PGO LIGERO-50 Service Manual
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PGO LIGERO-50 Service Manual

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This manual offers all service specialists with the technological
procedures of maintenance, repairing for LIGERO-50 detailedly show
those whom may concern how to maintain, repair, change parts,
troubleshoot and reassemble, etc.
At every important section we illustrate by assembly, explosion
diagrams and photographs, if necessary, please check the diagrams
already shown.
Though we have tried our best, please kindly instruct us any
faults found in this manual.
MOTIVE POWER INDUSTRY CO., LTD.
PREFACE

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Summary of Contents for PGO LIGERO-50

  • Page 1 PREFACE This manual offers all service specialists with the technological procedures of maintenance, repairing for LIGERO-50 detailedly show those whom may concern how to maintain, repair, change parts, troubleshoot and reassemble, etc. At every important section we illustrate by assembly, explosion diagrams and photographs, if necessary, please check the diagrams already shown.
  • Page 2 CONTENTS The specification Service information (1)The operation notice (2)Looking torque value (3)Lubrication instruction (4)Wiring diagram (5)Troubleshooting Checking and adjustment (1)Checking table (2)Battery (3)Clean the air cleaner (4)Oil screen (5)The final reduction mechanism oil (6)Spark plug (7)Compression pressure measurement (8)Valve clearance (9)Ignition timing Idle Adjustment (10)
  • Page 3 Electric equipment (1)Troubleshooting (2)Battery (3)Recharge system (4)Ignition system (5)Starting system (6)Starting clutch (7)Handle bar switch...
  • Page 4 SPECIFICATIONS Model Transmission LIGERO-50 Overall Length Primary 1780mm Direct reduction Overall width 645mm Secondary ratio 52/13*44/13 110CC Overall height 1060mm Seat height 770mm Reverse Wheelbase 1210mm differential Dry weight 99kgs Frame Steel pipe Engine Model Front fork Telescopic Piston displacement...
  • Page 5 Vehicle model reorganization: 1. Movable model 2. Fixed model...

  • Page 6: Service Information

    2. Service information: (1)The notice for operation-------------------------------------------------------------------- 6 (2)Locking torque value----------------------------------------------------------------------- 7 a. For engine b. For chassis c. Others (3)Lubrication instruction--------------------------------------------------------------------- 9 a. For engine b. For chassis c. Wheel bearing -------------------------------------------------------------------------12 (4)Wiring diagram----------------------------------------------------------------------------13 (5)Troubleshooting 1. Hard starting or no starting 2.
  • Page 7 2. When tighten screws or nuts, lock tightly as per specified locking torque, and in the sequence of cross direction. 3. Use PGO, or PGO Recommended parts. 4. After dismantling please wash all parts necessary for checking and grease all contact surface when reassembling.
  • Page 8 (2) TORQUE VALUE 1. Engine: Thread Locking Remarks Locking location torque kg-m Dia (mm) Cylinder head 1.0~1.4 When the engine is cold Flywheel outer 3.2~4.0 Rear brake lever 1.0~1.2 Driving pulley 3.2~4.0 Clutch outer 3.5~4.0 Right crankcase 1.0~1.2 Drive gear box cover 1.0~1.2 Left crankcase 1.0~1.2...
  • Page 9 3.Other parts please refer the following table: Standard torque values: Item Torque (kgf- m) 1 5mm bolt and nut 0.45-0.6 2 6mm bolt and nut 0.8-1.2 3 8mm bolt and nut 1.8-2.5 4 10mm bolt and nut 3.4-4.0 5 12mm bolt and nut 5.0-6.0 6 5mm screw 0.35-0.5...
  • Page 10 (3)Lubrication instruction: A. Engine Lubrication location Oil type Remarks Crankcase: rotating part, Auto-separated Sliding part Premium 2 stroke Lubrication Motorcycle oil Cylinder: rotating part, Or SAE#30 Sliding part. Drive gear box SAE85-140 Total 110 c.c. Replacement 90c.c Gasket of starter shaft Clean grease (#3) Start idle gear sliding...
  • Page 11 B.CHASSIS Steel ball, steering Front brake fluid Front brake cam...
  • Page 12 C.WHEEL BEARING Motor oil Final transmission mechanism gear oil Speedometer gear-clean grease Front wheel bearing-clean grease...
  • Page 14 (5)Trouble shooting: 1.Hard starting or can’t start: Check and adjust Trouble condition The reason loosen carburetor draining screw, check if inside of carburetor have fuel or not •check there is fuel or not ‚pipe between fuel tank and The fuel supplies carburetor No fuel supplies carburetor is blocked enough or smooth...
  • Page 15 2.Unsmooth rotation(Weak acceleration ; inefficient horsepower) Check and Adjust The reason Trouble condition start engine and open throttle gradually. check and inspect •air cleaner blocked ‚fuel supply system abnormal ƒfuel tank cover blocked engine can’t rot- engine can rotate „muffler blocked ate up completely …auto cock is malfunctioned †auto chock is malfunctioned...
  • Page 16 Engine running not smoothly(low speed and idling): Check and adjust Trouble condition The reason Check ignition timing correct Not correct • CDI faulty ‚pulse generator faulty Adjust carburetor oil screw • mixture too rich good faulty adjustment adjustment (loosen the screw) ‚...
  • Page 17 4.Engine running unsmoothly(high speed) Check and adjust Trouble condition The reason Check ignition timing •CDI sets faulty correct not correct ‚pulse generator faulty Adjust valve gap •bad adjustment correct Not correct ‚valve base faulty Check auto cock, Fuel supply system •fuel level is too low good unsmoothly...
  • Page 18 5.Charging abnormal(battery over charing, or over discharging) Check and adjust Trouble condition The reason Measure batter’s Voltage then start engine •Battery is dead Voltage re main Voltage goes up The Same To normal value, But after engine Stop ,the Voltage ‚Battery malfunction Goes down again Check voltage rectifier...
  • Page 19 6.No sparking, spark plug Check and adjust Trouble condition The reason Replace new spark Plug, then check again Weak sparking spark plug faulty Good sparking Or no sparking Check spark plug, cap And H.V. cable is Loosen or not good loose spark plug cap loosen Check the CDI plug...

  • Page 20: Checking And Adjustment

    3.Checking and Adjustment: (1)Periodical checking table (2)Battery (3)Clean air cleaner (4)Oil screen (5)The final reduction mechanism oil (6)Spark plug (7)Cylinder pressure (8)Valve clearance (9)Ignition timing Idle adjustment (10) Front brake adjustment (11) Rear brake adjustment (12) Tire (13) Throttle cable adjustment (14)
  • Page 21 (1) Periodical checking table: 1.[○] mark indicates periodical checking 2.[＊] indicates changing the parts Checking period Gen- First Home Office Judgement eral Month Per 6 per12 Per1 per3 per12 Check item Remark standard che- Months months Months months months cking Initial 500km 5000km...
  • Page 22 Checking period Gen- First Home Office Judgement eral Month Per6 per12 Per1 per3 per12 Check item Remark standard che- Months months Months months months cking Initial 500km 5000km 1000km 1000km 2500km 10000km Wheel Front ○ ○ ○ ○ ○ ○ Bearing of axle, Looseness ○...
  • Page 23 Checking period Gen- First Home Office Judgement eral Month Per6 per12 Per1 per3 per12 Check item Remark standard che- Months months Months months months cking Initial 500km 5000km 1000km 1000km 2500km 10000km Engine Engine Performance, ○ ○ ○ ○ ○ parts noise Low speed,...
  • Page 24 Checking period Gen- First Home Office Judgement eral Month Per6 per12 Per1 per3 per12 Check item Remark standard che- Months months Months months months cking Initial 500km 5000km 1000km 1000km 2500km 10000km ○ ○ ○ ○ ○ ○ Performance Lamp system Dirty, cracked ○...
  • Page 25 Battery: Recharge when run out of it 1.Remove the floor mat. 2.Screwing out the two screws on the battery cover; remove the battery cover. 3.Remove the negative cable and then the positive cable, take out the battery to recharge. 4.Re-assembling the battery as the opposite procedure of disassembling after recharging. Note: Do not take out the sealed bolt when recharging.
  • Page 26 (3) Clean air cleaner 1. Remove air cleaner cover. 2. Take out the air cleaner filter. 3. Clean the filter by compressed air. 4. Assemble the air cleaner by the opposite procedure. Attn: Do not start engine when air cleaner is not installed. (4)MOTOR lubricant oil take off the cap of oil tank check the level of oil.
  • Page 27 (5) The final reducing mechanism 1.Change the oil in the gear box: a. Turn off the engine after warm up. b. Put a bowl under the engine. c. Remove the draining bolt and filling bolt to drain the gear oil off. d.
  • Page 28 (6)Spark plug 1.Remove spark plug. 2.Check the spark plug electrode and see whether it is burnt out/ carbonized or not. 3.Clean the electrode, if it is dirty. Spark plug specification NGK: BP7HS or BPR7HS equivalent Gap of spark plug:0.6~0.7mm spark plug Electrode burnt out Carbon piled up or not Washer is distorted or not...
  • Page 29 (8) Ignition Timing Note: It is no need to adjust ignition timing and CDI set. When ignition timing is not correct, just check the ignition system. 1.Remove the checking hole cover of ignition timing. 2.Using the ignition timing light to assure the ignition timing is correct.
  • Page 30 (9) Idling Adjustment Note: Adjust idling only when the engine is warm. 1.Remove the checking hole cover of carburetor. 2.Start the engine and connect the tachometer. 3.Adjust the throttle valve screw to the specified revolution. 4.Specified idling revolution: 1900 ± 100rpm If rpm is still unsteady or fuel up is not smooth, please re-adjust the fuel intake screw.
  • Page 31 (11) Rear Brake Adjustment 1.Check the clearance of rear brake lever. Clearance: 10~20mm 2.If the clearance is beyond the above Standard, adjust it by rotation the screw. a. Left-handed rotation-Enlarge the clearance. b. Right-handed rotation-Reduce the clearance. Note: When the arrow of rear brake indicator align with the arrow of left crankcase, cha nge the brake lining.
  • Page 32 3.Check if there is any sharp object piece the tire. 4.Check the depth of wheel stripe. Depth (front and rear): According to the mark of tire” ” indicating the necessity to change a new tire. (13) Throttle cables Adjustment 1.Check the clearance of throttle 2.Normal clearance: 1.5-3.5mm Adjust it by rotating the adjust nut.
  • Page 33 4. Dismantling, Maintaining, Repairing and assembling operation Lubrication system Plastic parts of Chassis Engine dismantling Drive pulley, starter, clutch, driven pulley Cylinder head and valve Cylinder and piston AC generator Final transmission mechanism Crankcase, crank shaft (10) Carburetor (11) Steering stem, front wheel, frt brake comp., frt fork (12) Rear wheel, rear brake, rear damper (13) Fuel tank...
  • Page 34 (3)Engine Dismantling A. Dismantling engine. 1.Take off the luggage compartment. 2.Take off the left and right body covers. 3.Take off the lower mudguard fender. 4.Remove vacuum pipe, fuel pipe, auto choke, cap of spark plug, rear Brake cable carburetor pipe, engine flywheel shelf’s nut, starter Motor cable plate and rear damper bolt.
  • Page 35 (4)Drive pulley, starter & clutch A. Troubleshooting: a. Engine starts, but vehicle does not move. 1.driving belt worn out 2.driven plate worn out 3.clutch lining worn out 4.driving plate’s spring broken b. The vehicle stops or trembles when running, 1.clutch lining spring cracked or broken. c.
  • Page 36 C. Driving pulley. 1.Take off the 8 screws of left Cover, remove the left cover. 2.Take off the left cover.
  • Page 37 3.Remove the fixing nut of the clutch. 4.Take off the ramp plate. 5.Take off the belt and the rear clutch. 6.Take off the driving plate. • Take off the driving gear start set.
  • Page 38 7.Remove the start idle gear fixing plate. 8.Take off the idle gear.
  • Page 39 9.To assemble the driving pulley, please reverse above procedure. Locking torque: 1.Nut of driving pulley:M10: 3.2~4.0kg- m 2.Locking nut of clutch:M10: 3.5~4.0kg- m 10.Checking the driving belt (1)check whether it is cracked or not or its rubber and fiber are loose or not check also if they are extraordinarily worn out.
  • Page 40 13.Assemble the slide driving plate. (1)Clean the inner surface of slide driving plate, then assemble the roller. (2)Assemble the ramp plate. (3)Please reverse the procedures of disassembling to finish assembling.
  • Page 41 D. Starter dismantling 1.Dismantle the left crankcase cover 2.Remove the hexagon nut, then remove the starter lever. 3.Remove five screws of isolating plate. 4.Remove the starter spring from the start returning positioner. 5.Remove the driven gear comp of kick starter. 6.Remove the retaining c-type clip 7.Remove the spindle comp.
  • Page 42 E. Clutch driven pulley 1.Dismantle the clutch a. Remove left crankcase cover. b. Remove driving plate. c. Remove driving belt. d. Remove the M10 locking nut, then the clutch. 2.Assembling the clutch: please follow the opposite procedure of dismantling. Locking torque: M10: 3.5~4.0kg- m 3.Checking the clutch: Dismantling the clutch needs the special...
  • Page 43 c. Check driven spring free length: standard: 87.9mm Limit of use: change it as it Is below 82.5mm(50cc) d. Check wearing condition of driving plate set. Outer diameter measurement: Limit of use: change it as it Is above 33.950mm e. Check wearing condition of slide driven plate.
  • Page 44 (5)Cylinder and piston: A. Troubleshooting. a. compression pressure is too low, difficult to start engine and running unsmoothly. 1. Cylinder head gasket cracked. 2. Spark plug is not well- locked. 3. Piston ring worn out or cracked. 4. Cylinder, piston worn out. 5.
  • Page 45 D. cylinder head, cylinder, and piston dismantling. 1.Remove the engine. 2.Screwing out the two M6-bolt of cooling cowl. 3.Screwing out the two M6-blot of fan cover. 4.Remove the cooling cowl and fan cover.
  • Page 46 5.Remove the spark plug. 6.Remove the two M6 nuts on the muffler and cylinder. Also remove the two M8-bolt of crankcase. 7.Remove muffler. 8.Remove the four M7-nut on the cylinder head, then remove the cylinder head and cylinder head gasket.
  • Page 47 9.Remove the Cylinder and the gasket. 10.Remove the c type clip on the piston and piston pins by the nipper. •Take off piston. 11.Dismatling of the piston ring Take off the first piston ring then the second ring. 12.When assembling please reverse the procedures of dismantling. Locking torque: Opening end of piston ring M7:1.0-1.4kg- m...
  • Page 48 (6)A.C. Generator, Flyweel A.Dismantling AC generator 1.Remove fan cowl. 2.Remove the M6 screws(4) 3.Remove Screws of flywheel magneto 4.Remove the AC flywheel magneto by special tool.
  • Page 49 5.Remove the flywheel. 6.Remove the electric plug of AC Flywheel magneto. Take out the magneto. B. Install AC generator To install, please reverse the dismantling procedures. Locking torgue : M6: 1.0~1.2kg- m M10: 3.2~4.0kg- m...
  • Page 50 (7)Final Transmission Mechanism A. Trouble shooting lEngine can be started, but vehicle doesn’t move. 1.Gear worn-out or cracked. 2.Gear burnt out. lNoise occurs when running. 1.Gear worn out, burnt or gear surface damaged. 2.Bearing worn out or loosen. lOil leakage 1.Too much oil.
  • Page 51 3.Remove the 6 bolt in gear box cover 4.Take off the gear box. 5.Take out the final reduction gear and idle gear shaft. 6.Clean up the gear box...
  • Page 52 C. Check the final transmission mechanism 1.Check the wearing condition of the driving shaft and gears. 2.Check the wearing condition of the idle gear shaft and idle gears. 3.Check the wearing condition of the final reduction gear. 4.Check the wearing condition of the oil seal and bearing. D.
  • Page 53 E. Check for the flatness of cylinder head & cylinder. Check the flatness of contact surface of cylinder head & cylinder. Limit of use: If it exceeds 0.1mm Change a new one. F. Combustion chamber cleaning lClean out the carbon piled up in combustion chamber. lDo not scratch the combustion chamber and contact surface of the cylinder during cleaning operation...
  • Page 54 G. Check cylinder and piston: 1.Check the wearing and damage condition on the contact surface of the cylinder and piston. 2.Clean out the carbon on the cylinder exhausting port. Be careful not to scratch the inner Surface of cylinder. 3.Cylinder bore measurement: (1)Measure each point (A)(B)(C) orderly, and in X.Y.
  • Page 55 4.Piston outer diameter measurement: (1)Measure at the skirt area where is 12 mm from the skirt lower end of skirt. (2)Limit of use: 50cc-change if when below 39.895mm (3)Calculate the clearance between the cylinder and piston. Limit of use: change it when over 0.100mm 5.Inner diameter measurement of the piston pin hole Limit of use: change it when over 14.032mm...
  • Page 56 6.Outer diameter measurement of the piston pin limit of use: change it when under 9.970mm(50cc ENGINE) 7.Check piston ring: Measure piston ring gap: Limit of use: change new ones when the first ring and second ring are over 0.4mm Push the piston ring into the cylinder By piston, the measure the gap...
  • Page 57 8.Check connecting rod small end (1)lnstall piston pin, bearing onto the connecting rod small end, then check the looseness of the piston pin. (2)Measure the inner diameter of the connecting rod small end. Limit of use: replace a new one when over 14.025mm.(50cc ENGINE) H.
  • Page 58 (8)Crankcase, Crankshaft: A. Disassembling diagram...
  • Page 59 B. Troubleshooting. Engine noise: 1.The bearing of final transmission mechanism is loose. 2.Crank pin bearing is loose. 3.The bearing of gear box is loose. C. Data Measuring Item Standard value Limit of use.(mm) Clearance of connecting rod big end 0.20-0.50 0.71(50cc) (Parallel direction to rod) Clearance of connecting rod big end...
  • Page 60 D. Dismantle the crankcase and crankshaft please follow the following procedures: 1.Remove the engine. 2.Remove the left crank case, the driving pulley (driving plate) clutch and belt. 3.Remove the air cleaner.
  • Page 61 4.Remove the carburetor. 5.Remove the intake manifold and reed valve. 6.Remove the oil pump, fan cowl and fan itself.
  • Page 62 7.Remove the AC flywheel magneto. 8.Dismantle the right and left crankcase. There are all together 7 bolts. 9.Remove center stand, left and right crankcase and take out the crankshaft.
  • Page 63 E. Check the crankshaft: 1.measure the clearance between crank shaft and co-rod big end.(Parallel direction to rod) Limit of use: Replace a new when above 0.71mm 2.check the looseness on X.Y. axis of the connecting rod big end(Perpendicular directions to rod) Limit of use: Replace a new one when above 0.04mm...
  • Page 64 3.measure the swingness of crank shaft neck. Limit of use Change it when Change it when Above 0.1mm Above 0.1mm 60mm 4.check the slackness of crankshaft bearing, if it is slack, change a new one. F. Assemble the crankcase. 1.To assemble the crankcase, please reverse the procedures of disaseembling. 2.The locking torque value for bolts and nuts are all described in the previous chapters Please refer.
  • Page 65 (9)Carburetor, Reed Valve and Auto cock A. Fuel system diagram Fuel Cap Fuel Gauge Fuel Tank Carburetor...
  • Page 66 B: Carburetor dismantling diagram 01 CARBURETOR ASSY. 13 HOLDER, NEEDLE JET 02 TOP SET 14 MAIN JET 03 SPG., COMP. 15 FLOAT VALVE SET 04 PLATE SET 16 PIN, ARM 05 TUBE SET 17 FLOAT SET 06 JET NEEDLE 18 FLOAT CHAMBER SET 07 THROTTLE VALVE 19 TUBE SET 08 SCREW SET...
  • Page 67 C. Troubleshooting: a. Engine can not be started. 1.No fuel in the fuel tank. 2.Fuel pipe is blocked. 3.There is too much fuel in the cylinder. 4.Air cleaner is blocked. b. Engine idling(RPM)unsteady, running not smoothly 1.Improper adjustment of the carburetor idling. 2.Ignition disorder.
  • Page 68 D. Dismantling carburetor 1.Remove the luggage box. 2.Loose the hose clamp between the carburetor and the air cleaner. Then remove the air cleaner. 3.Unscrew the fuel draining screw of the carburetor. Drain off the fuel inside the carburetor. 4.Remove the fuel pipe and the vacuum pipe on the carburetor.
  • Page 69 F. Reed valve 1.Dismantling reed valve. (1)Take off the luggage box (2)Remove the air cleaner (3)Remove the carburetor. (4)Unscrew the locking screw of the intake manifold. (5)Remove the intake manifold. (6)Remove the reed valve. 2.checking for the reed valve. §chang a new one when the reed valve is worn out or distorted. §change a new one too when the base of the reed valve is cracked, injured or distorted.
  • Page 70 G. Check the auto cock 1.When the engine stop, remove the fuel pipe from carburetor and check if there is fuel flow Out or not. It means auto lock functions well if the residue fuel(for the amount of 5-10cc)flows out From the auto cock and fuel pipe.
  • Page 71 (11)Steering stem, front wheel, frt brake comp and front fork. A. Troubleshooting B. Data C. Steering handlebar E. Front wheel F. Front brake G. Front fork...
  • Page 72 A.Troubleshooting 1.steering handlebar is abnormal, too tight. a. steering mechanism; washer of conical bush locked too tightly. b. steering mechanism; steel ball is cracked. c. steering mechanism; steel ball base and washer of conical base is damaged. d. wheel pressure is too low. 2.steering handlebar is aslant.
  • Page 73 C.Changing the speedometer cable 1.Remove the fixed screws of the front cover. 2.Remove the nut of speedometer cable. 3.Remove the front handle cover. 4.Remove the fixed screws of speedometer cable on the right of front wheel. 5.Draw out the damage speedometer cable.
  • Page 74 (D)Steering handlebar 1.Remove the LH/RH back mirrors. 2.Remove the upper handle cover. 3.Remove the nuts on front fork and handlebar. 4.Take off the fixing bolt. 5.Remove the nut and bolt of the front fork fixed on The handlebar. 6.Take off the handle bar. 7.When assembling, please follow the opposite procedures.
  • Page 75 (E)Front wheel 1.Remove the locking nut of the front wheel on the right side. 2.Draw out the axle of front wheel, remove the ring and take off the gear sets of speedometer. 3.Remove the front wheel assy. 4.Assemble the front wheel follows the opposite procedure of dismantling.
  • Page 76 6.Front wheel bearing checking Turn the tire. If the bearing is Loosen or any occurrence for noise, Please change a new one. 7.Front wheel rim checking (1)Check the swing of the front wheel rim. (2)Limit of use: Horizontal direction: Change a new one when above 2.0mm. Vertical direction: Change a new one when above2.0mm.
  • Page 77 (F)Front brake 1. Disassembling and assembling of the front brake comp. a.Remove two bolts fixed on the front brake comp and the front fork. b.Remove the front brake comp. c.Assemble the front brake comp. Follows the opposite procedure of dismantling. Locking Torque: M8: 2.0~3.0kg- m 2.Air releasing of the front brake comp...
  • Page 78 3.Front fork checking: If it is bent or cracked, please replace with a new one. 4.Front shock absorber checking Check is there any unusual damage or worn-out condition, and whether the guide rod of the Front fork is crooked or not. Front fork oil type: SAE 10W20 Capacity (each side): 70 CC...
  • Page 79 5.Disassembling and assembling the front brake-disk. a. Remove the front wheel. b. Remove three nuts on the disk. c. Remove the disk. d. Assemble the disk follows the disassembling procedure. Locking torque M8: 2.0~3.0kgm 6.Checking the front brake-disk. Standard thickness of disk: 3.6mm Limit of usage: change it when below 3.1mm 7.Checking the front brake-lining.
  • Page 80 (12)Rear wheel, rear brake, rear damper: A.Troubleshooting. B.Data. C.Dismantling the rear wheel. D.Checking the rear wheel. E.Rear brake. F.Rear damper.
  • Page 81 A.Troubleshooting. 1.Rear wheel swings. a.wheel rim is distorted. b.wheel is abnormal. c.improperly assemble the wheel axle. 2.Rear damper is too soft a.rear damper spring fatigue. 3.Bad braking a.the adjustment of brake is not good. b.the brake lining is dirty. c.the brake lining is worn out. d.the cam of brake lining is worn out e.the brake cam lever is worn out.
  • Page 82 C.Dismantling and assembling The rear wheel. 1.Remove the fixed screws and bolts of the exhaust pipe. 2.Remove the fixed screws of the rear wheel drum. 3.Remove the bolts. 4.Remove the rear wheel. 5.To assemble the rear wheel, please reverse the dismantling procedures.
  • Page 83 E.Rear brake: 1.Rear brake disassembling diagram. (1)Checking rear brake hub: a.measure the inner diameter of rear brake hub. b.limit of use:change it as the diameter is above 111.0mm (2)Checking brake lining: a. measure the thickness of rear brake lining. b.Limit of use: As the thickness is less than 2mm, change it.
  • Page 84 F.Rear damper 1.Rear damper disassembling diagram:...

  • Page 85: Fuel Tank

    (13)Fuel tank A. Troubleshooting: 1.Engine can’t start: a. No fuel in fuel tank. b. Fuel pipe is blocked. c.. Auto cock and fuel filter is blocked. d. The membrane of fuel cock over extended. 2.The mixture is too lean. a. Ventilation hole is blocked. b.
  • Page 86 5.Remove the fuel pipe. 6.Remove the connecting terminal of the fuel gauge. 7.Remove the fuel gauge. 8.Remove the fixing blot of the fuel tank. 9.Take off the fuel tank. 10.When re-assembling, please follow the opposite procedure of disassembling. Locking torque: M6: 1.0-1.2kgf- m...

  • Page 87: Electric Equipment

    5.Electric equipment: (1)Troubleshooting (2)Battery 1.check specific gravity of eletrolyte 2.recharge (3)Recharge system 1.the wiring diagram of recharge system 2.check A.C. flywheel magneto 3.check regulator/ rectifier. (4)Ignition system 1.the wiring of ignition 2.check spark plug 3.check H.T. Cable and H.T. coil 4.check C.D.I.
  • Page 88 lCurrency is unstable. (1)Troubleshooting: A.Recharge system: 1.The wiring of battery connects lNo power: improperly. 1.battery over charge 2.Ignition system connects abnormally. •No electrolyte in battery. 3.Ignition system is short circuit. ‚Battery becomes white. 4.Lamp system connects abnormally or ƒShort circuit in battery. Short circuit.
  • Page 89 (2)Battery: Always, remove the battery negative Cable(-), then remove positive cable (+). But connect the positive cable (+)first, then connect the negative cable(-) when assembling. 1.Recharging Connection method: Connect the positive cable(+)of the recharger to the positive cable(+)of the battery; and The negative cable(-)of the recharger to the negative cable(-)of the battery.
  • Page 90 2.Testing the recharging performance This test needs to be done under the Battery has been recharged completely a. This test needs to be done after engine is warm- up. And take off the luggage case Firstly. b. Disconnect the orange cable of regulator.
  • Page 91 (3)Recharge system 1.Recharge system diagram...
  • Page 92 2.Check A.C. flywheel magneto. a. Remove the LH side strip and LH body cover. b. Measure the resistance value of terminals. Yellow black 0.1-1.0 White black 0.2-2.0 3.Check regulator measure the resistance value between each terminal, it should be in specified range, otherwise change a new one.
  • Page 93 (4)Ignition system: 1.the wiring of ignition 2.CDI Resistance inspection Pocket tester range: * 1k range...

  • Page 94: Spark Plug

    2.Check the spark plug. Spark Plug 3.Check the H.T. cable and H.T. coil by using the CDI tester. Please follow the instruction manual. 4.CDI sets checking. Check with the CDI tester and Please follow the instruction Manual. If the CDI is broken down, please Change a new one.
  • Page 95 (5)Starting system 1.Starting wiring...
  • Page 96 2.Checking Other spare parts comp. Checking. Change a new one when there is any scratch, damage or burnt on the surface. Any adherent metal powder in-between the layers of the direction exchanger sho uld be cleaned. The conductivity check among each contact surfaces to other parts.
  • Page 97 (7)Handle bar switch The colors for each switch cables: Head Light Switch Operation Dark green Yellow Yellow/black Blue Starting Button /Color ● ● Operation Green/White Black /Color ● ● ● FREE PUSH ● ● HI/LO bean Horn Switch Operation Blue Brown/White Purple/White Operation...

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