Boreem Jia Owners Manual
The author of this manual has the conviction that the only way in which a meaningful and easy to follow text can be written is first to do the work himself, under conditions similar to those found in the average household. As a result, the hands seen in the photographs are those of the author. Even the machines are not new: examples that have covered a consider- able mileage were selected so that the conditions encountered would be typical of those found by the average owner. Unless specially mentioned, and therefore considered essential, Honda service tools have not been used.
There is invariably some alternative means of slackening or removing some vital component when service tools are not available and isk of damage has to be avoided at all costs. Each of the six Chapters is divided into numbered Sections. Within the Sections are numbered paragraphs. In consequence, cross reference throughout this manual is both straightforward and logical. When a reference is made ‘See Section 5.12′ it means Section 5, paragraph 12 in the same Chapter.
If another Chapter were meant, the text would read ‘See Chapter 2, Section 5.12′. All photographs are captioned with a Section/paragraph number to which they refer and are always relevant to the Chapter text adjacent. Figure numbers (usually line illustrations) appear in numerical order, within a given Chapter. 1.1 therefore refers o the first figure in Chapter 1. Left-hand and right-hand descriptions of the machines and their component parts refer to the right and left of a given machine when the rider is seated normally. Motorcycle manufacturers continually make changes to specifications and recommendations, and these, when notified,mare incorporated into our manuals at the earliest opportunity.
We take great pride in the accuracy of information given in this manual, but motorcycle manufacturers make alterations and design changes during the production run of a particular n motorcycle of which they do not inform us. No liability can be ccepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from, the information give Incoming search terms:. Always make a pre-ride inspection before you start the engine. You may prevent an accident or equipment damage. 2 Many accidents involve inexperienced riders.
Most countries require a special riding test or license. Make sure you are qualified before you ride. NEVER lend your motorcycle to an inexperienced rider. 3 Many car/motorcycle accidents happen because the car driver does not “ see the motorcyclist.
Jul 10, 2011 I need the manual for a Boreem Jia 602-i scooter. It has this number on the plate covering the battery underneath - Qianjiang QJ150-J question.
Make yourself conspicuous to help avoid the accident that is not your fault:. Wear bright or reflective clothing. Don’t drive in another motorist’s “blind spot” 4 Obey all national, and local laws and regulations Excessive speed is a factor in many accidents.
Obey the speed limits am NEVER travel faster than conditions warrant. Signal before you make a turn or lane change. Your size and manoeuvrability can surprise other motorists.5 Don’t let other motorists surprise you. Use extra caution at intersections, parking entrances and exits and driveways. 6 Keep both hands on the handlebars and both feet on the footrests while riding. A passenger should hold onto the motorcycle or the rider with both hands, and keep both feet on the passenger footrests.
PROTECTIVE APPAREL 1 Most motorcycle accidents fatalities are due to head impact. ALWAYS wear a helmet. You should also wear a face shield or goggles; boots, gloves, and protective clothing. A passenger needs the same protection. The exhaust system becomes very hot during operation, and it remains hot after operation.
Never touch any part of the hot exhaust system. Wear clothing that fully covers your legs. 3 Do not wear loose clothing which could catch on the control levers, footrests, or wheels. Installation To prevent accidental vehicle start-up, which could cause death or serious injury, remove maxi-fuse before proceeding. (00251a) 1 WARNING 1 WARNING ® Kit Numbers 41279-04, 41282-04, 41463-05, 41467-05, 41633-05, 41634-05, 41640-05, and 41639-05 1 of 3 Figure 1. Rear Wheel Removal i02495 1. Axle (keep) 2.
Axle adjuster (keep) 3. Axle nut (keep) 4. “E”-clip (keep) 5. Spacer (3) (keep) 6. Torx screw (5) (replace) 7. Brake disc (keep) 8. Wheel assembly (replace) 9.
Valve cap (keep) 10. Compensator bowl (keep) 11. Compensator cushion (keep) 12.12 pt screw (5) (keep) 13.
Lockwasher (5) (keep) 14. Sprocket assembly (keep) 1.
Refer to the Service Manual and follow the MAXI-FUSE instructions to remove the right-side cover and maxi- fuse. Proceed to Step 2 for the wheel being replaced. Rear Wheel 2. See Figure 1. Remove the rear wheel per the REAR WHEEL, REMOVAL instructions in the Service Manual. Disassemble, clean and inspect all parts to be re-used per Service Manual instructions.
Re-assemble all saved components to the new chrome rear wheel assembly. See REAR WHEEL, ASSEMBLY in the Service Manual. Do not re-use brake disc screws. Re-using disc screws can result in torque loss and damage to rotor and/or brake assembly. Fasten the brake disc to the valve stem side of the wheel using the Torx®screws from the kit. Install the compensator bowl with the 12-point screws and lockwashers saved earlier.
Install the new wheel to the rear fork. Refer to REAR WHEEL, INSTALLATION in the Service Manual. Proceed to Step 7. Front Wheel 2. See Figure 2. Remove the front wheel per the FRONT WHEEL, REMOVAL instructions in the Service Manual. Disassemble, clean and inspect all parts to be re-used per Service Manual instructions.
Mark the left and right brake discs so they can be re-installed to the same location. Re-assemble all saved components to the new chrome front wheel assembly. See FRONT WHEEL, ASSEMBLY in the Service Manual. Do not re-use brake disc screws.
Re-using disc screws can result in torque loss and damage to rotor and/or brake assembly. Using the Torx ® shoulder bolts from the kit, and the saved spring washers fasten the brake discs to the same side of the wheel from which they were removed.
Install the new wheel to the front forks per the FRONT WHEEL, INSTALLATION instructions in the Service Manual. Proceed to Step 7. Front and Rear Wheels 7.
Refer to the Service Manual and follow the MAXI-FUSE instructions to replace the maxi-fuse and right-side cover. After servicing brakes and before moving motorcycle, pump brakes to build brake system pressure. Insufficient pressure can adversely affect brake performance, which could result in death or serious injury. (00279a) After servicing the brake system, test brakes at low speed. If brakes are not operating properly, testing at high speeds can cause loss of control, which could result in death or serious injury. (00289a) Maintenance and Cleaning Chrome parts must be maintained regularly to ensure that they keep their original shine and luster.
Clean heavily-soiled wheel surfaces using Harley Wheel and Tire Cleaner, part number 94658-98, applied with Harley Wheel and Spoke Brush, part number 43078-99. Thoroughly clean chrome with a good quality chrome cleaner, such as Harley Bright Chrome Cleaner, part number 94683-99. After cleaning and polishing, seal the finish with a good quality sealer such as Harley Glaze Polish and Sealant, part number 99701-84 Incoming search terms:.
Cover the throttle bodies to prevent anything from dropping into the engine. Remove the front seat and disconnect the battery. (Refer to Service Manual, Page 8-8) 2. Lift up the fuel tank. (Refer to Service Manual, Page 5-3) 3.
Remove the air cleaner box. (Refer to Service Manual, Page 5-14) 4. Remove and replace the ISC valve. (Refer to Service Manual, Page 5-25) NOTE: Since the ECM is also being replaced there is no need to perform the ISC valve preset operation. Install the air cleaner box in reverse order of removal.
(Refer to Service Manual, Page 5-14) 6. Lower the fuel tank. (Refer to Service Manual, Page 5-3) 7. Remove the upper seat rail plate. Disconnect and remove the ECM. (Figure 1) @ ISC Valve Mounting Screw Torque: 2.1± ±0.6 N.m (1.5± ±0.4 lb-ft)!
Carefully insert the ISC valve straight into the throttle body hole to prevent damaging the o-ring. Turn the ISC valve slightly to confirm that the o-ring has not twisted.
Using the new screw provided in the replacement parts kit, make sure the screw is completely seated on the plate after the screw has been tightened to the specified torque. Remove and replace the ISC valve.
(Refer to Service Manual, Page 5-25) NOTE: Since the ECM is also being replaced there is no need to perform the ISC valve preset operation.! Cover the throttle bodies to prevent anything from dropping into the engine. Remove the front seat and disconnect the battery. (Refer to Service Manual, Page 8-8) 2. Lift up the fuel tank. (Refer to Service Manual, Page 5-3) 3. Remove the air cleaner box.
(Refer to Service Manual, Page 5-14) REPLACEMENT PROCEDURE: 8. Install the new ECM in reverse order of removal. Apply thread lock to the upper plate mounting bolts when reinstalling the upper seat rail plate. Incoming search terms:. REMOVAL Prepare for Service 1. Position motorcycle on a suitable lift. NOTE If vehicle is equipped with Harley-Davidson Smart Security System, see owner’s manual for instructions to disarm the system.
To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. Disconnect battery cables, negative (-) battery cable first. Remove seat according to the instructions in the service manual.
Refer to service manual to remove left saddlebag and side cover. When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity.
Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. Remove fuel tank according to the instructions in the service manual. Remove Engine Components 1. Remove existing air cleaner assembly. Discard backplate but save remaining parts. Refer to AIR CLEANER REMOVAL in service manual.
Remove existing exhaust system. Refer to EXHAUST SYSTEM REMOVAL in service manual. Remove engine from chassis following the instructions in the service manual. Disassemble engine top end and bottom end. Refer to appropriate ENGINE sections in service manual. Remove existing clutch diaphragm spring. Refer to CLUTCH REMOVAL in service manual.
The procedures in this instruction sheet should be performed by one experienced in precision measuring techniques. Failure to meet tolerances called for in this instruction sheet can result in engine damage. (00511b) -J04793 1 2 is03517 1.
O-ring counterbore 2. Spigot bore Figure 1. Spigot Bore and O-Ring Counterbore Dimensions Table 1.
Spigot Bore and O-Ring Counterbore Dimensions Depth Bore Description 1.625 +/- 0.010 in. (41.3 +/- 0.25 mm) 4.205 +/- 0.010 in. (107 +/- 0.25 mm) Spigot Bore 0.085 +/- 0.003 in. (2.16 +/- 0.08 mm) 4.415 +/- 0.002 in. (112 +/- 0.05 mm) O-Ring Counter- bore is03456 Figure 2. Cylinder Wall MACHINE CRANKCASE Crankcase Boring Preparation NOTE During final assembly of the engine, Harley-Davidson recommends replacing the OE cylinder studs with Screamin’ Eagle High Tensile Studs (16505-01).
Remove cylinder studs from the engine crankcase. Mask off all bearings and oil holes to prevent debris and contaminants from entering those areas. Inspect and clean engine case mating surfaces. See Figure 6. Reassemble engine case with OE screws, except the top center screw between the cylinders, and tighten to specifications listed in service manual. NOTE To prevent damage to crankcase boring tool, it is important to replace the top center screw with a modified top center screw (1093). This screw is included in the Crankcase Boring Tool Kit (94419-06) and can be purchased separately from a Harley- Davidson dealer.
Install modified top center screw (1093) between the cylinders and tighten to 50-90 in-lbs (5.6-10.2 Nm). See Figure 1 and Table 1. Machine crankcase cylinder spigot bore and O-ring counterbore to the dimensions shown. Modify Crankcase Incoming search terms:.
REMOVAL To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. Disconnect negative battery cable. See BATTERY MAINTENANCE in Service Manual. Remove primary cover, primary drive, and clutch. See DRIVE COMPONENTS in Service Manual.
Remove primary chaincase according to the instructions in the Service Manual. See Figure 2. Pull off the alternator rotor (1) using two bolts inserted through the holes in the rotor face. Remove the two T-27 TORX screws (2). Unplug the voltage regulator and remove the stator (3). See VOLTAGE REGULATOR in Service Manual. Disassemble connector 46B (A).
See DEUTSCH ELECTRICAL CONNECTORS in Service Manual. NOTE Contact cleaner, alcohol, or glass cleaner sprayed on rubber grommet (B) will provide lubrication when pulling it through crankcase hole. Move grommet (3) to one side and spray contact cleaner into gap. Repeat for other side. Pull rubber grommet (B) through crankcase hole. Pull wires through crankcase hole. INSTALLATION 1.
Insert wires through crankcase hole. See Figure 1.
Push rubber grommet (B) through crankcase hole. If necessary, apply the same lubricant used during removal. Insert wires into connector 46B (A). Mate connector 46. See VOLTAGE REGULATOR in Service Manual. Is03776 Figure 1. Voltage Regulator 5.
See Figure 2. Install the stator (3) on the crankcase and fasten in place using new TORX screws (2). Tighten to 55-75 in-lbs (6.2-8.4 Nm). Install the rotor (1) on the sprocket shaft. Apply Loctite Threadlocker 262 (red) to sprocket nut threads.
Tighten sprocket nut to 150-165 ft-lbs (203.4- 223.7 Nm). Install primary chaincase according to the instructions in the Service Manual. Install clutch, primary drive, and primary cover. See DRIVE COMPONENTS in Service Manual.
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Connect negative battery cable. See BATTERY MAINTENANCE in Service Manual Incoming search terms:.