Page 1 Service and Maintenance Manual (50ccm)
Page 2 PREFACE The service manual has been specially prepared to provide all the necessary information for the proper maintenance and servicing. You have now 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 Those who will be servicing the scooter should carefully review the manual before...
Page 4: General Information
GENERAL INFORMATION CONTENTS TYPE IDENTIFICATION FUEL AND ENGINE OIL BREAK-IN PROCEDURE PRECAUTIONS AND GENERAL INSTRUCTIONS SPECIFICATIONS...
Page 5: Fuel And Engine Oil
TYPE IDENTIFICATION ENGINE NUMBER ENGINE NUMBER 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. Some specifications are as follows: FUEL Unleaded, the minimum octane number is 95 or more.
Page 6 PRECAUTIONS AND GENERAL INSTRUCTIONS Correctly abide by the following items when disassembling and assembling scooter: Don’t run engine indoors without 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 Be very carefull to install new circlip for fear that the end hatch of circlip exceeds required sliding surface for shaft After installing circlip, inspect whether it has been completely clipped into the groove.
Page 7 SPECIFICATIONS DIMENSION AND NET WEIGHT Transmission system OVERALL LENGTH 1830 mm Clutch system dry auto a centric OVERALL LENGTH 695 mm Gearshift mechanism CVT stepless OVERALL HEIGHT 1160 mm Operating mode of gears shift mechanism WHEELBASE 1295 mm Automatic a centric NET WEIGHT 92 kg Step less shift range...
Page 8 Periodic maintenance and service CONTENTTS Periodic maintenance and service schedule Maintenance and service procedures Storage battery Spark plug Cylinder head nut and exhaust pipe bolt Cylinder head and cylinder Fuel level line Air cleaner Throttle cable Engine idle speed Oil pump Gear oil Braking Tire...
Page 9 Periodic maintenance and service schedule The following table lists all required intervals for maintenance and service following which, you are assured to have your scooter perform in the best way. Note Do more frequent maintenance when often riding on bad road Periodic maintenance table Interval (first 500 than...
Page 10 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 every 6000KM 4000 miles 12 months thereafter Uncover seat, and then remove the battery box cap in the Middle of helmet barrel.
Page 11 Cylinder head nuts and exhaust pipe bolts Tighten at 500 km, and each service. 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: Remove the frame lower covers.
Page 12 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 13 AIR CLEANER Clean every 3000KM 2000 miles 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. Remove clamp 1 and screw 2 take down air cleaner Unscrew tapping screw 3 remove air cleaner cap 4 Fill a washing pan of a proper size with...
Page 14 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 500km and every year. The engine oil is fed by the oil pump to the engine. 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 15 GEAR OIL Change as shown in the service schedule. Inspect gear oil periodically as follows: Remove the cover and hose Remove the kicking starter lever Remove clutch cover Remove oil level bolt and inspect oil level, if oil level is below oil hole, add oil until oil flows from the level hole.
Page 16 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 marked on the pad.
Page 17 NOTE when bleeding the braking 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 18 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 19 Front shock absorber Adjust at initially 500km and each service. Inspect the front shock absorber for oil leakage or other damage, and replace the defective parts, if necessary. Rear shock absorber Adjust at initially 500km and each service. Inspect front shock absorber for oil leakage and other damage, and replace the defective parts if necessary. Item Kg-m Front axle nut...
Page 21 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 22 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 23 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 24 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 25 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 26 Remove starting driven ratchet wheel by removing the nuts. Remove fan and V-belt . Disassemble the movable drive face . Remove electric gear press board, electric gear and super clutch Remove starter motor...
Page 27 Remove the clutch housing with the special tool. (Peg key) drain gear oil remove rear axle nut remove rear wheel remove brake shoe and rear axle Remove the rear brake cam lever indicator plate and camshaft .
Page 28 remove spring remove cotter pin and shaft remove main stand remove gearcase cover Remove paper gasket and middle gear assy Remove output gear assy. remove carburetor remove intake pipe remove reed valve and paper gasket.
Page 29 Remove crankcase fixing shaft disassemble crankcase with special tools first remove right crankcase cover. Remove crankcase with special tools Remove crankshaft bearing with special tools SLIDING SHOAFT Warning use a new sliding shaft.
Page 30 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.
Page 31 Remove circlip Remove bearing with special tool. CAUTION Replace the removed bearing with a new one. Remove inner 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 Replace the removed oil seal with a new one.
Page 32 Remove gearcase cover bearing with special tool Remove left crankcase oil seal 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 use a new bushing wrap the oil seal with two appropriate size of sheet irons and clamp it, shown as fig.
Page 33 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 34 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 35 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 36 Automatic clutch inspection scooter is equipped with an automatic clutch and variable ratio belt drive transmission. The engagement of the clutch is governed by engine RMPS 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.
Page 37: 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 38 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 39 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 40: Piston Rings
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 Piston pin bore Use a caliper gauge to measure the piston pin bore inside diameter,. If reading exceeds the following service limit, replace it with a new one.
Page 41 Standard clearance 1st 0.04-0.06mm(0.0016-0.0024in) 2nd 0.02-0.04mm(0.0008-0.0016in) Reed valve Check the clearance A between reed valve and its seat and the dimension B. If the clearance A is noted to exceed 0.2mm, replace the reed valve assembly. The dimension B is at least 1mm.
Page 42 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 43 shock absorber bushing positon install bearing in the cover. Don’t install the bearings on the crankshaft. Install shock absorber bushing Install crankshaft (without bearings)
Page 44 CRANKCASE Wipe the crankcase mating surfaces with clraning solvent. Apply GENERIC 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 45 install output axle gearshift install middle gear, position pin by installing middle gear axle , gasket and thrust gasket 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 46 install the bearing in the fixed driven face with the special tool. install sliding bearing...
Page 47 Install the bearing with special tool install the spacer and circlip: install the new oil seals and 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. GENERIC special super grease NOTE: When reinstalling the movable face to the fixed face,...
Page 48 Install the movable driven face seat . install the clutch shoe assembly tighten the nut to the specified torque with the special tool. tightening torque 40-60 Nm (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 49 Apply grease to all the sliding and rolling surfaces for six roller weights. For each weight, approximately 1.5g of grease should be used. GENERIC super grease Mount the three dampers on the movable drive plate and install it on the movable drive face. Position the O-RING on the movable drive face.
Page 50 Insert the spacer 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 fan tighten the nut to the specified torque with special tool.
Page 51 Starter assy. Inject lubrication into start bearing and lubrication in the end of starter shaft GENERIC SPECIAL LUBRICATION Tighten starter shaft gasket Install starter ratchet wheel and circlip...
Page 52 Install the dowel pins install the new gaskets( apply GENERIC bond no. 1215 to the clutch cover as shown in the illustration. GENERIC bond no. 1215 NOTE: Install the kick starter lever as shown in the illustration. Tightening toque 8-12Nm (0.8-1.2kg-m, 6.0-8.5Ib-ft) PISTON install the piston rings on the piston.
Page 53: Oil Pump
apply oil for the piston and install the piston to the connecting rod. NOTE The arrow mark 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 54 Reed valve install a new reed valve paper gasket. Install reed valve Install oil hose Intake pipe install intake pipe Magneto clear crankshaft and magneto rotor install half circle key install paper gasket and stator coil, and fix them tighten to specified torque with special tool specified torque 35-45Nm (3.5-4.5kg.m,25.5-31.0Ib-ft)
Page 55 install cooling fan install guiding cover install fan guiding cover install pipe screw and screw for tightening muffler to their specified torque. 8-12Nm (0.8-1.2kg.m,6.0-8.5Ib-ft) 18-28Nm (1.8-2.8kg.m,13.0-20.0Ib-ft) lubricate brake cam shaft with GENERIC grease.
Page 56 FUEL AND LUBRICATION SYSTEM CHAPTER 4 CONTENTS FUEL SWITCH CARBURETOR OIL PUMP...
Page 57 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 it pressed down the spring which supports the diaphragm so that the fuel passageway is opened and fuel is fed to the carburetor.
Page 58 CARBURETOR equal vacuum Carburetor manufacturer/type CARBURETOR PZ19JB Identification code Throat tube diameter 19mm 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 59 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 60 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 61 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 tatates, an AC current is induced in the coil. Then current induced in the direction charges up the capacitor.
Page 62 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. Electronic tester Ignition coil testing lead Use portable tester to check it.
Page 63 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 64 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 65: Starter System
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 66 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 67 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 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 wire between B/M and Y/B wiers coming from the main wiring harness.With the ignition switch tuined ON,the fuel meter should indicate“F”.
Page 68 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 lit white the other unit.
Page 69: Main Switch
MAIN SWITCH LIGHT CONTROL SWITCH RED WHITE DARK GREEN BLACK PINK YELLOW GREEN RED YELLOW RED YELLOW HEAD LIGHT PASSING LIGHT LOCK EXCHANGE LIGHT SWITCH BREAK SWITCH RED/SWITCH PURPLE YELLOW RED BULE AZURY HIGH BEAM DIPPED HEADLIGHT HORN SWITCH DIRECTION SWITCH BROWN RED WITHE GREEN BLACK...
Page 70 BATTERY SPECIFICATIONS Type designation YB4L-B Capacity 12V 4Ah Standard electrolyte 1.28(20 ) INITIAL CHARGING FILLNG ELECTROLYTE Remove the aluminum tape sealing the battery electrolyte filler holes. Remove the caps NOTE * After filling the electrolyte completely,use the removed cap the sealed caps of battery-filler holes. * Do not remove or pierce the sealed areas of the electrolyte container.
Page 71 RECHARGING OPERATION Apply multimeter to measure the voltage of battery. If the reading is below 12.0V it should be charged. NOTE: When recharging, remove the battery form the vehicle. NOTE: When recharging, don’t remove the sealing cap off battery top. Recharging time 0.4A or for 5 hours or 4.0A for 1 hour.
Page 72 CHAPTER 6 CHASSIS CONTENTS LEG SHIELD AND FRAME SIDE COVERS LEG SHIELD REMOVAL LEG SHIELD REMOUNTING FARME SIDE COVER REMOVAL FARME SIDE COVER REMOUNTING HANDLEBAR COVERS REMOVAL REMORNTING FRONT WHEEL REMORAL INSPECTION AND DISASSEMBLY REASSEMBLY AND REMOUNTING FRONT BRAKE BRAKE PAD REPLACEMENT CALIPER REMOVAL AND DISASSEMBLY CALIPER AND DISC INSPECTION CALIPER REASSEMBLY...
Page 73 Side cover removal remove seat and helmet barrel by opening seat and loosing tightening screw loose hexad screw and remove decorating cap rear carrier and oil tank lock remove side cover by loosing side cover screw unlock oil pump cap and remove it, two tapping screw are exposed, remove them;...
Page 74 under cover removal unscrew screw and bolt removing under cover by loosing the left and right tapping screws under cover installation 3 The sequence if installation is ther reverse of removal. front cover removal 1 Unscrew tapping screw , and remove front cover by removing front cover screw...
Page 75 LEGSHIELD AND PEDAL REMOVAL 1. Remove power lock housing by unscrewing bolt 3. remove legshield and pedal by unscrewing the four bolts Legshield and pedal installation 4. the sequence of legshield and pedal is the reverse of reomval...
Page 76 HANDLE COVER REMOVAL Remove front handle cover by unscrewing the six tapping screws 2. Remove master cylinder by removing the bolt...
Page 77 Disconnect throttle cable and oil pump cable 4 Remove rear brake cable adjusting nut...
Page 78 Handle cover removal 5. remove all cables 6 Remove handle cover by unscrewing bolt Handle cover unstallation 7. The sequence of removal is the reverse of reomval...
Page 79: 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 remove Remove the front brake caliper by removing the mounting bolts.
Page 80 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 81 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 82 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 10. connecting board tightening bolt 11. hose mounting bolt 12.
Page 83 Remove the brake pads. CAUTION: Replace the brake pads as a set,otherwise braking performance will 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 84 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. Ralpace the dise if the thickness exceeds the service limit.
Page 85 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 reassembly. Never use cleaning solvent or gasoline to wash them.Apply brake fluid to the calliper bore and piston to be inserted into the bore.
Page 86 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 87 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.
Page 88 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.right switch comp.
Page 89 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. remove front fork remove bearing lower race by chisel. Remove steel balls.
Page 90 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 91 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.
Page 92 install handlebar and tighten the screw and bolt to the specified torque 37-44N.M 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 93 REAR WHEEL AND BRAKE 1. Tire 130/70-12 2. rear rim assy. 3. brake pad kit assy. 4. brake pad kit spring 5. rear brake tension 6. rear indicator 7. anti-dust cover 8. rear brake camshaft 9. bolt M6 30 10.valve 11.nut M16 1.5 12.rear brake arm valve cap...
Page 94 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. Brake shoes Check the brake shoe and decide whether it should be replaced or not from the thickness of the brake shoe lining.
Page 95 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 on the camshaft to the rear axle shaft side. Install the protrusion of indicator plate to the groove of Camshaft.
Page 96 SERVICING INFORAMTION CONTENTS Troubleshooting Battery Vehicle Wiring diagram Wire, cable and brake hose routing Special tools Thread parts tightening torque Service data...
Page 97: 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 98 Complaint Symptom and possible causes Remedy Engine runs Excessively worn cylinder or piston rings. Replace. poorly Stiff piston ring in place. Replace. high-speed Spark plug gaps to narrow. Adjust. range. Ignition not advanced sufficiently due to poorly working CDI & Replace.
Page 99 Complaint Symptom and possible causes Remedy 1. Main jet or main air jet is clogged. Check and clean. Medium- high-speed 2. Needle jet is clogged. Check and clean. 3. Fuel level is improperly set. Check and replace. trouble. 4. Throttle valve operating Check throttle valve for operation.
Page 100 1. Battery run down. Recharge and replace. 2. Defective switch contacts. Replace. Starter button is 3. Brushes not seating properly on commutator Repair or replace. not effective. in starter motor. 4. Defective starter relay. Replace. 5. Defective starter pinion gears Replace.
Page 101 1. Not enough grease. Refill. Noisy front 2. Loose nuts on suspension. Retighten. suspension. 1. Distorted wheel rim. Replace. Wobbly rear wheel. 2. Defective or incorrect tire. Replace. 3. Loose nuts on the rear shock absorber. Replace. 4. Worn engine mounting bushing. Replace.
Page 103 WIRE, CABLE AND BRAKE HOSE ROUTING...
Page 104 carburetor...
Page 106 Starting relay Ignition coil HORN POWER SWITCHH...
Page 107 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...
Page 109 TIGHTENTING TORQUE O F SCREW THREAD PARTS ENGINE 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 Magneto stator coil lock screw 10-12...
Page 110: 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 111 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) Clutch engagement 3000 300r/min Clutch closedown 6000 300r/min 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 112 Regulated voltage More than 12-14V at 5000r/min 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...