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Vento Triton R4 Service Maintenance Manual

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Triton R4
Service& Maintenance
Manual
VENTO MOTORCYCLES
Rev no.01/.Page 1 of 143

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Anthony
April 15, 2025

Wiring diagram from stator outputs of each wire

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1 comments:
Mr. Anderson
April 15, 2025

The stator of the Vento Triton R4 has a dual circuit, half-wave single-phase system. It includes two main outputs:

1. Green/Red (Grn/Rd) wire – This is the low power AC output from the stator. It supplies power directly to the headlight switch and choke sensor before reaching the rectifier. It provides around 27–35V AC at idle and powers the lighting circuit directly without converting to DC.

2. Charging coil output – This AC output goes to the regulator/rectifier, which converts it to 12–14V DC at 5000 RPM to charge the battery.

The lighting coil powers headlight, taillight, and meter lights with regulated AC, while the charging coil handles battery charging through the rectifier.

This answer is automatically generated

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Summary of Contents for Vento Triton R4

  • Page 1 Triton R4 Service& Maintenance Manual VENTO MOTORCYCLES Rev no.01/.Page 1 of 143...
  • Page 2 VENTO MOTORCYCLES Rev no.01/.Page 2 of 143...
  • Page 3 INDEX information for the proper maintenance and servicing of VENTO Triton R4 Scooter. GENERAL INFORMATION The Triton R4 has many features such as: V-belt drive automatic transmission • PERIODIC MAINTENANCE PROCEDURE Fan air-cooling system •...
  • Page 4 VENTO MOTORCYCLES Rev no.01/ page 4of 143...

  • Page 5: General Information

    GENERAL INFORMATION 1 1 1 1 CONTENTS MODEL IDENTIFICATION…………………………………………….… 1-1 FUEL AND ENGINE OIL…………………………………………………. 1-1 BREAK-IN PROCEDURES……………………………………………… 1-1 PRECAUTIONS AND GENERAL INSTRUCTIONS……………………1-2 SPECIFICATIONS …………………………………………………………1-3 VENTO MOTORCYCLES Rev no.01/ page 5of 143...
  • Page 6 Upon reaching an odometer reading of 1600 Kms(1000 miles) you can subject the motorcycle to • full throttle operation. Do not maintain constant engine speed for on extended time period during any portion of the • ‘‘BREAK-IN’’ period, try to vary the throttle position. VENTO MOTORCYCLES Rev no.01/ page 6of 143...

  • Page 7: Precautions And General Instructions

    After reassembly, recheck parts for tightness and operation. REPLACEMENT COMPONENTS Be sure to use genuine VENTO spare parts or their equivalent. Genuine VENTO components are high quality parts, which are designed specially for VENTO vehicles. CAUTION Scooter/motorcycle may damage by using non genuine parts or parts that is not equivalent to VENTO parts and will be affecting performance also.
  • Page 8 Carburetor………………Side draft Gear Reduction ratio The first gear-------------------------4.0 Air cleaner…………..Dry PU foam The second gear---------------------2.933 Starting system………..Electric and kick start Drive System ------------------------V-Belt drive Lubricating system…… Lubrication by oil CVT Reduction ratio----------------0.8~2.2 pump VENTO MOTORCYCLES Rev no.01/ page 8of 143...
  • Page 9 Spark plug-----------------------------------------------------------------------------2- 4 Fuel level line-------------------------------------------------------------------------2- 4 Air cleaner-----------------------------------------------------------------------------2- 5 Throttle cable-------------------------------------------------------------------------2- 5 Engine idle speed--------------------------------------------------------------------2- 5 Oil pump-------------------------------------------------------------------------------2- 6 Gear oil---------------------------------------------------------------------------------2- 7 Braking---------------------------------------------------------------------------------2- 7 Tire -------------------------------------------------------------------------------------2-10 Steering--------------------------------------------------------------------------------2-10 Front shock absorber---------------------------------------------------------------2-11 Vehicle bolts and nuts--------------------------------------------------------------2-11 VENTO MOTORCYCLES Rev no.01/ page 9of 143...

  • Page 10: Periodic Maintenance Schedule

    Replace every 4 years Brake fluid Replace every 2 years Steering Front fork Rear shock absorber Tire Vehicle body bolts and nuts Note: I=inspect clean adjust lubricate or replace if necessary A=adjust C=clean R=replace T=tighten VENTO MOTORCYCLES Rev no.01/ page 10of 143...
  • Page 11 • Positive terminal / Cable of Battery Measure the voltage between the +ve and –ve terminal of Battery charge the Battery if the • voltage is below the specified limit. VENTO MOTORCYCLES BATTERY TESTING PROCEDURE Rev no.01/ page 11of 143...
  • Page 12 BATTERY CHARGING CIRCUIT TEST Triton R4 battery charging circuit The MAGNETO generated AC current, which is rectified into DC current by Voltage Regulator .It, is automatically charging the battery depending upon condition of the battery, load and engine rpm.
  • Page 13 Breather tube should be properly routed. Incase if Motorcycle/ Scooter is not being used for longer • period, then first charge the battery fully & then connect only positive terminal to Motorcycle / Scooter. VENTO MOTORCYCLES Rev no.01/ page 13of 143...
  • Page 14 Carbon deposition at the exhaust port of the cylinder will prevent the flow of exhaust gases, reducing the output. Remove carbon deposits periodically as per specified schedule. VENTO MOTORCYCLES Rev no.01/ page 14of 143...
  • Page 15 Tighten the spark plug to the specified torque. Spark plug Tightening torque:15-18N.m NOTE: To check the spark plug, first make sure that the fuel used is unleaded gasoline. Confirm the Specification, thread size and reach while replacing the spark plug. VENTO MOTORCYCLES Rev no.01/ page 15of 143...

  • Page 16: Throttle Cable

    B- CCI OR CCI Super oil or SAE 80 or 90 Gear oil. THROTTLE CABLE Adjust at initially 1000Kms 630 miles or after 2 months And after every 6000 Kms 3780 miles or after12 months thereafter VENTO MOTORCYCLES Rev no.01/ page 16of 143...

  • Page 17: Engine Idle Speed

    Finally adjust the throttle cable play . FUEL LINE Inspect at initially 1000 km 630 miles or after 2 months) and Every 6000 km (3780 miles or after12 months), replace after every 4 years. VENTO MOTORCYCLES Rev no.01/ page 17of 143...
  • Page 18 If the marks are not aligned, loosen lock nuts and turn the adjuster in or out to align the marks. After align the marks, tighten the locknuts . Caution Oil pump cable adjustment must be done after throttle cable adjustment. VENTO MOTORCYCLES Rev no.01/ page 18of 143...

  • Page 19: Gear Oil

    Do not use any brake fluid taken from old, used or unsealed containers. Never re-use the brake fluid left over from the last servicing or stored for long periods. VENTO MOTORCYCLES Rev no.01/ page 19of 143...
  • Page 20 Fill up the master cylinder reservoir to the upper end of the inspection window. Replace the reservoir cap to prevent entry of dirt. Attach a pipe to the caliper bleeder valve, and insert the free end of the pipe into a receptacle. VENTO MOTORCYCLES Rev no.01/ page 20of 143...
  • Page 21 Handle brake fluid with care: The brake fluid reacts chemically with paint, plastics, and rubber materials, etc. 2-9 PERIODIC MAINTENANCE AND ADJUSTMENT PROCEDURE: BRAKELEVR PLAY(REAR BRAKE) : Turn adjusting nut so that the play of Brake lever should be 15-25mm(0.6~0.8) as shown VENTO MOTORCYCLES Rev no.01/ page 21of 143...
  • Page 22 When operating the brake, check to see that • the tip of indicator is within the range. If the tip of indicator is beyond the range, • the brake shoe assembly should be replaced with a new set of shoe. VENTO MOTORCYCLES Rev no.01/ page 22of 143...
  • Page 23 Check that there is no play in the front fork assembly by supporting the machine so that the front wheel is off the ground, with wheel straight ahead, grasp lower shock absorber near the axle and pull forward. If play is found, perform steering bearing adjustment. VENTO MOTORCYCLES Rev no.01/ page 23of 143...

  • Page 24: Front Fork

    Rear wheel fixing nut 100-130 10-13 Rear brake rocker arm fixing bolt 0.5-0.9 Rear shock absorber under fixing bolt 22-29 2.2-2.9 Start pedal mounting screw 15-20 1.5-2 Rear shock absorber top fixing bolt 37-44 3.7-4.4 VENTO MOTORCYCLES Rev no.01/ page 24of 143...
  • Page 25 VENTO MOTORCYCLES Rev no.01/ page 25of 143...

  • Page 26: Compression Pressure Check

    • Fit the Compression gauge in plug hole, while taking care that the connection tight. • Keep the throttle grip in full open position. • While cranking the engine a few seconds with the starter, and record the maximum gauge reading as the compression of that cylinder. VENTO MOTORCYCLES Rev no.01/ page 26of 143...

  • Page 27: Automatic Clutch Inspection

    AUTOMATIC CLUTCH INSPECTION This VENTO Triton R4 is equipped with an automatic clutch and variable ratio belt drive transmission. The engagement of the clutch is governed by engine RPM and centrifugal mechanism located in the clutch. To ensure proper performance and longer lifetime of the clutch assembly it is essential that the clutch engagement smoothly and gradually.
  • Page 28 Bearings…………………………………………………………………. Bushings…………………………………………………………… Crankcase………………………………………………………………. Rear axle shaft…………………………………………………………. Transmission………………………………………………………………. Starter pinion and starter gear…………………………………………. Movable driven and clutch……………………………………………. Movable drive………………………………………………………. Kicking starter………………………………………………………. Piston ……………………………………………………………. Oil pump and oil pump driven gear………………………………… Intake pipe…………………………………………………………. Magneto ………………………………………………………… VENTO MOTORCYCLES Rev no.01/ page 28of 143...
  • Page 29 Engine center • Intake pipe • Reed valve • Oil pump • Oil pump gear • Cylinder head • Cylinder • Piston Engine right side • Cooling fan • Magneto • Starter motor VENTO MOTORCYCLES Rev no.01/ page 29of 143...
  • Page 30 • Remove cooling fan • Remove magneto nut with special tools. • Remove magneto rotor and half circle key with special tools. • Remove magneto stator and paper gasket • Remove oil pump VENTO MOTORCYCLES Rev no.01/ page 30of 143...
  • Page 31 • Remove worm wheel and oil seal press board Remove cylinder head and cylinder Place a cloth stopper below the piston and remove the circlip with a plier. Remove the piston pin and piston. Remove the piston rings from the piston. VENTO MOTORCYCLES Rev no.01/ page 31of 143...
  • Page 32 Remove the kick starter lever. Remove side cover. Remove movable ratchet wheel and clip VENTO MOTORCYCLES Rev no.01/ page 32of 143...
  • Page 33 Remove starting driven ratchet wheel by removing the nuts. ○ ○ Remove fan 5 and V-belt Disassemble the movable drive ○ Face Remove electric gear press board, electric gear and super clutch. Remove starter motor VENTO MOTORCYCLES Rev no.01/ page 33of 143...
  • Page 34 Remove the clutch housing with the special • tool. • Drain gear oil • Remove rear axle nut • Remove rear wheel ○ ○ • Remove brake shoe 5 and rear axle VENTO MOTORCYCLES Rev no.01/ page 34of 143...
  • Page 35 Remove cotter pin 5 and shaft ○ Remove main stand • Remove gear case cover ○ • Remove paper gasket 1 and middle ○ gear assy. ○ • Remove output gear assy. VENTO MOTORCYCLES • Remove carburetor Rev no.01/ page 35of 143...
  • Page 36 • Remove intake pipe • Remove reed valve and paper gasket. VENTO MOTORCYCLES Disassemble crankcase with special tools Rev no.01/ page 36of 143...
  • Page 37 Remove crankcase with special tools Remove crank shaft from crankcase. Remove crankshaft bearing with special tools. VENTO MOTORCYCLES Rev no.01/ page 37of 143...
  • Page 38 Releasing the hand suddenly may cause the following parts to fly apart. ○ • Clutch shoe nut ○ • Clutch shoe assembly ○ • Spring VENTO MOTORCYCLES CAUTION Rev no.01/ page 38of 143...
  • Page 39 4 , movable ○ driven face 5 and fixed driven ○ face ○ • Remove circlip • Remove bearing with special tool. Remove bearing with special tool. VENTO MOTORCYCLES CAUTION Replace the removed bearing with a new Rev no.01/ page 39of 143...
  • Page 40 CAUTION Replace the removed oil seal with a new one. Remove the bearing with special tool CAUTION Replace the removed bearing with a new one. Removing the bearings with special tools. VENTO MOTORCYCLES Rev no.01/ page 40of 143...
  • Page 41 Remove the bearing with special tool CAUTION Replace removed bearing with a new one. ○ Remove the drive shaft bearing ○ and idle shaft bearing CAUTION: removed bearings should replaced with new ones. VENTO MOTORCYCLES Rev no.01/ page 41of 143...
  • Page 42 BUSHING INSPECTION: Inspect the bushing for wear or damage. If any defects are found, replace the bushing With a new one. VENTO MOTORCYCLES CRANKCASE BUSHING DISASSEMBLY Use two steel tubes of appropriate size to press Rev no.01/ page 42of 143...

  • Page 43: Engine Components Inspection And Servicing

    Clear bearing with solvent and lubricate with engine oil before inspection. Rotate the bearing inner race by finger to VENTO MOTORCYCLES inspect for abnormal play, noise and smooth rotation while the bearings are in Rev no.01/ page 43of 143...
  • Page 44 The method can also check the extent of wear VENTO MOTORCYCLES on the parts of the connecting rod‘s big end. If wear exceeds the limit, replace connecting rod, crank pin and crank pin bearing.
  • Page 45 Visually inspect the clutch springs for stretched coils or broken spring coils. CAUTION Clutch shoes or springs must be changed as a set and never separately. VENTO MOTORCYCLES CLUTCH HOUSING INSPECTION: Inspect visually the condition of the inner surface of Rev no. 01/ Page 50 of 143...
  • Page 46 Inspect each roller and sliding surface for wear or damage. Measure the diameter of roller with a venire calipers. If any defects are found or measurement exceeds the specified limit, replace the roller as a complete set. VENTO MOTORCYCLES Rev no. 01/ Page 51 of 143...
  • Page 47 If any stickiness or hitches are found, visually inspect the lip of oil seal, driven face sliding surface and sliding pins VENTO MOTORCYCLES for wear or damage. Driven face Inspection: Rev no. 01/ Page 52 of 143...
  • Page 48 Inspect the belt contacting surface of both driven faces for any scratches, wear and damage. Replace driven face with a new one if there is any abnormality. VENTO MOTORCYCLES Rev no. 01/ Page 53 of 143...

  • Page 49: Cylinder Head Distortion

    Oversize pistons are available in two sizes: 0.5mm and 1.0mm. Service limit 40.075mm (1.5778 In) Measuring Instrument: Cylinder Bore gauge VENTO MOTORCYCLES Rev no. 01/ Page 54 of 143...
  • Page 50 The VENTO MOTORCYCLES measurement for the bore diameter should be taken in the intake-to-exhaust port direction and at 20mm from the cylinder top surface.
  • Page 51 Service Limit: 12.30mm(0.48 In) VENTO MOTORCYCLES Piston pin outside diameter Use a micrometer to measure the piston pin outside diameter at three positions...
  • Page 52 Fix the piston ring in the piston ring groove, measure the ringside clearance with the thickness gauge while matching the sliding surface of piston and ring. Standard clearance: 1st 0.04-0.06mm(0.0016-0.0024in) 2nd 0.02-0.04mm(0.0008-0.0016in) VENTO MOTORCYCLES Rev no. 01/ Page 57 of 143...

  • Page 53: Reed Valve

    A between reed valve and its seat and the dimension ○ If the clearance A is noted to exceed 0.2mm, replace the reed valve assembly. ○ The dimension B is at least 1mm. VENTO MOTORCYCLES Rev no. 01/ Page 58 of 143...

  • Page 54: Engine Reassembly

    BEARINGS: Install the new bearings with a set of the special tools. Install the new bearing and oil seals into the crank case cover with VENTO MOTORCYCLES Rev no. 01/ Page 59 of 143...
  • Page 55 Using two steel tubes of appropriate size and a vise, press mounting ○ ○ bushings 1 and 2 into the crankcase holes as shown in the illustration. Bushing Bushing Crankcase crankcase VENTO MOTORCYCLES Rev no. 01/ Page 60 of 143...
  • Page 56 CRANK SHAFT • Decide the length between the webs refer the figure at right when assembling the crankshaft. Standard width between webs: 38±0.1mm(1.496±0.004in) VENTO MOTORCYCLES • When mounting the crankshaft into Rev no. 01/ Page 61 of 143...
  • Page 57 CAUTION: Never fit the crankshaft into the the crankcase by driving it with a plastic hammer. Always use special tool, otherwise crankshaft alignment accuracy will be affected. VENTO MOTORCYCLES Rev no. 01/ Page 62 of 143...
  • Page 58 VENTO MOTORCYCLES • Apply grease lightly on the rear brake cam pivot part and install it to the Rev no. 01/ Page 63 of 143...
  • Page 59 Cutaway Tang • When installing the cam lever to the cam, align the line on the cam with the slit of cam lever. VENTO MOTORCYCLES • Tighten the cam lever nut to the specified torque. Tightening Torque Rev 01/ page90 of 143...
  • Page 60 6~8N.m(0.6~0.8kgm) • Install the brake shoes. • Install the rear wheel VENTO MOTORCYCLES Rev 01/ page91 of 143...
  • Page 61 When installing, determine the direction Thrust of thrust being applied and position the cir-clip so that it supports the thrust with it sharp corner securely pressing the shaft groove as shown in the illustration. VENTO MOTORCYCLES Sharp corner Rev 01/ page92 of 143...
  • Page 62 • Fill the gearbox with engine oil up to the oil level hole. Oil Capacity:100ml (SAE 85W/40) Starter pinion and starter gear: • Apply grease on the pinion shaft and install the starter pinion subassembly. VENTO MOTORCYCLES • Assemble the starter pinion ○ subassembly Rev 01/ page93 of 143...
  • Page 63 • Install the starter gear over the left crankshaft end. ○ • Install the new O-RING ○ Install the starter motor . When tightening the attachment screws, secure the clamp together with the upper front screw. VENTO MOTORCYCLES Rev 01/ page94 of 143...

  • Page 64: Movable Driven And Clutch

    MOVABLE DRIVEN AND CLUTCH VENTO MOTORCYCLES Rev 01/ page95 of 143...
  • Page 65 ○ ○ Install the bearing in the fixed driven face with the special tools. ○ Install needle bearing VENTO MOTORCYCLES Rev 01/ page96 of 143...
  • Page 66 ○ • Install the pin at three places on the driven face hub. • Apply grease lightly to the cam part VENTO MOTORCYCLES where the pins are placed. ○ • Install two O-Rings Rev 01/ page97 of 143...
  • Page 67 Thoroughly clean the clutch housing to be free from oil and • position it over the clutch shoe assembly. • Tighten the clutch-housing nut to the specified torque with the special tool. Torque 50-60 N.M (5.0~6.0 kg.m) VENTO MOTORCYCLES Rev 01/ page98 of 143...
  • Page 68 1 on the movable ○ drive plate 2 and install it on the movable drive face. • Position the O-RING on the movable drive face. VENTO MOTORCYCLES ○ • Install the movable drive face cover NOTE: Rev 01/ page99 of 143...
  • Page 69 When installing washer face the resin surface of washer to outside. • Install the retainer . • Continue turning the fixed drive VENTO MOTORCYCLES ○ face by hand until the belt is seated in and both the drive and Rev 01/ page100 of 143...
  • Page 70 • Fill the final gearbox with engine oil up to the level hole. Oil capacity 100 ml Tighten the oil level bolt to the specified torque. Tightening torque 9-15N.M (0.9~1.5 Kg.m) KICK STARTER VENTO MOTORCYCLES Rev 01/ page101 of 143...
  • Page 71 Position the kick-starter shaft return ○ spring and hook the spring end ○ on the clutch cover boss ○ Install the dowel pins ○ Install the new gaskets 2 and ○ VENTO MOTORCYCLES Rev 01/ page102 of 143...
  • Page 72 • Fix the gasket to the clutch cover as shown in the illustration. NOTE: Install the kick starter lever as shown in the illustration. Tightening Torque 8~12N.M (0.8-1.2kg-m) VENTO MOTORCYCLES Rev 01/ page103 of 143...
  • Page 73 • Position the cylinder base gasket. • Apply CCI oil on the position and cylinder wall surfaces and install the cylinder over the piston carefully. OUTSIDE VENTO MOTORCYCLES Rev 01/ page104 of 143...
  • Page 74 • Install right crankcase oil seal press board • Apply grease to the oil pump driven gear and install into the crankcase. • Install the oil pump into the crankcase and tighten with specified torque. Tightening Torque 3~5N.m(0.3~0.5 kgm) VENTO MOTORCYCLES Rev 01/ page105 of 143...
  • Page 75 Install reed valve paper gasket. Install reed valve Install oil hose INTAKE PIPE • Install the gasket and intake pipe with reed valve to the crankcase. • Install the clamps. • Install the oil hose. VENTO MOTORCYCLES Rev 01/ page106 of 143...
  • Page 76 Install the stator and retainer and tighten with specified torque. Apply thread lock super “1322”to the rotor nut and tighten it to the specified torque with the special tool. Tightening torque 40-45N.m (4.0-4.5kg.m) VENTO MOTORCYCLES Rev 01/ page107 of 143...
  • Page 77 ○ • Install the magneto lead wire and starter motor lead wire correctly. ○ • Install the cooling fan cover ○ ○ • Tighten the screw A and • Install fan guiding cover VENTO MOTORCYCLES Rev 01/ page108 of 143...
  • Page 78 • Install exhaust pipe ○ ○ screw 4 and screw tightening muffler to their specified torque. TIGHTENING ORQUE: ○ 4 8~12N.m(0.8-1.2kg.m) ○ 5 18~28N.m(1.8-2.8kg.m) ○ • Lubricate brake cam shaft with special grease. VENTO MOTORCYCLES Rev 01/ page109 of 143...
  • Page 79 CHAPTOR 4 FUEL AND LUBRICATION SYSTEM CONTENTS FUEL SWITCH………………………………………………. CARBURETOR………………………………………………. OIL PUMP …………………………………………………. VENTO MOTORCYCLES Rev 01/ page110 of 143...
  • Page 80 The fuel valve in the fuel is then forced to open (due to this diaphragm operation) and allows fuel to flow into the carburetor float chamber. Fuel switch VENTO MOTORCYCLES Rev 01/ page111 of 143...
  • Page 81 Main jet size Idle needle jet size 57.5 Fuel needle clamp position groove from top Idle air adjusting screw 1 ± extrude 1 turnout 13±1mm Float height 3~6 mm (0.1~0.2 In) Throttle cable play VENTO MOTORCYCLES Rev 01/ page112 of 143...
  • Page 82 And the positions of adjustable parts should not be changed except when compensation for the mixture ratio due to altitude differences or other climatic conditions. When adjustment is necessary, refer to the following. VENTO MOTORCYCLES Rev 01/ page113 of 143...
  • Page 83 AIR- FUEL FLOW CHART FUEL Atmosphere Fuel tank Air cleaner assy. Strainer fuel cock Filters Sedimentation bowl Fuel Tap Filter Venturi Inlet Floater Chamber Diffuser of Jet Venturi outlet Combustion chamber VENTO MOTORCYCLES Rev 01/ page114 of 143...
  • Page 84 • Medium speed------------------------------------- 15~17: 1 • High speed----------------------------------------- 13~15:1 • CARBURETTOR CIRCUITS : TRITON R4 CARBURETOR HAS FOLLOWING 6 MAIN CIRCUITS Fuel Intake circuit Choke circuit Idling speed circuit Slow speed circuit Medium speed circuit High speed circuit VENTO MOTORCYCLES...
  • Page 85 VENTO MOTORCYCLES Rev 01/ page116 of 143...
  • Page 86 (Brass tube) for better mixing of fuel with air in the main jet diffuser. Main jet started supplying air fuel mixture in economy range i.e. more air with less quantity of fuel as per engine requirement. VENTO MOTORCYCLES Rev 01/ page117 of 143...
  • Page 87 NOTE: • After installation check for any fuel leakage from the carburetor or fuel line. • Check for the throttle smooth movement; if necessary adjust throttle grip free play 3 to 6 mm. VENTO MOTORCYCLES Rev 01/ page118 of 143...
  • Page 88 • Align the groove on the side of the throttle valve with the guide pin in the carburetor body. Check for its smooth movement. Tighten the top cap over carburetor body. • VENTO MOTORCYCLES Rev 01/ page119 of 143...
  • Page 89 While running engine in Idling speed turn the handle bar to the extreme left or right hand side, if any change in idling speed noticed, the accelerator cable may be wrongly routed or improperly adjusted. Correct the same before test ride. VENTO MOTORCYCLES Rev 01/ page120 of 143...
  • Page 90 ELECTRICAL SYSTEM CONTETNS • IGNITION SYSTEM …………………………….. • CHARGING AND LIGHTING SYSTEM……….. • STARTER SYSTEM……………………………….. • FUEL GAUGE…………………………………….. • OIL LEVEL CHECK LIGHT AND TURN SIGNAL • INDICATOR……………………………………….. • SWITCHS ……………………………………… • BARTTERY. ……………………………………….. VENTO MOTORCYCLES Rev 01/ page121 of 143...

  • Page 91: Ignition System

    Set the test selector knob to “P.E.I”. Connect the power lead to the appropriate AC source. Switch the power on. VENTO MOTORCYCLES Rev 01/ page122 of 143...
  • Page 92 (black with red tracer). • Using a Multimeter, measure the resistance between the B/R lead wire and ground. If the resistance checked is incorrect, replace the coil. Exciting coil restance 140-220 Ω Ω Ω Ω VENTO MOTORCYCLES Rev 01/ page123 of 143...
  • Page 93 H e a d lig h t T a illig h t L ig h t On the other hand, lighting coil supplies AC current to the headlight, taillight, and meter light under the regulated condition. VENTO MOTORCYCLES Rev 01/ page124 of 143...
  • Page 94 VENTO MOTORCYCLES...
  • Page 95 5000 RPM with light switch turned on Battery condition. NOTE: When making the test, be sure that the battery is fully charged condition. Digital Tachometer: For measuring engine RPM Specified charging output Voltage 12~14 Volt at 5000 RPM VENTO MOTORCYCLES Rev 01/ page 125 of 143...
  • Page 96 Disconnect the lead wire coupler. Using the Multimeter ×1 Ω Range , measure the resistance between the terminals as shown in the following table. If the resistance checked is incorrect, replace the regulator/rectifier. UNIT: Ω VENTO MOTORCYCLES Rev 01/ page 126 of 143...

  • Page 97: Starter System

    Starter relay Fuse Battery Starter motor Starter button Front brake switch Ignition switch Rear brake switch VENTO MOTORCYCLES Rev 01/ page 127 of 143...
  • Page 98 Service Limit 3.5mm (0.14in) Segment Commutator If the commutator surface is dirty, starting performance will decrease. Polish the commutator with #400 or similar fine Mica emery paper when it is dirty. Service Limit 0.2mm (0.008in) VENTO MOTORCYCLES Rev 01/ page 128 of 143...
  • Page 99 ● Disconnect the starter relay lead wire coupler. Check the coil for “open”, “ground” and ohmic resistance. The coil is in good condition, if the resistance is as follows: STANDARD RESISTANCE: 80~150 VENTO MOTORCYCLES Rev 01/ page 129 of 143...
  • Page 100 Check the oil level switch for continuity between the lead wires. If the tester does not show the value of 1 ohm when the switch ring is in bottom position, file the contact surface or replace the unit. VENTO MOTORCYCLES Rev 01/ page 130 of 143...
  • Page 101 When the turn signal switch is turned on and the turn signal light flashes, the turn signal indicator light (oil level check light) also flashes, both being not concurrently but alternatively as one being lit white the other unit. (pl refer electric diagram below) SWITCHES VENTO MOTORCYCLES Rev 01/ page 131 of 143...
  • Page 102 BATTERY SPECIFICATIONS Type designation YUASA/YB4L-B Capacity 12V-4Ah Specific gravity (Fully charged) 1.24~1.28 at 27 Needs Charging Below 1.220 INITIAL CHARGING FILLNG ELECTROLYTE Remove the aluminum tape sealing the battery electrolyte filler holes. VENTO MOTORCYCLES Rev 01/ page 132 of 143...
  • Page 103 20 minutes. NOTE: If no air bubbles are coming up from a filter port, tap the bottom of the two or three times. Never remove the container from the battery. VENTO MOTORCYCLES Rev 01/ page 133 of 143...
  • Page 104 • If battery voltage is still less than 12.5Volt please replace the battery with a new one. • When the motorcycle is not used for a long period, check the battery every one-month to prevent the battery discharge. VENTO MOTORCYCLES Rev 01/ page 134 of 143...
  • Page 105 MASTER CYLINDER INSPECTION·················································· MASTER CYLINDER REASSEMBLY AND REMOUNTING································ STEERING STEM AND FRONT SUSPENSION·················································· REMOVAL AND DISASSEMBLY························································· INSPECTION·········································································· REASSEMBLY AND REMOUNTING······················································ IGNITION SWITCH································································· REAR WHEEL AND BRAKE································································ REMOVAL AND DISASSEMBLY······················································· INSPECTION········································································ REASSEMBLY AND REMOUNTING···················································· VENTO MOTORCYCLES Rev 01/ page 135 of 143...
  • Page 106 7 and remove decorating cap,rear carrier. ○ 3. Unlock fuel tank cap and remove it, open two tapping screws and then remove side cover. 4. The sequence of assembly is the reverse of removal. VENTO MOTORCYCLES Rev 01/ page 136 of 143...
  • Page 107 Under cover assembly 3 The assembly sequence is the reverse of disassembly. Front cover removal ○ ○ ○ 1 Unscrew tapping screw 1 , and remove front cover 2 by removing front cover screw VENTO MOTORCYCLES Rev 01/ page 137 of 143...
  • Page 108 LEGSHIELD REMOVAL ○ ○ 1. Remove power lock housing 2 and open bolt 3. Remove leg shield by opening ○ the four bolts 4. The assembly sequence is the reverse of disassembly. VENTO MOTORCYCLES Rev 01/ page 138 of 143...
  • Page 109 HANDLE COVER REMOVAL ○ a) Remove front handle cover 2 by ○ unscrewing the six Tapping screws 1. Remove master cylinder by removing the two ○ bolts VENTO MOTORCYCLES Rev 01/ page 139 of 143...
  • Page 110 ○ b) Disconnect throttle cable 3 and oil pump ○ cable c) Remove rear brake cable adjusting ○ VENTO MOTORCYCLES Rev 01/ page 140 of 143...
  • Page 111 Handle cover removal 5. Remove all wiring couplers. 6 Remove handle cover by unscrewing ○ bolt 7. The assembly sequence is reverse of removal sequence. VENTO MOTORCYCLES Rev 01/ page 141 of 143...

  • Page 112: Front Wheel

    Remove the left & right decorating cover. • ○ Remove front fender • Support the scooter on jack or wooden shelf. • Remove front wheel by removing front axle shaft. • VENTO MOTORCYCLES Rev 01/ page 142 of 143...
  • Page 113 An excessive run out is usually due to worn or loose wheel bearings and can be reduced by replacing the bearings.If bearing replacement fails to reduce the runout,replace the wheel. Service Limit: 2.0mm (0.08in) VENTO MOTORCYCLES Rev 01/ page 143 of 143...
  • Page 114 Install the brake disc as shown in photo. • When installing this speedometer gear box, align • the two driving poles with the two reaxes of the wheel hub. Tighten the nut with special tool. • VENTO MOTORCYCLES Rev 01/ page 144 of 143...
  • Page 115 16. Brake pad 2 17. Front brake switch 18. Brake disc BRAKE PAD REPLACEMENT ○ Remove the calliper by removing the mounting bolts NOTE: Do not operate the front brake lever while dismounting the calliper. VENTO MOTORCYCLES Rev 01/ page 145 of 143...
  • Page 116 Place a rag over the piston to prevent popping up.Froce out the • piston with a air gun. CAUTION: Do not use high pressure air to prevent piston damage. • Remove the dust seal and piston seal . VENTO MOTORCYCLES Rev 01/ page 146 of 143...
  • Page 117 With the disc mounted on the wheel, check the disc face for runout with a dial gauge as shown. Replace the disc if the run out exceeds the service limit. Service Limit: 0.3 mm(0.012 in) VENTO MOTORCYCLES Rev 01/ page 147 of 143...
  • Page 118 Completely wipe off any brake fluid adhering to any part of motorcycle. The fluid reacts chemically with paint, plastics, rubber materials, etc. Remove the master cylinder. • VENTO MOTORCYCLES Remove the brake lever and brake switch. • Rev 01/ page 148 of 143...
  • Page 119 Inspect the master cylinder bore for any scratches or other damage. Check the piston surface for scratches or other damage. • Check the primary cup and dust boot for wear or damage. • VENTO MOTORCYCLES Rev 01/ page 149 of 143...
  • Page 120 Reassemble and remount the master cylinder, When remounting the master cylinder on the handlebar, first tighten the clamp bolt for upside. CAUTION: Bleed air after remounting the master cylinder. VENTO MOTORCYCLES Rev 01/ page 150 of 143...
  • Page 121 Remove front wheel • Disconnect the front and rear • ○ brake light switch lead wires ○ Remove the rear brake cable • ○ Remove throttle grip assy • ○ Remove throttle cable • VENTO MOTORCYCLES Rev 01/ page 151 of 143...
  • Page 122 • Remove bearing lower race by special tool. • Remove steel balls. • Number of steel balls Upper lower • Remove the upper and lower bearing inner races with an appropriate bar VENTO MOTORCYCLES Rev 01/ page 152 of 143...
  • Page 123 INSPECTION Check the removed parts for the following abnormalities. • Bearing race wear and brinelling. Worn and damaged steel balls. Distortion of steering stem or handlebar. Check the suspension for damage • VENTO MOTORCYCLES Rev 01/ page 153 of 143...
  • Page 124 NOTE adjustment will vary from scooter to scooter. Be sure that the steering turns smoothly and easily, left to right. Install a locknut by installing locknut and anti-dust cover • Screw locknut with special tool, and adjust front fork • bearing to get smooth turning. VENTO MOTORCYCLES Rev 01/ page 154 of 143...
  • Page 125 After performing the adjustment and installing the handlebar, Rock the front wheel forward and backward to ensure that there is not play and that the procure is accomplished correctly. If Play is noticeable, readjust the steering outer race nut. VENTO MOTORCYCLES Rev 01/ page 155 of 143...
  • Page 126 4. Brake pad kit spring 5. Rear brake tension 6. Rear indicator 7. Anti-dust cover 8. Rear brake camshaft 9. Bolt M6Χ30 10. Valve 11. Nut M16Χ1.5 12. Rear brake arm 13. Valve cap VENTO MOTORCYCLES Rev 01/ page 156 of 143...
  • Page 127 110.7mm, replace it with a new one. Brake shoes Check the brake shoe and decide whether it should be replaced or not from the thickness of the brake shoe lining. Service limit 2.5mm(0.09in) VENTO MOTORCYCLES Rev 01/ page 157 of 143...
  • Page 128 When installing brake shoes, be sure to daub camshaft with • adequate grease. CAUTION: Be careful not to daub the camshaft with too much grease. If grease gets on the lining, brake effectiveness will be lost. VENTO MOTORCYCLES Rev 01/ page 158 of 143...
  • Page 129 SERVICING INFORAMTION CONTENTS Troubleshooting Battery Vehicle Wiring diagram Wire, cable and brake hose routing Special tools Thread parts tightening torque Service data VENTO MOTORCYCLES Rev 01/ page 159 of 143...

  • Page 130: Trouble Shooting

    5. Defective CDI & ignition coil unit. Replace. 6. Defective magneto stator coil. Replace. 7. Float-chamber fuel level out of adjustment in Replace. VENTO MOTORCYCLES carburetor. Clean or adjust. 8. Clogged jets in carburetor. Replace. 9. Broken or damaged reed valve.
  • Page 131 2. Air leaking from carburetor’s joint, vacuum pipe joint, or Check and replace. troubles. starter. 3. Pilot outlet is clogged. Check and clean. 4. Starter plunger is not fully close. Check and replace. VENTO MOTORCYCLES Rev 01/ page 161 of 143...
  • Page 132 Replace the battery. Magneto 1. Internal short-circuit in the battery. Replace the battery. overcharges. 2. Resistor element in the regulator/rectifier Replace. damaged or defective. 3. Regulator/rectifier unit poorly grounded. Clean and tighten ground connection. VENTO MOTORCYCLES Rev 01/ page 162 of 143...
  • Page 133 3. Distorted steering stem. Replace. 4. Not enough pressure in tires. Adjust. Wobbly handle. 1. Loss of balance between right and left Replace. front suspension. 2. Distorted front axle or crooked tire. Replace. VENTO MOTORCYCLES Rev 01/ page 163 of 143...
  • Page 134 Tighten. mounting. Front 1. Weakened springs. Replace. suspension too 2. Oil leakage of shock absorber, Replace. soft. Front 1. Not enough grease, Refill. suspension too 2. Worn suspension arm spacer Replace. stiff. VENTO MOTORCYCLES Rev 01/ page 164 of 143...
  • Page 135 5. Excessively worn shoes and/or drum. Leakage of Replace or repair 1. Insufficient tightening of connection joints. brake fluid. Replace. 2. Cracked hose. Replace. 3. Worn piston seal. Brake drags. 1. Rusty moving parts. Replace VENTO MOTORCYCLES Rev 01/ page 165 of 143...
  • Page 136 WIRE, CABLE AND BRAKE HOSE ROUTING VENTO MOTORCYCLES Rev 01/ page 166 of 143...
  • Page 137 VENTO MOTORCYCLES Rev 01/ page 167 of 143...
  • Page 138 VENTO MOTORCYCLES Rev 01/ page 168 of 143...
  • Page 139 Starting relay Ignition coil HORN POWER SWITCH VENTO MOTORCYCLES Rev 01/ page 169 of 143...
  • Page 140 “T”shape of sleeve Sleeve tools 7mm,8mm,10mm,12mm,13mm Flywheel remover Sleeve (18mm,24mm) Screw remover Cylinder pressure gauge Piston pin remover Spark plug remover Flywheel lock bolt remover T 11 Clutch clamp ○ ○ ○ VENTO MOTORCYCLES Rev 01/ page 170 of 143...
  • Page 141 ○ ○ ○ ○ ○ ○ ○ VENTO MOTORCYCLES Rev 01/ page 171 of 143...
  • Page 142 Exceeding clutch outside lock screw 10-12 Electrical start idle press board screw 10-12 Gear case lock bolt 10-12 Left crankcase discharging oil hole lock 22-25 bolt Left crankcase positioning pin shaft 18-22 locknut VENTO MOTORCYCLES Rev 01/ page 172 of 143...
  • Page 143 Conrod deflection 3.0(0.12) Conrod web to web width 38-38.1(1.496-1.500) Crankshaft runout 0.05(0.002) OIL PUMP DESCRIPTION SPECIFICATION Pump reduction ratio 30.000(30/1) VENTO MOTORCYCLES CCI pump discharge 1.1-1.3ml/5min(working pressure is 0.06Mpa and rotating ratio(full open) speed 118r/min) Rev 01/ page 173 of 143...
  • Page 144 Lighting <2 White Ground Charging <2 Blue White or Green 200±20 at 20 Exciting White Ground Generator no-load voltage More than 52 V at 5000r/min VENTO MOTORCYCLES Regulated voltage More than 12-14V at 5000r/min Rev 01/ page 174 of 143...
  • Page 145 5.2L Gear oil SAE85/90 Gear oil capacity 0.10 ±0.01L Gear oil change 2000 Kms period Engine Oil tank 0.9±0.1L capacity Engine oil grade 2 T Oil Brake fluid grade DOT3 or DOT4 VENTO MOTORCYCLES Rev 01/ page 175 of 143...
  • Page 146 VENTO MOTORCYCLES Rev 01/ page 176 of 143...

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