Professional Documents
Culture Documents
SHIN ERAY
FOREWORD
Thank you for your purchasing this motorcycle.
This manual covers the main data, basic structure, and main procedmes of operation,
adjustment, maintenance and troubleshooting of this motorcycle. It will help you familiarize
yourself with all the necessary skills so that you will bring your vehicle into full , best play with
minimized trouble for a long service life.
Products are always subject to further improvement, which will cause some difference
between the vehicle and .this manual, without further notici.
CONTENTS
I. Safe Drive .................. .. .. .. ....... . .. . ..... .... .. . .. . ........ ..... 1
II.
Fuel Cock .................... ... ....... .. ...... ... ........ ... ... ... .. 9
Adj ustment of Front Brake .... ....... ..... .... ...... .. . .. ... .. 21
Adj ustment of Chain ..... .. -.. ... ...... ... ..... ... ... 22
Vehicle Washing .......... . .. ......... . ...... ..... .... ... ... ....25
Check-up & Cleaning of Air Filter .. ..... . .. ....... .. ... ... ..... 16
SAFE DRIVE
Rules for Safe Drive
Check must be conducted, before starting the engine, to prevent mishaps and damage to components.
Only the qualified person, who has passed the drive examination and to whom a drive license h~
been issued, is permitted to drive the vehicle but not anybody else without a drive license.
Full preoccupation is required during drive , paying attention to the following points to avoid any
possible hurt to you by other motorized vehicles :
Do not drive too close to other vehicles;
Never contend for lane.
Strictly observe the local traffic rules.
As driving at overspeed is the cause of many accidents, do not drive at a speed the actual situation
does not permit.
Tum on the tumlight when making a tum or changing the lane.
Particular care should be exercised at the level crossing of roads, entrance and exit of parking lot or
on the automobile lane.
During drive, grasp the left handlebar by the left hand and the throttle twist grip by the right one,
with feet cin the footrests.
The luggage carrier is designed for carrying light goods, which should be sec urely fastened,to
prevent loose movement that may cause mishaps during drive.
Prote ti ve Wear
1. Protective wear such as helmet w;th protective mask, dustproof glasses and gloves should be worn
during drive for the sake of personal safety .
2. The passenger should wear hight boots or long clothes to protect legs from hurt by the hea ted exhaust
s ile ncer during ride.
3. Loose clothes are not suitable for motorcycle drive or ride as they may get caught on the O;)erating
lever, kick lever, footrest or wheel, result to dan ger.
Modification of the vehicle
Caution:
Any 'u naut horized modification of the vehicle or replacement of the original parts can not ensure driving
safety and is illicit. The user mus t observe the regulations of the traffic control authori ti es. We are not respo nsible for any vehicle with unauthorized modification.
Loading of goods
Caution:
Th design of the motorcycle requires distribution of the canied goods in certain extent of equilibrium
and improper arrangement of goods will adversely affec t the performa nce a nd stabili ty of the vehicle . The
manufacturer ~hall not take any responsibility due to the reason men tioned above.
MAIN DATA
125c:r:
Overall
lcn~lh
2080mm
Climhnbilitv
200('('
150r:c:
~?20
830mm
Overall height
l240nun
Compression ratio
Wheelhuse
1320mm
Output,max.
9.0:1
8. 2kW/CX'f.J..Rfrrri n 8.5kW/<xXXk/min 11.5kW/8500rlmin
Dead weinghl
I 17kg
TorCJue,max
Payload
l50kg
Idling spP.erl
Overall width
I 500rlmin
Fronlwhed
RP.ar wheel
SpeP.d, Max
90km/h Spnrk
BmkC' distance(30km/h)
7m
I.IL
pl u~
fi2 .2mm
1420r/rnin
I500r/ruirr
1 49.4~rrl
196.9rrrl
D7TC
D8TC
O.(i- 0 .8mrn
gap
0.6 - 0.7111111
0.05mm
O.OCJrrnn
0.08mm
0.08rnrrr
El
MAIN DATA
125rr
ISO rr
125r:r:
200r:r:
Bauyn y
9L
200r;c
!2V7Ah
Ignition means
Transmission ratio
150 r:r:
CDI
1st gear
2.769
2.545
2nd gr:ar
1.R82
1.6R8
3rd gear
1.400
1.2RO
4th gear
1.1 30
1.042
5rh gear
0.960
0.903
6th gear
Final reduction
II
4.055
Crounrl elr:aranec>.
0.8 15
250
Left handlebar
Switches on left handlebar
Ser.No
Name
Description
CD
Speedometer
lnkmfh
Turn indicator
The left indicator is lit up when the tumlight is to the left and the right one lit up as the latter to the righl
Neutral indicator
Odometer
(5)
Tachometer
Trip mileometer
/; /
Froot tumlight ~
Rear turnlight
Front
Fuel cock
I
Seat cushion
Fuel Cock
N. OPERATION
Ignition Switch
*Ignition swicth
Positoin
Function
Remarks
To . stop the vehicle Thekeycanb..-e-
moved outtaker
ON
LOCK
of fuel tank)
OFF
ON
fu el supply.
OFF: With the handle of the fuel cock
Engine Starting
CD Set
po ition.
where it
" B", full y open the choke when the engine is sufficiently warmed up.
*Caution:
The engine can only be started after the neutral
happen .
Unnecessary idle running( especialy at a high
speed) is harmful to the engine.
turn.
Start the engine by the electric starting system.
@ Slightly turn the throttle twist grip to increase Lhe speed of the engine so as to warm up the
engine.
@ Tum the carburetor choke bar downward to
CD Headlight switch
"
" (a white
point).
" 09:- " When the switch is in this position, tail the headl ight and meter lights are
all
lit up.
"P ~ " : When the swi tch is in this po-
Ill
Turnlight switch
t-Position, Left
----+Position, Right
@ Horn button
press this button to horn.
Gear Shifting
Warm up the engine f'>r normal runing.
CD When
Shifting forward
5
3
2
l
Shifting backwardS
3:
()
Pl
::r
::3
(b
~.
-22 - 4 14 32 50 68 86 104
VIS-
CD Drain
0. 6 -0. 7mm
D8EA(NGK)
Air filter
Collar cla mp
Caution :
The idling speed adju tnHnr of tlw <'nv;ine
help of the idling speed adj u-,ti nv. s<rf' l\' with tfJt:
~pe t'd:
the free operating movement again. R peat the adjustment if necessary until it is as required.
Adjus ti ng nut
Idling s pct~d
Locking nul
\'C-
CD Remove
the caps of the central hole and the top hole ( the ignition timing observation hole) in the left crankcasf
cover.
@ Remove the caps of the two air valves on the cylinder head.
@ Insert the "T" key into the central hole of the crankcase cover ,jam it against the nut of the fl ying wheel and then turn
the flying wheel clockwise unti l the engraved
"T" mark on the flying wheel aligns with the engraved line on the lop of the
crankcase cover. Swing the rocking arm slightly. A loose rocking arm (which indicates the .existence of clearance) shows that
the piston is in the upper stop position of the compressing stroke, where the valve can be adjusted. A tight rocking arm mea{IS
that the piston is in the lower stop position of the compressing stroke. In this case, continuously tum the "T" key clockwise for
360 degrees until the alignment of those engraved marks, where the valve can be adjusted. Afterwards, check the valve gap b]
inserting a feeler in between the valve adjusting screw and the end of the valve.
T he specified air valve gap :0. 05m m for the intake and exhaus t valves respectively.
@ U the adjustment needed, loosen the locking nut of the valve, tum the adjusting nu t till a slight
resistance is felt on inserti ng the feeler.
At the end of the adjustment, tighten the "Locking nut" to prevent loosening and cond uct another
check to make sure that the valve gap is OK before all those dismounted caps are refitted on .
Valve cap
the adjusted dutch works normally .
Adjuslment of Clutch
Brake Checking
right side.
fp.~ii:~--
lO - 20mm
( 2) If adjustment is needed, turn the adjustmg nut near the lower side of the front hub,
elockw ise to red uce and counterclockwise to incrf'ase the fret> operating movement of the brake
le1er.
( 3) After adjustment , the groove of the adjusting nut should be aligred with the pi n of the
brake ann.
Caution :
After adjustment , check the front braking
syst m. Tlw braking light should be lit up on time
when the fron t brake is ap pli ed by gripping the
brake lever.
Adjustment of Chain
lubrication.
Brake cam
Caution :
After regulation, check the rear braking
Adjusting nut
Bear axle
Battery Checking
Replacement of Fuse
lower one,
Negative( - )
co nnector
I:=-
I ever
ave
h
t e
e1ec-
"OFF"
Vehicle Washing
Cleaning the vehicle regularly can slow down the color fading of its body make it easier to check if
there is any damage and any oil leakage with il.
Caution:
Washing the motorcycle with over- pressurized water may cause damage to some of its components. Therefore, do not jet over- pressurized water direc tly on to-the follow ing parts :
-Wheel hub
-Exhaust pipe
-Fuel tank and lower portion of cushion
-Carburetor
-Headlock and ignition switch
-Meters
(I) After pre - wiping, the vehicle should be washed with clean water to remove dirty residues so as to,
prevent coiTosion. Plastic s ubassemblies should be cleaned by wiping with colth or s ponge soaked in ne ulral
detergent solution, followed by wash ing with clean water.
( 2 ) After the cleaned vehicle is air dried, grease the chain and run the engine at idling :,.peed for a few
minutes.
( 3) Prior to driving, carefully check braking system repeatedly and repair or adjust it if necessary.
@ Take
out the s park plug, fill about J 5 -20m! of clean lubricating oil i nt~ the cyliQder, s te p down the kick lever
repetitively for sev("ral times and finall y fit the s park plug bac k on.
Atte ntion:
The igniti on s witch key mus t be set to "OFF" position before stepping down the kick lever. To protect the ign ition
sys tem from damage, the spark plug should be put on its cap and earthed.
@ Disma ntl e the battery a nd put it in a shady, coo l and well - ventilated place. It is s uggested that the battery be
charged once a month.
Cleiln the vehic le, s pray the colored part with color fas tening age nt and appl y antimst oil to the part vul nerable to
rust.
(J) Inflate the tyre as required and pad the vehicle up with the two wheels clear of the ground.
Put th e covering over the motorcycle.
Resumption of Service
CD Remove the cover and clean the vehicle. Change the lubricating oil if the vehicle has been off service for
over 4months.
(2) Charge the battery and remount it.
@ Drain off the an tirust solution from the fuel tank, followed by filling fuel therein to the required level.
@ Prior to driving, test the vehicle at low speed in a safe place.
Maintenance Routine Diagram
"('means: Check, cleaning, adjustment, lubrication and/ or replacemnet are needed.
"C" means: Cleaning is needed.
"R" means: Replacement is needed.
"A" means: Adjustment is needed.
"L" means: Lubrication is needed.
"*"means: This item of maintennace should be carried out at a service center. It may be also done by the
user himself with reference to this manual provided he has special tools, sparts and is capable of this job.
"* * " menas: This item can only be carried out by the serviceman at Kington service center in order to
ensure safety.
Notes : 1. Maintenance should be conducted more frequently when the motorcycle drives in dusty areas.
2. When the read -out of the odometer exceeds the maximum figures specified in the table, maintenance
should be still cycled according to the interval of mileage stated herein.
~~
h em
of Maintenance
fuel filter
Throttle operating sysern
Choke of carburetor
Spark plug
Air Ya!V<: gap
Air va lve gap
r.,1gine lubricating oil
**
**
*
*
*
*
**
R ~_yearl y
R -_l'corlv
4000km
I
12000km
1
I
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1
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1
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1
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R
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R
A
Remark
l, L every 500 km
R-4ear
I
r-2 vear
8000km
Monthl v
Ten~ion
of c hain
Idling speeci of r.arburetor
Oriviug chain
Battery
Wear of brake shoes
Hear braking sytem
Braking liquid hose
Cup ol brakjng liquid
Braking liquid
Front braking system
Rear bmking light switc h
Lrght changmg ol haadllght
C lutch
Side s tand
Suspension
Nuts, bolts & other faste ners
~f-Wheel/ spokes
B~ruing of sterin~~: handle
**
**
Odometer kmJ.Note 2)
lOOOkm
*
*
*
*
*
*
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ELECTRICAL DIAGRAM
B- Biack
Y-Ye/Jow
W-White
BJ-Biue