RT200-5维修手册

7/16/2019 RT200-5

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前言

由于摩托车的品种日益增多，新结构和新技术不断被采用。为了使广大

润通用户及维修人员更好地掌握RT200-5型摩托车的保养、调整和维修技术。

我们编写了本维修手册。愿本手册给广大润通用户及维修人员带来方便和给

予维修技术上的指导。

本手册第一章至第三章的内容，适用于摩托车的各部分调整。第四章至

第十五章，则根据摩托车的各个组成部分而分别叙述。

有关标准程序，维修注意事项及一般修理知识，没有纳入本维修手册中，

如用户或维修人员需查阅上述内容，请参考有关资料。

本手册所载的全部资料，图表和各种数据，性能指标，到本手册印刷为止，

均为最新的产品资料。重庆润通动力有限公司有权在任何时候对本手册进行修

改，而无需事前通知。本手册中的任何一部分，均属于重庆润通动力有限公司

版权所有，任何单位或个人，未得到本公司的书面同意，不得翻印。

As more and more motorcycles come into the market, new designs and technologies have been widely used. This instruction manual is prepared to enable users and service

personnel of the RATO RT200-5 vehicle to master the skills of maintenance, adjustment

and repair. We hope that this book can be as instructive as it is wished to both the users

and service personnel.

The information contained in Sections 1 to 3 is applicable for making necessary

adjustments of the vehicle, while Sections 5 to 15 deal with each component part of the

vehicle respectively.

Standard procedures, precautions and general knowledge are not included in this manual.

The user will have to refer to other sources if he or she hopes to get such information.

All the information, charts and tables and performance data contained in this book reflectthe latest condition of the product. RATO reserves the right to revise any part of the book

any time without giving prior notice. All rights reserved, no part of this manual shall be

reproduced in any form or by any means without the prior written permission of RATO.

Foreword

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目录

1、概述

2、润滑系统

3、检查和调整

4、燃油系统

5、发动机拆卸和安装

6、汽缸头与气门

7、汽缸及活塞

8、离合器、油泵与换档机构

9、磁电机

10、曲轴箱、曲轴、变速传动、起动装置

11、转向系统、前轮、制动器、悬挂装置

12、后轮、制动器、悬挂装置

13、蓄电池与充电系统

14、点火与电启动系统

15、开关

16、故障判断

发动机

车架

电器

1

12

16

28

34

38

47

54

62

64

74

98

108

113

117

121

Table of Contents

Engine

Frame

Electrics

General Information

Lubrication System

Checks and Adjustments

Fuel supply system

Disassembl ing and Reassembl ing the Engine

Cylinder Head and Valves

Cylinder and Piston

Clutch, Oil Pump and Gearshif t Mechanism

Magneto

Crankcase, Crankshaft , Gearbox and Starter

Steering System and Front Wheel, Brake and Suspension

Rear Wheel, Brake and Suspension

Battery and Charging System

Ignition and Electric Starting System

Switches

Troubleshooting

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1

概述

维修注意事项

主要性能技术数据

标准扭矩值

专用工具

维修周期表

电器系统图

操纵线和电缆线的布置

维修注意事项

1、应使用重庆润通动力有限公司生产或润通认可和推荐使用

润滑油和其它辅助材料。如果使用零件不符合“润通”规格或要求，则

可能损坏摩托车。

的零配件、

2、凡拆卸后重新装配时，应更换新垫圈、密封件和开口销等。

3、紧固螺栓或螺母时，应按对角交叉顺序进行，分2~3次逐步拧紧达到规定

的扭矩。

4、清洗零件时，应采用不能燃烧或高燃点的清洗液。组装前，应在零件滑动

表面上涂上润滑油。

5、组装后，应检查各部位零件是否安装正确，进行旋转、移动和操作检查。

6、拆装摩托车，必须按规定使用专用和通用工具。

1

General Description

Notes to Maintenance

Major Technical Data

Standard Torque Value

Special-purpose Tools

Maintenance Schedule

Electric Diagram

Control Cables and Power Cables


1.Use parts, oil and other auxil iary materials produced, approved or recommended by RATO only. Use of parts not conforming to RATO specifications or requirements may cause damage to your vehicle.

2.Always use new washers, seals, split pins, etc. to replaceold ones once these parts are removed during maintenanceor repair of the vehicle.

3.Bolts or nuts should be tightened diagonally in 2-3 timesto the required torque.

4.Use detergents nonignitable or of a high ignition point for cleaning parts. Apply oil to slide surfaces between partsbefore putting them together.

5.Always check the parts for proper function as by turning,moving and operating after they are assembled to ensurecorrect function.

6.The designated general-purpose and special-purpose toolsmust be used for disassembling or reassembling the vehicle.

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主要性能技术参数

项目参数

尺寸

全长全宽

全高

轴距

离地间隙

净重

2100mm

700mm

1030mm

1340mm

180mm

122Kg

车体

车架形式

前悬挂装置后悬挂装置

前轮尺寸及压力

后轮尺寸及压力

前制动

后制动

油箱容积

备用油容量

前悬挂后倾角

前悬挂液压筒注油量

管式

双向复合套筒单向复合套筒

2.75-18, 225Kpa

100/90-18, 280Kpa

盘式

鼓式

16L

1.4L

26

160mL

发动机

形式

汽缸排列

汽缸直径 X行程

压缩比

标定功率

最大扭矩

空气滤清器

气门间隙（冷态）

怠速

单缸四冲程自然风冷中置凸轮顶杆式

0与铅垂线前倾成15 夹角

67X55.7mm

9.2：1

10.0kw/7000r/min

13N.m/5500r/min

聚氨酯泡沫过滤

进气门 0.06mm

排气门 0.08mm

1500±

100r/min

2

气缸容积 196.4mL

Major Technical Data

Dimension

Description Data

Full lengthWidthHeightAxle baseGround clearanceNet weight

Frame shape

Front suspension

Rear suspension

Front tire size and pressure

Rear tire size and pressure

Front brake

Rear brake

Fuel tank capacity

Reserve oil capacityFront suspension caster angle

Front sus pensi on hydraul icoil capaci ty

Tube

Two-way composite sleeve

Unidirectional composite sleeve

Disk

Drum

Body

Engine

Type

Cylinder arrangement

Bore×stroke

Compression ratio

Cylinder capacity

Rated power

Max. Torque

Air cleaner

Valve gap (in cool state)

Idle speed

4-stroke, air-cooled, central cam

push rod, single cylinder

15 forward tilt with vertical plane

Polyurethane foam filtered

Intake valve

Exhaust valve

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项目参数

传动系统

离合器

变速装置最初减速比

变速比

最终减速比

换挡形式

起动装置

油浴多片式

五档常啮合循环

3.333

Ⅰ 2.909

Ⅱ 1.867

Ⅲ 1.390

Ⅳ 1.150Ⅴ 0.955

2.8

左脚操纵往返式顺序Ⅰ—N—Ⅱ—Ⅲ—Ⅳ—Ⅴ

电启动及脚踏反冲式

电器系统

点火系统

发电机

蓄电池容量

断电保护器

火花塞

火花塞间隙

起动电机

起动继电器

CDI电子点火

永磁交流发电机

12V7A.h

10A

D8RTC

0.6~0.7mm

励磁式

机械式

3

Transmission

Clutch

Gearbox

Initial reduction gear ratio

Transmission gear ratio

Final reduction gear ratio

Gearshift

Starter

Oil bath, multi-plate

5-gear, constant-mesh

Left food operated back-and-forth

in order of I-N-II-III-IV-V

Electric and kick

Electric system

Ignition

Generator

Battery capacity

Fuse

Spark plug

Spark plug gap

Starting motor

Starting relay

Magneto AC generator

Excited

Mechanical

CDI

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标准扭矩值

发动机

项目数量螺纹直径mm 扭矩值N.m

汽缸头盖螺栓

磁电机转子固定螺栓

机油滤清器锁紧螺母

机油过滤网盖螺母

变速鼓定位板螺栓

变速鼓与拨板连接螺栓

3

1

1

1

1

6

8

16

36

6

6

10~14

45~53

40~50

10~20

8~12

23~28

项目数量螺纹直径mm 扭矩值N.m

车体

前轮轴螺母

后轮轴螺母

后叉轴螺母

发动机悬挂螺母

转向手把固定螺栓

转向立管连接螺母

前悬挂液压筒密封螺栓

传动主动链轮螺母

1

1

1

7

2

2

1

2

2

12

14

12

8

10

6

22

22

6

35~45

50~60

40~55

25~35

35~45

9~11

40~50

15~20

10~14

1

4

汽缸头紧固螺栓 4 8 23~30

铰制孔用螺栓 3 8

8~12

Standard Torque Values

Engine

Bolt, cylinder head

Item

Lock bolt, cylinder head

Set bolt, magneto rotor

Lock nut, oil cleaner

Nut, oil filter cover

Bolt, gearshift drum plate

Bolt connecting gearshift drum and pusher

Bolt for reamed hole

Thread Diameter (mm) Torque ValueQ'ty

Body

ItemQ'ty Thread Diameter Torque Value

Bolt, front axle

Bolt, rear axle

Nut, rear fork shaft

Nut, engine suspension

Bolt, handlebar fastening

Nut, steering tube connecting

Bolt, front suspension hydro-cylinder packing

Nut, driving sprocket wheel

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除以上表中所列重要部位的扭矩值外，其余标准紧固件的扭矩值范围按下表

名称及规格

5mm螺栓和螺母

6mm螺栓和螺母

8mm螺栓和螺母

10mm螺栓和螺母

12mm螺栓和螺母

5mm螺钉

6mm螺钉

6mm带帽螺栓和螺母

8mm 螺栓和螺母

10mm 螺栓和螺母

4.5~6

8~12

18~2530~40

50~60

3.5~5

7~11

10~14

20~30

30~40

扭矩值（N.m）

专用工具

工具名称

6mm空心扳手工具套

离合器固定座

滚球座拆卸器

气门导管扩径器

参考章节

11

8

11

6

一般工具

工具名称

浮子水准计

轮辐扳手

锥子扳手

气门调整扳手10X10

气门调整器

锁紧螺母扳手20X24

锁紧螺母扳手30X32

延伸杆

转子拔除器

气门导管拆卸器5-5

气门导管驱动器（B）

轴承驱动器32X35

参考章节

4

3

11

3

38

8

8

8

6

6

12

11

5

Besides those important parts which were listed above, the rest of the standardspare parts conform to the table chart below

Description and Specification Torque Value (N.m)

5mm bolts and nuts

6mm bolts and nuts

8mm bolts and nuts

10mm bolts and nuts

12mm bolts and nuts

5mm screw

6mm screw

6mm capped bolts and nuts



Special-purpose Tools

Description Reference Section Number

6mm hollow wrench

Clutch holder

Roller ball base fixture

Valve guide tube diameter enlarger

General-purpose Tool Reference Section Number

Tool descript ion

Float level gauge

Spoke wrench

Pricker wrench

Valve adjust ing wrench 10×10

Valve adjuster

Locknut wrench 20×24

Locknut wrench 30×32

Extension bar

Rotor puller

Valve guide tube remover 5-5

Valve guide tube driver (B)

Bearing driver 32×35

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工具名称

轴承驱动器外套37X40

轴承驱动器导筒15

轴承驱动器握杆外套

叉架密封环驱动器体

叉架密封环驱动器附属工具（B）

气门弹簧压缩器

减震器压缩器

参考章节

11

12

11

11

11

6

12

气门座修整刀

工具名称

气门座修整刀进气

气门座修整刀排气

平面铣刀进气

平面铣刀排气

内部修整刀进气 /排气

修整刀固定座

参考章节

6

6

6

6

6

6

6


Bearing driver sleeve 37×40

Bearing driver guide tube 15

Bearing driver grip bar sleeveFork sealing ring driver body

Fork sealing ring driver tool (B)

Valve spring compressor

Shock absorber compressor


Valve holder t rimmer, intake

Valve holder tr immer, exhaust

Valve holder t rimmer, exhaust

plane mill ing cutter, exhaust valve

Internal trimmer, intake/exhaust valve

Trimmer fastening base

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7

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维修周期表

燃油系统通路

保养次数

保养项目

燃料滤清器

节气门操作系统

化油器阻风门

空气滤清器滤芯

火花塞

气门间隙

发动机润滑油

润滑油过滤网

化油器怠速

驱动链

蓄电池

制动蹄块磨损

制动系统

制动灯开关

前照灯调光

离合器

侧支架

悬架

螺母、螺栓、紧固件

车轮 /辐条

转向手把轴承

项目

周期

里程表km

备注1

每年

每年R

每月

备注

C C C C

C C C

C

Ⅰ

Ⅰ

Ⅰ

Ⅰ

Ⅰ

Ⅰ

Ⅰ

Ⅰ

Ⅰ

Ⅰ

Ⅰ

Ⅰ

Ⅰ

Ⅰ

Ⅰ

Ⅰ

Ⅰ

Ⅰ

Ⅰ

Ⅰ

Ⅰ

Ⅰ

Ⅰ

Ⅰ

Ⅰ

Ⅰ

Ⅰ

Ⅰ

Ⅰ

Ⅰ

Ⅰ

Ⅰ

Ⅰ

Ⅰ

Ⅰ

Ⅰ

Ⅰ

Ⅰ

Ⅰ

Ⅰ

Ⅰ

Ⅰ

Ⅰ

Ⅰ

Ⅰ

Ⅰ

Ⅰ

Ⅰ

Ⅰ

Ⅰ

Ⅰ

Ⅰ

Ⅰ

Ⅰ

Ⅰ

Ⅰ

Ⅰ

Ⅰ

Ⅰ

Ⅰ

Ⅰ

Ⅰ

1000km 4000km 8000km 12000km

R 每2000km R

Ⅰ、L Ⅰ、L Ⅰ、L Ⅰ、L

**

*

*

*

*

*

*

*

*

**

**

车辆应按规定的维修时间进行维修，表中各种符号的意义如下：

C：清洗。 R：更换。 A ：调整。L：润滑。 Ⅰ：进行检查、清洗、调整、润滑或更换。

*：该项目由润通维修站的人员维修，如果自行检修，也应参照本维修手册。

**：凡此项目，本厂建议由润通维修站的人员维修以保障安全。

注：在尘土较大的地区行驶，应经常进行清洗。

8

Maintenance Schedule

Targeted Part s

Frequency

Interval

Odometer Reading

R per 2,000 km of travel

(Note)

Each year

R each year

Each month

Fuel supply system

Fuel filter

Throttle control

Carburetor choke

Air filter

Spark plug

Valve gap

Engine oil

Oil filter

Carburetor idle speed

Drive chain

Battery

Brake lining wear

Brake system

Brake lamp switch

Headlamp beam function

Clutch

Side stand

Suspensions

Nuts, bol ts and fas teners

Wheel spoke

Handlebar bearing

The vehicle should be maintained at the specified intervals. The mean of signs are showed as follow

C: clean; R: replace; A: adjust; L: lubricate; I: inspect, clean, adjust . Lubricate or replace.

*: it should be maintained by RATO service personnel in principle. Subject to the servicemanual if owners do it by themselves.

**: it should be maintained by RATO service personnel for safety.

Note: Cleaning should be intensified if the vehicle is used in a dusty environment.

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操纵线和电缆线的布置

操纵线和电缆线的安装

安装操纵线和电缆线时应注意以下各点：

1、凡是操纵线或电缆线松脱，将可能导

致危险。安装之后，应检查线路是否紧固。

2、在使用焊接式夹紧装置时，不要将电缆

线或操纵线强行塞入焊接部位或夹紧装置端头。

3、凡车体部位与电缆线的连接，要按各相

关位置采用不同的箍带。并使箍带上的绝缘部分

与电缆线接触。

9

Installation of Control Cables and Power Cables

Installation of the control cables and power cables

The following instructions should be noticedwhen installing the control cables and power cables:

Control cable or power cables may loose andget out, because of this ,it may contribute todanger. Therefore, check the cables whether they are tightened for safety after they are installed.

When welded clamps are used, do not try tocram the power cable or control cable intothe welded part of end of the clamp.

Use different binders to fasten the cable to thebody according to the location and in such away that the insulating part of the binder touchesthe power cable.

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4、若连接塑料组合插头，锁定扣一定要对

准才能扣上。拆开时，一定要先拉开锁定扣才能

拆开。连接组合插头之前，先检查各接头是否

装好，接头是否弯曲。连接时应尽量插入到不

能再插入时的位置为止。并对准锁定扣扣牢。

5、安装电缆线时，松紧要适宜，不能太

紧，也不能太松。

6、操纵线和电缆线安装紧固后，还需转动

或移动各活动部位。特别是手把转向部位，检查

是否干涉或影响转向灵活性。

7、操纵线或电缆线的安装应远离排气消声

器或其它温度较高的部位。

10

Plastic combination plugs can be connected witheach other only if their lock tabs are well aligned.To disconnect them, always disengage the lock tabsfirst. Before connecting the combination plugs,check the joints to see whether they are properlyfitted and bent. Insert the plug into the socket asmuch as possible and engage the lock tabs.

Connect the power cables with a proper

degree of tightness, it means) neither tootight nor too loose.

After the control or power cables are installed andfastened, turn the related moving parts of the vehicle,especially the handlebar, to see if they interfere witheach other or is able to make easy turns.

The control or power cables should be far from the exhaust muffler or other hot surfaces.

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2

润滑系统

维修须知润滑油的更换

故障排除润滑油滤网的清洗

发动机润滑系统润滑油滤清器的清洗

润滑油的检查整车润滑位置

维修须知

本节介绍发动机的润滑系统及该系统各部位的清洗，检查和更换。同时也介绍摩托车整车各润滑部位。检查、润滑系统时，可以不拆下发动机，但在检查、清洗前，需将发动机内的润滑油放掉。

故障排除

润滑油消耗过快

1、发动机有漏油现象；

2、活塞环磨损；

3、进排气门导杆磨损；

4、挡油罩磨损或损伤。

润滑油不清洁

1、未按维修周期表更换润滑油；

2、注油口螺纹损伤。

润滑不正常

1、油面过低；

2、油道及节流孔或滤网堵塞；

3、油泵损坏。

发动机的润滑

发动机润滑系统如图所示。

发动机润滑油：

本车出厂时加注的润滑油是15W/40QE

级汽油机润滑油，不能使用普通机油或其它

油类。

润滑油的黏度应根据不同地区和气温的变化

分别选用。右图介绍在不同气温下推荐使用的润滑油牌号。

发动机机油容量：

发动机分解组装后的容量为1.1L。

放油后再加注时为1.0L。

油泵流量：5L/min（1000r/min）

10W

15W/40

5W20

20W40

4030

20

20W

15W3015W10W3010W20

5W30

5W

-30 -20 -10 0 10 20 30 40 50

12

Lubrication System


Troubleshooting

Engine Lubrication System

Checking of Oil Level

Replacement of Oil

Cleaning or Oil Filter

Cleaning of Oil Cleaner

Lubrication Position


This section tell s you how to clean, check and replace parts of the engine lubrication systemas well as describes the lubrication poin ts. The lubrication system can be checked and cleanedwithout removing the engine but the engine oil should be drained off first.

Troubleshooting

Oil running out too quickly

Engine leaking;

Piston ring abrasion;

Intake/Exhaust valve guide abrasion;

Oil retainer abrasion or damaged.

Oil is not replaced as scheduled;

Dirty engine oil

Oil filler threads are damaged.

Insufficient lubrication

Oil level are too low;

Oil gallery and throttle opening or filter are clogged;

Oil pump are damaged.

Lubrication of Engine

The engine lubrication system isas shown in the sketch below.

Engine Oil

This vehicle has been filled with the 15W (40GE)graded gasoline engine oil before delivery, No

ordinary or other types of oil should be used.

The viscosity of oil should correspond tothe geographic and climatic conditions under which the vehicle is used. the chart shown onthe right are the recommended types of oil.

Oil Capacities

After disassembling and reassembl ing: 1.1 liter

refilling after draining off: 1.0 liter

Oil pump flow rate: 5 liters per min (1,000 rpm)

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润滑油的检查

用主支架将摩托车支撑在平地上，可用油

尺检查机油量。如果油面低于下刻线，则应

补充推荐使用的润滑油，使之注满至上刻线。

可以通过发动机右侧盖上的机油观察孔对油

面进行观察。

润滑油的更换

更换润滑油时，应在发动机温热且尚未

冷却前进行。这样才能保证迅速、彻底地排

除曲轴箱内的机油。更换时，旋开机油过滤网盖，拆下弹簧和过滤网。

润滑油滤网的清洗

将滤网用清洗剂清洗干净。装上滤网和弹簧。

装上滤网盖，并按规定的扭矩值旋紧。

从注油口加注1.0L新的润滑油。

装上带油尺的螺塞。然后，起动发动机，

使其在怠速情况下运转4~5分钟后停止运转。

然后，将车身保持平正，检查油面高度，此

时，油面高度一定要达到下刻线上，并检查

有无漏油现象。

13

Checking of Oil Level

Place the vehicle on a flat surface and check theoil level with a dipstick. If the oil level is below thelower line mark, fill the engine with the commendedtype of oil until the upper line mark is reached. Theoil level can be seen through the watch hole in theright side cover of the engine.

Replacement of Oil

Replace oil while the engine is still warmas this facilitates quick, thorough draining off of old oil from inside the crankcase. To replacethe oil, unscrew the filter cover and remove thespring and filter.

Cleaning of Oil Filter

Clean the oil filter with a cleaning detergent and

put it and the spring back in place.

Put on the filter cover and tighten it to the specified torque.

Pour 1.0 liter of fresh oil through the filler opening into the crankcase.

Screw in the screw plug with dipstick and then start the engine.Leave the engine running idle for 4~5 minutes and shut it off.

Then, while keeping the vehicle in a level position, check theoil level to make sure it is above the lower line mark and thencheck the crankcase for leakage.

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10 20 mm

润滑油滤清器的清洗

注意：在曲轴箱注入机油之前，须先清洗机油滤

清器。

拆下滤网盖；拆下滤网并将机油放干净；

拆下排气消声器和脚蹬；

拆下离合器操纵线和发动机转速表软轴线；

拆下起动臂，打开右曲轴箱盖。

拆下机油滤清器盖，并将机油滤清器清

洗干净，使其保持良好的工作状态。然后，

再装上机油滤清器盖及右曲轴箱盖。

将离合器操纵线连接好。

装好脚蹬和起动臂。

装好滤网及滤网盖。装好排气消声器。将推荐使用的润滑油注入到曲轴箱内，

起动发动机。

将发动机熄火后，检查机油量，检查

是否有漏油的现象。

油泵的拆卸、检查，组装及安装详见

第8章。

14

Cleaning of Oil Filter

Note : Clean the oil filt er before pouring oil through

it into the crankcase.

Remove the filter cover;

Remove the filter and drain off oil from the crankcase;

Remove the exhaust muffler and footrest;

Remove the clutch control cable and speedometer flexible shaft;

Remove the starting lever and open the right crankcase cover.

Non -sh edd ing c lot hRemove dirty from spindle

lRemove the oil filter cover and clean the oil filt er torestore it to good condit ion. Then put on the oil filter cover and right crankcase cover.lConnect the clutch control cable and put the footrestand starting lever back in place.

lPut the oil filter and its cover back in place, put on theexhaust muffler and finally pour the recommended typeof oil into the crankcase and start the engine.lShut off the engine, check the oil level and thecrankcase for leakage.lRefer to Section 8 for disassembling, checkingand reassembling the oil pump.

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前叉

后制动拉杆滚球轴承发动机

制动踏板支点

15

碟刹盘后制动器

应定期对离合器操纵线，油门操纵线，前制动操纵线及里程表软轴进

是将各操纵线及软轴线的上端连接处拆下，用钙基润滑脂（俗称黄油）

进行充分的润滑和保养。

凡本手册未注明使用的润滑油，一律采用普通常用的润滑油。

凡本图中未显示出的滑动表面，均涂上润滑油或润滑脂。

各操纵线及软轴的润滑

行润滑。其方法

对钢丝绳和各支点

整车润滑位置

Lubrication of Control Cables and Flexible Shaft

The clutch cable, throttle cable, front brake cable and odometer shaft should be lubricatedon a periodical basis. Proceed as follows: Remove these cables and flexible shaft from the jointsand coat the pivot points of these cables with calcium-base grease (customarily called yellow grease).

Lubricating Position

Unless otherwise specified in this manual, general-purposelubricating oils should be used.Unlessotherwise shown in thepicture below, all the sliding surfacesshould be coated with lubricating oil or grease.

Brake pedal pivot pointEngine

Rolling ball bearing

Front fork

Rear brake Brake disk

Rear brake lever

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3检查和调整

维修须知技术要求

发动机空气滤清器输油管道燃油过滤器火花塞气门间隙点火正时油门操纵化油器怠速正时链条的张紧力汽缸压缩力

车体驱动链条

蓄电池制动系统制动灯开关前照灯调光离合器自由行程侧支架前悬挂系统立管转向轴承车轮及辐条螺栓、螺母及紧固件

维修须知

本书介绍了RATO RT200-5型摩托车各部位的检查和调整。同时介绍调整、检查时的技术

要求。关于润滑系统的检查、清洗详见第二节。

技术要求

发动机

推荐火花塞：

火花塞间隙：

气门间隙：

点火正时：

油门转把自由行程：

怠速：

汽缸压缩力：

D8RTC

0.6~0.7mm

进气 0.08mm 0.02±

排气 0.08mm 0.02±

上止点前15 ±1°（1500±100r/min）

2~6mm

1500±150r/min

1274kpa±147kpa

16

Checks and Adjustments

l Notes to Maintenance

lTechnical requirements

EnginelAir cleaner

lFuel supply pipeline

lFuel filter

lSpark plug

lValve gap

lIgnition timing

lThrottle control

lCarburetor idle speed

lTiming chain tension

lCylinder pressure

l

lBody

lDrive chain

lBatterylBrake system

lBrake lap switch

lHeadlamp beam operation

lClutch free play

lSide stand

lFront suspension system

lHead pipe bearing

lWheels and spokes

lBolt, nuts and fastener s


This section tells you how to make checks and adjustments of the RT200-5 motorcycle.It also provides the technical requirements for such checks and adjustments. Refer to Section 2for checking the lubricat ion system.

Technical Requirements

Engine

Recommended spark plug model

Spark plug gap

Valve gap

Ignition timing

Throttle grip free play

Idle speed

Cylinder pressure

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10~20mm

10~20mm

20~30mm

225kpa

280kpa

2.75-18-4PR

100/90-18-6PR

17

空滤器螺钉

Cleaning Squeezing Soaking Squeezing

车体

离合器操纵手柄自由行程

前制动操纵手柄自由行程

后制动踏板自由行程

轮胎气压前轮

后轮

轮胎尺寸前轮

后轮

空气滤清器

拆下右边盖。

拆下空气滤清器盖上的固定螺钉。

拆下空气滤清器盖。

拆下空气滤清器芯。用不能燃烧或高燃

点的清洗剂，将空气滤清器芯洗干净，然

后使其干燥。

注意：不能用汽油清洗。

将空气滤清器芯浸入汽油机机油中，

然后取出并挤出过量的汽油机机油。

空气滤清器的安装和拆卸时的顺序相反。

Body

Clutch lever free distance

Front brake lever free distance

Rear brake pedal free distance

Tire pressure Front

Rear

Rear

Front

Air cleaner

Remove the right side cover.Unscrew the fastening screw from the air cleaner cover.Remove the air cleaner cover.

Soak the air filter into engine oil and thenremove it and squeeze off engine oil.Put the air cleaner in the reverse order in which it is removed.

Remove the air filter and clean it withnon-igni table or high ignition point detergentand dry it.

Note: Do not clean it with gasoline.

Air filter screw

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18

油管燃油开关Fuel filter Fuel pipe

输油管道

检查油管是否老化，损伤或破裂，必要

时应更换。

燃油过滤器

检查燃油过滤器是否变色或堵塞。如果

过滤器是黄色或堵塞，应更换新的过滤器。

更换时，油开关应处于关闭状态。

火花塞

用套筒扳手拆下火花塞。目视火花塞绝缘体有无损伤。电极是否烧蚀。如有，则应更换。

用厚薄规检查电极间隙。火花塞电极间

隙0.6~0.7mm。

用火花塞清洗器或钢丝清除积碳、脏物。然后谨慎地调整火花塞间隙。检查火花塞密封垫是否处于良好状态。

Fuel Supply Pipeline

Check the fuel pipe to see if it is aged,damaged or broken and replaceit when necessary.

Fuel Filter

Check the fuel filter to see if it has changed color or clogged. Replace it if it has turned yellow or isclogged. The fuel cock should be off beforereplacing the fuel filter.

Spark Plug

Remove the spark plug cap.

Unscrew the spark plug with a socket wrench

and check visually the insulator for damageand the electrode for corrosion. If yes, replacethe spark plug.

拆下火花塞帽。

Gap: 0.6~0.7mm

Checking Gap

Deposit

Electrode corrosion

Check the gasket for tightness

Cleaning:Use the spark

plug cleaner or steel wirefor cleaning.

After assembled,tighten it by handand then turn further it by 1/2~3/4 turns.

Check the gap between the electrodes witha feeler gauge to make sure it is within 0.6-0.7mm.Remove carbon deposit s or dirt with a spark plugcleaner or piece of steel wir e and then carefu llyadjust the gap.Check the spark plug pack ing ring to see if it is ingood condition

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19

阻风门手柄

安装火花塞时，应先用手将火花塞旋入。

拧紧后，再用套筒扳手拧紧。再盖上火花塞帽。

阻风门手柄

检查阻风门手柄是否移动灵活，定位准确。

如果移动时有滞阻现象，则应将轴和轴套

进行打磨，清洗并涂上润滑油。

气门间隙

拆下坐垫和油箱。拆下视孔盖和上视孔盖。

逆时针旋转磁电机飞轮，使飞轮上的“T”

记号与左前盖上的指示记号对准。注意活塞

一定要处于压缩行程的上止点位置。

To install the spark plug, turn the spark plug by hand first, t ighten it with the socket wrenchand then put on the spark plug cap.

Choke knob

Check the choke knob to see if it is able to turnfreely and position accurately. If the turning isnot smooth, grind the shaft and the bush, clean

and oil them.

Valve Gap

Note: The valve gap should be adjusted while theengine is cool (with a temperature of below 35℃).

lRemove the seat and fuel tank.lRemove the lower and upper watch hole covers.Turn the magneto flywheel counterclockwise untilthe T mark is aligned with the indicating mark onthe left front cover. Note that the piston must be inthe TDC position of the compression stroke.

Choke knob

注意：气门间隙应该在冷机的时候调整（温度应低于35℃）

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20

拆下气缸头盖。

用厚薄规插入调整螺钉与气门杆之间检

查其间隙。

气门间隙：进气门：0.06mm

排气门：0.08mm

调整时，扭松锁紧螺母，然后旋转调整螺钉，直到厚薄规感到有轻微的被拉动

的感觉为止。然后用气门调整器调整螺钉后，再旋紧锁紧螺母。

再检查气门间隙。

然后，装好气缸头盖，视孔盖和上视孔盖。装上油箱及坐垫。

点火正时

注意：点火正时是不能调整的。因为CDI（电容放电点火）不能调整。如果点火不正时，则应检查CDI点火器，脉冲触发器和磁电机，并更换有故障的电器件。

拆下上视孔盖。

连接好正时灯；

启动发动机，并使其处于怠速状态。

如果磁电机转子上的“F”记号与左前盖上的指示记号能对准，则说明正时正确。怠速为1500±100r/min。

Remove the cylinder head cover.

Check the gap between the adjusting screw

and valve rod with a feeler gauge.

Intake valve gap: 0.06mm

Exhaust valve gap: 0.08mm

To adjust the valve gap, loosen the lock nut and thenturn the adjusting screw until a drag is felt on the feeler gauge. Then turn the screw with the valve adjuster andtighten the lock nut.

Check the valve gap again.

Finally put the cylinder head cover, upper, lower watch hole covers, fuel tank and seat back in place.

Ignition Timing

Note: Ignition timing is not adjustable because theCDI (capacitor discharging ignition) is not adjustable.If the ignition time is not correct, check the CDI, pulsetrigger and magneto and replace the malfunctioningelectrical parts.

Remove the upper watch hole cover;

Connect the timing lamp;

Start the engine and leave it runningat the idle speed.

If the F mark on the magneto rotor is aligned with themark on the front left cover, it means the timing is correctand the idle speed is 1,500±100 rpm.

Alignment mark

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21

Loosen

Tighten

Increase

Decrease

然后将发动机增大转速，检查下列项目；2140±200r/min超前启动3740±200r/min超前停止（指示符号应介于超前记号之前）

油门操纵

首先检查油门操纵线是否变形，扭结或损伤。然后测量油门凸缘位置的自由行程。

自由行程：2~6mm

检查油门是否能在任何位置由全开到全关顺利转动。

如果有滞阻现象则应调整或更换。拉开胶套，扭松锁紧螺母，转动调整螺管，以调整到满意的自由行程。扭紧锁紧螺母，装好胶套。

化油器怠速

注意：在发动机其它项目已调整到规定的范围，再检查、调整化油器怠速。

调整时，发动机应处于热机状态下。将车用主支架支撑，旋转柱塞止动螺钉。怠速：1500±150r/min

lThen increase the engine speed and check the following:lAdvance start at 2,140±200 rpmlAdvance stop at 3,740±200 rpm (the indicating mark should be in front of the advance mark)

Throttle Control

Check the throttle control cable for deformation,twist or damage and then measure the free distanceof the throttle flange.

Free distance: 2~6mm

Check the throt tle grip to see if it can be turnedfreely from fully open to fully close.

If the thrott le grip cannot be turned free ly in this way,adjust or replace it by removing the rubber jacket,loosening the lock nut and turning the adjustingthimble until the desired free distance is obtained.

Carburetor Idle Speed

Note: The carburetor idle speed should be checkedonly if other items of the engine have been adjustedto the specified value.

lAdjust the carbure tor idle speed while the engine is warm.lPlace the vehi cle on the main stand and turn the plunger stop screw.

lIdle speed: 1,500 150 rpm±

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22

压缩力的测试

将发动机预热，然后使发动机熄火，并拆下火花塞。然后在火花塞安装处装上压力表，并将阻风门和油门转把完全打开。用力踩下起动臂4~6次。

注意：检查压力表各连接部位是否有漏气现象。对发动机不断地进行启动，直到压力表停止上升为止。压力表的最大读数通常经过4~6次启动后即可达到。

汽缸压缩力： 1274±147kpa

驱动链条

将摩托车用主支架支撑并将变速器设在空

档位置上。检查驱动链条的弛度。方法是

用手指上下按动链条。并检查位于下方中部链条。

弛度。

链条弛度：10~20mm

调整方法

旋松后轮轴螺母和两侧的锁紧螺母。转动调整器上的调整螺栓。

注意：两端上的链条调整器上的刻线一定要一致。

Testing Cylinder Pressure

Warm up the engine and then shut it off. Removethe spark plug.Screw in a pressure gauge, turn the choke andthrottl e fully open and push the starting lever for 4-6 times.

Note: Check to make sure the pressure gauge is welltightened. Start the engine repeatedly until thepressure gauge reading remains unchanged.

The maximum value could be reached after kicking the start lever 4-6 times

Cylinder pressure: 1274±147Kpa

Drive Chain

Place the vehicle on the main stand and set thegearbox to the neutral gear. Check the slacknessof the drive chain by pushing it with the finger and checking the lower middle part of the chain.

Slackness: 10-20mm

Chain slackness adjustment

Loosen the rear axle nut and the lock nut on both sides.Turn the screw on the adjuster.

Note: The line marks on the adjusters on both sidesmust be aligned to each other.

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23

再旋紧后轮轴螺母，扭矩：50~80N.m再检查驱动链条的弛度和后轮自由转动灵活程度。

链条的清洗、检查

首先拆下链条卡子和活动链板，将链条

取下。再用清洗液清洗干净并搽干，检查链条

是否磨损或破裂。如损坏，则应更换链条。

再将链条安装好，并涂上链条润滑剂或发动机

机油。

注意：安装链条卡子时，应使卡子的开口方向与链条的运动方向相反。

蓄电池

检查蓄电池的电解液是否在上下限之间。当电解液接近下限位置时，则注入蒸馏水。

直到注至上限为止。并清洁两电极端接头和蓄电池外表面。再检查电解液的比重。

注意：蓄电池内只能加注蒸馏水。如加注自来水，将缩短蓄电池的寿命。

Tighten the rear axle nut to a torque of 50-80 N.mand then recheck the chain slackness and the rear wheel to see if it turns freely.

Cleaning and Checking the Drive Chain

Remove the chain clip and movable chain plate first andthen the drive chain. Clean it with detergent and dry it.Check the chain for damage and replace it if it is damaged.Put the chain back into place and coat with chain lubricantor engine oil.

Note: When fi t the chain clip, make sure its openingis faced against the direction in which the chain turns.

Battery

Check the battery solution leve l to see if it is between the upper and lower l imits. Add d is ti lledwater if the level is close to the lower limit andclean the battery terminals and outside surface.Then check the specific weight of the battery solution.

Note: Only di st il led water can be used to di lute thebattery solution. Using tap water may shorten the

battery lif e.

Specific weight

Upper limit

Lower limit

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24

紧

松

调节螺母Adjusting nut

后制动踏板自由行程

后制动踏板的自由行程：20~30mm

如果需要进行调整，转动调整螺母即可。

前制动系统

Front brake System

Rear brake pedal

The rear brake pedal should have a distance of 20-30mm.

Turn the adjusting nut to adjust the distance if required.

(1) The front brake is disc brake,when the motorcycle is in production,the

disc brake is already good debugging,the normal user can not adjust on theirown.

(2) If adjustment is needed, please

go to professional repair station to

conduct inspections and adjustments.Caution:Disc structure more complex, self-

adjustment of the disc will affect

traffic safety, please carefully.

（1)本车前制动为碟刹，在摩托车生产出厂的时候，刹车已经调试到了合适的位置，普通用户是不能自己进行调整的。（2）如果有必要进行调整，请到专业维

修站进行调整。注意：碟刹的结构非常复杂，自行调整碟刹会

影响整车的安全性，请仔细操作。

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25

箭头标记

刹车灯开关上的调整螺母

10~20mm

Arrow mark

Adjusting nut on brake lamp switch

离合器的自由行程

离合器的自由行程为10~20mm。

Free distance of Clutch Lever

The clutch lever should have a free distance of 10-20mm.

制动灯开关

调整好制动踏板的自由行程后，即可

调整制动灯开关。当制动踏板向下移动

20mm距离时，刹车灯应开启。

调整时，旋转刹车灯开关上的调整螺母

即可。

注意：不得转动刹车灯开关体。

Brake Lamp Switch

After the free distance of the brake pedal is adjusted,adjust the brake lamp swit ch so that when the brake pedal moves down by 20mm, the brake lamp should be turned on.

To adjust the brake lamp switch, simply turn theadjusting nut on the brake lamp switch.

Note : Do not turn the switch body.

制动蹄块磨损指示

将制动手柄或制动踏板操纵到位后，如果

制动盖上的标记与指示板上的箭头对准，

则应更换制动蹄块。

Brake Lining Wear Indication

Turn the brake lever or push the brake pedal into posi tion and see if the mark on the brake cover isaligned with the arrow on the indicating plate.If yes, replace the brake lining.

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紧

松调节螺管Lock nut

Tighten

Loosen

26

调整器

侧支架弹簧

如果需要对离合器进行调整，先旋松锁

紧螺母，再转动调整螺母。

该调整装置可进行较大范围的调整。

如果要进行微调，在手把上的调整器上可

以进行微调。调整好后，再检查离合器自

由行程。

侧支架

检查侧支架是否损坏或丧失弹力，是否

能自由转动。

如果用弹簧测力器拉动侧支架下端，测力器的力度应为20~30N.m

悬挂系统

前叉的检查

将前制动器处于制动状态，并压前叉架数次，检查前悬挂是否工作正常。

如果发出不正常的噪音或喀嚓声，则应检查全部紧固件，并按规定的扭矩值扭紧。

To adjus t the clutch, loosen the lock nut andturn the adjusting nut.

The adjuster can be used to make rough adjustments.

The adjust er on the handlebar can be used tomake fine adjustments. After adjustment,recheck the free play of the clutch.

Side Stand

Check the side stand to see if it is damaged or has lost elasticity and if it is able to turn freely.

Pull the lower end of the side stand with a forcebalance and see if the force is within 20-30 N.m.

Suspension System

Checking the front fork

Apply the front brake and push the front fork severaltimes to see if the front suspension works normally.

If an unusual noise or creaky sound is heard,

check all the fastener and tighten them to thespecified torque values.

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27

后悬挂

用力将后轮朝一侧推，检查后叉轴套是否磨损或损坏。如损坏，应更换。再检查整个悬挂总成是否安装牢固，有无损伤或变形。最后，检查后轮的同轴度，有无扭曲变形。

转向轴承

注意：检查操纵线及电缆线是否与转向手把的

转动相干涉。

将前轮抬离地面，检查转向手把是否能自由转动，如果转向手把不能平衡转动，或者有卡滞现象，则应调整前叉立管调整螺母。

车轮

注意：在轮胎冷却时才可检查胎压。

胎压

检查轮胎是否有切口，嵌入铁钉或者其它

锋利的物品。

推荐使用的轮胎压力。

驾驶员一人前225kpa

后280kpa

全部螺栓、螺母及紧固件

全部螺栓、螺母和紧固件应按保养周期表加以扭紧。并检查全部开口销及安全夹、锁等。

Rear Suspension

lPush the rear wheel hard to one side and check the rear fork for wear or damage. Replace it if damaged.lCheck the whole suspension system for tightnessand abrasion or deformation.lFinally check the wheels for concentricity, twistor deformation.

Steering Bearing

Note : Check the cont rol cable and power cable tosee if they interfere with the turning of the handlebar.

Lift the front wheel off the ground and check thehandlebar to see if it is able to turn freely. If it isunable to turn evenly or gets stuck, adjust theadjusting nut for the front fork tube.

Wheels

Not e: Tire pre ssure can be checked only in cool condition

Tire Pressure

Check the tires for cuts, nails or other sharp objects.The recommended tire pressures for solo ride are:225kpa for front tire and 280kpa for rear tire.

Bolts, Nuts and Fasteners

All the bolts, nuts and fasteners should be tightenedaccording to the maintenance schedule. Check all thesplit pins, safety clamps, locks, etc.

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4

燃油系统

浮子 /浮子针 /喷嘴

浮子高度的调整

节气门的安装

化油器的安装

定位螺钉的调整

维修须知

故障排除燃油箱

空气滤清器

化油器的拆卸

节气门的分解

维修须知

总则

1、处理汽油时，应特别小心，应经常记住在空气流通、通风良好的场地下进行，并远离火花和火焰。

2、拆卸燃料系统各零部件时，要注意“O”型环的安装位置。在重新安装时，一定换用新“O”型环。

3、浮子室下端有放油螺钉，可以旋松螺钉，使残存在浮子室的汽油排泄干净。

故障排除

一、发动机可以点火，但不能启动

1、燃油箱内没有燃油；

2、没有燃油流入化油器内；

3、进入汽缸内的燃油太多；

4、空气滤清器堵塞。

二、混合气太稀

1、化油器喷嘴堵塞；

2、燃油箱盖通气孔堵塞；

3、燃油过滤器堵塞；

4、燃油管流动不畅通；

5、浮子针有故障；

6、化油器内油平面太低。

三、混合气太浓

4、浮子卡住或浮子针有故障；

1、阻风门关闭

2、化油器内油平面太高；

3、化油器空气喷嘴堵塞；

5、空气滤清器不清洁。

四、发动机怠速不稳定，失速或转动不良

1、怠速调整不当；

2、混合气过浓；

3、混合气过稀；

4、汽缸压缩力过低；

5、空气滤清器堵塞；

6、燃油中掺入了杂质；

7、燃油存放过久。

28

GASOLINE SYSTEM


Troubleshooting

Fuel Tank

Air Cleaner

Removal of Carburetor

Removal of Throttle

Float (Float Needle) Nozzle

Adjustment of Float Height

Installation of Throttle

Installation of Carburetor

Adjustment of Locating Screw


General Requirements

1.Special care should be used when handling gasoline. Keep the workplace wenti latedand away from sparks or flames.2.When removing parts from the fuel supply system, note the locations of O-rings andalways use new ones to replace old ones once they are removed.3.There is a drain screw at the bottom of the float chamber which can be loosened todrain off fuel from the float chamber.

Troubleshooting

Engine able to get ignited but unable to get started

No fuel in fuel tank;

No fuel supplied into carburetor;

Too much fuel in cylinder;

Air cleaner clogged.

1.Carburetor nozzle clogged;

2.Vent in fuel tank cap blocked;

3.Fuel filter clogged;

4.Fuel unable to flow freely in fuel pipe ;

5.Float needle failed;

6.Fuel level in carburetor too low.

Gas mixture too thin

1.Choke closed;

2.Fuel level in carburetor too high;

3.Carburetor air nozzle clogged;

4.Float stuck or float needle failed;

5.Air cleaner dirty.

Gas mixture too thick

Engine idle speed instable

1.Idle speed not properly adjusted;

2.Gas mixture too thick;

3.Gas mixture too thin;

4.Cylinder pressure too low;

5.Air cleaner clogged;

6.Fuel dirty;7.Fuel aged;

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空滤器螺钉Air filter screw

29

油箱固定螺栓

油位传感器

空气滤清器滤芯

Fuel tank bolt

Fuel level sensor

Air filter

关掉燃油开关，并拆下燃油通路的连接。

拆下两边的侧盖。然后拆下坐垫连接螺栓，

取下坐垫。

拆下燃油存量传感器联结器，并旋出燃油

箱固定螺栓。然后将油箱往后拉，即可拆下燃油箱。

注意：火焰或火花不能接近汽油。凡溢出汽油，应

立刻擦干净。

空气滤清器

拆下右边的侧盖和坐垫，然后拆下油箱

及油箱胶垫。再拆下与化油器的连接管,

取出空气滤清器滤芯。

Removal of Fuel Tank

lTurn off the fuel switch, disconnect the fuel passage .lRemove the two side covers, unsc rew the sea t boltsand remove the sea t.lRemove the fuel level sensor connecto r and unscrewthe fuel tank bolt.lPull the fuel tank backward to remove it.

Note: Keep the fuel from flame or sparks. Spil led fuelshould be cleaned immediately.

Air Cleaner

Remove the right side cover and seat, remove

the fuel tank and rubber gasket, disconnect thecarburetor pipe, and remove the air filter.

油箱的拆卸

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节

气门柱塞

30

柱塞弹簧

卡子油针柱塞

Plunger spring

ClipFuel needlePlunger

T h r o

t t l e p l u n g e r

化油器的拆卸

关闭燃油开关，并拆下燃油管路的连接。拆下两边的侧盖。拧松化油器放油螺钉，将化油器内的燃油放出。

拆下化油器与进气管的连接螺母。拧松与空气滤清器连接箍带螺钉。然后拆下化油器盖，将节气门柱塞拉出。并卸下化油器。

节气门柱塞

在节气门柱塞上的凹槽里将油门操纵线

端头的连接拆下。拆卸时应将节气门弹簧

压下。

拆下油针固定环，然后从节气门柱塞内

将油针和油针固定挡圈一同拆下。

检查节气门柱塞和油针表面是否干净、

光滑，有无划伤或磨损现象。

注意：火焰或火花不能接近汽油。凡溢出汽油，应

立刻擦干净。

Removal of Carburetor

lTurn off the fuel switch, disconnect the fuel pipe and remove the two side covers.lLoosen the carburetor drain screw to drainoff fuel from the carburetor.lUnscrew the nut connecting the carburetor and air pipe.lLoosen the screw from the connecting stripof the air cleaner.lRemove the carburetor cover and pull out

the throttle plunger and remove the carburetor.

Note: Keep the fuel from flame or sparks.Spilled fuel should be cleaned immediately.

Throttle Plunger

lDisconnect the thrott le control cable joint fromthe slot in the plunger and be sure to compress thethrott le spring when doing the disconnection.lRemove the fuel needle fastening ring and thenremove the needle and retainer ring from insidethe throttle plunger.lCheck the surfaces of the throttle plunger andfuel needle to see if they are clean, smooth andfree of scratches or wear.

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浮子、浮子针、喷嘴的拆卸

拆下浮子室盖的连接螺钉和浮子室盖。

然后将浮子臂销拉出。取下浮子和浮子针。

检查浮子针的接触面是否有磨损和损伤。

必要应更换新的浮子针。拆下主量孔、发泡管喷嘴，怠速量孔和

柱塞止动螺钉。

再拆下定位螺钉。

注意：拆下螺钉之前要先测定螺钉的安

装位置。记住拆下螺钉转动的次数。否

则，在安装定位螺钉时会造成不必要的

麻烦。

然后用清洗液对化油器所有孔道及表面

进行清洗。清洗完后，用压缩空气对全

部孔道进行吹气。将脏物等清除。

然后，按拆卸顺序依次对怠速量孔、发

泡管喷嘴、主量孔和柱塞止动螺钉进行

安装。再装好定位螺钉，并拧到拆卸前

的安装位置。定位螺钉的开启位置，拧到位后退7/4转。

31

浮子

浮子臂销

浮子针

发泡管怠速微调螺钉

怠速微调螺钉

柱塞微调螺钉

柱塞微调螺钉

Removal of Float, Float Needle and Nozzle

lUnscrew the float chamber cover screw andthen remove the float chamber cover.lPull out the float pin and remove the float andfloat needle.lCheck the contact surface of the float needlefor abrasion and damage and replace the floatneedle when necessary.

lRemove the main orifice, foam tube nozzle,idle speed orifice and plunger stop screw.lRemove the locating screw.

Note: Before removing the screw, be sure to identify the installing posi tion of the screw and remember the number of turns used to removethe screw. Otherwise the reinstal lationof the screw will be unnecessarilytroublesome.

lClean all the orifice recesses and surface of thecarburetor with detergent. After cleaning, blowthe orifice recesses with compressed air to makethem dry.lThen reassemble the idle speed orifice, nozzle,main orifice and plunger stop screw, put in thelocating screw and tighten it to the position before removal.lTurn the locating screw all the way into positionand then turn it back by 7/4 turn to reach its

open position.

Float

Float pin

Float needle

Foam tube

Idle speed fine-adjusting screw

Plunger fine-adjusting screw

I d l e s p e e d f i n e - a d j u s t i n g s c r e w

P l u n g e r f i n e - a d j u s t i n g s c r e w

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安装好浮子、浮子针、再插上浮子臂销。

浮子高度的调整

先用高度计测量浮子的高度。

浮子高度：15±1mm

需要调整浮子高度时，慢慢地将浮子臂

改变角度，直至浮子臂的尖端刚刚与浮

子针相触为准。也可以在浮子高度检测

仪上调整浮子的高度。

节气门柱塞的组装

先在油针的环槽内装上挡圈。

标准定位位置：第三格环槽。

32

第三格环槽

挡圈

浮子组件

Reinstal l the float and float needle and put in the float pin.

Adjustment of Float Height

Measure the float height with a height gauge.Float height: 15±1mm

To change the float height, slowly turn the floatarm until its sharp end is jus t in touch with the

float needle. It is also possible to change thefloat height through the height gauge.

Reassembly of Throttle Plunger

Put the retainer ring into the ring groovein the fuel needle.

rdStandard position: the 3 ring groove

Third ring groove

Retainer ring

R e t a

i n e r

r i n

g

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33

再将油针装入柱塞内，安上固定环。

然后，将柱塞弹簧装入油门操纵线的端

头内。再将操纵线与节气门柱塞连接好。

化油器的安装

将节气门柱塞装入化油器体内。

注意：节气门柱塞的凹槽应对准化油器体上的

止动螺钉。

再旋紧化油器顶端的端盖。

装好化油器之后，用油门操纵线上的调整装置调整油门手把的自由行程。

油门手把的自由行程：2~6mm

定位螺钉的调整

先将定位螺钉向顺时针方向旋，直到与

螺孔座接触为止。然后再朝反方向旋直到达到标准位置。定位螺钉的标准位置：7/4转

注意：如果定位螺钉与螺孔座拧得太紧，则可能损坏螺孔座。

将发动机启动升温到工作温度，调整节

气门止动螺钉使怠速达到1500±150r/min。不断地操纵油门手把，检查发动机是否

能很稳定地加速或减速。

再调整定位螺钉，直到达到最高转速为止。

然后，再调整柱塞止动螺钉，将怠速重

新调整到1500±100r/min

Put the fuel needle into the plunger and puton the fastening ring. Then insert the plunger spring into the end of the throttle control cableand connect the cable with the throttle plunger.

Installation of Carburetor

Put the throttle plunger into the carburetor body.

Note : The groove in the plunger should bealigned to the stop screw on the carburetor body.

lTighten the end cover on top of the carburetor.lAfter the carburetor is installed, adjust thethrottle grip free play using the adjuster onthe throttle control cable.lThrottle grip free distance: 2-6mm

Adjustment of Locating Screw

Turn the locating screw clockwise until it touchesthe end of the screw hole and then turn itcounterclockwise until it reaches the standard position.Standard position of locating screw: 7/4 turns

Note: The screw hole may be damaged if thelocating screw is turned too tight into it.

Start the engine to warm it up to the workingtemperature and turn the throttle stop screwuntil the idle speed reaches 1,5000±150 rpm.Turn the throttle grip repeatedly to check if theengine is able to accelerate or decelerate.Turn the locating screw again until the highestspeed is reached. Then turn the plunger stop

screw to bring the idle speed back to 1,500±150 rpm.

Increase

Decrease

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34

5发动机的拆卸和安装

维修须知发动机的拆卸发动机的安装

总则

在拆卸和安装发动机时，把车用主支架支撑起来，若是在升降台上拆卸和安装，要把前轮

固定好。对以下各项零件和组件，要先将发动机自车架上拆下，方可进行保养维修。

反冲启动机构

变速机构

规格：

发动机重：30kg

发动机容量：分解后的注入量是1.0L。

扭矩：发动机悬挂螺栓：27—33N.m

排油螺栓：20—30

换挡踏板螺栓：8—12

启动臂螺栓：8—12

N.m

N.m

N.m

发动机的拆卸

先将发动机内的机油放干。关闭燃油阀，并拆开燃油通路的连接。拆下左右两边的侧盖。拆下座垫。拆下燃油箱。

维修须知

曲轴

Disassembling and Reassembling of Engine


DisassemblingReassembling


General Requirement

The vehicle should be propped up with the main stand when performing disassembling or reassembling of the engine. If the engine is disassembled or reassembled on an elevating

platform, the front wheel should be fastened. To service the following parts , the engine must

be removed from the frame.Kick starter CrankshaftGearshift mechanism

Specifications

Engine weight: 30 kg

Oil capacity: 1.0 liter when refilled after reassembling

Torque requirement

Suspension bolts: 27-33 N.m

Oil drain bolt: 20-30 N.m

Gearshift pedal bolt: 8-12 N.m

Starting lever bolt: 8-12 N.m

Disassembling of Engine

lDrain off oil from the engine.lClose the fuel cock and disconnect

the fuel supply passage.lRemove the two side covers.lRemove the seat.lRemove the fuel tank.

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35

拆下发动机变速踏板和左后盖。

拆开磁电机的电线连接，并取出交流发电机机线。

拆下排气消音器固定螺栓和下固定螺栓。

拆下排气消音器。

拆下发动机下方四颗螺栓之后，即可拆下脚踏板和边支架。

用钳子拆下驱动链条夹和固定环。

拆下驱动链条。

拆下固定螺栓，即可将化油器与汽缸头分开。

拆下高压线缆。

lRemove the gearshi ft pedal and main rear cover.lUnwire the magneto and disconnect the AC generator.lUnscrew the exhaust muffler bolt and lower set bolt.lRemove the exhaust muffler.lUnscrew the four bolts from under the engine and removethe footrest and side stand.lRemove the drive chain clip and fastener ring with pliers.lRemove the drive chain.lLoosen the clutch control cable lock nut and disconnectthe clutch cable and U-clamp.lRemove the clutch control cable.

lUnscrew the fastener bolt and disconnect the carburetor from the cylinder head.lRemove the high-tension cable.

链条夹

固定环Fastener ring

Chain clip

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36

注意：在发动机拆卸时，其下方应先放置千斤顶或垫块。

拆下发动机前悬架螺栓和螺母。

将发动机前悬架支撑拆开。

先拆下发动机上的固定螺栓和螺母，即可

将发动机上的悬架垫板拆下。

拆下发动机后固定螺栓。

拆下发动机。

注意：在发动机的拆卸过程中，应尽量保证发动

机平稳，不能晃动过大。

发动机的安装

发动机在安装时，按照与拆卸相反的顺序进行。

注意：先查明全部电线的正确接法。调整好油门线的自由行程。调整好离合器线的自由行程。调整好驱动链条的驰度。将曲轴箱内注满推荐使用的机油，注满到适当的位置而止。

Note: Before disassembling the engine,be sure to place a jack or pad.

Unscrew the bolts and nuts from the front suspension.

Remove the front suspens ion support.

Unscrew the fastener bolts and nuts from the engineand remove the suspension plate.

Unscrew the rear fastener bolt from the engine.

Remove the engine.

Note: Whi le disassembling the engine, be sure to keepit securely fastened and free of shaking.

Reassembling of Engine

Follow the reverse order of disassembling toreassemble the engine.

Note:

lCheck the wiring for correctness. lAdjust the free distance of the throttle control cable . lAdjust the free distance of the clutch control cable. lAdjust the slackness of the driver chain. lFill the crankcase with the recommended type

of oil up to an appropriat e level.

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37

扭矩：

M8悬挂螺栓 /螺母27~33N.m

M10悬架螺栓 /螺母30~40N.m

注意：先暂时装上车架上全部螺栓，然后在依次扭紧。

装好悬架垫板，悬架支撑，悬架螺栓。

Torque Requirement

Suspens ion bolt/nut M8: 27-33 N.m

Suspension bolt/nut M10: 30-40 N.m

Note: Put all the bolts into the frame andthen tighten them one by one.

Put on the suspension plate, support and suspension bolt.

7/16/2019 RT200-5


汽缸头与气门

维修须知挺杆的检查

故障排除汽缸头的检查

汽缸头盖的拆卸汽缸头的装配

上摇臂组合的拆卸

上摇臂组合的检查

汽缸头的拆卸

汽缸头的分解

气门和气门导管的检查汽缸头的安装

维修须知

各部规格

汽缸头头部的润滑油是经由发动机外壳上的控制油孔而注入到汽缸头的。此油孔决不能堵塞。而在安装汽缸头之前，0形圈和定位销一定要先安装好。

装配时，在上摇臂组合的转动部及球窝处涂好二硫化钼润滑剂，作为基础润滑。

项目标准值mm 维修极限mm

上摇臂组合

轴向间隙0.05~0.12 0.15

进、排气摇臂和摇臂轴向间隙0.005~0.041 0.08

气门弹簧 0.05

外簧

内簧

气门间隙

气门气门杆外径

气门杆导管内径

气门杆至导管间隙

气门座宽度

扭曲度

气门座宽度

汽缸头

进气

排气

进气

进气

排气

排气

气门

45.5 41.00

39.4 35.50

0.05~0.08

5.450~5.456 5.42

5.430~5.445 5.4

5.475~5.485 5.53

5.475~5.485 5.53

0.01~0.035 0.07

0.070.03~0.055

1.7 2.0

—

0.1

1.1~1.3 1.5

—

6

38

Cylinder Hea d and Valves

Not es to Ma inte nan ce

Troubleshooting

Removal of Cylinder Head Cover

Removal of Upper Rocke r Arm Assembly

Checking of Upper Rocke r Arm Assembly

Removal of Cylinder Head

Disassembling of Cylinder Head

Checking of Valves and Valve Guides

Checking of Tappet

Checking of Cylinder Head

Assembling of Cylinder Head

Installation of Cylinder Head


As the oil enters the cylinder head through the control orif ice in the engine casing, this orific e should always remainunblocked. Before installing the cylinder head, the O-ring and locating pin should be installe d first.

Before insta lling, coat the turning part of the upper rocker arm asse mbly and spherical pit with molybdum

disulfate for basic lubrication.

Part Specifications

Item Standard Value Repair Limit

Upper rocker arm assembly

Axial gap

Axial gap between intake/exhaust rocker arm and shaft

Valve spri ng

Outer spring

Inner spring

Valve gap

Valve

Outside diameter of valve rod

Inner diameter of valve rod

Gap between valverod and sleeve

Intake

Exhaust

Intake

Exhaust

Intake

Exhaust

Valve seat wi dth

Cylinder head

Twist

Valve seat widt h

7/16/2019 RT200-5


故障排除

汽缸头盖的拆卸

上摇臂组合的拆卸

上摇臂组合的检查

缸内气压低

1、气门

气门间隙调整不正确

气门密封不严

配气正时不对气门弹簧断裂

2、汽缸头

火花塞与汽缸头连接不紧密

汽缸头垫有渗漏或损坏

汽缸头有裂纹或损坏

3、缸体、活塞

活塞环间隙过大或断裂

活塞有裂纹或损坏

缸体内径过大或有砂眼

排气有蓝烟

1、气门导管磨损

2、挡油罩渗漏或损坏

3、汽缸头垫渗漏

4、活塞环间隙过大噪音过大

1、气门调整不正确

2、气门卡住或气门弹簧断裂

3、上摇臂轴向间隙过大

4、配气正时不准

5、挺杆钢球脱落

6、气门弹簧力值偏小。

先拆下汽缸盖上的三颗螺钉，再拆

下汽缸盖。拆下异型密封圈。

先拆下上摇臂组合处的三颗固定螺栓；取下上摇臂组合；取出挺杆。

检查摇臂是否有磨损、毁坏或油孔堵塞。检查零件是否有变形、摇臂与轴间隙大小。检查上摇臂组合的轴向间隙。理论值：0.05~0.12mm

极限值：0.15mm

39

异型密封圈

上摇臂组合

挺杆

Troubleshooting

Cylinder pressure low

Valve

Valve gap incorrec t

Valve not tigh t

Gas make-up timing incorrect

Valve spring broke n

Cylinder head

Spark plug and cylinder not closely connected

Cylinder head gasket leaking or damaged

Cylinder head fissured or damaged

Cylinder block and piston

Piston ring gap too wide or broken

Piston fissured or damaged

Cylinder bore too large or pitted

Exhaust containing blue smoke

1.Valve guide worn

2.Oil retainer leaking or damaged

3.Cylinder head gasket leaking

4.Piston ring gap too wide

Too much noise

1.Valve not properl y adjusted

2.Valve stuck or valve spri ng broken

3.Upper rocker arm shaft gap too wide

4.Gas make-up timing not correct

5.Tappet ball c ome off

6.Valve spring too weak

Removal of Cylinder Head Cover

Unscrew the three screws from the cylinder head,remove the cylinder head cover and the irregular form gasket.

Removal of Uppe r Rocker Arm Assembly

Remove the three fastener bolts from the upper rocker arm assembl y and then remove the latter.Remove the tappet.

Checking of Upper Roc ker Arm Assembly

lCheck the rocker arm for wear, damageor orifice blockage.lCheck the part for deformation and width

of gap between the rocker and shaft.lCheck the axial clearance of the upper

rocker arm assembly.Theoretical value: 0.05~0.12mmLimit value: 0.15mm

Tappet

Upper rocker arm assembly

Irregular-form gasket

7/16/2019 RT200-5


挺杆的检查

汽缸头的拆卸

汽缸头的分解

气门和气门导管的检查

挺杆应笔直，不弯曲。

理论值：141.15~141.45mm

极限值：141.00mm

拆下进气管。

拆下四颗异型螺母。

拆下侧螺栓8X79mm

最后取下汽缸头。

用气门拆卸器将气门弹簧压下，拆下气门锁夹。然后放松气门拆卸器，取下气门弹簧座、气门弹簧和气门。

注意：为了防止气门弹簧产生永久性变形，不能过分地压缩气门弹簧，只

须能拆下气门锁夹即可。

拆下的全部零件均应作上记号，确

保在装配时达到原来的装配位置。

检查各气门是否弯曲，烧蚀或气门杆有不正常的磨损。

检查气门在气门导管中的运动及测量其外径。

维修极限值：进气：5.42mm

排气：5.40mm

并将各气门插入导管内，观察其运动情况。

40

异型螺母侧螺栓8X79mm

汽缸头

气门拆卸器

气门弹簧和气门

Checking of Tappet

The tappet should be straight and free from bending.

Theoretical value: 141.15~141.45mm

Limit value: 141.00mm

Removal of Cylinder Head

Remove the intake pipe.

Unscrew the four irregular-form nuts.

Unscrew the side bolt 8×79mm.

Finally remove the cylinder head.

Disassembling of Cylinder Head

Remove the valve spring with the valve fixture andremove the valve clamp. Then loosen the valve fixtureand remove the valve spring seat, spring and valve.

Note:To prevent the valve spring from gettingpermanently deformed, do not compress

it more than the valve clamp which can be just removed.All of the removed parts should be markedto ensure they are returned to their original

positions.

Check the valves for bending, corrosion or unusual wear of valve rod.

Check the valve movement inside the guideand measure the outside diamete r.

Repair limit valueIntake: 5.42mm

Exhaust: 5.40mm

Insert the valve into the guide and watch its movement inside.

Irregular-form nutSidle bolt 8×79mm

Cylinder head

Valve fixture

Valve sprin g and valve

7/16/2019 RT200-5


用外径千分尺或专用测量用具测量每个气门导管的内径。最后算出气杆与

气门

导管之间的间隙。

维修极限间隙：进气：0.12mm

排气：0.14mm

注意：测量气门导管的内径前，应先将导管内的积碳完全清除干净。

如果需要更换气门导管，则气门座应重新进行表面研磨处理。

将燃烧室内的积碳完全清除干净。

将汽缸头平面的残留物用刮刀清除干净。

注意：不能损坏汽缸头平面。如果将汽缸头和密封垫浸入清洁剂中，将损坏密封垫清除干净。

检查火花塞孔及气门座是否有裂纹。

检查汽缸头是否变形，并用刀口尺和塞尺检查汽缸头的平面度。维修极限值：0.1mm

测量气门内外弹簧的自由长度。

维修极限值：（进气和排气）

外弹簧：41.0mm

内弹簧：35.50mm

汽缸头的检查

气门弹簧的检查

41

外径千分尺

塞尺

Measure the inside diameter of each valve guidewith an outside micrometer or special gauge andthen figure out the gap between the valve rod andvalve guide.

Repair limit value Intake: 0.12mm

Exhaust: 0.14mm

Not e:Before measuri ng the inside diameter of the

valve guide, be sure to remove carbon depositsfrom inside the valve guide.

If the valve guide is replaced, the surface of thevalve holder should be lapped.

Remove all the carbon deposits from inside thecombustion chamber.

Remove the residue from the cylinder headsurface with a scraper.

Note:Take care not to damage the cylinder head surface.

Immersing the cylinder head and gask et into detergentwill cause damage to the gasket.

Checking of Cylinder Head

Check the spark plug hole and valve seat for cracks.Check the cylinder head for deformation and check its flatness with a straightedge and feeler gauge.Repair limit value: 0.1mm

Checking of Valve Spring

Measure the free length of the inner and outer valve springs.

Repair limit value (for intake and exhaust valves)

Outer spring: 41.0mm

Inner spring: 35.50mm

Outside micrometer

Feeler gauge

7/16/2019 RT200-5


气门导管的更换

气门座的检查、研磨

将汽缸头固定好，用气门导管拆卸工具将气门导管从气门孔向外拆下。

注意：拆卸气门导管时，不要损坏汽缸头。

在汽缸头上，将新的气门导管和“0”

形圈压装好。然后对新安装的气门导管

进行扩孔。

注意：扩孔时，须在绞刀上涂上切削油。

装入或取出绞刀时，到应进行转动。

最后，用清洗剂对汽缸头进行清洗，并用

压缩空气清除存在汽缸头上的全部金属切屑。

首先，清除进排气门上的积碳，再在气门座上涂上研磨剂，然后用橡胶头的研磨工具吸上气门，对气门座进行

研磨。

拆下气门并检查气门，接触面的宽度。

标准值：1.2~1.6mm

维修极限值：2.0mm

注意：如果气门接触面很粗糙，磨蚀不均匀或与气门座不能正常接触，则应更换气门。

42

清洗

Replacement of Valve Guide

Fasten the cylinder head and remove the valveguide from the valve hole with the valve guide fixture .

Not e:Take ca re not to damage the cylinder headwhen removing the valve guide.

Push the new valve guide and O-ring into thecylinde r head and enlarge the bore of the valve guide.

Not e:Coa t the reamer with cut ting oi l beforeusing it and turn the reamer when putting it inor pulling it out.

Finally clean the cylinder head with a detergentsolution and remove all the metal chips from itwith compressed air.

Checking and Lappi ng of Valve Holder

Remove carbon depos its from the intake andexhaust valves, coat the valve seat with abrasivepaste and then lap the valve sea t with the lapping tool.

Remove the valve and check it for the widthof the contact surface.

Standard value: 1.2~1.6mm

Repair limit value: 2.0mm

Note:Replace the valve if its contact sur face is so rough,corroded or worn that normal contact with valveseat is impossible.

Clean

7/16/2019 RT200-5


测量气门座接触面的宽度


如果气门座太宽、太窄或存在凹痕，则应修磨气门座，使之达到密封程度。

气门座铣刀

三种不同角度的铣刀

0

用32 铣刀铣销气门座上部环带。

0

用60 铣刀铣销气门座底部环带。

4343

Measurement of Valve Holder Contact Width


Trim the valve holder if it is too wide, too narrowor have dents in it to achieve a tight contact .

Valve HolderCutter

Cutters of three different angles are provided toserve different purposes.

Use the 32 cutter to machine the topcircumference of the valve holder

Flat surface finish cutter Valve seat finish cutte r Internal surface finish cutter

Width of old valve seat

Use the 60 cutter to machine the bottomcircumference of the valve holder.

7/16/2019 RT200-5


0

再用45 铣刀，精加工气门座的工

作面，使其达到正确的宽度。

工作面宽度标准值：1.2mm

在气门座上涂上印油，套入气门进行转

动，然后取出气门，观察接触面是否正

确良好。

注意：气门与气门座接触面是否良好，

对发动机的密封性而言，将是一个非常重要的因素。

0

如果气门接触面太高，可用32 铣

刀铣销，将接触面降低。

0

如果气门接触面太低，则用60 铣刀铣销，将接触面升高。

0

最后，再用45 铣刀进行加工铣销，

将气门座接触面加工到规定的宽度为止。

气门座加工完毕后，应在气门座上涂上一

层研磨剂。然后装上气门，用橡胶头研磨

器吸上气门进行研磨。研磨完成后，清洗

所有残留在汽缸头、气门、气门座及气门

导管上的研磨剂。

44

Use the 45 cutter to finish the working faceof the valve holder to the correct width.Standard value of working face: 1.2mm

Coat the valve seat with stamp ink, put in thevalve and turn it and then remove it to seeif the contact is correct.

Note:A good contact of the valve with the seat isof vital importance for the tightness of the engine.

If the contact face of the valve is too high,machine it with the 32 cutter to lower it.

If the contact face of the valve is too low,machine it with the 50 cutter to heighten it.

Finally use the 45 to finish the contact faceof the valve seat to the required width .

After the valve seat is machined, coat it with a layer of lapping compound, put in the valve and lap it withthe rubber lapper. After lapping, clean the cylinder head, valve, valve seat and valve guide of lapping

compound.

7/16/2019 RT200-5


45

汽缸头的组装

注意：在组装气门前，应先将挡油罩套入气门导管上。

将进、排气门杆上涂上润滑油后，装入气门导管内。装好气门弹簧和气门弹簧座。

注意：安装气门弹簧时，应使弹簧的节矩较稀的一端，朝向汽缸头上方。

再用气门拆卸器压下气门弹簧，然后将气门锁夹装入气门弹簧座内。

注意：为防止气门弹簧产生永久变形，

不能过分压缩弹簧，以能装入气门

锁夹即可。

然后用塑橡锤轻敲气门杆端部，使

锁夹牢牢陷入环槽中。

汽缸头的安装

将密封垫拆下后，对汽缸平面清洁干净。

然后，装上新的密封垫，再装上“0”形

环和定位销。

注意：不能让尘土和杂质掉入汽缸内。

Assembling of Cylinde r Head

Note : Before assembling the valve, put the oilretainer on the valve guide first.

Coat the intake and exhaust valve rods with oil, put them into the valve guides, and then put in thevalve springs and spring seats.

Note:When assembling the valve spring, make surethe end with a wider pitch is directed to the topof the cylinder head.

Compress the valve spring with the valvefixture and then put the valve clamp intothe valve spring seat.

Note :To prevent the valve spring from permanentdeformation, do not compress the spring morethan just enough to put in the valve clamp.

Tap on the end of the valve rod with a plast ichammer to get the valve clamp into the ring groove.

Assembling of Valve Head

Remove the gasket, clean the cylinder surface,

put in the new gasket and then put in the O-ringand locating pin.

Note:Prevent dust and dirt from getting into the cylinder.

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46

装上进气管。

装上汽缸头。

装汽缸头四颗异型螺母和挺杆支架。

扭矩：23~30N.m

装上8mm螺栓

扭矩：18~23N.m

装上摇臂组合并紧固三颗固定螺栓。

扭矩：23~28N.m

紧固时，按2次到3次将异型螺母逐步

扭紧，并按交叉方式进行。

调整气门间隙。

汽缸头盖的安装

将异型密封圈嵌入汽缸头盖的凹槽中。

注意密封圈平整。

装上汽缸头盖并拧紧三颗螺栓。

Connect the air intake pipe.

Put on the cylinder head.

Screw the four regular-form nuts onto thecylinder head and install the tappet support.Torque requirement: 23-30 N.m

Screw in the 8mm bolt.

Torque requirement: 18-23 N.m

Put on the upper rocker arm assemblyand tighten the three fastening bolts.Torque requirement: 23-28 N.mTighten the irregular-form nuts one byone for two or three times following a

diagonal order.Adjust the valve gap.

Installation of Cylinder Head Cover

Inlay the irregular-form packing ring intothe groove in the cylinder head cover, making

sure it remains neat and flat in the groove.Put on the cylinder head cover and tightenthe three bolts.

7/16/2019 RT200-5


汽缸体及活塞

维修须知中摇臂轴的检查

故障排除波纹垫圈的检查

汽缸体的拆卸活塞的拆卸

汽缸体的分解活塞的安装

中摇臂的检查汽缸体的安装

总则

汽缸体是发动机构成中的重要零件，工作环境恶劣，对发动机的性能有着决定性影响，应注意对其进行妥善保养，而在安装汽缸之前，应先装了新垫圈和定位销。

各部规格

故障排除压缩力低或不稳定

1、汽缸或活塞环有磨损。

2、汽缸、活塞或活塞环有磨损

3、活塞环的安装不正确

4、活塞或汽缸壁有刮痕或刮伤

过热

1、活塞积碳

2、有爆震或不正常的噪音

3、活塞或汽缸有磨损

4、活塞积碳过多

5、中摇臂磨损异常

不能使灰尘和尘埃渗入曲轴箱内。

项目标准值mm 维修极限mm

—

汽缸体

汽缸体内径

锥度

失圆度

顶部扭曲度

活塞、活塞环

和活塞销

活塞外径

活塞销孔内径

活塞销与活塞销间隙

活塞环端隙

活塞销与活塞凹槽间隙

顶环 /第一环

油环

顶环

第二环

汽缸体与活塞间隙

连杆小端

中摇臂轴

中摇臂

内径

内径

小端外径

与活塞销间隙

活塞销上径

56.50~56.51 56.60

—

—

0.1

0.1

0.05

56.45~56.48 56.40

15.002~15.008 15.04

0.002~0.014 0.02

0.150~0.350 0.10

0.010~0.040 1.10

0.030~0.050

0.020~0.050

0.02~0.06

14.994~15.000

15.010~15.028

0.01~0.034

11.97~11.99

12.00~12.02

0.10

0.10

0.10

14.96

15.06

0.10

11.95

12.05

7

47


Troubleshooting

Removal of Cylinder Block

Disassembling of Cylinder Block

Checking of Middle Rocke r Arm

Checking of Middle Rocke r Arm Shaft

Checking of Corruga ted Washer

Checking of Piston

Installation of Piston

Installation of Piston

Cylinder Block and Piston

General Requirement

The cylinder block is a vital part of the engine. It works under severe condit ions and has a decisive influenceon the engine performance. Therefore the cylinder block should be carefully maintained. Before installing thecylinder, be sure to put on a new gasket and the locating pin.

Care should be taken not to allow dust and dirt to get into the crankcase .

Part Specifications

ItemStandard Value Repair Limit

Cylinder block

Bore

Taper

Off-roundness

Top distortion

Outside diameter of piston

Inside diameter of piston pin hole

Gap between piston pins

Piston ring end gap

stTop ring/1 ring

Oil ring

Top ring

nd2 ring

Gap between pistonring and groove

Piston, piston ringand piston pin

Gap between cylinder block and piston

Upper diameter of piston pin

Small end

of conrod

Inside diameter

Gap with piston pin

Middle rocker arm shaft Outside diameter of small end

Middle rocker arm Inside diameter

Troubleshooting

Compression force low or instable

1.Cylinder or piston ring worn

2.Cylinder, piston or piston ring worn

3.Piston ring not installed correctly

4.Piston or cylinder wall scratched or damaged

Overheating

1.Piston full of carbon deposits

2.Explosive shock or unusual noise

3.Piston or cylinder worn

4.Piston covered with too much carbon deposits

5.Middle rocker arm unusually worn

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48

螺丝刀Screwdriver

汽缸体的拆卸

拆下汽缸头（参阅第6节）

拆下两颗6X25螺钉

拆下定位销、0形密封圈和汽缸垫。

拆下汽缸头

注意：拆汽缸时不能将异物坠入曲轴箱内。

将汽缸体表面余留的纸垫用刮刀刮干净。

注意：如将纸垫浸入汽油中，则很容易拆开。进行此项作业时，避免将缸体接触面损坏。

汽缸体的分解

将汽缸体倒置，用一字螺丝刀将中摇臂轴撬出。

注意：不能使汽缸表面受伤。

依次取出中摇臂、中摇臂轴、波纹垫圈。

Removal of Cylinder Block

Remove the cylinder head (See Section 6).

Unscrew the two 6×25 screws.

Remove the locating pin, O-ring and cylinder gasket.

Remove the cylinder block.

Note: Take care not to allow anyt hing to get intothe crankcase when removing the cylinder block.

Remove the paper gasket residue from the surfaceof the cylinder block with a scraper.

Note:It wil l be easier to remove the paper gasketif it is immersed in gasoline. When doing this job,take care not to damage the contact surface of thecylinder block.

Disassembling of Cylinder Block

Place the cylinder block up side down and bring out themiddle rocker arm shaft with a minus-tipped screwdriver.

Note: Take care not to damage the surface of thecylinder block

Remove the middle rocker arm,shaft and corrugated washer.

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汽缸体的检查

检查汽缸体是否有磨损或损坏。

量汽缸体内径，应量取三个位置，即活塞行程的顶部，中部和底部，而且应互成直角的两个方向。


算出锥孔和失圆度。

失圆度：0.1mm

锥度：0.1mm

活塞的拆卸

用钳子拆下活塞销挡圈。

注意：不能将挡圈坠入曲轴箱内。

将活塞销从活塞内抵出，然后拆下活塞。

活塞 /活塞环的检查

测量活塞环与活塞环凹槽之间的间隙。

维修极限值：

第一环：0.09mm

第二环：0.09mm

拆下活塞环。

注意：在拆卸时，不要损坏活塞环。

将每一活塞环插入汽缸内，然后量取端隙。

维修极限值：

第一环 /第二环：0.5mm

检查活塞是否有磨损或裂痕，活塞环凹槽是否有磨损。

量活塞销孔内径。


49

活塞销挡圈

钳子

塞尺

量活塞销孔内径。

Checking of Cylinder Block

Check the cylinder block for abrasion or damage.

Measure the bore of the cylinder at three location s, i.e. the top, middleand bottom parts of the piston stroke, in two directions vertical to each other.


Calculate the taper and off-roundness.

Off-roundness: 0.1mm

Taper: 0.1mm

Pliers

P i s

t o

n

p i n

r e

t a

i n

i n

g

r i

n g

Feeler gauge

Removal of Piston

Remove the piston pin retaining ring.

Note: Take ca re not to drop the re taining ring into the crankcase.

Push the piston ring out of the piston and then remove the piston

Checking of Piston/Piston Ring

Measure the gap between the piston ring and the piston ring groove

Repair limit value:

st1 ring: 0.09mm

nd2 ring: 0.09mm

Remove the piston ring.

Not e: B e carefu l not t o damage the pi ston ri ng when removi ng i t.

Insert each ring into the cylinder and measure the end gap.

Repair limit value

st nd1 /2 r ing: 0 .5mm

Check the pist on for wear or crack and the piston ring groo ve for wear.

Measure the inside diameter of piston pin.


Measure the inside diamete r of piston pin.

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测量位于距活塞裙部底端之上10mm位置的外径。


算出汽缸与活塞之间的间隙。


量取活塞销外径。


算出活塞与活塞销之间的间隙。


活塞环的安装

将活塞环凹槽彻底清洗干净。

装上活塞环。

注意：

在安装时，应防止活塞及活塞环受到毁坏。

安装顶环和第二环时应注意标记朝上。安装活塞环时，有记号的一面应向上，

装好后，活塞环应能自由转动。

不要将顶环和第二环的安装位置颠倒。

将活塞环端隙隔开120度，不要将各环的间隙互相对准。

由三件圆环组成的油环，各环之间的间隙，应该与隔圈的间隙相配合。安装油环时，应先安装隔圈，然后再安装侧环。

50

量取活塞销外径。

活塞裙部

Measure the outside diameter at 10mm abovethe bottom end of the piston skirt.


Calculate the gap between the cylinder and piston.


Piston shirt

Measure the outside diameter of the piston pin

Installation of Piston Ring

Clean the piston ring groove.

Put in the piston ring.

Note:Be careful not to damage the piston and piston ringwhen doing the installation.Make sure the mark is faced up when instal ling thetop ring and second ring.Be sure that the marked side is faced up wheninstalling the piston ring.The piston ring should be able to turn freely after installation.Do not confuse the mounting position of the topring with that of the second ring.

Separate the end gap of the piston ring by 120and do not align the ring gaps with each othe r.

The gap between the three rings of the oil ring should bematch the spacer ring. When mounting the oil ring, besure to put in the spacer ring before putting in the side ring.

Top ring

nd2 ring

Oil ring

Piston ring mark

Top ringnd

2 ring

Side race

Spacer ring

Side race20mm or greater

Gap20mm or greater

Measure the outside diameter of the piston pin



Calcula te the gap between the and piston. piston

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51

将活塞、活塞销及新活塞挡圈装好。

纸垫定位销

缸体

活塞的安装

将活塞、活塞销及新活塞挡圈装好。

注意：安装活塞时，印有“IN”记号的一侧要对正进气门。

活塞销挡圈端隙应与活塞切口部位错开。

注意：在分解后再装配时，一定要用新活塞挡圈。不能让活塞销挡圈坠入曲轴箱内。

汽缸体的安装

装好新纸垫、定位销和0形环。将汽缸体和活塞环涂上一层机油。安装汽缸。

注意：安装时，要避免毁坏活塞和活塞环。应使两只中摇臂分开，不能合拢。

装好新纸垫。装好定位销和0形环。装好汽缸头。

Installation of Piston Ring

Put the piston, pist on pin and new piston reta ining ring in place.

Note:When install ing the piston ring, make sure theside marked with IN is lined up to the intake valve.The end gap of the piston pin at the retaining ring sideshould be staggered from the opening of the piston.

Not e:Always use replace the piston ring with a new one whenreassembling the disassemble piston. Be careful not toallow the piston pin to drop into the crankcase.

Installation of Cylinder Block

Put on the new paper gasket, locating pin and O-ring.Coat the cylinder block and piston ring with a layer of oil.Put on the cylinder.

Note:Take care not to damage the piston and piston ring.The two rocker arms should be separated insteadof being kept close.

Put on the new paper gasket.Insert the locat ing pin and put on the O-ring.Put on the cylinder head.

Put in the piston, piston pin and new retaining ring.

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中摇臂的拆卸

拆下汽缸头8mm螺栓，

拆下汽缸头和汽缸体，

用手握住中摇臂，将轴朝箭头方向移动，

用螺丝起子扳开摇臂轴。

中摇臂的检查

检查中摇臂轴是否有磨损、损伤、裂伤。

测量中摇臂内径

理论值：12.00~12.02mm


52

轴

中摇臂

Removal of Middle Rocker Arm

Unscrew the 8mm bolt from the cylinder head.

Remove the cylinder head and cylinder block.

Hold the middle rocker arm by hand and turn

the shaft toward the arrow mark.

Open the rocker arm shaft with a screwdriver.

Checking of Middle Rocker Arm

Check the middle rocker arm for abrasion ,damage and crack.

Measure the inside diamete r of the middle rocker arm.



Shaft

Middle rocker arm

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中摇臂轴的检查

测量中摇臂轴的外径

理论值：11.97~11.99mm


中摇臂轴的安装

按拆卸的相反程序将中摇臂、中摇

臂轴及波纹垫圈依次装好。

将轴转动，直至螺栓的底端插入轴

上的孔为止。

53

Checking of Middle Rock er Arm Shaft

Measure the outside diameter of the middle rocker arm shaft.



Installation of Middle Rocker Arm Shaft

Put the middle rocker arm, shaft and corrugat edwasher back in place following the reverse order in which they are removed.

Turn the shaft until the bottom end of the bol t get s int o the hole in the shaft.

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离合器、油泵与换档机构

维修须知离合器的检查

故障排除变速机构的拆卸 /安装

右曲轴箱盖的拆卸机油泵的分解 /检查

离合器的拆卸 /安装机油泵的安装

离合器的分解右曲轴箱盖的安装

维修须知

说明在拆下右曲轴箱盖后，有关离合器、油泵和换档机构的拆卸、安装和维修工作无须拆下发动机也可以进行。如更换离合器时，则在离合器装配前，应在离合器的圆盘上涂上发动机油。

扭矩值

右曲轴箱盖 8~12N.m

16mm锁紧螺母（机油滤清器） 40~50N.m

启动装置（启动臂） 10~15N.m

技术规格

故障排除离合器

离合器在操作中，如发生故障，通常也可借调整离合器手把自由行程而得到较好的校正。

加速时离合器打滑1、自由行程不够

2、摩擦片有磨损

3、离合器片弯曲手把压力过大1、离合器线缆粘结、毁损或不洁

2、提升机构损坏油压太低

1、油泵有故障

2、油泵驱动齿轮破裂

变速踏板不能回弹

1、回位弹簧断裂

2、变速轴与曲轴箱或曲轴箱盖干扰

放开离合器后，车辆会慢慢驶动

1、自由行程太大

2、离合器片弯曲

离合器操作困难

1、定位板弯曲或磨损

换档困难

1、定位板弯曲或磨损

2、离合器调整不正确

换档齿轮跳档

1、定位板弹簧断裂或弹力不够

项目标准值（mm）维修极限值（mm）

离合器

油泵

手把自由行程

弹簧自由长度

离合器主动片厚度

离合器从动片厚度

顶部间隙

转子至阀体间隙

端间隙

10~20—

35.50 34.20

2.90~3.00 2.60

— 0.20

0.15 0.20

0.30~0.36 0.40

0.15~0.20 0.25

8

54

Clutch, Oil Pump and Gearshift Mechanism

Not es to Maintenance

Troubleshooting

Removal of Right Crankcase Cover

Removal/Installation of Clutch

Disassembling of Clutch

Checking of Clutch

Removal/Installation of Gearshift Mechanism

Disassembling/Checking of Oil Pump

Installation of Oil Pump

Installation of Right Crankcase Cover


After the right crankcase cover is removed, the clutch, oil pump and gearshif t mechanism can be removed,installed and repaired without having to remove the engine. Before replacing the clutch, the clutch disc

should be coated with engine oil before assembling it.

Torque Requirement

Right crankcase cover: 8~12 N.m

16mm lock nut (for oil cleaner): 40~50 N.m

Starter (starting lever): 10~15 N.m

Part Specifications


Free play of clutch lever

Free length of springThickness of driving plate

Thickness of driven plate

Top clearance

Gap between spindle and valve body

End gap

Clutch

TroubleshootingClutch

If the clutch goes wrong during operation, it can normally be put right by adjusting its free play of the clutch lever.

Clutch slippin g when speeding up the engine

1.Free distance insufficient

2.Clutch plate worn

3.Clutch plate bent

Clutch lever pressure too high

Clutch cable stuck, damaged or dirty

Lifter damaged

Oil pressure too low

Oil pump failure

Oil pump driving gear broken

Gearshift pedal unable to spring back

Return spring broken

Gearshift shaft interfering with crankcase or crankcase cover

Vehicle moving slowl y when clutch is releasedFree distance too great

Clutch plate bent

Clutch difficult to operate

Locating plate bent or worn

Gearshift difficult

Locating plate bent or worn

Clutch incorrectly adjusted

Shifting gear skipping

Locating plate spring broken or lacking elasticity

Oil pump

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55

离合器操纵杆

右曲轴箱盖

机油滤清器

离合器

Right crankcase cover

Oil cleaner

Clutch

Clutch lever

右曲轴箱盖拆卸

先将机油放干，

拆开离合器操纵线的连接，拆下排气消音器，

拆下换档踏板，

拆下启动臂，拆下右曲轴箱盖。

离合器

拆下离合器分离杆和销钉，

拆下101轴承，

然后拆下机油滤清器盖固定螺钉，

拆下机油滤清器盖。

Removal of Right Crankcase Cover

Drain off the oil.Disconnect the clutch control cable.Remove the exhaust muffler.Remove the gearshift pedal.Remove the starting lever.Remove the right crankcase cover.

Clutch

用四爪拆下16mm圆螺母和碟形垫圈。

拆下机油滤清器

拆下离合器升板和离合器弹簧固定螺栓后，取下离合器升板和弹簧。

注意：拧松螺栓时，应分二次或三次成交叉

方式拧松。

Remove the clutch disengagement lever and pin.Remove the bearing 101.Unscrew the fastening screws from the oil cleaner.Remove the oil cleaner cover.

Remove the 16mm round nut and butterflywasher with the 4-jaw wrench.Remove the oil cleaner.

Remove the bolts fastening the clutch plateand spring and remove the latter.

Note: Be sure to loosen the bolts in a diagonalorder for two or three times.

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用挡圈钳取下弹簧卡圈。

拆下离合器中心套、离合器主动片、离合器

从动片、离合器压盘。

拆下离合器外罩上的花键垫圈，

拆下离合器外罩和主动齿轮。

离合器的分解

56

10

8

14

13

7

9

11

13

4

5

4

5 6

12 2

15

16

Remove the spring circlip with the retaining ring pliers.

Remove the central clutch sleeve,clutch driving and driven plates and hold-down disc.

Remove the splined wasther from the clutch cover.Remove the clutch colver and driving gear.

1.蝶形垫圈Butterfly washer 2.离合器外壳Clutch cover 3.离合器中心架Central frame4.离合器摩擦盘Friction disc5.摩擦铁片Friction lining6.离合器压盘Hold-down disc

7.离合器分离盘Disengagement disc8.离合器分离轴套Disengagement shaft bush9.离合器弹簧Clutch spring10. 法兰面螺栓Flange bolt11.圆螺母Round nut12. 离合器挡圈Retaining ring13. 离合器端盖轴承End cover bearing14. 垫圈Washer 15. 推杆Push rod16. 离合器总成Clutch assembly Clutch Dissembled

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离合器摩擦片的检查

如离合器主动片出现擦伤或褪色的痕迹，即应更换。测量每片离合器主动片厚度。


检查离合器从动片表面是否有扭曲，检查时要用侧隙规进行。


离合器外罩的检查

检查外罩鼓型上的齿槽是否因离合器压盘摩擦面产生伤口、伤痕。

变速机构的拆卸 /安装

拆下变速轴组合，

拆下变速鼓拨板，

拆下定位板组合。

注意：检查拨板是否有磨损或毁坏。

57

离合器弹簧的检查

测量每一离合器弹簧自由长度。


变速鼓拨板

Checking of Clutch Spring

Measure the free length of the clutch spring.

Repair limit value:34.20mm

Checking of Friction Lining

Check the driving friction lining for scratch or discoloration marks and replace it if such defectsare found. Measure the thickness of the lining.


Check the driven friction lining for distortionwith a feeler gauge.


Checking of Clutch Cover

Check the tooth groove in the drum-shapedsurface of the cover for possible damages or cuts caused by friction with the clutch hold-down disc.

Disassembling/Reassembling of Gearshift Mechanism

Remove the gearshift gear shaft component.

Remove the gearshift drum push plate.

Remove the locating plate component.

Not e: Check the push plate for wear or damage

G e a

r s h

i f t d

r u m

p u s h

p l a

t e

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58

定位销

变速凸轮Gearshift cam

变速机构的装配

将定位销装入变速鼓安装孔内。

将拨板装在变速鼓上，拨板的定位销孔应与变速鼓上的定位销对准，然后拧紧螺栓。

分装好定位板组合。

注意：将定位板复位弹簧嵌入曲轴箱支承座上。

装好定位板组合，拧紧螺栓。

注意：装好之后，转动变速鼓上的拨板，看变速鼓的操作是否灵活。

装好变速轴。

注意：安装前，检查变速轴上是否有推力垫圈。安装前，注意保护左箱体内的变速轴油封。

离合器的安装

装好主动齿轮、离合器外罩和花键垫圈。

注意：安装花键垫圈时平面一边应朝外。

将离合器升板、摩擦压盘、离合器主动从动片和离合器中心套装配好。

注意：分别将压盘和离合器片敲紧，装配前将离合器压盘涂上一层薄薄的机油。

将上述部件装入离合器外罩。

注意：离合器在进行装配时应转动压盘和离合器中心套。

Reassembling of Gearshift Mechanism

Put the locating pin into the gearshift drum mounting hole.

Put the push plate on the gearshift drum, align the

locating pin hole in the push plate with that in thegearshi ft drum and tighten the bolt.

Put the locating plate component separately.

Note: Inlay the ret urn spring of the locating pla teinto the bearing case seat.

Put on the locating plate componen t and tighten the bolt.

Note: Afte r the parts ar e put toge ther, turn the push plate to see if the gearshift drum works freel y.

Put in the gearshift shaft.

Note:Before assembling, check the gearshift shaft to seeit the thrust washer in on it.Also before assembling, give protection to the gearshiftoil seal in the left case.

Installation of Clutch

Put on the driving gear, clutch cover and spline washer.

Note: The flat surface of the spl ine washer must bedirect outward when putting it in place.

Assemble the clutch lifting plate, hold-down disc,driving and driven linings and central sleeve.

Not e:Tighten the hold-down disc and clutch lining together bytapping then with a hammer and be sure to coat thehold-down disc with a thin layer of oil.

Put the above parts into the clutch cover.

Note:Be sure to turn the hold-down disc and centralsleeve when assembling the clutch.

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59

弹簧卡圈

销钉

固定螺钉Fastening screw

Dowel pin

Spring circlip

装好弹簧卡圈。

装好离合器弹簧和离合器升板，

拧紧离合器升板法兰面螺栓。

注意：拧紧螺栓时，应按交叉方式分二次或三次拧紧。

装好机油滤清器和圆螺母。

注意：安装锁紧垫圈时，有标记的一边应朝外。

拧紧锁紧螺母

扭矩值：40~50N.m

装好机油滤清器盖

装好离合器分离杆及销钉。

机油泵

转动油泵齿轮，直到从齿轮孔中看到螺钉。拆下2颗固定螺钉，拆下机油泵组件。取下2个0形环。

Put in the spring circlip.

Put in the clutch spring and clutch lifting plate.

Tighten the flange bolts of the clutch lift ing plate.

Note:Th e bolts should be tightened diagonally in two or three times.

Put in the oil cleane r and put on the round nut

Note: The marked s ide should be direc ted outwardwhen putting on the round nut.

Tighten the lock nut.

Torque requirement: 40-50N.m

Put on the oil cleaner cover.

Put in the clutch disengagement lever and dowel pin.

Oil Pump

Turn the oil pump gear until the screw can be seenfrom the hole in the gear.Unscrew the two fastening screws and remove the oil pump.

Remove the two O-rings.

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60

机油泵的检查

测量内外转子的径向间隙。

理论值：0.15mm


Checking of Oil Pump

Measure the radial gap between the inner and outer spindles.

Theoretical value: 0.15mm


测量油泵体与外转子的径向间隙。


Measure the radial gap between the pump body and outer spindle.


测量油泵体与转子的端面间隙。


注意：装好垫圈后，测量转子端间隙。

Measure the end face gap between the oil pump and spindle.

Note: Measure the end gap of the spindl e after the washer is put in.


机油泵的装配

将机油泵传动齿轮和油泵传动轴装入油泵体内。

注意：油泵传动齿轮的平面端应与油泵传动轴的平

面端对准。

装好油泵体内、外转子。

装好纸垫和油泵下盖。

注意：油泵下盖上的凸出块应与油泵体的切口部位对准。

拧紧油泵上盖螺钉。

检查油泵是否能顺利操作。检查时，用手转动油泵传动齿轮即可。

Assembling of Oil Pump

Put the oil drive gear and drive shaft into the oil pump body.

Note: The flat side of the oi l pump drive gear should belined up to the flat side of the drive shaft

Put in the inner and outer spindles of the oil pump.

Put in the paper gasket and lower cover of the oil pump.

Not e:The protrusion on the lower cover of the oil pumpshould be aligned to the notch in the pump body.

Tighten the upper cover screw.

Check the oil pump for normal function by turningthe drive gear of the oil pump by hand.

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61

0形环O-ring

机油泵的安装

装上新0形环，

装好油泵。

注意：0形环一定要安装正确。

Installation of Oil Pump

Put on the O-ring.

Install the oil pump.

Note: The O-r ing must be put on correct ly.

右曲轴箱盖的安装

装好右曲轴箱盖，将离合器操纵线连接好，装好启动臂，装好排气消声器，装好变速踏板。

Installation of Right Crankcase Cover

Put on the right crankcase cover.Connect the clutch control cable.Put on the starting arm.Put on the exhaust muffler.

Put on the gearshift pedal.

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62

磁电机

维修须知磁电机的安装

左前盖的拆卸左前盖的安装

磁电机的拆卸

维修须知

说明本节所介绍磁电机的拆卸和安装，只要拆下左曲轴箱盖，无需拆下发动机即可完成。

关于磁电机的检查可以参阅蓄电池充电系统章节的方法。

扭矩值

磁电机转子螺栓

45—53N.m

左前盖的拆卸拆下变速踏板，

拆下左上盖，

拆下双联齿轮。

拆下左前盖。

9

Magneto


Removal of Front Left Cover

Removal of Magneto

Installation of Magneto

Installation of Front Left Cover


The magneto can be removed and installed by simplyremoving the front left crankcase cover withouthaving to remove the engine. For checking of the magneto, refer to the section regarding the batte rycharging system.

Torque requirement

Magneto rotor bolt: 45-53 N.m

Removal of Front Left Cover

Remove the gearshift pedal.

Remove the gearshift pedal.

Remove the duplex gears

Remove the front left cover.

General

Torque requirement

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63

磁电机的拆卸

拆下轴齿轮，

将磁电机转子用抱箍固定好，

拆下磁电机螺栓。

安装好飞轮拔出器，拆下磁电机转子。

拆下限位板，拆下盘型齿轮。

磁电机的安装

安装好盘型齿轮和轴齿轮，

安装好磁电机转子。

注意：曲轴半圆键应与磁电机转子凹槽对齐。

按规定扭矩拧紧磁电机螺栓.

左前盖的安装

装好左前盖组件，交叉紧固螺栓，将磁电机引出线与空挡线安装好，装好电缆压板，

装好双联齿轮及左上盖，装好左后盖，装好变速踏板。

Removal of Magneto

Remove the shaft gear.

Fasten the magneto rotor with the clamp.

Remove the magneto bolts

Put on the flywheel puller and remove the magneto rotor.

Remove the limit plate and then the disc gear.

Installation of Magneto

Put on the disc gear and shaft gear.

Put on the magneto roto r.

Not e:The half-round key of the crankshaf t should bealigned to the groove in the magneto rotor.

Tighten the magneto bolts to the required torque.

Installation of Front Left Cover

Put on the front left cover and tighten the boltsin a diagonal order.Connect the wire lead from the magneto to theneutral gear wire.Put on the power cable hold-down plate.Put on the duplex gears and upper lef t cover.Put on the rear left cover.Install the gearshift pedal.

RAT O

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曲轴箱、曲轴、变速传动、启动装置

曲轴的检查

变速组件的分解

启动机构的分解

启动机构的安装

变速组件的安装

曲轴的安装

曲轴箱的装配

凸轮齿轮的安装

维修须知

故障排除

凸轮齿轮组合的拆卸

凸轮齿轮组合的检查

凸轮齿轮轴的检查

张紧器的分解

张紧器的安装

曲轴箱分离

曲轴的拆卸

维修须知

本节介绍变速器、曲轴和启动机构拆装，进行上述工作时，应将曲轴箱先进行分离。关于发动机的其它部件的拆卸应在曲轴箱分离之前进行。

曲轴箱分离之前的工作

汽缸头的拆卸

汽缸 /活塞的拆卸

离合器、油泵、换档机构的拆卸

磁电机的拆卸

规格

项目标准值(mm) 维修极限值(mm)

换档拨叉

曲轴

启动机构

凸轮齿轮组合

凸轮齿轮轴

内径

拨叉厚度

外径

偏转度

连杆小头内径

连杆大端侧间隙

轴向

径向

启动轴外径

启动齿轮内径

内径

外径

凸轮高度

换档拨叉轴

12.000~12.018

4.93~5.00

11.976~11.994

15.010~15.028

0.05~0.30

0.004~0.008

19.954~19.980

20.000~20.021

32.768~32.928

14.060~14.081

14.024~14.006

_

12.05

4.50

11.96

0.1

15.08

0.6

0.05

19.90

20.05

32.628

14.101

13.986

10

64

Crankcase, Crankshaft, Gearbox, Starter


Troubleshooting

Removal of Cam Gear Assembly

Checking of Cam Gear Assembly

Checking of Camshaft

Disassembling of Tensioner

Assembling of Tensioner

Parting of Crankcase

Removal of Crankshaft

Checking of Crankshaft

Disassembling of Gearbox

Disassembling of Starter

Assembling of Starter

Assembling of Gearbox

Installation of Crankshaft

Installation of Cam Gear


This section provides procedures for disassembling and reassembling of the gearbox, crankshaft and starter.

Before performing such jobs, the crankcase shoul d be parted. Other parts of the engine should be removed before the crankcase is parted.

Jobs to be done before crankcase parting

Removal of cylinder head

Removal of cylinder/piston

Removal of clutch, oil pump, gearshift mechanism

Removal of magneto

Part Specifications


Inside diameter

Thickness

Outside diameter

Deflection

Inside diameter of small end of conrod

Side gap of bigend of conrod

Axial

Radial

Outside diameter of starting shaft

Inside diameter of starting gear

Height of cam

Inside diameter

Outside diameter

Gearshift fork

Gearshift fork shaft

Crankshaft

Starter

Cam gear assembly

Cam gear shaft

Assembl ing of Cam Gear Assembly

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故障排除

换档困难

1、拨叉弯曲变形

2、拨叉轴弯曲

变速器跳档

1、换档齿轮棘爪有磨损

2、拨叉弯曲或损坏

3、拨叉轴弯曲

曲轴噪音

1、连杆大端轴承有磨损

2、连杆弯曲

3、连杆滚针轴承磨损

变速机构噪音

1、主副轴齿轮磨损

2、花键轴磨损

凸轮齿轮噪音

1、凸轮磨损

2、凸轮齿轮磨损

3、凸轮齿轮轴配合间隙大

4、张紧器弹簧力减少

5、斜齿轮啮合间隙大

凸轮齿轮组合的拆卸

拆下弹簧压板，取出弹簧，

拆下凸轮齿轮轴。

拆下凸轮齿轮组合，

拆下张紧器组合。

凸轮齿轮组合的检查

测量凸轮的高度

标准值：32.768~32.928mm


65

弹簧压板

弹簧压板凸轮齿轮组合

Troubleshooting

Change of gears difficult

1.Fork bent or deformed

2.Fork shaft bent

Gearshift skipping

1.Gearshift gear ratchet worn

2.Fork bent or damaged

3.Fork shaft bent

Crankshaft noisy

1.Conrod big end bearing worn

2.Conrod bent

3.Conrod roller bearing worn

Gearbox noisy

1.Main and secondary shaft gear worn

2.Splined shaft worn

Cam gear noisy

1.Cam worn

2.Cam gear worn

3.Tensioner spring weak

4.Cam gear shaft fitting gap too wide

5.Helical gear meshing gap too wide

Removal of Cam Gear Assembly

Remove the spring hold-dow n plate and remove the spring

Remove the cam shaft gear

Remove the cam gear assembly

Remove the tensioner assembly

Checking of Cam Ge ar Assembly

Measure the height of the cam.

Standard value: 32.768-32.928mm


Spring hold-down plateCam gear assembly

Spring hold-down plate

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测量凸轮齿轮内径。

标准值：14.04~14.061mm


测量凸轮齿轮的外径。

标准值：14.006~14.024mm


张紧器的分解 /组装组装好张紧器时，将弹簧涂满油脂，避免在安装张紧器时塞子掉落。

张紧器的安装

组装张紧器时，要按一按张紧器，用手

指将0型圈涂上机油，待定位后，牢牢紧固。

注意：张紧器塞子的方向不能装反。

66

压销体顶销弹簧

Measure the inside diameter of the cam gear.



Measure the outside diameter of the cam gear



Disassembling/Asse mbling of Tensioner

After the tensione r is assembled, coat the spring withgrease to prevent the plug from falling while thetensioner is installed.

Installation of Tensioner

When assembling the tensioner, be sure to give it a push,coat the O-ring with oil with a finger and tighten thetensioner after it is positioned.

Note: Take care not to put the tensi oner plugin the reverse direction.

Pin pusher Knock pin Spring

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密封垫

定位销

Packing gasket

曲轴箱的分离

将发动机右曲轴箱朝上安置。

拆下离合器拉筋定位板。

拆下6mm合箱螺钉。

将左右曲轴箱分开，

拆下密封垫和定位销。

曲轴箱的拆卸

从右箱体内取出曲轴组件。

曲轴的检查

将曲轴放在 V 型铁上。

用百分表测量曲轴的偏转。（径跳）

A 点和B点

最大值：0.02mm


测量连杆端轴承间隙， X和 Y 方向的两个点的径向间隙。


67

2

3 13

4

138

12

11

6

5

7

10

11

9

1

Parting of Crankcase

Place the right crankcase in an upward position.

Remove the locating plate for the clutch rib.

Unscrew the 6mm screws holdingthe two parts of the crankcase.

Separate the left part from theright part of the crankcase.

Remove the packing gasket and locating pin.

Disassembling of Crankcase

Remove the crankshaft component fromthe right part of the crankcase.

1. 曲柄连杆组件Crank-conrod component2. 活塞环Piston ring3. 活塞Piston

4.活塞销

Piston pin5. 连杆Conrod6. 曲柄Crank 7. 曲柄Crank 8. 曲柄销Crankpin9. 曲轴正时齿轮Crankshaft timing gear 10. 半圆键Half-round key11. 曲轴滚动轴承Crankshaft bearing12. 滚针轴承Roller bearing13. 活塞销挡圈Piston pin retaining ring

Checking of Crankshaft

Place the crankshaft on a V-block.

Measure the deflection (or radial runout)of the crankshaft with a dial indicator.

From Poin t A to Point B:

Maximum value: 0.02mm


Measure the gap of the conrod bearing., i.e. the radial

gap between two point s in the X and Y directions.Repair limit value: 0.05mm

Locating pin

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68

测量连杆大端侧隙。测量连杆大端侧隙。

维修极限值：0.8mm维修极限值：0.8mm

用手转动曲轴轴承，并检查其径跳和端跳。用手转动曲轴轴承，并检查其径跳和端跳。

如果发动机有噪音或径跳和端跳过大，则应更换。如果发动机有噪音或径跳和端跳过大，则应更换。

正时齿轮拆卸 /安装正时齿轮拆卸 /安装

拆卸拆卸

在正时齿轮带有圆形标记的齿上，在正时齿轮带有圆形标记的齿上，

由齿顶朝齿轮中心划冲印刻线，在左由齿顶朝齿轮中心划冲印刻线，在左

曲轴上过键槽中心划一条线，然后取曲轴上过键槽中心划一条线，然后取

下正下正时齿轮。时齿轮。

安装安装

在新的正时齿轮上，用同样的方法在新的正时齿轮上，用同样的方法

划一条线，然后压装，让齿轮上的刻线与划一条线，然后压装，让齿轮上的刻线与曲轴上的刻线对齐。曲轴上的刻线对齐。

注意：划线不要超出规定范围，否则油封会受损。注意：划线不要超出规定范围，否则油封会受损。因齿轮较软，应小心安装，注意不要使齿轮因齿轮较软，应小心安装，注意不要使齿轮

碰、划伤及产生大的变形。否则，将引起发动碰、划伤及产生大的变形。否则，将引起发动机较大的噪音。机较大的噪音。

变速组件的分解变速组件的分解

抽出拨叉轴，再拆下拨叉，抽出拨叉轴，再拆下拨叉，

拆下变速鼓，用双手将主副轴拉出。拆下变速鼓，用双手将主副轴拉出。

Measure the conrod big end side gap.Measure the conrod big end side gap.

Repair limit value: 0.8mmRepair limit value: 0.8mm

Turn the crankshaft bearing and check the radial runout and end runout.Turn the crankshaft bearing and check the radial runout and end runout.

Replace the bearing if it makes the engine noisy or its radial cunou t and end runout is too great.Replace the bearing if it makes the engine noisy or its radial cunou t and end runout is too great.

Removal/Installa tion of Timing GearRemoval/Installa tion of Timing Gear

RemovalRemoval

Draw a line on the timing gear tooth having a roundmark from the addendum toward the center of the gear.Draw another line passing the center of the keyway onthe crankshaft and then remove the timing gear.

Draw a line on the timing gear tooth having a roundmark from the addendum toward the center of the gear.Draw another line passing the center of the keyway onthe crankshaft and then remove the timing gear.

InstallationInstallation

Draw a line on a new timing gear and then push the gear intoposition on the crankshaft, making sure the line on the gear isaligned with that on the crankshaft.

Draw a line on a new timing gear and then push the gear intoposition on the crankshaft, making sure the line on the gear isaligned with that on the crankshaft.

Note:Do not draw the line beyond the specified range. Otherwise the oilseal will be damaged. As the gear is relati vely soft, take ca re not tohit it on other parts, scr atch it and deform it. Otherwise much greate r

engine noise will result.

Note:Do not draw the line beyond the specified range. Otherwise the oilseal will be damaged. As the gear is relati vely soft, take ca re not tohit it on other parts, scr atch it and deform it. Otherwise much greate r

engine noise will result.

Disassembling of Gearshift ComponentDisassembling of Gearshift Component

Remove the fork shaft and then the fork.Remove the fork shaft and then the fork.

Remove the gearshif t drum and pull out the mainand secondary shafts.Remove the gearshif t drum and pull out the mainand secondary shafts.

Free playFree play

RadialRadial AxialAxial

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拨叉 /拨叉轴 /变速鼓的检查

检查各拨叉是否有磨损、弯曲或其它任何故障，测量拨叉内径和厚度。维修极限值：0.05mm

检查换档拨叉轴是否有磨损毁坏或

弯曲。测量外径。


检查变速鼓和空挡开关接触片是否有磨损或毁坏。

拆下主轴和副轴

检查各齿轮止动销是否有过量或不正常的磨损。

测量叉爪的厚度

69

拨叉

拨叉轴

变速鼓

主副轴

叉爪

Checking of Fork/Fork Shaft/Gearshift Drum

Check each fork for wear, bending or any other irregularity and measure the inside diameter and

thickness of the fork.Repair limit value: 0.05mm

Check the gearshif t fork for wear, damage or bending and measure the outside diameter.Repair limit value: 11.96mm

Check the gearshift drum and neutral gear contact for wear or damage.

Remove the main shaft and secondary shaft

Check the stop pin of each gear for excessiveor unusual wear.

Measure the thickness of the fork pawl.

Fork

F o r k

s h a f t

Gearshift drum

Main and secondary shafts

Fork pawl

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启动轴组件的拆卸

拆下启动轴组件。

启动轴组件的分解

拆下推力垫圈、弹簧内套、回位弹簧和弹簧座。

拆下16mm 弹簧卡圈，然后依次拆下拨叉组合件、16mm垫圈、棘轮弹簧和启动棘轮。

拆下16mm弹簧卡圈，然后依次拆下推力垫圈和启动齿轮。

启动齿轮的检查

检查启动齿是否有磨损或损坏，并测量启动齿轮内径。

启动轴的检查

测量位于启动齿轮滑动表面处芯轴

的内径。维修极限值：19.90mm

维修极限值:20.5mm

70

启动轴

启动齿

启动轴

Removal of Starting Shaft Component

Remove the starting shaft component.

Disassembling of Starting Shaft Component

Remove the thrust washer, inner spring bush, return spring and spring seat.Remove the 16mm spring circlip and then take off the fork pawl component,16mm washer, ratchet spring and starting ratchet wheel.Remove the 16mm spring circlip and then remove the thrust washer and starting gear.

Checking of Starting Gear

Check the starting teeth for wear or damageand measure the inside diameter of the starting gear.


Checking of Starting Shaft

Measure the inside diameter of the shaft at thesliding surface of the starting gear.Repair limit value: 19.90mm

Starting teeth

Starting shaft

Starting shaft

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71

启动轴的安装

将启动齿轮、推力垫圈和16mm弹簧卡圈装上芯轴。

装好启动棘轮。

注意：棘轮和芯轴所作的冲印号要相互对准。

装好棘轮弹簧、推力垫圈、拨叉组合件和

16mm弹簧卡圈，装好弹簧座，回位弹簧和推力垫圈。

启动轴组件的装配

注意：将启动轴弹簧的端头扣上右曲轴箱凹槽内。 Note:Inlay the end of the staring shaft spring into the groove inthe right part of the crankcase.

将复位弹簧端部插入右曲轴箱孔内。

将启动棘轮拉出，朝顺时针方向旋转，然后将拨叉组合件、启动棘轮推进去啮合。Insert the end of the return spring into the hole in the right part of the crankcase.Pull out the starting ratche t, turn it clockwise and then push in the fork component andstarting ratchet wheel to get them engaged.

变速鼓和主副轴的安装

注意：装配前，每一零件均应涂好机油。 Note: Coat each of the parts with oi l before assemble it .

Assembling of Starting Shaft

Put the starting gear, thrust washer and16mm spring circlip on the shaft.

Put on the starting ratchet wheel.

Note:The marks made on the ratchet wheel andshaft must be aligned to each other.

Assemble the ratchet spring, thrust washer,fork component and 16mm spring circlip,spring seat, return spring and thrust washer.

Assembling of Starting Shaft Component

Right crankcase

Starting ratchet teeth

Assembling of Gearshift Drum and Main and Secondary shafts

Secondary shaft

Low-speed gear rd

3 -speed gear th4 -speed gear

th5 -speed gear nd

2 -speed gear

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72

将主轴和副轴装好。

注意：推力垫圈和弹簧卡圈的安装方向。卡圈应正确的装入轴上环槽内。

将主副轴安装到右曲轴箱内。

注意：安装时，用手指拨住推力垫圈，使推力垫圈位于安装位置。

将右拨叉安装在副轴滑移齿轮间。

注意：安装右拨叉时，有记号的一面朝下。

装好变速鼓。

注意：用手拉高齿轮，使右拨叉导销与变速鼓滑槽

啮合。

将中心拨叉从副轴一侧，插入主轴第4档齿轮凹槽内。

将左换档拨叉插入副轴第5档齿轮凹槽内。

注意：安装中心拨叉时，有记号的一面朝上。

将拨叉轴自顶部拨叉孔内插入右曲轴箱内。

0注意：装配好之后，检查齿轮是否能正反360

转动灵活，没有卡滞现象。

Put the main and secondary shafts in place.

Note:Pay attenti on to the fi tting direction of thethrust washer and spring circlip. The circlip should be put cor rectly into the ci rcu lar groove in the shaf t.

Put the main and secondary shafts into the right cran kcase.

Note: Hold the thrust washer wi th the finge rs to getit into the mounting position.

Put the right fork in between the main and secondary shafts .

Not e:When assembling the right fork, the marked sideshould be faced down.

Put in the gearshift drum

Not e: Ra ise the gear by hand to get the right fork guide

pin into mesh with the s lide groove in the gearshift dr um.

thInsert the central fork into the groove in the 4 -speed gear on the main shaft from the side of the secondary shaft and

th ththe 5 -gear fork into the groove in the 5 -speed gear.

Note: When in stalling the central fork ,the marked side should be faced up.

Insert the fork shaft into the right crankcase through the hole in the top.

Note:After assembli ng, check the gear to see if i t is able to turnclockwise and counterc lockwise through 360 without getting stuck.

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将曲轴箱装入右曲轴箱内。

注意：安装曲轴时，右手保持曲轴呈竖直状态，左手保持右箱的稳定。不得用任何工具敲击曲轴。

曲轴箱的安装

装好定位销和密封纸垫。

装上左曲轴箱体，拧紧合箱螺栓，

注意：垫圈一定要安装在正确位置。扭紧合箱螺栓时，按对角交叉方式进行。

将发动机右曲轴箱朝上，装上离合器拉筋定

位板，然后扭紧螺栓。

凸轮齿轮组合的安装

将曲轴旋转到活塞上死点位置（半圆键朝上）安装凸轮齿轮组合。

注意：安装时，应使凸轮齿轮组合上的标记与正时齿轮上的标记对准。

保持凸轮齿轮组合的清洁，不要让灰尘、杂质进入左箱型腔内。

安装好凸轮齿轮轴，安装好压簧及压板，扭紧螺栓，安装好Φ50油封。

Put the crankshaft into the right crankcase.

Note:When installing the crankshaft , hold it upright with the

right hand and keep the right crankcase with the left hand.Do not hit the crankshaft with any tool.

Installation of Crankcase

Put on the left crankcase.

Tighten the joining bolts.Put in the locating pin and paper gasket.

Note :The washers must be put into the correct posi tion.Tighten the bolts in a diagona l order.

Face the right crankcase up, put on the clutchrid locating plate and tighten the bolts.

Installation of Cam Gear

Turn the crankshaft to the top dead center of the piston(with the half -round key faced up) and put in the can gear component.

Not e:When assembli ng the cam gear, t he mark on i t shouldbe aligned to the mark on the timing gear.Keep the cam gear component clean and prevent dust and dirt from getting intothe cavity of the left crankcase.

Put in the cam gear shaft.Put in the spring and hold-down plate and tighten the bolt.Put on the 50 oil seal.?Φ

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转向系统、前轮、制动器、悬挂装置

维修须知

技术规格

前轮轴径向跳动量 0.2mm 紧固件扭矩值

轮辋径向跳动极限值 2 mm 前轮轴螺母 50-70N.m

轮辋轴向摆动极限值 2mm 立管盖型螺母 60-90N.m

前叉弹簧自由长度极限值 476mm 手把管固定螺栓 9-11N.m

前叉管直径极限值 30.9mm 连接板固定减震器螺栓 10-14N.m

制动鼓内径极限值 130mm 下连接板固定减震器螺栓 20-25N.m

制动蹄块摩擦片厚度极限值 2mm 减震器上端密封螺母 40-50 N.m

转向困难

1、转向立管调整螺母扭得太紧；

2、立管推力轴承磨损；

3、立管推力轴承刚球磨损；

4、前轮胎气压不够。

行驶时朝一个方向偏驶

1、前叉管弯曲；

2、前轮轴弯曲，车轮安装部正确；

3、立管架变形或弯曲。

Steering difficult

Steering tube adjusting nut too tight;

Steering tube bearing worn;

Steering tube thrust bearing ball worn;

Front tire pressure insufficient.

Tending to one side during travel

Front fork tube bent;

Front axle bent, wheel not installed correctly;

Steering tube bent or deformed.

前轮摆动

1、轮辋扭曲；

2、前轮轴承磨损；

3、车轮辐条变形或松动；

4、轮胎损坏；

5、前轮轴螺母松脱。

悬挂装置刚度不够

1、前叉弹簧的弹力不够；

2、前叉内液压油注油量不够。

Front wheel wobbling

Wheel rim twisted;

Front axle bearing worn;

Wheel spokes deformed or loosened;

Tire damaged;

Front axle nut loosened.

Suspension not rigid enough

Front fork spring weak;

Front fork containing less hydraulic oil than enough.

故障排除

11

74

Steering System, Front Wheel, Brake, Suspension

维修须知前轮

故障排除制动器前车头灯的拆装前悬挂

仪表转向立管

转向手把


Troubleshooting

Removal/Installation of Headlamp

Meters

Handlebar

Front Wheel

Front Brake

Front Suspension

Steering Tube


Technical Specifications

Radial runout of front axle

Limit value of radial runout of wheel rim

Limit value of axial runout of wheel rim

Limit value of free length of spring

Limit value of front fork tube

Limit value of inside diameter of brake drum

Limit value of thickness of brake lining

Required Fastener Tightening Torque Values

Front axle nut

Steering tube cap nut

Handlebar fastening nut

Shock absorber fastening bolton upper plate

Shock absorber fastening bolt on lower plate

Packing nut on upper end of shock absorber

Troubleshooting

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75

悬挂装置刚度太大

1、前叉内液压油加注太多悬挂装置有噪音

1、前叉管滑动块卡死；

2、前叉内液压油不够；

3、前叉松动。

Suspension too rigid

Too much hydraulic oil in front fork

Suspension noisy

Front fork tube slide jammed;

Insufficient hydraulic oil in front fork;

Front fork loosened;

制动器性能不良

1、制动器没有按规定调整；

2、制动蹄块摩擦片磨损；

3、制动蹄块上有水或油污；

4、制动鼓磨损；

5、制动凸轮磨损；

6、制动臂安装部正确。

Brake inefficient

Brake not properly adjusted;

Brake lining worn;

Brake lining wet with wate r or oil;

Brake drum worn;

Brake cam worn;

Brake arm not properly installed.

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组合仪表组合仪表的拆装

拆下头灯外壳。拆开软轴螺母，然后拆开

组合仪表的连接。拆下仪表固定螺母，即可拆下仪表板。

Combination Meter

Removal /Instal lation of Combination Meter

Remove the headlamp case, unscrew the flex ibleshaft nut and disconnect the combination meter. Unscrew the fasten ing nut and remove the meter panel.

仪表板的分解

先拆下仪表盘各连接螺钉，然后即可拆下仪

表板盖。

76

软轴螺母

Disassembl ing of Meter Panel

Unscrew the fastening screws from the meter paneland then remove the panel cover.

仪表板照明灯的更换

先撬开灯泡的橡皮接套。

换上一支新灯泡，如果灯不亮，则应检查是否短路断路或短路，或电缆连接松脱。

Replacemen t of Meter Lamp

Pry open the rubber sleeve of the bulb.

Put in a new bulb. If it does not go on, check the wiring

for breaking or shorting or loose cable connection.

各指示灯的更换

撬开各灯泡的橡皮套，然后即可拆下车速

计和转速计各灯泡。

Replacement of Indicator Lamps

Pry open the rubber sleeve of each bulb and removethe speedometer and tachometer bulbs.

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拆下手把锁紧六角螺栓。

77

转向手把

转向手把的拆卸

拆开转向手把左右两侧的开关电线线束。

拆下手把及开关后，再拆下离合器操纵线的连接。

Handlebar

Removal of Handlebar

Disconnect the switch wires on the left and right sideof the handlebar.

Remove the handgrips and switches and disconnectthe clutch control cable.

Remove the handlebar fastening seat andthen the handlebar.

转向手把的安装

转向手把的安装，按照与拆卸相反的顺

序进行。

注意：在安装手把卡子时，支座上的标记应与手把管上的标记对齐。 Note:When assembling the clamps to the handleba r,the mark on the base should be aligned with the mark on the handlebar tube.

Follow the reverse order of the above steps toinstall the handlebar.

Installation of Handlebar

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点火开关

车轴螺母Axle nut

Ignition switch

装好油门手把，并将底端支座上的插销，

插入转向手把的锁孔内，只插入一半的程度。

然后扭紧前部螺钉后按相同的扭矩扭紧后部

各螺钉。

注意：安装节气门手把前，再转向手把的节气

门手把部位，应涂好油。

将电线束箍带装好。

前轮

前轮的拆卸

在发动机的下方用木塞或其它支架抬高，

使车轮离开地面。拆开固定螺钉即可拆开车速

计传动软轴、前制动操纵线连接。

扭松并拆下车轴螺母，将车轴自前轮拉出。

装好点火开关。

Put on the throttle grip and insert the pin on the

bot tom base into the lock hole in the hand lebar. Be sureto insert only half of it and then tighten the front screwsand then rear screws to the same torque.

Not e:Coa t the throttle gri p with oil befo re putt ing it in place.

Install the ignition switch.

Put in the wire harness fastening band.

Front Wheel

Removal of front wheel

Place a wood pad or stand under the engine to li ft thewheels off the ground. Unscrew the fastening screws toremove the speedometer shaft and disconnect the front brake cont rol cab le.

Loose and remove the axle nut and remove the axle

from the front wheel.

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79

衬套

Lining bush

前车轴的检查

将前车轴放在 V 型铁上，表盘式指示器偏摆。

实际偏摆位总读数的1/2。

维修极限值：0.2mm。

车轮轮轴的检查

把车轮放在校正台上，以手拨动车轮作高

速运转，检查车轮的轴承自由行程。

如果听到杂音或者自由行程过宽，则需更

换新的轴承。

然后把车轮放在校正台上，检查轮辋的偏

摆。然后以手拨动车轮使其旋转使用表盘指示

器读取其上所示偏摆值。

维修极限值：径向 2.0mm

轴向 2.0mm

车轮轴承的更换

拆下右侧的衬套。

Checking of Front Axle

Place the fron t axle on V-blocks and measure its runoutwith a dial indica tor. The actual runout should be 1/2 of thetotal reading.


Checking of Wheel Bearing

Place the wheel on a straightening table, make thewheel rota te fast by hand and check the free play of thewheel bearing.

Replace the bearing if an unusual noise is heard or thefree play is found too wide.

Place the wheel on the straightening table, check thedeflect ion of the wheel rim and then make the wheel rotate by hand and then read value shown on the d ial indicator.

Repair limit value: Axial 2.0mmAxial 2.0mm

Replacement of Wheel Bearing

Remove the lining bush from the right side.

Free play

Free play

Axial Radial

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80

将前轮的上下轴承更换。

将轴承拆卸工具轴插入轴承拆卸工具开口内，敲轴承拆卸工具轴，直到将车轮轴承牢牢牢固紧为止。

Replace the upper and lower bearings on front wheel.

Insert the bearing tool shaft into the opening in the tool,tap on the tool shaft until the axle is securely fastened.

按图示方法敲轴承拆卸工具轴，然后拆下车轮轴承。

Tap on the bearing too l as shown in the picture on theright and remove the axle bearing.

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81

前轮的安装

在车轮轴承的内腔涂好润滑油。然后装上右轴承和衬套，再装上左轴承。

注意：安装轴承时，将封口朝外轴承顶入一定要垂直。

装上新尘封。

装好右侧的衬套。

将前制动器装上前轮轮毂。

安装前轮时，使左前叉底筒上的凸块嵌入制动器凹槽内。自右侧把车轴插入。

扭紧车轴螺母。

连接好车速表软轴，将车速表软轴端头与齿轮箱连接好，并扭紧固定螺钉，用手拨动前轮，看能否顺利转动。调整好前制动手柄的自由行程。

Installation of Front Wheel

Coat the cavity of the wheel bearing with grease and put on the left bea ring and bush and then r igh t bea ring.

Not e:When ins tall ing the bear ing, be sure to push in the bearing with the seal opening faced out in a ver tical pos it ion.

Put in a new dust seal.

Put on the lining bush on the right side.

Put the front brake on the front wheel hub.

When instal ling the front wheel, be sure to inlay the protrus ion lug on the bottom tube of the lef t fork cylinde r into the groove in the brake and then insert the axle fromthe right side.

Tighten the axle nut.

Connect the flexible shaft of the speedometer to thegearbox and tight en the screw. Turn the front wheel to seeif it is able to rotate freely. Adjust the free play of the front brake lever.

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1

2

3

4

5

5

5

6

6

7

8

9

10

11 12

13

14

15

1617

18

19

2021

22

1

2

3

4

5

6

7

8

16

17

18

19

20

21

22

右手柄

手柄螺栓

螺母M6

碟刹上泵

垫圈

过油螺栓

碟刹油管

管夹

罩

下泵密封圈

缓冲器支座

防噪弹簧

碟刹蹄片

缸套

碟刹下泵

管夹

螺栓M6×12

安装座

螺栓M6×20

螺栓M8×32

螺栓杆

罩

9

10

11

12

13

14

15

上下泵组件结构Construc tion of Upper and Lower Pump Assembly

1. Right handle

2. Handle bolt3. M6Nut M64. Upper disc brake pump5. Washer 6. Oil passage bolt7. Disc brake oil pipe8. Pipe clip

9. Cover

10. Lower pump packing ring11. Buffer seat12. Noise-absorbing spring13. Disc brake lining14. Cylinder liner 15. Lower disc brake pump

16. Pipe clip17. M6×12Bolt M6×1218. Mounting base19. M6×20Bolt M6×2020. M8×32Bolt M8×3221. Bolt bar 22. Cover

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摩擦衬块更换

1.拆卸：

定位螺栓 1

卡钳壳 2

2.拆卸：

制动器摩擦衬块

摩擦衬块弹簧

定位弹簧

4

1

2

3

3.检查：

卡钳托架

卡钳壳裂纹或损坏更换

橡胶罩裂纹或损坏更换

1

2

3

4.润滑：

导向销

5.安装：

定位弹簧

摩擦衬块弹簧

摩擦衬块

1

2

3

注意：安装时，摩擦衬块的凸起

部 a 务必朝后 A 。

Replacement of Brake Lining

Remove the locating bolt①

and remove caliper case②.

Remove the brake lining ①,lining spring ② and locating spring ③.

Check the caliper holder ①,caliper case ② and rubber cover ③ for fissure or damage.

If yes, replace them.

Lubricate the guide pin ④.

Note: The pro trusion on the brake lining

must be directed toward A.

Install the locating spring ①,lining spring ② and lining ③.

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84

6.润滑：

定位螺栓

7.安装：

卡钳壳

定位螺栓

1

2

卡钳解体

1. ：拧松

联接螺栓

2.拆卸：

定位螺栓

3.拆卸

卡钳壳


摩擦衬块弹簧

定位弹簧

1

2

Lubricate the locating bolt ①.

Install the caliper case ② and locating bolt.

Disassembling of Caliper

Loosen the fastening bolt ①.

Remove the locating bolt ②.

Remove the caliper case, brake lining,lining spring and locating spring.

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4. 拆卸

卡钳托架

5.拆卸

联接螺栓

铜垫圈

6.拆卸：

活塞

1

1

2

1

7.拆卸

防尘密封件

活塞密封件

1

2

Remove the caliper holder ①.

Remove the fasteni ng bolt ① and remove the copper washer ②.

Remove the piston ①.

Remove the dust seal ① and piston seal ②.

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86

主缸解体

1. 拆卸

后视镜

制动器杆罩

螺母

螺栓

1

2

3

4

2. 拆卸

制动器杆

回位弹簧

制动开关

1

2

3

3.拧松

联接螺栓 1

4.拆卸：

主缸

联接螺栓

垫圈

1

2

3

5.拆卸：

主缸盖

膜片

橡胶罩

弹性挡圈

主缸组件

1

2

3

4

5

如图所示：用小螺丝起子向上抬起止动器即可拆卸制动开关。

注意：

Disassembling of Master Cylinder

Remove the back mirror ①, brake lever cove r ②,nut ③ and bolt ④.

Remove the brake lever ①,return spring ② and brake switch ③.

Note:As shown in the sketch, lif t the stopwith a small screwdriver to removethe brake switch.

Loosen the fastening bolt ①.

Remove the master cylinder ①,fastening bolt ② and washer ③.

Remove the master cylinder cover ①,diaphragm ②,rubber cover ③ and elastic retaining ring ④ and master cylinder component ⑤.

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87

检查与修理

1. 检查

卡钳式油缸：磨损或刮痕痕更换

活塞：刮痕、生锈或磨损更换

卡钳托架：裂纹或损坏更换卡钳组件

卡钳壳：裂纹或损坏更换卡钳组件

橡胶罩：裂纹、损坏或磨损更换

供液孔：用压缩空气吹净

主缸：磨损或刮痕更换主缸组件

主缸体：磨损或刮痕更换

1

2

供液道：用压缩空气吹净

主缸组件 1

刮痕、损坏或磨损成套更换

Checking and Repairing

Checking:

Caliper cylinder: Replace it if wear or scratch is found.

Piston : Replace it if scratch, rust or wear is found.

Calipe r holder: Replace it if fissured or damaged.

Caliper case: Replace it if fissured or damaged.

Rubber cover: Replace it if fissured, damagedor worn.

Oil hole: Clean it with compressed air.

Master cylinder ①: Replace it if damaged or scratched.

Cylinder body ②: Replace it if worn or scratched.

Oil passage: Clean it with compressed air.

Master cylinder component: Replace it altogether if damaged or worn.

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88

2、测量

摩擦衬块厚度

超出摩损极限值0.8mm 更换

制动盘测量：

最大挠曲极限0.3mm

千分表测制动盘厚度

制动盘厚度 a 应为4.00mm

Measuring

Thickness of brake lining: Replace itif worn out of the 0.8mm limit.

Brake caliper: Maximum distortionlimit 0.3mm

Thickness of brake caliper on a

micromet er: Thickness to be 4.00mma

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89

卡钳组装

1. 安装

活塞密封件

防尘密封件

活塞

1

2

3

2. 安装

卡钳托架 1

3. 安装

定位弹簧

摩擦衬块弹簧


卡钳壳

定位螺栓

4. 安装

垫圈

制动器软管

联接螺栓

1

2

3

注意：把制动软管的管口 a 部分装入卡钳壳上的凹槽 b

Assembling of Caliper

Install

Piston seal ①Dust seal ②Piston ③

Install

Install

Install

Caliper holder ①

Brake lining springBrake liningCaliper caseLocating bolt

Washer ①Brake hose ②Fastening bolt ③

Not e:Inl ay the opening a of the brake hose into the groove in the calipe r case b .

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90

主缸组装

1. 安装

主缸组件

弹性挡圈

橡胶罩

1

2

3

2. 安装

主缸 1

3. 安装

垫圈

制动软管

联接螺栓

1

2

3

注意：如图所示，安装制动管

A

A

90

90

4. 安装

制动开关

弹簧

制动杆

制动杆罩

后视镜

1

2

3

4

5

Assembling of Master Cylinder

Install

Install

Install

Master cylinder component ①Elastic retaining ring ②Rubber cover ③

Master cylinder ①

Washer ①Brake hose ②Fastening bolt ③

Note:As shown in the sketch, install

the brake hose at .

Install

Brake switch ①Spring ②Brake lever ③Brake lever cover ④Back mirror ⑤

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91

连接板的螺栓Linking plate bolt

前叉

在发动机下方用一木塞或支架将前车轮顶离地面。拆下前车轮。

拆下制动器。拆下前挡泥板。

分别拆下每一前叉架，并用手转动前叉管。

扭松叉架上连接板和下连接板的螺栓。

(见81页）

(见

82页）

Front Fork

Place a piece of wood or stand under the engineto lift the front wheel off ground.

Remove the front wheel (See Page 81).Remove the brake (See Page 82).Remove the front mudguard.

Remove each front fork holder and turn the front fork tube.

Loosen the bolt connecting the upper linking platewith the lower linking plate.

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92

476mm

泄油螺栓Oil drain bolt

前叉的分解

用虎钳将前叉管钳住。拆下前叉密封螺栓。拆下前叉弹簧。

弹簧的检查

测量弹簧的自由长度。维修极限值：476mm。

拆下泄油螺栓，将叉架液自前叉管内泄出。将叉架抽吸数次，使剩余的液全部排出来。

Disassembling of Front Fork Hold the front fork tube in a bench vice.Remove the packing bolt from the fork tube.

Checking of Spring

Measure the free length of the spring.Repair limit value: 476mm

Unscrew the oil drain bolt to drain off oil from the

front fork tube. Draw it severa l times to empty it thoroughly.

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用虎钳将底筒叉住。用内六方扳手拆下套头螺栓。拆下叉管，车座管和油封件。检查各零件是否有磨损或损坏。如有磨损或损坏，则应更换。

叉管偏摆

将叉管放在 V 型铁上，并读取偏摆值。取其总值1/2定为实际的磨损度。维修极限值：0.2mm。

量叉管外径，应沿滑动面多量几个部位。维修极限值：30.9mm。

拆下油封：

注意：拆下油封和卡环时，不要将滑动表面的内外两侧毁损。

拆下防尘密封盖。用卡环钳拆下卡环。

Hold the bottom cylinder in the vice and unscrewthe sleeve bolt with an in inner hex wrench. Remove the

fork tube, base tube and oil seal. Check the parts for wear or damage. Replace the worn or damaged ones.

Checking of Fork Tube Runout

Place the fork tube between two V-blocks and measure the runout wit h a dial indicator. Take 1/2of the total value as the amount of wear.


Measure the outside diameter of the fork tube andtake measurements at several more points on the slidingsurface.


Remove the oil seal.

Not e:When removing the oil s eal and ci rcl ip, takecare not to damage the inner and oute r sides of thesliding surface.

Remove the dust seal cover and remove the circlip

with the circlip pliers.

Oil seal

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底筒的检查

检查底筒内侧滑动表面是否有磨损或损坏。量底筒的内径。维修极限值：31.1mm。

前叉的装配

装配前，将零件用溶剂清洗后，并彻底抹干净。

将座管插入底筒内，使油封件位于座管的短头位置。将前叉管插入底筒滑动部位，

并用内六方扳手将套头螺栓拧紧。

注意：套头螺栓应涂好密封剂。

将前叉管衬套与油封顶入底筒。

Checking of Bottom Cylinder

Check the inside sliding surface of the bottom cylinder for wear or damage and measure the inside diameter of the bot tom cyl inder.


Assembling of Front Fork

Before assembling, clean the parts in acleaning solvent and dry them completely.

Insert the base tube into the bottom cylinder sothat the oil seal is in the sho rt end of the base tube.Insert the front fork tube into the sliding part of the bot tom cyl inder and ti ghten the sleeve bolt with ahex wrench.

Note: The sleeve bol t should be coated wi th sealant.

Push the fork tube sleeve and the oil seal intothe bottom cylinder.

Groove

Oil seal

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卡环

叉管弹簧Fork tube spring

Circlip 将卡环用卡环钳装入底筒的凹槽内。按规定量倒入8号低凝汽油机油。

注意：装油不要太多。

规定油量：159ml。

将叉管弹簧装入叉管。

注意：安装弹簧时，弹簧节距较密的一头朝上。

用虎钳钳住前叉管扭紧密封螺栓。扭矩：40-50N.m。

前叉架的安装

将叉管经上，下连接板孔中插入，同时用手转动即可装好。

扭紧叉管上连接板螺栓、下连接板螺栓。装好前挡泥板。装好前轮。

Inlay the circlip with the pliers into the groovein the bottom cylinder and pour the specified amountof #8 low condensation point gasoline engine oil.

Note: Do not ove r-f il l the bot tom cyl inder.

Specifi ed amount of oil: 159ml

Put the spring into the fork tube.

Note: When putt ing in the spr ing, be sure the endwith a shorter pitch should be faced up.

Hold the front fork tube in the vice andtighten the packing bolt.

Torque requirement: 40-50N.m

Installat ion of Front Fork Frame

Insert the fork tube through the upper and lower linking plates and meanwhile turn it by hand to get itinto position.

Tighten the upper and linking plate bolts on the fork tube.Put on the front mudguard.Install the front wheel.

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转向调整螺母

立管组件

钢球

Steering adjusting nut

Steering tube component

Steel ball

转向系统

拆下转向手把。拆下车头灯和仪表板。拆下前轮。用螺母扳手拆下盖形螺母。拆下上连接板。

拆下转向调整螺母。

注意：请勿使钢球落下。

从车架上拆下立管组件。用钢球座圈拆卸器拆下轴承座圈。检查轴承座圈是否磨损或毁坏。如有须更换。

检查钢球和轴承圈是否有磨损或损坏，如有则应更换。

Steering System

Remove the handlebar.Remove the headlamp and meter panel.Remove the front wheel.Unscrew the cap nut with a wrench and remove the

upper linking plate.

Unscrew the steering adjusting nut.

Note: Do not drop the steel balls.

Remove the steering tube component from the frame.Remove the bearing race with a special tool .Check the lower bearing race for wear or damage and

replace it if it is worn or damaged.

Check the steel balls and race for wear or damageand replace them if it is worn or damaged.

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检查下轴承圈是否有磨损，如有应更换。

转向立管的安装

用轴承座圈驱动将滚针轴承压入立管内。将钢球、轴承座圈和轴承圈涂好机油。将立管自底端经车架立管装入。

装好调整螺母并扭紧，直到与上轴承座

啮合为止。

注意：当螺母扭紧后倒扭1/8转，，一定不能存在垂直方向的运动，而立管也能自由转动。

装好车头灯支架。装好上连接板。装好前叉架。扭紧盖型螺母。装好转向手把，仪表、车头灯和前轮。

Check the lower bearing race to see if it is damaged.If yes, replace it.

Installat ion of Steering Tube

Push the roller bearing into the steering tube withthe bearing race driver.

Coat the steel balls, upper and lower bearing raceswith grease and put in the steering tube through the framefrom the bottom end.

Put on the adjusting nut and tighten it into engagement with the upper bearing base.

Note:Tighten the nut and then loosen it by 1/8 turn. No vert ical movement i s allowed and yet thesteering pipe is able to turn freely.

Install the headlamp bracket.Install the upper connecting plate.Install the front bracket.Tighten the cap nut.Install the handlebar, meter, headlamp and front wheel.

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后轮、制动器、悬挂装置

维修须知

概述

本节介绍后轮、后制动器、后减震器的拆卸、安装和保养。拆卸时，先将发动机用千斤顶或支架将后轮抬高。

各部规格

扭矩：

车轴螺母

后叉架枢轴螺栓螺母

后制动连接杆螺栓

减震器螺栓

从动链轮

制动凸轮固定螺栓

Torque Requirements:

Axle nut

Rear fork pivot shaft bolt and nut

Rear brake conrod bolt

Shock absorber bolt

Driven sprocket wheel

Brake cam fastening bolt

50-80N.m

50-80N.m

55-65N.m

55-65N.m

30-40N.m

30-40N.m

30-40N.m

30-40N.m

20-25N.m

20-25N.m

8-12N.m

8-12N.m

12

Rear Wheel, Brake, Suspension

维修须知 Not es to Maintenance

后制动器Rear brake

故障排除Troubleshooting

后减震器Rear Shock Absorber

后轮Rear Wheel Rear Fork

后叉


This section provides procedures for disassembling and reassembling of the rear wheel,rear brake and rear shock absorber. Before removing these parts, raise the engine with a jack or s tand so that the rear wheel is l ifted off ground.

Part Specifications

Item Standard Value(mm) Repair Limit(mm)

Wheel rim runout

Inside diameter of brake drum

Brake lining thickness

Free length of shock absorber spring

项目

Axle runout 车轴偏转度

轮辋偏转度

制动鼓内径

衬片厚度

减震器弹簧自由长度

轴向Axial径向Radial

标准值（mm）维修极限值（mm）

130.0

3.9-4.1

225.6

0.2

2.0

2.0

221.0

2.0

131.0

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调整螺母

车轴螺栓驱动链调整螺栓

Adjusting nut

Axle bolt Drive chain adjusting bolt

故障排除

摩托车摆动或振动

1、车轮轴承松。

2、轮辋不正。

3、后轮轴变形。

4、胎压不正确。

5、车轴螺母松脱。

悬架的钢性不够

1、弹簧的弹力太弱。

2、后减震器力度不够。

悬架的钢性太大

1、固定器松脱。

2、减震器止动橡皮块有故障。

3、减震器轴弯曲。

Vehicle body wobbling or vibrating

Wheel bearing run loose;

Wheel rim distorted;

Rear axle bent;

Tire pressure incorrect ;

Axle nut run loose.

Suspension not rigid enough

Spring weak;

Rear shock absorber not strong enough;

Suspension too rigid

Fastener run loose;

Shock absorber stop rubber piece faulty;

Shock absorber shaft bent.

悬架有噪音

1、固定器松脱。

2、减震器止动橡皮块有故障。

3、减震器漏油。

4、减震器与弹簧粘住。

制动器功能不好

1、制动器调整不好。

2、制动蹄有磨损。

3、制动器摩擦蹄片污损。

4、制动鼓磨损。

5、制动臂花键啮合不正确。

Suspension noisy

Fastener run loose;

Shock absorber stop rubber piece faulty;

Shock absorber leaking oil;

Shock absorber stuck with spring.

Brake not functioning efficiently

Brake not adjusted correctly;

Brake shoe worn;

Brake lining dirty or damaged;

Brake drum worn;

Brake arm spline not correctly meshed.

后轮

用千斤顶或木架将发动机抬高，

使后轮离开地面。将后制动器调整螺母朝外扭出并推后制动踏板，使后制动臂和制动杆脱开。

扭松车轴螺母，驱动链锁紧螺母以及驱动链调整螺栓。

拆下止动螺栓。将车轮朝前推，移动后车轮。

用钳子拆开驱动链接头固定环。然后拆下驱动链。将后轮朝后拉拆下后轮。

Loosen the axle nut, drive chain lock nutand drive chain adjusting nut.

Remove the stop bolt, push the wheel forwardand move the rear wheel.

Remove the fastener ring of the drive chain joint with pl iers, remove the drive chain,and pull the rear wheel backward to remove it.

Troubleshooting

Rear Wheel

Raise the engine with a jack or woodstand so that the rear wheel is lifted off ground. Turn the rear brake-adjusting nutoutward and push the rear brake pedal todisengage the brake arm from the brake lever.

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主轴弯度的检查

车轮轴承的检查

轮辋

后制动鼓的检查

将主轴放在 V 形台座上，并读取轴的弯度

数值。轴的实际弯度为总读数值的1/2。


把车轮放在校正台上，以手拨动车轮作

高速转动，检查车轮轴承的自由行程。如听到杂音或自由行程过宽，则须更换新的轴承。

把车轮放在校正台上，检查轮辋的偏摆。然后以手拨动车轮使其旋转。使用表盘式指

示器，读取其上所示偏摆值。

维修极限值：径向：2.0mm

轴向：2.0mm

测量后制动鼓内径。

维修极限值：131mm

Checking of Main Shaft Straightness

Place the main shaf t on two V-blocks and read the bending from the dia l indicator. The actual bending is 1/2of the total value.


Checking of Wheel Bearing

Place the wheel on a inspection table, pushit by hand to make it turn fast and check the free play of the wheel bearing. If a noise is heard or free play too wide, replace the bearing.

Wheel Rim

Place the wheel on the inspection table andcheck the runout of the wheel rim. Then push thewheel by hand to make it turn fast. Read therunout from a dial indicator.

Repair limit value:Radial: 2.0mmAxial: 2.0mm

Checking of Rear Brake Drum

Measure the inside diameter of the bake drum.

Repair limit value: 131mm

Free play

Free play

Axial Radial

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轴承Bearing

缓冲套的检查

车轮轴承的拆卸

后轮的安装

检查缓冲套是否丧失弹力或毁损，如有，

必须立即更换。

将轴承拆卸工具插入轴承中，敲轴承拆

卸工具直到使车轮轴承牢牢紧固为止。

敲轴承拆卸工具即可拆下车轮轴承。

在轴承内腔涂好润滑油。

Fill the cavity of the bearing with grease.

顶入左轴承。Push in the left bearing.

插入轴套。Insert the shaft sleeve.

顶入右轴承。Push in the right bearing.

注意：把轴承垂直顶入。装配轴承时，

把封口朝外。

Checking of Buffer Sleeve

Check the buffer sleeve to see if it has lost elasticityor damaged. If yes, replace it immediately.

Removal of Wheel Bearing

Insert the bearing-removing tool into the bearingand tap on it until the wheel bearing is tightened.

Tap on the tool to remove the wheel bearing.

Assembling of Rear Wheel

Not e: Push in the bearing vertica lly. Whenassembling the bearing, be sure thatthe seal opening is faced outward.

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固定螺栓Fastening bolt

Good Should be replaced

从动链轮的检查

装好固定螺栓，直到螺栓突缘很正确的

位于从动链轮之间。

检查末端从动链轮齿的情况。Check the condition of the driven sprocket wheel at the end.

链轮如有磨损、残缺，则应更换。Replace the sprocke t wheel if it is worn or broken.

链轮与驱动链条。

装好车轴，两侧的链条调整器和隔环以

及车轴螺母，不要装得太紧。

注意：后制动器盖上的定位板应安装正确。

后轮的安装

Put in the fastening bolt until its flange getscorrectly into the driven sprocket wheel.

Checking of Driven Sprocket Wheel

Not e: If the driven sprocket wheel is worn or broken, thedriving sprocke t wheel and drive chain should also

be checked .

Installation of Rear Wheel

Put in the axle, chain adjuste rs on both ends andaxle nut, making sure they are not too tight.

Not e:The loca ting plate on the rea r brake cover

should be correctly installed.

注意：从动链轮如已磨损、残缺，尚需检查驱动

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Moving direction

将驱动链条装在驱动链轮和从动链轮上。

装好驱动链条固定环和链条夹钳。

注意：驱动链条固定钳的安装方向。

装好止动螺栓并拧紧。

将后制动器杆与制动臂连接好，并装好

后制动器调整器，调整好驱动链条。

装好后轴螺母，并拧紧。

扭矩：50—80N.m

后制动器

在拆下后轮后，即可拆下后制动器。

Instal l the drive chain on the driving and drivensprocket wheels and then joint the chain with the joiningring and chain clip.

Note: The direc tion of the dr ive chain clipshould be correct.

Put in the stop bolt and tighten it.Connect the rear brake lever and brake arm,

install the rear brake adjuster and adjust the drivechain slackness.

Put on the rear axle nut and tighten it .


Rear Brake

The rear brake can be removed only after the rear wheel is removed.

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制动蹄片

弹簧Spring

Brake lining

后制动器摩擦片的检查

测量制动器摩擦片的厚度Measure the thickness of the rear brake lining.



后制动蹄片的更换

将制动蹄片朝固定件向两侧拉开，拆下弹簧，再取出制动蹄。

后制动盖的装配

在制动凸轮的表面涂上润滑脂。Coat the surface of the brake cam with grease.

安装制动凸轮。Install the brake cam.

安装新制动蹄片。Install the new brake lining

安装弹簧。Install the spring

警诫：沾有润滑脂的制动器摩擦片会降低制动作用。应保持衬片不沾润滑脂。应从凸轮上

擦去多余的润滑脂。

Checking of Rear Brake Lining

Replacement of Rear Brake Lining

Pull the brake lining fastener sideways, removethe spring and then remove the brake shoe.

Assembl ing of Rear Brake Cover

Warning: The contaminat ion of the brake lining with greasewill degrade the brake performance. Thereforekeeping the brake lining clean is of great importance. Always remove excessive grease from thecam after it is assembled.

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221mm

后减震器

后减震器的拆卸Removal of Rear Shock Absorber

拆下上、下减震器安装螺栓。Unscrew the upper and lower shock absorber fastening bolts.

拆下减震器。Remove the shock absorber.

安装制动臂

注意：将凸轮上的冲印记号与制动臂上的冲印记号对准。

按规定扭矩拧紧螺栓和螺母。

扭矩：8—12N.m

后减震弹簧的检查

测量弹簧自由长度

维修极限值：221mm

Measure the free length of the spring.

Repair limit value: 221mm

用专用工具压缩后减震弹簧，拧紧锁紧

螺母，取下减震器弹簧。

Installation of Brake Arm

Note: The print mark on the cam should be aligned to the print mark on the brake arm.

Tighten the bolt and nut to the specif ied torque.


Checking of Rear Shock Absorber

Compress the rear shock absorber spring with aspecial tool , tighten the lock nut and remove the spring.

Rear Shock Absorber

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后减震弹簧的装配

用减震器压缩器压弹簧，使刚好能装上

弹簧固定板为止。

注意：在防松螺纹上涂好粘接剂，再装上减震弹簧。

106

后减震器的安装

安装左、右后减震器。Install the left and right rear shock absorbers.

扭矩：30—40N.m


用手按压框架末端数次，检查减震器情况。Push the end of the frame by hand several times tocheck the condition of the rear shock absorber.

注意：左、右后减震器应按照同一比例调整好。

后叉

后叉的拆卸Removal of Rear Fork

拆下排气消音器。Remove the exhaust muffler.

拆下驱动链条盒。Remove the driven chain cover.

拆下驱动链条。Remove the drive chain.

拆下后轮。Remove the rear wheel.

拆下减震器。Remove the shock absorber.

拆下后叉轴螺栓。Remove the rear fork shaft bolt.

Installation of Rear Shock Absorber

Note: The lef t and r ight rear shock absorbers mus t beadjusted to the same rigidity.

Rear Fork

Assembling

Compress the spring with a spring compressor to a space just enough to put in the spring fastener.

Note:Coat the screw threads with adhesivebefore installing the shock absorber spring.

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后叉螺栓Rear fork bolt

后叉的分解

注意：用较软的榔头将轴套敲出，绝不能将轴套

敲坏。装好后再涂上润滑脂

后叉的检查

检查后叉的裂纹或损伤。Check the rear fork for crack or damage.

检查衬套的损伤或其它故障。Check the lining bush for damage or other defects.

后叉的安装

装好后叉上的制动止动臂。Put the stop arm on the rear fork.

装好开口销，并将开口销尾脚分开，将

后叉用螺栓装上车架。

扭矩：55—65N.mTorque requirement: 55-65 N.m

Disassembling of Rear Fork

Note:Knock out the shaft s leeve with a sof t peen hammer to avoid damaging the sleeve. Coat it with greaseafter assembling it.

Checking of Rear Fork

Installation of Rear Fork

Put in the split pin and separate its two legs. Fastenthe rear fork with the bolts.

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蓄电池与充电系统

维修须知

概述：

蓄电池的电解液液面应经常检查，如液面低于下限刻线应及时加注蒸馏水，正确

的充电方法是把蓄电池从车上拆下，用充电机慢慢进行充电，最好不要采用快速充电

的方法。

若必须在车上对蓄电池进行充电时，应在其附近避免使用火源，原因时由于充电时

会产生释放出易燃、易爆气体—氢。

技术规格

故障检修

点火开关接通时无电

1、蓄电池的电能用完—电解液蒸发过多，极板作用物质脱落，充电系统有故障。

2、蓄电池电缆的连接脱落或断路。

3、保险丝被烧断。

4、点火开关有故障。

No power when igni tion switch is switched on

Battery power running out battery solution evaporated too much, grid coating come off,

charging system faulty.

Battery power cable disconnected or containing broken wires inside.

Fuse blown.

Ignition switch failed.

蓄电池

磁电机

项目标准值

电解液比重

两端电压白天夜间

直流电阻值

黄——黄

蓝黄——绿

黑红——绿

1500r/min

8500r/min

14.0V 以上 13.5V 以上

14.6V 以上14.6V 以上

0.9—1.2

220±50

550~680

1.280 0.010g/cm3(25℃)

13

Battery and Charging System

维修须知 Notes to Maintenance

电解液比重的测试Testing of Specific Weight of Battery Solution

故障排除Troubleshooting

蓄电池充电Charging of Battery

蓄电池Battery Checking of Charging System 充电系统的检查


General:

The battery solution level should be checked often. Replenish the battery with distilledwater if the level is lower than the lower limit. For battery charging, the correct procedure is toremove the battery from the vehicle and charge it slowly with the charger. Normally do not usethe quick-charging process.

When the battery has to be charged on the vehicle, make sure there is no fire being usednearby as the battery will produce the easily ignitable and explosive hydrogen gas during thecharging process.


Battery

Magneto

Item

Specific weight of battery solution

Voltage

DC resistance

Yellow-Yellow

Blue, Yellow-Green

Black, Red-Green

Standard Value

Daytime Nightt ime

Roubleshooting

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断续性供电Discontinuous power supply1、蓄电池连接松动 Battery in loose connection2、充电系统连接松动 Charging system in loose connection3、点火开关有故障 Ignition switch faulty

充电系统故障Charging system failure1、充电回路连接松脱，断路或短路 Charging circuit connection run loose, cut off or shorted.2、磁电机有故障 Magneto defected

3、调压整流器有故障 Voltage-regulating rectifier defected

拆下右侧盖板。Remove the right side cover.

拆开蓄电池正、负极连接线及通气管。Disconnect the positive and negative terminalsand vent tube.拆开蓄电池固定箍带，然后拆下蓄电池。Remove the fastening stri p from the battery andremove the battery.

注意：先拆下蓄电池负极线（—），然后拆开

正极线（+）。

用比重计对蓄电池的电解液比重进行测试。

规格比重：（20度）

注意：1、如果电解液比重低于1.250时，则应立即对蓄电池进行充电。2、电解液比重是随温度变化而变化的，请参照下表“温度与比重关系”来确定电解液配制。3、如蓄电池极板有明显的硫化现象或在电池极下方堆积了沉淀物时，则应更换蓄电池。

蓄电池的拆卸

电解液比重的测试

充电足够时

充电不足够时

1.270~1.290

1.260

点火开关接通时电力很弱

1、蓄电池的电力不足—电解液液面偏低，电解液比重偏低，充电系统有故障。

2、蓄电池电缆接头接触不良。

Power too weak when ignition switch is pushed on

Battery power too low battery solution level too low, specific weight of battery solution too

small, charging system faultily.

Battery power cable lead not in good connection.

Removal of Battery

Note: Always disconnect the negative terminal (-) beforedisconnecting the positive terminal (+).

Testing of Specific Weight of Battery Solution

Test the specific weight of the battery solut ionwith a densimeter.

Standard value at 20℃

Sufficiently charged

Insufficiently charged

Note:1、The battery should be charged immediately if the specific weight of the battery solutionis less than 1.250.

2、The specific weight of the battery solut ion changes with its temperature. Preparethe battery solution according to the following chart showing the relationship betweenthe temperature and specific weight.

3、Replace the battery if the grid of the battery is sulfurized or full of deposit.

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注意：配制或加注电解液时，应避免硫酸沾上皮

肤、眼睛和衣服，配制时应将硫酸缓慢加入蒸馏水中，决不允许蒸馏水往硫酸里倒。

拆下蓄电池的6个盖塞。Remove the six plugs from the battery.

将充电器电源正极（+）和蓄电池正极

（+）连接，将充电器电源负极（—）和蓄电

池负极（—）连接。

充电时间：0.7~1.0A

Charging current: 0.7-1.0A

充电时间直到电解液比重达到1.270~

1.290为止（温度20度）

注意：1、充电前必须取下蓄电池上的6个塞盖。2、充电时，在蓄电池附近应避免火源。3、电源开关应接在充电器上。

4、当电解液温度超过45度时，则应停止

充电。5、只能在不考虑蓄电池寿命的紧急情况

下可快速充电，一般均宜慢速充电。

注意：弄清蓄电池通气管位置，如图所示，接好

通气管，并在通气管的两端20mm处，双面开5mm长的通缝。

蓄电池充电Charging of Battery

Connect the positive terminal (+) of thecharger to that of the battery and the negativeterminal of the charger to that of the battery.

Charging time:as long as the specificweight of the battery solution reaches 1.270-1.290(at 20℃.

Note: 1、The six covers must be removed from the battery before charging.

2、The battery must be kept away from fir ewhen being charged.3、The power switch should be located onthe battery charger.4、Stop charging when the temperature of the battery solution gets up to more than 45℃5、Quick-charging is used only in emergencysituat ions where the battery life is notconsidered or otherwise the slow-charging process used be sued.

Note: Determine the location of the battery vent tube.As shown in the sketch, connect the vent tubeand cut a 5mm long through join t both sides20mm from both ends of the vent tube.

Only distil led water can be used inside the battery.

Specific weight

Specific weight

Upper limit

Lower limit

Relationship between temperature and specificweight of battery solution

Solution temperature,℃

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充电系统的检查

磁电机输出测试

照明系统绕组的测试

调压整流器的测试

进行充电系统输出测试，应先启动发动

机并使其增温。

注意：进行这项测试应用工作状态良好的蓄电池

来测试。

按图示接好电流表和电压表，慢慢提高发

动机转速，然后查读电流表和电压表上的读数。

按以上方法接上电流表和电压表，如测得

输出不在此表范围内，则应更换磁电机。

按照图示测量以下各接线头之间的电阻值

黄色和黄色之间0.9~1.2Ω，蓝 /黄色和绿

色之间220±50Ω，黑 /红色和绿色之间550~

680Ω。

拆下左侧盖。Remove the left side cover.

拆开调压整流器连接。Disconnect the rectifier.

拆下调压整流器。Remove the rectifier.

项目

状态照明开关关照明开关开

转速（r/min）

开始充电怠速

1500

8500

电压（ V ）电压（ V ）

14.0以上

14.6以上

13.5以上

14.6以上

≤1500〈1500

Checking of Battery Charging System

Test the output of the charging system.Start the engine to warm it up.

Note: For this test, a battery in good condition should beused.

Connect the ammeter and voltmeter as shown,slowly increase the engine speed and read out thevalues on the meters.

Magnet Output Test

Connect the ammeter and voltmeter as describedabove to get the reading. Replace the magneto if thevalue is not within the range specified in the table below.

Condition

ItemLighting Switch Off Lighting Switch On

Speed (rpm)

Idle speed at beginningof charging

Voltage (V) Voltage (V)

above 14.0 above 13.5

above 14.6above 14.6

Testing of Lighting System Winding

Check the resistance between each pair of wire

leads as shown to see if it is 0.9-1.20 betweenyellow and yellow, 220±50 , between

blue/yellow and green and 550-680 between black/red and green.

ΩΩΩ

Testing of Voltage Regulating Rectifier

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如图所示，测量调压整流器各接线柱之间

的电阻，如读数不在下表范围内，则应更

换调压整流器。

注意：此项测试应采用三用表欧姆档RX1k Ω或Rx100Ω档位进行测量。

调压整流器测试阻值表

黄色

黑色

红色

绿色

∞黄色

绿色

0.4~5

∞

∞∞ ∞

∞

∞

∞

∞

黄色黄色红色

单位：k Ω

∞

黑色

∞ 2.5

2.5 2.5

∞

∞

2.5

6

As shown in the picture, measure the resistance betweenthe wiring terminals of the voltage regulating rectifier.Replace the rectif ier if the reading is not within the rangeof the following table.

Note:This test should be carried out a multimeter set to

the R ×1 or position.k Ω Rx100Ω

Test Resistance of Voltage-regulating Rectifier

Unit: k Ω

Yellow Yellow

Yellow

Yellow

Black

Black

Red

Red

Green

Green

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点火与电启动系统

维修须知 Notes to Maintenance

电子点火器的检查和拆卸Checking and Removal of Electronic Igniter

故障排除 Troubleshooting

充电绕组的检查Checking of Charging Winding

点火线圈的拆卸和检查 Removal and Checking of Ignition Coil

脉冲发生器的检查Checking of Pulse Generator

启Removal of Checking of Starting Motor

动电机的拆卸和检查单向导电器的检查Checking of One-way Conductor 启

Checking of Starting Relay动继电器的检查

维修须知

概述General

故障排除

本车点火系统采用先进的CDI方式，不需人为调整，如点火系统发生故障，应检查电子点火器、磁电机、脉冲发生器、点火线圈等，并更换有故障的零件。

技术规格

发动机脚踏启动不能启动Engine unable to get started when start pedal is pushed

1、火花塞无火花—火花塞损坏，无初级电流，火花塞帽内阻增大。Spark plug generating no sparks spark plug damaged, no current in primary coil,internal resistance too great

2、点火开关有故障—点火开关未打开，点火开关失灵短路。Ignition switch failed ignition switch not turned on, ignition switch shorted

3、点火不正时。Ignition timing not correct

4、电子点火器损坏。Electronic igniter damaged

5、熄火开关关闭。Shut-off switch not on

项目火花塞

点火正时

点火线圈

标准值

磁电机充电绕组电阻

脉冲发生器电阻

启动电机电阻

启动继电器电阻

国产

间隙

最大超前

初级线圈电阻

次级线圈电阻

怠速时

D8RTC

0.6~0.7mm0

15 （BTDC）0

35 （BTDC） /3740r /min

0.53Ω±10%

2.0~4.0k Ω550~680Ω

220±50Ω

0〈R≤0.5

0〈R≤0.5

14

Ignition and Electric Starting System


This vehicle is fitted with an advanced CDI that requires no manual adjustment.If the ignition system gets into trouble, check the CDI, magneto, pulse generator,ignition coil, etc. and replace the faulty parts.


Item Standard Value

Spark Plug

Ignition Timing

Ignition Coil

Magneto charging winding resistance

Pulse generator resistance

Starting motor resistance

Starting relay resistance

Chinese-made

GapLead at idle speed

Maximum lead

Primary coil resistance

Secondary coil resistance

Troubleshooting

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万用表

点火线圈Ignition coil

Multimeter

6、点火线圈损坏 Ignition coil damage

7、磁电机有故障 Magneto failed8、脉冲发生器有故障 Pulse generator failed

9、点火系统电源回路有断路或短路现象。 Ignition system circuit cut off or shorted

发动机运转不稳定

1、点火不正时—电子点火器有故障，脉冲

发生器有故障，磁电机有故障。 Ignition timing in correct electronic igniter, pulse generator defective or magneto defective

2、火花塞有故障。 Spark plug failed

3、点火线圈有故障。 Ignition coil failed4、电源回路接错或接触不良。

Power supply incorrectly wired or poorly contacted

发动机电启动不能启动

1、蓄电池电能不足或无电 Battery power weak or run out

2、保险丝烧断 Fuse blown3、启动电机有故障

Starting motor failed4、单向导电器有故障 One-way conductor failed5、启动离合器打滑 Clutch slipping6、启动继电器损坏 Starting relay damaged7、电起动线路中有短路或断路现象 Starting coil shorted or cut off 8、空挡开关不导通或变速器不在空挡。 Neutral gear switch not on or gearbox not setin neutral gear

点火线圈的拆卸

点火线圈的检查

拆下燃油箱，Remove the fuel tank.拆开点火线圈的电线连接。Disconnect the ignition coil.

拆下紧固螺钉后拆下点火线圈。Unscrew the fastening screw and remove theignition coil.

拆开火花塞和火花塞帽的连接。Unscrew the spark plug from the cap.

拆下高压电缆的夹扣。Remove the clip from the high-tens ion cable.

如图所示，测量点火线圈初级和次级电阻。

初级电阻：0.53±10%

次级电阻：2.0~4.0k Ω

如读数不在规定范围内，则应更换点火线圈。

Engine speed instable

Engine unable to get started electrically

Removal of Ignition Coil

Checking of Ignition Coil

As shown in the picture, measure the resistancesof the primary and secondary ignit ion coils.

Primary coil resistance: 0.53±10%

Secondary coil resistance: 2.0~4.0k Ω

Replace the ignition coil if the resistance is notwithin the specified range.

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电子点火器Remove

电子点火器的拆卸

电子点火器的检查

电子点火器测量对照表

充电绕组的检查

拆下右侧盖，Remove the right side cover.

拆开电子点火器连接，然后拆下电子点Disconnect the electric igniter and remove it.

火器。

如图所示，测量电子点火器各接线柱之

间的电阻，如所测读数不在下列范围内，则应

更换电子点火器。

注意：此项测试应采用三用表欧姆档RX1k Ω或R X100Ω档位进行。

拆下左侧盖，Remove the left side cover.

拆开充电绕组连接。Disconnect the charging winding.

测量黑 /红色与绿色线之间的电阻。Measure the resistance between the red wire andgreen wire.

点火绕组电阻：550~680ΩΩIgnition winding resistance: 550-690

如测量读数不符合上述规定，则应更换点火绕组。Replace the ignition winding if the resistance is notwithin the specified range.

点火开关

充电绕组

点火线圈

脉冲发生器E1E2

接地

点火开关充电绕组点火线圈脉冲发生器E1E2 接地

0.1~50

100~∞

0.5~100

∞

20~50

5~50

10~200

∞ ∞ ∞

100~∞100~∞

∞ ∞ ∞ ∞

∞

∞

∞0.1~50

Removal of Electronic Igniter

Checking of Electronic Igniter

As shown in the picture, measure the resistance between the wiring poles of the electronic igniter.Replace the electronic igniter if the resistance isnot within the range specified in the following table.

Note : Perform this check with a multimeter setto the or position.RX1k Ω X100Ω

Specified Range of Resistance for Electronic Igniter

Ignition Switch Charging Winding Ignition Coil Pulse Generator 1EE2

Pulse Generator 1EE2

Grounding

Ignition Switch

Charging Winding

Ignition Coil

Grounding

Checking of Charging Winding

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启动继电器

启动电机

Starting relay

脉冲发生器的检查

启动电机的拆卸

启动电机的检查

启动继电器的检查

拆下左侧盖，Remove the left side cover.拆开脉冲发生器连接，Disconnect the pulse generator.

测量蓝 /黄色线与绿色线之间的电阻，

Measure the resistance between the blue/yellow wire and green wire.

脉冲发生器电阻：220±50

220±50Pulse generator resistance:如测量读数不符合上述规定，则应更换

脉冲发生器。Replace the pulse generator if the resistance isnot within the specified range.

拆下正负极连接线。Unwire the positive pole.

拆下紧固螺钉。

Unscrew the fastening screw.然后取下启动电机。Remove the starting motor.

测量启动电机正负极之间电阻。Measure the resistance between the positive andnegative poles of the starting motor.

启动电机电阻值：0 R 0.5

Starting motor resistance: 0＜R ＜0.5

如测量读数不符合上述规格，则应更换启动电机。

Replace the starting motor if the resistance is notwithin the specified range.

当启动继电器引出线接通DC12V 电源时，

应听到该继电器“喀嚓”动作声，并用万用

表欧姆档测量动触点螺栓之间的电阻值。

启动继电器电阻值：0〈R≤0.5Starting relay resistance: 0＜R ≤0.5如测量读数不符合上述规格或接通DC12V

电源无“咔嚓”动作声，则应更换启动继电器。

单向导电器检查

将万用表拨到欧姆档，按右表进行检查。

单向导电器检查表

如果检查数据不符合表中规定，则应更换单向导电器。

红表笔

黑表笔粉红

浅绿 /红

1~10

500~∞

浅绿 /红

粉红

单位：k

Checking of Pulse Generator

Removal of Starting Motor

Checking of Starting Motor

Checking of Starting Relay

A clicking sound should be heard from the relaywhen the wire lead is connected to the 12V DC power supply. Measure the resis tance betweenthe movable contact bolts with a multimeter setto the resistance-checking mode.

Replace the staring relay if the resistance is notwithin the specified range or no clicking sound isheard when the 12V DC power is switched on.

Checking of One-way Conductor

Set the multimeter to the resistance-checking modeand test the resistance according to the table.

Replace the one-way conductor if the resistance is notwithin the specified range.

Specified Range of Resistance for One-way Conductor

Unit:k

Red probe

Black probe

Pink

Light green/Red

Light green/Red Pink

Starting motor

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开关

维修须知转向灯开关 /喇叭开关的检查

故障排除前制动灯开关的检查

点火开关的检查后制动开关的检查

照明开关的检查燃料传感器 /燃料表的检查

维修须知

故障排除

概述

全车电线均用不同颜色作标记，接线时将相同颜色连接，注意观察电线的颜色标记。当有两种

或更多的线被联在一起时，在靠近接头的地方，配有与需连接的那种线相同颜色的胶管。

技术规格

当打开点火开关时，灯不亮

1、蓄电池有故障——蓄电池损坏，蓄电池电量放完，蓄电池连接线松脱。 Battery not working battery damaged, battery power used up, or battery wires come off

2、点火开关有故障——开关电阻过大，开关线脱落。 Ignition switch failed switch resistance too great, or switch wires come off

3、保险丝熔断。 Fuse blown

4、灯泡烧毁。

Bulb blown5、电源线有断路或短路现象。 Power wires broken or shorted

项目标准值数量

车头灯

尾灯 /制动灯

转向灯

位置灯

远光指示灯

左转向指示灯

右转向指示灯

空挡指示灯

仪表指示灯

35W/35W

21W

1

4

1

2

1

1

1

1

15

Switches


Troubleshooting

Checking of Ignition System

Checking of Lighting Switch

Checking of Front Brake Lamp Switch

Checking of Rear Brake Lamp Switch

Checking of Fuel Sensor and Fuel Meter


General

All the wires of the electric system have been identified with different colors. When connecting thewires, always note the color difference.When two or more wires are to be connected together,

plastic tubes having the colors of the wires to be connected are provided at the wire ends.


Item Standard Value Quantity

Headlamp

Tail lamp/Brake lamp

Turn signal lamp

Position lamp

High-beam indicator

Left turn indicator

Right turn indicator

Neutral gear indicator

Meter lamp

Troubleshooting

No lamp going on when igni tion switch is turned on

10W

5W

1.7W

1.7W

1.7W

1.7W

1.7W 2

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打开转向灯开关，转向灯不闪光Turn signal lamps not flashing when switched on

1、闪光器损坏 Flasher damaged2、蓄电池电压太低 Battery power too low3、灯泡功率过大或过小

Bulb power capacity to great or too small

操作变光开关，光束不变化Headlamp beam not changed when beam switchis operated

1、变光开关有故障 Beam switch failed2、灯泡失效或烧毁 Bulb failed or damaged3、远、近光电源线短路 High/Low beam wires shorted

操作喇叭开关，喇叭不响

Horn making no sound when horn button is pushed1、喇叭开关有故障 Horn button failed

2、蓄电池无电 Battery having no power 3、喇叭有故障 Horn failed4、电源回路有短路或断路的现象 Power circuit shorted or having broken wire

拆下车头灯壳Remove the headlamp cover from the vehicle.

拆开车头灯电线连接Disconnect the headlamp.

在下表内测各颜色线之间是否具有通断性。Check the color wires for correct on-off condition as shown in the following table.

拆下车头灯壳Remove the headlamp cover.

拆开变光开关，照明开关电线连接Disconnect the beam switch and lighting switch.

测量下表内各颜色线之间是否具有通断性。Check the color wires for correct on-off condition as shown in the following tables.

点火开关

变光开关、照明开关

开

关

黑 /白黑色红色棕色

Ignition Switch

Black/White Black Red Brown

ON

OFF

Beam Switch and Lighting Switch

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转向灯开关

喇叭开关

前制动开关

拆开头灯壳Remove the headlamp cover.

拆开转向开关电线连接Disconnec t the turn signal lamp switch.

测量下表内各颜色之间是否具有通断性。Check the color wires for correct on-off

condition as shown in the following table.

拆下头灯壳Remove the headlamp cover.

拆开喇叭开关电线连接

Disconnec t the horn button.

测量下表内各颜色之间是否具有通断性Check the color wires for correct on-off condition as shown in the following table.

拆下车头灯壳

检查绿黄色线和黑色线之间是否如下表

具有通断性。

远光

（中）

近光

白色兰色蓝 /黄色黑色褐色褐 /白色

变光开关照明开关

关

位置

开

蓝 /黄色

左

（中）

右

深褐色灰色墨绿色

放开

按下

棕色粉红色

放开

捏住闸把

黑色绿 /黄色

Beam Switch Lighting Switch

High Beam

(Central)

Low Beam

White Blue Blue/Yelllow

OFF

Position

ON

Blue/Yellow Black Brown Brown/Yellow

Turn Signal Lamp Switch

Dark brown Gray Dark green

Left

(Central)

Right

Horn Button

Dark brown Gray

Released

Pushed

Front Brake Lamp Switch

Remove the headlamp case.

Check the on/off condition between the green/yellowwire and black wire to see if it is as shown in thetable below:

Green/yellowBlack

Brake lever squeezed

Released

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燃油传感器

后制动开关Rear Brake Lamp Switch

Fuel Sensor

后制动开关

燃油传感器和燃油表

燃油传感器的检查

燃油表的检查

检查后制动开关黑色和绿 /黄色线之间是否如下表具有通断性。

踏下后制动臂时，绿 /黄色线和黑线之间应接通，放开时两线断开。

燃油传感器的拆卸Removal of Fuel Sensor:

拆下车座垫和左边侧盖。Remove the seat and left side cover.

拆开燃油传感器连接。Disconnect the fuel sensor.拆下油箱。Remove the fuel tank.

拆下燃油传感器。Remove the fuel sensor.

用三用表测量传感器的电阻值，将传感器浮子分别移到顶端和底端位置，查移动时

传感器阻值有无变化，有变化属正常，反之

则损坏。

将传感器与电缆连接好，打开点火开关。

Connect the fuel sensor with the power cable and turn on the ignition switch.将传感器浮子移到顶端位置，查看燃料表Move the sensor float to the top position and check the function of the fuel meter.

功能。

浮子位置在顶端，燃油表指针在“满”的位置。浮子位置在底端，燃油表指针应在

“备用”和“完”位置。With the float on top, the fuel meter pointer should be in the FULL position, and with thefloat at bottom, it should be in the RESERVE and EMPTY position.

注意：此项检查，蓄电池应在完好并电量充足情况

下才能进行。

放开

捏住闸把

黑色绿 /黄色

Rear Brake Lamp Switch

Check the black and green/yellow wires of therear brake lamp switch for correct on-off condition as shown in the following table.

When the brake lever is pushed, the green/yellowwire and black wire should be on and when therear brake lever is released, they should be off.

Black Green/yellow

Released

Squeezed

Fuel Sensor and Fuel Meter

Checking of Fuel Sensor

Measure the resistance of the fuel sensor with amultime ter. Move the float of the sensor to thetop and bottom position respectively to see if theresistance is changing. If yes, the fuel sensor isnormal, if no, it is damaged.

Checking of Fuel Meter

Note :

This check should be made only if the batteryis in good condition and full of power.

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1６

故障判断

发动机不能起动或起动困难

检查方向

1、检查燃油是否达到化油器→没有进入化油器→已进入化油器

1、油箱内无燃油 2、油开关堵塞 3、油管堵塞 4、化油器浮子针卡住

No fuel in fuel tank

Fuel cock clogged

Fuel pipe clogged

Carburetor float needle stuck

2、取下火花塞检查火花→火花弱或完全无火→火花正常

1、火花塞损坏或不清洁 2、磁电机故障

3、点火开关故障 4、传感器故障 5、点火器故障 6、点火线圈故障 7、高压电缆故障

Spark plug damaged or dirty

Magneto failed

Ignition switch failed

Fuel sensor failed

Igniter failed

Ignition coil failed

High-tension cable failed

3、检查汽缸压力→压力太低→压力正常 1、起动机构打滑，不能转动发动机。

2、气门间隙太小或没有间隙

3、气门导杆弯曲 4、汽缸头座和气门配合不好。

5、汽缸和活塞环磨损。 6、汽缸头密封垫密封不好。 7、装配不到位。 8、配气正时不正确。

Starter slipping and unable to start engine

Valve gap too nar row or valve hav ing nogap at all

Valve guide bent

Cylinder head base not fitted nicely withvalve

Cylinder and piston ring worn

Cylinder head gasket not tight

Fitting not done properly

Valve timing not correct

Troubleshooting

Engine Performance Low at High Speeds发动机不能起动或起动困难

Engine Unable or Difficult to Start 发动机在高速时性能很差

车辆动力不足

Vehicle Lacking Powe

发动机有异响Engine Making Unusual Noise

发动机低速或怠速性能差Engine Performance Low at Low Speeds or Idle Speed

操纵部分故障Control Failure

Engine Unable or Difficult to Start

Troubleshooting Clues

Check to see if the fuel has reached the carburetor No Yes→ →

可能原因Possible causes

Remove the spark plug and check the sparks Few or no sparks

Sparks normal

→

→

Check the cylinder pressure Pressure too low

Pressure normal

→

→

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5、拆下火花塞→火花塞潮湿→火花塞干燥

1、化油器富油。 2、化油器阻风门未打开。 3、油门开启过大。

Carburetor too full of fuel

Carburetor choke not opened

Throttle opening too wide

1、制动器未松。 2、车轮轴承磨损或损坏。 3、车轮轴承润滑不够。 4、传动链过紧。

Brake not disengaged

Axle bearing worn or damaged

Axle bearing not well lubricated

Drive chain too tight

1、离合器打滑 2、离合器片磨损。 3、离合器摩擦片变形。

Clutch slipping

Clutch plate worn

Clutch plate deformed

1、燃油系统供油不畅。 2、化油器阻风门关闭。 3、空气滤清器堵塞。 4、化油器盖空气孔堵塞。

5、消声器堵塞。

Fuel supply not normal

Carburetor choke closed

Air filter clogged

Carburetor vent clogged

Muffler clogged

4、再起动发动机→发动机能点火但仍不能起动→发动机不点火

Restart the engine Ignition possible but engine

still unable to get started Ignition impossible

→→

1、节气门开度过大。 2、化油器柱塞微调螺钉调整不当。

3、进气管漏气。 4、点火正时不正确。

Throttle opening too grea

Carburetor plunger fine-adjusting screw

not properly turned

Air intake pipe leaking

Ignition timing not correct

Remove the spark plug for checking

Spark plug wet Spark plug dry→ →

6、关闭阻风门，重新起动发动机。Close the choke and restart the engine.

车辆动力不足Vehicle Lacking Power

检查方向可能原因Troubleshooting Clues Possible causes

1、把车轮升离地面并旋转→不能自由旋转→能自由旋转。Lift the wheels off ground and turn them by hand

Unable to turn freely Able to turn freely

→

→

2、检查胎压→压力太低→胎压正常 1、轮胎漏气。 2、车轮气嘴漏气。

Tire leaking

Tire valve leaking

Check the tire pressure Pressure too low Pressure normal→ →

3、由怠速快速增至高速→松开离合器车速无变化→车速正常。

Disengage the clutch when changing from idle speedto high-speed No change of speed Change of speednormal

→ →

4、逐步提高发动机转速→发动机转速没有变化→发动机增速正常。

Increase the engine speed gradually No change of

speed Change of speed normal

→→

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5、检查点火正时（用点火正时灯）→点火开关不正确→点火正时正确。

1、CDI点火器损坏。 2、磁电机有故障。 3、脉冲发生器故障。

CDI damaged

Magneto failed

Pulse generator failed

Check the ignition timing (using the ignition timing lamp)

Ignition timing not normal Ignition timing normal→ →

6、检查气门间隙→气门间隙不正确→气门间隙正确

1、气门间隙调整不当 2、气门座磨损。

Valve gap not correctly adjusted

Valve seat wornCheck the valve gap Valve gap incorrectValve gap correct

→ →

7、检查汽缸压力→汽缸压力太低→汽缸压力正常

1、气门间隙太小 2、气门弯曲或卡死 3、气门座磨损。 4、汽缸及活塞环磨损。 5、汽缸垫损坏。 6、配气正时不正确。 7、火花塞未装配到位。

Valve gap too narrow

Valve bent or stuck

Valve seat worn

Cylinder and piston ring worn

Cylinder gasket damaged

Valve timing incorrect

Spark plug not correctly installed

Check the cylinder pressure Pressure too lowPressure normal

→ →

8、检查化油器→化油器堵塞→化油器未堵塞

1、燃油不干净。 2、未定期对化油器进行清洗。

Fuel dirty

Carburetor not cleaned regularly

Check the carburetor Carburetor clogged

Carburetor not clogged

→

→

9、检查火花塞→火花塞积碳过多或颜色不对→火花塞正常

1、没有做定期保养工作。 2、火花塞热值不对。 3、火花塞电极间隙过小。

Spark plug not maintained regularly

Incorrect thermal value of spark plug

Electrode gap too narrow

Check the spark plug Too much carbon

deposit or unusual coloring Spark plug normal

→→

10、取出机油尺检查机油量→机油量不正确→机油量正常

1、机油面太高 2、机油面太低 3、机油不清洁。

Oil level too high

Oil level too low

Oil not clean

Take off the dipstick and check the oil level with it

Oil level incorrect Oil level normal→ →

11、拆下气门盖，检查气门的润滑情况→气门润滑不正常→气门润滑正常

1、机油油管堵塞 2、机油泵工作不正常。

Oil pipe clogged

Oil pump not working properlyCheck the engine for overheating Overheated

Not overheated

→→

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12、检查发动机是否过热→发动机过热→发动机不过热

1、燃烧室积碳过多。

2、使用的燃料不符合规格。 3、离合器打滑。 4、混合气过浓。 5、机油量过多。

Too much carbon deposit in combust ionchamber

Incorrect type of fuel being used

Clutch slipping

Air-fuel ratio too high

Oil level too high

Check the engine for overheating Overheated

Not overheated

→→

13、在高速行驶中→发动机发出爆震声→发动机无爆震声。

1、活塞和汽缸磨损。 2、燃烧室积碳太多。

3、使用燃油不符合规格。

4、点火正时超前太多。

Piston and cylinder worn

Too much carbon deposit in combust ionchamber

Incorrect type of fuel being used

Ignition too early

Ride the vehicle at high speeds Engine giving

off explosive noise No explosive noise Possib le causes

→→

发动机低速和怠速时性能很差Engine Performance Low at Low Speeds and Idle Speed

检查方向

1、检查点火正时和气门间隙→不正确→正确

可能原因

1、CDI故障。

2、磁电机故障。 3、传感器故障。 4、气门间隙太小。

CDI failed

Magneto failed

Sensor failed

Valve gap too nar row

Troubleshooting Clues Possible causes

Check the ignition timing and valve gapIncorrect Correct

→→

2、检查化油器连接是否漏气→有漏气现象→无漏气现象。

1、化油器密封环变形。 2、化油器连接松脱。 3、密封环和垫破裂。

Carburetor packing ring deformed

Carburetor disconnected

Packing ring and gasket broken

Check the carburetor for leaking

Carburetor leaking No leaking

→→

3、检查火花塞跳火情况→火花很弱或间歇跳火→火花正常

1、火花塞损坏。 2、磁电机故障。 3、点火线圈故障。 4、CDI 故障。 5、传感器故障。 6、点火开关故障。 7、火花塞帽故障。

8、电源回路有接错或短路现象。

Spark plug damaged

Magneto failed


CDI failed

Sensor failed


Spark plug cap defected

Power supply incorrectly wired or shorted

Check the spark plug for sparking

Too few or no sparks Sparks normal

→→

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发动机高速时性能很差Low Engine Performance at High Speed

检查方向可能的原因

Troubleshooting Clues Possible causes

1、检查点火正时和气门间隙→不正确→正确

1、磁电机故障。 2、CDI故障。 3、传感器故障。 4、气门间隙不当。

Magneto failed

CDI failed

Sensor failed

Valve gap incorrect

Check the ignition timing and valve gap

Incorrect Correct→ →

2、拆开化油器燃料管→燃油流量受限制→燃油能自由流出

1、燃油箱内燃料已用完。

2、油箱锁盖通气孔堵塞。 3、油箱至化油器油路堵塞。

4、油开关堵塞。 5、汽油滤网堵塞。

Fuel tank getting empty

Fuel tank cap vent blocked

Fuel supply from fuel tank to carburetor blocked

Fuel cock clogged

Fuel filter clogged

Remove the carburetor fuel pipe Fuel flow

rate restricted Fuel able to flow freely

→→

3、检查化油器→化油器堵塞→化油器未堵塞。

1、浮子针堵塞。 2、浮子油平面太低。 3、化油器量孔堵塞。 4、浮子卡住。

Float needle clogged

Float fuel level too low

Carburetor orifice clogged

Float stuck

Check the carburetor Carburetor cloggedCarburetor not clogged→ →

４、检查火花塞高速跳火情况→跳火不正常→跳火正常

1、磁电机故障。 2、CDI故障。 3、传感器故障。

4、点火开关故障。 5、点火线圈故障。 6、火花塞帽故障。 7、火花塞损坏。 8、电源回路有短路现象。

Magneto failed

CDI failed

Sensor failed



Spark plug cap defected

Spark plug damaged

Power supply circuit shorted

Check the spark plug for parking

Sparking not normal Sparking normal

→→

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发动机有异响Engine Making Unusual Noise

检查方向

检查方向

可能的原因

可能的原因



Possible causes

Possible causes

1、气门发出异响 1、气门间隙过大。 2、气门磨损。

Valve gap too wide

Valve worn

Valve making unusual noise

2、活塞和汽敲击 1、活塞和汽缸体磨损。 2、活塞销和连杆小端磨损。 3、曲柄连杆大头磨损。

Piston and cylinder block worn

Piston pin and conrod small end worn

Crank conrod big end worn

Piston colliding with cylinder

3、轴承异响 1、曲柄连杆轴承损坏。

2、凸轮轴轴承磨损。Crank conrod bearing damaged

Camshaft bearing worn

４、离合器有振动异响1、离合器减震弹簧弹力太弱。

５、传动齿轮和从动齿轮异响 1、齿轮的加工精度不够。

操纵部分故障

1、转向不灵活 1、转向装置调整螺母扭得太紧。

2、转向轴承座圈或钢球磨损。

Steering tightness adjusting nut tightenedtoo much

Steering bearing race or ball worn

2、车轮摆动 1、车轮轴承的自由行程太大。

2、轮辋变形。 3、轮辋安装调节不当。

4、后叉减震套磨损严重。

5、车架变形。 6、传动链条调整不当。 7、车轮轴螺母太松。

8、胎压严重不足。

Axle bearing having too much free play

Wheel rim deformed

Wheel rim not correctly installed or adjusted

Rear fork shock absorbing sleeveseriously worn

Frame deformed

Drive chain not correctly adjusted

Axle nut too loose

Tire pressure too low

Control Trouble

Steering difficult

Wheels wobbling

Bearing making unusual noise

Clutch making unusual noise due to vibrationClutch buffer spring weak

Driving and driven gears making unusual noise Gear not precisely machined

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3、在行驶中摩托车跑偏 1、减震器不平衡。 2、转向轴承损坏。 3、前叉弯曲。

4、车架弯曲。 5、前后轮不在一条线上。

Shock absorbers not balanced

Steering bearing damaged

Front fork bent

Frame bent

Front and rear wheels not lined up

Vehicle running to one side during travel

Documents

RT200-5维修手册