TGB CH1 Owner's Manual
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TGB CH1 Owner's Manual

50 cc
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CH1/CR1 50 ㏄
OWNER-MANUAl
MAINTENANCE HANDBOOK
TAIWAN GOLDEN BEE CO.,LTD.

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  • Page 1 CH1/CR1 50 ㏄ OWNER-MANUAl MAINTENANCE HANDBOOK TAIWAN GOLDEN BEE CO.,LTD.

  • Page 2: Table Of Contents

    CONTENTS CONTENTS GENERAL INFORMATION/TROUBLE DIAGNOSIS ........1 MAINTENANCE INFORMATION ..............2 LUBRICATION SYSTEM................3 FUEL SYSTEM .....................4 ENGINE REMOVAL..................5 CYLINDER HEAD/VALVE................6 CYLINDER/PISTON..................7 "V" TYPE BELT DRIVING SYSTEM/KICK STARTER ARM .......8 FINAL DRIVING MECHANISM..............9 A.C. GENERATOR/STARTING CLUTCH ............10 CRANKCASE/CRANKSHAFT ..............11 SPECIAL TOOL....................12...

  • Page 3: General Information/Trouble Diagnosis

    1. GENERAL INFORMATION/TROUBLE DIAGNOSIS SPECIFICATIONS......1-1 TROUBLES DIAGNOSIS ....1-4 TORQUE VALUES (ENGINE) ..1-2 SPECIFICATIONS MAKER MODEL CH1/CR1 Primary Overall Length 1780mm BELT Reduction Secondary Overall Width 695mm GEAR Reduction Overall Height 1075/1170mm Clutch One-way Wheel Base 1285mm Transmission C.V.T. Exhaust Pipe Position...
  • Page 4 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS TORQUE VALUES (ENGINE) THREAD DIA TORQUE ITEM Q'TY REMARKS (mm) VALUE(Kg-m) Cylinder head cover bolts 0.8~1.2 Cylinder head nuts 1.0~1.4 Apply oil thread Cylinder/cylinder head 0.7~1.1 Tighten to crankcase two-ends bolts Cylinder head left bolts 0.8~1.2 Valve adjustment fixing nuts 0.7~1.1 Apply oil to thread...
  • Page 5 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS The torque values listed in above table are for more important tighten torque values. Please see standard values for not listed in the table. Standard Torque Values for Reference TYPE TIGHTEN TORQUE TYPE TIGHTEN TORQUE 0.45~0.60kgf-m 0.05~0.08kgf-m 5mm bolt、nut 3mm screw...
  • Page 6 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS TROUBLES DIAGNOSIS A. Engine hard to start or can not be started Check and adjustment Fault condition Probable causes 1. No fuel in fuel tank Loosen carburetor drain 2. Check if the pipes, fuel tank to bolt to check if there is carburetor and intake vacuum, gasoline inside the...
  • Page 7 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS B. Engine run sluggish (Speed does not pick up, lack of power) Check and adjustment Probable causes Fault condition Try gradual acceleration and check engine speed 1. Air cleaner clogged 2. Poor fuel supply Engine speed can be Engine speed can not be 3.
  • Page 8 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS C. Engine runs sluggish (especially in low speed and idling) Check and adjustment Fault condition Probable causes Check ignition timing (using ignition lamp) Abnormal Normal 1. Incorrect ignition timing (malfunction of CDI or AC alternator) Adjust the air screw of carburetor 1.
  • Page 9 1. GENERAL INFORMATION/TROUBLE DIAGNOSIS E. CLUTCH, DRIVING AND DRIVING PULLEY FAULT CONDITIONS PROBABLE CAUSES 1. Driving belt worn out or deformation 2. Driving disk damaged Engine can be started but 3. Driving pulley spring broken motorcycle can not be moved. 4.

  • Page 10: Maintenance Information

    2. MAINTENANCE INFORMATION PRECAUTIONS IN OPERATION ..2-1 CARBURETOR IDLING SPEED ADJUSTMENT ..2-2 IGNITION SYSTEM/SPARK PLUG .. 2-6 PERIODICAL MAINTENANCE SCHEDULE LUBRICATION SYSTEM ....2-3 . 2-7 CYLINDER COMPRESSION PRESSURE VALVE CLEARANCE ADJUSTMENT 2-4 DRIVING SYSTEM......2-7 PRECAUTIONS IN OPERATION Specification capacity 850 c.c.
  • Page 11 Code: I ~ InspecT or replace if necessary A ~ adjustment R ~ Replacement C ~ Cleaning (replaced if necessary) L ~ Lubrication Have your motorcycle checked, adjusted, and recorded maintenance data periodically by your TGB Authorized Dealer to maintain the motorcycle at the optimum condition The above maintenance schedule is established by taking the monthly 1000 kilometers as a reference which ever comes first.
  • Page 12 2. MAINTENANCE INFORMATION LUBRICATION SYSTEM Engine Oil Capacity Caution The vehicle must be parked on a level ground when checking oil capacity. Run the engine for 2-3 minutes then stop, wait about 2-3 more minutes allowing engine oil to settle before checking the oil level.
  • Page 13 2. MAINTENANCE INFORMATION Gear oil refilling bolt Gear Oil Inspection Check gear oil if leaking. Park the motorcycle with main stand on flat level place. Turn off engine and remove the gear oil draining plug. Place a measurement cup under the draining hole.
  • Page 14 2. MAINTENANCE INFORMATION Check & adjust valve clearance with feeler Feeler gauge gauge. Valve clearance (IN/EX): 0.06±0.02 mm Loosen fixing nut and turn the adjustment nut for adjustment. Caution It has to make sure that valve-rocker arm is be adjusted to standard level when adjusting it, and re-check the valve clearance after tightened the fixing nut.
  • Page 15 2. MAINTENANCE INFORMATION IGNITION SYSTEM F mark Ignition timing Caution C.D.I ignition system is set by manufacturer so it can not be adjusted. Ignition timing check procedure is for Ignition light checking whether C.D.I. function is in normal or not. Remove right side cover.
  • Page 16 2. MAINTENANCE INFORMATION CYLINDER COPMRESSION PRESSURE Warn up engine and then turnoff the engine. Open the seat. Remove the luggage box. Remove spark plug cap and spark plug. Install compression gauge. Full open the throttle valve, and rotate the engine by means of stepping the kick-starting lever.

  • Page 17: Lubrication System

    3. LUBRICATION SYSTEM MECHANISM DIAGRAM ....3-1 CLEANING ENGINE OIL STRAINER... 3-3 OPERATIONAL PRECAUTIONS ..3-2 OIL PUMP ..........3-4 TROUBLE DIAGNOSIS......3-2 GEAR OIL ..........3-7 ENGINE OIL ........3-3 MECHANISM DIAGRAM Valve rocker Forcedly lubrication Camshaft Scoop lubrication Inner passage Connecting rod Forcedly lubrication Crankshaft...
  • Page 18 3. LUBRICATION SYSTEM OPERATIONAL PRECAUTIONS General Information This chapter contains maintenance operations for the engine oil pump, engine oil and gear oil. Oil viscosity Specifications Engine oil quantity Disassembly 850 c.c. Replacement 750 c.c. Oil viscosity SAE 10W-30 or equivalent (Recommended King-Mate serial oils) Gear Oil...
  • Page 19 3. LUBRICATION SYSTEM ENGINE OIL Turn off engine, and park the motorcycle in flat ground with main stand. Check oil level with oil dipstick after 3-5 minutes. Do not rotate the dipstick into engine as checking. If oil level is nearly low level, fill out recommended oil to upper level.
  • Page 20 3. LUBRICATION SYSTEM OIL PUMP Oil Pump Removal Remove the alternator (refer to chapter10). Remove the engine right crankcase cover. Make sure that the pump axle can be rotated freely. Remove the oil pump driving gear nut. pump driving gear nut 3 bolts Remove oil pump body bolts (3 bolts).
  • Page 21 3. LUBRICATION SYSTEM Oil Pump Inspection Check the clearance between oil pump body and outer rotor. Limit: below 0.12 mm Check clearance between inner and outer rotors. Limit: below 0.12 mm Check clearance between rotor side face and pump body. Limit: below 2.0 mm Oil Pump Re-assembly Install inner and outer rotors into the pump...
  • Page 22 3. LUBRICATION SYSTEM 2 O-rings Oil Pump Installation Install the 2 O-rings. Install the oil pump pin. 3 bolts Install the oil pump. Install the oil pump body bolts (3 bolts). Install the oil pump driving gear nut. Install the alternator (refer to chapter10). Install the engine right crankcase cover.
  • Page 23 3. LUBRICATION SYSTEM Filling bolt GEAR OIL Oil Level Inspection Park the motorcycle on flat ground with main stand. Turn off engine and remove both engine oil filling bolt and oil draining bolt. Draining bolt Remove gear oil filling hole bolt and place a measurement cup under the draining plug.
  • Page 24 4. CARBURETOR/ AIR CLEANER PRECAUTIONS IN OPERATION ..4-1 AUTO BY-STARTER ......4-6 TROUBLE DIAGNOSIS......4-2 FLOAT CHAMBER ......4-7 CARBURETOR REMOVAL ....4-3 INSTALLATION OF CARBURETOR .. 4-8 VACUUM CHAMBER ......4-3 IDLE SPEED ADJUSTMENT ..... 4-8 AIR CUT-OFF VALVE ......4-5 AIR CLEANER........

  • Page 25: Fuel System

    4. CARBURETOR/ AIR CLEANER TROUBLE DIAGNOSIS Power insufficiency and fuel consuming Poor engine start Fuel system clogged No fuel in fuel tank Malfunction of ignition system Clogged fuel tube Too much fuel in cylinder No spark from spark plug (malfunction of ignition system) Clogged air cleaner Malfunction of automatic by-starter...
  • Page 26 4. CARBURETOR/ AIR CLEANER throttle valve cable vacuum Carburetor Removal hose Open the seat. Remove the luggage box. Loosen the adjustment nut and fixing nut of throttle valve cable, and release the cable from carburetor. Remove fuel pipe, vacuum hose. Disconnect auto by-starter connectors.
  • Page 27 4. CARBURETOR/ AIR CLEANER Remove fuel needle seat, spring, and fuel needle injector needle. seat Check if the vacuum piston for wear out, fuel needle crack or other damage. spring Check if the diaphragm for damage or crack. injector Cautions needle Do not damage vacuum diaphragm.
  • Page 28 4. CARBURETOR/ AIR CLEANER AIR CUT-OFF VALVE Removal Remove the vacuum hose clamp and then the vacuum hose. Screws ×2 Remove the screws (screw x 2) of the air cut-off valve and its cover. screws vacuum diaphragm Remove the spring and vacuum diaphragm. Check if the vacuum diaphragm for deterioration or crack.
  • Page 29 4. CARBURETOR/ AIR CLEANER AUTO BY-STARTER Inspection Turn off engine and waiting for over 10 minutes for cooling. Check resistance across the two terminals of the auto by-starter Resistance value: Max. 10Ω (Measured after engine stopped for more than 10 minutes) Replace the auto by-starter with a new one if resistance value exceeds standard.
  • Page 30 4. CARBURETOR/ AIR CLEANER FLOAT CHAMBER float Disassembly float pin Remove 4 mounting screws and then the float chamber cover. Remove the float pin and float valve. screws× 4 Checking Check float needle valve and valve seat for float pin drop difference damage, wear out, dirty or clogged.
  • Page 31 4. CARBURETOR/ AIR CLEANER Installation Install main jet, fuel needle jet seat, fuel needle jet, slow speed jet and fuel amount adjustment screw. Cautions Set the adjustment screw in according to number of turns noted before it was removed. fuel amount adjustment screw Install the float valve, float, and float pin.
  • Page 32 4. CARBURETOR/ AIR CLEANER AIR CLEANER Removal Open the seat and remove the luggage box . Loosen the clamp strip of air cleaner. Remove evaporative return hose. Remove body side cover. Remove the air cleaner body bolts (2 bolts). Remove the air cleaner. air filter strap Installation Install the air cleaner in the reverse order of...

  • Page 33: Engine Removal

    5. ENGINE REMOVAL OPERATIONAL PRECAUTIONS ..5-1 INSTALLATION OF ENGINE ....5-4 ENGINE REMOVAL ......5-2 OPERATIONAL PRECAUTIONS General Information Engine must be supported by a bracket or adjustable tool in height. The following parts can be serviced with the engine installed on the frame. 1.
  • Page 34 5. ENGINE REMOVAL ENGINE REMOVAL pulse generator Generator connector connector Remove the power connector of auto by- start. Remove the generator wire and pulse generator connector. Auto by-start connector Remove the spark plug. Spark plug Remove the fuel pipe, vacuum hose, and Throttle valve cable Spark plug throttle valve cable from the carburetor.
  • Page 35 5. ENGINE REMOVAL Remove the rear wheel (Nut × 1). Nut ×1 Remove the air cleaner connection bolts (2 bolts). Bolts×2 RR. Brake cable RR. Brake cable nut Remove the rear brake cable nut. Remove the rear brake cable. Remove the rear shock absorber lower bolt. Rear shock absorber lower bolt...
  • Page 36 5. ENGINE REMOVAL Loose the strap screw of engine left guide. Strap screw of guide Remove the engine suspension nut and bolt , and then remove the engine. Caution With a bracket to support the engine to prevent from it damage by falling down as removing the engine.
  • Page 37 5. ENGINE REMOVAL RR. Brake cable RR. Brake cable nut Caution Notice both feet and hands safety for squeezing as engine installation. Do not bent or squeeze each wires or hose. Route all cables and wires in accordance with the routine layout. Engine suspension nut: Torque Value: 4.5~5.5kgf-m Engine suspension nut...

  • Page 38: Cylinder Head/Valve

    6. CYLINDER HEAD/VALVE MECHANISM DIAGRAM ....6-1 CYLINDER HEAD INSPECTION..6-8 PRECAUTIONS IN OPERATION ..6-2 6-10 VALVE SEAT INSPECTION AND SERVICE TROUBLE SHOOTING.......6-3 CYLINDER HEAD REASSEMBLY ..6-12 CAMSHAFT REMOVAL .....6-4 CYLINDER HEAD INSTALLATION ..6-13 CYLINDER HEAD REMOVAL ....6-6 CAMSHAFT INSTALLATION ....6-13 CYLINDER HEAD DISASSEMBLY ..6-7 VALVE CLEARANCE ADJUSTMENT ..
  • Page 39 6. CYLINDER HEAD/VALVE PRECAUTIONS IN OPERATION General Information This chapter is contained maintenance and service for cylinder head, valve, and camshaft as well as valve rocker arm. Cylinder head service cannot be carried out when engine is in frame. Specification unit: mm Item Standard...
  • Page 40 6. CYLINDER HEAD/VALVE TROUBLE SHOOTING Engine performance will be effected by troubles on engine top end. The troubles usually can be determinate or by performing cylinder compression test and judging the abnormal noise generated. Rough Idle Low compression pressure. Low compression pressure 1.
  • Page 41 6. CYLINDER HEAD/VALVE CAMSHAFT REMOVAL Blow-by hose Remove the shroud of the engine. Remove the crankcase blow-by system hose from the cylinder head. Remove the cylinder head bolts and then the cylinder head (4 bolts). A.I. 4 bolts Loosen the bolt of camshaft chain adjuster bolt and remove O-ring.
  • Page 42 6. CYLINDER HEAD/VALVE Remove the camshaft holder and rocker arm set. Remove the camshaft chain from the camshaft sprocket. Remove the camshaft. Camshaft Inspection Inspect cam lobe height for damaged. Camshaft Service Limit bearing IN: Replacement when less than 25.29 mm EX: Replacement when less than 25.12 mm Inspect the camshaft bearing for looseness or wear out.
  • Page 43 6. CYLINDER HEAD/VALVE Measure the valve rocker arm I.D. Service Limit: Replace when it is above 10.100 mm Measure the active O.D. of the valve rocker arm shaft and valve rocker arm. Service Limit: Replace when it is above 9.910 mm Calculate the clearance between the rocker arm shaft and the rocker arm.
  • Page 44 6. CYLINDER HEAD/VALVE dowel pins Remove the 2 cylinder head mounting bolts from cylinder head left side cover. Remove cylinder head gasket and 2 dowel pins. Remove chain plate. Clean up residues from the matching surfaces of cylinder and cylinder head. Caution Do not damage the matching surfaces of cylinder and cylinder head.
  • Page 45 6. CYLINDER HEAD/VALVE CYLINDER HEAD INSPECTION Check if spark plug and valve holes are crack. Measure cylinder head flat with a straightedge and flat feeler gauge. Service limit: 0.5mm Valve spring free length Measure the free length of intake and exhaust valve springs.
  • Page 46 6. CYLINDER HEAD/VALVE EX→ 0.10mm...
  • Page 47 6. CYLINDER HEAD/VALVE Caution If clearance between valve stem and valve guide exceeded service limit, check whether the new clearance that only replaces new valve guide is within service limit or not. If so, replace valve guide. Correct it with reamer after replacement. If clearance still exceeds service limit after replaced valve guide, replace valve stem too.
  • Page 48 6. CYLINDER HEAD/VALVE VALVE SEAT INSPECTION AND SERVICE Clean up all carbon deposits onto intake and exhaust valves. Apply with emery slightly onto valve contact face. Grind valve seat with a rubber hose or other manual grinding tool. Caution Do not let emery enter into between valve stem and valve guide.
  • Page 49 6. CYLINDER HEAD/VALVE Use 60° cutter to cut a quarter lower part out. Remove the cutter and check new valve seat. Old valve seat width 60° Use 45° cutter to grind the valve seat to specified width. 1.0mm Caution Make sure that all roughness and uneven faces had been grinded.
  • Page 50 6. CYLINDER HEAD/VALVE After the valve seat grinded, coat valve seat surface with emery and then slightly press the grinded surface. Clean up all emery coated onto cylinder and valve after grinded. Valve cotters Valve stem CYLINDER HEAD REASSEMBLY oil seal Lubricate valve stem with engine oil, and Valve spring then insert the valve into valve guide.
  • Page 51 6. CYLINDER HEAD/VALVE CYLINDER HEAD INSTALLATION Cylinder head gasket Lock pins Install the lock pins and new cylinder head gasket onto the cylinder head. Install the camshaft chain plate. Chain plate Install the cylinder head. CAMSHAFT INSTALLATION Assemble the camshaft holder. 5mm blot Install the exhaust valve rocker arm set onto the camshaft holder showing “EX”...
  • Page 52 6. CYLINDER HEAD/VALVE Install the lock pins. Install the camshaft holder, gasket and nut onto the cylinder head. Tighten the cylinder head nuts. (4 nuts) At first, tighten the 4 nuts on the cylinder top and then tighten the 2 bolts on the left side of cylinder head.

  • Page 53: Cylinder/Piston

    7. CYLINDER/PISTON MECHANISM DIAGRAM ....7-1 PISTON REMOVAL......7-5 PRECAUTIONS IN OPERATION ..7-2 PISTON RING INSTALLATION..7-7 TROUBLE DIAGNOSIS......7-2 PISTON INSTALLATION....7-8 CYLINDER REMOVAL .......7-3 CYLINDER INSTALLATION....7-8 MECHANISM DIAGRAM 0.8~1.2kgf-m...
  • Page 54 7. CYLINDER/PISTON PRECAUTIONS IN OPERATION General Information Both cylinder and piston service cannot be carried out when engine mounted on frame. Specification unit: mm Item Standard Limit 39.00 － Bend/wrap age 0.050 Cylinder Roundness 0.005 0.050 Cylindrical 0.005 0.030 Top ring 0.025~0.060 0.090 Clearance between...
  • Page 55 7. CYLINDER/PISTON CYLINDER REMOVAL 2 bolts Cylinder Remove cylinder head. (refer to chapter 6) Remove 2 bolts and then take out the cam chain auto-adjuster. Cam chain Cam chain guide auto-adjuster Remove cam chain plate. Remove cylinder. Remove cylinder gasket and lock pins Clean the residues attached onto the matching surfaces of cylinder and crankcase.
  • Page 56 7. CYLINDER/PISTON Cover the holes of crankcase and cam chain with a piece of cleaning cloth. Clean up all residues or foreign materials from the two matching surfaces of cylinder and crankcase. Caution To soap the residues into solvent so that the residues can be removed more easily.
  • Page 57 7. CYLINDER/PISTON PISTON REMOVAL Plug crankcase opening with a cleaning cloth to prevent from piston pin snap ring or other parts falling into crankcase when disassembling. Hold another snap ring with pliers. Push out the piston pin from the side that not removed the snap ring.
  • Page 58 7. CYLINDER/PISTON Measure the outer diameter of piston pin. Service Limit: 12.994mm Measure the inner diameter of connecting rod small end. Service Limit: 13.020mm Measure the inner diameter of piston pin hole. Service Limit: 13.040mm Calculate clearance between piston pin and its hole.
  • Page 59 7. CYLINDER/PISTON PISTON RING INSTALLATION Clean up piston top, ring groove, and piston shirt. Install the piston ring onto piston carefully. Place the openings of piston ring as diagram shown. Caution Do not damage piston and piston rings as installation. All marks on the piston rings must be forwarded to up side.
  • Page 60 7. CYLINDER/PISTON PISTON INSTALLATION Install piston and piston pin, and place the IN IN mark mark on the piston top side forward to intake valve. Install new piston pin snap ring. Piston pin Caution Do not let the opening of piston pin snap ring align with the opening piston ring.
  • Page 61 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM MAINTENANCE DESCRIPTION ..8-1 DRIVING BELT........8-3 TROUBLE DIAGNOSIS......8-1 SLIDING PULLEY ......8-5 LEFT CRANKCASE COVER ....8-2 CLUTCH/DRIVEN PULLEY....8-8 KICK STARTER ARM......8-2 MAINTENANCE DESCRIPTION PRECAUTIONS IN OPERATION GENERAL INFORMATION ‧ Driving pulley, clutch, and driven pulley can be serviced on the motorcycle. ‧...

  • Page 62: V" Type Belt Driving System/Kick Starter Arm

    8. V-BELT DRIVING SYSTEM/KICK STARTER ARM air cleaner lock nut LEFT CRANKCASE COVER Left crankcase cover removal Remove air cleaner. (2 bolts) Remove kick starter arm. (1 bolt) Loosen vent strap on the front-left side of cover, and then remove the vent. Remove engine left-side cover (8 bolts).
  • Page 63 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM DRIVING BELT sliding pulley Removal Remove left crankcase cover. Hold the sliding pulley with a universal fixture, and then remove the nut and sliding pulley. Universal fixer Hold driving pulley with universal fixture, and driving pulley remove nut and clutch outer.
  • Page 64 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM Installation Pull out the driving pulley and then insert the driving pulley. Sliding driven Caution pulley Pull out driving pulley and then insert the driving belt into the driving pulley so that the driving belt set can be installed onto sliding pulley more easily.
  • Page 65 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM SLIDING PULLEY Starter gear driving pulley REMOVAL Remove left crankcase cover. Hold driving pulley with universal fixture, and then remove driving pulley nut. Remove driving pulley. Remove the driving belt from the pulley. Sliding pulley Remove sliding pulley set and driving pulley hub from crankshaft.
  • Page 66 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM Inspection The operation of sliding pulley is means of Weight roller the weight roller to pressing on it with centrifuge force. And then the speed is changed by the title plate rotation. Thus, if weight rollers are wear out or damage, the centrifuge force will be effected.
  • Page 67 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM Apply with grease 4~5 g to inside of driving shaft hole, and install driving pulley hub. Caution The pulley surface has to be free of grease. Clean it with cleaning solvent. Pulley surface Install siding pulley assembly onto crankshaft. Sliding pulley Crankshaft Pulley hub...
  • Page 68 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM CLUTCH/DRIVEN PULLEY Special nut wrench DISASSEMBLY Remove driving belt and clutch/driven pulley. Install clutch spring compressor onto the pulley assembly, and operate the compressor to let nut be installed more easily. Caution Do not press the compressor too much. Clutch spring compressor Hold the clutch spring compressor onto bench vise, and then remove mounting nut...
  • Page 69 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM Clutch lining Clutch lining Measure each clutch lining thickness. Replace it if exceeds service limit. Service limit: 2.0mm Clutch Driven pulley spring Measure the length of driven pulley spring. Replace it if exceeds service limit. Service limit: 93.2mm Free length Driven pulley...
  • Page 70 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM Clutch Block Replacement Driving plate Remove snap and washer, and the remove Spring clutch block and spring from driving plate. Check if spring is damage or insufficient elasticity. Snap ring Clutch block Shock absorption rubber Check if shock absorption rubber is damage or deformation.
  • Page 71 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM Install snap ring and mounting plate onto setting pin. Snap ring REPLACEMENT OF DRIVEN PULLEY BEARING Oil seal Remove inner bearing. Outer bearing Caution If the inner bearing equipped with oil seal on one side in the driven pulley, then remove the oil seal firstly.
  • Page 72 8. V-BELT DRIVING SYSTEM/KICK STARTER ARM INSTALLATION OF CLUTCH/DRIVEN Oil seal PULLEY ASSEMBLY Install new oil seal and O-ring onto sliding pulley. Apply with specified grease to lubricate the inside of sliding pulley. Specified grease O-ring Guide pin Sliding pulley Oil seal Install sliding pulley onto driven pulley.

  • Page 73: Final Driving Mechanism

    9. FINAL DRIVING MECHANISM OPERATIONAL PRECAUTIONS ..9-1 INSPECTION OF FINAL DRIVING MECHANISM TROUBLE DIAGNOSIS......9-1 BEARING REPLACEMENT ....9-3 ..9-2 ..9-5 DISASSEMBLY OF FINAL DRIVING MECHANISM RE-ASSEMBLY OF FINAL DRIVING MECHANISM OPERATIONAL PRECAUTIONS Specification Torque value Application gear oil: 4-stroke lubricant Gear box cover 2.0~2.4 kgf-m Recommended oil: KING MATE serial gear...
  • Page 74 9. FINAL DRIVING MECHANISM DISASSEMBLY OF FINAL DRIVING 7 bolts MECHANISM Remove the rear wheel. (refer to chapter 15) Remove the clutch. Drain gear oil out from gear box. Remove gear box cover bolts (7bolts) and then remove the gear box cover and the final driving shaft.
  • Page 75 9. FINAL DRIVING MECHANISM Check bearings on the gear box cover. bearing Rotate each bearing’s inner ring with fingers. Check if bearings can be turned in smooth and silent, and also check if bearing outer ring is mounted on gear box & cover tightly. If bearing rotation is uneven, noising, or loose bearing mounted, then replace it.
  • Page 76 9. FINAL DRIVING MECHANISM Driving shaft Press out the driving shaft from the crankcase. Remove oil seal from the crankcase. Remove the driving shaft bearing from the gear box cover with the inner type bearing puller. Caution Using the bearing protector as pressing out the driving shaft from the gear box cover.
  • Page 77 9. FINAL DRIVING MECHANISM RE-ASSEMBLY OF FINAL DRIVING final driving shaft countershaft MECHANISM Install final driving shaft and final driving gear, countershaft, and countershaft gear. final shaft gear Install the setting pins(2 pins) and new gasket. dowel pins Apply with grease onto the oil seal lip of final driving shaft.

  • Page 78: Generator/Starting Clutch

    10. A.C. GENERATOR/STARTING CLUTCH PRECAUTIONS IN OPERATION ..10-1 ..10-4 RIGHT CRANKCASE COVER INSTALLATION A.C.GENERATOR REMOVAL ...10-2 ..10-4 MOUNTED COIL SET INSTALLATION . 10-3 FLY WHEEL INSTALLATION..... 10-4 RIGHT CRANKCASE COVER REMOVAL PRECAUTIONS IN OPERATION General information Refer to chapter 5: Engine removal and installation Refer to chapter 1: The troubleshooting and inspection of A.C.
  • Page 79 10. A.C. GENERATOR/STARTING CLUTCH A.C. GENERATOR REMOVAL Flywheel Pulse generator Cooling fan Cooling fan shroud Coil Drain out the engine oil. Cooling fan shroud Remove the exhaust muffler. (2 bolts, 2 nuts) Remove the fan shroud. Exhaust muffler Remove the fan. (4 bolts) Cooling fan Hold the flywheel with the universal fixture.
  • Page 80 10. A.C. GENERATOR/STARTING CLUTCH Remove the flywheel with the flywheel puller. Special service tools: Flywheel puller Shaft protector Caution Install a shaft protector on the right end of crankshaft to avoid damaging the crankshaft before installing the flywheel puller. Flywheel puller generator connector Remove the connectors of the A.C.
  • Page 81 10. A.C. GENERATOR/STARTING CLUTCH RIGHT CRANKCASE COVER INSTALLATION Install setting pin and new gasket on the crankcase. Replace the right crankshaft oil seal of the crankcase and apply some oil onto the oil seal lip. Install right crankcase cover onto the right crankcase.
  • Page 82 10. A.C. GENERATOR/STARTING CLUTCH Install the cooling fan. (4 bolts) Cooling fan Install the cooling fan shroud. (4 bolts) Cooling fan shroud Install the exhaust muffler. (2 bolts, 2 nuts) Add some engine oil according the specified quantity. Exhaust muffler 10-5...

  • Page 83: Crankcase/Crankshaft

    11. CRANKCASE/CRANKSHAFT ... 11-1 ..11-4 OPERATIONAL PRECAUTIONS CRANKSHAFT INSPECTION ....11-1 ..11-5 TROUBLE DIAGNOSIS ASSEMBLY OF CRANKCASE . 11-2 DISASSEMBLY OF CRANKCASE OPERATIONAL PRECAUTIONS General Information This Section contains descriptions concerning disassembly of the crankcase so that the crankshaft can be serviced.
  • Page 84 11. CRANKCASE/CRANKSHAFT DISASSEMBLY OF CRANKCASE 1 bolt Remove the 1 bolt from the right crankcase. Remove the cam chain tensioner (hex socket 1 hex socket bolt bolt) from the left side of crankcase. Place the left side of crankcase upward, and then install the crankcase remover/set onto the crankcase.
  • Page 85 11. CRANKCASE/CRANKSHAFT Remove the crankshaft from the right crankcase. Caution The left and right bearings of crankshaft is to press-fit onto the crankshaft. Remove gasket and dowel pins (2). Scrape gasket residues off the crankcase contact surface. Caution Do not damage contact surface of the crankcase.
  • Page 86 11. CRANKCASE/CRANKSHAFT CRANKSHAFT INSPECTION Measure left and right clearance of connecting rod big end. Service limit: Replace when it is more than 0.55 mm Measure the radical clearance of the big end at the vertical directions. Service limit : 0.05 mm Place the crankshaft onto a V-block and measure run-out of the crankshaft with dial gauge.
  • Page 87 11. CRANKCASE/CRANKSHAFT ASSEMBLY OF CRANKCASE Install cam chain into the chain hole of the left crankcase, and then split out the cam chain. Caution Do not damage the cam chain as installing the crankshaft. Install crankshaft into the left crankcase and then install two dowel pins and new crankcase gasket.
  • Page 88 11. CRANKCASE/CRANKSHAFT Apply with some grease onto the oil seal lip and then install it onto the left crankcase. Press-fit the oil seal to specified position with the oil seal installer. Special service tools: the oil seal installer 11-6...

  • Page 89: Special Tool

    12. SPECIAL TOOL ITEM:L/R CRANK DISASSEMBLE TOOL ITEM:CLUTCH NUT WEENCH NO:TGB-9020200 PURPOSE:CRANKSHAFT DISASSEMBLE PURPOSE:LOOSE THE CLUTCH NUT ITEM:UNIVERSAL HOLDER ITEM:CLUTCH SPRING COMPRESSOR NO:440646 NO:TGB-2301000 PURPOSE:HOLDER THE MDF/CLUTCH PURPOSE:DISASSEMBLE THE CLUTCH OUTER ITEM:TAPPET ADJUSTING WRENCH ITEM:ACG FLYWHEEL PULLER NO:TGB-2210100 PURPOSE:ADJUST VALVE CLEARANCE...
  • Page 90 12. SPECIAL TOOL ITEM:OIL SEAL DRIVER ITEM:OIL SEAL DRIVER PURPOSE:OIL SEAL INSTALLATION PURPOSE:OIL SEAL INSTALLATION ITEM:GY6 STARTER GEAR PULLER ITEM:CRANK PULLER NO:TGB-2822100-GY6 NO:TGB-1130000 PURPOSE:REMOVE THE STARTER GEAR PURPOSE:INSTALL CRANKCASE ITEM:OUTER BEARING PULLER NO:TGB-6204010 PURPOSE:OIL SEAL INSTALLATION 12-2...
  • Page 91 15. BRAKE SYSTEM 16-1...

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