Related Manuals for KAYO MOTOR BULL 150
Summary of Contents for KAYO MOTOR BULL 150
- Page 1 KAYO AU150 BULL 150 Maintenance Manual WWW.KAYOMOTO.US VERSION CODE：20190316 VERSION NAME：AU150 Maintenance Manual...
- Page 2 ZHEJIANG KAYO MOTOR CO. LTD March of 2019 Introduction This manual contains detailed operation for AU150 (ATV), including maintenance and adjustment processes, dis-assembly and installation notes, inspection and maintenance points, troubleshooting methods and maintenance technical data, and graphics. CONTENTS Please read the manual carefully and follow...
- Page 4 Conversion table Unit conversion Item 1kgf/cm =98.0665kPa；1kPa=1000Pa 1PSI=0.0689kgf/cm pressure 1mmHg=133.322Pa=0.133322kPa 1kgf·m=9.80665N·m Torque 1mL=1cm =1cc volume 1L=1000cm Moment 1kgf=9.80665N Length 1in=25.4mm Danger/warning/attention Please take the safety precautions below seriously. During maintenance, and especially during engine service. Danger Be on high alert for danger. Warn to be alert to moderate danger.
- Page 5 1. Maintenance information 1.1 Operation note………………………………………………………………………………1 1.2 VIN Number……………………………………………………………………………………3 1.3 Main specifications list………………………………………………………………………4 1.4 Maintenance specifications list…………………………………………………………6 1.5 Torque tightening……………………………………………………………………………9 1.6 Lubricant, sealant……………………………………………………………………………10 1.7 Cable, hose and wiring diagram………………………………………………………11 Operation notes Safety notes 1. Wear work clothes (coveralls), hat and safety boots suitable for operation. In some conditions safety glasses, dust masks, gloves and other safety protective supplies are needed to protect you from injury。...
- Page 6 5. Snap rings can be deformed if opened or closed too much during disassembly. Please do not use snap rings that have been compromised. 6. After disassembly and inspections, clean the parts and blow the cleaning agent away with compressed air before measurements. Grease the moving surfaces before assembly. 7.
- Page 7 contact surface must be removed uniformly with a whetstone or resurfaced. 21. Do not bend the cables or hoses excessively. Deformed and damaged cables can cause poor range of motion, leaks or breaks. 22 When assembling the protective cap parts, if there is a groove insert the protective cap into the groove.
- Page 8 VIN number ① VIN number ② Metal plate ③ Engine number MODEL AU150 VIN NUMBER ENGINE NUMBER...
- Page 9 Main Specifications ITEM Specification Model AU150 Length（mm） 1663 Width（mm） Height（mm） Wheelbase（mm） 1050 Engine model 156FMJ Displacement（ml） Fuel type No. 91octane or above Weight（kg） Rider No. 1 person（Only the rider, no passenger） 1 person ＋ 60kg = 120kg Max loading quality Front tire AT20×7-10 Tire spec...
- Page 10 ITEM Specification Air filter type Paper filter core Type Plunger throttle Throttle Body Mix valve diameter 30mm Fuel tank volume Clutch Automatic Speed changing way 3 gears+ reverse gear Gears Forward gears:1 2 3 Reverse gear:R Transmission Gear changing order By foot/ R N 1 2 3 Drive mode Chain driven rear axle...
- Page 11 Maintenance Specs list Lubricating device Item Standard Limits 600ml（No oil filter core replaced） － Change oil Engine oil Change oil 700ml（replace the oil filter core） capacity － Full capacity 800ml Only use SAE 15W/40-SE oil. Don’t use other brand of mixing use different Recommended engine oil brand as this will cause engine damaged and may cause accidents...
- Page 12 Battery/charging device/Trigger coil ITEM STANDARD Type Permanent-magnet alternator Three-phase full wave Output Magneto trigger coil resistance Magneto No-load voltage（engine in Magneto cold condition） Magneto maximum output power 180w Regulated voltage 14.5 ± 0.5V trigger coil peak voltage ≥1V，200r/min；≥8.5V，2000r/min Rectifier type Full wave rectification Capacity 12V 7Ah...
- Page 13 Light / Meter / Switch ITEM STANDARD Fuse Front light 12V—35W Light, bulb Tail light/brake light 12V—2.8W Valve mechanism + cylinder cover（see 05-engine section） Cylinder + piston + piston ring + crank connecting link（see 05-engine section） Clutch + Transmission mechanism （see 05-engine section）...
- Page 14 1.5 Tightening torque of fasteners Note: When installing threads, please put antirust grease on the thread and connecting surface. Tightening torque at specified position-whole vehicle （N·m） Install position Bolt specification Torque Suspension lower rocker GB5789 M10×1.25×70 45~59 arm bolt Front shock bolt GB5787 M10×1.25×40 45~59 Rear shock bolt...
- Page 15 Cross head tapping screw GB845-85 ST4.2 — — Cross head machine screw GB828-88 M5×16 — Cross head big fat machine — — screw Rim mounting nut GB6187-86 M10×1.25 45~59...
- Page 16 Tightening torque at specified position - engine（see 05-engine section） Tightening torque for fastener in non-specified position Spec Spec torque N·m Torque N·m 5mm bolt, nut 5mm bolt 4.5~6 3.5~5 6mm bolt, nut 6mm bolt 8~12 7~11 8mm bolt, nut 6mm Convex bolt 18~25 10~14 10mm bolt, nut...
- Page 17 1.7 Wiring diagram of cable, hoses and cable 1. Reverse indicator connector(older models 2017 ) 2. Digital gear indicator connector 3. Headlight connector 4. Neutral indicator connector (older models 2017 )5. Key switch connector 6.Multifunction switch Connector 7. CDI connector Note: To inspect the above parts, must remove the front rack and hood.
- Page 18 8. Brake switch (left and right) 9. Throttle cable 10. Front and Rear brake lines 1.Carburetor 2. carburetor overflow hose 3.Starter motor cable 4. Crankcase vent hose 5.Stator/ignition pickup connector 6. Gear indicator connector 7.Voltage regulator connector Note: To inspect the above parts, must remove the shift lever, and left footrest. Please refer to 02-Plastics.
- Page 19 8. Starter Relay 9. Battery negative terminal 10. Starter cable 11. Battery positive terminal 12.Voltage regulator/rectifier 1. Tail light connector 2.Tail light...
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Page 20: Table Of Contents
2 Plastics 2.1 Inspection item………………………………………………………………………15 2.2 Mounting torque…………………………………………………………………15 2.3 Dis-assembly and Assembly of seat and racks 2.3.1 Seat………………………………………………………………………16 2.3.2 Front rack……………………………………………………………………16 2.3.3 Rear rack……………………………………………………………………17 2.4 Dis-assembly and Assembly of hood, gear display front cover, gear display, foot gear rod mounting combination 2.4.1 Front number plate……………………………………………………………………17 2.4.2 Gear display front cover…………………………………………………………18 2.4.3 Gear display……….………………………………………………………18... -
Page 21: Plastics 2.1 Inspection Item
2.1 Inspection information Working notes. When replacing plastics with warning stickers, please reapply new stickers accordingly. Refer to this chapter when plastics need to be dis-assembled to inspect inner parts This chapter describes the order of dis-assembly and assembly of plastics ... -
Page 22: Dis-Assembly And Assembly Of Seat And Racks 2.3.1 Seat
Dis-assembly and assembly of seat and racks 2.3.1 Seat Dis-assembly Lift the seat latch 1 Lift up the rear of seat, and then pull it backward. 2 Remove the seat. Assembly Install in reverse order from dis-assembly Check if the seat is installed in place and firm 2.3.2 Front rack Dis-assembly... -
Page 23: Rear Rack
2.3.3 Rear rack Dis-assembly Dis-assemble mounting bolt from rear rack 1(left and right） Dis-assemble rear rack 2 Assembly Install in reverse order from dis-assembly 2.4 Front plate, gear display front cover, gear display, foot gear rod mounting combination 2.4.1 Hood Dis-assemble front rack（→... -
Page 24: Gear Display
2.4.2 Gear display front cover Dis-assembly Pull out oil breather pipe 1 Dis-assemble front cover 2 Assembly Install in reverse order from dis-assembly 2.4.3 Gear display Dis-assembly Dis-assemble meter front cover（→ 2.4.2） Back out 2 nuts 3 Dis-assemble gear display 4 Assembly Re assemble in reverse order from dis-assembly... -
Page 25: Left Footrest Plate
2.5.1 Left footrest plate Dis-assembly Dis-assemble foot gear rod（→ 2.4.4） Dis-assemble fasten screw 1 Dis-assemble fasten screw 2 Dis-assemble left footpeg from lower to upper 3 Assembly Install in reverse order from dis-assembly 2.5.2 Right footrest plate Dis-assembly Dis-assemble fasten screw 4 Dis-assemble fasten screw 5 Dis-assemble right footrest from lower to upper 6... -
Page 26: Bumper
2.6.2 Bumper Dis-assembly Dis-assemble front rack（→ 2.3.2） Dis-assemble mounting screw1 （left and right each 2） Dis-assemble bumper 2 Assembly Take it back in reverse order from dis-assembly 2.7 Dis-assembly and Assembly of fuel tank cover plate, front and rear assy. plate 2.7.1 Front assy. -
Page 27: Rear Assy. Plate
Dis-assembly Dis-assemble front plate（→ 2.4.1） Dis-assemble front assy. Mounting screw（→2.7.1） Dis-assemble foot gear rod（→ 2.4.4） Dis-assemble left footpeg plate（→ 2.5.3） Dis-assemble right footpeg plate（→ 2.5.4） Dis-assemble mounting screw 2 Dis-assemble rear assy. plate3 Assembly Re install in reverse order from dis-assembly Note: Disconnect battery and necessary wires... -
Page 28: Regular Maintenance And Adjustment Maintenance Information
3 Regular and adjustment maintenance Maintenance information…………………………………………………………………22 3.1 Maintenance circle……………………………………………………………………23 3.2 Way of maintenance……………………………………………………………………24 3.3 Steering column, brake system………………………………………………………27 3.4 Wheels…………………………………………………………………………………32 3.5 Suspension system……………………………………………………………………………34 3.6 Gear shift mechanism, fuel device………………………………………………………………35 3.7 Throttle inspection……………………………………………………………………………36 3.8 Gear display…………………………………………………………………………37 3.9 Light device……………………………………………………………………………37 Maintenance information Operation cautions Note: ... - Page 29 3.1 Maintenance Schedule Engine maintenance is a regular periodic work, according to a certain time interval for engine maintenance is very important, standard maintenance is helpful for well engine performance, reliable work, economic and durable, the following is the AU150 engine maintenance period ：...
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Page 30: Maintenance Circle
3.2 Way of maintenance Maintenance item Maintenan ce circle Standard Maintenance item Maintenance position Steering wheel Operating flexibility ○ Damage ○ Steering Installation status of steering ○ device Steering system Ball pin shaking ○ Pedal travel ○ ○ Brake pedal Braking effect ○... - Page 31 fuel should be reach the opening...
- Page 32 Maintenance item Circle Maintenance Maintenance item Standard position Loose of connecting place ○ ○ Output shaft (transmission Transmissi Shacking of Spline part ○ shaft） on device State of spark plug ○ Spark plug gap：0.6mm~0.7mm Ignition device Ignition period ○ Battery Terminal connection status ○...
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Page 33: Steering Column, Brake System
3.3 Steering column and brake system With the vehicle on a sturdy flat surface hold handlebar firmly and push up and down as it shown in the picture. Check for rattles, shaking or excessive play If there is, check steering column, bearings, and fastening parts. - Page 34 Front master cylinder fluid level Check the Check the fluid level in the sight glass 3, fluid level drops below If the the lower limit, stop using the vehicle. Check for leaks in master cylinder, brake line and all connections, if they are all normal, then check the brake caliper and pistons and replace if necessary.
- Page 35 Front brake disc and brake pads (break pad wear) Note: Brake pads should be changed as a set. Checking brake rotors Check blueing, the surface of brake disc discoloration or warping 3.0mm, replace. If its thickness ≤ Front brake disc thickness limits: no less than 3.0mm.
- Page 36 Rear brake master cylinder fluid level Check the Check the fluid level in the sight glass 3, fluid level drops below If the the lower limit, stop using the vehicle. Check for leaks in master cylinder, brake line and all connections, if they are all normal, then check the brake caliper and pistons and replace if necessary.
- Page 37 Rear brake disc and brake block〈wear of brake block〉 Check the wear condition of brake block, if condition is bad, then replace it. Note: Brake pads should be changed as a set. Checking brake rotors Check blueing, the surface of brake disc discoloration or warping 3.0mm, replace.
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Page 38: Wheels
Wheels Lift the front wheel with the tool in a horizontal position, and make sure there is no force on the wheel. Shake the front wheel left and right to check whether the connection of the front wheel is tight. If there is movement, check and fasten the rocker arm, axle, rim bolt and nut. - Page 39 Tire pressure Check the tire pressure with a barometer. Note: Check the tire pressures while the tire is cold for a more accurate reading Appointed pressure/Tire Front tire Rear tire Pressure ） ） 35kPa（0 .35kgf/cm 35kPa（0.35kgf/cm Tire size See chapter 1 See chapter 1 Wheel pattern Check tread depth if is less than 3mm, replace.
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Page 40: Suspension System
Check the loose of front wheel axle, rear wheel axle nut: 1 and pin, if there is loose, fasten it as per the appointed torque. Torque: Front wheel axle nut： 126N·mm～218N·mm （12.6kgf·mm ～ 22kgf·mm） Rear wheel axle nut：199N·mm～311N·mm （20kgf·mm ～ 31kgf·mm） Shaking of Wheel hub Use tools to hang up the front wheel, turn the wheels as per the axle direction when... -
Page 41: Gear Shift Mechanism, Fuel Device
Rear shock pre-load adjustment Use Shock spanner wrench to adjust the adjust cam of shock according to the load capacity: 1 Clockwise turning is from high to low. 3.6 Gear box and fuel system Gear box Shift lever Click through the forward gears with your heel operation should be smooth with firm clicks between each gear. -
Page 42: Throttle Inspection
Throttle Free-play : 1 Clearance：2 ~ 6 mm When the freeplay is not within the range, adjust throttle at the cable. Remove sleeve: 3 Loose throttle cable nut: 2 Adjustment, adjust the freeplay of the throttle to within spec. After adjustment, fasten lock nut: 2 and then assemble the sleeve: 3 3-5mm *Replace throttle cable if cable adjustment is... -
Page 43: Gear Display
Horn checking. 3.8 Gear display Checking the gear display The Gear indicator should power up as soon as the key is turned on. Shift through the gears to make sure the gear indicator shows the correct gear. R-N-1-2-3 **When shifting into or out of reverse come to a complete stop before changing gears 3.9 Lighting system Headlight Operation... - Page 44 Engine components …………………………………………………………………38 Maintenance information ………………………………………………………………………39 Fuel system ………………………………………………………………………39 Air intake system ………………………………………………………………………40 Exhaust system …………………………………………………………41 Disassembly and assembly of engine Maintenance information Precautions ● Before operation and maintenance, please ensure that the vehicle is shut down and cooled completely, to avoid injury. ●...
- Page 45 Fuel system Dis-assembly Dis-assemble foot gear, seat, gear display front cover, front assy. Plate(see 02: plastics) Dis-assemble mounting bolt: 1 Turn the fuel switch 3: to OFF position Dis-assemble fuel pipe: 4(connecting to carburetor position) Remove fuel tank 2 Note Gasoline is flammable;...
- Page 46 Dis-assemble fuel tank（→4.1 Dis-assembly and Assembly of fuel tank） Loose hoop 1 Dis-assemble air filter 2 Assembly In reverse order from dis-assembly Re-install all components 4.3 Exhaust system Dis-assembly Dis-assemble foot gear rod, seat, gear display front cover, front assy. Plate, rear assy.
- Page 47 Remove muffler pipe clamp bolt: 3 Remove muffler pipe mounting bolt: 2 Remove muffler pipe 4 Remove exhaust head pipe 1 Assembly Re-assemble in reverse order from dis-assembly 4.4 Dis-assembly and assembly of engine Dis-assembly Dis-assemble shift lever, seat, gear display front cover, left and right footpeg plate, rear assy.
- Page 48 Remove spark plug cap: 2 Disconnect oil cooler hoses banjo bolts: 1, reinsert bolts after lines are removed to prevent oil leaking. Disconnect gear display connect wire （→1.7） Disconnect magneto trigger connect wires （→1.7） Disconnect starter motor plug: 4 Disconnect carburetor hoses: 3 Remove engine mounting bolts: 8 remove engine from left side: 9 Assembly...
- Page 49 5 Engine 5.1 Maintenance information……………………………………………………………….……….………44 5.2 Introduction to fuel and engine oil……………………………………………………………………46 5.3 Grinding-in of engine……………………………………………………………………….……46 5.4 Maintenance of engine…………………………..………………………………………….………47 5.5 Maintenance of machine……………………………………………………………………..……69- 5.6 Dis-assembly, assembly and maintenance of carburetor....……………………….……78 5.7 Maintenance of air in-take and out-put system…………………………………………………….……81 5.8 Dis-assembly, assembly and maintenance of air out-put system……………………………….…..…82 5.9 Dis-assembly, assembly and maintenance of air adding system…………………………………….….83 5.10 Dis-assembly, assembly and maintenance of start motor……………………………………………..85...
- Page 50 Maintenance information Conversion table refers Item Unit conversion 1kgf/cm =98.0665kPa 1kPa=1000Pa Pressure 1mmHg=133.322Pa=0.133322kPa 1 kgf · m = 9 .8 0 6 6 5 N ·m Torque 1mL=1cm =1cc Volume 1L =1000cm 1kgf=9.80665N Torque 维 Danger/warning/attention Take below definitions seriously, which are very important for maintenance Danger Be on high alert for danger.
- Page 51 Warning: · If parts need to be replaced during maintenance, please choose parts which recommended or provided by Kayo. · Disassembled parts that need to be reused should be arranged in order, to aid in assembly. · Use special tools as specified in the maintenance manual. ·...
- Page 52 Fuel: Use octane 91# or higher unleaded gasoline Engine oil：Use sae15w-40 oil for 4 stroke motorcycle, quality grade according to the classification of the API SG level or by the superior, if no SAE15W - 40 oil, according to the engine using the environment temperature, as the picture on the right is shown.
- Page 53 5.4 Maintenance of engine Details maintain times Odometer reading 1000km 4000km 8000km 12000km Items Fuel system Clean Clean Clean Clean Oil filter Clean Clean Clean Clean Control Adjust Adjust, clean Adjust, clean Adjust, clean Carburetor Clean Clean Clean Clean Air cleaner Clean Clean Clean...
- Page 54 5.4.1 Disassemble, assemble and maintenance cylinder head Right view of the 150 engine. Left view of the 150 engine Remove the locknut of cylinder head from its holding place Remove cylinder head. Check the state of paper pad. Replace .
- Page 55 Dismantle the fixing bolt of left cover. Remove left cover and inspect the paper pad for damage. Replace. Dismantle the fixing bolt of right cover.
- Page 56 Remove the right cover of cylinder head. Inspect the gasket for damage and replace. Remove inlet/exhaust valve cap .Check the state of seal ring of valve cap and replace if worn or if reuse is questionable.
- Page 57 Remove the fixing bolt of timing driven sprocket. Remove the connecting bolt of cylinder head. Remove cylinder head assembly.
- Page 58 Remove timing driven sprocket. Inspect the timing driven sprocket for wear and damage. Replace if necessary. Check whether there is excessive carbon deposit in combustion chamber. Clean and replace if necessary Remove the cylinder head. Pour gasoline into inlet/exhaust pipe to inspect the seal condition. Grind the valve and valve seat if there is gasoline leaking into the combustion chamber.
- Page 59 Remove inlet/exhaust valve spring and check the state. Replace if necessary. Inspect the oil seal of inlet/exhaust valve for damage. Replace if necessary. Remove the spark plug to clean the carbon, deposit and dust .Check the spark plug gap and set it to 0.6 to 0.7 if necessary.
- Page 60 For the troubleshooting of cylinder head ,please refer to the following table Description Damage Form Problem Cause Correction Too much oil dirt or sand Poor heat The engine overheats. Remove the oil dirt or on the cooling fins. radiation of the sand fins on cylinder head.
- Page 61 The fixing nut is not Air leakage between The engine starts hard or fails to Tighten the fixing nut properly tightened the cylinder head and start. Insufficient engine output; cylinder Engine speed changes during idle run Improper clearance Weak or no sparking Oil leakage between the Adjust electrode gap to between electrodes...
- Page 62 5.4.2Disassemble, assemble and maintain cylinder block Dismantle connecting bolt of cylinder block. Remove cylinder gasket and dowel pin to check for wear and damage. Replace if necessary. Dismantle the fixing bolt of timing chain of guide wheel. Remove the cylinder block. Remove the guide wheel of timing chain to inspect for wear and damage.
- Page 63 Remove the piston of piston pin to check whether it is damaged. Replace if necessary. Inspect the paper pad for worn or damage .Replace if necessary. Check whether there is residual gasket on cylinder. Clean with gasoline if necessary.
- Page 64 Check the state of cylinder inner wall .Replace if worn or if reuse is questionable. Check whether the internal diameter has exceed the limit value. Measure the diameter form upper, middle and lower position. The limit value is 50.05mm.Replace the cylinder block if it has beyond this value.
- Page 65 Troubleshooting of the cylinder body, please refer to the following table Maintenance of Cylinder Body Description Damage form Trouble Cause Correction Excessive oil dirt Poor heat The engine overheats Remove the oil or sand on the radiation of the dirt or sand radiating fins fins on cylinder body...
- Page 66 5.4.3Disassemble, assemble and maintain crankcase Remove the cover of right crankcase half. Check whether the oil seal of starting shaft and seal edge of gearshift lever are worn. Replace if necessary. Check the state of right crankcase cover and replace if necessary. Left view of right crankcase half is shown in figure and check whether bearing of main shaft and...
- Page 67 Dismantle fixing bolt of left crankcase cover. Remove the neutral indicator and check the state. Replace if necessary. Dismantle the fixing bolt of magneto stator and remove the stator.
- Page 68 Check the condition of left crankcase cover and replace if necessary. Troubleshooting of crankcase, please refer to the following table. Trouble Description Problem Consequences Correction Crack in the crank case Oil leakage from the Repair or replace crankcase the crankcase Oil leakage from the The crankcase gasket is Replace the gasket...
- Page 69 The oil seal is damaged Oil leakage is ineffective Oil leakage from the oil Replace the oil seal or the oil seal edge is seal damage/worn/aged Right crankcase The right crankcase Oil leakage form the Repair or replace cover cover is worn or cracked case cover the case cover The gasket of right...
- Page 70 Remove left crankcase half. Take care not to forget the washer of main shaft and countershaft when removing the left crankcase. Remove the paper pad to inspect for wear and damage. Replace if necessary. Remove the connecting rod assembly. Inspect connecting rod bearing for wear and damage.
- Page 71 Check gap of big-end of connecting rod. Reset the gap if necessary. Check diameter of piston pin using a micrometer. Replace the piston pin if the value is over the maintenance limit value. Check the axial and radial jumping of connecting rod bearing.
- Page 72 Check whether there is excessive carbon deposit on piston top and groove. Remove if necessary. Check the state of piston and replace if worn or if reuse is questionable. Measure diameter of piston skirt. Replace it if the value is beyond the maintenance limit value. Assemble the piston ring according to the figure and check whether piston ring is damaged or the elasticity is weaken.
- Page 73 For the troubleshooting of crankshaft connecting rod mechanism, please refer to the following table. Maintenance of Crankshaft Connecting Rod Mechanism Description Damage from Trouble Cause Correction The engine over- heats Carbon deposit on piston Remove the carbon top 活塞顶部积碳 deposit Carbon deposit in the ring The piston ring is seized in ring The engine starts hard or fails to...
- Page 74 The crankshaft bearing is Abnormal sound during the Replace the over worn or damaged crankshaft bearing transmission crankshaft bearing The piston ring is fractured The piston ring is The engine starts hard or fails to Replace the piston fractured start. Insufficient engine output; ring set Thick blue and white fume form The piston ring is over...
- Page 75 Timing The gear is over worn of Abnormal sound during sprocket Replace the timing sprocke damage driving sprocket 5.5 Maintenance of Mechanism 5.5.1Disassemble, assemble and maintain valve mechanism Remove rocker arm shaft Remove the rocker arm of inlet/exhaust valve and check the state...
- Page 76 Remove the timing cam, rocker arm , rocker arm shaft to inspect for wear. Replace if necessary. Remove the circlip of inlet and exhaust valve. Remove inlet vale stem and exhaust valve stem take care and don`t miss the valve clip. Measure length of valve spring to check whether the spring is damaged or worn.
- Page 77 Check the external diameter of valve stem using a wedge. Replace the valve stem if the valve is beyond the maintenance limit valve. Measure the width of valve contact surface to check whether the contact surface is rough or abnormal. Replace the valve stem if the valve is large than 1.5mm.
- Page 78 Inspect the timing camshaft bearing for wear and check the state of camshaft. Replace if necessary. Check the gap of rocker arm shaft and rocker arm. Replace the rocker arm shaft and rocker arm if the gap is large. Check the external diameter of rocker arm using a micrometer.
- Page 79 Remove the fixing bolt of timing tensioner and check the state. Replace if worn or if reuse is questionable. Remove the timing tensioner arm to inspect for wear and damage. Replace if necessary. Remove the oil tube and spring and check the state.
- Page 80 Adjust valve clearance as follows; Remove the valve cap and check the condition. Adjust valve clearance of front cylinder. Turn magnetic rotor counterclockwise to make piston locate at top dead center and make T mark aimed to the mark of left crankcase cover.
- Page 81 For the troubleshooting of engine distribution mechanism, please refer to the following table Maintenance of Distribution Mechanism Descriptions Damage form Trouble Cause Correction Valve oil seal The edge of valve oil seal is Thick blue and white fume form Replace the worn, age or damage.
- Page 82 Valve The valve clearance is too The valve is impossible to The engine starts hard or fails to Readjust the valve small close completely start. Insufficient engine output; clearance to 0.05~0.06mm Engine speed changes during idle Valve striking sound The valve clearance is too Readjust the valve clearance to...
- Page 83 Replace the valve The valve stem is deformed It is impossible to close the The engine starts hard or fails to valve completely star Valve The spring is ineffective or It is impossible to fit the The engine starts hard or fails to Replace the valve spring fractured...
- Page 84 5.6 Disassemble, assemble and maintain carburetor Dismantle the fixing bolt of carburetor and circlip of air cleaner. Remove the carburetor .Remove and clean throttle Clean the carburetor as follows: 。Remove the dirt and clean inner oil way. Dismantle the fixing bolt of float chamber cap.
- Page 85 Remove the throttle and oil needle and check the condition replace if necessary. Check the state of float case and replace as necessary. Adjust the height of float case by moving the float up or down. Take out the main jet to check whether the jet hole is clogged.
- Page 86 Remove the idle jet and check for plugged. Clean the jet with compressed air if necessary Dismantle the mixture adjustment screw and inspect for worn. Replace if necessary. Adjust mixture screw of carburetor as the following. Standard: Tighten mixture screw, and turn it one And a half turns clockwise Measure height of float case to check whether it is distorted or there is oil...
- Page 87 5.7 Maintenance of Intake/Exhaust System 5.7.1 Disassemble, assemble and maintain intake system Dis-assemble hoop of air filter Dis-assemble air filter Clean dust on the air filter surface and then dis-assemble the air filter and clean inside. As the air filter core is made of paper, can’t be cleaned. So replace the air filter core. For the troubleshooting of the air cleaner, please refer to the following table.
- Page 88 5.8 Disassemble, assemble and maintain exhaust system Dismantle locknut of muffler Dismantle suspension bolt of muffler to check whether the suspension support is damaged. Repair or replace if necessary. Remove the muffler to inspect for broken and damage. Replace or repair if necessary. Remove the washer of muffler to inspect for damage.
- Page 89 For the troubleshooting or the exhaust muffler, please refer to the following table. Description Damage form Trouble Cause Correction 修理方法 Exhaust pipe leakage Exhaust pipe The gasket is Engine exhaust noise is Replace exhaust pipe gasket broken too loud. gasket enclosure broken Exhaust The muffler...
- Page 90 Dismantle the fixing bolt of air pump and check the state of air pump. Replace the air pump if it is worn or if reuse is questionable. Remove the secondary inlet air cleaner and inspect for wear and damage. Clean and replace if necessary.
- Page 91 connecting hose get loose noise is too big Replace connectin Emission fails to g hose meet the standard Gasket Replace large noise from air leaks form secondary Emission fails to secondary inlet inlet meet the standard Poor combustion muffler too much carbon deposit Emission fails to Remove exhaus...
- Page 92 Dis-assemble left crankcase cover Dis-assemble gasket to check condition. Change if damage or can’t use. Dis-assemble magneto stator fixing bolt trigger bolt.
- Page 93 Check stator condition with a multiple-use meter. Replace if damage or can’t use. Dis-assemble rotor fixing bolt Dis-assemble rotor with a dedicated tool. Check if rotor is with magneto. Change if necessary.
- Page 94 Dis-assemble over running clutch fixing bolt. Dis-assemble clutch, check clutch holder, ball and spring for damage and ware. Change if necessary. Check transmission sprocket and gear for damage and ware, change if necessary. Dis-assemble start sprocket paper pressing paper.
- Page 95 Dis-assemble tension band of clutch and check condition for damage and problem, change if necessary. Dis-assemble retainer ring of start motor sprocket. Dis-assemble driving sprocket and chain.
- Page 96 Dis-assemble start motor fixing bolt. Dis-assemble start motor. Check if the start motor winding is damaged, change if necessary. Dis-assemble oil separating plate and check condition, change if necessary.
- Page 97 Check the oil seal edge if damaged, change if necessary. Dis-assemble seal ring and check condition, change if damaged.
- Page 98 For the troubleshooting of engine electric starter, please refer to the following table Maintenance of Electric Starter Description Damage form Trouble Cause Correction Carbon brush is over Starter motor has insufficient Replace carbon brush worn. The carbon brush rotation force or it is out of work. spring is fractured or has Starter motor has insufficient...