Motoped PRO Assembly Manual
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Motoped PRO Assembly Manual

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Copyright 2015 Cyclepedia Press LLC

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Summary of Contents for Motoped PRO

  • Page 1 Copyright 2015 Cyclepedia Press LLC...

  • Page 2: Table Of Contents

    Motoped Pro Assembly Manual Motoped Pro Assembly Manual Table Of Contents Welcome Welcome ..........2 Component List ..........4 Brakes ........... 25 Crankset ..........44 Fork Installation ..........77 Frame Assembly ..........86 Fuel Tank ..........98 Handlebar ..........104 Headset Installation .........

  • Page 3: Component List

    Motoped Pro Assembly Manual Motoped Pro Assembly Manual While the instructions, photographs and illustrations in this manual have been reviewed Component List for accuracy it is up to the individual performing the procedures to use good judgement when performing any procedures described. Every precaution has been taken in the...
  • Page 4 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Side covers and hardware Rear fender and hardware Seat Handlebar 5 / 222 6 / 222 Copyright 2015 Cyclepedia Press LLC...
  • Page 5 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Extra grips Remove the wheels from the wheel box. Fuel tank, mounts, and petcock Front wheel Wheels and Tires 7 / 222 8 / 222 Copyright 2015 Cyclepedia Press LLC...
  • Page 6 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Rear wheel Inner tubes Tires Rim strips Headset Kit and Chain/Sprocket Kit Box 9 / 222 10 / 222 Copyright 2015 Cyclepedia Press LLC...
  • Page 7 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Handlebar stem, star nut components, headset (steering bearings) components, chain roller/tensioner and hardware Open the headset kit and chain/sprocket kit box. Chains and sprockets 11 / 222 12 / 222 Copyright 2015 Cyclepedia Press LLC...
  • Page 8 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Stem spacer Open the brake kit box. Brake Kit Box Brake discs 13 / 222 14 / 222 Copyright 2015 Cyclepedia Press LLC...
  • Page 9 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Front and rear hydraulic brake assemblies and mounting hardware Bottom bracket, side plates, chain roller/tensioner, and hardware Bottom Bracket Box Muffler Box Open the muffler box. 15 / 222 16 / 222...
  • Page 10 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Muffler and hardware Open the suspension box. Sub-frame and hardware Suspension Box 17 / 222 18 / 222 Copyright 2015 Cyclepedia Press LLC...
  • Page 11 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Note the owner's manuals and documentation inside the suspension box. Front fork and axle 19 / 222 20 / 222 Copyright 2015 Cyclepedia Press LLC...
  • Page 12 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Rear shock absorber Throttle cable, throttle, and grips Crankset Pedals Swingarm 21 / 222 22 / 222 Copyright 2015 Cyclepedia Press LLC...
  • Page 13 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Rear axle tensioners Swingarm and jackshaft. 23 / 222 24 / 222 Copyright 2015 Cyclepedia Press LLC...

  • Page 14: Brakes

    Motoped Pro Assembly Manual Motoped Pro Assembly Manual Make sure the disc direction of rotation is correct. Brakes SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Discs Install the brake disc mounting bolts (pre-applied thread locking agent).
  • Page 15 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Brake Hose Routing Remove the brake pad separator plate. Do not squeeze the brake lever when the separator plate or disc isn't between the pads. Install the front brake master cylinder to the left side of the handlebar, and the rear brake master cylinder to the right side of the handlebar.
  • Page 16 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Fit the front brake caliper and mounting bracket into place. Guide the disc between the brake pads. Route the brake hose up through its guides on the left fork leg. Install the bracket mounting bolts with the pre-applied thread locking agent. Tighten the caliper mounting bracket bolts to specification with a 5 mm hex socket.
  • Page 17 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Tighten the hose clamp securely with a 3 mm hex wrench to secure the hose. Insert the master cylinder clamp bolts. Fit the master cylinder into place on the handlebar. Tighten the clamp bolts evenly so the gap is equal on both sides of the clamp. Tighten the...
  • Page 18 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Loosen the caliper mounting bolts with a 5 mm hex socket. Squeeze the brake lever and Fit the rear brake caliper bracket into place. align the caliper with the brake disc. While holding the brake lever, gently wiggle the caliper to position it in its natural centered position over the disc.
  • Page 19 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Install the caliper spacers. Fit the rear brake caliper into place. Guide the disc between the brake pads. Remove the brake pad separator plate. Do not squeeze the brake lever when the separator Install the caliper mounting bolts and washers.
  • Page 20 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Loosen the caliper bracket mounting bolts and adjust the caliper front-to-rear position so that the brake pad linings make good contact with the disc. Make sure the disc isn't Loosen the caliper mounting bolts with a 5 mm hex socket. Squeeze the brake lever and contacting the caliper body.
  • Page 21 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Install the rear brake master cylinder in the same manner as the front brake master Route the brake hose up to the handlebar as shown, and secure it with the wire bands.
  • Page 22 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Caliper Alignment Tool Insert the feeler gauges between the disc and pad linings. The caliper alignment tool can be used to aid in caliper alignment and prevent brake pads from dragging on the disc.

  • Page 23: Crankset

    Motoped Pro Assembly Manual Motoped Pro Assembly Manual Torque (N-m) Torque (ft-lbs.) Crankset 12.43 9.17 SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Burnishing Disc brakes require a special burnish period to achieve maximum braking power. This burnish period last for about 30-40 stops. During this period some noise may occur.
  • Page 24 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Install the drive chain roller/tensioner bracket mounting bolts. Install the collars on each side of the bearings. Tighten the drive chain roller/tensioner bracket bolts to specification with a 5 mm hex Install the drive chain roller/tensioner onto its bracket.
  • Page 25 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Fit the crank arm onto the bottom bracket spindle. Temporarily tighten the nut and bolt to secure the drive chain roller/tensioner with a 13 mm socket and 6 mm hex wrench. The standalone crank arm goes on the left side, and the crank arm with the chain ring goes on the right.
  • Page 26 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Install the spindle bolt and tighten it to specification with an 8 mm hex socket. Install the spindle bolt. Torque (N-m) Torque (ft-lbs.) Tighten the spindle bolt to specification with an 8 mm hex socket.
  • Page 27 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Thread the freewheel onto its boss on the jack shaft and tighten it by hand. Inspect the chain ring to freewheel sprocket alignment. Use the freewheel wrench tool to remove the freewheel from its boss if necessary.
  • Page 28 Motoped Pro Assembly Manual Motoped Pro Assembly Manual The bottom bracket can move side to side in its clamps. Make sure the crank arms will not contact the engine or kick starter. Also, make sure the chain ring isn't contacted when the Loosen the jack shaft cap bolt with a 5 mm hex socket.
  • Page 29 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Remove the freewheel and boss from the jack shaft. Return the freewheel and boss to the jack shaft. Change the spacer with a thicker or thinner piece to adjust the position of the freewheel Install the jack shaft cap and cap bolt with a 5 mm hex socket.
  • Page 30 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Tighten the freewheel boss set screw securely with a 3 mm hex wrench. Install the bicycle chain roller/tensioner bracket mounting bolts and tighten them to specification with a 4 mm hex socket.
  • Page 31 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Use a pair of slip joint pliers to push the open end of the master link clip towards the chain Remove the side plate. link pin at the closed end of the clip.
  • Page 32 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Join the bicycle chain ends on the freewheel sprocket. Install the side plate from the outside. Install the master link from the inside. Position the closed end of the clip so that it points in the direction of chain rotation.
  • Page 33 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Install the master clip and pop it in position by using slip joint pliers to push the closed end Install the bicycle chain roller/tensioner bolt and washer. of the clip against the pin next to it.
  • Page 34 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Install the bicycle chain roller/tensioner washer. Adjust the amount or thickness of the Use a pair of 5 mm hex wrenches to move the roller/tensioner into place and tighten. washers as necessary for proper fitment of the roller to the chain.
  • Page 35 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Fit the roller/tensioner into place against the chain tighten it securely. The left pedal has reverse threads. Install the left pedal into the left crank arm. Torque (N-m) Torque (ft-lbs.) Tighten the pedals securely with a pedal wrench.
  • Page 36 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Locate the master link on the final drive chain. Remove the master link clip. Use a pair of slip joint pliers to push the open end of the master link clip towards the chain Remove the side plate.
  • Page 37 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Free the chain ends from the master link. Install the master link from the inside. Route the final drive chain around it's drive sprocket on the jack shaft and fit the ends of Install the side plate.
  • Page 38 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Position the closed end of the clip so that it points in the direction of chain rotation. Make sure the clip is fully seated. Install the master clip and pop it in position by using slip joint pliers to push the closed end The final drive chain should have around an inch or 25 mm of free play.
  • Page 39 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Tighten the axle tensioner nuts to reduce the chain free play. Turn the adjuster nuts evenly on both sides of the wheel. Loosen the rear axle nuts with an 18 mm socket.

  • Page 40: Fork Installation

    Motoped Pro Assembly Manual Motoped Pro Assembly Manual Fork Installation SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Install the headset, cut the steerer tube to the proper length, and install the star nut. See the Headset Installation topic for more information.
  • Page 41 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Install the centering sleeve onto the steerer tube and into the upper bearings. Slide on the upper fork crown. Install the upper bearing cap. Install the spacer/s and stem onto the steerer tube. The top of the steerer tube should sit about 3 mm below the stem.
  • Page 42 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Install the cap, bolt, and washer. Thread the cap bolt into the star nut. Tighten the cap bolt Install the bump stop. to take any slack out of the headset assembly. All vertical play in the steerer tube stack should be eliminated.
  • Page 43 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Torque (N-m) Torque (ft-lbs.) Position the bump stops so they will contact the frame before the fork leg. Loosen the stem clamp bolts with a 5 mm hex socket and align the stem. Tighten the stem clamp bolts to specification with a 5 mm hex socket.

  • Page 44: Frame Assembly

    Motoped Pro Assembly Manual Motoped Pro Assembly Manual Frame Assembly SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Move the steering back and forth and check for any vertical play. Loosen the stem and upper fork crown to steerer tube clamps and tighten the cap nut to remove any play if needed.
  • Page 45 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Sub-Frame Tighten the sub-frame mounting bolts to specification with a 5 mm hex head socket. Torque (N-m) Torque (ft-lbs.) Fit the sub frame into place. 13.6 Side Plates Install the four M6 x 25 mm hex head bolts.
  • Page 46 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Fit the side plates into place. Install both side plates as shown. Install the two M10 x 25 mm bolts with each side plate. Bottom Bracket Tighten the side plate bolts to specification with an 8 mm hex socket.
  • Page 47 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Snug the bolts down with a 5 mm hex socket. Remove the swingarm pivot holders. Torque (N-m) Torque (ft-lbs.) 30.9 Swingarm Fit the swingarm into place and install the pivot holders. Remove the swingarm pivot bolts with 6 mm hex socket.
  • Page 48 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Shock Absorber Make sure the swingarm pivot bearings are centered in their mounts on the frame. Remove the upper shock absorber mounting nut, bolt and washers from the frame. Note the position of the washers.
  • Page 49 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Remove the lower shock absorber mounting bolt, nut, and washers. Note the position of Install the upper and lower shock absorber mounting bolts, nuts and washers. the washers. Fit the shock absorber into place.

  • Page 50: Fuel Tank

    Motoped Pro Assembly Manual Motoped Pro Assembly Manual Fuel Tank SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Install the engine and carburetor prior to the the fuel tank and seat. See the Engine chapter for more information.
  • Page 51 Motoped Pro Assembly Manual Motoped Pro Assembly Manual and one for the rear of the fuel tank. Place the O-ring on the petcock. Install the metal collars into the grommets. Install the petcock into the fuel tank so the fuel valve faces out.
  • Page 52 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Install the petcock mounting bolts. Fit the fuel tank onto the frame. Tighten the petcock mounting bolts securely with a #3 Phillips screwdriver. Install the fuel tank mounting bolts with washers. 101 / 222...

  • Page 53: Handlebar

    Motoped Pro Assembly Manual Motoped Pro Assembly Manual Handlebar SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Install the fork and stem. See the Fork Installation topic for more information. Tighten the fuel tank mounting bolts securely with a 6 mm hex wrench.
  • Page 54 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Position the handlebar as desired. Tighten the face plate bolt in a crisscross pattern in one turn increments. Tighten the face place bolt to specification with a 5 mm hex socket. Torque (N-m) Torque (ft-lbs.)

  • Page 55: Headset Installation

    Motoped Pro Assembly Manual Motoped Pro Assembly Manual Lift off the upper fork crown. Headset Installation SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Crown Race Remove the bump stops. Loosen the upper fork crown pinch bolts with a 5 mm hex socket.
  • Page 56 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Remove the lower fork crown and steerer tube from the fork tubes. The fork crown race must be pressed to the lower fork crown. Set the crown race on the steerer tube.
  • Page 57 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Use the 1.5 inch installer insert. Use hammer and strike top of tool until race fully seats. The sound will change as it seats. Place tool and insert over the fork steerer.
  • Page 58 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Make sure to install the cups into their correct position. The upper and lower cups are Lower Cup different. Use the HH-2 Bearing Cup Press tool to install the bearing cup. Upper Cup Adjust threaded press plate of HHP-2 until top is flush with end of hex shaft thread.
  • Page 59 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Guides are used to maintain cup alignment while pressing. Before using cup guide, insert Engage sliding press plate onto hex shaft, and push plate upward until headset cup meets guide into cup.
  • Page 60 Motoped Pro Assembly Manual Motoped Pro Assembly Manual top of threads. Re-engage sliding plate to a higher notch, and continue to press cups. NOTE: Never use a extender bar to extend leverage of handles. If cups will not press using handles, other problems are present and should be addressed.
  • Page 61 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Install the lower bearing onto the crown race. Install the upper bearing. Guide the steerer tube and bearing into the head set. Continue supporting the lower fork Install the centering sleeve onto the steerer tube and into the upper bearings.
  • Page 62 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Install the upper bearing cap. Pull up on the steerer tube to take any slack out of the bearing stacks and temporarily tighten the upper fork crown steerer tube clamp bolt to secure the steering components in the frame.
  • Page 63 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Install the stem and temporarily tighten the bolts with a 5 mm hex socket. When the cut steerer tube is installed it should sit just about 3 mm below the top of the stem or below any spacers placed on top of the stem.
  • Page 64 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Place the steerer tube in the saw guide SG-7.2 to cut the steerer tube. This tool holds the Cut through tube applying pressure only in a forward direction, and do not apply excessive fork square to the saw blade.
  • Page 65 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Use the TNS-4 threadless nut setter tool to install the star nut. Place the TNS-4 over the top of the steerer tube. Hold the TNS-4 straight and in line with the steering column.

  • Page 66: Seat

    Motoped Pro Assembly Manual Motoped Pro Assembly Manual Seat SAFETY FIRST: Protective gloves and eyewear are recommended at this point. The star nut should now be secure in the steerer tube. Fit the rear fender onto the back of the seat.
  • Page 67 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Tighten the screws securely with a #2 Phillips screwdriver. Line up the side cover mounts with the holes on the seat. Fit the side covers onto the front of the seat. Install the side cover mounting screws.
  • Page 68 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Tighten the side cover mounting screws securely with a #2 Phillips screwdriver. Guide the tabs at the front of the seat under the brackets on the sub frame. Fit the seat assembly into position.
  • Page 69 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Install the upper side cover bolts and grommets. Install the side cover nuts and bolts. Tighten the fasteners securely with a 10 mm wrench and socket. Torque (N-m) Torque (ft-lbs.) Tighten the upper side cover bolts securely with a #2 Phillips.

  • Page 70: Wheels And Tires

    Motoped Pro Assembly Manual Motoped Pro Assembly Manual Torque (N-m) Torque (ft-lbs.) Wheels and Tires SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Wheel Inspection and Truing Inspect the wheels and spokes. True the wheels as necessary.
  • Page 71 Motoped Pro Assembly Manual Motoped Pro Assembly Manual If the right side is out you will need to loosen several spokes on the right side where the wobble is and spin the wheel to see if this helped. If so tighten the spokes evenly and recheck.
  • Page 72 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Apply soapy water to the tire bead to aid in installation. Fit the tube inside the tire. Insert the valve stem through its hole. Fit one bead of the tire onto the rim.
  • Page 73 Motoped Pro Assembly Manual Motoped Pro Assembly Manual reapply soapy water to the bead. Work tire bead onto rim with hands. If tire bead will not seat using hand, use tire lever as a last resort. Use caution when using tire levers to avoid pinching inner tube. When using the tire lever, try to feel where the tube is before inserting the tire lever, this will Set the tire pressure to specification and install the valve cap.
  • Page 74 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Loosen the axle pinch bolts with a 5 mm hex socket. Apply a light coat of water-proof grease to the axle. Remove the front axle bolts cap bolts with an 8 mm hex socket.
  • Page 75 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Guide brake disc into the brake caliper so the disc fits between the brake pads. Tap the axle into place with a rubber mallet if needed. Insert the axle. Install the axle cap bolts.
  • Page 76 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Torque (N-m) Torque (ft-lbs.) 2 - 2.5 1.5 - 1.8 Rear Wheel See the Brakes topic for information on installing the brake disc and hydraulic brake system. Tighten the axle cap bolts to specification with an 8 mm hex socket.
  • Page 77 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Insert the bolts. Loosen the rear axle nuts with an 18 mm socket. Remove the axle nuts and washers from the rear axle. Tighten the rear sprocket bolts to specification with a 5 mm hex socket.

  • Page 78: Carburetor

    Motoped Pro Assembly Manual Motoped Pro Assembly Manual Carburetor SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Guide the rear wheel into the swingarm. Apply a medium strength, non-permanent thread locking agent to the threads of all bolts.
  • Page 79 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Tighten the throttle clamp screws securely with a #2 Phillips screwdriver. Fit the end of the throttle cable into the throttle tube. Fit the throttle cable and housing into place as shown.
  • Page 80 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Install the throttle cable cover. Route the throttle cable down the left side of the frame. Install the two throttle cable cover screws and tighten them with a #2 Phillips screwdriver. Move the rubber cover into place as shown.
  • Page 81 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Fit the intake manifold and gasket into place. Make sure the O-ring is in place on the carburetor opening. Install the intake manifold mounting bolts and tighten them with an 8 mm socket.
  • Page 82 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Install the carburetor mounting bolts and tighten them with an 8 mm socket. Install the seal into the carburetor cap. Torque (N-m) Torque (ft-lbs.) Install the spring. Fit the throttle cable into the carburetor cap.
  • Page 83 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Allow the spring to extend into the throttle valve. Pull back the spring and slip the throttle cable into the throttle valve. Install the throttle valve, needle and carburetor cap. There is a pin in the carburetor body that must line up with the full length slot in the throttle valve.
  • Page 84 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Tighten the air filter clamp securely. Install the breather hose onto the air filter (stock air filter). Install the air filter onto the mouth of the carburetor. Note: If using a foam filter, make sure to oil it according to the filter manufacture's instructions.
  • Page 85 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Connect the float bowl drain hose to the float bowl and secure the hose with a clamp. Loosen the locknut with a 10 mm wrench and turn the adjuster to set the throttle cable free play if necessary.

  • Page 86: Engine Components

    Motoped Pro Assembly Manual Motoped Pro Assembly Manual Engine Components Ignition Coil Open the engine box and remove the components. Engine Kill Switch Ignition Box 169 / 222 170 / 222 Copyright 2015 Cyclepedia Press LLC...
  • Page 87 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Wiring Harness Wire Bands Ignition Switch Intake Manifold 171 / 222 172 / 222 Copyright 2015 Cyclepedia Press LLC...
  • Page 88 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Intake Insulator Plate Exhaust Gasket Carburetor Shift Pedal 173 / 222 174 / 222 Copyright 2015 Cyclepedia Press LLC...
  • Page 89 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Kick Start Pedal Engine Air Filter 175 / 222 176 / 222 Copyright 2015 Cyclepedia Press LLC...

  • Page 90: Engine Installation

    Motoped Pro Assembly Manual Motoped Pro Assembly Manual Engine Installation SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Fit the engine into place and align the lower engine mount. Apply a medium strength, non-permanent thread locking agent to the threads of all bolts.
  • Page 91 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Raise the engine up and line up the upper engine mount. Install the washers and nuts onto the engine mounting bolts. Install the upper engine mounting bolt and washer. Hold the mounting bolts to keep them from turning.
  • Page 92 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Tighten the engine mounting nuts to specification. Remove the magneto cover. Torque (N-m) Torque (ft-lbs.) Inspect the engine drive sprocket to jack shaft driven sprocket alignment with a straight edge. The sprockets should be aligned so the engine drive chain has a straight run.
  • Page 93 Motoped Pro Assembly Manual Motoped Pro Assembly Manual The engine sprocket may need to be moved closer to the engine for correct drive chain Rotate the fixing plate to line up its teeth with the grooves on the countershaft. alignment.
  • Page 94 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Remove the engine sprocket. Install the washers between the fixing plate and the sprocket and insert the bolts. Make sure the fixing plate is secure in its groove. Use washers between the sprocket and fixing plate to adjust the position of the sprocket.
  • Page 95 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Install the side plate from the outside. Install the engine drive chain around the engine sprocket and have the ends meet on the driven sprocket on the jack shaft. Position the closed end of the clip so that it points in the direction of chain rotation. Install the master clip and pop it in position by using slip joint pliers to push the closed end of the Install the master link from the inside.
  • Page 96 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Make sure the clip is fully seated. Install the magneto cover. Adjust the roller/tensioner into place against the chain and tighten the nut and bolt with a Tighten the magneto cover bolts to specification with an 8 mm socket.
  • Page 97 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Remove the gear shifter bolt with a 10 mm socket. Tighten the bolt securely with a 10 mm socket. Slide on the shift pedal. Remove the kick pedal bolt with a 10 mm wrench.
  • Page 98 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Tighten the bolt securely with a 10 mm wrench. Fit the kick start pedal onto the kick start shaft. Inspect the engine oil level before staring the engine the first time. Position the vehicle upright on a level surface.

  • Page 99: Exhaust System

    Motoped Pro Assembly Manual Motoped Pro Assembly Manual Exhaust System SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Remove the dipstick and clean the measuring surface. Insert the dip stick without threading it in. Remove the dipstick and inspect the oil level. The oil level should be in the indicated range.
  • Page 100 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Fit the exhaust pipe into place. Fit the muffler into place and connect it to the exhaust pipe. Install the exhaust pipe joint nuts. Wait to tighten the nuts until the muffler is installed.
  • Page 101 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Torque (N-m) Torque (ft-lbs.) Install the muffler mounting bolts and tighten them to specification with a 5 mm hex socket. Torque (N-m) Torque (ft-lbs.) Tighten the exhaust pipe nuts to specification. 199 / 222...

  • Page 102: Ignition System

    Motoped Pro Assembly Manual Motoped Pro Assembly Manual Ignition System SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Install wire harness ground to the frame and tighten the bolt securely with a 5 mm hex socket. Torque (N-m) Torque (ft-lbs.)
  • Page 103 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Fit the stud on the ignition coil bracket through the frame. Fit the spark plug cap onto the spark plug. Install the ignition coil nut and tighten it to specification. Fit the ignition box into place.
  • Page 104 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Secure the ignition box with a wire band and plug in the wire harness connectors. Plug in the magneto connector. Plug in the ignition coil connector. Plug in the kill switch connector.
  • Page 105 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Plug in the key switch connector. Secure the wires and throttle cable with wire bands. 207 / 222 208 / 222 Copyright 2015 Cyclepedia Press LLC...
  • Page 106 Motoped Pro Assembly Manual Motoped Pro Assembly Manual Route the kill switch wires up the left side of the frame. Tighten the kill switch clamp screws securely with a #2 Phillips screwdriver. Install the kill switch on the left side of the handlebar.

  • Page 107: Special Tools

    Motoped Pro Assembly Manual Motoped Pro Assembly Manual Special Tools Standard Metric Tools Metric Socket Set Metric Allen Sockets or Wrenches Torx Socket Set or Wrenches Bicycle Tools The RT-2 Head Cup Remover makes headset cup removal easy. The tool is pulled through the frame until the flared ends snap in behind the cup.
  • Page 108 Motoped Pro Assembly Manual Motoped Pro Assembly Manual The TNS-4 makes it quick and easy to install star-fangled nuts used with 1” and 1-1/8” threadless headset systems. Using a durable steel driver and built-in guide, the TNS-4 perfectly aligns the star-fangled nut and sets it to the proper depth every time. The unique design virtually eliminates pinched fingers.
  • Page 109 Motoped Pro Assembly Manual Motoped Pro Assembly Manual CCP-22 Crank Puller for Square Taper Cranks SG-7.2 Oversized Saw Guide The CCP-22 uses a long comfortable handle and extra fine thread that provides the needed leverage to remove even the tightest cranks.
  • Page 110 Motoped Pro Assembly Manual Motoped Pro Assembly Manual hammer, tap firmly on the end cap of the tube and seat the race into its proper place safely and accurately. The CRS-15 will work on forks with column length of 330 mm or less.
  • Page 111 Motoped Pro Assembly Manual Motoped Pro Assembly Manual independently provides flexibility to fit around most potential interferences with fork top caps or crown protrusions. Bicycle Tire Lever Set Universal design works with 1”, 1-1/8”, 1-1/4” and 1.5 forks (suspension or rigid) and crown races with outside diameters up to 64mm Accepts steering columns from 14 to 43cm (5.5 to 17 inches) in length...

  • Page 112: Torque Specifications

    Motoped Pro Assembly Manual Motoped Pro Assembly Manual Used to remove the freewheel Torque Specifications Basic Torque for General Fasteners Thread dia. (mm) Torque ft-lb 3.4 - 4.9 2.5 - 3.5 5.9 - 7.8 4.4 - 5.7 14 - 19 10.0 - 13.5...

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