Generic XOR 125 Service Manual
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Generic XOR 125 Service Manual

Maxi scooter
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XOR 125
Maxi scooter

Service Manual

Holtvej 8-10, Høruphav, 6470 Sydals
Telefon: +45 73 15 11 00
Fax: +45 73 15 11 01
E-mail: info@scanmi.dk · www.scanmi.dk
CVR: 27 73 31 07
November 2010

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  • Page 1: Service Manual

    XOR 125 Maxi scooter Service Manual Holtvej 8-10, Høruphav, 6470 Sydals Telefon: +45 73 15 11 00 Fax: +45 73 15 11 01 E-mail: info@scanmi.dk · www.scanmi.dk CVR: 27 73 31 07 November 2010...
  • Page 2 Those who will be servicing the scooter should carefully review the manual before performing any repair or services. Major modifications and changes incorporated later will be advised to GENERIC product distributor in each market. Therefore, if newest information is requested in the future, please contact the local GENERIC distributor.
  • Page 3 GENERAL INFORMATION CONTENT TYPE IDENTIFICATION FUEL AND ENGINE OIL BREAK-IN PROCEDURE PRECAUTIONS AND GENERAL INSTRUCTIONS SPECIFICATIONS...
  • Page 4 FUEL Unleaded, the minimum octane number is 95 or more. ENGINE OIL For GENERIC SYSTEM, we recommend special engine oil, you can choose high quality Four-stroke engine oil (SHELL ULTRA 4 – 15W40) GEAR OIL Use high quality, all-purpose 80W90 engine oil for your vehicle.
  • Page 5 REPLACEMENT COMPONENTS Be sure to use genuine GENERIC components or their equivalent.. Genuine GENERIC components are high quality parts which are designed specially for your vehicle. CAUTION Damage to the scooter may result from use of replacement components which are not Equivalent in quality to genuine GENERIC parts, and it can lead to performance problems.
  • Page 7 SPECIFICATIONS DIMENSION AND NET WEIGHT OVERALL LENGTH 1770 mm OVERALL WIDTH 702 mm OVERALL HEIGHT 1085 mm WHEELBASE 1280 mm NET WEIGHT 100 kg CHASSIS Front shock absorber spring, oil damp Rear shock absorber spring, oil damp Front wheel 120/70-12 Rear wheel 130/70-12 Front brake...
  • Page 8 Periodic maintenance and service CONTENTS Periodic maintenance and service schedule Maintenance and service procedures Storage battery Spark plug Cylinder head nut and exhaust pipe bolt Cylinder head and cylinder Fuel level line Air cleaner Throttle cable Engine idle speed Oil pump Gear oil Braking Tire...

  • Page 9: Periodical Maintenance Schedule

    The above maintenance schedule is established by taking the monthly 800 kilometers as a reference which ever comes first. Have your motorcycle checked and adjusted periodically by your GENERIC Authorized Dealer to maintain the motorcycle at the optimum condition. Code:...
  • Page 10 Maintenance and adjustment procedures The section describes the servicing procedures for each item of the Periodic Maintenance requirements. Storage battery Inspect twice a year the contact. Clean if any corrosion. Remove the battery and charge before you store the vehicle for long time. Uncover seat, and then remove the battery box cap in the Middle of helmet barrel.
  • Page 11 Cylinder head nuts and exhaust pipe bolts Tighten at each service. If cylinder head nuts are not tightened to the specified torque, may result in leakage of compressed fuel-air mixture and reduce output, tighten the cylinder head nuts in the following procedures:： 1．...
  • Page 12 SPARK PLUG Neglecting the spark plug maintenance eventually leads to difficult starting and poor performance. If the spark plug is used for a long time, the electrode gradually burns away and carbon builds up along the inside part. In accordance with the periodic table, the plug should be removed for inspection, cleaning and to reset the gap.
  • Page 13 AIR CLEANER Clean every 3000KM If the air cleaner is clogged with dust, intake resistance will, be increased with a resultant decrease in power output and an increase in fuel consumption. Check and clean the element in the following manner. Remove screw 1 and screw 2，take down air cleaner Unscrew tapping screw 3，remove air cleaner cap 4 Fill a washing pan of a proper size with Non-flammable cleaning solvent.
  • Page 14 Tachometer Adjust the throttle stop screw to obtain the idle r/min as follows: Idle speed：1600±100r/min Finally adjust the throttle cable play.
  • Page 15 GEAR OIL Change as shown in the service schedule. Inspect gear oil periodically as follows: The transmission oil level can not be checked. It must be replaced as listened in the manual. 0,11 L is required. Tightening toque：9-15N.m （0.9-1.5 kg-m ，6.5-11.0 lb-ft） BRAKES Inspect at initially 500 km and every service, replace brake fluid every 2 years, replace brake hose every 4 years.
  • Page 16 WARNING： Brake fluid, if it leaks, will interfere with safe running and immediately discolor painted surfaces. Check the brake hoses for cracks and hose joints for leakage before riding. Brake pads Wearing condition of brake pads can be checked by observing the limit line marked on the pad.
  • Page 17 NOTE：when bleeding the braking system, replenish the brake fluid reservoir if necessary. Make sure that there is always some fluid visible in the reservoir. Close the bleeder valve, disconnect the pipe. Fill the reservoir with brake fluid to the upper end of the inspection window.
  • Page 18 Tire Inspect at initially 500km and every 2500km thereafter Tire pressure： If the pressure is too high, the scooter will tend to rede stiffly and have poor traction. Conversely, if tire pressure is too low, stability will be adversely affected. Thereafter, maintain the correct tire pressure for good roadability and to prolong tire life.
  • Page 19 Front shock absorber Adjust at initially 500km and each service. Inspect the front shock absorber for oil leakage or other damage, and replace the defective parts, if necessary. IMPORTANT: If the front fork is too weak us 60 – 70 ml (depends on the weight of the driver) of W15 fork oil to improve the damping.
  • Page 20 ③ ① ② ④ ⑥ ⑤ ⑦ ⑨ ⑧ ⑩...
  • Page 21 LUBRICATION Proper lubrication is important for smooth operation and long life of each working part of the scooter. The major lubrication points are indicated below： NOTE： Lubricate exposed parts which are subject to ruse with engine oil. Before lubricating each part, clean off any rusty spots and wipe off any grease, oil dirt of grime. WARNING：Be careful not to apply too much grease to the rear brake camshaft, otherwise brake slippage will result from the presence of grease in brake drum.
  • Page 22 ENGINE CONTENS Engine components removal with the engine in place Engine removal and remounting Engine removal Engine remounting Engine disassembly Engine components inspection and servicing Bearings Oil seals crankshaft automatic clutch inspection cylinder head cylinder piston reed valve engine remounting oil seals bearings bushings...
  • Page 23 Engine components removable with the engine in place The parts listed below can be removed and reinstalled without removing the engine from the frame. Engine left side Kicking starter lever Clutch brake pad kit Driver left face V-belt Driver belt right face Electric starter gear Super clutch Driven face...

  • Page 24: Torque Values

    TORQUE VALUES STANDARD ● 5 mm bolt and nut 5 N.m (3.5 lbf.ft) ● 6 mm bolt and nut 10 N.m (7.2 lbf.ft) ● 8 mm bolt and nut 22 N.m (16 lbf.ft) ●10 mm bolt and nut 35 N.m (25 lbf.ft) ●12 mm bolt and nut 55 N.m (40 lbf.ft) ENGINE...

  • Page 25: Specifications

    CYLINDER HEAD / VALVES SERVICE INFORMATION CYLINDER HEAD REMOVAL TROUBLESHOOTING CYLINDER HEAD INSTALLATION CAMSHAFT COMPOSITION REMOVAL SERVICE INFORMATION GENERAL This section describes cylinder head, valves, camshaft and the other parts maintenance. The engine must be removed from the frame to service cylinder head. Camshaft lubrication oil is fed to the cylinder head through an oil orifice in the engine case.

  • Page 26: Trouble Shooting

    TROUBLE SHOOTING Engine top-end problems usually affect engine performance. These problems can be diagnosed by a compression test, or by tracing engine noise to the top end with a sounding rod or stethoscope. LOW COMPRESSION Valve  I ncorrect valve adjustment ...
  • Page 27 Remove the air cleaner and carburetor. Remove the inlet pipe assy. Remove the shroud compositions. Relax the cam chain adjuster screw. Remove the screw and O-ring and tighten the cam chain adjusting bolt with clockwise direction. Remove the nuts and washers. Remove the camshaft holder and dowel pins.
  • Page 28 INSPECTION Inspect the cam lobes surface and height of cam lobes for wear or damage. Inspect the camshaft and bearings for wear or damage and replace them if necessary. Screw a 5mm bolt into the rocker arm shaft threaded end. Pull on the bolt to remove the shafts and rocker arms.
  • Page 29 Measure the I.D. of each rocker arm. SERVICE LIMIT: 10.10 mm Measure the O.D. of each rocker arm shaft. SERVICE LIMIT: 9.91 mm CYLINDER HEAD REMOVAL Remove the flange bolts and cylinder head. Remove the cylinder head gasket and dowel pins. Remove the cam chain guide.
  • Page 30 CYLINDER HEAD DISASSEMBLY Remove the valve cotters, spring retainers and valve springs with a valve spring compressor. INSPECTION Clean off all carbon deposits from the combustion chamber. Check the spark plug hole and valve area for cracks. Measure the cylinder head diagonally for warpage with a straight edge and feeler gauge.
  • Page 31 Inspect each valve for turning, burning, scratches or abnormal stems wear. Check the valve movement in the guide. Measure and record each valve stem O.D. SERVICE LIMITS: 4.90 mm Measure and record the valve guide I.D. SERVICE LIMITS: IN / EX 5.30 mm Calculate the stem-to-guide clearance.
  • Page 32 INSTALLATION Install the new gasket and dowel pins. Install the cam chain guide. Install the cylinder head. CAMSHAFT COMPOSITION INSTALLATION Install the rocker arms and rocker arm shafts into the camshaft holder.
  • Page 33 Align the “T” mark on the flywheel with the index mark on the alternator cover by turning the flywheel counter - clockwise. Position the camshaft gear with cam chain so that its “I” mark aligns with the cylinder head surface and the circle hole forwards front.
  • Page 34 Relax the cam chain-adjusting bolt with counterclockwise direction and install the o-ring and screw. Install the cylinder head cover.
  • Page 35 CYLINDER / PISTON SERVICE INFORMATION PISTON REMOVAL TROUBLESHOOTING PISTON INSTALLATION CYLINDER REMOVAL CYLINDER INSTALLATION SERVICE INFORMATION GENERAL Camshaft lubrication oil is fed to the cylinder head through an oil orifice in the cylinder head and engine case. Before installing the cylinder head make sure the orifice is not clogged and the gasket, O-ring and dowel pins are in place.
  • Page 36 CYLINDER REMOVAL Remove the cylinder head. Remove the cylinder. Remove the cylinder gasket and dowel pins. Clean off any gasket materials from the cylinder surface. NOTE: Be careful not to damage the gasket surface.
  • Page 37 PISTON REMOVAL Stuff a shop towel into the crankcase. Remove the piston pin clip with needle nose pliers. NOTE: Do not allow the clip fall into the crankcase. Remove the piston pin from the piston. Remove the piston. Spread each piston ring and remove it by lifting up at a point opposite the gap.
  • Page 38 Measure and record the cylinder I.D. at three levels in both an X and Y-axis. Take the maximum reading to determine the cylinder wear. SERVICE LIMIT: 57.50 mm Calculate the piston-to-cylinder clearance. Take the maximum reading to determine the clearance. SERVICE LIMIT: 0.10 mm Calculate cylinder taper at three levels in an X and Y-axis.
  • Page 39 Inspect the piston for wear or damage. Insert each piston ring into the cylinder and measure the ring end gap. NOTE: Push the rings into the cylinder with the top of the piston to be sure they are squarely set in the cylinder. SERVICE LIMITS: TOP 0.5 mm SECOND 0.5 mm Measure the piston pin O.D.
  • Page 40 Calculate the piston-to-piston pin clearance. SERVICE LIMIT: 0.02 mm Measure the connecting rod small end I.D. SERVICE LIMIT: 15.06 mm PISTON INSTALLTION PISTON RING INSTALLATION Clean the piston ring grooves thoroughly and install the piston rings with the marks facing up. NOTE: Don’t interchange the top and second rings.

  • Page 41: Cylinder Installation

    PISTON INSTALLATION Install the piston with it’s “IN“ mark on the intake valve side. Install the piston pin with new pin clips. Do not align the piston pin clip end gap with the piston cutout. NOTE: Do not allow the clip to fall into the crankcase.
  • Page 42 Coat the cylinder bore and piston rings with engine oil and install the cylinder. NOTE: Avoid piston rings damage cylinder bore during installation. Do not allow the cam chain fall into the crankcase. Install the cylinder head.
  • Page 43 CHAPTER 4 FUEL AND LUBRICATION SYSTEM CONTENTS FUEL SWITCH CARBURETOR...
  • Page 44 FUEL SWITCH When the engine has started, a negative pressure (vacuum) is generated at the intake port. The negative pressure acts upon the diaphragm of the fuel switch and it pressed down the spring which supports the diaphragm so that the fuel passageway is opened and fuel is fed to the carburetor. When the engine has stopped, the spring presses the valve, the fuel passageway is closed, and no fuel flows to the engine.
  • Page 45 CARBURETOR CARBURETOR Carburetor manufacturer/type Identification code Corundum or QJ Main jet size PD24J Idle needle jet size #158 #37,5 Idle air adjusting screw extrude 1 ± turnout Float height 17±1mm...
  • Page 46 CARBURETION Proper carburetion is determined according to the results of various tests, mainly concerning engine poer, fuel consumption and cooling effect of feul on engine, and jet settings ard made so as to satisfy and balance all of these conditions. Therefore, the jet should not be replaced with a size other than the original. 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.
  • Page 47 CHAPTER 5 ELECTRICAL SYSTEM CONTENS IGNITION SYSTEM CHARGING AND LIGHTING SYSTEM STARTER SYSTEM FUEL GAUGE OIL LEVEL CHECK LIGHT AND TURN SIGNAL INDICATOR SWITCHS BATTERY...
  • Page 48 IGNITION SYSTEM CDI&Ignition coil unit MAGNETO Spark plug The ignition system consists of a flywheel magneto, a CDI&Ignition coil unit and a spark plug. As the rotor tatates, an AC current is induced in the coil. Then current induced in the ○, A direction charges up the capacitor.
  • Page 49 ● Note the spark in the spark gap window. It should be strong and continuous, not intermittent, acrossa preset 8mm(0.32in) gap. Allow the spark to jump the test gap for at least five minutes continuously. To insure proper operation under the temperature of actual riding.
  • Page 50 CHARGING AND LIGHTING SYSTEM The charging system uses the flywheel magnetoas shown in the figure. The charging and lighting coils are mounted on the magneto stator and generate AC as the flywheel rotor turns. AC generated in the charging coil flows to the regulator/recifier which changes AC to DC.
  • Page 51 NO-LOAD PERFORMANCE Disconnect the magneto lead wire coupler. Start the engine and keep it running at 5000r/min. Using a pocket tester, measure the AC voltage between the white and red tracer lead wire and ground. If the tester reading is as follows, magneto is in good condition. Standard no-load performance: more than 65v(AC)AT 5000R/MIN.
  • Page 52 STARTER SYSTEM DESCRIPTION The starter system is shown in the diagram below: namely, the starter motor, relay, starter switch and battery. depressing the starter button while squeezing the front or rear brake lever energizes the relay, causing the contact points to close which connects the starter motor to the battery. Starter motor removal and disassembly Remove the starter motor Disassemble the starter motor as shown in the illustration...
  • Page 53 STARTER MOTOR INSPECITION CARBON BRUSHES When the brushes are worn, the motor will be unable to produce sufficient torque, and the engine will be difficult to turn over. To prevent the , periodically inspect the length of the brushes and replace them when they are too short or chipping.
  • Page 54 FUEL LEVEL METER/GAUGE FUEL METER INSPECTION To test the Fuel Meter two different checks may be used. The first,and simplest test will tell if the mete is operating but will not indicate the meters accuracy throughout the range.To perform the test,lift the seat and remove the right frame cover,then disconnect the B/W and Y/B lead connector of the fuel gauge sending unit.Connect a jumper wire between B/M and Y/B wiers coming from the main wiring harness.With the ignition switch tuined ON,the fuel meter should indicate“F”.
  • Page 55 SIGNAL SYSTEM The same bulb is used tor both oil level check light and turn signal indicator light.The circuitry is shown below.When the oil level has fallen to a certain level (the remaining amount of oil has become approximately 160 ml,the oil level check light turns on and remains lit.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.

  • Page 56: Main Switch

    SWITCH MAIN SWITCH LIGHT CONTROL SWITCH DARK GREEN BLACK RED / WHITE YELLOW YELLOW PINK GREEN / RED YELLOW / RED HEAD LIGHT PASSING LIGHT LOCK EXCHANGE LIGHT SWITCH BREAK SWITCH RED/SWITCH PURPLE YELLOW / RED BULE AZURY HIGH BEAM DIPPED HEADLIGHT HORN SWITCH...
  • Page 57 BATTERY SPECIFICATIONS Type designation YB4L-B Capacity 12V 4Ah Standard electrolyte 1.28(20 ) INITIAL CHARGING FILLNG ELECTROLYTE Remove the aluminum tape sealing the battery electrolyte filler holes. Remove the caps . NOTE： * After filling the electrolyte completely,use the removed cap as the sealed caps of battery-filler holes.
  • Page 58 RECHARGING OPERATION Apply multimeter to measure the voltage of battery. If the reading is below 12.0V，it should be charged. NOTE: When recharging, remove the battery form the vehicle. NOTE: When recharging, don’t remove the sealing cap off battery top. Recharging time：0.4A or for 5 hours or 4.0A for 1 hour. NOTE: The current should be not more than 4A at any time.
  • Page 59 CHAPTER 6 CHASSIS CONTENTS LEG SHIELD AND FRAME SIDE COVERS LEG SHIELD REMOVAL LEG SHIELD REMOUNTING FARME SIDE COVER REMOVAL FARME SIDE COVER REMOUNTING HANDLEBAR COVERS REMOVAL REMORNTING FRONT WHEEL REMORAL INSPECTION AND DISASSEMBLY REASSEMBLY AND REMOUNTING FRONT BRAKE BRAKE PAD REPLACEMENT CALIPER REMOVAL AND DISASSEMBLY CALIPER AND DISC INSPECTION CALIPER REASSEMBLY...
  • Page 60 Side cover removal 1. remove seat and helmet barrel by opening seat and loosing tightening screw . 2. loose hexad screw and remove decorating cap , rear carrier and oil tank lock ，remove side cover by loosing side cover screw ；...
  • Page 61 under cover removal 1. unscrew screw and bolt 2. removing under cover by loosing the left and right tapping screws ； ② ② ① ① ② ② ① ② under cover installation 3. The sequence if installation is ther reverse of removal. ①...
  • Page 62 LEGSHIELD AND PEDAL REMOVAL 1. Remove power lock housing by unscrewing bolt . ② ① 3. remove legshield pedal unscrewing the four bolts Legshield and pedal installation 4. the sequence of legshield and pedal is the reverse of reomval；...
  • Page 63 ①② HANDLE COVER REMOVAL 1． Remove front handle cover by unscrewing the six tapping screws ①① ①① Remove master cylinder by removing the bolt ; ①① ①③...
  • Page 64 3． Disconnect throttle cable and oil pump cable ①③ ①④ 4．Remove rear brake cable adjusting nut ①⑤...
  • Page 65 Handle cover removal 5. remove all cables； 6．Remove handle cover by unscrewing bolt ⑥ Handle cover unstallation 7. The sequence of removal is the reverse of reomval...
  • Page 66 Front wheel front rim middle bushing oil seal roller bearing GB6201-2RS tire valve mouth nut GB6817 front shaft front wheel left bushing gearcase valve mouth cap ① remove Remove the front brake caliper by removing the mounting ② bolts. NOTE：Do not operate the front brake lever while dismounting caliper ③...
  • Page 67 INSPECTION AND DISASSEMBLY WHEEL BEARING Inspect the play of bearing inner ring by hand while mounted in the wheel. Rotate the inner ring by hand to inspect if any abnormal noise occurs or rotating smoothly, Replace the bearing if there is anything ucusual. ·Remove the dust seal.
  • Page 68 Reassembly and remounting Reassemble and remount this front wheel in the reverse order of removal, and also carry out the following steps: install this wheel bearing with the special tools as shown in this illustration. CAUTION: Install this wheel bearing for left side.. Install the brake disc as shown in photo.
  • Page 69 FRONT BRAKE SYSTEM 1. disc brake assy. 2. disc brake handle lever 3. tightening bolt 4. nut M6 5. master cylinder 6. tightening seat 7. bolt M6X23 8. brake hose assy. 9. brake caliper 10. connecting board tightening bolt 11. hose mounting bolt 12.
  • Page 70 ·Remove the brake pads. CAUTION: Replace the brake pads as a set,otherwise braking performance will be adversely affected. Reassemble and remount the calliper. CALIPER REMOVAL AND DISASSEMBLY Remove the brake hose and catch the brake fluid in a suitable receptacle. CAUTION: Nevere re-use the brake fluid left over from the last servicing and stored for long periods.
  • Page 71 CALIPER AND DISC INSPECTION Inspect the calipe cylinder bore wall or micks,scratches or other damage. Inspect piston for damage and wear. Inspect each rubber part for damage and wear. Check the disc for wear with a micrometer.Its thickness can be checked with disc and wheel in place.
  • Page 72 BRAKE CALIPER REASSEMBLY Reassemble and remount the calliper in the reverse order of removal and disassembly, and also carry out the following steps. CAUTION: Wash the calliper components with fresh brake fluid before reassembly. Never use cleaning solvent or gasoline to wash them.Apply brake fluid to the calliper bore and piston to be inserted into the bore.
  • Page 73 Remove the brake lever and brake switch. Remove the dust boot. Remove the circlip with the special tool. Remove the piston/primary cup with return spring. Remove the reservoir cap and diaphragn. Drain brake fluid. MASTER CYLINDER INSPECTION Inspect the master cylinder bore for any scratches or other damage.
  • Page 74 Inspect the piston surface for scratches or other damage. Inspect the primary cup and dust boot for wear or damage. MASTER CYLINDER REASSEMBLY AND ERMOUNTING Reassemble and remount the master cylinder in the reverse order of removal and disassembly,and also carry out the following steps. CAUTION: Wash the master cylinder components with fresh brake fluis before reassembly.
  • Page 75 STEERING STEM AND FRONT SUSPENSION 1. handle jointing assy. 2. bolt GB5789 M10X1.25X45 3. nut GB6187 M10X1.25 4. left handlebar 5. throttle grip assy. 6. screw GB818 M5X10 7. rear brake cable assy. 8. throttle cable assy. 9. left switch comp. 10.
  • Page 76 □ remove disc brake system by unscrewing tightening bolt. □ remove handle by removing tightening bolt □ unscrew locknut with special tool □ remove fornt fork assy. by removing upper outer steel bowl NOTE: Not drop the steering stem balls. □...
  • Page 77 INSPECTION □ inspect the removed parts for the following abnormalities. bearing race wear and brinelling. Worn and damaged steel balls Distortion of steering stem or handlebar. □ Inspect the suspension for damage...
  • Page 78 Reassembly and remounting reassemble and remount the steering stem, handlebar and front fork in reverse order of disassembly andremoval, and also carry out the following steps. Install the right left suspension arms. Steel ball Apply grease when installing the upper and lower steel balls. QTY：upper ：21 lower ：21 Tighten the steering outer race with special tool, then extrude it...
  • Page 79 install handlebar and tighten the screw and bolt to the specified torque：37-44N.M NOTE: 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 procuder is accomplished correctly. If play is noticeable, raadjust the steering outer race nut.
  • Page 80 REAR WHEEL AND BRAKE 1. Tire 130/70-12 2. rear rim assy. 3. brake pad kit assy. 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.
  • Page 81 REMOVE □ Place the scooter on level ground. □ Remove muffler. □ Remove rear small fender. □ Remove locknut and rear wheel. □ Remove brake shoes. INSPECTION REAR RIM Measure inner diameter of rear rim hub with micrometer, if measured diameter exceeds 110.7, 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.
  • Page 82 REASSEMBLY AND REMOUNTING Reassemble and remount the rear wheel and brake in the reverse of removal, and also carry out the following steps: □ Turn the punched mark on the camshaft to the rear axle shaft side. □ Install the protrusion of indicator plate to the groove Camshaft.
  • Page 83 SERVICING INFORAMTION CONTENTS Troubleshooting Battery Vehicle Wiring diagram Wire, cable and brake hose routing Special tools Thread parts tightening torque Service data...
  • Page 84 TROUBLESHOOTING ENGINE Complaint Symptom and possible causes Remedy Engine does not Compression too low start, or is hard Excessively worn cylinder or piston rings. Replace. to start. Stiff piston ring in place. Repair or replace. Gas leaks from the joint in crankcase, cylinder or Repair or replace.
  • Page 85 Complaint Symptom and possible causes Remedy Excessively worn cylinder or piston rings. Replace. Engine runs Stiff piston ring in place. Replace. poorly high-speed Spark plug gaps to narrow. Adjust. range. Ignition not advanced sufficiently due to poorly working CDI & Replace.
  • Page 86 CARBURETOR Complaint Symptom and possible causes Remedy Trouble with Starter jet is clogged. Clean. starting. Air leaking from a joint between starter body and carburetor. Check starter body carburetor for tightness, and replace gasket. Air leaking from carburetor′s joint or vacuum hose joint. Check and replace.
  • Page 87 ELECTRICAL Complaint Symptom and possible causes Remedy No sparking or Defective CDI & ignition coil unit. Replace. poor sparking. Defective spark plug. Replace. Defective magneto stator coil. Replace. Loose connection of lead wire. Connect/tighten. Spark plug Adjust carburetor. 1． Mixture too rich. soon becomes Adjust carburetor.
  • Page 88 BATTERY Symptom and possible causes Remedy Complaint Battery runs The charging method is not correct. Check the magneto and regulator/rectifier down quickly. Cell plates have lost much of their circuit connections, make necessary active material as a result of adjustments obtain specified charging...
  • Page 89 CHASSIS Complaint Symptom and possible causes Remedy Handling feels Steering stem nut overtightened. Adjust. too heavy. Broken bearing/race steering Replace. stem. Replace. Distorted steering stem. Adjust. Not enough pressure in tires. Loss of balance between right and Replace. Wobbly handle. left front suspension.
  • Page 90 BRAKES Complaint Symptom and possible causes Remedy Insufficient Leakage of brake fluid from hydraulic Repair or replace. brake power. system. Replace. Worn pad. Clean disc and pads. Oil adhesion on engaging surface of Replace. pad. Bleed air. Worn disc. Replace. Air entered into hydraulic system.
  • Page 91 WIRE, CABLE AND BRAKE HOSE ROUTING...
  • Page 92 carburetor...
  • Page 94 Starting relay Ignition coil HORN POWER SWITCHH...
  • Page 95 SPECIAL TOOLS LISTED BELOW FOR REMOVAL AND REINSTALLATION DESCRIPTION TOOL NUMBER “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 lockbolt remover clutch clamp...
  • Page 97 TIGHTENTING TORQUE O F SCREW THREAD PARTS ENGINE ITEM N．M Cylinder guide cover tapping screw Fan guide cover lock bolt 10-12 Cylinder cover locknut 15-18 Spark plug 15-18 Inlet pipe lock bolt 10-12 Cooling fan impeller lock screw 10-12 Flywheel lock bolt 45-50 Magneto stator coil lock screw 10-12...

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