KEEWAY Focus Maintenance Manual
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KEEWAY Focus Maintenance Manual

Keeway focus/matrix motorcycles maintenance manual
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Matenance Manual
Model: Focus/Matrix
COPY RIGHT:
KEEWAY INTERNATIONAL DEVELOPMENT CO.,LTD.
FEB.2006
1

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Summary of Contents for KEEWAY Focus

  • Page 1 Matenance Manual Model: Focus/Matrix COPY RIGHT: KEEWAY INTERNATIONAL DEVELOPMENT CO.,LTD. FEB.2006...
  • Page 2 If you have any problems can not fnd the solution in this manual, please fell free to contact with: KEEWAY INTERNATIONAL DEVELOPMENT CO.,LTD 2000 SZENTENDRE U.8 KOZUZO. HUNGARY TEL:0036-26-500005 FAX:0036-26-312034 EMAI: info@keewaymotor.com Our engineer are very glad to give you the necessary assistance...
  • Page 3 FOCUS/MATRIX. The FOCUS/MATRIX is a new type of scooter that has many techinal features such as: V-belt drive automatic transmission Forced air-cooling system CDI ignition system Electric starter system The FOCUS/MATRIX fits the needs of a wide variety of scooter user.
  • Page 4 Index General principles Termly maintenance and repair Engine Fuell and lubricate system Electrical system Frame Maintenance information...
  • Page 6 GENERAL PRINCIPLES CONTENTS TYPE IDENTIFICATION FUEL AND ENGINE OIL BREAK-IN PROCEDURE PRECAUTIONS AND GENERAL INSTRUCTIONS MAINTENANCE TOOLS SPECIFICATIONS...

  • Page 7: General Principles

    1-1 GENERAL PRINCIPLES TYPE IDENTIFICATION ① ① ① ① ENGINE NUMBER ENGINE NUMBER① is carved on rear crankcase as Shown in figure. Both FRAME NUBER AND ENGINE NUMBER are Designed specially for registering your scooter and ordering spare parts. FUEL AND ENGINE OIL Be sure to use specified fuel and engine oil.

  • Page 8: Precautions And General Instructions

    1-2 GENERAL PRINCIPLES PRECAUTIONS AND GENERAL INSTRUCTIONS Correctly abide by the following items when disassembling and assembling scooter: □ Don’t run engine indoors with little or no ventilation; □ Be sure to replace new bushings, circlips, O-rings and cotter pins with new ones； CAUTION It is forbidden to use the circlip removed from shaft, only use new one；...

  • Page 9: Specifications

    1-3 GENERAL PRINCIPLES SPECIFICATIONS Turning signal indicator light… 12V/3W DIMENSION AND NET WEIGHT OVERALL LENGTH…… CAPACITY 1830mm OVERALL LENGTH……… FUEL TANK……………5.2L 695mm OVERALL HEIGHT……… ENGINE OIL TANK……………1L 1160 mm WHEELBASE……………… GEAR OIL……………0.1L 1295mm Transmission system NET WEIGHT……………… 92kg Clutch system ． ． ． ． ． ． ．dry auto acentric Gearshift mechanism．...

  • Page 10: Table Of Contents

    TERMLY MAINTENANCE AND REPAIR CONTENT Periodic maintenance and service schedule……………………… 2-1 Maintenance and service procedures…………………………… 2-2 Storage battery………………………………………………… Spark plug………………………………………………………… 2-3 Cylinder head nut and exhaust pipe bolt……………………… Cylinder head and cylinder…………………………………………2-4 Fuel level line………………………………………………………2-4 Air cleaner……………………………………………………………2-5 Throttle cable…………………………………………………………2-5 Engine idle speed……………………………………………………2-5 Oil pump………………………………………………………………2-6 Gear oil………………………………………………………………2-7 Braking…………………………………………………………2-7...

  • Page 11: Periodic Maintenance And Service Schedule

    Periodic maintenance and service schedule The following table lists all required intervals for maintenance and service，following which, you are assred to have your scooter perform in the best way. Note Do more frequent maintenance when often riding on bad road Periodic maintenance table Mile 4000...

  • Page 12: Storage Battery

    Maintenance and adjustment procedures The section describes the servicing procedures for each item of the Periodic Maintenance requirements. Storage battery Inspect at initially 1000KM（600 miles，2 months） ， andevery 6000KM （4000 miles， 12 months） thereafter □ Uncover seat, and then remove the battery box cap in the Middle of helmet barrel.
  • Page 13 Cylinder head nuts and exhaust pipe bolts Tighten at initially 1000 km（600 miles，2 moths） ，and every 6000 km（4000 miles，12 months） If cylinder head nuts are not tightened to the specified torque, may result in leakage of compressed fuel-air mixture and reduce output, tighten the cylinder head nuts in the following procedures:：...

  • Page 14: Spark Plug

    SPARK PLUG Neglecting the spark plug maintenance eventually leads to difficult starting and poor performance. If the spark plug is used for a long time, the electrode gradually burns away and carbon builds up along the inside part. In accordance with the periodic table, the plug should be removed for inspection, cleaning and to reset the gap.

  • Page 15: Air Cleaner

    AIR CLEANER Clean every 3000KM（2000 miles） ① ① ① ① If the air cleaner is clogged with dust, intake resistance will， be increased with a resultant decrease in power output and an increase in fuel consumption. Check and clean the element in the following manner.

  • Page 16: Oil Pump

    Connect an electric tachometer to the connecting protiion of the magneto lead wire as shown I nthe illustration. Use the selector key “C’ position. Tachometer Adjust the throttle stop screw to obtain the idle r/min as follows: Idle speed：1400±100r/min Finally adjust the throttle cable play. OIL PUMP Inspect at initially 1000KM （600 miles ，2 months ）...

  • Page 17: Gear Oil

    GEAR OIL Inspect at initially 1000 km （ （ （ （ 600 miles， ， ， ， 2 months） ） ） ） and every 6000 km（ （ （ （ 4000 miles， ， ， ， 12 months） ） ） ） thereafter. Inspect gear oil periodically as follows: Remove the cover and hose Remove the kicking starter lever Remove clutch cover...
  • Page 18 WARNING： ： ： ： Brake fluid, if it leaks, will interfere with safe running and immediately discolor painted surfaces. Check the brake hoses for cracks and hose joints for leakage before riding. Brake pads Wearing condition of brake pads can be checked by observing the limit Line ①...
  • Page 19 NOTE： ： ： ： when bleeding the brakign system, replenish the brake fluid reservoir if necessary. Make sure that there is always some fluid visible in the reservoir. Close the bleeder vavle, disconnect the pipe. Fill the reservoir with brake fluid to the upper end of the inspection window.

  • Page 20: Tire

    Tire Inspect at initially 1000KM （600 miles， 2 months） and every 6000KM（4000 miles，12 months）thereafter Tire pressure： If the pressure is too high, the scooter will tend to rede stiffly and have poor traction. Conversely, if tire pressure is too low, stability will be adversely affected.

  • Page 21: Front Shock Absorber

    Front shock absorber Adjust at initially 1000KM（600 miles，2 months）and every 6000 km（4000 miles，12 months）thereafter. Inspect the front shock absorber for oil leakage or other damage, and replace the defective parts, if necessary. Rear shock absorber Adjust at initially 1000KM （600 miles， 2 months） and every 6000 km（4000 miles，12 months）thereafter.
  • Page 22 ③ ③ ③ ③ ① ① ① ① ② ② ② ② ④ ④ ④ ④ ⑥ ⑥ ⑥ ⑥ ⑤ ⑤ ⑤ ⑤ ⑦ ⑦ ⑦ ⑦ ⑨ ⑨ ⑨ ⑨ ⑧ ⑧ ⑧ ⑧ ⑩ ⑩ ⑩ ⑩...
  • Page 23 LUBRICATION Proper lubrication is important for smooth operation and long life of each working part of the scooter. The major lubrication points are indicated below： NOTE： 1. Lubricate exposed parts which aare subject to ruse with engine oil. 2. Before lubricating each part, clean off any rusty spots and wipe off any grease, oil dirt of grime. WARNING：Be careful not to apply too much grease to the rear brake camshaft, otherwise brake slippage will result from the presence of grease in brake drum.
  • Page 24 ENGINE CONTENS Engine components removal with the engine in place Engine removal and remounting Engine removal Engine remounting Engine disassembly Engine components inspection and servicing Bearings Oil seals crankshaft automatic clutch inspection cylinder head cylinder piston reed valve engine remounting oil seals bearings bushings...

  • Page 25: Engine Right Side

    Engine components removable with the engine in place The parts listed below can be removed and reinstalled without removing the engine from the frame. Engine left side Kicking starter lever Clutch brake pad kit Driver left face V-belt Driver belt right face Electric starter gear Super clutch Driven face...
  • Page 26 ENGINE ASSY. Remove the muffler Remove cooling fan cover Remove cylinder cover Remove cooling fan Remove magneto nut with special tools. remove magneto rotor and half circle key with special tools. remove magneto stator and paper gasket remove oil pump...
  • Page 27 Remove worm wheel and oil seal press board remove cylinder head and cylinder Place a cloth stopper beneath the piston and remove the circlip with a plier. remove the piston pin and piston. Remove the kick starter lever. Remove side cover Remove movable ratchet wheel and clip...
  • Page 28 Remove starting driven ratchet wheel by removing the nuts. Rmove fan⑤ and V-belt⑥. Disassemble the movable drive face⑦. Remove electric gear press board, electric gear And super clutch Remove starter motor...
  • Page 29 Remove the clutch housing with the special tool. drain gear oil remove rear axle nut remove rear wheel remove brake shoe⑤ and rear axle⑥。 Remove the rear brake cam lever①， indicator plate② and camshaft③.
  • Page 30 remove spring④ remove cotter pin⑤ and shaft⑥ remove main stand⑦ remove gearcase cover Remove paper gasket① and middle gear assy.②, Remove output gear assy.③ remove carburetor remove intake pipe remove reed valve and paper gasket.
  • Page 31 Remove crankcase fixing shaft disassemble crankcase with special tools Remove crankcase with special tools Remove crankshaft bearing with special tools Sliding shaft Warning： ： ： ： use a new sliding shaft.
  • Page 32 Unscrew clutch shoe nut with special tools. Remove the nut while holding down clutch shoe assy. by both hands as shown in the illustration. WARNING：Gradually back off the clutch shoe assy. pressed down by hands to counter the clutch sparing load. Releasing the hand suddenly may cause the following parts to fly apart.
  • Page 33 Remove circlip Remove bearing with special tool. CAUTION： Replace the removed bearing with a new one. Remove bearing with special tool. CAUTION： ： ： ： Replace the removed bearing with a new one. Remove the spacer Remove the oil seal from the gearcase cover with the speical tool. CAUTION：...
  • Page 34 Remove gearcase cover bearing with special tool Remove left crankcase oil seal do it with special tool warning： ： ： ： use a new oil seal remove left crankcase bearing with special tool warning： ： ： ： use a new one remove left crankcase shock absorber bushing with special tool warning：...
  • Page 35 Remove right crankcase oil seal with special tool Warning： ： ： ： use a new oil seal remove right crankcase bearing sliding bearing warning： ： ： ： use a new bearing...

  • Page 36: Engine Components Inspection And Servicing

    ENGINE COMPONENTS INSPECTION AND SERVICING BEARINGS Clear bears with solvent and lubricate with engine oil before inspecting. Turn the inner ring and check to see that the inner rieng turns smoothly. If it does not turn lightly, quietly and smoothly, or if noise is heard, the bearing is defective and must be replaced with a new one.

  • Page 37: Automatic Clutch Inspection

    OIL SEAL Damage to the lip of the oil seal may result in leakage of the fuel-air mixture or oil. Inspect for damage and be sure to replace the damaged seal if found. CRANKSHAFT CRANKSHAFT RUNOUT Support crankshaft by“V” block, with the dial gauge rigged to read the runout as shown.
  • Page 38 and centrifugal mechanism located in the clutch. To insure proper performance and long lifespan of the clutch, it is essentiall that the clutch engages smoothly and gradually. Two inspection checks must be performed to thoroughly check the operation of the drivetrain. Follow the procedures listed. 1．Inspect initial engagement Warm scooter...

  • Page 39: Drive Belt

    If the engine R/MIN doesn’t coincide with the specified r/min range, then disassemble the clutch. Clutch shoe---inspect the shoes visually for chips, cracking, uneven wear and burning, and check the thickness of the shoes with vernier calipers. If the thickness is less than the following service limit, replace them as a set.

  • Page 40: Cylinder Head

    Roller and sliding surface Inspect each roller and sliding surface for wear or damage. Driving face spring Measure the free distance of the driven face spring. If the length is shoter than the service limit, replace the spring with a new one. service limit: 104.5mm(4.11in) Driven face pin and oil seal Turn the driven face and check to see that the driven faces...
  • Page 41 If the largest reading at any portion of the staightedge excees the limit, rework the surface by rubbing it against emery paper laid flat on the surface plate in a lapping manner. The surface must ge smooth and perfectly falt in order to secure a tight join: a leaky joint can be the cause of reduced power output and increased fuel consumption.
  • Page 42 be taken in the intake-to-exhaust port direction and at 20mm from the cylinder top surface. Unit：mm Standard service limit Cylinder 40.005-40.020 40.075 Piston 39.94-39.955 39.885 Cylinder to piston 0.06-0.07 0.120 Decarboning Decarbon the piston and piston ring grooves, as illustration. After cleaning the grooves, fit the rings and rotate them in their respective grooves to be sure that they move smoothly.
  • Page 43 with a new one. The end gap of each ring is to be measued with the ring fitted squarely into the cylidner bore and held at the least worn part near the cylidner bottom, as shown in the illustration. Service limit：0.75mm(0.030in) As the piston ring wears, its end gap increases reducing reducing engine power output becaust of the resultant blow by through the enlarged gap.
  • Page 44 ENGINE Reassembly Reassembly is generally performed in the reverse order of disassembly, but there are a number of reassembling steps that demand or deserve detailed explanation or emphasis. These steps will be taken up for respective parts and components. Oil seals fit the oil seals to the crankcase following the procedure below.
  • Page 45 shock absorber bushing positon Install shock absorber bushing Install crankshaft bearing Press bearing into cankshaft Install crankshaft...
  • Page 46 Decide th length between the webs referring to the figure at righ when rebuilding the crankshaft. Standard width between webs:： ： ： ： 38±0.1mm(1.496±0.004in) when mounting the crankshaft into crankcase, it is necessaryto pull its left end into the crankcase with the special tool.
  • Page 47 CRANKCASE Wipe the crankcase mating surfaces with clraning solvent. Apply QIANJIANG NO.1215 evenly to the mating surface of the right half of the crankcase Tighten the crankcase screws securely. Check if crankshaft rotates smoothly. Install gearcase bearing Install new bearing and oil seal into gearcase cover with special tool, and tighten anchor pin.
  • Page 48 install output axle gearshift install middle gear, position pin by installing middle gear axle①, gasket② and thrust gasket③ install gearcase cover into crankcase and lock bolt. tighten each screw screw oil drain nut○ tightening torque： ： ： ： 4-7 N.m (0.4-0.7kg-m,3.0-5.0 Ib-ft)
  • Page 49 install the bearing② in the fixed driven face① with the special tool. install sliding bearing ③。...
  • Page 50 Install the bearing ① with special tool install the spacer ② and circlip③. install the new oil seals④ and ⑤ to the movable driven face with the special tool. apply grease to the lip of oil seals and groove of inside of movable driven face. QIANJIANG special super grease NOTE: When reinstalling the movable face to the fixed...
  • Page 51 Install the movable driven face seat①. install the clutch shoe assembly② and nut ③. tighten the nut③ to the specified torque with the special tool. tightening torque： ： ： ： 40-60 N.M (4.0-6.0kg.m 29.0-43.5Ib-ft) insert the V-belt between the driven faces as deep inside possible while pulling the movable driven face all the way outside to provide the maximum ble clearance.
  • Page 52 Apply grease to all the sliding and rolling surfaces for six roller weights. For each weight, approximately 1.5g of grease should be used. QIANJIANG supre grease Mount the three dampers ① on the movable drive plate② and install it on the movable drive face.
  • Page 53 Insert the spacer④ Position the movable drive face subassembly on the crankshaft as shown in illustration. ： ： ： ： NOTE Thoroughly clean the belt contact to be free from oil. Install the fixed drive fan①. tighten the nut to the specified torque with special tool.
  • Page 54 fill the final gear box with engine oil up to the level hole. Oil capacity： 90ml tighten the oil level bolt to the specified torque. Tightening torque：9-15M.M Starter assy. Inject lubrication into start bearing and lubrication in the end of starter shaft QIANJIANG SPECIAL LUBRICATION Tighten starter shaft gasket Install starter ratchet wheel and circlip...
  • Page 55 Install the dowel pins ① install the new gaskets(② and ③) apply QIANJIANG bond no. 1215 to the clutch cover as shown in the illustration. QIANJIANG bond no. 1215 NOTE: INSTALL the kick starter lever as shown in the illustration. Tightening toque：...
  • Page 56 apply oil for the piston and install the piston to the connecting rod. ： ： ： ： NOTE The arrow mark ① on the piston head should point the exhaust side. The circlip should be mounted in such a position that the mating ends of the circlip do not coincide with the grovve portion of the piston.

  • Page 57: Reed Valve

    Reed valve install reed valve paper gasket. Install reed valve Install oil hose Instake pipe install intake pipe Magneto clear crankshaft and magneto rotor install half circle key install paper gasket and stator coil, and then fix them tighten to specified torque with special tool specified torque：...
  • Page 58 install cooling fan install guiding cover install fan guiding cover screw ① screw install pipe tightening muffler to their specified torque. ①：8-12N.m(0.8-1.2kg.m,6.0-8.5Ib-ft) ②：18-28N.m(1.8-2.8kg.m,13.0-20.0Ib-ft) lubricate brake cam shaft with QIJIANG SPECIAL grease.
  • Page 59 FUEL AND LUBRICATION SYSTEM CHAPTER 4 CONTENTS FUEL SWITCH CARBURETOR OIL PUMP...
  • Page 60 FUEL SWITCH When the engine has started, a negative pressure(vacuum) is generated at the intake port. The negative pressure acts upon the diaphragm of the fuel switch and ti pressed down the spring which supports the diaphragm so that the fuel passageway is opened and fuel is fed to the carburetor.
  • Page 61 CARBURETOR QIANJIANG-WENLING-CHINA，equal vacuum Carburetor manufacturer/type CARBURETOR PZ19JB Identification code 19mm Throat tube diameter Main jet size #57.5 Idle needle jet size groove Oil needle clamp position Idle air adjusting screw extrude 1 ± turnout Float height 13 ± 1mm...
  • Page 62 CARBURETION Proper carburetion is determined according to the results of various tests, mainly concerning engine poer, fuel consumption and cooling effect of feul on engine, and jet settings ard made so as to satisfy and balance all of these conditions. Therefore, the jet should not be replaced with a size other than the original.

  • Page 63: Electrical System

    CHAPTER 5 ELECTRICAL SYSTEM CONTENS IGNITION SYSTEM CHARGING AND LIGHTING SYSTEM STARTER SYSTEM FUEL GAUGE OIL LEVEL CHECK LIGHT AND TURN SIGNAL INDICATOR SWITCHS BARTERY...
  • Page 64 IGNITION SYSTEM CDI&Ignition coil unit MAGNETO Spark plug The ignition system consists of a flywheel magneto, a CDI&Ignition coil unit and a spark plug. ①As the rotor tatates, an AC current is induced in the coil. Then current induced in the ○ A direction charges up the capacitor.

  • Page 65: Frame

    ● ● ● ● Note the spark in the spark gap window. It should be strong and continuous, not intermittent, acrossa preset 8mm(0.32in) gap. Allow the spark to jump the test gap for at least five minutes continuously. To insure proper operation under the temperature of actual riding.
  • Page 66 CHARGING AND LIGHTING SYSTEM The charging system uses the flywheel magnetoas shown in the figure. The charging and lighting coils are mounted on the magneto stator and generate AC as the flywheel rotor turns. AC generated in the charging coil flows to the regulator/recifier which changes AC to DC.

  • Page 67: No-Load Performance

    NO-LOAD PERFORMANCE Disconnect the magneto lead wire coupler. Start the engine and keep it running at 5000r/min. Using a pocket tester, measure the AC voltage between the white and red tracer lead wire and ground. If the tester reading is as follows, magneto is in good condition.

  • Page 68: Starter Motor Removal And Disassembly

    STARTER SYSTEM DESCRIPTION The starter system is shown in the diagram below: namely, the starter motor, relay, starter switch and battery. depressing the starter button while squeezing the front or rear brake lever energizes the relay, causing the contact points to close which connects the starter motor to the battery. Starter motor removal and disassembly Remove the starter motor Disassemble the starter motor as shown in the illustration...

  • Page 69: Starter Relay Inspection

    STARTER MOTOR INSPECITION CARBON BRUSHES When the brushes are worn, the motor will be unable to produce sufficient torque, and the engine will be difficult to turn over. To prevent the , periodically inspect the length of the brushes and replace them when they are too short or chipping.
  • Page 70 FUEL LEVEL METER/GAUGE FUEL METER INSPECTION To test the Fuel Meter two different checks may be used. The first,and simplest test will tell if the mete is CABLE ASSY. operating but will not indicate the meters accuracy throughout the range.To perform the test,lift the seat and remove the right frame cover,then disconnect the B/W and Y/B lead connector of the fuel gauge sending unit.Connect a jumper wirebetween B/M and Y/B wiers coming from the main wiring...
  • Page 71 SIGNAL SYSTEM SIGNAL SYSTEM SIGNAL SYSTEM SIGNAL SYSTEM The same bulb is used tor both oil level check light and turn signal indicator light.The circuitry is shown below.When the oil level has fallen to a certain level (the remaining amount of oil has become approximately 160 ml,the oil level check light turns on and remains lit.When the turn signal switch is turned on and the turn signal light flashes,the turn signal indicator light (oil level check light)also flashes,both being not concurrently but alternatively as one being...
  • Page 72 SWITCH SWITCH SWITCH SWITCH 电源锁 灯控开关 红 红/白 墨绿 黑 绿/红 黄/红 黄 粉红 黄 开 大灯 关 会车灯 锁定 关 变光开关 刹车开关 黄/红 蓝 浅蓝 红/白 紫 开 远光 近光 关 喇叭开关 转向开关 红/白 棕 橙 绿/黑 绿/白 开 左转...
  • Page 73 B B B B ATTERY ATTERY ATTERY ATTERY SPECIFICATIONS SPECIFICATIONS SPECIFICATIONS SPECIFICATIONS Type designation YB4L-B Capacity 12V 4Ah Standard electrolyte 1.28(20℃) INITIAL CHARGING INITIAL CHARGING INITIAL CHARGING INITIAL CHARGING FILLNG ELECTROLYTE ·Remove the aluminum tape ① sealing the battery elec- trolyte filler holes.
  • Page 74 RECHARGEING OPERATION RECHARGEING OPERATION RECHARGEING OPERATION RECHARGEING OPERATION · Apply multimeter to measure the voltage of battery. If the reading is below 12.0V ， it should be recharged. NOTE: When recharging, remove the battery form the vehicle. NOTE: When recharging, don’t remove the sealing cap off battery top. Recharging time：...
  • Page 75 CHAPTER 6 CHASSIS CONTENTS LEG SHIELD AND FRAME SIDE COVERS · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · LEG SHIELD REMOVAL ·...
  • Page 76 Side cover removal 1. remove seat and helmet barrel by opening seat and loosing tightening screw ①. 2. loose hexad screw ③ and remove decorating cap②,rear carrier and oil tank lock④，remove side cover ⑥ by loosing side cover screw⑤⑦； ③ ②...
  • Page 77 ③ under cover removal 1. unscrew screw ② and bolt① 2. removing under cover by loosing the left and right tapping screws ④； ② ② ① ① ② ② ① ② under cover installation 3．The sequence if installation is ther reverse of removal. ④...
  • Page 78 LEGSHIELD AND PEDAL REMOVAL 1. Remove power lock housing ② by unscrewing bolt ①. ② ① 3. remove legshield and pedal by unscrewing the four bolts ③ ③ Legshield and pedal installation 4. the sequence of legshield and pedal is the reverse of reomval ；...
  • Page 79 ①② HANDLE COVER REMOVAL 1 ． Remove front handle cover ② by unscrewing the six Tapping screws ① ①① ①① 2. Remove master cylinder by removing the bolt ③; ①① ①③...
  • Page 80 3 ． Disconnect throttle cable ③ and oil pump cable④ ①③ ①④ 4．Remove rear brake cable adjusting nut⑤ ①⑤...
  • Page 81 Handle cover removal 5. remove all cables ； 6 ． Remove handle cover by unscrewing bolt ⑥ ⑥ Handle cover unstallation 7. The sequence of removal is the reverse of reomval...

  • Page 82: Front Wheel

    Front wheel 1. front rim 2. middle bushing 3. oil seal 4. roller bearing GB6201-2RS 5. tire 6. valve mouth 7. nut GB6817 8. front shaft 9. front wheel left bushing 10. gearcase 11. valve mouth cap ① ① ① ① ②...

  • Page 83: Inspection And Disassembly

    INSPECTION AND DISASSEMBLY WHEEL BEARING Inspect the play of bearing inner ring by hand while mounted in the wheel. Rotate the inner ring by hand to inspect if any abnormal noise occurs or rotating smoothly, Replace the bearing if there is anything ucusual. ·Remove the dust seal.

  • Page 84: Reassembly And Remounting

    Reassembly and remounting Reassemble and remount this front wheel in the reverse order of removal, and also carry out the following steps: ． install this wheel bearing with the special tools as shown in this illustration. CAUTION: Install this wheel bearing for left side.. Install the brake disc as shown in photo.

  • Page 85: Front Brake System

    FRONT BRAKE SYSTEM 1. disc brake assy. 2. disc brake handle lever 3. tightening bolt 4. nut M6 5. master cylinder 6. tightening seat 7. bolt M6X23 8. brake hose assy. 9. brake caliper connecting board tightening bolt 11. hose mounting bolt 12.

  • Page 86: Caliper Removal And Disassembly

    ·Remove the brake pads. CAUTION: Replace the brake pads as a set,otherwise braking performance Will be adversely affected. Reassemble and remount the calliper. CALIPER REMOVAL AND DISASSEMBLY Remove the brake hose and catch the brake fluid in a suitable receptacle. CAUTION: Nevere re-use the brake fluid left over from the last servicing And stored for long periods.

  • Page 87: Caliper And Disc Inspection

    CALIPER AND DISC INSPECTION Inspect the calipe cylinder bore wall or micks,scratches or other damage. Inspect piston for damage and wear. Inspect each rubber part for damage and wear. Check the disc for wear with a micrometer.Its thickness can be checked with disc and wheel in place.

  • Page 88: Master Cylinder Removal And Disassembly

    BRAKE CALIPER REASSEMBLY Reassemble and remount the calliper in the reverse order of removal and disassembly, and also carry out the following steps. CAUTION: Wash the calliper components with fresh brake fluid before reasse- mbly. Never use cleaning solvent or gasoline to wash them.Apply b- rake fluid to the calliper bore and piston to be inserted into the bore.

  • Page 89: Master Cylinder Inspection

    Remove the brake lever and brake switch. Remove the dust boot. Remove the circlip with the special tool. Remove the piston/primary cup with return spring. Remove the reservoir cap and diaphragn. Drain brake fluid. MASTER CYLINDER INSPECTION Inspect the master cylinder bore for any scratches or other damage.
  • Page 90 Inspect the piston surface for scratches or other damage. Inspect the primary cup and dust boot for wear or damage. MASTER CYLINDER REASSEMBLY AND ERMOUNTING Reassemble and remount the master cylinder in the reverse order of Removal and disassembly,and also carry out the following steps. CAUTION: Wash the master cylinder components with fresh brake fluis before reassembly.

  • Page 91: Steering Stem And Front Suspension

    STEERING STEM AND FRONT SUSPENSION 1. handle jointing assy. 2. bolt GB5789 M10X1.25X45 3. nut GB6187 M10X1.25 4. left handlebar 5. throttle grip assy. 6. screw GB818 M5X10 7. rear brake cable assy. 8. throttle cable assy. 9. left switch comp. 10.
  • Page 92 □ remove disc brake system by unscrewing tightening bolt. □ remove handle by removing tightening bolt □ unscrew locknut with special tool □ remove fornt fork assy. by removing upper outer steel bowl NOTE: Not drop the steering stem balls. □...

  • Page 93: Inspection

    INSPECTION □ inspect the removed parts for the following abnormalities. bearing race wear and brinelling. Worn and damaged steel balls Distortion of steering stem or handlebar. □ Inspect the suspension for damage...

  • Page 94: Reassembly And Remounting

    Reassembly and remounting reassemble and remount the steering stem, handlebar and front fork in the reverse order of disassembly andremoval, and also carry out the following steps. Install the right left suspension arms. Steel ball Apply grease when installing the upper and lower steel balls. QTY ：...
  • Page 95 install handlebar and tighten the screw① ① ① ① and bolt to the specified torque： 37-44N.M ① NOTE: After performing the adjustment and installing the handlebar, Rock the front wheel forward and backward to ensure that there Is not play and that the procuder is accomplished correctly. If Play is noticeable, raadjust the steering outer race nut.

  • Page 96: Rear Wheel And Brake

    REAR WHEEL AND BRAKE 1. Tire 130/70-12 2.rear rim assy. 3. brake pad kit assy. 4.brake spring rear brake tension 6. rear indicator 7. anti-dust cover rear brake camshaft 9. bolt M6 Χ 30 10.valve 11.nut M16 Χ 1.5 12. rear brake arm 13.

  • Page 97: Inspection

    REMOVE □ Place the scooter on level ground. □ Remove muffler. □ Remove rear small fender. □ Remove locknut and rear wheel. □ Remove brake shoes. INSPECTION REAR RIM Measure inner diameter of rear rim hub with micrometer, if measured diameter exceeds 110.7, replace it with a new one.

  • Page 98: Reassembly And Remounting

    REASSEMBLY AND REMOUNTING Reassemble and remount the rear wheel and brake in the reverse of removal, and also carry out the following steps: □ Turn the punched mark ① on the camshaft to the Rear axle shaft side. □ Install the protrusion ② of indicator plate to the groove ③ of Camshaft.
  • Page 99 SERVICING INFORAMTION CONTENTS Troubleshooting Batteru Vehicle Wiringd diagram Wire, cable and brake hose routing Special tools Thread parts tightening torque Service data...

  • Page 100: Troubleshooting

    TROUBLESHOOTING ENGINE Complaint Symptom and possible causes Remedy Engine does not start, Compression too low or is hard to start. 1. Excessively worn cylinder or piston rings. Replace. 2. Stiff piston ring in place. Repair or replace. 3. Gas leaks from the joint in crankcase, cylinder or cylinder Repair or replace.
  • Page 101 Complaint Symptom and possible causes Remedy Engine runs Replace. Excessively worn cylinder or piston rings. poorly Replace. Stiff piston ring in place. high-speed Adjust. Spark plug gaps to narrow. range. Replace. Ignition not advanced sufficiently due to poorly working CDI & ignition coil unit. Replace.
  • Page 102 Complaint Symptom and possible causes Remedy Medium- 1. Main jet or main air jet is clogged. Check and clean. high-speed 2. Needle jet is clogged. Check and clean. trouble. 3. Fuel level is improperly set. Check and replace. 4. Throttle valve operating Check throttle valve for operation.
  • Page 103 1. Battery run down. Recharge and replace. Starter button is 2. Defective switch contacts. Replace. not effective. 3. Brushes not seating properly on commutator Repair or replace. in starter motor. 4. Defective starter relay. Replace. 5. Defective starter pinion gears Replace.
  • Page 104 Noisy front 1. Not enough grease. Refill. suspension. 2. Loose nuts on suspension. Retighten. Wobbly rear 1. Distorted wheel rim. Replace. wheel. 2. Defective or incorrect tire. Replace. 3. Loose nuts on the rear shock absorber. Replace. 4. Worn engine mounting bushing. Replace.

  • Page 105: Wiringd Diagram

    WIRING DIAGRAM...

  • Page 106: Wire, Cable And Brake Hose Routing

    WIRE, CABLE AND BRAKE HOSE ROUTING...
  • Page 107 carburetor...
  • Page 109 Starting relay Ignition coil HORN POWER SWITCHH...

  • Page 110: Special Tools

    SPECIAL TOOLS LISTED BELOW FOR REMOVAL AND REINSTALLATION DESCRIPTION TOOL NUMBER “ T ” shape of sleeve sleeve tools （ 7mm,8mm,10mm,12mm,13mm ） flywheel remover sleeve (18mm,24mm) screw remover cylinder pressure gauge piston pin remover spark plug remover flywheel lockbolt remover clutch clamp ①...
  • Page 111 ⑤ ⑥ ④ ⑦ ⑧ ⑨ ⑩...
  • Page 112 TIGHTENTING TORQUE O F SCREW THREAD PARTS ENGINE N ． M ITEM Cylinder guide cover tapping screw Fan guide cover lock bolt 10-12 Cylinder cover locknut 15-18 Spark plug 15-18 Inlet pipe lock bolt 10-12 Cooling fan impeller lock screw 10-12 Flywheel lock bolt 45-50...

  • Page 113: Service Data

    SERVICE DATA CYLINDER+PISTON+PISTON RING Unit：mm(in) ITEM STANDARD TOLERANCE Piston cylinder 0.06-0.07 0.120 clearance (0.0024-0.0028) (0.0047) Cylinder bore 40.005-40.020 40.075 (1.5750-1.5756) (1.5778) Cylinder diameter 39.94-39.955 39.885 (1.5724-1.5746) (1.5703) Cylinder distortion 0.04 (0.0016) Cylinder head distortion 0.04 (0.0016) Piston ring free cotter end ring 0.02~0.06mm clearance...
  • Page 114 CLUTCH Unit: mm(in) ITEM STANDARD LIMIT Clutch wheel inner diameter 112.00-112.15(4.410-4.415) 112.5(4.429) Clutch shoe thickness 1.8(0.071) 1.2(0.005) 3000 ± 300r/min Clutch engagement 6000 ± 300r/min Clutch closedown UNIT：mm(in) EXCEPT RATIO TRANSMISSION SYSTEM+DRIVING CHAIN ITEM STANDARD TOLERANCE Final reduction ratio Gear reduction ratio Drive belt width 16.8-17.2(0.6614-0.6772) 16.4(0.6457)
  • Page 115 WATTAGE ITEM SPECIFICATION Headlight high beam/ 35W/35W Dipped headlight Taillight 21W/5W Front turn light Rear turn light Turning signal indicator light High beam indicator 1.7 W light Meter indicator light 1.7 W Alarm indicator light Light diode Brake and rim Item Specification Tolerance...

This manual is also suitable for:

MatrixFocus - 25 km/tMatrix - 45 km/tHurricane

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