Haoiue HJ125-7
Haojue HJ125-7
PAE
EA ATA
AAC ENEE
JIANGMEN DACHANGJIANG GROUP CO., LTD.
HJ125-7
OWNER'S MANUAL
This manual should be considered a permanent part of the motorcycle
and should remain with the motorcycle when resold or otherwise
transferred to a new owner or operator. The manual contains
important safety information and instructions which should be read
carefully before operating the motorcycle.
ENGLISH
PRECAUTIONS
GUIDELINES TO FOLLOW DURING THE BREAK-IN (RUN IN) PERIOD:
The first 500 kilometers mileage, known as the break-in period, is of great importance for the future performance and condition of your
motorcycle. Following the guidelines during this period will help ensure optimal performance and a longer life for your motorcycle. The parts
of this motorcycle are made of superior material and manufactured with high precision. The break-in period will smooth the friction of moving
parts ensuring better performance. The future reliability and performance of the motorcycle depends on usage restraint and special care during
the break-in period. Itis particularly important not to ride in a way that would cause the engine parts to overheat.
Please refer to Break-in (run in) for new motorcycles section for detailed break-in guidelines.
FOREWORD
Thank you for purchasing this motorcycle. We have designed,
manufactured and tested this motorcycle using the most advanced
technology in order to bring you an enjoyable, interesting and safe
riding experience. After you get familiar with the information
contained in this OWNER'S MANUAL, you will feel that riding a
motorbike is not only an exciting sport, but also an enjoyable and fun
experience. This MANUAL outlines instructions for the proper
maintenance and service of the motorcycle. Your motorcycle can
provide optimal performance and trouble-free operation by simply
following the instructions contained in this MANUAL. Your dealer,
with its experienced and professionally trained personnel, as well as
its complete set of tools and equipments, is your best choice when it
comes to servicing your motorcycle.
All illustrations, images and specifications presented in this
MANUAL are compiled according to the latest product information at
the time of its publication. However, due to continuing improvements
and other changes, the motorcycle's specifications might slightly
differ from those described in this manual. Please consult your dealer
for guidance if necessary.
The Q/DJO1.0Haojue Series Motorbike Standardapplies to this
motorcycle.
WARNING / CAUTION / NOTE
Please read this manual and strictly follow the instructions described
herein. To emphasize important issues, the words ceWarning, Caution
and Note are used in this manual. Please pay special attention to those
definitions.
WARNING. === enn. May involve the personal safety of the rider,
neglecting this information might lead to
harm and injury.
CAULIOÓON 2==== ==. Highlights special precautions or procedures
that must be followed in order to avoid
damaging the motorcycle.
U eek Special explanations for easier maintenance
or further clarification of important
instructions.
CONTENTS
Note to the rider ------------------------------------- >
Recommendations fôr safe riding---—-=-====————— >
Location of parts-——————<—""<"""rasenesenanamassssses 3
Controls -------------------------------------------- 5
Fuel and engine oil insructions--------------------------- 10
Running in of à new motorcycle --—-—-—-—--—--—-------==—"--=== 10
Inspection before riding ----——-=—=—=—-<—————esecines 10
Riding Tips----------------------------------------- 11
Inspection and maintenance-------=------ en 13
Troubleshooting -------------------------------------- 22
Notice on battey usage--------------------------------- 23
Maintenance and Servicing of the Muffler ------------------ 24
Economic fuel consumption----------------------------- 24
Table of specifications --------------------------------- 25
Circuit diagram-------------------------------------- 26
NOTE TO THE RIDER
There is a great variety of accessories available in the marketplace
that you can install onto your motorcycle, but their quality and
compatibility are beyond our direct control. Incompatible accessories
might be dangerous to the rider safety. Although we cannot check each
of those accessories, your dealer can help you select quality
accessories and install them correctly.
To assist you in the selection and installation of accessories, we
have formulated a set of guidelines for your reference and knowledge
about the installation method:
(1)Accessories that bring extra weight or are subject to the wind
must be mounted at the lowest position as possible and as close to the
motorcycle and its center of gravity as feasible. Cargo racks and
attached parts must be checked carefully to ensure secure installation.
Insecure installation will lead to instability of the motorcycle to incur
danger. The most important rule to observe for the installation of
accessories is to pay attention to the weight balance as well as
fastening stability.
(2)Inspect for proper ground clearance and bank angles of
accessories. Inappropriate installation could critically reduce these
two safety factors. Make sure that the accessories do not interfere with
the operation of suspension, steering and other controls.
(3)Accessories that are to be installed on the handlebars or the front
fork may create stability problems. This extra weight will affect the
steering flexibility which may result in front wheel shock and unstable
riding. Accessories to be installed on the handlebars or the front fork
should be kept to the lowest weight possible.
(4) Accessories such as windshields, back rests, saddle sacks,
suitcases, etc are all subject to the wind which may affect the stability
of your motorcycle while riding, particularly in cross-winds or when
being passed by larger vehicles. Improperly mounted or badly
designed accessories may threaten riding safety. Therefore special
attention should be paid to the selection and installation of accessories.
(5) Some accessories may displace the rider from his normal
position, restricting the rider freedom of movement. This may affect
his/her control ability.
(6) Additional electric accessories will overload the original
electric system. Serious overload might damage wiring, or lead to a
loss of electric power during operation, compromising the safety of
the rider.
RECOMMENDATIONS FOR SAFE RIDING
Motorcycle riding is a fun activity as well as an exciting sport. But
italso requires some precautions to ensure the safety of the rider:
-WEAR A HELMET-
Wearing a quality helmet is the most important precaution to ensure
your safety. The most serious injuries are those that involve head
injury. Make sure that you wear a helmet while riding. It is also
recommended to wear eye protection.
—RIDINGAPPAREL-
Loose, fancy clothing might be uncomfortable and unsafe when
riding your motorcycle. Choose fit, high quality apparel when riding.
“INSPECTION BEFORE RIDING-
Read the explanations in the INSPECTION BEFORE RIDING
section of this MANUAL carefully. Always remember to perform a
full safety inspection in order to safeguard the safety of both the rider
and the passenger.
—FAMILIARIZE YOURSELF WITH YOUR MOTORCYCLE-
Your riding skills and mechanical knowledge constitute the basis
for safe riding. You can first practice at an open place with little traffic
until you are thoroughly familiar with the performance and operation
methods ofthe motorcycle. Remember: Practice improves your skills!
"KNOW YOUR LIMITS-
You should always ride within the boundaries of your own skills.
Accidents can be avoided by staying within your limits.
—-BE EXTRA CAUTIOUS ON RAINY DAYS -
Riding on rainy days requires extra caution. Bear in mind that
braking distance will double on wet surfaces. When riding, avoid
painted road surfaces, covered holes and greasy surfaces in order to
prevent skidding. Be particularly cautious on railway crossings, metal
gratings and bridges. You should be particularly cautious, and reduce
speed if you cannot clearly determine the road conditions.
MOTORCYCLE MODIFICATIONS
Modifying the motorcycle at will compromise your riding safety
and is illegal. Your must abide by the traffic rules promulgated by
traffic control authorities.
POSITION OF SERIALNUMBER
The vehicle identification number (VIN) and the engine number
are used for the registration of motorcycles. When ordering
accessories or requesting special services, this number can help ensure
that a better service will be provided by your dealer.
Vehicle identification number (VIN) is engraved on the frame's
steering column. Vehicle frame name plate is riveted on the steering
column. The engine number is engraved on the left side of the crank
case.
Please write the numbers down in the boxes provided below for
future reference:
D Vehicle identification —— (у IN)
2) Frame nameplate 3) Engine number
| Vehicle identification number (VIN):
|
| Engine number:
LOCATION OF PARTS
TT
(1) Clutch lever
(2) Left handlebar switches
(3) Speedometer
(4) Ignition switch / steering lock
YO
©
—
©
Tachometer
3) Right handlebar switches
) Throttle grip
Front brake lever
(9) Fuel valve
(10) Gearshift lever
(1) Side stand
(12) Toolbox
(13) Main Stand
(14) Rear brake pedal
(15 Engine oil level check window
CONTROLS
KEY
This motorcycle comes with two
identical keys. The spare key should be
kept in a safe place.
IGNITION SWITCH
The ignition switch has three positions:
"OFF" position
In this position all circuits are
disconnected. The key can be removed.
"ON" position
In this position, the ignition circuit is connected and the engine is
ready for ignition. At this position the key cannot be removed.
"LOCK" (handlebar locked) position
To lock the steering, turn the handlebar to the left end, insert the key
and turn it to the "LOCK" position. Remove the key, the steering is
then locked.
WARNING:
® Do not move the motorcycle while the steering mechanism is
locked, otherwise it may become unbalanced.
INSTRUMENT PANEL
Odometer (1)
The odometer displays thetotal
mileage of this motorcycle from
its beginning of operation.
Speedometer (2)
The speedometer indicates the riding
speed in kms per hour.
Turn Signal Indicator (3)
When the turn signal switch is ales to left or right, the esa turn
indicator will flash accordingly.
On
CAUTION:
If the turn indicator fails to light up due to a broken bulb or wire
mismatch, the turn indicator on the panel will light up continuously
or blink at higher frequency.
Gear position indicator (4)
The indicator on the panel indicates the current gear position the
motorcycle is in. There are gear 1, 2, 3, 4 and 5. When shifting gears
these indicators will flash on in turn, while all number indictors will
turn off and the neutral indicator (green) will flash on when shifting to
neutral position.
Tachometer (5)
Tachometer displays the revolving speed of the engine, indicating
its rotation times per minute.
Trip meter (6)
It 1s mainly used to calculate distance of a short-ride, or for oil
consumption calculation.
Reset know (7)
To reset the distance on the trip meter, just turn the know ©
counterclockwise.
High beam indicator light (8)
The high beam indicator light will be lit when the headlight high
beam is turned on.
Neutral gear indicator light (9)
When the transmission is at neutral position, this indicator will be
lit. If another gear is engaged, this indicator will be off. FUEL FUEL
Fuel gauge (1)
When the hand points in the red area "E", it indicates that fuel in the
fuel tank is running out, the rider should refuel at the nearest gas
station. When the hand points to "F", it indicates that the fuel tank is
full.
LEFT HANDLEBAR ASSEMBLY
Dimmer switch D
High/low beam operation
When the dimmer switch is put on the
"DD" position, the high beam headlight
will light up, and the high beam light
indicator on the instrument panel will be
lit. When the switch is put on the "20"
position, the lower beam headlight will
light up, the high beam light and the high
beam light indicator will be off.
Turning signal switch 2)
Moving the switch to the "&" position will flash the left turn signals
and the left turn indicator on the instrument panel will also be lit.
Moving the switch to the "=>" position will flash the right turn signals
and the right turn indicator on the instrument panel also be lit. To
switch off the turn light, simply push the switch backwards and release
WARNING:
® When changing lanes, make sure you develop the habit of
giving turn signals beforehand, and turn off the turn lights upon
completion of a lane change or turn.
Horn button ©)
The horn will sound when pressing this button.
Clutch lever 4)
When starting up engine or shifting gears, grasp this handle to cut
o
power transmission. Grasping the clutch lever can separate friction
sheets of the clutch.
Passing switch ©)
The high beam light will be turned on when the button is pressed
and restored to its previous state when the button is released. Pressing
this button when overtaking will enhance safety.
Choke lever ©)
This motorcycle features a choke system for a convenient engine
startup. To start a cold engine, move the choke lever to position "(A)".
When the engine is started, return the choke lever half-way to position
"(В)" to preheat the engine to a satisfactory temperature level. Then,
move the lever back to its original position " ©)".
It is not necessary to use this
method to start the engine when the
engine is hot.
RIGHT HANDLE CONTROL SYSTEM
Front braking handle (1)
The engine can only be started
when the switch is placed at the " ( 2"
position which connects the
circuit. When the switch is at the " 53"
position, the ignition circuit is
disconnected. This is an emergency
stop switch.
Front braking handle 2)
When applying brakes on the front wheel, it is necessary to grasp
the front brake handle, because the motorcycle uses hydraulic disk
brakes, therefore there is no need to use excessive grasping force when
decelerating.
When grasping front braking handle, the brake light will light on
automatically.
Light switch 3)
"Y" position: Front light, instrument panel lights, front and rear
position lights, are all turned on.
" ро
200€ " position: Instrument panel lights, front and rear position lights,
are all turned on.
" ® "position: All the above mentioned lights are turned off.
Electric startup button 4)
Pressing this button enables the connection of the startup circuit.
Before startup, the gear must be placed at neutral position. Ensure that
the engine power-off switch is at the " (2 " position, and grasp the
clutch lever to cut off power to ensure safety.
WARNING:
® Do not start the engine for more than 5 seconds at a time in case
ofrepeated electric ignition, as too much discharge will lead to
excessive heating of the circuit and startup motor. If several
repeated startup attempts fail to start up the engine, the fuel
supply and ignition systems should be checked.(Please refer to
the "Troubleshooting" section)
Throttle grip ©)
The throttle grip is used to control the engine revolving speed.
Turning it towards the rider will increase the speed, and turning it
away from the rider will decrease the speed.
FUEL TANK CAP
When opening the cap, insert the key, turn it clockwise. While the
key is in, lift up and remove the fuel tank cap. When closing the cap,
(DOI level
Tank filling hole
place the arrow mark towards the front, push firmly the cap towards
the tank with the key inserted, until you hear a “click”. The key can
then be pulled out.
WARNING:
® Do not refuel excessively to prevent the oil from spilling out
onto the heated engine; the oil level should be no higher than
the oil level shown in the above figure, otherwise the fuel will
expand and overflow after heating.
® When refueling, the engine must be turned off, and the key
must be turned to the "off" position. Never refuel close from a
smoke or fire source.
NOTE:
When washing the motorcycle, do not use high pressure water to
rinse the fuel tank cover in order to prevent water from entering the oil
tank.
FUEL SWITCH
This motorcycle is not equipped with a manual fuel switch. It
provides three positions:
"U" Open position
Under normal circumstances, the switch is at this position, when
the oil level in the carburetor decreases, fuel will be supplied to the
carburetor through this valve.
Li oy Di
"7" Position
" Y "Reserve position
If the oil level in the oil tank is too low, turn the handle to this
position to enable continual usage of 2.0 liter reserve oil.
" @" Close position
If the motorcycle is to remain inactive for a relatively long period of
time, the switch should be moved to this position.
CAUTION:
The carburetor might overfill or fuel might even flow into the
engine if the fuel switch is often kept at "7 " position after the
motorcycle 1s stopped. The engine may suffer serious damage if
started under such circumstances.
EN NOTE:
When moving the switch to the "Y" please go to the nearest fuel
station to add fuel, Then move the switch back to the "U" position.
GEAR SHIFT ROD
Front tread
7 r @ — © с Rear tread
! ©
“a 5”. 2
This motorcycle is equipped with 5-shift transmission. Its
operation is shown in above figure. The gear shift rod is connected to
the ratchet mechanism in the transmission box. When a shift position
is selected, the shift rod will return to the original position to enable the
next shift selection.
CAUTION:
When the gear is in neutral position, and the gear shifting
indicator is on, it is advised to loosen up the clutch lever slowly in
order to ensure neutral gear is in place.
When shifting from lower to higher gear, you must first let the
motorcycle accelerate, then depress the front rod of the shifting lever
and reduce the engine speed slightly before the automatic return of the
shift lever.
Shifting according to the above instructions will reduce gear
impact in the transmission system as well as unnecessary wear of the
rear tires.
REAR SHOCK ABSORBER(REAR DAMPER)
Spring Adjustment
The shock-absorber of the rear wheel
can be adjusted according to the rider’s
preferences, loading condition, riding
manner and road condition. Five
positions are available for adjustment.
First stabilize the motorcycle with main
parking stand or side parking stand,
then turn the adjustor on the damper to
the desired position. The first position is
the softest, whereas the fifth has the
highest rigidity. Motorcycles of this
model are all initially set to the second
position in the factory.
WARNING:
® The damping springs on both sides of the motorcycle must be
adjusted to the same position. Improper adjustment will affect
operational stability.
REAR BRAKE PEDAL
Apply the rear brake by stepping
down on the rear brake pedal. The
brake light will be turned on when the
rear brake is operated.
HELMET LOCK
Insert the key and promptly turn it
to open the hook clip, then hook the
clip ring with the hook clip, rotate the
key counterclockwise and draw out
the key.
WARNING:
O Never ride with the helmet locked up; otherwise the helmet
might be trapped by the rear wheel and may endanger your
safety.
KICK START LEVER
A kick starter lever is installed on
the right side of the engine. The kick
start mechanism allows the rider to
start the motorcycle at neutral shift or E
any shift position when the clutch is
detached.
WARNING:
® Ensure that the start lever is returned to its original position
after starting the engine.
TOOL BOX
The tool box is located under the
seat cushion and can be reached by
opening the cushion.
PARKING STAND
(1) Main stand
2) Side stand
(3) Rear cargo rack
@) Lifting lever
This motorcycle is equipped
with a main stand and a side stand.
MAIN STAND
To support the motorcycle using the main stand, first tread on the
rod of the main stand, hold the steering handlebar with the left hand,
grasp the handle on the rear rack with the right hand and lift the
motorcycle upward with force.
SIDE STAND
Side stand is for temporary parking. To support the motorcycle, just
revolve it to the lower position.
WARNING:
® The loaded weight of the rear rack must not exceed 5 kgs
otherwise the motorcycle may become unbalanced when
riding, resulting in dangerous riding as well as causing frame
damage.
® Carefully check the position of the side stand before riding by
ensuring that if it is in its upper position and does not show
symptoms such as being loose, shaking, etc.
FUEL AND ENGINE OIL INSTRUCTIONS
FUEL
Use unleaded gasoline with a rating of 90-97.
NOTE:
Unleaded gasoline helps extend the service life of the spark plug.
ENGINE OIL
Using quality four-stroke engine oil can extend the engine's service
life. Please choose Four-stroke engine oil for motorcycles especially
formulated for this model, which is available at your authorized
dealer. API SG grade authentic engine oil with a viscosity of SAE
10W-40 can also be used. Alternatively, the rider might choose an
appropriate substitute product in regard to the local climate conditions
based on the following table.
20W-50 APT Quality Classification
IC Ll
15W-40, 15W-50 SG
Engi il bere ina HIGH
EMS RS | 10W-40, 10W-50
| E a aa SF
10W-30
pie Me
5W-30 SE
°C —30 —20 —10 0 10 20 30 40 LOW
Че 1 + T SD
| = gas 14 32 50 68 86 104
RUNNING IN OF ANEW MOTORCYCLE
Correct break-in can improve the motorbike's service life, and at
the same time fully bring out the motorbike's performance. The
following guidelines explain proper break-in procedures:
Recommeded throttle opening limit
Throttle opening must not reach maximum during new motorcycle
running-in period, it is suggested to be less than 3/4 of the maximum
while snap-acceleration must be avoided during driving.
10
Variation of engine speed
Engine speed should be varied frequently and not be held at a
constant speed.During the break-in period, snap accelerations should
be avoided. This will help properly complete the grinding-in of the
engine parts.
Avoid constant low speeds
An engine running at constant low speeds (under light load) may
result in insufficient fitting between the parts. Provided that the
recommended throttle openness is not excessive (i.e., does not exceed
3/4 of its maximum). The engine can undertake accelerations to any
speed, but for the initial 500 kms of the break-in period, the throttle
openness must not exceed 3/4.
Let the engine oil circulate before riding
Before either warm or cold engine startup, give the engine ample
idling time to let engine oil flow and reach all critical engine
components.
First and most critical service call
The first 1000 km service is the most important service that your
motorcycle will receive. During the break-in period, all engine parts
might have undergone changes, therefore, in the first service, all parts
will be readjusted, tightened up, fastened. Engine oil, contaminated by
wear-in debris, will be replaced. Replacing the engine oil filter and
making an earnest check for the first 1000 km not only can ensure that
your motorcycle will deliver optimal performance, but also extend its
service life.
INSPECTION BEFORE RIDING
Please check the following items carefully before riding. Never
neglect the importance of these checks. All checks and necessary
repair must be completed before riding.
Check item | Important steps for carrying out the inspection:
р 1) Stable
Décaritg 2) Easy to turn
Steering 3) no play or looseness
1) correct gap exists between braking handle and braking
Braking pedal
PR 2) no spongy feeling peculiar to poor brake
3) no oil leaking
1) correct air pressure;
Tires 2) proper tire tread depth;
3) no cracks or wounds
Fuel Ensure that there is enough fuel for the planned distance
Operate all lights — front light, front and rear position light,
Lighting braking light, instrument panel illumination light, turn signal
light ‚front position light.
Kl High beam indicator, neutral gear indicator, turning indicator,
UREA gear indicator
Hem and braking They should function normally
switch
Engine oil Correct oil level
Throttle 1) Appropriate spare gap for the throttle cable ;
AGERE 2) Smooth oil supply and fast oil return
Clutel 1) Proper tension, neither too loose, nor too tight;
ne 2) Appropriate lubrication
Transmission 1) proper tension, neither too loose, nor too tight:
chain 2) Appropriate lubrication
RIDING TIPS
WARNING:
® If you have never riden this type of motorcycle before, it is
highly recommended to practice on a non-public road until you
are familiar with the controls and riding method of this
motorcycle.
® Single hand riding is the most dangerous way of riding, the
rider should ride with both hands firmly grasping the handles,
11
with the feet placed on front footrests. Never take your hands
off the handles when riding.
® Please do not change gear or brake hard when making a turn,
you should reduce the speed to a safe speed before making a
turn.
® On wet or slippery roads, the tires will have less friction, and
thus naturally braking and turning abilities are reduced.
® Therefore, you must reduce speed well in advance. Cross-
winds will most likely occur at tunnel exits, hilly areas or when
being overtaken by large vehicles; stay calm and reduce speed.
® Follow the traffic rules and limit your speed.
ENGINE STARTUP
First check if the fuel valve is at the startup position" U ". Then
check if the engine power-off switch is at the " (7) " position. Insert the
key and turn it clockwise to the "ON" position. Make sure that the
motorcycle’s gear is at neutral position. The neutral gear indicator on
the instrument panel should be on.
WARNING:
® Always keep the transmission at neutral gear when starting up,
fully release the throttle, and press on the brakes, for fear that
the motorcycle would run forward in case of a wrong gear
selection.
COLD STARTUP
Move the carburetor choke lever to the end as indicated by the
arrow, close the throttle and start the engine by pressing the start
button. Move the choke lever back half-way after the engine is started
to to preheat the engine to a satisfactory temperature level (Please
refer to page 7). Then move the lever back to its original position.
NOTE:
The colder it is, the longer it takes to pre-heat the engine. Riding
with the engine fully pre-heated can reduce engine wear.
WARM STARTUP
Turn the throttle 1/8 to 1/4, press the startup button to start the
engine. When the engine is hot, it is not necessary to use the carburetor
choke to start the engine.
WARNING:
e Do not start the engine in a poorly ventilated or unventilated
room, as the carbon monoxide exhausted by the engine is toxic
and life-threatening. Do not leave a motorcycle unattended
with its engine running even for a short moment.
CAUTION:
When not riding, idle time should not be too long. Excessively
long idle running will easily overheat the engine and thus damage
the engine parts.
RIDING
Grasp the clutch lever firmly, step once on the gear lever to engage
low speed gear. Slowly turn the throttle and gradually release the
clutch lever, the motorcycle will move forward.
To change to a higher gear, first accelerate, then release the throttle,
at the same time grasp the clutch lever firmly, step on the gear lever
downward to engage the next gear. After that, gradually loosen clutch
lever, and turn the throttle slowly. Change gears in the same way to get
the top gear.
WARNING:
e Before the vehicle starts moving, the side stand must be
retracted to its upper position. It should not be left in another
position.
USING THE TRANSMISSION
Transmission will enable the engine run smoothly within its normal
operating range. Gear ratios have been carefully selected based on the
engine characteristics. The rider should select the most suitable gear
position in view of riding condition. Never cruise along without
engaging the clutch, for it will cause danger. Lower the gear when
reducing speed, so as to enable the engine to run within normal
operating range.
CAUTION:
The engine speed must never be allowed to reach a level that is
within the red section of the tachometer.
UPHILL RIDING
9 When riding up a steep slope, the motorcycle speed will decrease
due to lack of power. Lower the gear to let the engine run within a
normal operating range. Swiftly change gear to avoid loosing too
much speed.
e When riding down a slope, the engine can be used to achieve
braking by changing to a lower gear.
® Remember: Don't let the engine's revolving speed run too high.
BRAKING AND STOPPING
® Rotate the throttle handle outwards tofully return the throttle.
® Meanwhile, evenly apply force on the front brake grip and rear
brake pedal.
® Move the shift rod to a lower gear to decelerate when the speed is
low enough.
e Grip the clutch handle firmly (to detach the clutch), move the shift
rod to neutral, bring the motorcycle to a standstill. The neutral gear
indicator on the instrument panel will light on when the shift rod is
in neutral position.
e If you are about to park the motorcycle with the side stand on a
gentle slope, be sure to move the shift rod to a low gear to prevent
overturning caused by a shaky side stand. But do not forget to shift
it back to neutral when starting the engine.
® Turn the ignition switch to “OFF” to stop the engine.
e Lock the handlebar for safety.
e Draw outthe key.
WARNING:
® Operating at high speeds requires correspondingly longer
braking distance. The ride must assess the distance between
him and the vehicle or object ahead, and make a judgement as
to whether the distance is sufficient for braking.
e Inexperienced riders tend to only use the rear braking system,
which will speed up wear and lengthen the braking distance.
® Only using either the front or rear break can be very dangerous,
and lead to skidding and loss of control. The braking system
should be used carefully on wet or slippery road surface and at
turning places. Hard braking on uneven road surface or
slippery road will make motorcycle uncontrollable.
INSPECTION AND MAINTENANCE
The following chart indicates checkup items for each periodic
service, whose intervals should be based on time or mileage,
whichever comes first. During each inspection, should be checked by
following the methods as described in the chart.
If your motorcycle has been used under tough conditions, such as
continuous full throttle operation, operation in a dusty environment,
special items should be checked for in order to ensure the continuing
reliability of your motorcycle. In such a case, your dealer can provide
you with needed advice. In particular, the steering system, shock
absorbers and wheel components are items that require special
inspection. For safety, we suggest that these items be checked by your
dealer or an experienced mechanic.
CAUTION:
The items of the first service after the initial 1000 kms break-in
period must be strictly followed to ensure that your motorcycle
provides lasting reliably and optimal performance.
Check regularly with this manual to ensure that proper
inspection and maintenance is timely carried out.
13
Whether or not you are an expert, those items marked with a (*)
in the table should be handled only by a qualified mechanic. You
can carry inspection for unmarked items by yourself in
accordance with the instructions in this section.
WARNING:
e The items of the first service after the initial 1000 kms of the
break-in period must be strictly followed to ensure that your
motorcycle provides lasting reliably and optimal performance.
® Check regularly with this manual to ensure that proper
inspection and maintenance is timely carried out.
REGULAR INSPECTION TABLE
pipe bolt, nut
Interval | Kilometer First 1,000 Every 3,000 | Every 6,000
ltem Months 3 6 12
*Battery Inspection Inspection ый
*Cylinder cover, body and exhaust Tighten
Tighten | =
Air filter
First cleaning after first 1000km, thereafter
every 2000~3000km, to be replaced when
broken
rubber tube
*Valve clearance
(cold status intake 0.03-0.05mm Inspect Inspect —
Discharge 0.05-0.08mm)
Spark plug Inspect Inspect —
*Fuel hose, secondary air Inspect | Inspect -
To be replaced every four years
Engine oil
First replacement after the first S00km, then
replacedafter 1000km, thereafter replaced every
2000~3000km
Engine oil filter (filter core)
First cleaning after first 1000km, thereafter
every 2000-3000km, to be replaced when
broken
Carburetor Inspect Inspect —
Clutch Inspect Inspect =
Filter cartridge for fuel switch - Inspect Replace
В Inspect Inspect —
Transmission Chain To be oiled every 1000 km
Inspect Inspect -
els es
Brake fluid hose To be replaced every four years
*Brake fluid To be replaced every two years
*Brake Inspect Inspect —
Tire Inspect Inspect —
*Steering system Inspect Inspect =
*Front fork and rear damper — Inspect —
*Frame bolts and nuts Inspect Inspect —
NOTE: The "Inspect" instruction includes operations such as further cleaning,
tightening, adjustment or replacement of parts 1f necessary, whereas "-" does not
contain such requirements.Maintenance for "*" items must be performed by
professional staff from an appointed dealer.
REGULAR MAINTENANCE CHART
Interval Every 6000km Every 12,000 km
Item or 6 months Or 12 months
Throttle cable Engine oil -
Throttle control handle = Grease
Clutch cable Engine oil -
Tachometer pivot = Grease
Speedometer pivot Es Grease
Speedometer gear box - Grease
Transmission chain Applied with Engine oil every 1,000km
Braking pedal axle Grease or Engine oil -
*Brake cam shaft = Grease
i ‘ Apply grease once every two years
*Steering bearing PP'Y E ) y
or every 20,000 Km.
| *Bearing spacing of the Apply grease once every two years
rear fork or every 20,000 Km
NOTE: "-" indicates no requirements;"*" item must be performed by professional
staff from specified dealer.
BATTERY
Open the right side cover to check the
remaining quantity of electrolyte. The
liquid level should be kept between “Upper
Level” and “Lower Level”. If the liquid
level 1s below the lower level, add distilled
water till it reaches upper level. Never add
tap water.
CAUTION:
Once the battery has started being used, dilute sulphuric acid
cannot be added anymore.
CAUTION:
Do not distort, obstruct or change the itinary of the battery
ventilating hose. Make sure one end of the pipe is tightly linked to
the battery whereas the other end is open.
When connecting the two terminals of the battery, make sure
they connected correctly. The red wire should be connected to the
positive terminal and the black wire should be connected to the
negative terminal. Wrong connection will result in damaged
charging system and battery.
AIR FILTER
The air filter of this motorcycle is made of foam plastics. If air filter
has become obstructed with dust, the intake resistance will increase
resulting in a decrease of output power and an increase in fuel
consumption,
CAUTION:
When riding in dusty conditions, the air filter replacement
frequency should be increased.
ilter core holder
Screw ® Е
® Filter core
@ Outer cover
(1) Remove left side cover;
(2) Unscrew screws (D) on the outer cover of the filter, remove outer
cover @ ;
(3) Take out the filter core holder ©) AR
Y >
(4) Separate filter core |
@ and filter core @©— — [|
holder ©). i
CLEANING OF FILTER CORE
(A) Non-inflammable detergent liquid
(B) Engine oil
Clean the filter core as described below:
(1)Put non-inflammable detergent liquid into a washing basin of
appropriate size, place the filter core in it and wash it clean.
(2)Press the washed filter core with both palms to squeeze out the
detergent. Don’t twist it to avoid breaking it.
(3)Next, immerse the filter core into engine oil, squeeze out any
remaining oil, leave the filter core slightly oiled.
CAUTION:
Please watch out for any cracks in the filter core before or
during washing. If there is a crack, the filter core should be replaced.
Do not leave it un-repaired until the next scheduled maintenance.
(4) Re-install the clean filter core in reverse order of removal, make sure
the filter core is fitted properly and securely in the prescribed
position, then seal itup properly.
CAUTION:
When riding in dusty conditions, please shorten the mileage or
time interval for checking, washing and replacing filter core. If
any defect such as clogging, damage or dust infiltration occurs,
please replace it immediately, do not wait until the motorcycle is
in need of repair. Starting up the engine without the filter core will
increase wearing of the engine. Pay attention to and check the
filter core’s condition frequently, for improper checkup or
servicing of this simple component will often affect the longevity
ofthe motorcycle.
SPARK PLUG
Use an iron wire or a metal brush to
remove accumulated carbon on the
spark plug. Then use a spark plug gap
thickness gauge to adjust the gap of
spark plug to between 0.7-0.8.
When cleaning accumulated carbon,
please also pay attention to the color of
its porcelain tip. The color can give you
clues as to whether you should use a
standard spark plug. A spark plug in |
normal operating condition should be TE
light brown in color. If the spark plug
appears wet and is black in color, it
might be better to use a high-pressure
heat type spark plug. If it is white and glows, it might be working in
overheated conditions and should be replaced with a cold type spark
plug.
Guidelines for spark plug replacement
TORCH | NHSP Remarks
D7RC DRTC N ph sah hs appears wet, replace it with
D8RC DSRTC | Standard spark plug.
E. [EE | Te pk po nettoie,
CAUTION:
The spark plug should not be screwed on too tightly, or have a
misplaced screw thread in order not to damage the screw thread of
the cylinder lid. When removing the spark plug, don’t let dirt enter
the engine through the spark plug hole.
The standard spark plug supplied with this motorcycle has
been carefully chosen and is capable of being used under most
operation conditions. If the color of the spark plug differs from
that of standard spark plug, please consult your dealer before
replacing it with a spark plug with different heat tolerance
specification. Inappropriate selection of spark plug may bring
serious damage to the engine.
Using a spark plug from another manufacturer may result in
difficulty in engine operation. Therefore, please consult your
dealer before choosing a spark plug from another manufacturer.
CLEANING OR REPLACEMENT OF THE FUEL FILTER
The fuel filter is installed between the fuel switch and the carburetor.
It must be replaced and cleaned regularly. After replacement or
Compressing air
|
®
2) Filter cartridge 3) Seal ring
cleaning, please pay attention to the assembly direction of the filter
core, so as to ensure the flowing direction of fuel conforms to the
direction of the arrow visible on the filter core.
ENGINE OIL
The longevity of the engine largely depends on using quality oil
and replacing ot on a regular basis. Two important and indispensable
tasks in repair items are the checkup of the engine oil level and regular
replacement of engine oil.
CHECKING THE ENGINE OIL LEVEL
Check the oil level of the engine as
follows:
(1)Support the motorcycle with the main
stand on flat ground;
(2)Start up the engine and let it run for
several minutes;
(3)Turn off the engine and keep it in still
for several minutes, then unscrew the oil scale and clean it, plug in
again without screwing it, take it out to check the oil mark, which
should be within the upper and lower limit;
CAUTION:
If the engine oil level 1s at the lower limit mark or lower, don’t
start up the motorcycle. When adding oil, don’t let the oil level
exceed the upper limit.
OIL REPLACEMENT AND FILTER CLEANING
Replacing old oil with new oil should be done when the engine is
warm, in this way used engine oil can be replaced completely. The
steps for replacing oil are as follows:
1)Place the motorcycle on the main stand on even ground.
2)Remove the lid of oil hole
3)Remove the oil drain plug under the engine to totally drain out the
used engine oil.
NOTE:
A drain plug is not available on the lower part of chain engine. To
drain engine oil, just unscrew the filter cover. The rest of the procedure
is similar to that for the engine with top rod.
PIO
© ®
a Oil drain plug
: @ Filter screen
(3) Filter cover
(4)Remove the filter cover, take out the screen and washit.
(5)Before restoring the filter cover, please check carefully if the filter
cartridge and seal ring are correctly installed.
(4) Seal ring
O) Spring
CAUTION:
It is recommended to replace seal ring every time the filter is
replaced.
(6)Putthe filter cover on. Do notover-tightenit.
(7)Add about 900ml of new engine oil through the filler hole, then
tighten the filler cap.
(8)Start up engine and let it run idle for several minutes.
CAUTION:
Check carefully to ensure that no oil leakage occurs around the
filter cover.
(9) Turn off the engine for several minutes before checking the oil
level. The level should be between the upper and lower limit of the oil
scale.
CAUTION:
Please use the engine oil recommended in "Instructions for
usage of fuel and machine" section.
CARBURETOR
Stable carbureting evaporation is the most fundamental requirement
for the carburetor. The carbureting evaporation has been accurately set
in the factory. Please do not change its setup. You only need to pay
attention to two things: idle speed and throttle cable free-play.
ADJUSTMENT OF IDLE SPEED
(1) Start the engine, let it run idle till fully
pre-heated.
(2) After the engine has been pre-heated,
return the throttle, turn the adjusting screw
(D to right and left to keep the revolving
speed between 1300-1500 turn/min.
= Pe nut
CAUTION:
Adjusting the idle speed of the engine should be done when the
engine has been fully pre-heated.
Adjustment of throttle cable
(1) Loosen lock-up nut (1)
(2) Turn the adjustment bolt (2) to adjust cable gap to between 0.5~1.0 mm
(3) After adjustment is over, tighten up lock-up nut (1
>e
| (1) Lock-up nut
Fa 0.5-1.0mm
2) Adjustment bolt
WARNING:
e After the adjustment of throttle is done, check the throttle grip
movement. Make sure that the adjustment of the throttle has
not raised the engine idle speed. In the meantime, the throttle
grip position should be restored automatically.
CLUTCH
a
The clutch is adjusted by inspecting the cable play U. When feeling
that the grip is firmly held and the friction disc is detached, a gap of 4mm
should be left. Ifthe gap is not correct, adjust it as follows:
Remove the rubber @), loosen the nut 2), turn adjustment screw
shaft 3), turn clockwise fully. Loosen the lock-up nut (6), then turn the
adjustment screw (5) forward and backwards. Allow for a play of the
handle of about Imm. Use the adjuster (3) for fine tuning. After
everything is set, lock up nuts @and ©and put the rubber back on @.
TRANSMISSION CHAIN
WARNING:
® To ensure safety, checkup and adjustment of the transmission
18
chain should be carried out before riding.
At a regular checkup, please inspect the following items
regarding the transmission chain:
(1) Loose chain pin
(2) Damaged roller
(3) Dried or rusty chain segments
(4) Twist or adhesion
(5) Excessive wear-off
(6) Chain droop
If the transmission chain shows any of the above symptoms, the
most probable reason is a damaged chain wheel. Please check the
following:
(1) Whether the chain wheel has excessive wear
(2) Whether wheel teeth are broken or damaged
(3) Whether the chain wheel is loose
Cleaning and lubrication of transmission chain
Dirty transmission chain will not |
only speed up the wearing of the chain “3
itself, but also damage the chain
wheel. Therefore, after every 1000km,
the chain must be cleaned and
lubricated with chain oil or engine oil | A
after being cleaned with detergent h VA › |
solution. A
Adjustment of the transmission chain
Adjust the transmission chain to
keep it in normal condition. Under ¿=
difficult riding conditions, the chain a
adjustment should be adjusted more
frequently than the motorcycle
normal checkup schedule.
WARNING:
® An excessively loose chain will result in the chain coming off
the chain wheel. This may cause an accident or seriously
damage the engine. Please adjust the transmission chain as
described below:
(1) Support the motorcycle on the main stand
(2) Loosen the rear axle nut @).
(3) Loosen the locking nut (2).
(4)Turn the bolt left and right to adjust the chain tension. Meanwhile,
pay attention to the alignment of the front and rear chain wheels. To
facilitate this procedure, there are marks on each chain adjuster and
the rear wheel fork. Once adjustment is done, it is necessary to make
sure the marks are all aligned with each other.
(D Adjustment nut of the
transmission chain
2) Locking nut
(8) Marks
(4) Rear axle nut
After aligning the marks and
adjusting the chain tension to
10~20 mm, re-tighten the rear
axle nut, then tighten the locking nut on the adjustment bolt and make
a final check.
CAUTION:
The transmission chain of this motorcycle is made of special
raw materials carefully processed. Use authentic parts (428H, 116
segments) when replacing the transmission chain. Using parts
with different specifications may cause early damage to the chain.
NOTE:
Whenever replacing transmission chain, please check the
wearing conditions of both front and rear chain wheels, replace
chain wheel at the same time if necessary.
19
When installing transmission chain,
please make sure the opening direction
of lock ring 1s the opposite of the
direction of the chain movement. i
After adjusting the transmission
chain, ensure that you have checked the
free travel of the rear brake. Regarding
"free travel", please refer to the "Braking
system" section of this manual.
Braking system
The front wheel of the motorcycle uses a disc brake, while the rear
wheel uses a drum brake. Correct braking operation is very important
for the rider's safety while riding. Remember to check braking system
regularly, and ensure that it is done by your qualified dealer.
WARNING:
® The brakes are a component of critical importance for the
safety of the rider. It must therefore be frequently inspected and
adjusted.
FRONT WHEEL BRAKE
Brake fluid
WARNING:
® [t is harmful if the brake fluid is swallowed by mistake or
splashed into the eyes or the skin. Please visit a doctor for
diagnosis immediately. The swallowed liquid should be spitted
out compulsively. Use large amount of water to rinse the eyes
or skin contaminated by the brake liquid.
CAUTION:
This motorcycle uses ethanol brake fluid, which should not be
mixed with liquids of silicic acid or petrol categories; otherwise it
will seriously damage the braking system. Do not use brake fluid
stored in open containers. Do not use leftover brake fluid from an
Daily checkup items for th i 7 :
earlier maintenance task. for old brake fluid can absorb water y Р o e braking system are as follows:
from the air. Only use DOT3 or DOT4 brake fluid. Please keep in (1) Check the front wheel braking system for leaks.
mind that brake fluid should be kept away from paint or plastic (2) Check the brake fluid tube for leaks or cracks.
surfaces, for it will damage the surface of these materials. (3) Both the break lever and the brake pedal must not be loose when
applied.
Because when the brake pads are — UPPER (4) Check the front wheel brake pads for wear.
worn, the brake fluid in the brake = WARNING:
liquid tank will be automatically [1 ll : E © After replacing the brake pads, don not ride the motorcycle
injected into brake fluid tube to | и eT immediately. Squeeze and release the brake lever repeatedly.
lower the liquid level. Replenishing This will allow the break pads to fit and restore their normal
brake fluid is an important item for feel, allowing brake fluid to circulate steadily.
regular checkup.
BRAKE PAD
The key point for checking front
wheel brake pad is to check if the
pad has worn down to the limit
mark. If the limit mark has been
reached, then the brake pad has to be
ВЕ - E 20mm—30mm
EN replaced. (D Limit mark
D Freetravel (2 Adjustment nut
REAR BRAKE
Adjustment of rear wheel brake pedal
WARNING: | | When adjusting the free travel of the rear brake pedal, first fix it into
e If the braking system or brake pads are in need for repair, we the place which is most comfortable for riding, so that it can be
strongly advise you to let your dealer take care of the task. They . o =
bOoSsess a complete set of tools and the necessary skills to do it adjusted by turning the limit bolt of pedal, then rotate the adjustment
E (9) , y
in a way that will be both economical and will ensure your nut (2 to keep the free travel within 20-30 mm.
safety. WEARING LIMIT OF REAR BRAKE
The rear brake of this motorcycle is fitted with wear limit marks.
CAUTION: When checking wearing condition, please follow the steps below:
Disc brake systems use high pressure for braking. To ensure (1) Check if braking system is properly adjusted.
safety, the replacement schedule of the brake fluid tube and brake (2) Operate the braking system to check if the limit mark line falls is
fluid should not exceed that specified in the repairs section of this kept within the allowed range, as shown in Figure A.
manual. (3) If the marking line exceeds the allowed range, as shown in Figure
20
B, please have the brake assembly replaced by your dealer to ensure
safe operation.
Allowed range
) | Marking line
Figure A The mark line falls within the allowed range
Figure B The mark line exceeds the allowed range
FRONT BRAKE LIGHT SWITCH
The front brake switch is located on
the front brake lever. Loosen the screw
to adjust the switch position by moving
back and forth, find a proper point to turn
on the light when gripping the lever.
REAR BRAKE LIGHT SWITCH
The rear braking switch is located ®
under the right side cover. Adjust this
switch by screwing the bolt in or out
until the brake light to light up when ©
feeling a little pressure by stepping
down on the pedal.
TIRES
Periodic checks should be performed for tire pressure and tread
depth conditions. To ensure maximum safety and service life
longevity, check the tire pressure, in addition to the scheduled service
inspections.
21
TIRE PRESSURE
Insufficient air pressure of the tire will not only speed up the
wearing of tire, but also seriously affect riding stability. Lack of air
pressure will make turning difficult, while excessively high air
pressure will reduce the tire’s contact area with the ground, causing
the motorcycle likely to skid and lose control. It is imperative to
maintain air pressure within the prescribed limit. Adjustment of tire
pressure should be done under normal temperature.
Specifications for tire pressure under normal temperature
| Single riding Double riding
| 175kg/em 1.75kg/cm’
Front wheel 175kPa 175kPa
2kg/em’ 2.25kg/cm’
Rear whee] 200kPa 225kPa
TIRE TREAD
Riding the motorcycle under excessive tire
wear conditions will decrease stability, and
might cause loss of control. The tire must be
replaced when the tread depth of front tire is
less than 1.6 mm. The rear tire should be
replaced when its tread depth is less than 2 mm.
WARNING:
® The specifications for the tires used by your motorcycle are:
Front wheel: 2.75-18 4PR
Rear wheel: 3.25-18 4PR
e Using tires other than the standard might create problems. We
strongly recommend you to choose the standard tires.
O Tire pressure and wear conditions are very important for the
operation and safety of the motorcycle. Make sure to check
tread depth andtire pressure on a regular basis.
REPLACEMENT OF BULBS:
The rated power of each bulb is shown in the following table. When
replacing broken bulbs, Make sure to use bulb with the same rated power.
If a different bulb is used, it might cause overload of electric system and
early breakdown of the bulb.
Headlight 12V 35W/35W
Taill/braking light 12V SW/21W
Turn signal light 12V 10W
Position light 12V 4W
FUSES
The fuse box is located on the fastening
belt of the battery. If a sudden power failure
or circuit disconnection occurs while
riding, the fuse box should be checked
first.
CAUTION:
You be advised to choose fuses with the correct rated current
(15A). Do not use substitutes, such as aluminum foil or iron sire. A
fuse that melts within a short period of time is an indication that the
lighting system is defective. Check with your dealer immediately.
WARNING:
O It is very dangerous to use fuses that do not match the supplied
specification. Doing so will seriously affect the electric system,
and may even cause fire, burning, or loss of engine power.
TROUBLESHOOTING
If the engine fails to start, please check the following to help identify
the cause:
(1) Check ifthe oil tank is filled with sufficient fuel oil.
22
(2) Unplug the oil pipe from the carburetor, turn the fuel switch to the
“ Y " position and check if the fuel flows freely.
(3) Check ifthe fuel flows freely from the fuel switch into the carburetor.
(4) If the fuel can freely flow into the carburetor, then inspect the ignition
system.
WARNING:
® Don't let fuel spill on the ground; instead it should be collected
with a container. Don’t move the fuel close to a heated engine and
exhaust pipe. When carrying out the inspection, be careful not to
cause any fire or fumes and do not move close to any fire or heat
source.
(5) Remove the spark plug, and connect it to high voltage line.
(6) Fix the spark plug onto the motorcycle frame, move the ignition
switch to the "ON” position, and power-off switch to the " (7) "
position. Then, press down startup button. If the ignition system is
normal, there will be blue sparks between the two poles of the spark
plug. If there is no spark, consult your dealer for repair.
WARNING:
® Do not perform the above check with the spark plug located near
the spark plug hole of the cylinder to make the above check, as the
combustible air mixture in the cylinder might cause fire due to the
sparks.
e To reduce the risk of electric shock, it is advised to fix the metal
casing of the spark plug on the paint-free metal surface of the
motorcycle frame.
e Persons with heart disease or wearing cardiovascular modulator
should avoid performing this operation.
CAUTION:
You are advised to consult your dealer before proceeding with
repairs. Your dealer will assist you in solving problems.
NOTICE ON BATTERY USAGE
1. INSTALLATION OF NEW BATTERY
1.1 Addition of electrolyte
1.1.1 Check the appearance of the battery, which should be free of any
wound or crack. The terminals should not be rusty or deformed.
1.1.2 Pull off the sealed rubber cap of the ventilating nozzle. Take off
the filling hole plug.
1.1.3 Take out the special battery electrolyte provided together with
the battery, cut open the electrolyte container cap, put on the
plastic tube, fill electrolyte slowly into the filling hole, until the
liquid level reaches the upper level; put it aside for 20 minutes
after adding electrolyte, if the liquid level lowers down,
replenish till the upper level. Note: Please do not exceed the
upper level mark.
1.1.4 Thirty minutes after adding electrolyte to the battery, the engine
can be started. If conditions permit, recharge for 3-5 hours
before riding, which will further improve startup performance
and extend the battery longevity. In winter when the
temperature is low or after long periods of ex factory storage,
the battery should be recharged for 3-5 hours before usage.
1.1.5 Close the filling hole plug tightly, rinse away any electrolyte
outside the battery with clean water, use cloth to wipe it clean.
1.2 Installation
1.2.1 Put the ventilating hose onto the ventilating nozzle, make sure
that the pipe is not distorted or crushed, otherwise the
battery might explode. If any electrolyte is spilt out, corrosion
may occur to both your clothes and the motorcycle.
1.2.2 First connect the positive (+) terminal (marked with red), then
connect negative (-) terminal, NOTE: please note that
reversing the wires can damage the electric components
23
such as the ignition device and the voltage stabilizer.
1.2.3 After tightening the bolt , apply grease or jelly on the bolt, nut
and terminal, so as to avoid poor connection caused by rust.
2. USAGE AND MAINTENANCE
2.1 Each time’s startup should not exceed 5 seconds. If startup fails
after several attempts, the rider should check the oil supply
system and the startup and ignition system.
2.2. The following conditions will lead to excessive battery discharge
or insufficient recharging, which will shorten its service
longevity;
(1)Frequent startup, short riding distance;
(2)Low speed riding for a long period;
(3)Grip brake lever or step down the rear brake pedal during riding
causing the brake indicator to constantly lit up;
(4)Installation of electric accessories or an electric light.
2.3 When starting the engine becomes difficult, lights are dim, or
the horn does not sound resonantly, please recharge immediately.
2.4 Check the electrolyte level at an interval of 1-3 months, if the
electrolyte level is below the lower level, replenish with
distilled water or putrefied water to raise the level to upper level
line. Be definitely sure not to add electrolyte. After addition
of water, it is advisable to charge the storage battery.
2.5 If you intend not to use the motorcycle a long period of time,
make sure to charge the battery before you stop using it and
charge it once a month.
2.6 Charging
2.6.1 Please use special charger to charge the battery. Before
charging, please take off the filling hole plug, keep the room
well ventilated. Open fire is forbidden.
2.6.2 Recharging can be classified into standard recharging and fast
recharging, unless pressed for time, use standard recharging
as much as possible, so as to extend the battery’s service life.
Standard recharging: Current: 0.7-0.8 A, Time: 5-15 hours
Fast recharging: Current: 7-8 A, Time: 30 minutes at most
2.6.3 Stop recharging if the temperature of electrolyte exceeds 45°
when recharging; wait till it cools off then start recharging
again. When the battery produces a lot of bubbles, stop
recharging. Close the filling hole plug tightly, wash clean and
dry off the battery.
3. PRECAUTIONS
3.1 During usage and recharging, the battery will produce an
explosive gas; do not get close to a fire. Avoid short circuit of
positive and negative terminals and loosening of the terminals,
in order to prevent an explosion.
3.2 There is strong acid in the electrolyte, avoid splashing it onto
skin, eyes or clothing. Once there is any contact, please rinse
with large amount of water. If drunken by mistake, please
immediately drink large amount of water or milk, and go to
hospital for further treatment.
3.3 Please place the electrolyte at places that cannot be reached by
children.
3.4 Installation of anti-burglar alarm will also affect the battery. It is
suggested to use anti-burglar alarm recommended by Haojue,
other alarms might lead to abnormal operation of the circuit
system, or even damage the battery or ignition device,
stabilized rectifier.
24
MAINTENANCE AND SERVICING OF THE
MUFFLER
In order to improve the longevity of the muffler, it is imperative to
perform periodic checks of the muffler as described below:
(1)Remove the muffler, block the water discharge hole at the
lowest part of the middle of the muffler (with adhesive band).
(2)Add about 50ml anti-rust oil into the flank between the muffler
and the engine. Shake the muffler to let the anti-rust oil flow
inside. Then reinstall the muffler.
(3)At engine startup, due to the gradual increase of temperature in
the muffler, the anti-rust oil will evaporate after heating, and the
tail of muffler will emit blue smoke. However, the blue smoke
will disappear after riding about 20 kilometers. When no more
blue smoke 1s produced, remove the blocking stem from the
discharge hole.
It is recommended to have a lubrication servicing after registration.
A lubrication servicing should be done twice a year. If anti-rust oil is
not available, engine oil used for four stroke engine can be used as a
substitute.
WARNING:
9 When the engine is on, the muffler and exhaust pipe will be
extremely hot. To avoid burns, please do not touch these parts.
ECONOMIC FUEL CONSUMPTION
Economic fuel consumption refers to the lowest possible fuel
consumption per 100 kilometers.
TABLE OF SPECIFICATIONS
Size and weight
Length 1945mm
Width 710mm
Height 1110mm
Wheelbase 1265mm
Minimum distance to ground 160mm
Kerb mass 117kg
Maximum load mass (including rider) 160kg
Engine
Type single cylinder, air-cooled, four stroke
Cylinder bore 56.5mm
Stroke 49.5mm
Displacement 124ml
Compression ratio Y
Startup method electric startup
Lubrication method pressure and splashing
Standard power/ Relative RPM -------------------—- 6.8/8000kw(r/min)
Max power/Relative RPM 7.6/8500kw(r/min)
Transmission
Clutch multi-disc wet
Transmission five shift gear transmission
Initial speed ratio 4.055
Final speed ratio 2.600
Gear ratio Shift 1 2.769
Shift 2 1.882
Shift 3 1.400
Shift 4 1.130
Shift 5 0.960
Performance
Economic fuel consumption
<2.1L/100km
Test economic fuel consumption
Maximum speed
1.49L/100km
=95Km/h
Climbing ability
Braking distance
=20°
=< 6m(V=30km/h)
=
Riding
Turn clearance circle 4.2m
Front tire 2.75-18 4PR
Rear tire 3.25- 18 4PR
Electric System
Ignition method CDI
Spark plug See page 16
Battery 12V 7Ah
Fuse 15A
Headlight 12V 35W/35W —
Position light 12V 4W
Taillight / brake light 12V 5W/21W
Turn light 12V 10W
Capacity
Fuel tank (including reserve) 121.
Reserve only 2.0L
Engine oil 1000ml
CIRCUIT DIAGRAM iris
Instrument combination
Rear brake light switch Teming relay
Lighting switch
Speedometer Tachometer ————— Power off switch Startup switch ; ;
PES TE A al Ignition coil Ignition device Stabilized rectifier
Fuel pipe
Spark plug
Fuel transducer
Rear right tum signal light
Front right turn signal light
Tail light combination
Headlight
Rear left turn signal light
Front left tum signai light
Fuse box
15A
Start relay
7
| стенной
Anti-burglar alarm
Storage Battery
Start motor
ignition switch
Frame grounding Engine ground strap
Magnetic motor
Horn switch Tuming switch
Engine siop switch
Gear switch
26
Left handlebar switches
Haojue HJ125-7 99011H055
200905 VOI
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