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CJ750 instruction     

CJ750 instruction

1.Running-in of CJ750

In initial operation period of engine,improper operation will speed up wearing of parts because the parts have not been completely run in.Therefore Running-in must be done for new motorcycle.Running-in period is divided into two phases:the first phase is from 0 to 1000 km and the second one is from 1000 to 2000 km.During running-in period,top speed of the sidecar should not exceed limitations given in the following table.

In order to limit the maximum speed of the sidecar in running-in period,the caps of the two carburetters are provided with stop screws The lifted height of throttle valve is limited by the sciew.At each end of running-in period,the stop screw should be cut off from the slotted position.Although the stop screw can limit speed,it is necessary to control and operate the sidecar carcfully in running-in period.

Long distance driving is not allowed within 0 to 500 km running-in period to avoid engine temperature rising.Keep on checking temperature of the engine,gear box,rear drive and brake drum.In the meantime,check all parts and components for fixation,adjust gap and tighten loosened parts in time.

Keep on checking quality of oil in crankcase in the running-in period.If viscosity becomes worse and metal particles are found in the oil within the desired travelling mileage,the oil should be replaced with fresh one.After finishing the running-in period,the oil in gear box and rear drive should be replaced in hot status.Normal oil refilling and replacing should be performed according to the sidecar lubrication table.

Try to avoid driving the sidecar on bad road in the running-in period.It is not allowed to drive the sidecar for long duration at high speed and under overloading condition.Load can be increased gradually when the running-in period is nearly over.The load should be increased gradually after finishing the running-in period.Only when 3000 km travelling is obtained.The sidecarcan run at top speed and with maximum load.On completion of running-in period,tighten the screw of cylinder cap in hot condition of cylinder.

2.Operation of CJ750

<1> Freparation before start

(1)Casoline filling

Before start,check gasoline and oil quantity first.Refill it if gasoline or oil is insufficient.Fill gasoline directly through the filter to gasoline tank.The gasoline level should be 15-20mm below the edge of filler port.

(2)Oil filling

The oil level should be maintained between the uooer and lower mark lines of oil dipstick inside crankcase. To measure oil,the threaded plug should not be screwed in but be on the filler edge.The oil inside gear box and rear drive casing should be filled to start of threads of the plug.Before oil filling,check the oil drain threaded plugs for being tightened.

(3)After gasoline and oil filling,check handle bar,brake and clutch .Check pressure of tyres.Contact the battery power line.

<2>Engine start

Our CJ750 have two kinds of starting devices:kickstarter and electric starter.

Turn on the gasoline control knob.Down position is ON,up position is STANDBY(20km),left position is OFF.Set the hand gear shift lever or foot gear shift lever to neutral gear position between gear positions No.1 and No.2 Press down the button attached on the float chamber vover until the gasoline spills out from the float chamber cover of the carburetter.Close the air valve approximately by half(1/2).Turn outwards the throttlc twist grip to the end,then bring it back to 1/8 full travel.Step the kick starter for 4-5 times to make the crank shaft operate.The cylinders suck in some mixed air and oil is supplied to part surfaces in advance which need to be lubricated.Cut-in the ignition switch by use of key(Turn left is daytime,turn right is nighttime.)Then you can start your sidecar by kickstarter or electrice starter.

After the engine is started,slowly open the air valve according to the engine operating condition.According to the operation sound of the engine,rotate the throttle grip to warm up the engine at low speed and then drive the sidecar.

Use reverse Our sidecar have two style reverse gear box:the 52 style and 331 style,now I show you hao to use the 52 style reverse gear box. If you want use reverse,you must stop your motorcycle and set the gear to position No.1 or neutral(the 331 style gear box must set it to neutral )first.then apply the astern lever with left tiptoe or left sole to astern position.Drive astern the sidecar with normal driving method.

3.Components checking and adjusting

As the sidecar had been adjused and tested before delivery,there is no need to make any readjustment.In case there is any fault with the motorcycle,trouble shooting should be performedas the folloeing:

<1>Spark plug gap adiusting

When new spark plug is used or after the sidecar has been driven for 1000 km,spark plug gap should be checked with feeler gauge.If necessary,adjust the gap to 0.6-0.7mm.Whon the spark plug is needed to be cleaned,it should be clcaned in gasoline eith brush.(use of metal wire brush is not allowed.)

<2>Mixture valve opening checking and adjusting

Inadequate valve opening will directly affect the engine power,which will cause difficult starting,unsteady idling,high fuel consumption and poor acceleration.So the valve opning must be properly adjusted.

Open the valve chamber cover.remove rubber block from observation hole in crankcase,apply kickstarter to operate the crank shaft.When inlet valve of left cyinder opens,apply gently kickstarter to make the"0"scale line on flywheel be in the center of observation hole.Loosen the locknut,adjust and check the opening,which should be 0.06mm for hot cylinder and 0.1mm for cold cylinder. If opening does not meet the requirement,loosen nut and readjust the opening. Check repeatedly readjust thentighten the nut. Refit the valve chamber cover.If the opening is still too wide,which can not be adjusted,the relative parts such as tappet should be changed.

<3>Distributor platinum contact gap checking and adjusting

Remove distributor cover.Rotate ignition camshaft by applying kickstarter to push the mocable arm of platinum contact to upper most position.Use feeler gauge to check max gap between upper and lower platinum contacts,which should be 0.35-0.45 mm. If the gap does not meet the requirement,loosen the securing screw,adjust the gap to 0.35-0.45 mm by turning the platinum contact adjusting screw.Then tighten the securing screw.

<4>Ignition angle checking and adjusting

remove rubber block from observation hole in crankcase,apply kickstarter to operate the crank shaft.When inlet valve of left cyinder opens,apply gently kickstarter to make the"6"scale line on flywheel be in the center of observation hole.Loosen distributor pressing nut and turn the installation plate to make the scale align with the center scale on front crankcase and then tighten the pressing nut..Turn on ignition switch,rotate the distributor till the indicating light just comes on(at this moment the platinum conacts are just setting apart to the extent of a paper-thick clearance).Then tighten the securing bolt,reoperate the crankshaft .Check to see if the"6"scale line on flywheel be in the center of observation hole when the indicating light just comes on,if it is not,it should be readjusted.Otherwise,it should be readjusted.The ignltion angle of the two cylinders should not exceed +_2.

<5>Carburetter adjusting

Two carburetters are used on left and right cylinders in operation.Since two carburetters are used in operation simultanously,they must operate in same state.Otherwise,engine power,fuel consumption,starting performance and low speed stability will be poorer.So the carburetters should be adjusted one by one.

Adjusting at idling Start the engine,carry out the following steps after the engine warms up to normal temperature.Turn outwards throtte twist grip fully home.Screw in the idling adjusting screw clockwise to raise the throttle valve,increase slightly with throttle at minimum operating state.Remove the high tension cable from the other cylinder and ground it. Turn slowly idling mixture adjusting screw to increase the engine RPM to maximum and to make engine operate stably and continously at that speed. Screw out gradually the idling adjusting screw to reduce the throttle valve to mininum engine RPM and to keep engine operating stably at that speed. Repeat to make the engine operate at min stable RPM. Tighten lock must of the two screws.Adjust the other cylinder at idle speed by using the above methods.Improper adjustment at idling will result in uneasy strting,unstable when a high tension cable is removed from the other cylinder to checking it's operation.

Adjusting at intermeidate speed. Turn inwards the throttle twist grip for about a quarter stoke.Alternately remove high tension cable from cylinders,and listen to the operation sound of the other cylinder.Remove rubber cover from carburetter upper cover of lower speed cylinder,adjust the steel cable connector. Check carefully the two cylinders for identical operation and then tighten steel cable connector nut. To check the carburetter operation,turn the throttle twist grip rapidly to center position.At this moment,engine RPM should increase sensitively. If it increases sluggishly,adjust it as per the above method.The two cylinders should operate in balance when the throttle twist grip is turned outwards fully and rapaidly.If flameout happens,adjust it as per the method for adjusting at idling.

If acceleration is not satisfactory when two cylinders are operating in same state.In this case,lean mixture or rich mixture can be checked by closing the air valve narrower or opening the air valve wider.If it's power performance becomes better after closing the air valve narrower,it is the lean mixture eausing the problem,which can be solved by checking fuel line for being unimpeded or by raising needle in throttle valve for 1-2 grids.If exhaust sound is heavy it is rich mixture,which can be solved by dropptng appropriately needle in throttle valve.For the well-adjusted engine,the surface of spark plug insulator skirt should be dry and brown.

<6> Foot gear shift lever adjusting

Gear shift is realized by applying foot gear shift lever or hand gear shift lever.If trip stop happens in operation by applying foot gear shift lever,hand gear shift lever can be used to shift the gear to proper position.If trip stop still exists after using hand gear shift lever,joint sleeve,driving fork and sector plate should be repaired or replaced.If trip stop disappears after using hand gear shift lever,the cause is that the foot gear shift lever is not properly adjusted.Then adjust it as follows:

If trip-under stop happens in shifting from lower to higher gear position,screw out the lower adjusting screw. If trip-over stop happens in shifting from lower to higher gear position,screw in the lower adjusting screw. If trip-under stop happens in shifting from higher to lower gear position,screw out the upper adjusting screw. If trip-over stop happens in shifting from higher to lower gear position,screw in the upper adjusting screw.

<7> Front and rear brakes adjusting

The front and rear wheels are equipped with mechanically controlled and unbalanced shoe brakes,which are driven by cams.The front wheel brake is applied by hand.The suitable steel cable free stroke is so adjusted that brake rocker end can move 10-15 mm before brake begins to function.Tthe steel cable free stroke can be adjusted by adjusting hollow screw in front hub cap and the rocher position.

The rear wheel brake is applied by foot.It's suitable free stroke is so adjusted that front end of foot brake pedal goes down 25 mm before brake begins to function.The free stroke can be adjusted by adjusting the butterfly nut on rear brake rod.

4.CJ750 electric system

5.CJ750 troubleshooting