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Panterra Fusion Service Manual

Gasoline powered scooter
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Summary of Contents for Panterra Fusion

  • Page 2 Chapter 5 covers the operation and repair of the servicing or repair of this scooter, contact the fuel system including the carburetor. PanTerra Customer Service at 626 336 1128 Between the hours of 8am & 5pm PST Chapter 6 covers the removal and installation of the engine to the scooter.

  • Page 3: Table Of Contents

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL Table of Contents Chapter Topic Page CHAPTER 1: Introduction CHAPTER 2: Body Cover and Exhaust System CHAPTER 3: Scheduled Maintenance CHAPTER 4: Lubricating System CHAPTER 5: Fuel System CHAPTER 6: Engine Removal and Installation...
  • Page 4 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 1. General Information Topic Page Topic Page Engine and Frame Number Positions 1-1 Tools 1-12 Product Specifications Oil and Grease Supply Chart 1-13 and Technical Data Control Cables and Wiring Diagram 1-14 Technical Tips...

  • Page 5: Chapter 1: Introduction

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 1. General Information Product Specifications and Technical Data Scooter Model Retro Power 2.2 HP @ 8000 RPM Fusion Torque 4.5 ft lbs @ 6000 RPM Intake timing 6˚ BTDC-28˚ ATDC Freedom Exhaust timing 38˚ BBDC-6˚ BTDC Length 1685mm (66.5 inches)

  • Page 6: General Information

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 1. General Information Technical Tips •Replace all gaskets, o-rings, circlips •Special service tools may be required and cotter pins when performing to perform maintenance and repairs on maintenance on the scooter. Nuts and this scooter. Always use the proper tools bolts on all engine covers should be to prevent damage to the scooter.
  • Page 7 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 1. General Information Technical Tips (continued) •When performing maintenance on the •When disconnecting the battery, always scooter, make sure that all moving parts disconnect the negative terminal first. and controls move freely and return to their proper position.
  • Page 8 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 1. General Information Technical Tips (continued) •When replacing fuses, always use an •When assembling wire connectors, exact replacement. Do not use fuses of press firmly to assure the lock tab fully a higher amp rating! engages.
  • Page 9 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 1. General Information Technical Tips (continued) •Make sure that all wiring connectors are fully •Never reuse damaged wire terminals or seated and lock tubs engaged. connectors. •Check if almuce of connector is covered and •Replace all rubber covers on wire connectors...
  • Page 10 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 1. General Information Technical Tips (continued) •Make sure that all wire clips are •Make sure that the wiring harness and properly attached. all wires do not contact hot components or surface parts of the scooter.
  • Page 11 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 1. General Information Technical Tips (continued) •Do not pull wires too tightly. •Use tape to protect against sharp edges. •Make sure that all rubber grommets are in place to protect the wiring harness. •Do not reuse broken or frayed wires.
  • Page 12 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 1. General Information Technical Tips (continued) •Do not twist or knot wires when •Make sure that you understand the proper performing maintenance on the scooter. use of test equipment to perform maintenance on the scooter. This will prevent accidental damage to the electrical system of the scooter.
  • Page 13 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 1. General Information Technical Tips (continued) Definitions of diagrams The following icons are used to highlight important operations in the service of the scooter. Lubricating oil required. Grease required. Engine oil required. Special tools required.

  • Page 14: Torque Settings

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 1. General Information Torque Settings Standard Torque Settings General Torque Requirements for Standard Fasteners Fastener Type Torque Fastener Type Torque 5mm Cap Screw .5 kg/cm 5mm Socket Head Screw .4 kg/cm 6mm Cap Screw...
  • Page 15 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 1. General Information Tool Requirements For general maintenance and repair of the scooter, a complete basic set of metric sized tools is required. This should include; Open-end wrenches, sockets and ratchet, hex keys, straight...
  • Page 16 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 1. General Information Lubrication Requirements: Engine Item Location Recommended Lubricant valve guide valve stem moving part SAE 5W 30 Engine Oil cam shaft lug surface API-SG Grade Engine Oil valve rocking arm friction surface...
  • Page 17 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 1. General Information Chassis •Apply oil to the following parts. •Use grease in the parts other than specified ones. •Apply engine oil or grease to the moving parts to prevent abnormal noise and to raise durability.
  • Page 18 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 1. General Information Cable Routing Diagram FRONT BRAKE CABLE SPEEDOMETER CABLE FRONT BRAKE REAR BRAKE SWITCH LEAD SWITCH LEAD THROTTLE CABLE REAR BRAKE CABLE MAIN SWITCH HEADLIGHT LEAD CONNECTOR VOLTAGE REGULATION/RECTIFIER HEADLIGHT RESISTANCE AUTOMATIC BY-PASS...
  • Page 19 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 1. General Information VOLTAGE REGULATION RECTIFIER MAIN HARNESS THROTTLE CABLE HEADLIGHT RESISTANCE AUTOMATIC ENRICHMENT RESISTANCE THROTTLE CABLE REAR BRAKE CABLE FRONT DISC BRAKE HOSE SPEEDOMETER CABLE 1-16 CHAPTER 1: INTRODUCTION...
  • Page 20 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 1. General Information FUSE RED BATTERY CABLE POSITIVE GREEN BATTERY CABLE NEGATIVE 1-17 CHAPTER 1: INTRODUCTION...
  • Page 21 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 1. General Information FUEL LINE IGNITION COIL THROTTLE IGNITION CABLE CRANKCASE VENT VACUUM LINE ROCKER COVER VENT 1-18 CHAPTER 1: INTRODUCTION...
  • Page 22 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 1. General Information FUEL VAPOR RETURN PIPE FUEL PASSAGE CRANKCASE BREATHER FUEL SENSOR FVC (FUEL CONTROL VALVE) MAIN WIRING HARNESS THROTTLE CABLE VACUUM LINE STARTER ENRICHMENT CABLE IGNITION COIL VACUUM LINE SPARK PLUG MAIN WIRING...
  • Page 23 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 1. General Information 1-20 CHAPTER 1: INTRODUCTION...

  • Page 24: Trouble Shooting Guide

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 1. General Information Trouble Shooting Guide Starter Failure or Hard Starting Check Adjust Faulty Condition Cause of Trouble Loosen carburetor overflow screw No fuel in tank and check if there is fuel in it...
  • Page 25 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 1. General Information Trouble Shooting Guide (under speed, no power) Check Adjust Faulty Condition Cause of Trouble Supply engine with fuel and watch Air filter blocked Fuel choke Engine RPM OK Low Engine RPM...
  • Page 26 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 1. General Information Trouble Shooting Guide (under speed, no power) Check Adjust Faulty Condition Cause of Trouble Adjust ignition time C.D.I. bad Normal Abnormal Trigger coil bad Adjust carbureator adjusting screw Mixture lean (to loosen screw)
  • Page 27 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 1. General Information Trouble Shooting Guide (high speed) Check Adjust Faulty Condition Cause of Trouble Adjust ignition timing C.D.I. bad Normal Abnormal Trigger coil bad Adjust valve gap Adjustment improper Normal Abnormal Camshaft worn...
  • Page 28 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 1. General Information Trouble Shooting Guide-Improper Battery Charging (Battery overdischarge or overcharge) Check Adjust Faulty Condition Cause of Trouble Start engine and measure battery terminals for limited voltage Battery service life over Battery voltage uncharged Normal (12.5-14V)
  • Page 29 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 1. General Information Trouble Shooting Guide (no spark) Check Adjust Faulty Condition Cause of Trouble Replace spark plug and check again Spark weak or sparkless Spark strong Former spark plug bad Check spark plug cap and ignition coil for looseness...
  • Page 30 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 1. General Information Body Exploded View 1-27 CHAPTER 1: INTRODUCTION...

  • Page 31: Chapter 2: Body Cover And Exhaust System

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 2. Body Cover and Exhaust System Topic Page General Information Body Cover Removal Exhaust System Removal General Information •Do not use excessive force when removing body panels. Use a firm, consistent force to disengage the tabs and remove the panels.
  • Page 32 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 2. Body Cover and Exhaust System Body Cover Removal Front Panel Removal 1. Remove one front cover screw from front of panel. 2. Remove two screws on both left and right sides. Remove front panel. Install front panel in the reverse order.
  • Page 33 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 2. Body Cover and Exhaust System Body Cover Removal 1. Remove middle luggage SEAT box after opening the seat and removing the four lock nuts. 2. Remove two center cover screws. 3. Remove center cover.
  • Page 34 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 2. Body Cover and Exhaust System Right and Left Side Mold Removal 1. Remove two rear body screws. 2. Remove three screws in either side of mold. 3. Remove left and right side panels.
  • Page 35 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 2. Body Cover and Exhaust System Front Box Removal FRONT BOX 1. Remove front cover and front panel. 2. Remove two catch bolts in the front of the floor panel. 3. Remove the front box catch bolt.

  • Page 36: Scheduled Maintenance

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 3. Scheduled Maintenance Topic Page Topic Page Frame and Tire Type Drive Belt Maintenance Chart Rear Brake Arm Fuel Filter Brake System Front Brake Throttle Operation Lever Rear Brake Air filter Front Lamp Adjustment...
  • Page 37 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 3. Scheduled Maintenance Frame •Front brake lever free play: 10-20mm •Rear brake lever free play: 10-20mm Tire unit: kg/cm 1 Person 2 Persons Front 1.5, 17 dsi 1.75, 19 dsi Rear 2.0, 23 dsi 2.2, 28 dsi...

  • Page 38: Maintenance Chart

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 3. Scheduled Maintenance Maintenance Chart I: Inspect, clean, lubricate, add fix or replace Perform regular maintenance, according to when necessary. maintenance handbook. A: Adjust B: Clean C: Replace D: Tighten Mileage (Km) Frequency Whichever...

  • Page 39: Fuel Filter

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 3. Scheduled Maintenance Fuel Filter 1. Remove luggage box (2-2) 2. Check fuel line for ageing or damage. 3. Replace with a new one in case damaged or leaking. Throttle Lever Operation 1. Check throttle for proper operation.

  • Page 40: Air Filter

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 3. Scheduled Maintenance Air Filter Filter Replacement 1. Remove air filter cap, fix screw and remove the air filter cap. 2. Check filter for dirt or damage. Replace as necessary. Do not attempt to clean the filter element.

  • Page 41: Valve Adjustment

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 3. Scheduled Maintenance Valve Adjustment Always check and adjust with engine temperature lower than 35˚C (95˚F) 1. Remove cylinder head cover. CYLINDER HEAD COVER 2. Rotate cooling fan to camshaft. Locate mark at center top, aligning magneto fly wheel mark with that on crankcase.

  • Page 42: Ignition Timing

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 3. Scheduled Maintenance Ignition Time Equipped with CDI, there is no need for ignition setting. Check ignition system if ignition time is incorrect. 1. Dismount right body cover. 2. Remove ignition timing inspection. 3. Check ignition timing using the timing light.
  • Page 43 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 3. Scheduled Maintenance GEAR OIL INLET Final check of gear engine oil reduction HOLE/CHECK HOLE Checking oil volume, build up main foot rest so that build up body becomes vertical on plain ground. 1. Dismount gear oil adjusting bolt after stopping engine.

  • Page 44: Rear Brake Arm

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 3. Scheduled Maintenance Rear Brake Arm 1. Change new pedal when brake bar is pulled to stopping position and the sparrow of brake arm is in alignment with the brake plate mark. ROTATE NUT Brake System-Front Brake 1.

  • Page 45: Front Lamp Adjustment

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 3. Scheduled Maintenance Front Lamp Adjustment UNDERSIDE OF COVER 1. Rotate nut to adjust free gap when it exceeds proper adjustment. 2. Turn main switch to “on” and start engine. 3. Rotate adjusting screw of front lamp to aim the light.

  • Page 46: Nut And Bolt Tightness

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 3. Scheduled Maintenance Nut and Bolt Tightness 1. Check all nuts and bolts for proper tightness. 2. Adjust torque as necessary. Collar Rim Tire 1. Check tire pressure. Measure tire pressure when tire is cold.
  • Page 47 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 3. Scheduled Maintenance Steering 1. Swing handlebars left and right to check if there is interference from the wires. 2. Grasp handlebars and rotate from left to right while holding the front wheel straight. There should be slippage.

  • Page 48: Chapter 4: Lubricating System

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 4. Lubricating System Lubricating System ROCKER ARM CRANKSHAFT FILTER SCREEN ENGINE OIL PUMP CHAPTER 4: LUBRICATING SYSTEM...
  • Page 49 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 4. Lubricating System Topic Page Topic Page Overall engine requirements Engine Oil Pump Removal Problem diagnosis Oil Pump Disassembly Engine oil/filter screen Checking Oil Volume Assembling Oil Changed Installation Overall Engine Requirements Special Attention Use proper motor oil SAE 10W 30.

  • Page 50: Engine Oil/Filter Screen

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 4. Lubricating System Engine Oil/Filter Screen Oil Volume 1. Check oil with scooter parked on level ground on center stand. Put scooter on the plain place when oil volume is checked. Run engine for two or three minutes and then turn it off.
  • Page 51 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 4. Lubricating System Oil Pump Removal 1. Remove engine right outer cover fan magnetor. 2. Remove alternator rotor. WASHER 3. Remove stator pules coil. 4. Remove eight bolts of right crankshaft case cover and take off crankshaft case cover.

  • Page 52: Oil Pump Disassembly

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 4. Lubricating System Oil Pump Disassembly OIL PUMP BODY 1. Remove three fixed screws in oil pump FIXED SCREWS body. 2. Disassemble oil pump. OIL PUMP BODY EXTERNAL ROTOR Checking 1. Check the gap between the oil pump module body and the external rotator.

  • Page 53: Assembling

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 4. Lubricating System Assembling 1. Assemble inner and outer rotators and oil pump shaft. EXTERNAL ROTOR PUMP SHAFT INTERNAL ROTOR Be careful of alignment between pump bearing unfilled corner and inner rotator unfilled corner.
  • Page 54 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 4. Lubricating System 4. Install gear of oil pump and then fix nut. •Torsion value: 0.8-1.2kg-m •7-8ft lbs WASHER 5. Assemble right crankshaft case cover, 8 screws and tighten. 6. Assemble pulse coil, stator and rotor.

  • Page 55: Chapter 5: Fuel System

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 5. Fuel System REGULATOR 5 OHM RESISTOR ENRICHMENT WHITE YELLOW GREEN/BLACK CHAPTER 5: FUEL SYSTEM...

  • Page 56: Fuel System

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 5. Fuel System Topic Page Topic Page General information Disassembly of Accelerator Pump 5-10 Troubleshooting Checking Accelerator Pump 5-10 Disassembly of Carburetor Assembly of carburetor 5-11 Checking Auto-choke Disassembling Fuel tank 5-12 Air cutoff valve...

  • Page 57: Troubleshooting

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 5. Fuel System Troubleshooting Misfire under acceleration Engine is hard to start •Poor spark •No spark •Air mixture screw too lean •Low compression •Bad accelerator pump •No fuel in carburetor -Blocked fuel line Poor drivability -Blocked fuel filter...

  • Page 58: Disassembly Of Carburetor

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 5. Fuel System Disassembly of carburetor 1. Remove seat and helmet storage tub. 2. Remove right side body panel. 3. Disconnect cable connector for auto choke. 4. Loosen carburetor drain screw and drain fuel from float bowl.
  • Page 59 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 5. Fuel System 5. Check pin and seat for wear. 6. Replace if necessary. 7. Place auto choke in mounting location and press down firmly. 8. Put lock ring in position and SCREW fasten screw...

  • Page 60: Air Cutoff Valve

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 5. Fuel System Air Cut Off Valve 1. Disassemble two screws in fuel guide fixed plate and remove fixed plate. 2. Disassemble two screws in air cut off valve. 3. Take off spring and vacuum plate.

  • Page 61: Vacuum Chamber-Break Down

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 5. Fuel System Vacuum Chamber-Break down 1. Remove two screws and take off cover. COVER 2. Remove spring, diaphragm piston. 3. Remove fuel pin and slide. Take special care not to damage diaphragm. Replace if damaged.
  • Page 62 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 5. Fuel System Float Bowl Disassembling 1. Disassemble three screws and take off float bowl. 2. Remove float pin spring. 3. Remove high-speed jet, low-speed jet and fuel volume control screw. Be careful not to break the FLOAT AREA fuel jets and control screw.
  • Page 63 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 5. Fuel System Checking 1. Check float valve and valve seat for damage. MAIN FUEL JET LOW SPEED 2. Check float valve and valve seat FUEL PIN wear, pitting or buildup of dirt. FUEL PIN SPRAY NOZZLE 3.
  • Page 64 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 5. Fuel System Accelerator Pump 1. Remove two screws on pump and take off cover. 2. Take off spring and acceleration pump plate. O-RING Checking 1. Check acceleration pump plate COVER for cracks or hardening of the rubber.

  • Page 65: Assembly Of Carburetor

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 5. Fuel System Assembly of Carburetor 1. Slide carburetor carefully into the manifold, making sure to align the tab on the manifold with the notch on the carburetor. Securely tighten the clamp screw to fix the carburetor in place. Do...

  • Page 66: Disassembling Fuel Tank

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 5. Fuel System Disassembling Fuel Tank 1. Disassemble the body cover. VACUUM LINE CONTROL VALVE 2. Disconnect the wiring harness from the fuel level sending unit. 3. Disconnect the fuel line and vacuum line from the auto fuel valve.

  • Page 67: Carburetor Adjustment

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 5. Fuel System Carburetor Adjustment NOTE: SOME COMPONENTS REMOVED FOR CLARITY. It is generally not necessary to adjust the mixture screw on the side of the carburetor. This screw is FUEL VOLUME REGULATION preset at the factory and...

  • Page 68: Automatic Fuel Valve

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 5. Fuel System Automatic Fuel Valve 1. Disconnect the fuel line and the vacuum line from the control valve and from the carburetor VACUUM LINE CONTROL VALVE and intake manifold. Carefully inspect these lines. Any blockage, deterioration, damage, or cracking of these lines can cause improper functioning of the fuel valve.

  • Page 69: Air Filter Inspection

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 5. Fuel System Air Filter Inspection 1. Remove air filter cover screws. 2. Remove cover. 3. Remove air filter element. 4. Remove clamp on air inlet tube. AIR PIPE AIR FILTER 5. Disconnect air tube from carburetor.

  • Page 70: Chapter 6: Engine Removal And Installation

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 6. Engine Removal and Installation Topic Page Special requirements Engine removal Engine installation Special Requirements •Remove all body panels carefully to provide ease of access to the engine. •Use care when disconnecting the battery cables and fuel lines.

  • Page 71: Engine Removal And Installation

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 6. Engine Removal and Installation Engine Removal 1. Disconnect the battery ground wire. 2. Remove body panels to expose engine. 3. Disconnect the engine ground wire. 4. Remove the spark plug cable from the spark plug and the ignition coil.
  • Page 72 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 6. Engine Removal and Installation 10. Disassemble the brake control cable from the UNDERSIDE OF SCOOTER brake control arm. CHASIS 11. Remove the rear shock absorber. 12. Remove the engine support bolt and move the chassis up the forwards.
  • Page 73 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 6. Engine Removal and Installation Engine Installation 1. Attach front engine support bolt into position and tighten to 5kg-m (35 ft-lbs). 2. Slide chassis to the rear to align the rear mount and install the mounting bolt.

  • Page 74: Chapter 7: Cylinder Head Valve

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 7. Cylinder Head Valve CHAPTER 7: CYLINDER HEAD VALVE...

  • Page 75: Important Information

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 7. Cylinder Head Valve Topic Page Topic Page Important information Valve Seat Chamfer Cutting Tools 7-12 Trouble diagnosis Valve Seat Cutting 7-12 Camshaft Disassembly Building up of Cylinder Head 7-13 Checking of Camshaft Bearing Rocker Arm...

  • Page 76: Trouble Diagnosis

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 7. Cylinder Head Valve Torque Value Slow Speed Hitch •Camshaft bolt 16 ft lbs Compression pressure too low •Lubricate threads with oil Bad valve gap •Valve gap adjusting screw cap 7 ft lbs Burning or curving of valve...
  • Page 77 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 7. Cylinder Head Valve Disassembling of Camshaft 1. Disassemble middle cover. (2-2) 2. Remove four bolts and two nuts, take off valve cover. 3. Disassemble cam chair adjusting bolt and spring. 4. Use the kick-start lever to slowly turn engine CYLINDER until “T”...
  • Page 78 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 7. Cylinder Head Valve 6. Remove rocker arms and pivots. 7. Remove camshaft gear from camshaft chain. 8. Remove camshaft. PIVOTS 9. Check Camshaft 10. Check cam lift. •Use limit: IN: 25.681mm below change •EX: 25.524mm below change...
  • Page 79 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 7. Cylinder Head Valve MEMO CHAPTER 7: CYLINDER HEAD VALVE...
  • Page 80 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 7. Cylinder Head Valve Checking of Camshaft Bearing Rocker Arm 1. Check if camshaft bearing fixed seat and camshaft rocker arm and camshaft rocker bearing is worn or broken. CAMSHAFT FIXED SEAT 2. Measure outer diameter of camshaft bearing fixed seat and camshaft rocker arm.
  • Page 81 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 7. Cylinder Head Valve 4. Remove fan cover. 5. Remove bolt and screw of engine cover. 6. Disassemble and remove engine cover. 7. Pull up on cylinder head to break gasket and slide off cylinder stands.

  • Page 82: Checking Cylinder Head

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 7. Cylinder Head Valve Breaking Down of Cylinder Head 1. Use valve spring compressor to take off lock clip and supporter and valve spring, spring seat valve. Place parts in sequence after SPRING disassembling and assemble in reverse VALVE order during reassembly.

  • Page 83: Valve And Valve Guide

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 7. Cylinder Head Valve Valve and Valve Guide 1. Check if valve is beat, burnt or broken. VALVE PIPE REAMER 2. Check if valve and valve guide are blocked. 3. Measure every valve stem’s outer diameter.
  • Page 84 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 7. Cylinder Head Valve 3. Press in the new valve guide. Spread engine oil on new o-ring and build up new valve guide pipe. Make sure cylinder head is still warm when pressing in new guides.

  • Page 85: Valve Seat Chamfer Cutting Tools

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 7. Cylinder Head Valve Valve Seat Chamfer Cutting Tools \Refer to valve chamfered tool handbook for IN, EX: (30mm) 60˚ details. 1. Press and rotate with 4-5kg 10-12 lb force to polish and cut when correcting.

  • Page 86: Building Up Of Cylinder Head

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 7. Cylinder Head Valve 5. Trim valve seat to assigned 1.2mm seat width and valve seat width with 45 degree chamfered cutting (.047 in.) tool. Standard valve: 1.0 mm (.393 in.) Check contact place of valve 45˚...

  • Page 87: Installing Cylinder Head

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 7. Cylinder Head Valve 4. Use valve spring compressor accessory to make valve contact with valve collar. Use plastic mallet two or three times softly on the ends of the valve to seat collars.

  • Page 88: Camshaft Assembly

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 7. Cylinder Head Valve Camshaft Assembly 1. Assemble rocker arm and rocker shaft. ROCKER ARMS Make alignment between shaft end and fixed screw ROCKER SHAFT bolt hole of camshaft seat when valve rocker shaft is assembled.

  • Page 89: Camshaft Chain Regulator Assembling

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 7. Cylinder Head Valve Camshaft Chain Regulator Assembling 1. First, build up camshaft chain regulator and spacer. Second, lock two fixed bolts. Third, put spring into camshaft chain regulator. Last, assemble the o-ring and fixed bolt.
  • Page 90 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 7. Cylinder Head Valve 3. Lock fixed screw bolt of cylinder head cover. Torsion valve: 0.8-1.2 kg-m 4. Spread grease on threading position of camshaft fixed seat screw bolt. CYLINDER 5. Lock two or three times at HEAD diagonal of camshaft fixed seat...
  • Page 91 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 8. Cylinder and Piston CHAPTER 8: CYLINDER AND PISTON...

  • Page 92: Cylinder And Piston

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 8. Cylinder and Piston Topic Page Topic Page Material Removing the piston Troubleshooting Assembling the piston Removing the cylinder Assembling the cylinder Checking the Cylinder Important Points •The work on the cylinder and piston can be done on the engine without complete disassembly.
  • Page 93 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 8. Cylinder and Piston Removing the Cylinder 1. Detach the cylinder head (refer to 7-6). 2. Remove the chain guide of the cam CYLINDER HEAD chain. 3. Remove the cylinder. NOTE: CHAIN REMOVED FROM 4.
  • Page 94 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 8. Cylinder and Piston Checking the piston, the piston pin and the piston ring. Attention: Don’t damage or break the ring. PISTON PIN 1. Clear off all of the carbon deposits from the ring groove.
  • Page 95 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 8. Cylinder and Piston 6. Measure the OD of the piston pin. Maximum service allowance: Replace when it is below 12.96 mm, (.51 in.). 7. Measure the OD of the piston. PISTON PIN Attention:...
  • Page 96 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 8. Cylinder and Piston 3. Check the distortion of the cylinder. Maximum service allowance: Repair or replace when it goes beyond 0.05mm (.002 in.). 4. Measure the ID of the small end of the connecting rod.
  • Page 97 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 8. Cylinder and Piston 8. Install the chain guide lever of the cam. Attention: Make sure that the lug of the guide lever enters the notch of the cylinder. Assembling the Piston 1. Scrape away the gasket adhering on the surface of the crankcase.
  • Page 98 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 8. Cylinder and Piston Assembling the Cylinder 3. Install the locating pin and the gasket to the crankcase. 4. Coat the inner surface of the cylinder, the piston and the piston ring with oil.
  • Page 99 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 9. Driving Belt Device & The Starting Lever Topic Page Topic Page Important Points The Clutch/Transmission Pulley 9-10 Troubleshooting Removing the Clutch/ Detaching the Left Crankcase Cover Transmission Pulley Removing the Starting Pivot Disassembling the Clutch/...

  • Page 100: Important Points

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 9. Driving Belt Device & The Starting Lever Important Points •This chapter is about the driving unit, the •The surface of the driving belt and the drive units clutch/driven unit and the starting lever.

  • Page 101: Detaching The Left Crankcase Cover

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 9. Driving Belt Device & The Starting Lever CLIP OF THE AIR TUBE Detaching the Left Crankcase Cover 1. Unlock the clip for the air tube for the driving belt. 2. Remove eight bolts and then take off the left crankcase cover and the locating pin.

  • Page 102: Checking The Starting Pivot

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 9. Driving Belt Device & The Starting Lever Checking the Starting Pivot 1. Check if the pivot and the gear are worn. Check if there is any softness of the starting PIVOT SLEEVE return spring. Check if there is any excessive wear on the pivot sleeve.

  • Page 103: Assembling The Left Crankcase Cover

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 9. Driving Belt Device & The Starting Lever 2. As shown in the picture on the right, assemble the driven gear and the friction spring. Maintain the orientation as shown. 3. Install the starter pivot (3a).

  • Page 104: Checking The Driving Belt

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 9. Driving Belt Device & The Starting Lever Checking the Driving Belt Detach the left crankcase cover. Check if the driving belt is cracked, frayed, or if there is abnormal wear. Measure the width of the belt.

  • Page 105: Assembling The Driving Belt

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 9. Driving Belt Device & The Starting Lever Assembling the Driving Belt 1. Turn the driving pulley clockwise to keep DRIVING BELT the notches of the belt in expanded condition. Then install the new driving belt.

  • Page 106: Checking The Driving Pulley

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 9. Driving Belt Device & The Starting Lever 6. Remove the retainer. 7. Remove the rollers. ROLLER RETAINER Checking the driving pulley 1. Check the wear of the rollers. Measure the OD of the roller.

  • Page 107: Assembling The Driving Pulley

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 9. Driving Belt Device & The Starting Lever Assembling the Driving Pulley 1. Install the driving pulley sleeve and the driving pulley on the crankshaft (1a). Install the driving belt on the crankshaft (1b). Install the driving pulley and the washer (1c).

  • Page 108: The Clutch/Transmission Pulley

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 9. Driving Belt Device & The Starting Lever CLUTCH HOUSING The Clutch/Transmission Pulley Removing the Clutch/Transmission Pulley 1. Remove the driving pulley. Then use a spanner wrench to hold the SPANNER clutch housing to screw out the 10mm WRENCH (.39 in.) nut.

  • Page 109: Transmission Pulley

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 9. Driving Belt Device & The Starting Lever 8. Remove the guide rolling pin from the transmission pulley assembly, and then take out the o-ring and the oil seal. OIL SEAL O-RING Checking the Clutch...
  • Page 110 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 9. Driving Belt Device & The Starting Lever 4. Check the wear of the transmission pulley. Measure the OD of the pulley. Maximum service allowance: Replace when it is below 19.97mm (.79 in.). 5. Check the wear of the transmission pulley.
  • Page 111 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 9. Driving Belt Device & The Starting Lever 4. Drive in the new needle bearing, keeping the “mark” side up. The Clutch/Transmission Pulley Assembly 1. Assemble the transmission pulley guide pin and oil seal.

  • Page 112: Assembling The Clutch Housing

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 9. Driving Belt Device & The Starting Lever CLUTCH HOUSING 4. Assembling the clutch/transmission pulley, put the driving belt onto the clutch/transmission pulley, then onto the driving shaft. Assembling the Clutch Housing SPANNER WRENCH 5.

  • Page 113: Chapter 10: The Final Transmission Assembly

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 10. The Final Transmission Assembly 10-1 CHAPTER 10: THE FINAL TRANSMISSION ASSEMBLY...
  • Page 114 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 10. The Final Transmission Assembly Topic Page Topic Page General Information 10-2 Replacing the Bearing 10-5 Dismantling the Final 10-3 (on the side of the crankcase) Transmission Assembly Assembling the Final Gear Set 10-5...
  • Page 115 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 10. The Final Transmission Assembly Dismantling the final transmission assembly 1. Remove the rear brake cable. FIX BOLT 2. Remove the rear wheel (refer to 13-3). 3. Remove the left crankcase cover (refer to 9-2).
  • Page 116 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 10. The Final Transmission Assembly FINAL TRANSMISSION 4. Check if the bearing in the left SHAFT BEARING crankcase and the oil seal are worn SUB SHAFT BEARING or damaged. 5. Check if the driving shaft (the main clutch shaft) and the gear are worn or damaged.
  • Page 117 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 10. The Final Transmission Assembly Replacing the Bearing (on the side of the crankcase) 1. Remove the driving shaft (the clutch main shaft). DRIVING SHAFT Then remove the oil seal of the shaft. 2. Use a bearing puller to remove the bearing in the final transmission...
  • Page 118 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 10. The Final Transmission Assembly 3. Attach the sub shaft and the washer to the final transmission gearbox. Install the resin washer to SUB SHAFT the sub shaft; install the locating pin RESIN and the new gasket.

  • Page 119: Chapter 11: The Crankcase And The Crankshaft

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 11. The Crankcase and the Crankshaft 11-1 CHAPTER 11: THE CRANKCASE AND THE CRANKSHAFT...
  • Page 120 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 11. The Crankcase and the Crankshaft Topic Page Important points 11-1 Diagnosis 11-1 Dismantling the crankcase 11-3 The crankshaft 11-4 Assembling the crankcase 11-5 Important Points •The chapter gives instructions related to the •AC generator (refer to Chapter 14) crankshaft and dismantling the crankcase.
  • Page 121 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 11. The Crankcase and the Crankshaft Dismantling the Crankcase RETAINING SCREW 1. Detach the bolt of the OF THE CHAIN chain adjusting guide lever GUIDE LEVER of the cam and remove the lever. 2. Remove assembly bolts of the crankcase.
  • Page 122 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 11. The Crankcase and the Crankshaft 7. Scrape the gasket away from the joint surfaces. Attention: be sure not to scratch the joint surfaces. OIL SEAL 8. Remove the oil seal from the left crankcase.
  • Page 123 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 11. The Crankcase and the Crankshaft 2. Check the clearance of the journal of the big end of the connecting rod in X-Y directions. Maximum service allowance: Replace when it goes beyond 0.05mm (.002 in.).
  • Page 124 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 11. The Crankcase and the Crankshaft 2. Install the cam chain into the left crankcase. 3. Assemble the crankshaft into the left crankcase. LOCATING PIN LOCATING PIN CRANKSHAFT GASKET Attention: Be sure not to let the chain damage the oil seal.
  • Page 125 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 11. The Crankcase and the Crankshaft 6. Install the cam chain adjusting lever. 7. Install the o-ring onto the bolt of the chain adjusting lever. 8. Coat the o-ring with oil, and then lock it.
  • Page 126 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 11. The Crankcase and the Crankshaft MEMO 11-8 CHAPTER 11: THE CRANKCASE AND THE CRANKSHAFT...

  • Page 127: Chapter 12: The Front Wheel, Front Brake

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 12. The Front Wheel, Front Brake, Front Buffer and the Front Fork 12-1 CHAPTER 12: THE FRONT WHEEL, FRONT BRAKE, FRONT BUFFER AND THE FRONT FORK...
  • Page 128 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 12. The Front Wheel, Front Brake, Front Buffer and the Front Fork Topic Page Topic Page Instructions 12-2 Dismantling the Front Shock 12-10 Troubleshooting 12-3 Assembling Sequence 12-11 Removing the Steering Handlebars 12-4 The Front Fork...
  • Page 129 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 12. The Front Wheel, Front Brake, Front Buffer and the Front Fork Spanner wrench Drive bar Outer race puller 28x30mm Outer race driver 37x40mm Compressor for the shock Dismantling lever 10mm absorber Bearing puller...

  • Page 130: Removing The Steering Handlebars

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 12. The Front Wheel, Front Brake, Front Buffer and the Front Fork LEFT HANDLEBAR Removing the Steering Handlebars 1. Detach the front and rear covers of the handlebars. BOLT 2. Remove the two bolts of the left brake lever.

  • Page 131: Front Wheel Removal

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 12. The Front Wheel, Front Brake, Front Buffer and the Front Fork 3. Coat the end of the throttle grip with grease. 4. Install the throttle grip and then the cable. 5. To assemble, reverse order of disassembly steps.

  • Page 132: Dismantling Of Wheel

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 12. The Front Wheel, Front Brake, Front Buffer and the Front Fork 6. Check the run-out of the wheel rim. Maximum service allowance: Hop-longitudinal 2.0mm (.079 in.) Wobble-transversal 2.0mm (.079 in.) 7. Replace when it goes beyond the above value.

  • Page 133: Assembly Of Wheel

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 12. The Front Wheel, Front Brake, Front Buffer and the Front Fork 2. Detach the rim bearing and the spacer. Assembly of Wheel BEARING 1. Fill the bearing with grease 2. Drive the left bearing first.

  • Page 134: Assembling The Front Wheel

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 12. The Front Wheel, Front Brake, Front Buffer and the Front Fork 6. Coat the oil seal with grease, and COLLAR then install it. 7. Attach the collar. Assembling the front wheel. 1. Point the lug of the gear bank of the speedometer to the notch of the front fork leg.

  • Page 135: Dismounting The Front Shock

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 12. The Front Wheel, Front Brake, Front Buffer and the Front Fork Dismounting the Front Shock 1. Remove the front wheel (refer to 12-4). 2. Remove the lower front cover (refer to 2-1). 3. Remove the upper clamp bolt.

  • Page 136: Dismantling The Front Shock

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 12. The Front Wheel, Front Brake, Front Buffer and the Front Fork Dismantling the Front Shock TOP NUT 1. Remove the oil/dust seal. 2. Remove the outer retainer. Use a bench vise to hold the front...

  • Page 137: Assembling Sequence

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 12. The Front Wheel, Front Brake, Front Buffer and the Front Fork 5. Install the buffer spring on the guide lever of the damper, then into the front fork tube. Then install the buffer spring and lock the nuts.

  • Page 138: The Front Fork

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 12. The Front Wheel, Front Brake, Front Buffer and the Front Fork The Front Fork Front fork removal 1. Detach the handlebar (refer to 12-3). 2. Remove the front wheel (refer to 12-4). 3. Remove the cable of the...

  • Page 139: Assembling The Upper Race

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 12. The Front Wheel, Front Brake, Front Buffer and the Front Fork 2. Press in the new race. Attention: Be sure to press the race all the way RACE into place. Assembling the Upper Race 1.

  • Page 140: Checking The Brake Lining

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 12. The Front Wheel, Front Brake, Front Buffer and the Front Fork Checking the Brake Lining 1. Measure the thickness of the brake lining. Replace when it is below 2.0mm (.079 in.) Attention: Don’t have the oil adhere to the lining surface.
  • Page 141 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 12. The Front Wheel, Front Brake, Front Buffer and the Front Fork BRAKE 12-15 CHAPTER 12: THE FRONT WHEEL, FRONT BRAKE, FRONT BUFFER AND THE FRONT FORK...
  • Page 142 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 12. The Front Wheel, Front Brake, Front Buffer and the Front Fork MEMO 12-16 CHAPTER 12: THE FRONT WHEEL, FRONT BRAKE, FRONT BUFFER AND THE FRONT FORK...
  • Page 143 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 13. The Rear Wheel, the Rear Brake & Rear Shock 13-1 CHAPTER 13: THE REAR WHEEL, THE REAR BRAKE & REAR BUFFER...
  • Page 144 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 13. The Rear Wheel, the Rear Brake & Rear Shock Topic Page Topic Page Important points 13-2 Checking the Rear Brake 13-4 Troubleshooting 13-2 Dismantling the Rear Brake 13-4 Detaching the Rear Wheel 13-3...

  • Page 145: Detaching The Rear Wheel

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 13. The Rear Wheel, the Rear Brake & Rear Shock Detaching the Rear Wheel 1. Detach the exhaust pipe (refer to 2-8) 2. Remove the nut of the rear wheel axle. 3. Remove the rear wheel.

  • Page 146: Dismantling The Rear Brake

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 13. The Rear Wheel, the Rear Brake & Rear Shock Checking the Brake Lining 1. Measure the thickness of the brake lining. Replace when it is below 2.0mm (.079 in.). Attention: Don’t have the oil adhere to the lining surface.

  • Page 147: Dismounting The Rear Shock

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 13. The Rear Wheel, the Rear Brake & Rear Shock 11. Assemble the wear indication board and the brake arm. 12. Assemble the brake arm and the brake cam. Attention: Point the “gullet” mark of the brake arm to the “dot”...

  • Page 148: Assembling The Rear Shock

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 13. The Rear Wheel, the Rear Brake & Rear Shock Assembling the Rear Shock 1. Attach the rear shock. CHASIS 2. Install the top bolt of the shock. 3. Install the bottom bolt of the shock.

  • Page 149: Chapter 14: The Battery And The Charging System

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 14. The Battery and the Charging System MEMO 14-1 CHAPTER 14: THE BATTERY AND THE CHARGING SYSTEM...
  • Page 150 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 14. The Battery and the Charging System RECTIFYING VOLTAGE STABILIZER BATTERY RESISTOR FUSE A.C. MAGNETO RECTIFYING AUTO A.C. MAGNETO VOLTAGE ENRICHER 10.2 OHM HEAD LAMP BATTERY STABILIZER SWITCH 12V4AH GREEN/YELLOW GREEN YELLOW WHITE 14-2...
  • Page 151 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 14. The Battery and the Charging System Topic Page Topic Page Instructions 14-1 The Charging System Diagnosis 14-2 Testing short circuit 14-7 The battery 14-3 Assembling the magnetor 14-8 The charging system 14-4 The Magneto Charging Coil...

  • Page 152: Diagnosis

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 14. The Battery and the Charging System Tech Criteria Item Data Capacity/Type 12 V-4AH or 12V-5AH 13.1V Fully charging VOLT (20˚C) Low limit 12.3V Battery Charging CUR Standard: 0.4A; Fast: 2A Standard: 5-10 hrs; Fast 1hr...

  • Page 153: The Battery

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 14. The Battery and the Charging System Detaching the Battery 1. Remove the screws of the battery cover under the floor mat. 2. Open the cover and remove the battery cable attachment screws. Attention: First detach the negative (-) terminal wire, then the (+) terminal wire.
  • Page 154 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 14. The Battery and the Charging System Attention: •No sparks should be allowed around the battery. •Turn off the charger first, either at the beginning or the end of the charging, to prevent sparks, which can cause an explosion.

  • Page 155: The Charging System

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 14. The Battery and the Charging System The Charging System Testing short circuit 1. Detach the earth wire from the battery. 2. Connect the ammeter between the "-" terminal of the battery and the earth wire, the main switch being in the “off”...

  • Page 156: The Rectifying Voltage Stabilizer

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 14. The Battery and the Charging System The rectifying voltage stabilizer 1. Checking the main cable circuit. 2. Detach the 4P plug from the rectifying voltage stabilizer. 3. Check the conductivity between terminals of the main cable in the...

  • Page 157: Checking The Resistor

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 14. The Battery and the Charging System The Magneto Charging Coil Attention: The operation of the magneto charging coil can be done in the engine. Checking 1. Detach the connecting plug of the magneto.
  • Page 158 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 14. The Battery and the Charging System 3. Remove the four bolts and remove the cooling fan. COOLING 4. Use a universal solid wrench to secure the flywheel. Detach the fix nuts of the flywheel.

  • Page 159: Assembling The Magneto

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 14. The Battery and the Charging System 3. Detach the stator of the magneto. 4. Remove the bolts of the triggering coil. 5. Remove the rubber sleeve of the TRIGGERING COIL magnetor wire from the right crankcase.
  • Page 160 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 14. The Battery and the Charging System 4. Connect the connecting wire of the magnetor. 5. Clean the cone part of the crankshaft and of the flywheel. MAGNETO Be sure to lay the locating key of the flywheel into the keyway...
  • Page 161 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 14. The Battery and the Charging System 8. Install the fan cover and securely tighten fasteners. FAN COVER 14-13 CHAPTER 14: THE BATTERY AND THE CHARGING SYSTEM...
  • Page 162 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 14. The Battery and the Charging System MEMO 14-14 CHAPTER 14: THE BATTERY AND THE CHARGING SYSTEM...

  • Page 163: Chapter 15: Ignition System

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 15. Ignition System MAIN SWITCH SPARK PLUG A.C. MAGNETO PICKUP COIL MAIN SWITCH BI/Y SPARK IGNITION PLUG COIL UNIT FUSE BATTERY 12V4AH BLUE BLUE/YELLOW BLACK/YELLOW GREEN BI/Y 15-1 CHAPTER 15: IGNITION SYSTEM...

  • Page 164: Ignition System

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 15. Ignition System Topic Page General Information 15-2 Troubleshooting 15-3 CDI unit inspection 15-4 Ignition Coil Removal Steps 15-5 Magneto Pickup Coil Inspection 15-6 Spark Advance Angle Inspection 15-6 General Information •Make sure spark plug heat range is correct.
  • Page 165 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 15. Ignition System Troubleshooting High Tension Voltage Too Low •Crankshaft revolution too slow or battery voltage too low •Ignition system wiring loose •Faulty ignition coil •Faulty CDI unit •Faulty pickup coil High Tension Voltage Intermittent •Faulty main switch...
  • Page 166 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 15. Ignition System CDI Inspection 1. Remove the three screws from the battery case cover. 2. Disconnect the CDI module from the wire harness. 3. Test resistance of the terminals with a multi-meter. Attention:...
  • Page 167 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 15. Ignition System Ignition Coil Removal Steps 1. Remove the middle box. 2. Remove the spark plug cap. 3. Disconnect the wires, remove the ignition coil jam nuts and remove the ignition coil. Inspection 4.
  • Page 168 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 15. Ignition System Magneto Pickup Coil Inspection This test is to be conducted with the stator mounted in the engine. 1. Remove the fan cover. FAN COVER 2. Disconnect the magneto. 3. Test the pickup coil resistance between the blue/yellow and green lead terminals whose standard value is 80-160.

  • Page 169: Chapter 16: Starter System

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 16. Starter System BRAKE SWITCH BRAKE SWITCH STARTER START SWITCH RELAY RELAY MAIN SWITCH FUSE (10A) FRONT REAR BATTERY BRAKE LAMP START FUSE MOTOR BRAKE SWITCH YELLOW/RED GREEN/YELLOW GREEN 16-1 CHAPTER 16:STARTER SYSTEM...

  • Page 170: Starter System

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 16. Starter System Topic Page Topic Page General Information 16-2 Starter Motor Inspection 16-6 Troubleshooting 16-2 Starter Motor Installation 16-6 Starter Motor Removal 16-3 Starter Pinion Removal 16-7 Starter Disassembly 16-3 Starter Pinion Inspection...
  • Page 171 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 16. Starter System Starter Motor Removal Never work on the starter motor until main switch is turned off and the battery ground wire is disconnected to ensure that the motor cannot turn. 1. Remove the starter motor lead clamp.
  • Page 172 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 16. Starter System 6. Check the starter motor housing conductivity. Be sure there is no conduction current between the cable terminal and the starter motor housing. 7. Check conductivity between the lead terminal and the brush.
  • Page 173 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 16. Starter System 10. Apply grease to the dust cover. DUST COVER 11. Install spring brush in its holder. 12. Apply a light film of grease to both ends of the sliding surfaces of the armature shaft.
  • Page 174 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 16. Starter System 3. To inspect starter relay voltage: Stand the scooter on is center stand, measure the voltage between the starter relay negative terminal (green/yellow cable) and the ground. Turn the main switch to “on”, pull the brake levers and make sure the battery voltage is available at the relay (12 volts).
  • Page 175 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 16. Starter System 3. Remove the four bolts and remove the cooling fan. COOLING 4. Use a universal solid wrench to secure the flywheel. Detach the fix nuts of the flywheel. 5. Use a spanner wrench hold flywheel while removing the retaining nut.

  • Page 176: Chapter 17: Meters, Switches And Lighting System

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 17. Meters, Switches and Lighting System MEMO 17-1 CHAPTER 17:METERS, SWITCHES AND LIGHTING SYSTEM...
  • Page 177 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 17. Meters, Switches and Lighting System Topic Page Topic Page Maintenance information 17-2 Replacing the Horn Switch 17-5 Troubleshooting 17-2 Main Switch Inspection 17-5 Fuel Sensor Removal 17-3 Replacing the Main Switch 17-5 Fuel Sensor Installation...

  • Page 178: Fuel Sensor Removal

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 17. Meters, Switches and Lighting System Fuel Sensor Removal Avoid sparks and flames when working on the fuel system. 1. Remove the middle luggage box. 2. Remove the right body panel. 3. Disconnect the fuel sensor from the wire harness.

  • Page 179: Handlebar Switch

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 17. Meters, Switches and Lighting System Handlebar Switches Inspection 1. Remove the speedometer cover. 2. Disconnect the handlebar connector and YELLOW check each terminal for conduction. 3. Inspect each switch if abnormal. PINK BROWN...

  • Page 180: Replacing The Horn Switch

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 17. Meters, Switches and Lighting System Hom Switch Color Light Green BLACK Code BLACK Released LIGHT GREEN Depressed Replacing the horn switch: BLACK 1. Remove the front panel. BLACK/ WHITE GREEN 2. Remove the handlebar cover.

  • Page 181: Brake Light Switch Inspection

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 17. Meters, Switches and Lighting System Brake Light Switch Inspection 1. Remove the speedometer cover. 2. Disconnect the front brake switch lead. 3. Operate the front brake lever to check the switch for proper operation.

  • Page 182: Headlight Removal And Installation

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL 17. Meters, Switches and Lighting System Headlight Removal and Installation 1. Remove the speedometer cover (refer to 2-1). 2. Remove the headlight adjustable bolt. 3. Remove the alignment pin and HEADLIGHT headlight. ADJUSTABLE BOLT 4.

  • Page 183: Index

    NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL Index Page Auto-Choke- checking......................Ball Cone Race- replacing...................... Battery and Charging System- diagnosis................. Battery and Charging System- instructions................Battery..........................Bearing- Side Gearbox Cover- replacing.................. Bearing- Side of Crankcase- replacing..................Belt- Driving- assembly......................Belt- Driving- checking......................
  • Page 184 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL Index Clutch/Transmission- Pulley- disassembly................Clutch/Transmission- Pulley- removal..................Control Cables and Wiring Diagram..................Crankcase and Crankshaft- diagnosis..................Crankcase and Crankshaft- Important Points................Crankcase- assembly......................Crankcase Cover- left- assembly.................... Crankcase Cover- left- detaching.................... Crankcase- dismantling ......................
  • Page 185 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL Index Final Gear Set- assembling..................... Float Bowl- disassembly......................Fork- Front..........................Frame Type.......................... Front Wheel / Brake- instructions.................... Front Wheel / Brake- troubleshooting..................Front Wheel- assembly......................Front Wheel- removal......................Fuel System- information....................... Fuel System- troubleshooting....................
  • Page 186 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL Index Meter- Fuel Sending Unit......................Meters, Switches and Lighting System- maintenance information..........Meters, Switches and Lighting System- troubleshooting............Nut- tightening........................Oil and Grease Supply Chart....................Oil- Gear Engine........................Oil- volume..........................Oil-changed.......................... Oil-checking.......................... Overrunning Clutch- checking and assembling.................
  • Page 187 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL Index Shock- Front- dismantling....................... Shock- Front- dismounting...................... Shock- Rear- assembling....................... Shock- Rear- dismounting...................... Spark- Advance Angle Inspection.................... Spark Plug........................... Speedometer- removal and reinstallation................Starting Assembly- installation....................Starting Pivot- checking......................Starting Pivot- removing......................Steering System........................
  • Page 188 NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL Index Vacuum Chamber-breakdown....................Valve- adjustment........................Valve- Air Cutoff........................Valve- Air Cutoff- assembling....................Valve and Valve Guide......................Valve- Float- checking......................Valve Fuel- automatic......................Valve Seat Chamfer Cutting Tools................... Valve Seat Cutting......................... Voltage Stabilizer- Rectifying....................Wheel- assembly........................

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