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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.
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