Professional Documents
Culture Documents
th
PREFACE
Thank you for choosin g the motorcyc le. May you enjoy riding all time.
The manual co ntains the necessary instructi ons and g uidance with respect to the o peration and maintenance of the motorcycle, and BE SURE TO
READ IT CAREFULLY BEFORE YOU RIDE TH E MOTORC YCLE . Proper operation and maintenance can guarantee a sa fe riding to minimi ze lroubles
of the motorcycle and keep it in a sound condition, whi ch can extend the engine service life.
All rights reserved. No part of this publi cation may be reproduced without our prior written permi ss ion.
IMPORTANT NOTICES
Operator and Passenger
Thi s motorcycle is designed to carry the operator and one passenger. The max imum load weight of the motorcycle must not exceed 150kg .
Onroad
Thi s motorcycl e is designed for on-road use.
Pay special attention to statements preceded by the fo ll owing words:
.t.t,CA UTION: Indicates a possibility of equipmellt damage if illstructiolls are Iwt followed.
NOTE: Gives helpful information.
E nvironmental Protection (EP) : Indicates special precautions that must be taken to meet environment protection laws and regulations.
Improper use of a motorcycle may cause environment pollution.
If the o perator fail s to fo ll ow safe o perating and maintenance practices. the Co. will not take any responsibility to an y inj ury or dam age occured.
Thi s manual should be considered as a permanent part of the motorcycle and should remain with the motorcycle when resold.
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CONTENTS
MOTORCYCLE SAFE RIDING
Safe Riding Rules ................................................... 1
GENERAL INFORMATION
Pans Location ............................... .
... 2
....... 3
........ 3
. .. ....... 3
......... 4
Ri ght Handlebar Controls . .................................... 4
4
4
5
5
5
6
6
6
7
7
7
7
8
9
10
10
10
10
II
II
II
11
II
12
12
12
Dri ve Chain ........................................................... 12
Front Brake ........................................................... 13
Rear Brake
... .... ..... .......... ,..
......... 13
Brake Li ght ....... ............................................. ........ 13
How to Use Brake Wear Indicator ............. ........... 14
FrontlRear Shock Absorber and Suspen sion .......... 14
Tyre ........................................................................ 14
Front Wheel ...... .... ...... .......... .... .... ...... .... ........ .... .... 15
Rear Wheel
...... ...... .... ... .. ... ...... ..... .... ...... ..... 15
Fuse ............. .............. .......... ......................... .. ........ 15
Battery (EP) .................. .... ..... ............. ..... ............ 15
TROUBLESHOOTING, STORAGE AND OPTIONAL PARTS
Troubleshooting ..................................................... 16
Cleaning and Storage ............ ................................... 16
Removal from Storage .......... .... .........
....... ... 16
Anti -the Ft Dev ice (Optional) ................................. 16
ELECI'RICDIAGRAM .............................................. 17
SPECIFICATIONS .................................................... 18
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A lways make a pre-ride inspection before you start the engine. You may
prevent acc ident or equipment damage.
Most countries require a special motorcycle riding lest or license. Make
sure you arc qualified before you ride. NEVER lend your motorcycle to an
inexperienced rider.
. Signal before you make a turn or lane change to draw other motori sts '
attenti on.
. Use extra caution at intersections, parking lot en trances and exits .
Always re member to ride with both hands and keep both feet on the rider
footrest while the passenger grasps the handrail with both feel on the rear
footres t.
PROTECTIVE CLOTHS
For the safelY sake. always wear a helmet, a face shield. dust glasses and
prOlective clothing. Your passenger needs the same prOlection.
The exhausl system becomes hot during operation. and it remains hot for
a while after stopping Ihe engine. Tak e care nOI to tou ch the exh aust
system whi le it is hot. Wear clothing that fu ll y covcrs your Icgs.
. 00 not wear loose clothing that could catch on the control levers, whee ls,
etc.
REFITTING
&. WA RNING
original parts may make riding unsafe, and is illegal also. The user
must obey all national and local laws and regulations in relation to
vehicle and trame. If you have a good proposal concerning refitting of
the motorcycle, please write us. The refitment can be done with permission of the Co. Otherwise, the user will take the consequences.
LOADING
L!l. WARNING Addition of accessories and cargo may reduce the
motorcycle's stability, performance and safe operating speed.
.Keep cargo and accessory weight lower and close to the cenle r of the
motorcycle. Load weight equally on both sides to minimize imbalance. As
weight is located further from the motorcycle's center of gravity, handling
is proportionally affected .
Adju st tyre pressure and rear suspension to suit load weight and riding
conditions .
Make sure thai cargo is fastened on the vehicle .
. 00 not attach items to the handlebars. fork or fender. Otherwise, unstable
handling or slow steering response may occur.
. The maximum load weight of the motorcycle is 150kg. Please do not
overload.
ACCESSORIES
Genuine accessories of the Motors have been specifi ca ll y designed and
tested on the motorcycle. Beacuse the factory cannot test all orner accessories.
you are perso nally re-sponsible for selection , installation and use of acces
sori es not produced by the Co. AI-ways follow Safe Riding Rules and these
below:
. Carefu ll y inspect lhe accessory to make sure lhat it does nOi obscure ::my
lights, reduce ground clearance or banking angle, or limit suspension travel,
steering travel or control operation .
00 not install olher cooling equipment for the engine.
. Do 110t add electrical equipmenlthat will exceed the mOlorcycle's electrical system capac ity .
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GENERAL INFORMATION
PARTS LOCATION (Fig.I.2l
Fi g. I (Left-v iew)
Fig.2 (Right-view)
@) Gearshift pedal
CD Rearview mirror
Pillion footrest
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VIN RECORD
Engine oil must be selected in accorda nce w ith rul es below a nd o th e r o ils,
(Fig. 3-5)
such as ordinary engine o il. gear oil and vegetable oil , are fo rbidde n to be used .
The vehicl e has been fill ed with e ngine oil S A E 15W/40 S E be fore bein g
deli vered . The lubri cant is onl y suit abl e al a
te mpe rature ran ge within - IO 'C ........ +40 'C. lf
Fi g.3 Y IN
Fig. 4
Engine code
Fig. 5
Nameplate
I I II I I I I
II I I III
Please fill the VIN and e ngi ne code of your motorcycle in the bla nk below.
They w ill he lp o rde r spare parts a nd fin d out the vehicle when stolen.
NOT ES
CD
The Y IN is sla mped o n the ri ght of the steering ste m (Fig. 3).
(%) The e ngi ne code is stamped o n the botto m-left o f the crankcase (Fig. 4).
30
D 102D3OCI!ID'C
Fig. 6
<ID The vehicle nameplate is fixed on the left o f the steering stem (Fig. 5).
CONTROLLING PARTS
METER AND
INDICATORS (Fig. 7)
selection or fuel must follow the rules bel ow. Selected fuel mu st be unleaded
CD Speedo mete r
gasoline with octane No. RQ-93 or highe r. Using improper fuel could reduce
CD Odome te r
Left turn
Hi-beam
Thc qualily of the e ngine oil plays a vital role in decidi ng the engi ne pertonnance
and service.
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~ w i tc h
Lighting Switch
The 3-posi tion switch functions as fo ll ows:
:Thc headl ig hl. tai llight and meter lights arc bright.
FE : The parking light. tuil ight and meter lights are bright.
: (OFF) The headlight. tai lli ght. parking li ght and meter light s are off.
a spare one.
" , ~, " OFF: Engi ne and li ghts ca nn OI be
Emergency Switch
Parking
In an emerge ncy, deprc\sing the switch to~ ' J' '' will stall the eng ine at once.
In nomla! riding cases. always set the swi tch at "0 ".
Throtll e G rip
111e grip is used loconlrol engi ne power. Turning inlhe grip will increase fu el
suppl y, while turn ing out it will decrease fuel supply.
LEFf HANDLEBAR CONTROLS (Fig. 10)
(nsen the key i nto the lock core, and pres\) it w hile turn ing cou nl erc l oc k w i ~
Steering Lock
Horn Button
[0 p,.
position. then remove the key. In th is casco the ta illi ght and parki ng
li ght wi ll glow. and engine and other lights cannot be operated. To c.. nccl the
When the vehicle is nOI kept in use, always . . cl the switch to "OFF '
RIGHT HANDLEBARCONTROLS
(Fig. 9)
Starter Button
Depress the bu tton "'1)" to start up the eng ine.
..
hom.
Passing Signal Switch ..
(Fig. II)
When pass ing. press and release the
switch, the headl iglll wi ll wink to warn the
<D Starter button
<D Lighting sw.
vehicles.
:l) Emergency sw.
CHOKE LEVER (Fig. II)
Thrott le grip
T he c ho ke leve r is loca led o n the left
hand lebar contro ls. Pu sh the lever to open
Fig. 9
-1 the thrott le.
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< Hom
button
Fig. 11
Choke lever
The fucl cod.. is located m the left-bollom of the tank. With the fuel cock
in "OFF"
position. fue l cannot now from the tank to the carburetor. Turn
With the fuel cock in "'ON" posillon, fuel will Dow from the main fuel
rrom the reserve fuel supply to the carburetor. Use the reserve ruel only
when the main supp ly is gone. Refill the tank at the earliest opportun ity.
LhCAUTION
Fig. 12
LtWARNlNG
position. If it is in" RES" position, you may run out of fuel with no reserve.
Do not overfill the tank (there should be no fuel in the filler neck) .
Correct use of the fuel cock can avoid the state above-mentioned.
Do not smoke or allow flames or sparks in the area wh ere the fuel
15)
tank is refueled.
(r-'
Before refueling, make sure to filter fuel first. Spilled fuel vapor
may ignite. If any fuel is spilled, make sure the area is dry before
Fig. 14
Fig. 15
"RES "
/
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SIDE STAND
When parking the vehicle, turn the side sland clockwi se along the frame to
position. Before driving the vehicle, seL the stand to the initi al pos ition.
CAUTION
(Fig. 18)
(Fig. 17)
The shock absorber has 5 adjustment posit ions for different loads or riding
conditions. Position I is for light loads and smooth road conditions. Positions
II to V increase spring preload for a st iffer rear sus pen s ion , and ca ll be
used when the motorcycl e is heavil y loaded or ridden in rugged roads. Use
Fig. 18
position.
Fig. 17
IV
6
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PRE-RIDE INSPECTION
Inspect your motorcycle every time before you ride it. The items listed here
(green),
Sel the choke lever to the fully closed pos ition if the engine is cold .
wi ll only take a few minutes to in spect. and in the long run they can save
With the throlll e sli ghtl y open (less than liS of ils entire opening), oper
ale the sl'H1er so as to start the engine. Then push choke lever to half-open
1. Engine oil level- add eng ine oil if required . Check for leaks.
NOTE
Do not use the electric starter fOI' more than 5 seconds at a time.
Release the starter button for approximately 10 seconds before press
ing it again.
6. Thronle - check for smooth opening and full closing in all steeling positions.
Adjust or replace it if necessary.
7 . Lights and horn - check lhat head li ght. tail/slop li ght. w inkers. parking
light , indicalOrs and horn function properly.
BREAKING-lN
Help assure your motorcycle's future reliability and perfonnance by paying
eX ira allenlion
10
how you ride the first IOOOkm. During this period avoid
8. Drive chain - check condition and slack. Adjust and lubricate if necessary .
full lhrottle riding. be sure to drive at a speed no more than 80% of each gear
9. Fasteners - check that all nuts, screws and bolt s are mounted securely.
conduct maintenance so as to make co mpen sation for initial wear. The se rvice life will be extended obviously through such maintenance.
Attempting to start the engine with the tran smission in gear may result in
damage to equipment.
Before starting, confinn the following:
.Make sure the fu el in the lank is enough. Set fuel cock to "ON " position.
\.. In sert the ignition switch and turn it to
"0 "
position.
RIDING
Start the engi ne and warm up it.
While the engi ne idling, pull in the clutch lever and push down the gear
shift pedal to shift into low ( I st) gear.
Slowly release the clutch lever and at the same time graduall y increase
engi ne speed by opening the throttle.
1 When the motorcycle atlains a steady speed, close the throttle, pull in the
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cl utch lever and shift to 2nd gear by treading the gearshift pedal.
Thi s sequence is repeated to progressively shift to hi gher gears.
Coordin ate the throttle with brakes fo r smooth deceleration .
Both front and rear brakes should be used at the same Lime and sho uld not
may occ ur. Make sure the gearshift peda l is operated ge ntly and exactly.
Riding with your foot restin g on the brake peda l may suddenly change a
speed and/or damage the d riving mechani sm.
"jg!" pOS itio n and lock the steering lock. followed by remov in g the key.
8
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MAINTENANCE
~E
ITEM
Fuel filter
Throttle operation
Carburetor choke
Fig.19
@ Toolbag
MAlNTENANCESCHEDVLE
Maintenance work should be performed in light of Maintenance Schedule.
leiters in the table indicate as follows:
I: INSPECT AND CLEAN, ADJUST. LUBRICATE OR REPLACE IF
NECESSARY
C: CLEAN
R: REPLACE A: ADJUST L: LUBRICATE
The item should be serviced by your dealer, unless the owner has the
proper tools and is mechan ically qualified. Refer to the manua l.
In the interest of safety, we recommend these items should be serviced
on ly by you r dealer.
NOTES: <D C lean more frequently when riding in unus ual wet or du sty
area'i.
m Al higher odometer read ings. still follow the frequency in terva ls establi shed in this manual.
*
**
....
1.000km
C
I
R
A
C
A
I.L
I.L
I
I
1. L
I
Headlight adjustment
Clutch
Side st:md
Suspension
Nuts. bolts. fasteners
Wheels/spokes
Steering bearings
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Battery
Monthly
Brake shoes/pad wear
Brake syste m
Brake light switch
I
I
Every 2.000km-R
I
1. L
I
I
I
I
I
I
I
I
I
I
I
I
I
A
I
I
I
C lear away carbo n deposi t around the spar k plu g and pisto n ring. o n the
piston top. in the piston ring slot and combustion chamber regu larl y.
usc.
Place the motorcycle on a level ground
and keep it in vertica l position. Then
few minutes.
SlOp the engine so as to let the oi l
level be stab le. Check the oi l level
throught the sight g lass located at the
lower of the righ t crankshaft case.
The level must be maintained between the upper and lower level marks.
Add Lhe engine oil if necessary
Fig. 20
CD Oi l filler cap
CAUTION Running the engi ne with ins ufficie nt oil ca n cause seri-
(Fig. 22)
Spark Plug Type' A 7TC
Check and Replace
. Disconnect the spark plug cap from the spark
plug. Clea n any dirt from around the spark
plug base. Remove the spark plug by the
spec ial wrench.
. Inspect the electrodes and center porcelain
for deposits. i.lIld clean with a wire brush. If
the spark plug is damaged, replace it.
. Check the spark plug gap which should be O.
7 0.1 mm. and adjust by bending the side
electrode if necessary.
Side electrode
Fig. 22
CAUTION
When runnin g in very dusty conditi ons, oil chan ges
sho uld be performed mo r e freque nll y than s peci fcd in lhe nUlint enan ce schedul e.
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Fig. 23 Ai r cleaner
VALVE CLEARANCE
Excessive valve clearance w ill cause noise and eventual engine damage. Little
or no clearance will prevenllhe valve from clos ing and cause the damage 10
valve and loss of power. Check valve clearance when the engine is cold at the
rotatory signal with ECU and control the ai r now through EG R va lve, as a
FEATURES
I. By adoptin g e lectronic-controlled technology, the engi ne can ru n aI an
locknut.
Fig. 25
CD Throttle grip
<D Locknut
Q) Adj uster
<D
NOTE
CD Locknut
a:., C lutch cable holder
The carburetor has been sct accurate ly in factory. The user only needs to
adjust idle speed afler the engine is warmed up.
<ll Bool
Adjust idle speed with the throlLle SlOp screw 10 SCI idle speed at aboul
1300r/min. Tum the screw in direction A will increase idle speed. in directi on
"./~x~~
. ;( ~~
Fig. 27
,-
DRIVE CHAIN
(Fig. 28)
Check
Check the drive chain for wear and slack. Lubricate the chain if it !o,eems to be
screw, if necessary.
dry.
Throttle SlOp screw
Fig. 26
Slack should be I 0-20mm . Support the motorcycle with the center stand.
check slack in the lower chain run midway between the sprockets.
C hec k reg ularl y air su ppl y lin e. spec ially s uch as the joint between the
mufner and engine. the joint between the air cleaner. carburetor and in let
pipe. etc. for leakage, and repair or replace damaged parts once there are some
troubles to assure a normal air suppl y.
IO-20mm
On ... mg direction
~
Chain clip
. Measure the clutch lever Free play at the clutch lever flan ge. The free play
engi ne stalled.
Fig. 28
(D Chain
.Tum loose the locknu t at the clu tch cable ho lder located on the crankcase.
<ll NUl
@ Chainclip
s hould be IO ....... 20mm. Adjustment of the clutch should be done with the
and then make adjustment by screwi ng in or out the correspond ing adj usting
nul. After adjustment. Lighten up the lock nut.
I~
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Adjustment
Loosen the rear axle nut and locknut, turn both adjusting bolts until the chai n
slack meets the standard, and make sure left and right adjusters al ign with the
same index marks. After checking. tighten up the rear axle nut with a torque
of 50 - 60N.m.
NOTE Turning the adjusting nut in direction A wi ll increase the chain slack,
and in direction B decrease the s lack.
Check the chain for slack
If slack of chain is changed, it is necessary to relocate Lhe rear wheel, for
a:djustment wi ll affect the rear brake pedal free play.
*
*
Lubrication
Place the motorcycle on the level ground. Check the brake Ouid level thrOugh",
the sig ht glass. If Lhe fluid level is below the LOWER , loosen the cyli nd e r
cove r screws, remove the ule cover, add brake fluid up La the UPPER level
mark.
Pullout the chain clip with pliers, remove the joint and chain. Wash the chain
in cleansing so lu tion and dry it in the air. Check the chain including lin k
plates, bushings. and rol lers for damage, cracks, wear-out. Replace if necessary.
Lubricate the chain, then reinstall and adjust it.
CAUTION The cha in clip should be so installed as to make sure thaL its
closed end faces the direction of wheel rotation.
30)
Check
The fronL brake cylinder is located on the right
handlebar.
When operating the brake lever, the pads
equipped with cali per will c lamp the brake disc.
If any pad is worn to its limit depth, replace
bOLh pads as a set all the first opportunity.
Fig. 30
Fig. 29
Fig. 31
Q) Adjusting nut
Wear limit
Support the vehicle o n its side stand. Measure the distance the rear brake
pedal moves the brake starts to engage. The free play shoul d be 20 - 30ml11.
To adju st, turn the rear brake adjust in g nul. Turning it clockwise will decrease the free play, and counterclockwise increase the free play. Apply the
several Limes and check for free wheel rotation after the brake pedal is released.
CD Main cylinder
m Sighl glass
(J) Screw
Cover
(i) Brake caliper
3
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lock the front wheel. pump the front/rear shock absorber up and down
several times to see that it runctions well without noise or leakage. Check the
rear rork bushing for proper play by pressi ng the side of the rear wheel.
Make sure that all of the fasteners are tightened securely.
TYRE
Proper air pressure will provide maximum stab ility, riding comfort and prolong lyre li fe.
direction A.
10
TYRE PRESSURE
Wearlill1iL ]
'w
Fig. 33
Q) Fr. brake disc
Q) Fr. brake caliper
Q)
Fig. 34
CD Rr. brake panel
@)
Q) Reference mark
Tyrc Size
with the reference marks on full applicat ion of the brake. the brake shoes
must be replaced.
Q) Indicator
Rr.
brake ann
Fro nllyre
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1.6mm
II
Rear lyre
2.Omm
Fr. axle
Fig. 35
NOTES
Adjusting nul
Fig. 36
Installation shall be done in the reverse Ofder of removal.
Tightening torque o f rear axle nut: 50-60N.
Locknut
m Adjustment of rear brake and chain: refer
Brake link
to related items in the manual.
L!>.CAUTION
The suppon should be so
heigh and fast as to avoid the vehicle tuming
over.
FUSE (Fig. 37)
<
Fuse
The fu se is positioned behind me left cover
near the battery stay. The fuse will blow to
Fig. 37
protect the circuit aUlOmalically in the case ~
of rroubles suc h as a short circui t or an overload trouble. After the troubleshooting, fi t a
new fu se available in the fu se box .
1 \..
--
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Prevent the murner from gelling in water. the spark plug from being welled
down when washing the vehicle.
Storage
P.r<l~rl.x. Trylhe vehicle at low ~ed in a safe riding area away from traffic .
Cleaning
I. Check if the spark plug and inlets are installed or pluged securely before
cleaning the vehicle.
2. Hose the vehicle completely.
3. Dry the motorcycle using a soft cloth or sponge.
4. Lubricate the drive chain immediately after washing and drying to prevent
surfaces from getting rusty .
5. Start the engine, and allow it to run for several minutes.
CAUTION
Hi gh-pressure water can damage certain parts such as wheel
bearings, front fork , brakes, seal of transmission, electric equ ipmen t, etc.
I. Before usi ng the remote-controller. be sure that the vehicle is in neutral and
the ignition switch is turned off.
2. Electric starting by the remole-controller only warms up the engine. and
the engine will SlOp aUlOmatically in 2.5 minutes.
3. Don't apply both the front and rear brakes after starting the eng ine by the
remote-controller and before turning on the ignition switch. Olherwise. the
starting motor will run once more .
4. Don't ride without the key to insure that the function of anti-theft i5.
reliable enough.
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ELECTRIC DIAGRAM
SPEED
SENSOR
LIGHTING
EMERGENCY
STARTER
SW.
BunON
SW
IGNITION
RR. BRAKE SIARTING BAnERY
IGNITION
SW
RELAY
IGNfI!ON COil 2
COIL 1
CONTROlLER
IGNITION
SW.
~qq~
B~~ ~ ~I
RYG
FR. WINKER. RH
12Yl0W
Sb-
HI-BEAM INDIe.
HEADUGHT
12Y-35/35W
POSITION LIGHT
12Y-5W
f&i'i~~
o-
NEUTRAL IND1C .
TURN SIGNAL lNDIC . RH
TURN SIGNAL INDIC.. LH
~ c
tl:i BI ii5
G-
FR. WINKER. lH
12Y-l0W
ODOMETER
"
~I T
~ ~'flV10Ahl
-
'U~
>
< ~ ~P
.~ ~
w
b.-o:>--=
, -S
TO EN GINE CASE
G' -<~--'O
BI
STOP /I AlLUGHT
12Y-21/5W
~~~
Sb
Lj-
-0--
~w
~.;+B,
G-
lu'
I II
il
I I
LgG
1=@ill;iIIUIUI~
DIMMER
SW.
GIBI
PASSING
HORN
TURN SIGNAL SIGNAL HORN
FLASHING
SW.
SW. BunON
RelAY
"
BI G:::o ......
AUXILIARY
REALY
BI
>
G P
,. Jl
RR. WINKER RH
12V-5W
0, -0:>-1-06
RR. WINKER. LH
12Y-lOW
" -<30---'0
UCENSE LIGHT
12Y-5W
TOFRAM
SIDE SIAND
DIODE
FR. BRAKE ~W.
CLUTCH
SW.
SW.
MAGNETO RECTIFIER
j
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SPECIFICATIONS
Vehicle Model
250-8
I. DIMENSIONS AND PERFORMANCE
Overall dim.( L x B x H)
43
Ground clearance
150 mm
4800 111m
1495 mill
163 kg
150 kg
;;> 100 kmlh
Wheelbase
Kerb weight
Max. weight capacity
Top design speed
Eoon.speedfueICOll'<.
Grade ability
Front lyre size/pressu re
Rear lyre size/pressure
Front shock absorber
Rear shock absorber
3.0- 18/200kPa
5.0- 15/225kPa
Te lescopic Iype hydraulic drive
Coil spring-dampened
Di sc
Drum
Bore
)C
Stroke
Displacement
Compression ralio
Starting mode
14 L
2V49FMM
Twin-cylinder, 4-stroke, ai r-coiled
49 )( 66mm
248.9 ml
10.0: 1
Electric-starter
TCI
13/8000
19/6000
Ignition system
SAEI5W/40-SE
Engincoil
1.2 L
Press/sp lash
Engine oi l capacity
Lubrication
Fuel
Wet mulLi-platc
Transmission
3. 130
2.642
4th ( I,)
1.000
1.684
1.260
5th ( I.)
0.82 I
( I F)
2.8 12
3. ELECTRIC EQUIPMENT
Battery
Spark plug
Headl ight
Winker
Tail/stop light
Horn
Odometer light
Fuse
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12VIOAh
A7TC
12V-35W/35W
2V- I OW
12V-5WI2IW
12V
12V-3W
20A