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Buddy 50 Service Manual

1. fete fe e me P e 1 oe e eje o Parts dirty Carburetor thr ottle and choke Performance Carburetor Float height Carburetor Adjustment Fuel pipe per 4 years Changing Remark Checking period 12 Perl per3 perl2 Judgement Check item Months months Months months months standard i Dirty cracked Horn turn signal Performance Reflector Performance Rear view Check the Horn Turn signal mirror illumination Blinker linc Dirty Nese plate nu cracked Mber amp mark Instrument performance board ui Ass part Loose Muffler cracked silencer performance chassis The earlier Confirm it does Not happen Abnormal again condition Chassis Lubrication Decoking mixer muffler silencer 2 Battery Recharge when run out of it Remove the floor mat 2 Screwing out the two screws on the battery cover remove the battery cover 3 Remove the negative cable and then the positive cable take out the battery to recharge 4 Re assembling the battery as the opposite procedure of disassembling after recharging 2 2 RE L wit hath PPS a YTXZA BS 74 oe JE GE 2x A Do not tak
2. This manual offers all service specialists with the technological procedures of maintenance repairing for LIGERO 50 detailedly show those whom may concern how to maintain repair change parts troubleshoot and reassemble etc At every important section we illustrate by assembly explosion diagrams and photographs if necessary please check the diagrams already shown Though we have tried our best please kindly instruct us any faults found in this manual MOTIVE POWER INDUSTRY CO LTD 1 3 CONTENTS The specification 2 Service information 1 The operation notice 2 Looking torque value 3 Lubrication instruction 4 Wiring diagram 5 Troubleshooting Checking and adjustment 1 Checking table 2 Battery 3 Clean the air cleaner 4 screen 5 The final reduction mechanism oil 6 Spark plug 7 Compression pressure measurement 8 Valve clearance 9 Ignition timing 10 Idle Adjustment 11 Front brake adjustment 12 Rear brake adjustment 13 Tire 14 Throttle cables adjustment Dismantling maintaining repairing and assembling operation 1 Lubrication system 2 Plastic parts of chassis 3 Engine dismantling 4 Drive pulley starter clutch driven pulley 5 Cylinder head and valve 6 Cylinder and piston 7 AC generator flywheel 8 Final transmission mechanism 9 Crankcase crank shaft 10 Carburetor 1D Steering stem front wheel front brake comp front fork 1
3. and da Mage condition Front axle screw torque 5 0 6 0kg m rear axle torque 11 0 13 0kg m location Swingness ofr front Rear wheel rim Vertical swing 2mmbelow mm Bic 3 Wheel Front Bearing of axle Looseness Rear or damage Loose Damage sion Part loose Oil leakage damper assy s part Loose Clutch and Change Speed mechanism Electric Install Ment mechanis Motorpinion m Meshing Effect Electroly Te quantit battery Electroly Wire conn ecting Loose or cracked Initial 500km 12 months Checking period Perl per3 Months months Or Or 1000km 2500km 12 months or 10000km Judgement standard Clearance 0 6 0 7mm NGK BP7HS A OR SAME Level between UPPER AND LOWER WHEN 20 SPECIFIC GRAVITY 1 270 1 290 Checking period First Month Per6 12 Perl per3 perl2 Judgement d Or Months months Months months months standard Remark 1 or Engine Engine Performance parts noise Low speed Accleration Check the clolr Exhaustion Or exhausting air Air cleaner Cylinder cyl Locking torque Cylinder head inder head inlet cold f 1 0 1 2kg m Pipe locking Condition Compression Using stating Motor pressure 6 0kg c 750rpm Dae o pe
4. 2 Locking torque value a For engine b For chassis c Others 3 Lubrication instruction a For engine b For chassis c Wheel bearing 4 Wiring diagram 5 Troubleshooting 1 Hard starting or no starting 2 Not smooth rotation weak acceleration inefficient horse 3 Engine running not smoothly low speed 4 Engine running not smoothly high speed 5 Charging abnormal battery over charging or over discharging 6 No Sparking spark plug 6 1 The operation notice 1 Always replace gasket O ring cotter pins and clip whenever reassembled 2 When tighten screws or nuts lock tightly as per specified locking torque and in the sequence of cross direction 3 Use PGO or PGO Recommended parts 4 After dismantling please wash all parts necessary for checking and grease all contact surface when reassembling 5 Use grease recommended by P G O 6 When removing battery please dismantle the negative pole first when assembling please connect positive pole first 6 Before installing a new fuse confirm the specification is correct or not 7 After reassembling please re check that all connecting point locking parts circu
5. 3 Remove the 6 bolt in gear box cover 4 Take off the gear box 5 Take out the final reduction gear and idle gear shaft 6 Clean up the gear box Check the final transmission mechanism I Check the wearing condition of the driving shaft and gears 2 Check the wearing condition of the idle gear shaft and idle gears 3 Check the wearing condition of the final reduction gear 4 Check the wearing condition of the oil seal and bearing D Assemble the final transmission mechanism please follow the opposite procedures Of disassembling After locking the drain bolt refill 90c c of gear oil SAE 85W 140 Locking torque 1 0 1 2 kg m M10 3 5 4 0 kg m Drain bolt Ms 1 8 kg m Check for the flatness of cylinder head amp cylinder Check the flatness of contact surface of cylinder head amp cylinder Limit of use If it exceeds 0 1mm Change a new one F Combustion chamber cleaning e Clean out the carbon piled up in combustion chamber not scratch the combustion chamber and contact surface of the cylinder during cleaning operation G Check cylinder and piston 1 Check the wearing and damage condition on the contact surface of the cylinder and piston 2 Clean out the carbon on the cylinder exhausting port Be careful not to scratch the inner Surface of cylinder 3 Cylinder bore measurement 1 Measure each point A B C orderly and in X Y axis to find the smalles
6. Opiston and cylinder worn out mixture is too lean Gbad quality of the fuel too much carbon in the combustion room Gignition timing is too early too much carbon in the combustion room O bad quality of the fuel Gclutch slip mixture is too lean Gignition timing is too early 3 Engine running not smoothly low speed and idling Trouble condition Check and adjust eee m km m w Check if there is air Leakage on carburetor 1 gasket correct good adjustment No leakage Sparking abnormal Or no sparking J faulty adjustment The reason CDI faulty pulse generator faulty Q mixture too rich loosen the screw 2 mixture too lean tighten the screw heat protector gasket broke carburetor locking nut loose gasket crack hose ruptured Ospark plug is dirty CDI out of order Ac magneto abnormal Gignition coil faulty OH T coil faulty or short circuit main switch is abnormal D A C V faulty hose is damaged air pipe is blocked or damaged DT LET 4 Engine running unsmoothly high speed Check and adjust Trouble condition DCDI sets faulty pulse generator faulty Oba
7. 5 Reed valve 1s defective b compression pressure is too high engine overheating or abnormal noise l piston tip has too much carbon piled up c Abnormal piston noise 1 cylinder and piston worn out 2 Piston pin hole or piston pin worn out 3 Connecting rod small end or bearing worn out d Abnormal piston or cylinder noise piston ring worn out or cracked 2 Cylinder worn out or cracked B The operation notice 1 clean before operation to avoid particles dropping into engine 2 The connect surface of gasket must be clean 3 Dismantle the cylinder and the cylinder head by screw driver Do not scratch the contact surface 4 Cylinder inner surface and piston outer surface t be scratched The contact surface should be lubricated by specified oil C PISTON amp CYLINDER DATAS WT Standard Value Limit of use Part name description mm mm Cylinder head 0 100 39995 40015 40 050 Piston ring ring piston and 222 0 05 0 06 Piston outer diameter 39950 39 970 39 895 Measuring location of piston outer dia EN 12mm from the lower end of skirt Clearance b w piston and cylinder 0045 0085 O10 Piston pin hole inner dia 13022 13013 155 D cylinder head cylinder and piston dismantling 1 Remove the engine 2 Screwing out the two M6 bolt of cooling cowl 3 Screwing out the two M6 blot of fan cover 5 Remove the spark plug 6 Remove the two M6 nuts on the muffler and cylinder
8. Also remove the two M8 bolt of crankcase 7 Remove muffler 8 Remove the four M7 nut on the cylinder head then remove the cylinder head and cylinder head gasket 9 Remove the Cylinder and the gasket 10 Remove the c type clip on the piston and piston pins by the nipper e Take off piston 11 Dismatling of the piston ring Take off the first piston ring then the second ring 12 When assembling please reverse the procedures of dismantling Locking torque M7 1 0 1 4kg m Opening end of piston ring M6 1 0 1 2kg m end Ring Skirt 6 Generator Flyweel A Dismantling AC generator 1 Remove fan cowl 2 Remove the M6 screws 4 3 Remove Screws of flywheel magneto 4 Remove the AC flywheel magneto by special tool 5 Remove the flywheel 6 Remove the electric plug of AC Flywheel magneto Take out the magneto B Install AC generator To install please reverse the dismantling procedures Locking torgue 1 0 1 2kg m M10 3 2 4 0kg m 7 Final Transmission Mechanism A Trouble shooting e Engine can be started but vehicle doesn t move Gear worn out or cracked 2 Gear burnt out Noise occurs when running Gear worn out burnt or gear surface damaged 2 Bearing worn out or loosen Oil leakage 1 Too much oil 2 Seal worn out or damaged B Disassemble the final transmission mechanism Remove the rear wheel 2 Drain off the oil in the gear box
9. Limit of use 50cc Chanee it when above 20 123 mm 3 Check the wearing condition for driving pulley surface 4 Check the outer diameter of the driving plate s boss Check the wearing condition Limit of use change it when below 19 91 1mm 13 Assemble the slide driving plate 1 Clean the inner surface of slide driving plate then assemble the roller 2 Assemble the ramp plate 3 Please reverse the procedures of disassembling to finish assembling D Starter dismantling I Dismantle the left crankcase cover 2 Remove the hexagon nut then remove the starter lever 3 Remove five screws of isolating plate 4 Remove the starter spring from the start returning positioner 5 Remove the driven gear comp of kick starter 6 Remove the retaining c type clip 7 Remove the spindle comp Of kick starter 8 Checking the starter a Check the wearing condition of the outer diameter of the spindle comp and the inner diameter of bush and gear b Check the wearing condition of the shaft of driven gear comp gear sets and ratchet 9 Assembling the starter To assemble the starter please follow the opposite procedures of dismantling Locking torque M6 1 0 1 2kg m Note sure that on end of the torsion spring is hooked on the groove of driven gear and another end of the torsion spring 1s hooked on the poled inside the left crankcase Put some grease on shaft and gear sets before assembling E Clutch driven
10. fuel pipe auto choke of spark plug rear Brake cable carburetor pipe engine flywheel shelf s nut starter Motor cable plate and rear damper bolt 5 Remove the engine B Installing Engine 1 To install engine please reverse the above procedures 2 Locking torque 8 2 0 3 0kg m M10 3 0 4 0kg m M12 5 0 6 0kg m 3 After installing please do the following checking and adjustment Checking and adjustment a Wiring connection b Throttle cable and oil control cable c Rear brake adjustment d Fuel and oil route 4 Drive pulley starter amp clutch A Troubleshooting a Engine starts but vehicle does not move 1 driving belt worn out 2 driven plate worn out 3 clutch lining worn out 4 driving plate s spring broken b The vehicle stops or trembles when running I clutch lining spring cracked or broken c Can t reach high speed no pick up I driving belt worn out 2 Driving plate spring distortion 3 Weight roller worn out 4 Driving plate abnormal Note No grease and oil allowed to stain on driving belt and driven plate B CVT parts measurement data Standard value mm Limit of use mm Model 50cc Slide driving plate 20 035 20 085 20 123 The outer dia of boss movable 19 960 19 974 19 911 Driving plate 18 0 19 0 Clutch lining thickness Clutch outer diameter 117 0 117 2 117 5 Driving plate spring free length 87 9 The outer diameter of driven 33 965 34 025 33 95 plat
11. assemble the master cylinder cover c Put the spanner upon the drain screw d Lock and unlock the screw several times to Release the bubbles M D Operate slowly the brake lever several Low ooi times f Clamp the brake lever to the end Loose the drain screw then open the lever completely h Locking the drain screw and then loose it when the lever is opened completely i Repeat above procedure until all the air in the brake system has been released Completely Locking torque of leaking screw 0 6 kg m 3 Front fork checking If it is bent or cracked please replace with a new one 4 Front shock absorber checking Check is there any unusual damage or worn out condition and whether the guide rod of the Front fork 1s crooked or not Front fork oil type SAE 10W20 Capacity each side 70 CC NOTE If the guide rod is crooked it should be replaced by a new one or repaired E E 4 g 8 ud E 5 Disassembling and assembling the front brake disk a Remove the front wheel b Remove three nuts on the disk c Remove the disk d Assemble the disk follows the disassembling procedure Locking torque M8 2 0 3 0kgm 6 Checking the front brake disk Standard thickness of disk 3 6mm Limit of usage change it when below 3 1mm 7 Checking the front brake lining a standard thickness 4 0mm limit of u
12. bearing clean grease asian 17 521 4 1300 reb wt rsen supcr 2 wal 7 00 4 21300 parte 1005 4 TICON Ne ee f n 18 8 18 Tu WWE e g 1102 NOLLINOI 2 2 Lc M 8 397 TAN 8 NVLSAG DLNV M SU3N3VN d NTON INI inal AZI ESSTU Me k H3JHSV141 WNOIS H I AZ HOLIMS NIVN HM dAVT VNOS INi rey AAV T AZI OLSI5S 33 5 Sol Tya nai 99 E mcus 5 aia FEMS ars aped ae BR NI E HOLS OVIN pate avi NHOH m gt ae 2 Aiuvs Hau HILINE JM v1 WNOS B z 5 pd 1 q1300N 03 4 AINO AN UM SNILSVIS Ld 5 Trouble shooting 1 Hard starting or t start Check and adj ust screw check if s s s i nsi carburetor have fuel oosen carburetor ni ng de of or not The fuel supplies carburetor enough or snooth any spark Renove spark plug insert Spark plug cover and touch wth engi ne check there is there is sparking ir Spark pl ug Measurenent of conpressi on pressure start engi ne as the i nstructi on of starti nc engine has knocking Remove spark plug and check again eee w w m m
13. out of order 7 Wire disconnects or broken Currency is unstable 1 The wiring of battery connects improperly 2 gnition system connects abnormally 3 I gnition system is short circuit 4 Lamp system connects abnormally or Short circuit Abnormal recharge system 1 The plug part connects abnormally Wire broken or short circuit 2 Rectifier is abnormal 3 A C flywheel magneto is abnormal D Engine rotate unsmoothly l Ignition primary wiring Othe wire or plug of wiring connects Improperly main switch disconnects 2 Ignition secondary wiring Q Ignition coil is abnormal Spark plug is abnormal GH T coil 1s abnormal Spark plug cover electricity leakage 3 Ignition period DA C magneto is abnormal A C G coil disconnects C D I set is abnormal 8 Starting motor is out of order eStarting motor weak rotation battery recharges insufficiently 2 wiring disconnect 3 motor or gear some impure material drop in eStarting motor can rotate but engine Can t rotate l starting pinion is abnormal 2 starting motor is reverse rotation 3 battery is out of order 2 Battery Always remove the battery negative Cable then remove positive cable But connect the positive cable first then connect the negative cable when assembling Recharging Connection method Connect the positive cable of the recharger to the positive cable of the battery and The negative cable of the rechar
14. pulley I Dismantle the clutch a Remove left crankcase cover b Remove driving plate c Remove driving belt d Remove the M10 locking nut then the clutch 2 Assembling the clutch please follow the opposite procedure of dismantling Locking torque M10 3 5 4 0kg m 3 Checking the clutch Dismantling the clutch needs the special Tool please contact your dealers a Check the clutch driven face Check the clutch cover about its wearing Condition and inner diameter measurement Limit of use 5Occ Change it when above 117 5mm b Check the clutch lining wearing condition and measure the lining thickness limit of use change it below 2 5mm Check driven spring free length standard 87 9mm Limit of use change it as it Is below 82 5mm 50cc d Check wearing condition of driving plate set Outer diameter measurement Limit of use change it as it Is above 33 950mm e Check wearing condition of slide driven plate Inner diameter measurement Limit of use change it as it Is above 34 070mm f Check 15 there any wearing occur to the ditch Check wearing condition of seal location if necessary change a new one 5 Cylinder and piston A Troubleshooting a compression pressure 15 too low difficult to start engine and running unsmoothly 1 Cylinder head gasket cracked 2 Spark plug is not well locked 3 Piston ring worn out or cracked 4 Cylinder piston worn out
15. recharge system 2 check A C flywheel magneto 3 check regulator rectifier 4 Ignition system 1 wiring of ignition 2 check spark plug 3 check H T Cable and H T coil 4 check C D I set 5 Starting system 1 the wiring of starting 2 checking the starter 3 dismantling the starting motor 4 checking the starting motor 6 Starting clutch 7 Handle bar switch 1 Troubleshooting A Recharge system No power l battery over charge ONo electrolyte in battery Battery becomes white Short circuit in battery Regulator malfunction 2 the battery wires disconnected 3 fuse 15 broken 4 Ignition lock 1s abnormal e Voltage is too low 1 Battery recharges insufficiently 2 The connecting is abnormal 3 Recharge system is abnormal 4 Regulator malfunction B Ignition system e Ihe sparking of spark plug is abnormal 1 Spark plug is abnormal 2 Wire connects improperly broken or short Circuit Obetween A C flywheel magneto and CDI Sets between CDI sets and H T coil between CDI sets and main switch between main switch and spark plug 3 Main switch 1s out of order 4 H T coil 1s abnormal 5 CDI sets 1s out of order 6 A C flywheel magneto 1s abnormal C Starting system e Starting motor can t rotate 1 The fuse is broken 2 Battery recharges insufficiently 3 Main switch 16 abnormal 4 Switch of starting motor is out of order 5 Switch of front rear brake is out of order 6 Starter relay 15
16. 1 Checking rear brake hub a measure the inner diameter of rear brake hub b limit of use change it as the diameter is above 111 0mm 2 Checking brake lining a measure the thickness of rear brake lining b Limit of use As the thickness 15 less than 2mm change it F Rear damper 1 damper disassembling diagram b specified torque 2 0 3 0kg m specified torque 3 0 4 0kg m 13 Fuel tank A Troubleshooting 1 Engine can t start a No fuel in fuel tank b Fuel pipe is blocked c Auto cock and fuel filter is blocked d The membrane of fuel cock over extended 2 The mixture is too lean a Ventilation hole is blocked b Fuel pipe is crooked squeezed or blocked c Auto cock and fuel filter is dirty B Dismantling and assembling Fuel Tank 1 Remove the luggage box 2 Open the rear cover of the fuel Tank and take it off 3 Remove the left and right rear handle bars 4 the left and right side COVCTS 5 Remove the fuel pipe 6 Remove the connecting terminal of the fuel gauge gi a taig 5 7 Remove the fuel gauge 8 Remove the fixing blot of the fuel tank 9 Take off the fuel tank 10 When re assembling please follow the opposite procedure of disassembling Locking torque M6 1 0 1 2kgf m 5 Electric equipment 1 Troubleshooting 2 Battery 1 specific gravity of eletrolyte 2 recharge 3 Recharge system 1 wiring diagram of
17. 1 When the engine stop remove the fuel pipe from carburetor and check if there is fuel flow Out or not It means auto lock functions well if the residue fuel for the amount of 5 10cc flows out From the auto cock and fuel pipe However if it continues to flow out it means that the Vacuum pipe is blocked please clean it 2 Remove the vacuum pipe from the carburetor and suck it to produce a vacuum to have the Fuel flow out from the fuel pipe The fuel will stop flowing out if the vacuum disappear If the fuel does not flow out by the above operation please check the followings a Clean out blockage in the vacuum pipe b Blow air into the inlet pipe of the auto cock 3 Note Please remember to use a bowl to catch the flow out at the end of the fuel pipe Keep away from fire or even spark during operation 11 Steering stem front wheel frt brake comp and front fork A Troubleshooting B Data C Steering handlebar E Front wheel F Front brake G Front fork A Troubleshooting l steering handlebar is abnormal too tight a steering mechanism washer of conical bush locked too tightly b steering mechanism steel ball is cracked steering mechanism steel ball base and washer of conical base 15 damaged d wheel pressure is too low 2 steering handlebar is aslant a left and right damper is not even b Front fork is crooked c The axle of front fork 1s crooked wheel 15 aslant 3 front wheel swings a wheel ri
18. 2 Rear wheel rear brake rear damper 13 Fuel tank oil tank 19 20 24 25 26 26 27 27 28 28 29 29 30 30 31 32 33 37 42 44 53 58 63 66 70 74 78 87 92 5 Electric equipment 1 Troubleshooting 2 Battery 3 Recharge system A Ignition system 5 Starting system 6 Starting clutch 7 Handle bar switch 95 96 97 99 101 103 105 107 SPECIFICATIONS reduction 110CC Reverse differential Unleaded gas Capacity Ignition DI Steering angel Tail light 12V 21W SW Left 4 Right 41 Vehicle model reorganization 1 Movable model Hit bh Sli HH HE FX E H LI tel Adie E LET Bill s TE H k A PLATE TOR k i T LEASE DRE EE Sie T SE TT 2 Fixed model Parts Name for Fixed Model Back Mirror Side Stand HE vi E x Central Stand SERIES DuOAEE TER 4 rns p LHI F n LA IF A EE Sis mam r 4 THF 01 16 FUR wii Rear Luggage bracket Rear signal lamp Reamarks The equipments depand on the actual vehicle 2 Service information 1 The notice for operation
19. Troubl e condi ti on No fuel suppl ies car bur et or No sparki ng or weak spar ki ng unsuf fi ci ent or nc pressure engine knocking and can t start wet The reason Ocheck there is fuel or not pipe between fuel tank and carburetor is blocked float is blocked 9 Fuel gauze is blocked Auto cock is malfunctioned Ospark plug out of order 2 dirty CDI unit out of order pulse generator out of order Gignition coil cable disconnect or short circuit 9 gnition coil disconnect or short circuit main switch out of order amp defective magneto coil CO starting clutch out of order Q valve is too tight no clearance valve base out of order Cylinder piston piston ring out out of order Gcylinder gasket leakage valve burns out wrong valve timing Obad action of auto choke air trapped in intake manifold G wrong ignition timing bad adjustment of carburetor s fuel adjusting screw fuel level too high malfunction of auto choke Gthrottle valve open too largely 2 Unsmooth rotation Weak acceleration inefficient horsepower Check and Adj ust Trouble condition w s start engi ne and o throttle r adual E 1 Check and inspec ine t rot ate up conpl etel y Check ignition timing check E RECIEN teeter with ignition timing lamp bad ad
20. a Piston ring must be installed in the correct location b After installing the piston ring it should be abk to rotate freely c If it is necessary to change the new piston ring it must change the whole set 4 a The location of the piston ring gap and the lock pin must be in opposite side b The mark gt on the piston tip must be pointing to the exhausting port c Lubricate the piston pin before installation 5 Please follow the opposite procedure of dismantling to install cylinder and cylinder head S Crankcase Crankshaft A Disassembling diagram Troubleshooting Engine noise 1 The bearing of final transmission mechanism is loose 2 Crank pin bearing is loose 3 The bearing of gear box is loose C Data Standard value Clearance of connecting rod big end Parallel direction to rod as Clearance of connecting rod big end 0 04 Perpendicular direction to rod Swingness of the crank shaft neck D Dismantle the crankcase crankshaft please follow the following procedures Remove the engine 2 Remove the left crank case the driving pulley driving plate clutch and belt 3 Remove the air cleaner 4 Remove the carburetor 5 Remove the intake manifold and reed valve 6 Remove the oil pump fan cowl and fan itself 7 Remove the AC flywheel magneto Dismantle the right and left crankcase There are all together 7 bolts hn E Check th
21. d adjustment valve base faulty Check auto cock Fuel supply system D fuel level is too low fuel pipe or fuel filter is blocked cock faulty Check carburetor Is blocked or not RO TFT EP SUE No blocked blocked clean and wash it the mark of s timing correct Not correct gear does not align Check the valve s Reverse spring s ee good Spring broke or fatigue Spring faulty gt 5 Charging abnormal battery over charing or over discharging Check and adjust Trouble condition en Sac hap et MUS 1 Measure batter s Voltage then start 1 engine Check voltage rectifier Plug is loose or not 1 Check the voltage The red cable of Voltage rectifier Check the resistivity Between chassis and Voltage goes up OBattery is dead To normal value But after engine Stop the Voltage Goes down again Battery malfunction connection red cable disconncet Ovoltage rectifier MM CLE DM No voltage malfunction Q while cable disconnect Of A C generator coil dd eer Odefective coil Start engine connect Green cable to Chassi
22. e crankshaft measure the clearance between crank shaft and co rod big end Parallel direction to rod Limit of use Replace a new when above 0 71mm 2 check the looseness on X Y axis of the connecting rod big end Perpendicular directions to rod 3 measure the swingness of crank shaft neck Change it when Change it when Above 0 1mm Above 0 1mm 60 mm 4 check the slackness of crankshaft bearing Sway ing li if it is slack change a new one r W i horizontal vertical direction direction __ F Assemble the crankcase 1 To assemble the crankcase please reverse the procedures of disaseembling 2 The locking torque value for bolts and nuts are all described in the previous chapters Please refer 9 Carburetor Reed Valve and Auto cock A Fuel system diagram Fuel Cap Fuel Gauge Fuel Tank Carburetor dismantling diagram lt Lu ad lt lt EYL Akies Troubleshooting a Engine can not be started 1 No fuel in the fuel tank 2 Fuel pipe is blocked 3 There is too much fuel in the cylinder 4 Air cleaner 1s blocked b Engine idling RPM unsteady running not smoothly I Improper adjustment of the carburetor idling 2 Ignition disorder 3 Compression pressure is too low 4 Air mixture is too thick 5 Air mixture is too lean 6 Air cleaner is blocked 7 Air injection is not in good function 8 Fuel is di
23. e out the sealed bolt when recharging B Without refilling water for the battery Please recharging 12V as the following current Time standard 0 3A 5 10Hr or Rapid 3A 1Hr 3 Clean air cleaner Remove air cleaner cover Take out the air cleaner filter 1 2 3 Clean the filter by compressed air 4 Assemble the air cleaner by the opposite proce Attn Do not start engine when air cleaner is not installed 4 MOTOR lubricant oil B take off the cap of oil tank B check the level of oil 5 The final reducing mechanism oil 1 Change the oil in the gear box a Turn off the engine after warm up b Put a bowl under the engine c Remove the draining bolt and filling bolt to drain the gear oil off d Lock the draining bolt before refill 110c c gear oil and then lock the filling bolt e Locking torque 1 8kg m Draining bolt Filling Bolt 6 Spark plug 1 Remove spark plug 2 Check the spark plug electrode and see whether it is burnt out carbonized or not 3 Clean the electrode if it is dirty eSpark plug specification NGK BP7HS or BPR7HS equivalent Gap of spark plug 0 6 0 7mm spark plug Electrode burnt out Carbon piled up or not Washer is distorted or not Porcelain 1s cracked or not 7 Cylinder Pressure I Measure it when the engine 15 warm 2 Remove the cover at the right hand of the step floor 3 Remove the spark plug then place cylinder pressure gauge Then fully
24. e sets The inner diameter of slide 34 000 34 025 34 070 Driven plate The outer diameter of weight 15 992 16 008 15 50 Roller set Driving pulley 1 Take off the 8 screws of left Cover remove the left cover 2 Take off the left cover 3 Remove the fixing nut of the clutch 4 Take off the ramp plate 5 Take off the belt and the rear clutch 6 Take off the driving plate Take off the driving gear start set 7 Remove the start idle gear fixing plate r Tig a f j un ur r K Peal E o Ts v f 20 9 off the idle gear 9 assemble the driving pulley please reverse above procedure Locking torque 1 Nut of driving pulley M10 3 2 4 0kg m 2 Locking nut of clutch M10 3 5 4 0kgm 10 Checking the driving belt 1 check whether it 1s cracked or not or its rubber and fiber are loose or not check also if they are extraordinarily worn out 2 driving belt width limit of use change it below 17 0mm 11 Disassemble the slide driving plate set 1 Remove the bush of slide driving plate 2 Remove the screw and disassemble the cover of slide driving plate 3 Remove RAMP plate 4 Remove weight roller Belt width 12 Checking list 1 Check the wearing condition of the weight roller limit of use change it when below 15 5mm 2 Check inner dia of slide driving plate 5 gasket
25. e the front wheel assy 4 Assemble the front wheel follows the opposite procedure of dismantling Locking Torque M10 3 0 4 0kg m Note 1 Put the lock block of speedometer gear assy upon the extrusion of the front fork 2 Put the grease onto the grease sets of speedometer before assembling 5 Checking the front wheel axle a Check the bending degree of the front axle b Take note of the bending degree on the middle of axle c Limit of use Change it when above 0 2mm 6 Front wheel bearing checking Turn the tire If the bearing is Loosen or any occurrence for noise Please change a new one horizonta vertical direction direction ___ 7 Front wheel rim checking 1 Check the swing of the front wheel rim 2 Limit of use eHorizontal direction Change a new one when above 2 0mm e Vertical direction Change a new one when above2 0mm F Front brake 1 Disassembling and assembling of the front brake comp a Remove two bolts fixed on the front brake comp and the front fork b Remove the front brake comp c Assemble the front brake comp Follows the opposite procedure of dismantling Locking Torque 8 2 0 3 0kg m 2 Air releasing of the front brake comp A Fluid releasing The procedure of air releasing AE S valve a Fill the enough brake oil to the container 7 3 gt NN 2 Fluid Hose b Do not let the brake oil overflow from the lt A N master cylinder or container when
26. er a The air mix into the pipe caliper b The oil brake system 15 leaking Note Try brake le ver to see if it s loose Check the brake oil once air mixed in the oil pe which iciency or will reduce or damage the brake e even its function 3 Check the oil level a Refill the brake oil when the level is under the LOWER line b Oul specification SAE J 1703 or DOT3 orDOT4 Note a To prevent the oil splitting onto the parts or clothes put a piece of cloth on the bottom when refilling b Be caution not to mix water or particles into the master cylinder when refilling c Never use the oil that is not complied with spec d In case the oil stains on the eyes wash with water at once and then ask for medical care immediately 11 Rear Brake Adjustment 1 Check the clearance of rear brake lever Clearance 10 20mm 2 If the clearance is beyond the above Standard adjust it by rotation the screw a Left handed rotation Enlarge the clearance b Right handed rotation Reduce the clearance 12 Tire 1 Check Tire air pressure 2 Tire pressure Front tire 1 50kg cnf Rear tire 1 75kg cn 3 Tire specification Front tire 3 5 10 Rear tire 3 5 10 Note 1 Check and adjust the tire pressure when it 15 too low The pressure is according to the carrier driver passenger accessories and cruise speed 2 Proper loading is very important for steering riding braking performance and saf
27. ety Never carry any parcel unfastened Load the heaviest parcel on the center of vehicle balancing the weight on both sides Beware of the weight loaded properly and check the tire pressure The total weight of carrier driver passenger and accessories cannot exceed the approved limit An overload vehicle 15 easy to cause tire damage and accident for rider 3 Check if there is any sharp object piece the tire 4 Check the depth of wheel stripe eDepth front and rear According to 99 the mark of tire indicating the necessity to change a new tire 13 Throttle cables Adjustment 1 Check the clearance of throttle 2 Normal clearance 1 5 3 5mm Adjust it by rotating the adjust nut Change it if the throttle cables can t be adjusted s PTS um 4 Dismantling Maintaining Repairing and assembling operation 1 2 3 4 5 6 7 8 9 10 11 12 15 Lubrication system Plastic parts of Chassis Engine dismantling Drive pulley starter clutch driven pulley Cylinder head and valve Cylinder and piston AC generator Final transmission mechanism Crankcase crank shaft Carburetor Steering stem front wheel frt brake comp frt fork Rear wheel rear brake rear damper Fuel tank 3 Engine Dismantling A Dismantling engine 1 Take off the luggage compartment 2 Take off the left and right body covers 3 Take off the lower mudguard fender 4 Remove vacuum pipe
28. ger to the negative cable of the battery Recharging currency Please recharge 12V according to the following currency and time Standard 0 3A 5 10 OR Rapid 1Hr NOTICE 1 1 is not necessary to refill the battery liquid into the battery 2 Do not take off the sealed bolt while recharging NOTE eNo fire near battery when recharging eIhe ON or OFF of recharging currency must be operated by the switch ofrecharger It will cause spark or explosive if plug or unplug the cable directly 2 Testing the recharging performance This test needs to be done under the Battery has been recharged completely a This test needs to be done after engine is warn up And take off the luggage case Firstly b Disconnect the orange cable of regulator c Open the fuse box to remove the white cable d Connect currency meter between red white cable fuse While testing the red wire cable must not touch the frame d Set the headlamp switch at OFF engine rotation is at 2000 rpm while testing Then increase the rpm slowly Head Lamp Switch Recharging rpm 2 500 6 000rpm OFF DAY Under2 000upm 0 6A MIN 1 5 ON NIGHT Under2 000upm 0 6A MIN 1 5 If the testing result does not match standard value check the regulator 3 Recharge system 1 system diagram dum WITH durmpe j awg JO1EI U23 JV
29. he final reduction mechanism oil 6 Spark plug 7 Cylinder pressure 8 Valve clearance 9 Ignition timing 10 Idle adjustment 11 Front brake adjustment 12 Rear brake adjustment 13 Tire 14 cable adjustment 1 Periodical checking table mark indicates periodical checking 2 1 indicates changing the parts Checking period First Month Per 6 12 Perl per3 perl2 Judgement Check item Remark Or Months months Months months months standard Initial Or or Or or or 500km 5000km 1000km 1000km 2500km 10000km aq Steering Handlebar performance O O oO oO oO Suspension turning angle O O O O O b shaft fixed From steering Front fork s condition c shaft loose ee EH te B B Brake Clearance a mem Front 10 20mm Rear 10 20mm m 2 X CESERERERERESES EE Standard dia Rear 130 0mm Loose or damage brake Brake cables change a clearance between drum and plate Brake drum brake shoe and br And brake ake plate worn out c brake drum worn and Hoe mark type Limit of use Rear 131mm NEN Check rear Unit kg c Idriver U 1 5 1 75 3aplimit eel damage front axle dam age or cracked rear axle worn or damage Wheel pressure Wheel cracked Or damage Wheel gap and worn wheel Wheel surface Or other metals Axle nut screw Pin tightness Wheel rim swi
30. hecking eChange a new one when there is any scratch Front cover Screws for cover damage or burnt on the surface eAny adherent metal powder in between the layers of the direction exchanger should be cleaned eThe conductivity check among each contact surfaces to other parts eThe non conductivity check between the armature pivot and each layer of the direction exchanger eThe conductivity check of the outer cover of the starter motor eThe non conductivity check between the cable ends and the outer cover of the starting motor eThe conductivity check of the electric brush Start relay and the cable ends If there is anything abnormal change a new one eThe non conductivity check of the brush bracket If it is conductive change a new one 3 Start Relay starting check eRemove the body cover eWhen the main switch ON and press the starting motor button there should be a kata sound elf there is not a kata sound a Check the voltage of the start relay b Check the start s ground circuit Green Line c Check the start reply starting system Voltage check for the start relay ePut on the center stand Measure the voltage between the cable Green Line of the start relay and the body s ground circuit eTo switch ON for the main switch and clamp the brake lever The battery voltage has to meet the requirement eWhen there 15 no voltage at the start relay check the brake switch conducti
31. its polar characteristics are good before selling out 2 TORQUE VALUE 1 Engine m s ens 10 10 0 Bracket between eng and 5 When the engine is cold 2 a boos When the engine is cold uA 14 1 1 13 0 2 Chassis 1 9 _ 1 8 2 s 2 7755 perennes 1 1 n C 39935 jua 8 a 3 6 8 9 NIe NINI 3 Other parts please refer the following table Standard torque values 6 mmsmw 03505 omm flange serw 9 fmm flange bolt and screw 1914 3 Lubrication instruction A Engine Lubrication location Oil type Crankcase rotating part Auto separated 0008 Premium 2 stroke Lubrication Motorcycle oil Cylinder rotating part Or SAE 30 G sss Drive gear box SAES5 140 Total 110 c c Replacement 90c c m Gasket of starter shaft 3 Start idle gear sliding Clean grease 3 parts B CHASSIS Steel ball steering 1 w Dom is D Viu se ct Sg aur L Front brake fluid Front brake cam C WHEEL BEARING Motor oil Final transmission mechanism gear oil Speedometer gear clean grease Front wheel
32. justment heise aep on valve mm s s s s c Timing is not correct Valve clearance is incorrect Check cylinder conpressi on I pressure 1 use cylinder conpre ssi pressure gauge P Pressure is not normal Check carburetor s Is blocked or not I blocked Remove spark Plug and check it Dirty color No dirty and no change Col or change 1 Check the oil level in crankcase Is too much or dirtv Oil level is Oil level is Normal Not normal 7 Check the lubrication 1 Of cylinder head Check engine overheat Or not overheat Running accelerately or Dues duce High speed continuously The reason cleaner blocked fuel supply system abnormal Gfuel tank cover blocked muffler blocked Gauto cock is malfunctioned auto chock is malfunctioned unit is out of order alternator flywheel magneto is out of order Q Valve clearance adjustment is not correct Valve base is over worn out Clearance valve is over extruded piston worn out cylinder gasket leakage valve base is malfunctioned wrong valve timing clean the carburetor Oclean the dirt specification is not correct level is too high oil level is too low Goil does not interchange route is blocked insufficient oil pumping from oil pump
33. lin 1 main Q feq 47 yams pea asnp uM poy ETT 2 Check A C flywheel magneto a Remove the LH side strip and LH body cover b Measure the resistance value of terminals Yellow black 0 1 1 0 White black 0 2 2 0 3 Check regulator measure the resistance value between each terminal it should be in specified range otherwise change a new one Pocket tester range 1k range Probe of tester C Probe of tester Regulator 4 Ignition system 1 wiring of ignition NO Blue Black OFF CDI Ignition _ condensor coi Black Red _ RED Ignition coil Blue yellow F Pulse coil i Black 2 CDI Resistance inspection Pocket tester range 1k range Probe of tester re ase ae 2 av eme tee ona a Probe of tester 2 Check the spark plug Spark Plug 3 Check the H T cable and H T coil by using the CDI tester Please follow the instruction manual 4 CDI sets checking Check with the CDI tester and Please follow the instruction Manual If the CDI is broken down please Change a new one ACT IOV Coil Starting E Spark freguency Switch 5 Starting system Starting wiring Red Main switch Starting motor m Start button Front brake switch 2 Checking eOther spare parts comp C
34. m is distorted b bearing of front axle too free c wheel rib is distorted d Wheel is not good e Front wheel axle locked improperly 4 front damper is too soft spring fatigue 5 noise in front damper a noise comes from damper box b locking screw of damper 15 slackness B Data Standard value mm Limit of use mm Lining of frt brake 2 0 Swingness of frt rr wheel _ C Changing the speedometer cable 1 Remove the fixed screws of the front cover 2 Remove the nut of speedometer cable 3 Remove the front handle cover 4 Remove the fixed screws of speedometer cable on the right of front wheel 5 Draw out the damage speedometer cable 6 Assemble the new cable follows the opposite procedure of dismantling NOTE Put the grease onto the Inner cable before Assembling D Steering handlebar Remove the LH RH back mirrors 2 Remove the upper handle cover 3 Remove the nuts on front fork and handlebar 4 Take off the fixing bolt 5 Remove the nut and bolt of the front fork fixed on The handlebar 6 Take off the handle bar 7 When assembling please follow the opposite procedures Locking Torque M6 1 0 1 2 MIO 3 0 4 8 Before assembling please add grease on each cable E Front wheel 1 the locking nut of the front wheel on the right side 2 Draw out the axle of front wheel remove the ring and take off the gear sets of speedometer 3 Remov
35. open the throttle and act on the starter motor to measure the compression pressure Compression pressure 6 0kg cny at 750 rpm When the compression pressure is too low check the following a Gasket of the cylinder head 15 damaged b Piston ring worrr out c Piston or cylinder worn out The cylinder compression pressure is usually too high when there is too much carbonization in the combustion chamber and the piston tip 8 Ignition Timing Note It is no need to adjust ignition timing and CDI set When ignition timing is not correct just check the ignition system 1 Remove the checking hole cover of ignition timing 2 Using the ignition timing light to assure the ignition timing is correct 3 Under idling it means in good function when crankcase s mark matches to the F on the flywheel 4 Raise the engine revolution to 5000 rpm slowly it means in good function if the crankcase s mark matches with Entering point of the flywheel 9 Idling Adjustment Remove the checking hole cover of carburetor 2 Start the engine and connect the tachometer 3 Adjust the throttle valve screw to the specified revolution 4 Specified idling revolution 1900 100rpm elf rpm is still unsteady or fuel up is not smooth please re adjust the fuel intake SCICW 10 Front Brake Adjustment 1 Check the clearance of front brake lever Clearance 10 20mm 2 If the clearance is beyond standard check wheth
36. rty Air mixture 15 too lean 1 Carburetor main jet is blocked 2 The ventilation hole of the fuel tank cover is blocked 3 Fuel filter is blocked 4 Fuel pipe bended squeezed or blocked 5 Float valve is abnormal 6 Fuel level is too low 7 Air pipe is blocked d Air mixture 1s too thick 1 Float valve is abnormal 2 Fuel level 1s too high 3 Air jet is blocked D Dismantling carburetor 1 Remove the luggage box 2 Loose the hose clamp between the carburetor and the air cleaner Then remove the air cleaner 3 Unscrew the fuel draining screw of the carburetor Drain off the fuel inside the carburetor 4 Remove the fuel pipe and the vacuum pipe on the carburetor 5 Remove the oil pile on the carburetor 6 Remove the bolts on the intake manifold and carburetor E Dismantling float nozzle Note The auto choke has been properly adjusted already Please do not adjust it further When there is blockage the carburetor please clean it by air compressor Reed valve I Dismantling reed valve 1 Take off the luggage box 2 Remove the air cleaner 3 Remove the carburetor 4 Unscrew the locking screw of the intake manifold 5 Remove the intake manifold 6 Remove the reed valve 2 checking for the reed valve chang a new one when the reed valve is worn out or distorted change a new one too when the base of the reed valve is cracked injured or distorted G Check the auto cock
37. s then measure The voltage between disconnect 2 2 Voltage normal Chassis O and red cable Than specification poor connection charging abnormal over charging generator 5 white cable Check The nanqa ertet ter etit Of the cable of Voltage rectifier cable poor connection BEN Check the resistivity Of the body of Voltage rectifier poor connection of green cable Voltage rectifier faulty 6 sparking spark plug Check and adjust Trouble condition Replace new spark Plug then check again spark plug faulty Check spark plug And cable 1s re M d Loosen or not park plug cap loosen Check the CDI plug Is loosen or not plug is poor connection Between CDI Plug and main switch faulty Each terminals check i of defective magneto Se coil pulse generator faulty defective ignition coil D main cable broke poor connection of joints or sockets defective CDI abnormal DEM eck ignition coi defective ignition By the CDI tester abnormal coil 3 Checking and Adjustment 1 Periodical checking table 2 Battery 3 Clean air cleaner 4 screen 5 T
38. se As the thickness 15 below 2 0mm change it Note No grease on the lining 12 Rear wheel rear brake rear damper A Troubleshooting B Data C Dismantling the rear wheel D Checking the rear wheel E Rear brake F Rear damper A Troubleshooting Rear wheel swings a wheel rim is distorted b wheel 15 abnormal c improperly assemble the wheel axle 2 Rear damper is too soft a rear damper spring fatigue 3 Bad braking a the adjustment of brake 16 not good b the brake lining 1s dirty c the brake lining 15 worn out d the cam of brake lining 15 worn out e the brake cam lever is worn out f the brake hub is worn out assembling of brake lever gear trough 15 not good B Data Standard value mm Limit of use mm The swings of rear wheel l Brake hub inner diameter qe o 111 0 Thickness of brakelining 40 29 C Dismantling and assembling The rear wheel Remove the fixed screws and bolts of the exhaust pipe 2 Remove the fixed screws of the rear wheel drum 3 Remove the bolts 4 Remove the rear wheel 5 To assemble the rear wheel please reverse the dismantling procedures Locking torque 6 0 7 1 1 kg m M14 8 0 10 0kg m D Checking the rear wheel echeck the swings of rear wheel eradial direction change it as it is above 2 0mm ehorizontal direction change it as it is above 2 0mm E Rear brake Rear brake disassembling diagram
39. t value 2 Limit of use 50cc change it when over 40 050mm Cylinder gauge 4 Piston outer diameter measurement 1 Measure at the skirt area where is 12 mm from the skirt lower end of skirt 2 Limit of use 50cc change if when below 39 895mm 3 Calculate the clearance between the cylinder and piston Limit of use change it when over 0 100mm 5 Inner diameter measurement of the piston pin hole Limit of use change it when over 14 032mm 6 Outer diameter measurement of the piston pin limit of use change it when under 9 970mm 50cc ENGINE 7 Check piston ring Measure piston ring gap Limit of use change new ones when the first ring and second ring are over 0 4mm Push the piston ring into the cylinder By piston the measure the gap 8 Check connecting rod small end 1 Install piston pin bearing onto the connecting rod small end then check the looseness of the piston pin 2 Measure the inner diameter of the connecting rod small end H Installing cylinder and piston 1 the piston ring into the second ring ditch first then install the piston ring into the first ditch 2 a Piston ring should be installed into piston ring ditch by even force b After assembling be sure that the piston ring sliding surface is at the same height as the piston outer surface c If the piston ring can not fit into the ditch please clean up the carbon in the piston ring ditch or piston ring itself 3
40. vity and the cables 7 Handle bar switch The colors for each switch cables Head Light Switch Operation Dark green Yellow Yellow black Blue 17 Color FREE bean Horn Switch PUSH wt D Signal Light Switch Main Switch Operation Color Blue White Lock Off ra aci e Reawnie Wu Orange

Buddy 50 Service Manual

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