Vento zipr3i Service Manual
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Vento zipr3i Service Manual

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  • Page 2 Inspection/Service and overhaul of its main components. This Manual is intended those who have enough knowledge and skills for servicing of VENTO vehicles. Without such knowledge and skills you should not attempt servicing by relying on this manual only. Instead, please contact your nearly...
  • Page 3 CHAPTER 1 1-1 GENERAL INFORMATION TYPE & IDENTIFICATION FRAME NUMBER FRAME NUMBER is Engraving on the steel tube of frame as shown in figure. ENGINE NUMBER ENGINE NUMBER is Engraving on rear side Crankcase Shown figure. Both FRAME NUBER AND ENGINE NUMBER are designed Specially for registration your scooter and for spare part Orders.

  • Page 4: General Information

    After reassembly, recheck parts for tightness and operation. REPLACEMENT COMPONENTS Be sure to use genuine VENTO spare parts or their equivalent. Genuine VENTO components are high quality parts, which are designed specially for VENTO vehicles. CAUTION Scooter/motorcycle may damage by using non genuine parts or parts that is not equivalent to...
  • Page 5 1-3 GENERAL INFORMATION SPECIFICATIONS Ignition Timing...... 5000 RPM Spark Plug......NGK/R/BR8HSA DIMENSIONS AND NET WEIGHT Storage Battery....YUASA/YB4L-4 Battery Capacity......12V-4Ah Overall Length.......1620mm Magneto..........AC Overall Width......625mm Fuse..........10Amp Overall Height.......1010 mm Headlight......12V 35 / 35 Watt Wheelbase......1170mm Turn Indicators (X4)....12V / 3 Ground Clearance......90mm Watt Dead Weight........78kg Tail...

  • Page 6: Table Of Contents

    CHAPTER 2 PERIODIC MAINTENANCE AND SERVICE Contents Periodic maintenance and service schedule........5 Storage battery................7 Service and adjustment procedures..........9 Cylinder head nut and exhaust pipe bolt ........9 Cylinder head and cylinder ............9 Spark plug ...................10 Air cleaner..................11 Fuel level line................12 Throttle cable................12 Engine idle speed.................12 Oil pump..................13 Gear oil..................14...

  • Page 7: Periodic Maintenance And Service Schedule

    2-1 PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Mileages are expressed in terms of Kilometer, Miles and time for your convenience. Note More frequent servicing may be performed on motorcycles that are used under bad road condition.
  • Page 8 2-2 PERIODIC MAINTENANCE PROCEDURE BATTERY INSPECTION AND CHECKING PROCEDURE Storage Battery Inspect at initially 1000Kms 630 miles 2 months and every 6000 Kms 3780 miles 12 months. Open seat, and then remove the battery box cap in theMiddle of helmet box. Disconnect Negative terminal / Cable first then Positive terminal / Cable of Battery Measure the voltage between the +ve and ve terminal of Battery charge the Battery if the voltage is below the specified limit.
  • Page 9 BATTERY TESTING PROCEDURE Remove the battery from the Motorcycle/Scooter. Connect the battery on load tester ensuring Red lead of tester to (+ve) and Black lead to (-ve) terminal of battery. Check the terminal voltage of battery. It should be 12~14.5 Volts. Press the push button on the tester and watch the voltmeter reading on load. The battery voltage should not drop down less than 9 volts;...
  • Page 10 IMPORTANT TIPS ON BATTERY SPECIFIC The Specific Gravity of fully charged battery should be 1.220~1.240 GRAVITY Use Hydrometer to check each cell of battery. WARNING Remove negative terminal first, then positive terminal. If the battery is corroded by sulfur. Please exchange it. If the terminal of the battery has too much precipitate, please exchange it.

  • Page 11: Service And Adjustment Procedures

    2-3 PERIODIC MAINTENANCE AND ADJUSTMENT PROCEDURE Cylinder head nuts and exhaust pipe bolts Tighten at Initially 1000 km 630 miles or 2 Months and every 6000 km 3780 miles or 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: 1.

  • Page 12: Spark Plug

    2-4 PERIODIC MAINTENANCE AND ADJUSTMENTS PROCEDURE 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.

  • Page 13: Air Cleaner

    2-5 PERIODIC MAINTENANCE AND ADJUSTMENT PROCEDUR AIR CLEANER Clean every 3000 Kms 1890 miles Replace every 12000 Kms(1750 Miles) If the air cleaner is clogged with dust, Air Intake resistance will be increased with a result decrease in power output and will be increase in fuel consumption.

  • Page 14: Fuel Level Line

    THROTTLE CABLE Adjust at initially 1000Kms 630 miles or after 2 months. And after every 6000 Kms 3780 miles or after 12 months. Loosen locknut and adjust throttle cable play by turning adjuster in or out to obtain the following cable play. After adjusting the cable Play tightens the locknut.

  • Page 15: Oil Pump

    2-6 PERIODIC MAINTENANCE PROCEDURE OIL PUMP: Inspect at Initially 1000 Kms 630 miles 2 months and every 6000 kms 3780 miles or 12 months there after. The oil pump to the engine feeds the engine oil. The amount of oil fed to it is regulated by engine speed and oil pump control lever, which is controlled by amount of throttle opening.

  • Page 16: Gear Oil

    2-7 PERIODIC MAINTENANCE PROCEDURE GEAR OIL: Inspect at initially 1000 km 600 miles or 2 months and every 6000 km 3780 miles or 12 months thereafter. Inspect gear oil periodically as follows: Remove the cover and hose. Remove the kick-start lever. Remove clutch cover Remove oil level bolt and inspect oil level, if oil level is below the oil hole level, Add oil until oil flows from the level hole.

  • Page 17: Braking

    2-8 PERIODIC MAINTENANCE PROCEDURE BRAKE PADS (FRONT BRAKE) Observing the limit can check the Wear condition of brake pads Line marked on the pad. When the wear exceeds the limit mark, replace the pads with new ones. CAUTION: Replace the brake pad as a set, otherwise braking efficiency will be Adversely affected.
  • Page 18 2-9 PERIODIC MAINTENANCE AND ADJUSTMENT PROCEDURE BRAKELEVR PLAY (REAR BRAKE): Turn adjusting nut 2 so that the play @ of Brake Lever is 15-25mm (0.6~0.8) as shown. BRAKE SHOE WEAR: This vehicle is equipped with the brake lining limit Indicator on the rear brake. Inspect brake lining limit as follows: First check if the brake system is properly Adjusted.

  • Page 19: Tire

    TIRE Inspect at initially 1000Kms 630 miles 2 months and every 6000KM 3780 miles 12 months thereafter Tire pressure If the tire pressure is too high, the steering will be Adversely affected and tire wear increased. Conversely, if tire pressure is too low, stability will be adversely affected. Therefore, maintain the correct tire pressure for good Drivability and to prolong tire life.

  • Page 20: Front Shock Absorber

    FRONT FORK: Inspect &Adjust at initially 1000 kms 630 miles 2 months and every 6000 km 3780 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: Inspect &Adjust at initially 1000 kms 630 miles 2 months and every 6000 km 3780 miles 12 months thereafter.
  • Page 21 Rev no.01/ page 21of 128...
  • Page 22 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 Lubricate exposed parts, which are subject to rust with a rust preventive spray whenever the motorcycle has been operated under wet or rainy condition.

  • Page 23: Compression Pressure Check

    COMPRESSION PRESSURE CHECK The compression of the cylinder is a good indicator of its internal condition. The decision to overhaul the cylinder is often based on the results of a Compression test. Periodic maintenance records kept at your dealership should include compression readings for each maintenance.
  • Page 24 AUTOMATIC CLUTCH INSPECTION This VENTO Zip r3i is equipped with an automatic clutch and variable ratio belt drive transmission. The engagement of the clutch is governed by engine RPM and centrifugal mechanism located in the clutch. To ensure proper performance and longer lifetime of the clutch assembly it is essential that the clutch engagement smoothly and gradually.
  • Page 25 CHAPTER 3 ENGINE Contents Page Engine components removal with the engine in place ....24 Engine removal and reinstallation ..25 Engine components inspection and servicing........33 Crankshaft ......................33 Clutch shoe inspection ..................34 Drive belt inspection ...................35 Movable driven face inspection ................35 Roller and sliding surface inspection ..............35 Driven face pin and oil seal inspection ..............36 Rev no.01/ page 25of 128...

  • Page 26: Engine Components Removal With The Engine In Place

    The parts listed below can be removed and reinstalled without removing the engine from the frame. Engine left side Kick starter lever Clutch cover Kick starter shaft Kick driven gear Fixed drive fan Fixed drive gear V-belt Movable drive face Starter driven gear Starter drive gear Clutch housing...

  • Page 27: Engine Removal And Reinstallation

    Engine removal and reinstallation Engine removal Remove ignition coil Remove muffler Remove cylinder cover Remove cooling fan cover Remove cooling fan Remove magneto rotor nut. Remove the magneto rotor. Remove magneto rotor and key. Remove oil pump and retainer. Rev no.01/ page 27of 128...
  • Page 28 Remove oil pump gear. Remove cylinder head and cylinder. Place a cloth stopper below the piston and Remove the circlip with pliers. Remove the piston pin and piston. Remove the kick-starter lever. Remove clutch cover Remove the kick-starter shaft spring and Kick starter shaft.
  • Page 29 Remove the retainer after removing the screws. Remove spring, gasket and kick starter gear. Remove the kick-starter nut with the special a tool. : The nut has counter-clockwise thread. Caution Remove fan and v-belt. Disassemble the movable drive face. Remove the kick-starter shaft. Remove starter idle gear cap and starter pinion.
  • Page 30 Drain gear oil. Remove gear case cover. Remove starter shaft. Remove the circlip and final driven gear. Remove the idle gear shaft assay. Remove the rear axle nut. Remove the rear wheel. Remove brake shoes and rear axle shaft. Remove the rear brake cam lever indicator plate and camshaft. Remove spring Remove cotter pin and shaft Remove main stand...
  • Page 31 Disassemble crankcase with a special tool. Remove crankcase. Loosen the clutch shoe nut. Remove the nut while holding down clutch Shoe assembly with both hands (as shown). Rev no.01/ page 31of 128...
  • Page 32 Warning: Gradually back off the clutch shoe assembly pressed down by hands to reduce the clutch-sparing load. Releasing your hand suddenly may cause damage to the following parts. Clutch shoe nut Clutch shoe assembly Springs : Do not attempt to disassemble the clutch shoe assy. Otherwise the clutch shoe may be damaged. Caution Remove the movable driven face seat with a thin bared screwdriver.
  • Page 33 : Replace the removed oil seal. Caution Remove the bearing with special tool. : Replace the removed bearing with a new one. Caution Removing the bearings with special tools. Remove the bearing retainer. Remove oil seal with the special tools. : Replace the removed oil seal with a new one.

  • Page 34: Engine Components Inspection And Servicing

    Remove the right crankshaft oil seal with special tool. : The removed oil seal should be replaced with a new one. Caution Remove the right crankshaft bearing with the special tool. : The removed bearing should be replace with a Caution new one.

  • Page 35: Crankshaft

    Bearing: Clear bearing with solvent and lubricate With engine oil before inspection. Rotate the bearing inner race by finger to inspect for abnormal play, noise and smooth rotation while bearings crankcase. Replace the bearing if there is anything unusual. Damage to the lip of the oil seal may result in leakage of the fuel-air mixture or oil.

  • Page 36: Clutch Shoe Inspection

    CONROD DEFLECTION AND CONROD BIG END SIDE CLEARANCE Turn the crankshaft with the connecting rod to feel the smoothness of rotary motion in the big end. Move the rod up and down while holding the crankshaft rigidly to be sure that there is no rattle in the big end.

  • Page 37: Drive Belt Inspection

    Clutch housing inspection: Inspect visually the condition of the inner surface of clutch housing, for deep scratches or uneven wear or discoloration caused by burning. Measure the clutch housing inside diameter with inside calipers. Measure the diameter at several points to check for an out-of-round condition as well as wear.

  • Page 38: Driven Face Pin And Oil Seal Inspection

    Driving face spring inspection: Measure the free distance of the driven face spring. If the length is shorter than the service limit, replace the spring with a new one. Service limit: 104.5mm (4.11 in) Driven face pin and oil seal inspection: Turn the driven face and check to see that the driven faces turn smoothly.
  • Page 39 CHAPTER 4 Section 1.01 Section 1.02 FUEL AND LUBRICATION SYSTEM Contents FUEL SWITCH CARBURETOR ...39 OIL PUMP ..41 Rev 01/ page92 of 143...
  • Page 40 FUEL SWITCH When turning the starter motor, a negative pressure is generated in the combustion chamber. This negative pressure draws on the fuel tap diaphragm, (through a passage way in the carburetor intake pipe) and vacuum hose. Due to this, the negative pressure increases behind the fuel tap diaphragm, until it is higher than this valves spring pressure.
  • Page 41 CARBURETOR CARBURETION Proper carburetion is determined according to the results of various tests, mainly concerning engine power, fuel consumption and cooling effect of fuel on engine, and jet settings are 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 42 Rev 01/ page95 of 143...
  • Page 43 AIR FUEL SYSTEM AIR-FUEL FLOW CIRCUIT Fuel is being supplied to the carburetor from fuel tank by controlled fuel cock assy. Air filter box is fitted on the left side of the motorcycle. Fuel gets atomized and mixes with clean air in right proportion in the carburetor and then air fuel mixture is supplied to the combustion chamber of the engine.
  • Page 44 AIR FUEL MIXTURE RATIO 1. Starting ----------------------------------------------7~8: 1 2. Idling speed------------------------------------------10~12: 1 3. Slow speed ------------------------------------------12~14: 1 4. Medium speed---------------------------------------15~17: 1 5. High speed-------------------------------------------13~15:1 CARBURETTOR CIRCUITS: ZIP r3i CARBURETOR HAS FOLLOWING 6 MAIN CIRCUITS Fuel Intake circuit Choke circuit Idling speed circuit Slow speed circuit Medium speed circuit Highspeedcircuit...
  • Page 45 CARBURETTOR CIRCUITS 1. FUEL INTAKE CIRCUIT: From fuel tank fuel comes into float chamber of carburetor controlled fuel cock assy Separate vent is provided at LH side of carburetor body to maintain inside atmospheric pressure. When fuel starts filling the float chamber, float rises up words along with the float pin and after a certain level it stops further flow of fuel.
  • Page 46 . IDLING CIRCUIT: After starting operation choke is released, more air starts flowing thru the venturi. From slow jet fuel is sucked due to venturi effect. A separate passage from the air filter side is coming at the diffuser of the slow jet for the atomization of fuel in slow jet.
  • Page 47 1. HIGH SPEED CIRCUIT During acceleration the throttle valve (piston) is fully raised, more air is being supplied due to higher velocity. Hence pressure drops at the opening of throttle jet needle. Where as more fuel is sucked from the main jet due to tapperness of jet needle.
  • Page 48 CARBURETTOR ASSEMBLY DISASSEMBLY PROCEDURE FOR CARBURETTOR CLEANING: Remove the throttle valve from the accelerator cable by compressing the spring up from the seat in long slit. Remove the tip of the cable from the slot of the valve. Remove the jet needle from the throttle valve along with clip and plate. Remove the airscrew with spring.
  • Page 49 CARBURETTOR TUNING OR ADJUSTMENT PROCEDURE After installation the carburetor in the engine as per above said procedure, follow the following steps: Warming up the engine to the normal running temperature. Adjust Idling speed to 1800±100 RPM by throttle stop (Idle) screw. Turn the airscrew all the way inside until seats lightly in the carburetor body.
  • Page 50 Article II. CHAPTER 5 Article III. ELECTRICAL SYSTEM CONTETNS IGNITION SYSTEM ...49 CHARGING AND LIGHTING SYSTEM ...51 STARTER SYSTEM FUEL GAUGE ..57 OIL LEVEL CHECK LIGHT AND TURN SIGNAL INDICATOR SWITCHS .. 59 BATTERY..60 Rev 01/ page103 of 143...

  • Page 51: Ignition System

    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 As the rotor generates, an AC current is induced in the coil. Then current induced in the direction charges up the capacitor.
  • Page 52 NOTE: The spark in the spark gap window should be strong and continuous, not intermittent, across a 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 53: Charging And Lighting System

    CHARGING AND LIGHTING SYSTEM The charging system uses the flywheel magneto 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/rectifier, which changes AC to DC.
  • Page 54 CHARGING OUTPUT CHECKING: Start the engine and keep it running at Fuse 5000 RPM with light switch turned on Battery condition. NOTE: When making the test, be sure that the battery is fully charged condition. Digital Tachometer: For measuring engine RPM Specified charging output Voltage 12~14 Volt at 5000 RPM Rev 01/ page107 of 143...
  • Page 55 NO-LOAD PERFORMANCE Disconnect the magneto lead wire coupler. Start the engine and keep it running at 5000 RPM. Using a Multimeter, 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 56: Starter System Description

    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 relay Fuse Battery...
  • Page 57 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 58 ARMATURE COIL Using the Multimeter, check the coil for open and ground by placing probe pins on each commutator segment and rotor core and on any two segments at various places. With the brushes lifted off the commutator surface. If the coil is found open-circuited or grounded, replace the armature.

  • Page 59: Fuel Level Gauge

    FUEL LEVEL GAUGE INSPECTION OF FUEL LEVEL GAUGE The two different checks to be used for inspection of fuel level gauge. The first and simplest test will tell if the meter is 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.

  • Page 60: Signal System

    SIGNAL SYSTEM: The same bulb is used for both oil levels check light and turn signal indicator light. The circuit diagram 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.

  • Page 61: Switchs

    SWITCHES BATTERY SPECIFICATIONS Type designation YUASA/YB4L-B Capacity 12V-4Ah Specific gravity (Fully charged) 1.24~1.28 at 27 Needs Charging Below 1.220 INITIAL CHARGING FILLNG ELECTROLYTE Remove the aluminum tape sealing the battery electrolyte filler holes. Rev 01/ page114 of 143...

  • Page 62: Battery

    BATTERY Open the battery cap 1 Remove the electrolyte cap NOTE After filling the electrolyte completely, use the removed as the sealed caps of battery-filler holes. Do not remove or pierce the sealed areas of the electrolyte container. Insert the nozzles of the electrolyte container into the Battery s electrolyte filler holes, holding the container firmly so that it does not fall.
  • Page 63 After confirming that the electrolyte has entered into the battery completely, remove the electrolyte containers from the battery, wait for around 25 minuets. Insert the caps into the filler holes, pressing in firmly so that the top of the caps does not protrude above the upper surface of the battery s top cover.
  • Page 64 CHAPTER 6 SERVICING INFORAMTION Contents Troubleshooting ..............63 Wiring diagram...............65 Battery..................67 Wire,cable and brake hose routing........69 Special tools................75 Thread parts tightening torque..........77 Service data................78 Rev 01/ page117 of 143...

  • Page 65: Troubleshooting

    TROUBLE SHOOTING ENGINE Complaint Symptom and possible causes Remedy Engine does not Compression too low start, or is hard to 1. Excessively worn cylinder or piston rings. Replace. start. 2. Stiff piston ring in place. Repair or replace. 3. Gas leaks from the joint in crankcase, cylinder or Repair or replace.
  • Page 66 Engine idles poorly. 1. Excessively worn cylinder or piston rings. Replace. 2. Stiff piston ring in place. Replace. 3. Gas leaks from crankshaft oil seal. Replace. 4. Spark plug gaps too wide. Adjust or replace. 5. Defective CDI & ignition coil unit. Replace.

  • Page 67: Wiring Diagram

    Section 3.03 CARBURETOR Complaint Symptom and possible causes Remedy Trouble with 1. Starter jet is clogged. Clean. starting. 2. Air leaking from a joint between starter body and Check starter body and carburetor. carburetor for tightness, and replace gasket. Check and replace. 3.
  • Page 68 Spark plug 1. Spark plug too hot. Replace by cold type plug, electrodes 2. The engine overheats. Tune up. overheat or 3. Spark plug loose. Retighten. burn. 4. Mixture too lean. Adjust carburetor. 5. Not enough engine oil. Check oil pump. Magneto does 1.

  • Page 69: Battery

    BATTERY Complaint (i) Remedy (c) Symptom and possible causes 1. The charging method is not Check the magneto and regulator/rectifier circuit Battery runs correct. connections, and make necessary adjustments to down quickly. obtain specified charging operation. Replace the battery, and correct the charging system. 2.
  • Page 70 Handling feels 1. Steering stem over Adjust. too heavy. tightened. Replace. 2. Broken bearing/race Replace. steering stem. Adjust. 3. Distorted steering stem. 4. Not enough pressure in tires. Wobbly 1. Loss of balance between Replace. handle. right left front suspension. Replace.
  • Page 71 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 rear shock Replace. absorber. Replace. 4. Worn engine mounting bushing. Retighten.
  • Page 72 Leakage of Replace or repair 1. Insufficient tightening of connection joints. brake fluid. Replace. 2. Cracked hose. Replace. 3. Worn piston seal. Brake drags. 1. Rusty moving parts. Replace Rev 01/ page125 of 143...

  • Page 73: Wire,Cable And Brake Hose Routing

    WIRE, CABLE AND BRAKE HOSE ROUTING Rev 01/ page126 of 143...
  • Page 74 Carburetor Rev 01/ page127 of 143...
  • Page 75 Rev 01/ page128 of 143...
  • Page 76 Starting relay Ignition coil HORN Rev 01/ page129 of 143...
  • Page 77 Rev 01/ page130 of 143...

  • Page 78: 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 lock bolt remover T 11 Clutch clamp Rev 01/ page131 of 143...

  • Page 79: Thread Parts Tightening Torque

    Rev 01/ page132 of 143...

  • Page 80: Service Data

    TIGHTENTING TORQUE O F SCREW THREAD PARTS ENGINEITEM 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 Magneto stator coil lock screw 10-12...
  • Page 81 SERVICING DATA CYLINDER+PISTON+PISTON RING DESCRIPTION STANDARD TOLERANCE mm( In) Piston to 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) Piston 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 ring 0.02~0.06mm end clearance...
  • Page 82 Conrod web to web width 38-38.1(1.496-1.500) Crankshaft runout 0.05(0.002) OIL PUMP DESCRIPTION SPECIFICATION Pump reduction ratio 30.000(30/1) CCI pump discharge 1.1-1.3ml/5min(working pressure is 0.06Mpa and rotating ratio(full open) speed 118r/min) CLUTCH mm(in) mm(in) DESCRIPTION STANDARD LIMIT Clutch wheel inner diameter 112.00-112.15(4.410-4.415) 112.5(4.429) Clutch shoe thickness...
  • Page 83 Spark plug TYPE NGK/R/BR8HSA 0.6~0.8mm 0.020~0.028 Ignition coil resistance Primary 0.2 ~0.3 /7K ~10K Plug cap-ground /secondary DESCRIPTION SPECIFICATION NOTE Magneto coil resistance Green/Red Lighting <2 GROUND White Ground Charging <2 200±20 at 20 Blue White or Green Exciting White Ground Generator no-load voltage More than 52 V at 5000r/min Regulated voltage...
  • Page 84 Tire pressure Front tire air 175kpa Rear tire air 196kpa pressure pressure Fuel +Engine oil Description Specification Remark Fuel type Unleaded gasoline 90 or high octane number is recommended. Fuel tank capacity 5.2L Gear oil SAE85/90 Gear oil capacity 0.10 ±0.01L Gear oil change 2000 Kms period...
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