAUST VALVE GAP (mm) 0.08~0.10
FRONT＆REAR
or120/70-12＆120/70-12
TOP SPEED (km/hr) 90 FRONT 175
IDLING SPEED (rpm) 1800 ±100
TIRE
TIRE PRESSURE
(kPa)
REAR 210
MAX. TORQUE (N-m/rpm) 7.90 / 7800 LEFT 45
MAX. POWER (kW/rpm) 6.47 /7800
STEERING ANGLE ( °)
RIGHT 45
COMPRESSION RATIO 9.2：1 FRONT DISK
BRAKE
REAR DRUM
CYLINDER PRESSURE
(㎏/cm
2
– rpm)
12.8-570
FRONT TELESCOPE
ENGINE OIL TYPE SAE 10W - 40
SUSPENSION SYSTEM
REAR ROCKER ARM
ENGINE OIL QUANTITY (c.c.) 900 FRAME STEEL TUBE
GEAR OIL TYPE SAE 90#
ENGINE
GEAR OIL QUANTITY (c.c.) 120
5
BR9 PRODUCT SPECIFICATION
MODE BR9 AIR CLEANER TYPE PAPER FILTER
TOTAL LENGTH (mm) 1860 FUEL TANK (ℓ) 6.8＆3.9
TOTAL WIDTH (mm) 675 TYPE CVK
TOTAL HEIGHT (mm) 1145 THROTTLE VALVE DIA. (㎜) 26
DIMENSION
WHEEL BASE (mm) 1270 VENTURI DIA. (㎜) 23
FRONT 44
FUEL SYSTEM
CARBURETOR
THROTTLE VALVE TYPE BUTTERFLY
REAR 74 TYPE C.D.I.
DRY WEIGHT (kg)
TOTAL 118 SPARK ADVANCE BTDC 13°/ 2950rpm
FRONT 72 SPARK PLUG NGK CR7HSA
REAR 121
IGNIITION
SPARK PLUG GAP (㎜) 0.6~0.7
WEIGHT
TOTAL WEIGHT (kg)
I PERSON (75kg)
TOTAL 193
ELECTRIC SYSTEM
BATTERY 12V 7AH
PRIMA TRANSM. C.V.T.
TYPE
4T
SECONDARY TRANSM. GEAR
FUEL TYPE
92/95 UNLEADED
GASOLINE
CLUTCH TYPE
CENTRIFUGAL
TYPE
CYLINDER NO. SINGLE PRIMA 1/0.90~2.40
BORE ∗ STORKE (mm) 57.4 ∗ 58.4
TRANSMISSION
REDUCTION RATIO
SECOND
1/7.8 (15/42×14/39)
DISPLACEMENT (c.c.) 151 HEAD LAMP (H / L) 12V 35W/35W×1
STARTER ELECTRIC＆KICK REAR LAMP 12V 5W×1
BRAKE LAMP 12V 21W×1
COOLING
FORCED AIR
COOLING
LAMP
TURN LAMP 12V 10W×4
LUBRICATION PUMP ＆ SPLASH 130/60-13＆130/60-13
INTAKE VALVE GAP (mm) 0.08~0.10 or120/70-12＆130/70-12
EXAUST VALVE GAP (mm) 0.08~0.10
FRONT＆REAR
or120/70-12＆120/70-12
TOP SPEED (km/hr) 97 FRONT 175
IDLING SPEED (rpm) 1800 ±100
TIRE
TIRE PRESSURE
(kPa)
REAR 210
MAX. TORQUE (N-m/rpm) 11.14 / 6500 LEFT 45
MAX. POWER (kW/rpm) 7.89 /7250
STEERING ANGLE ( °)
RIGHT 45
COMPRESSION RATIO 10.8：1 FRONT DISK
BRAKE
REAR DRUM
CYLINDER PRESSURE
(㎏/cm
2
– rpm)
11.7-700
FRONT TELESCOPE
ENGINE OIL TYPE SAE 10W - 40
SUSPENSION SYSTEM
REAR ROCKER ARM
ENGINE OIL QUANTITY (c.c.) 1000 FRAME STEEL TUBE
GER OIL TYPE SAE 90#
ENGINE
GEAR OIL QUANTITY (c.c.) 120
6
BF9 PRODUCT SPECIFICATION
MODE BF9 AIR CLEANER TYPE PAPER FILTER
TOTAL LENGTH (mm) 1890 FUEL TANK (ℓ) 6.8＆3.9
TOTAL WIDTH (mm) 715 TYPE CVK
TOTAL HEIGHT (mm) 1115 THROTTLE VALVE DIA. (㎜) 26
DIMENSION
WHEEL BASE (mm) 1280 VENTURI DIA. (㎜) 23
FRONT 48
FUEL SYSTEM
CARBURETOR
THROTTLE VALVE TYPE BUTTERFLY
REAR 76 TYPE C.D.I.
DRY WEIGHT (kg)
TOTAL 124 SPARK ADVANCE BTDC 13°/ 2950rpm
FRONT 77 SPARK PLUG NGK CR7HSA
REAR 122
IGNIITION
SPARK PLUG GAP (㎜) 0.6~0.7
WEIGHT
TOTAL WEIGHT (kg)
I PERSON (75kg)
TOTAL 199
ELECTRIC SYSTEM
BATTERY 12V 7AH
PRIMA TRANSM. C.V.T.
TYPE
4T
SECONDARY TRANSM. GEAR
FUEL TYPE
92/95 UNLEADED
GASOLINE
CLUTCH TYPE
CENTRIFUGAL
TYPE
CYLINDER NO. SINGLE PRIMA 1/0.90~2.40
BORE ∗ STORKE (mm) 57.4 ∗ 58.4
TRANSMISSION
REDUCTION RATIO
SECOND
1/7.8 (15/42×14/39)
DISPLACEMENT (c.c.) 151 HEAD LAMP (H / L) 12V 35W/35W×1
STARTER ELECTRIC＆KICK REAR LAMP 12V 5W×1
BRAKE LAMP 12V 21W×1
COOLING
FORCED AIR
COOLING
LAMP
TURN LAMP 12V 10W×4
LUBRICATION PUMP＆SPLASH 130/60-13＆130/60-13
INTAKE VALVE GAP (mm) 0.08~0.10 or120/70-12＆130/70-12
EXAUST VALVE GAP (mm) 0.08~0.10
FRONT＆REAR
or120/70-12＆120/70-12
TOP SPEED (km/hr) 97 FRONT 175
IDLING SPEED (rpm) 1800 ±100
TIRE
TIRE PRESSURE
(kPa)
REAR 210
MAX. TORQUE (N-m/rpm) 11.14 / 6500 LEFT 45
MAX. POWER (kW/rpm) 7.89 /7250
STEERING ANGLE ( °)
RIGHT 45
COMPRESSION RATIO 10.8：1 FRONT DISK
BRAKE
REAR DRUM
CYLINDER PRESSURE
(㎏/cm
2
– rpm)
11.7-700
FRONT TELESCOPE
ENGINE OIL TYPE SAE 10W - 40
SUSPENSION SYSTEM
REAR ROCKER ARM
ENGINE OIL QUANTITY (c.c.) 1000 FRAME STEEL TUBE
GEAR OIL TYPE SAE 90#
ENGINE
GEAR OIL QUANTITY (c.c.) 120
7
BH8 PRODUCT SPECIFICATION
MODE BH8 AIR CLEANER TYPE PAPER FILTER
TOTAL LENGTH (mm) 1790 FUEL TANK (ℓ) 6.8
TOTAL WIDTH (mm) 675 TYPE CVK
TOTAL HEIGHT (mm) 1080 THROTTLE VALVE DIA. (㎜) 24
DIMENSION
WHEEL BASE (mm 1240 VENTURI DIA. (㎜) 22.1
FRONT 35
FUEL SYSTEM
CARBURETOR
THROTTLE VALVE TYPE BUTTERFLY
REAR 58 TYPE C.D.I.
DRY WEIGHT (kg)
TOTAL 93 SPARK ADVANCE BTDC 13°/ 2950rpm
FRONT 63 SPARK PLUG NGK CR7HSA
REAR 105
IGNIITION
SPARK PLUG GAP (㎜) 0.6~0.7
WEIGHT
TOTAL WEIGHT (kg)
I PERSON (75kg)
TOTAL 168
LECTRIC SYSTEM
BATTERY 12V 7AH
PRIMA TRANSM. C.V.T.
TYPE 4T
SECONDARY TRANSM. GEAR
FUEL TYPE
92/95 UNLEADED
GASOLINE
CLUTCH TYPE
CENTRIFUGAL
TYPE
CYLINDER NO. SINGLE PRIMA 1/0.77~1/2.19
BORE ∗ STORKE (mm) 52.4 ∗ 57.8
TRANSMISSION
REDUCTION RATIO
SECOND
1/8.61 (15/42×13/40)
DISPLACEMENT (c.c.) 124 HEAD LAMP (H / L)
12V 35W/35W×1
or 18W /18W×2
STARTER ELECTRIC＆KICK REAR LAMP 12V 5W×1
BRAKE LAMP 12V 21W×1
COOLING
FORCED AIR
COOLINE
LAMP
TURN LAMP 12V 10W×4
LUBRICATION PUMP＆SPLASH
INTAKE VALVE GAP (mm) 0.08~0.10
EXAUST VALVE GAP (mm) 0.08~0.10
FRONT＆REAR
120/90-10＆110/90-10
TOP SPEED (km/hr) 87 FRONT 175
IDLING SPEED (rpm) 1800 ±100
TIRE
TIRE PRESSURE
(kPa)
REAR 210
MAX. TORQUE (N-m/rpm) 7.90 / 7800 LEFT 45
MAX. POWER (kW/rpm) 6.47 /7800
STEERING ANGLE ( °)
RIGHT 45
COMPRESSION RATIO 9.2：1 FRONT DISK
BRAKE
REAR DRUM
CYLINDER PRESSURE
(㎏/cm
2
– rpm)
12.8-570
FRONT TELESCOPE
ENGINE OIL TYPE SAE 10W - 40
SUSPENSION SYSTEM
REAR ROCKER ARM
ENGINE OIL QUANTITY (c.c.) 900 FRAME STEEL TUBE
GEAR OIL TYPE SAE 90#
ENGINE
GEAR OIL QUANTITY (c.c.) 110
8
BK8 PRODUCT SPECIFICATION
MODE BK8 AIR CLEANER TYPE PAPER FILTER
TOTAL LENGTH (mm) 1880 FUEL TANK (ℓ) 6.8
TOTAL WIDTH (mm) 715 TYPE CVK
TOTAL HEIGHT (mm) 1160 THROTTLE VALVE DIA. (㎜) 24
DIMENSION
WHEEL BASE (mm) 1304 VENTURI DIA. (㎜) 22.1
FRONT 38
FUEL SYSTEM
CARBURETOR
THROTTLE VALVE TYPE BUTTERFLY
REAR 70 TYPE C.D.I.
DRY WEIGHT (kg)
TOTAL 108 SPARK ADVANCE
BTDC 13°/ 2950rpm
FRONT 64 SPARK PLUG NGK CR7HSA
REAR 119
IGNIITION
SPARK PLUG GAP (㎜) 0.6~0.7
WEIGHT
TOTAL WEIGHT (kg)
I PERSON (75kg)
TOTAL 183
ELECTRIC SYSTEM
BATTERY 12V 7AH
PRIMA TRANSM. C.V.T.
TYPE 4T
SECONDARY TRANSM. GEAR
FUEL TYPE
92/95 UNLEADED
GASOLINE
CLUTCH TYPE
CENTRIFUGAL
TYPE
CYLINDER NO. SINGLE PRIMA 1/0.90~2.40
BORE ∗ STORKE (mm) 52.4 ∗ 57.8
TRANSMISSION
REDUCTION RATIO
SECOND
1/9.45 (14/43×13/40)
DISPLACEMENT (c.c.) 124 HEAD LAMP (H / L) 12V 35W/35W×1
STARTER ELECTRIC & KICK REAR LAMP 12V 5W×1
BRAKE LAMP 12V 21W×1
COOLING
FORCED AIR
COOLING
LAMP
TURN LAMP 12V 10W×4
LUBRICATION PUMP & SPLASH 80/80-14 & 110/80-14
INTAKE VALVE GAP (mm) 0.08~0.10 or
EXAUST VALVE GAP (mm) 0.08~0.10
FRONT＆REAR
110/80-14 & 110/80-14
TOP SPEED (km/hr) 90 FRONT 175
IDLING SPEED (rpm) 1800 ±100
TIRE
TIRE PRESSURE
(kPa)
REAR 210
MAX. TORQUE (N-m/rpm) 7.90 / 7800 LEFT 45
MAX. POWER (kW/rpm) 6.47 /7800
STEERING ANGLE ( °)
RIGHT 45
COMPRESSION RATIO 9.2：1 FRONT DISK
BRAKE
REAR DRUM
CYLINDER PRESSURE
(㎏/cm
2
– rpm)
12.8-570
FRONT TELESCOPE
ENGINE OIL TYPE SAE 10W - 40
SUSPENSION SYSTEM
REAR ROCKER ARM
ENGINE OIL QUANTITY (c.c.) 900 FRAME STEEL TUBE
GEAR OIL TYPE SAE 90#
ENGINE
GEAR OIL QUANTITY (c.c.) 120
9
BK9 PRODUCT SPECIFICATION
MODE BK9 AIR CLEANER TYPE PAPER FILTER
TOTAL LENGTH (mm) 1880 FUEL TANK (ℓ) 6.8 & 3.9
TOTAL WIDTH (mm) 715 TYPE CVK
TOTAL HEIGHT (mm) 1160 THROTTLE VALVE DIA. (㎜) 26
DIMENSION
WHEEL BASE (mm) 1340 VENTURI DIA. (㎜) 23
FRONT 39
FUEL SYSTEM
CARBURETOR
THROTTLE VALVE TYPE BUTTERFLY
REAR 71 TYPE C.D.I.
DRY WEIGHT (kg)
TOTAL 110 SPARK ADVANCE BTDC 13°/ 2950rpm
FRONT 65 SPARK PLUG NGK CR7HSA
REAR 120
IGNIITION
SPARK PLUG GAP (㎜) 0.6~0.7
WEIGHT
TOTAL WEIGHT (kg)
I PERSON (75kg)
TOTAL 185
ELECTRIC SYSTEM
BATTERY 12V 7AH
PRIMA TRANSM. C.V.T.
TYPE
4T
SECONDARY TRANSM. GEAR
FUEL TYPE
92/95 UNLEADED
GASOLINE
CLUTCH TYPE
CENTRIFUGAL
TYPE
CYLINDER NO. SINGLE PRIMA 1/0.90~2.40
BORE ∗ STORKE (mm) 57.4 ∗ 58.4
TRANSMISSION
REDUCTION RATIO
SECOND
1/7.8 (15/42×14/39)
DISPLACEMENT (c.c.) 151 HEAD LAMP (H / L) 12V 35W/35W×1
STARTER ELECTRIC＆KICK REAR LAMP 12V 5W×1
BRAKE LAMP 12V 21W×1
COOLING
FORCED AIR
COOLING
LAMP
TURN LAMP 12V 10W×4
LUBRICATION PUMP＆SPLASH 80/80-14 & 110/80-14
INTAKE VALVE GAP (mm) 0.08~0.10 or
EXAUST VALVE GAP (mm) 0.08~0.10
FRONT＆REAR
110/80-14 & 110/80-14
TOP SPEED (km/hr) 97 FRONT 175
IDLING SPEED (rpm) 1800 ±100
TIRE
TIRE PRESSURE
(kPa)
REAR 210
MAX. TORQUE (N-m/rpm) 11.14 / 6500 LEFT 45
MAX. POWER (kW/rpm) 7.89 /7250
STEERING ANGLE ( °)
RIGHT 45
COMPRESSION RATIO 10.8：1 FRONT DISK
BRAKE
REAR DRUM
CYLINDER PRESSURE
(㎏/cm
2
– rpm)
11.7-700
FRONT TELESCOPE
ENGINE OIL TYPE SAE 10W - 40
SUSPENSION SYSTEM
REAR ROCKER ARM
ENGINE OIL QUANTITY (c.c.) 1000 FRAME STEEL TUBE
GEAR OIL TYPE SAE 90#
ENGINE
GEAR OIL QUANTITY (c.c.) 120
10
1-2 INSPECTION PRECAUTIONS
1. The measurements use IS system for bolts and bolt heads. Please do not
use British system for the bolts and nuts, otherwise it can damage the
motorcycle.
2. Please clean parts outside deposits before maintenance. Otherwise, the
deposits may drop into engine and damage engine in operation.
3. Please use kerosene or diesel to clean-up disassembled parts. Check
and measure parts after clean-up. The parts’ contact and sliding surface
should apply engine oil for lubrication.
4. The packing, metal gasket, O-ring, seal, clamp, and clipper should be
replaced with new ones after disassembly.
5. Please pay attention to the orientation and relative positions of the major
components. Arrange the parts in order during disassembly. Make
marks if necessary to avoid mistakes in re-assembly.
6. Loosing the parts should start from small to big, from outside to inside, and
in alternative parts. Assembly is in reverse order of disassembly
procedures.
7. The oil seals should be replaced with new ones after disassembly. The
contact surface should be cleaned-up. Check if the contact axle has
scratches or burry. Use special tools for assembly to avoid damaging
seal lip area, which may lead to oil leak. The manufacturer logo should
face outward in assembly. Apply grease at seal lip area.
8. Please do not presses, twist, and over scratch the wire cable to avoid bad
wire contact.
9. Disconnect the battery negative (-) terminal before maintenance.
Connect the positive (+) terminal first in assembly. Apply a thin layer of
grease on terminals, and cover with terminal caps.
11
1-3 SAFETY PRECAUTIONS
Warning: Engine Exhaust
Please keep good ventilation during engine operation. Do not operate engine in
closed-room. The toxic carbon-oxygen (CO) in exhaust may lead human to loss
conscious and even death.
Warning: Gasoline
The gasoline is very easy to burn or explode. Forbid any fire during inspection of
gasoline tank or gasoline leak.
Warning: Battery H
2
and Battery Liquid
1. The battery liquid is toxic sodium liquid. Please do not contact the liquid with
skin or eye. If any contact happens, please wash with massive clean water
and contact with doctor.
2. The released H
2
from battery is explosive. Please keep good ventilation
during charging battery and forbid any fire.
Watch: Brake Fluid
The brake fluid can damage the painting on plastic. Please cover the plastic parts
with towel or cloth during maintenance of brake disk. If the brake fluid is split on
plastic component, please remove the fluid and wash the surface with water right
away.
Watch: High Temperature of Engine
The engine cover, cylinder, and exhaust pipe have high temperature after starting
of engine. Please wear glove in maintenance of parts during engine operation, or
maintenance should be waited until engine is cooled.
12
1-4 SPECIAL TOOLS
Universal Wrench 440601
Hold for removing flywheel.
Hold for removing belt driver pulley.
Hold for removing belt driven pulley.
Four Legs Sleeve 440604
Used for removing starter clutch
gear lock nut.
Flywheel Remover 440602
Used for removing flywheel.
Starter Spring Assembly Tool
440605
Used for starter spring assembly.
Gear Remover 440603
Used for removing starter driven
gear.
Crank Shaft & Right Hand Crank
Case 440606
To draw the crank shaft into the
right hand crank case.
13
Inner Chain Wrench 440607
For disassembly the camshaft inner
chain.
Bush Remover 440610
For removing the crankcase
suspension bush.
Socket of Valve Adjusting Bolt
440608
Adjust the clearance of valve stem
and rock arm.
Fixing Nut Socket 440611
Used for removing steering shaft
nut.
Valve Cotter Tool 440609
For assembling valve cotter
14
1-5 TIGHTENING TORQUE
＊BR8 Representative Figure＊
*Standard Torque Values of Bolts and Nuts *
Specification
T orque (kg-cm) Specification Torque (kg-cm)
5 mm Bolt and Nut 40 8 mm Bolt and Nut 220
5 mm Flange Bolt and Nut 50 8 mm Flange Bolt and Nut 270
6 mm Bolt and Nut 100 10 mm Bolt and Nut 350
6 mm Flange Bolt and Nut 120 10 mm Flange Bolt and Nut 400
6 mm SH Bolt and Nut 90 12 mm Bolt and Nut 550
* Torque Values of Chassis Components *
No. Tightening Location Specification Torque
(kg-cm)
1 Front Wheel Axle Self-lock Nut M12 500~600
2 Brake Disk Hex Bolt M5 180~280
3 Brake Clipper Tightening Bolt M8x35 210~250
4 Speed Meter Cable Nut X 60
5 Front Fork Bearing Tightening Nut M25x1.0 600~650
6 Rear Wheel Axle Self-lock Nut M16x10 600~900
7 Rear Brake Connecting Rod Bolt M16x32 50~80
8 Rear Brake Pin Self-lock Nut M8 250~270
9 Rear Upper Cushion Tightening Bolt M10×46 200~300
10 Rear Lower Cushion Tightening Bolt M8×35 200~300
15
* Torque Values of Engine components *
Tightening Location Specification Torque Quantities
(kg-cm)
Cylinder Head Bolt M6 80~100 4
Cylinder Stud Bolt M8x182.5 500~800 2
M8x195.5 2
Cylinder Intake Pipe Stud Bolt M6x50 500~800 2
Muffler and Exhaust Pipe Tightening Screw M6 100~120 2
Muffler & Right Crankcase Upper Tightening Screw M8x42 300~400 1
Muffler & Right Crankcase Lower Tightening Screw M8x38 300~400 1
Spark Plug M10 100~120 1
Valve Gap Adjust Lock Bolt M5 50~90 2
Fuel Filter Nut Cap M30 150~200 1
Cooler Fan Lock CR M6x18 500~800 4
Wire Assembly Lock Screw M6x20 800~1000 2
Start Clutch Gear ightening Nut M22 (R.T.) 800~1000 1
Driven Belt Pully Assembly M12 400~600 1
Gearbox Cover Tightening Bolt M6x28 100~1200 3
M6x35 3
Gearbox Oil Fill Cover Screw M8 90~150 1
Gearbox Oil Drain Cover Screw M8x12 90~150 1
Clutch Side Cover Screw M6x40 50~80 6
M6x65 2
Starter Arm Tightening Screw M6x22 100~120 1
16
1-6 LUBRICATION POINTS
*BR8 Representative Figure*
* Chassis *
Lubrication Area Lubrication Type
Inner Side of Acceleration Lever Grease
Steering Bearing
Speed Meter Gear
Front Wheel Axle Bearing
Front Wheel Axle
Main and Side Stand Axles
Rear Wheel Bearing
Seat Cover Lock
Speed Meter Cable
Throttle Wire
Rear Brake Cable
Brake Assembly Brake Fluid
17
* Engine *
Lubrication Area Lubrication Type
Piston and Piston Rings
Piston Pin
Big End of Connecting Rod
Rocker Arm Frictional Contact Area
Cam Shaft and Chain
Cylinder Frictional Area
Oil Pump Chain
Gears Contact Surface
Bearing Operation Area
O Rings
Seal Lip Area
Satisfy SAE 10W-40 and API SE,SG Engine Oil
Starter Frictional Surface
Starting Cam Gear
Spring Operation Frictional Area
High Temperature Durable Grease
Generator Connector
Gearbox Ventilation Tube
Adhesives
18
1-7 PARTS NAME AND WIRING DIAGRAM
* Parts Name *
*BR8 Representative Figure*
19
1-8 TROUBLE SHOOTING
1-8-1 Troubleshooting for failure in starting the engine
b
a c
Does not work
Works
Check if the battery is
properly charged
Check if the starting gear and the
speeding clutch of the starting
motor suffer critical wear, if yes,
replace them
Bright light
Dim light or
light off
Check the
solenoid switch
of the starting
motor for noise
during work
Charge the battery or
replace it. In case of poor
charging, in addition to
recharging, check the
charging system of the
p
ower plant for failure.
No noise
Noise
a. Poor
contact of
starting
switch
b. Starting
relay
breaks or
in short
circuit
c. Loose
contact or
wiring
Check the starting
gear and speeding
gear of the starting
motor for abnormal
engagement.
Poor
Fai
r
Correct the
engagement
of the
starting
motor with
the speeding
clutch.
Replacement
of new
starting motor
and check for
work.
Engine does not start
Analysis of potential causes
Check if the crank shaft works
Does not work
works
Check if the starting motor works
Poor (too slow
)
Fai
r
Check battery charging
and contact of pins
Loosen the carburetor
leakage screw to check
for inlet of fuel.
Fai
r
Poo
r
Check for existence
of water or other
impurities in the
carburetor buoyant
Check
for fuel
in the
fuel tank
Fai
r
Poo
r
Check for fuel
spill in the
carburetor
Clean the
carburetor
and the
fuel filter
Poor
Fair
Repair or
replace
new
buoyant
and needle
valve
Check skips
in spark
No
skip
Ski
p
Refer to
1-8-3 No Skip
in Spark
Plugs for
checking
Poor
Fai
r
Recharge the battery
and be sure the pin is
properly secured.(In
case of poor
charging, proceed
with a new charging
and check the
charging system of
the power plant for
failure.
)
Check the
starting motor
and the switch
Poo
r
Fair
Repair
or
replace
with
new
ones
Check
the
engine
inside
(piston,
bearing
and
others)
for
failure
With
fuel
No fuel
Check the fuel
filter and the
tubing
Add in
designated
fuel
Poo
r
Fair
Clean fuel
filter and fuel
tubing or
replacement
Check fuel tank
ventilation
tubing for
obstruction
See page 17
20
a
c
b
Poor
Fair
Check engine
pistons,
bearings and
others
Replace the
original
starting motor
or repair it.
Check spark plug for cleanliness,
normal gap, pollution by gasoline. If
yes, check the choke of the
carburetor
Fai
r
Poo
r
Clean and adjust
spark plug gap or
replace with new
ones
Poo
r
Fai
r
Refer to
1-8-2 Poor
skip in
Spark
Plugs for
checking
Check if the
adjustment
screws of the
carburetor need to
be regulated
Poo
r
Fai
r
Test the
compression
Clean or replace the slow
nozzle or correct, replace
with new threshold
Check choke of
the carburetor
for troubles
Readjustment
Poo
r
Fai
r
Adjust or
replace new
choke parts
Check if the slop
nozzle of the
carburetor is
obstructed or the
threshold fails
Poo
r
Fair
Check air filter grill
for obstruction
Check cylinder washer for leakage,
check cylinder, piston, piston ring
for wear, with correction,
adjustment or replacement
Poor
skip
Fair
skip
Poo
r
Fair
Clean
ventilation
tubing
Adjustment or
replacement of
carburetor buoyant
needle valve
21
z No fuel
z Dirty fuel filter
z Obstructed fuel tubing
z Obstructed ventilation tubing of the fuel tank
z Poor carburetor buoyant needle valve
z Carburetor buoyant with impurities
z Poor carburetor buoyant
z No skip in spark plugs
z Poor skip in spark plugs
z Dirty spark plugs
z Incorrect spark plugs gap
z Dirty and wet spark plugs
z Loose adjustment screws in the carburetor
z Carburetor choke
z Obstructed carburetor slow nozzle
z Ailing carburetor threshold
z Obstructed air filter grill
z Leakage in cylinder washer
z Seriously damaged cylinder, piston, piston
z Dead battery
z Poor contact of battery pin and conductors
z Starting switch with poor or failure
z Starting relay with broken wire or short circuit
z Loose contact and wiring
z Starting gear and speeding clutch gear seriously worn
z Starting gear and speeding clutch gear in poor engagement
z Poor starting motor
22
1-8-2 Troubleshooting for poor skip of spark plugs
Poor skip of spark plugs
Analysis of potential causes
Check for spark plug cap, ignition coil
Normal
Loose
Replacement of new spark plug and
try skip again
Load in the spark plug
cap
Poor skip
z Loosen spark plugs
z Poor spark plugs
z Poor high-voltage wiring
z Poor distributor coils
z Poor PICK Ups
z Poor main switches
z Wiring relay
Poor or abnormal
C.D.I. or plugs,
replacement of
C.D.I. and mount
properly the plug
Check high-voltage
coils, main switches,
PICK UP, distributor
coil for normality
High sparks
Check for loose C.D.I.
plugs, terminal
conduction and
resistance values
Replacement of poor
spark plug
Abnormal
Normal
Poor high-voltage
coils, main
switches, PICK
Ups, distributor
coils
Abnormal
Normal
Check for
correct main
wiring contacts
and terminals, if
necessary,
correct them
23
1-8-3 Troubleshooting for no-skip of spark plugs
No skip of spark plugs
Analysis of potential causes
Check for proper loading of the spark plug cap
Fair
Poor
Replacement spark plug and test the
intensit
y
of the spark plugs
Load properly the spark
plug cap
Intense sparks
z Loose spark plug cap
z Poor spark plug
z Loose C.D. adapter
z Poor C.D.I.
z Poor PICK UP
z Poor distributor
high-voltage wiring
z Poor main switch
z Main wiring broken or in
short circuit
z Ignition coil broken or in
short circuit
z Poor adapter contact
Load properly the
C.D.I. adapter
Check C.D.I. terminals
passage and testing of
resistance
Weak sparks
Replacement of
p
oor spark plugs
Check for loose C.D.I.
contacts
Loose
Normal
a. Poor PICK UP
b. Poor main switch
c. Poor contact of
adapter
d. Broken main wiring
of short circuit
Abnormal
Normal
Use C.D.I. tester
for checks of
C.D.I.
Replacement of the poor
C.D.I.
Abnormal
Normal
Check ignition coil for
breaking or short
circuit, replace when
necessary
24
1-8-4 Troubleshooting for slow run (troubled engine)
Poor slow run
Analysis of potential causes
Check for contamination in spark plugs and excessive gap
Fair
Poor
Alarming abnormality of ignition timing
Cleaning and
adjustment
Poor
z Dirty spark plugs
z Incorrect spark plug
gaps
z Incorrect ignition
timing
z Obstructed air filter
grill
z Poor carburetor
buoyant needle valve
z Poor carburetor choke
valve
z Poor engagement of
carburetor and inlet
tube
z Obstructed carburetor
slow injection
z Poor engagement of
cylinder head washer
z Severe wear of
cylinder, piston, piston
ring
Replacement of
the filter grill
Is the carburetor buoyant
level normal ?
Fair
adjustment
Is the air filter grill
obstructed?
Poor
Fair
Adjustment or
replacement of the
buoyant needle valve
Fair
Poor
Check if the choke
valve fails (valve
does not open) ?
Check of for air between the
carburetor and the air inlet
Fair
Poor
Correction
Check for obstruction in the
carburetor slow injection
Fair
Poor
Add tightening force or
replacement of the washer
Fair
Poor
Cleaning T est the compression
Check for air leakage in the cylinder washer,
check wear of cylinder, piston, piston ring
and other elements with correction,
ad
j
ustment or replacement
25
1-8-5 Poor acceleration and horse power
a
Poor acceleration and horse power
Breakdown of potential causes
Check for drag of braking drum by braking plate
Fair
Poor
Check for obstructed air filter
Adjust or replace
braking plate
z Braking plate retaining braking
drum
z Air filter grill obstructed
z Dirty spark plugs
z Incorrect gap in spark plugs
z Incorrect ignition timing
z Poor skip in spark plugs
z Incorrect adjustment of
carburetor adjustment screw
z Poor choke valve in carburetor
z Dirty or obstructed carburetor
injection nozzle
z Poor carburetor buoyant needle
valve
z Dirty fuel filter
z Obstructed fuel circuitry
z Poor engagement of cylinder
washer
z Serious damage of cylinder,
piston, piston ring
Cleaning,
adjustment of
replacement of
new spark plugs
Check for
normal ignition
timing
Check for burn of spark
plugs and the gap
Replacement of the
filter grill
Intense
sparks
Poor skip
Check for normal
choke valve action
Adjustment
Check carburetor for
proper adjustment
Fair
Poor
Fair
Poor
Test of spark plugs,
sparks
Timing
Fair
Poor
See 1-8-2 poor
skip of spark
plug for
checking
methods
Fair
Poor
Check for
obstructed
injection nozzle
Correction or
replacement
Fair
Poor
26
a
Check for leakage in
cylinder washer; check
cylinder, piston, piston
ring for wear. Correct,
adjustment or
replacement when
necessary
Check for normal
fluid level in the
buoyant
Cleaning or
replacement
Fair
Poor
Check the
compression
Check of needle
valve and buoyant
Fair
Poor (low level)
Check fuel pipe
and carburetor for
obstruction
Adjustment or
replacement
Fair
Poor
Cleaning or
replacement
27
2. INSPECTION AND ADJUSTMENT
2-1 REGULAR MAINTENANCE SCHEDULE
Explanation:
(1) Please follow the regular maintenance schedule to ensure
the motorcycle’s function and life.
(2) I : Inspection (including clean up, lubrication, refill, or replace parts),
C: Clean, R: Replace, A: Adjust.
km or time
300 km 1000 km 2000 km 3000 km 4000 km 5000 km 6000 km 7000 km 8000 km 9000 km 10000 11000 12000
Maintenance Item
(1 mo.) (3 mo.) (6 mo.) (9 mo.) (12 mo.) (15 mo.) (18 mo.) (21 mo.) (24 mo.) (27 mo.) (30 mo.) (33 mo.) (36 mo.)
Engine Oil
R R R R R R R R R R R R R
Oil Strainer Screen
C C C
Gear Oil
R R R
Brake
I I I I I I I I I I I I I
Tire s
I I I
Air Cleaner
I R R
Battery
I I I
Spark Plug
C C C C
Fuel Filter
R R
Carburetor
I I C
Val ve
A A A A
V Belt
I
Bolts and Nuts
T
Note: (1) If ridden on dusty roads or raining days, please shorten the inspection and
replacement schedule for air filter.
(2) If ridden under heavy load, frequent long distance travel, please shorten the
replacement schedule for engine oil.
(3) Please clean the spark plug regularly, and replace the spark plug if necessary.
* Regularly Maintenance and Performance Relationship*
Performance100%
Ridden Time (or Mileage)
Curve A: With regular maintenance, the performance can be improved to optimal condition with
maintenance at scheduled time.
Curve B: Without regular maintenance, the performance drops and engine can be damaged.
Therefore, the engine needs repair to re-gain high performance, and the motorcycle’s
life can be shorten.
28
2-2 INSPECTION AND
CHANGE OF ENGINE OIL
Watch: Please place main stand to park the
motorcycle for inspection.
Inspection: Stop engine for 2~3 minutes when
it is warmed. Remove the engine oil level and
check if the oil level is bellow the lower limit.
Fill engine oil to the level between upper and
lower limits.
* Change Engine Oil *
Note: Please change engine oil according to
regular maintenance schedule. If ridden
on heavy load or long distance, please
shorten the maintenance schedule for oil
change.
● Please put oil tray under the left crankcase
and remove the oil drain plug. Re-install the
drain plug when the engine oil is drained.
* Clean up the oil filter *
Inspection:
(1) If O-ring is damaged, please replace with
new one.
(2) If there is any deposit, please use clean up
before re-assembly.
Note:
(1) Torque of oil strainer screen:
150 ~ 200 kg-cm.
(2) Lubrication Type: SAE 10W-40
Engine oil capacity
* BH8 / BR8 / BF8 *
125c.c. Engine disassembled : 900c.c.
change oil : 750 c.c.
* BR9 / BF9 *
151c.c. Engine disassembled : 1000c.c.
change oil : 900 c.c.
(3) Check if there is any leakage after oil
change. Warn the engine and check the
engine oil level again.
29
2-3 FINAL GEAR OIL
Watch: Please place main stand to park the
motorcycle for inspection. Clean grease
around the drain plug.
Disassembly:
Oil refill plug.◎
Oil drain plug.◎
Note: Put an used oil tray under the gearbox
before removing the drain bolt plug.
Inspection: Check if the oil drain plug washer
is damaged. Please replace with new one if it
is damaged.
Drain gear oil. ◎
Assembly:
■ Assembly drain plug.
■ Refill gearbox oil.
■ Reinstall oil refill plug.
Note:
(1) Torque on drain plug: 90 ~ 150 kg-cm.
(2) Oil type: SAE 90 #
(3) Oil capacity
* BH8 *
Gearbox disassembled : 110 c.c.
Regular Maintenance : 90 c.c.
* BR8 / BF8 / BR9 / BF9 *
Gearbox disassembled : 120 c.c.
Regular Maintenance : 100 c.c.
(4) Please check if there is any leaking after
oil refill.
30
2-4 BRAKE SYSTEM
A. Front Brake Lever Free Play
Note: Front brake lever free play is 10~20 mm.
Adjustment: This motorcycle uses “non-adjust
style”.
B. Brake Fluid
Inspection: The front brake fluid level should
above “MIN”. If it is below, refill the brake fluid
and check leakage of the brake system.
Warning: If there is low or no load when the
brake lever is hold, please check if there is air in
the brake system or fluid leakage.
C. Refill Brake Fluid
Watch: Please place main stand to park the motorcycle for inspection.
Disassembly:
2 tightening bolts on fuel cover. ◎
Fuel trap. ◎
Diaphragm.◎
Refill brake fluid to level between MIN and MAX.
Assembly: Assembly is in reverse order of disassembly procedures.
Warning:
(1) Please refill the same type of brake fluid. Different fluid type may create toxic chemical
ingredient and can damage the brake.
(2) Please do not let water into the master cylinder. Otherwise, the broil temperature may be
reduced and bubble can occur, then brake may not work.
(3) If the brake fluid is splashed on plastic parts or paints. Please wipe it out right away,
otherwise it may affect engine firing.
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