700Vario ServMan Motor

8/8/2019 700Vario ServMan Motor

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1.3 Tabulka pravideln drby

KADCH PRVN

msc 1 3 6 6 12

km 320 1,200 2,400 2,400 4,800

(mi) (200) (750) (1,500) (1,500) (3,000)

POLOKAINNOST Podle prvnho na ad

hodiny 20 75 150 150 300

Ventily Zkontrolujte vli ventilu.

Pokud je to nutn seite.

Svka

Zkontrolujte stav.

Uzpsobte mezeru a vyistte.

Pokud nutn - vymte.

Npl vzduchovho

filtru

Vyistte.

Pokud nutn - vymte.Kadch 20-40hodin

astji ve vlhkm nebo pranm prosted.

Karburtor*

Zkontrolujte a seite volnobh/funkci

startru.

Pokud nutn - seite.

Odvzdunn skn

hdele*

Zkontrolujte hadiku odvzdunn kvli

prasklinm nebo pokozen.

Pokud nutn - vymte.

Vfukov systm*

Zkontrolujte niky.

Pokud nutn uthnte.

Pokud nutn vymte tsnn.

Lapa jisker Vyistte.

Rozvod paliva*

Zkontrolujte palivovou hadiku

praskliny, pokozen.

Pokud nutn vymte.

Motorov olej

Vymte.(ped vyputnm zahejte motor.)

Npl filtru

motorovho olejeVymte.

Stko motorovho

oleje*Vyistte.

Olej pevodovky

Olej diferencilu

Zkontrolujte zda neunik olej.

Kadch 12 msc vymte


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Pedn brzda*

Zkontrolujte funkci/niky kapaliny.(Viz.

poznmka strana 8).

Seite pokud je to nutn

Zadn brzda* Zkontrolujte funkci

Sei

te pokud je to nutn

Lanko pky volby

Safety system

Zkontrolujte funkci

Seite pokud je to nutn.

Klnov emen* Zkontrolujte funkci.

Zkontrolujte praskliny nebo pokozen.

Kolo Zkontrolujte vyven/pokozen/

Opravte pokud je to nutn

Loiska kol* Zkontrolujte zda loiska nejsou voln/

pokozen.

Pokud je to nutn vymte.

Pedn a zadn

zaven*

Zkontrolujte funkci.

Seite pokud je to nutn.

Systm zen*

Zkontrolujte funkci/Vymte pokud je

pokozen

Zkontrolujte sbhn kol/pokud nutn

seite

Drive shaft universal

joint*

Mazejte mazivem na zklad lithiovho

mdla

Nvleky npravy* Zkontrolujte funkci.

Pokud jsou ponien vymte

Doplky a

upevnn*

Zkontrolujte vechny doplky a upevnn

asi

Pokud nutn opravte.

Svtla a spnae*

Zkontrolujte funkci.

Seite kuel svtla reflektoru


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2. Motor

2.1. Prohldka a sezen motoru

2.1.1 Prohldka hlavy vlce, pvodnho a vfukovho ventilu

Zkontrolujte tlak ve vlci

Zahejte motor, pot nastartujte naprzdno a vyndejte svku.

Vlote do otvoru mk tlaku.

Poznmka: Zkontrolujte upoutn mku tlaku. Tote motor

a ruika pestane stoupat. Maximln namen hodnota by

mla bt vy ne 0.7- 0.9Mpa pot co jsme nastartovalifor 4-6

krt. Viz. obrzek 2-1.

Obrzek 2-1

Zkontrolujte vli ventilu

Poznmka: kdy seizujeme vli ventilu, motor musme nechat

vychladnout.(Teplota by mla bt men ne 35)


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Oddlejte sedlo a palivovou ndr, oddlejte kryt kontrolnho

otvoru, otote setrvankem magneta proti smru hodinovch

ruiek a doshnete T znaky na pednm krytu vlevo.

Poznmka: Vlec mus bt uchycen u hornho otvoru.

Obrzek 2-2

Oddlejte kryt vlce, zkontrolujte vli pomoc lstkovho

spromru.

Vle ventilu: pvodn a odsvac ventil: 0.05 - 0.08mm.

Viz. obrzek 2-3.

Obrzek 2-3

Uvolnte matici, tote seizovacm roubem dokud se spromr


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nevytahuje. Pot upevnte seizovac roub pomoc seizovae

ventil, dothnte matici a zkontrolujte vli ventilu. Pot zptky

namontujte kryt ventilu vlce, kryt kontrolnho otvoru, palivovou

ndr a sedlo. Viz. obrzek 2-4.

Obrzek 2-4

2.1.2 Prohldka svky

1.Oddlejte epiku svky: klem oddlejte svku, prohldnte

zda izoltor svky a elektroda je pokozena nebo zanesena. Viz.

obrzek 2-5.

Obrzek 2-5


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1. Zkontrolujte mezeru sprovnkem zda je mezi 0.6 - 0.7mm.

Nebo nastavte mezeru, vyistte potaen istiem svek a

ocelovm kartem, a zkontrolujte tsnn svky (Obrzek 2-6).

Obrzek 2-6

3. Klem tote a uthnte svku na 18 - 20N.m, pot pipevnte

epiku svky.


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2.1.3 Vlec, pst, pstn krouek

Specifikace

poloka mmstandartn hodnota:

mm

mm

limitn hodnota:mm

Vnitn prmr vlce 84.503 84.527 84.6

zen 0.0040 0.005

mimo zaoblen 0.0035 0.005vlec

stupe zakiven 0.04 0.10

Vnj prmr pstu 84.47 84.45 84.35 84.25

Vnitn prmr otvoru

pstnho epu

20.002 20.01 20.05 20.1

Mezera mezi pstnm epem a

otvorem pstnho epu

0.002 0.019 0.03

Vle

pstnho

krouku

Horn

krouek/druh

krouek

0.2 0.4 0.5 0.7

olejov

krouek

0.03 0.15 0.3 0.5

vrchn

krouek

0.03 0.07 0.10 0.15

mezera mezi

pstnmkroukem a

pstn

drkou druh krouek 0.02 0.06 0.09 0.14

mezera mezi vlcem a pstem 0.033 0.062 0.07 0.10

Pst, pstn

krouek a

pstnep

vnj prmr pstnho epu 19.991 20 19.95 19.97

vnitn prmr 20.016 20.027 20.05

Klikov

hdel

mezera mezi malm

zakonenm spojnice a

pstnhoepu

0.018 0.036 0.05


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diagnza a eliminace selhn:

emise ernho koue opoteben vlce nebo pstu,

1. Vlec, pst, nebo pstn krouek je opoteben.

2. Pstn krouek nen sprvn usazen.

3. Pst nebo stna vlce je pokrbna.

peht

1 Nadmrn potaen pstu (vrstva povlaku)

2 Vstely a nezvykl hluk

3 Oden vlce nebo pstu

Kontrola vlce

1. Zkontrolujte zda je vlec pokozen.

2. Zmte prmr vlce ve tech bodech.

3. U vrchu, v prostedku a u spodn sti zdvihu pstu.

Zmte prmr vrtu v protnajcch se pravch hlech.

limitn hodnota u oprav:

0.05 mm mimo zaoblen: 0.005 mm

0.05mm zen 0.005mm


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Prohldka pstu a pstnho krouku

1. Zmte mezeru mezi pstnm kroukem a pstn drkou.

2. Prvn krouek

3. Druh krouek

Poznmka: Pi monti je zakzno niit pstn krouek.

Zkontrolujte zda pst a pstn drka je popraskan nebo

oden. Viz. obrzek 2-9.

Obrzek 2-9

0.5mm

Vlote pstn krouek do vlce a zmte mezeru.

Limitn hodnota opravy: prvn krouek/druh krouek: 0.5mm

Viz. obrzek 2-10 .

Obrzek 2-10


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Zmte prmr vrtu otvoru pstnho epu.

limitn hodnota opravy: Viz. obrzek 2-11.

Obrzek 2-11

Zmte vnj prmr 10mm nad spodnm okrajem plt pstu.

Extrmn pozice: mezera mezi vlcem a pstem

limitn hodnota opravy: 0.1mm

Viz. Obrzek 2-12.

1.

Obrzek 2-12

7. Zmte vnj prmr pstnho epu:

mezera mezi pstem a pstnm epem:

0.02mm


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limitn hodnota opravy: 0.02mm .Viz. Obrzek 2-13.

Obrzek 2-13

2.1.4 Kontrola hdele a ojnice

Zkontrolujte zda hdel a ojnice se mohou otet bez zaseknut a

zda vle mezi hdel a ojnic je 0.5 0.6mm. Skok hdele by ml

bt 0.05mm. Pokud ne, vymte ji. Viz. Obrzek 2-14-1, Obrzek

2-14-2.

Obrzek 2-14-1 Obrzek 2-14-2


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2.1.5 Prohldka spojky

Opoteben patky a techo pltu: Viz. Obrzek 2-15

Obrzek 2-15

2.1.6 Prohldka karburtoru

1. Zkontrolujte volnobh karburtoru.

Rychlost motoru by mla bt 1500150r/min 10 minut po

nastartovn za normlnho volnobhu a nevynechv pokud

rychle pidme plyn. Pokud tomu tak nen, tote seizovacm

roubkem volnobhu karburtoru ve smru hodinovch ruiek

abyste zvili otky volnobhu, protismru hodinovch ruiek

abyste je snily. When adjusting is unavailable, zkontrolujte zda

nen ucpan tryska karburtoru nebo jestli tsn sac trubice.

Viz. Obrzek 2-16.

Obrzek 2-16


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1.2.10 Barometer

To measure pressure of the tire

1.2.11 Magneto drawing device

To detach the magneto

1.2.12 Snap ring clampTo install

and detach snap rings

1.3Periodic maintenance chart

EVERY INITAL

month 1 3 6 6 12

km 320 1,200 2,400 2,400 4,800

(mi) (200) (750) (1,500) (1,500) (3,000)

ITEMROUTINE

Whicheve

comes first

hours 20 75 150 150 300

Valves Check valve clearance. Adjust if necessary.

Sparkplug

Check condition.

Adjust gap and clean.

Rep;ace if necessary.

Air fiter element clean. Replace if necessary.

Every20-40hours

More often in wet of dusty areas.

Carburetor*

Checkandadjustidlespeed/starteroperation. Adjust if necessary.

Crankcasebreathersystem*

Check breather hose for cracks of


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damage.

Replace if necessary.

Exhaust system*

Check for lecakage. Tighten if necessany. Replace gasket(s) if necessary.

Spark arrester Clean.

Fuel line*

Check fuel hose for cracks or damage.

Replace if necessaly.

Engine oilReplace.(Wamenginebefore draining.)

Engine oil filter

cartridgeReplace.

Engine oil strainer* Clean.

Final gear oil

Differential gear oil

Check for oil leakage. Replace eveny 12 months.

Front brake*

Check operation/fuid leakage.(See NOTEpage 8).

Correct if necessary.

Rear brake*

Check operation. Adjust if necessary.

Select lever safety

system cable Check operation. Adjust if necessary.

V-belt*

Check operation. Check for cracks or damage.

Wheel Check balance/damage/


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Repair if necessary.

Wheel bearing*

Check bearing assemblies for lossenss/damage.

Replace if necessary.

Front and rear

suspendion*

Check operation. Correct if necessary.

Steering system*

Checkoperation./Replace if damaged

Check toe-in./Adjust if necessaly.

Drive shaft universal

joint*

Lubricate with lithiumsoapbassedgrease.

Axle boots*

Check operation. Replace if damaged.

Fittings andfasteners*

Check all chassis fittings and fastenrs. Correct if necessary.

Lights and

switches*

Check operation. Adijust headinght beams.


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Engine

2. Inspection and adjustment of engine

2.1 Inspection of cylinder head, intake and exhaust valve

Preheat the engine ,then misfire and unplug the spark plug.Fix

pressure gauge into the hole, open the choke and throttle handle,and start

for 4-6 times.

Note: Giving a leakage check to the pressure gauge.Rotate the

engine until the pressure gauge stop rising.The maximum

reading would be greater than 0.7-0.9Mpa after starting

for 4-6 times.

See figure 2-1.

Figure 2-1

check the valve lash

Note:when adjust valve lash,the engine must be cooled. (The

tempreture should be less than 35 )

Remove the seat cushion and fuel tank,unplug the vision hole


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cover ,round the flywheel of magneto anti-clockwise to aim Tat the

signal of fore cover on the left.

Note: The piston must be fixed to the dead enter. (Figure 2-2)

Figure 2-2

Remove cylinder valve cover,check the lash between the valve stem

by feeler gauge .

Valve clearance:inlet and exhaust valve: 0.050.08mm.

See figure 2-3.

Figure 2-3

Loose the lock nut,rotate the adjusting screw until it appears that

the feeler gauge be pulled .Then fasten the adjusting screw by valve

adjuster,tighten the lock nut and check the valve lash .Afterword install

the cylinder valve cover , vision hole cover,the fuel tank and cushion.


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See figure 2-4.

Figure 2-4

2.2Inspection of spark Plug

1. Unplug the Spark-Plug cap:remove

the spark plug by box key,look over

whether the spark-plug insulator and

electrode is damaged or sooting.

If so ,see figure 2-5. Figure 2-5

2 Check the spark clearance

by feeler gauge whether it

is between 0.60.7mm.Or adjust

the gap,clean incrustation

with spark-plug cleaner and steel

wire brush and check if

the spark plug sealing washer(Figure 2-6). Figure 2-6

.


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3.Swirl the when spark plug and tighten to 1820N.m by box key ,then

fix the spark plug cap when assembling.

2.3 Inspection of cylinder, piston and piston ring

Camshaft lube is injected by a hole of engine body into

cylinder ,so the hole must not jam.It is necessary to fix the cushion

and adjer without dust permeated into the crank case before assembly.

itemstandard value:mm limit value:mm

bore diameter of cylinder 102102.03 102.1

taper 0.0040 0.005

out of roundness 0.0035 0.005

cylinder

degree of toruosity 0.04 0.06

external diameter of piston 101.95101.97 101.92

bore diameter of piston pin

hole22.00222.010 22.010

gap between piston pin and

piston pin hole0.0070.020 0.02

Piston ring

end

clearance

Top ring/the

second ring

0.250.40 0.5

oilring 0.30.9 1.2

top ring 0.30.07 0.10

gap between

piston ring

and piston

groove the second

ring0.020.06 0.09

gap between cylinder and

piston0.030.08 0.09

Piston,piston

ring and

piston pin

external diameter of piston

pin21.99521.990 21.96

bore diameter 22.01622.027 22.03connecting

rod

Gap between small end of

connecting rod and piston

pin

0.0160.033 0.035


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diagnosing and eliminating of malfunction:

Emission of black smoke for abrasion of cylinder or

piston,

1. Cylinder , piston of piston ring is worn out.

2.The piston ring is not properly assembled.

3. The piston or cylinder wall is scraped.

overheated

1Excessive incrustation of piston.

2Blast and abnormal noise.

3Abrasion of cylinder or piston.

Inspection of cylinder.

1.Check whether the cylinder is damaged.

2.Measure the bore diameter of cylinder at three spots.

3.At the top,the middle and the bottom of the piston stroke .And measure

the bore diameter at directions of right-angle intersection.

repairing limit value:

out of roundness: 0.005 mm

taper 0.005mm

Inspection of piston and piston ring

Measure the gap between piston ring and piston groove.

1.unplug the piston ring;


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Note:It is forbidden to damaging the piston ring when

assembling.Check whether the piston and the piston groove is cracked

and abraded.See figure 2-7

Figure 2-7

2.Insert piston ring into

cylinder,and measure the

end gap.repairing limit

value:the first ring/the

second ring: 0.5mm

See figure 2-8. Figure 2-8

Measure the bore diameter of piston pin hole.

repairing limit value: see figure 2-9

Figure 2-9


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3.Measure the external diameter 10mm

above the bottom of the piston skirt.

Extreme position :the gap between

cylinder and pistonrepairing

limit value: 0.1mm See figure 2-10 Figure 2-10

Measure the external diameter of piston pin:

the gap between piston and piston pin:

repairing limit value: 0.02mm .See figure 2-11

Figure 2-11

2.4 Inspection of crankshaft

heck that whether crank and connecting rod can rotate without stuck

and whether the clearance between crank and connecting rod is 0.5

0.6mm.The hop of crank shaft should be 0.05mm.If not so,replace it. See

figure 2-12-1, figure 2-12-2.

700Vario ServMan Motor

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