mini 50 service manual
Contents
1. 3 Remove the float pin 4 Remove the float 5 Remove the float valve FLOAT CHAMBER 1 Inspect the float valve amp valve seat for wear or clogging Mecdle seat 2 Remove the main jet slow jet needle seat and pilot screw 3 Clean all the jets and clean all of the openings by using compressed air FLOAT CHAMBER ASSEMBLY 1 Install the slow jet needle seat main jet and pilot screw S loy jet 2 Install the float float valve and float pin 3 Install the chamber cap PDF created with pdfFactory Pro trial version www pdifactory com S FUEL SYSTEM mE N N 8 gt E 8 7 8 7 gt FUEL HEIGHT INSPECTION Measure the fuel height by using a gauge Standard 20 5mm CARBURETOR INSTALLATION 1 The installation sequence is essentially the reverse of removal 2 Adjust the clearance of the throttle valve cable 3 Adjust the pilot screw Standard 2 1 2 1 4 turns out Adjust the idle speed Standard 17001100 R P M Float height measurement Measure the distance between the mating surface of the float chamber and top of the float using a gauge Standard 10 5mm PDF created with pdfFactory Pro trial version www pdffactory com 6 ENGINE REMOVAL gt2. _ gt gt gt gt gt gt DRIVEN PULLEY DISASSEMBLY Fix the driven pulley in the compressor Remove the special nut 28mm Release the compressor Remove the driven plate assy Torque 5 0 6 0kg m REMOVE MOVABLE DRIVEN FACE Remove spring collar spring seal collar DRIVEN FACE SPRING INSPECTION Measure the spring uncompressed length Service limit 92 8mm DRIVEN FACE INSPECTION Measure the driven face outer diameter Service limit 33 94mm MOVABLE DRIVEN FACE INSPECTION Measure the movable drive face inner diameter Service limit 34 06mm PDF created with pdfFactory Pro trial version www pdffactory com ls oe y 8 7 E a _ DISASSEBMLY FINAL TRANSIMSSION COMP Remove sprocket Remove L crankcase cover Remove clutch comp Take out oil in final transmission unit Remove bolts on the final transmission gearbox Remove gasket and fixed pin Remove gear box cover INSPECTION OF FINAL TRANSMISSION Check counter gear shaft Check final gear shaft Check oil seal amp bearing on Left crankcase Check shaft drive gear and bearing BEARING EXCHANGE Remove bearing using a bearing driver Change the bearing PDF created with pdfFactory Pro trial version
3. 4 1 ENGINE OIL OIL FILTER OIL LEVEL Put the vehicle flat ground when inspecting the level of the engine oil Start and stop the engine 2 3 minutes each time before checking the oil level Remove oil gauge and check the oil level shown on the gauge When oil level is shown in the low level add 10W 40 motorcycle grade engine oil to bring to the appropriate level on the oil gauge 4 2 OIL CHANGE Oil will flow easily after warming the engine Take off oil drain plug to let the oil drain out completely Take off the oil filter cap and oil filter Wash the filter with high pressuring air Check the O ring on the oil filter and change with anew one if it is defective Take off the oil filter and cap with spring Torque 1 5 Start the engine and run idle for few minutes then check the oil volume again 4 3 OIL PUMP Remove the oil pump Remove the exhaust muffler Remove the A C Generator fly wheel Remove the A C Generator coil amp Pulsar Remove the setting bolts of the right crankcase cover Remove the gasket amp dowel pins Remove the clip of pump driven gear Remove the pump driven gear PDF created with pdfFactory Pro trial version www pdffactory com A LUBRICATION SYSTEM pH x ee ee 27 8 7 Remove the pump setting bolts Remove the oil pump Take off the 2 O rings and check the
4. _ _ ee m 2 Remove the piston pin 3 Remove the piston PISTON PISTON RING INSPECTION 1 Remove the piston rings 2 Clean the grooves for carbon deposit completely Note Do not damage the piston ring during removal Measure the piston ring groove clearance with a feeler gauge Service limits TOP 0 09mm SECOND 0 09mm Insert each piston ring into the cylinder with the piston and measure the ring end gap in the cylinder to a point 10mm 0 4in from the bottom Service Limits TOP SECOND 0 45mm Measure piston pin bore inner diameter in two directions at right angle to each other Service Limits 13 04mm Measure the piston pin outer diameter at the front center and rear and in tow directions across from each other Service limit 12 96mm PDF created with pdfFactory Pro trial version www pdffactory com pu _ _ gt gt ee Measure the piston outer diameter at a point 10mm from the bottom Service Limits 38 9mm CYLINDER INSPECTION Inspect the cylinder bore for wear of damage Measure the cylinder inner diameter at three places top middle and bottom of piston travel and in tow directions at right
5. Check the sealing washer and replace with a new one if damaged With the sealing washer and replace with a new one if damaged With the sealing washer attached thread the spark plug in by hand to prevent cross threading Tighten the spark plug to specified torque TORQUE 12 19 N m 1 2 1 9kg m 9 14 ft Ib Connect the spark plug cap PDF created with pdfFactory Pro trial version www pdffactory com 3 MAINTENANCE x gt Z8 Z7 8 7 8 LL Z2 8 E 8 7 8 79 8 27 8 LZ B LZ B LL ZW _ 3 6 Valve Clearance Inspect and adjust valve clearance while the engine is cold below 35 C 95 F Remove cylinder head cover Turn the flywheel counterclockwise and align the mark with the index mark Make sure the piston 15 at T D C on the compression stroke Check the valve clearances by inserting a feeler gauge between the adjusting screw and valve stem VALVE CLEARANCES INTAKE EXHAUST 0 1 mm 0 004in Adjust by loosening the lock nut and turning the adjusting screw until there is a slight drag on the feeler gauge Hold the adjusting screw and tighten the lock nut TORQUE 7 10 N m 0 7 1 0kg m 5 7ft Ib 3 7 CARBURETOR IDLE SPEED Warm up the engine and connect a tachometer Turn the throttle stop screw as requires obtaining the specifi
6. cutter the seat apply lapping compound to the valve face and lap the valve using light pressure after lapping Wash all residual compounds off the cylinder head and valve PDF created with pdfFactory Pro trial version www pdffactory com 7 CYLINDER HEAD VALVE mr x MB N N gt LZ NL LZ BN LZ BN LZ 8 75 8 7 CYLINDER HEAD ASSEMBLY Lubricate each valve stem and stem seal with engine oil Insert the valve stem seal and stems into the guides Install the valve spring washers and retainers Compress the valve spring with a cotter into the retainer Note Install the new valve spring when disassembly PDF created with pdfFactory Pro trial version www pdifactory com pu m ce gt gt gt LLL Z8 278 78 78 gt gt 78 gt CYLINDER REMOVAL 1 Remove the cylinder head 2 Remove the lifter of cam chain tensioner To see CYLINDER HEAD VALVE 3 Remove the cam chain guide 4 Remove the cylinder 5 Remove the cylinder gasket amp dowel pin Note Clean all the material of the cylinder gasket with a scraper Piston remove 1 Remove the piston pin clip Note Do not allow the clip fall into the crankcase PDF created with pdfFactory Pro trial version www pdffactory com C MEI pu
7. PDF created with pdfFactory Pro trial version www pdffactory com 1 amp Crankcase _MINIATV s gt gt gt gt CHE QC HE QE QE gt OVE gt gt 22 m aa Remove the seal from the left crankcase Remove the seal from the right crankcase CRANKSHAFT INSPECTION Measure the connecting rod big end side clearance with a feeler gauge Service limit 0 55mm Measure the connecting rod big end radial clearance at two different points across from each other Service limit 0 05mm Place the crankshaft on a stand or V blocks and measure the run out using a dial gauge Actual bend is 1 2 of total indicator reading Service limit 0 1mm Check the crankshaft bearing play by placing the crankshaft in a V block and spinning the crankshaft by hand If they are noisy or have excessive play replace with a new crankshaft assembly PDF created with pdfFactory Pro trial version www pdffactory com 11 amp Crankcase _MINIATV H E gt gt gt OE OE QE CHE gt OVE OVE OVE gt CRANKCASE ASSEMBLY Install the seals of right amp left crankcase Install the cam chain to the left crankcase Install th
8. ple speed 1 Vemwidi EN hy par pty r Headlight Tail light PDF created with pdfFactory Pro trial version www pdffactory com 2 TROUBLE SHOOTING _MINIATY ss ss ae Im m com ENGINE WILL NOT START OR IS HARD START FLOW PATH BAD SITUATION PROBABLE CAUSE CHECK IF FUEL REACHES FUEL DOES NOT REACH 1 NO FUEL IN TANK CARBURETOR 2 CLOGGED FUEL LINE BETWEEN FUEL TANK AND CARBURETOR 3 CLOGGED FUEL VALVE 1 FUEL REACHES 4 CLOGGED FUEL TANK CAP BREATHER CARBURETOR HOLE 1 FAULTY OR FOULED PLUG 2 FAULTY C D I 3 BROKEN OR SHORTED HIGH TENSION CORD 4 FAULTY IGNITION SWITCH 5 INCORRECT IGNITION TIMING LOW COMPRESSION 1 ENGINE NOT CRANKED 2 NO VALVE CLEARANCE 3 VALVE STUCK OPEN 4 WORN CYLINDER AND PISTON RINGS 5 BLOWN CYLINDER HEAD GASKET NORMAL COMPRESSION 6 FLAW IN CYLINDER HEAD 7 INCORRECT VALVE TIMING 8 BURNED VALVE ENGINE FIRES BUT DOES 1 CHOKE VALVE OPEN 2 CARBURETOR PILOT SCREW OPEN 3 AIR LEAKING THROUGH IN TAKE PIPE 4 INCORRECT IGNITION TIMING REMOVE SPARK PLUG WETPLUG 1 FLOODED CARBURETOR H PLUG 2 CHOKE VALVE CLOSED START ENGINE WITH CLOSED ENGINE LACKS POWER FLOwPATH BADSITUATION PROBABLE CAUSE RAISE WHEELS OFF WHEELS DO NOT SPIN 1 DRAGGING GROUND AND SPIN FREELY 2 FAULTY WHEEL BEARING 1 WHEELS SPIN FREELY 3 OVERTIGHTENE
9. e UG z FRAME Thread TORQUE Quantity Diameter Q m kg m ft Ib m 6 81208127 50 60 5 0 6 0 8 180250825 25 30 2 5 3 0 35 43 3 5 4 3 35 43 3 5 4 3 10 Item m Handlebar upper holder bolt 4 Steering shaft nut Steering shaft bushing holder nut Wheel hub nut Tie rod lock nut Ball Joint nut 3403040 Torque specifications listed above are for important area points For other fasteners use the standards Handlebar lower holder nut Front axle castle nut Front brake arm nut Rear axle amp Rear wheel bolt castle nut Rear brake panel bolt Exhaust muffler mounting bolt 1 2 2 Engine hanger bolt given below STANDARD TORQUE VALUES TORQUE TORQUE Item Item m kg m ft Ib m kg m ft Ib 5mm bolt nut 4 5 6 0 45 0 6 3 4 3 5 5 0 35 5 2 4 6mm screw and 6mm 12 0 8 1 2 6 7 11 0 7 1 1 5 8 18 25 1 8 2 5 13 18 6mm flange bolt nut 10 14 1 0 1 4 7 10 10mm bolt nut 30 40 3 0 4 0 22 29 8mm flange bolt nut 24 30 2 4 3 0 17 22 12mm bolt nut 50 60 5 0 6 0 36 43 10mm flange bolt nut 35 45 3 5 4 5 25 33 PDF created with pdfFactory Pro trial version www pdffactory com 1 GENERAL INFORMATION MINI ATV 1 4 SPECIFICATIONS Rise 000 O po size x Feet tank capacity isplacement Boremdstoke 1 Maxpowroupu o Max torque O po Valve clearance cold Intake
10. POOR PERFORMANCE AT HIGH SPEED a FLOW PATH BAD SITUATION PROBABLE CAUSE CHECK IGNITION TIMING AND VALVE CLEARANCE INCORRECT TIMING AND 1 INCORRECT TIMING ADJUSTMENT CORRECT TIMING AND CLEARANCE 2 INCORRECT VALVE CLEARANCE CLEARANCE DISCONNECT FUEL LINE AT 1 EMPTY FUEL TANK CARBURETOR AND CHECK 2 CLOGGED FUEL LINE FOR CLOGGING RESTRICTED FUEL FLOW 3 CLOGGED FUEL TANK CAP UNRESTRICTED FUEL FLOW BREATHER HOLE 4 CLOGGED FUEL PETCOCK CHECK FUEL FILTER FUEL VALVE AND CARBURETOR 1 CLOGGED JET JET FOR CLOGGING 2 CLOGGED FUEL FILTER NOT CLOGGED 3 CLOGGED FUEL VALVE REPLACE CARBURETOR 1 JET SIZE TOO SMALL MAIN JET 2 IF CONDITION IS IMPROVED WITH CONDITION IMPROVED SMALL JET A CLOGGED AIR CLEANER B CHOKE NOT OPENED FULLY CHECK VALVE TIMING INCORRECT VALVE TIMING INCORRECT CORRECT ADJUSTMENT CHECK VALVE SPRING WORN OR BROKEN TENSION SPRING FAULTY VALVE SPRING SPRING TENSION CORRECT SMOKY EXHAUST B FLOW PATH BAD SITUATION PROBABLE CAUSE RUN MOTORCYCLE A LONG 1 WORN CYLINDER AND PISTON DISTANCE AT HIGH SPEED RINGS THIN EXHAUST EMITTED 2 OIL LEVEL TOO HIGH BLACK SMOKE EMITTED 3 PISTON RINGS INCORRECTLY INSTALLED 4 FAULTY PISTON OR CYLINDER 5 FLAWS IN CYLINDER HEAD RETURN THROTTLE GRIP 1 WORN INTAKE VALVE GUIDE OR QUICKLY STEM WHITE SMOKE EMITTED 2 EXCESSIVE VALVE TO GUIDE CLEARANCE PDF created with pdfFactory Pro trial version www pdffactory com 2 TROUBLE
11. VN Z8 Z8 78 LL ZZ 8 E 8 78 2 Z2 8 7 8 7 8 ZW LZ E _ SEAT REMOVAL 1 Pull the paddle under the seat 2 Pull up and remove the seat FENDER REMOVAL 1 2 Remove rear fender Remove the bolts the fender 3 Remove the handle bar 4 Remove the bolts on the front fender 5 Remove the front fender PDF created with pdfFactory Pro trial version www pdffactory com 6 ENGINE REMOVAL mE MB N N Z8 78 gt E 8 7 8 78 gt 7 8 79 8 27 8 7 _ Life up side of vehicle Remove the chain clip and remove the chain Remove the setting bolts of chain guard and rear axial Remove chain guard Remove the setting bolt of rear shock absorber Remove rear axial PDF created with pdfFactory Pro trial version www pdffactory com 6 ENGINE REMOVAL mE x MB N N LLL NE I NE gt 8 7 E _ m Switch off the fuel cock Remove the fuel pipe front carburetor Note watch out that the left fuel in the pipe does not flow out Remove the setting bolt of intake manifold Remove the throttle cable Remove the gas recycle pipe from cylinder head cover Remove setting bolts of muffler and ex
12. Remove the setting plate and bolts 2 Remove setting bolts of valve 3 Remove spring and vacuum valve 4 Check the valve for wear or damage ASSEMBLY OF THE AIR CUTTING VALVE 1 Install the vacuum valve onto the carburetor 2 Install spring and cap 3 Fasten the setting plate and bolts VACUUM CHAMBER VACUUM CHAMBER DISASSEMBLY 1 Remove two setting screws Remove vacuum chamber cap Remove the spring Remove the vacuum valve puc D T9 Remove the needle PDF created with pdfFactory Pro trial version www pdffactory com S FUEL SYSTEM mln E x MB N N gt gt gt 8 gt Z8 7 gt Remove spring and vacuum valve Remove needle and plastic plug Note Do not damage the diaphragm VACUUM CHAMBER INSPECTION Inspect the needle vacuum valve and membrane for any damage VACUUM CHAMBER ASSEMBLY 1 Install the vacuum valve onto the carburetor body 2 Install the spring 3 Install the vacuum chamber cap 4 Fasten the screws Note Do not damage the membrane while installing the gap FLOAT CHAMBER FLOAT CHAMBER DISASSEMBLY 1 Remove the 3 setting bolts 2 Remove the chamber cap PDF created with pdfFactory Pro trial version www pdifactory com 5 FUEL SYSTEM mln s MB N N LLL LZ 8 7 8 Z8 7 8 7
13. angle to each other Service limits 39 2mm Calculate the piston to cylinder clearance Service limits 0 1mm CALCULATE THE TAPER AND OUT OF ROUNDNESS Service limits OUT OF ROUND 0 05mm TAPER 0 05mm CYLINDER BLOCK FLATNESS INSPECTIONS Service limit 0 05mm CONNECTING ROD SMALL END INSPECTIONS Service limits 13 06mm PDF created with pdfFactory Pro trial version www pdifactory com _ eS a _ PISTON RING INSTALLATION Clean the piston ring grooves thoroughly Install the piston ring Space the piston ring end gaps 120 degrees apart The gap of the three piece oil ring should correspond with the gaps of the spacer When installing the oil ring install the spacer first Next install the rails Note Avoid piston and piston ring damage during installation y Allrings should be installed with the markings facing up y After installation the piston rings should be free to rotate in the grooves y Donot mix the top and second rings Piston installation Install the piston piston pin and new piston pin clips Note y Position the IN mark on the intake valve side y Do not let the piston pin clip fall into the crankcase CYLINDER INSTALLATION Install the cylinder gasket and dowel pins Coat the cylinder and piston rings with engine oil Install the cylinder P
14. spanner 4 Remove the Tie Rod Assy Install a new Tie Rod Assy Tighten the castle nut Tighten it using a wrench Install the tire and tighten the nuts Following he anti clockwise direction to remove the screw and following the clock wise direction to remove the screw Turn around the Tie Rod and adjust it in correct position by open end spanner Lock up the castle nut By the opposite direction of turning the castle nut Take down the lift PDF created with pdfFactory Pro trial version www pdffactory com SYSTEM m 8 8 Z2 8 7 8 gt gt DISASSEMBLY FRONT DRUM BRAKE Remove the cover of the brake assy Push the brake lever to bottom out Take off the brake caliper Use a screwdriver to pull open the spring Remove the brake shoes as the picture Check the brake shoes If the surface of shoes is becoming worn or thin replace with new pads ASSEMBLY BRAKE CALIPER Put the brake shoes as the picture s sequence Put the spring on the brake shoes and buckle it into the pin PDF created with pdfFactory Pro trial version www pdffactory com 13 BRAKE SYSTEM _MINIATY Mol 8 8 Z2 Z2 8 7 8 7 8 gt
15. with pdfFactory Pro trial version www pdffactory com 2 TROUBLE SHOOTING _MINIATY sss a se Im up om a m REMOVE CYLINDER HEAD COVER AND CHECK SUFFICIENTLY LUBRICATION INSUFFICIENTLY 1 CLOGGED OIL PASSAGE LUBRICATED 2 POOR OIL PUMP DELIVERY CHECK IF ENGINE OVERHEATS ENGINE DOES NOT ENGINE OVERHEATS OVERHEAT 1 EXCESSIVE CARBON IN COMBUSTION CHAMBER 2 INCORRECT FUEL 3 SLIPPING CLUTCH RAPIDLY ACCELERATE OR 1 WORN PISTON OR CYLINDER URN AT HIGH SPEEDS 2 MIXTURE TOO LEAN ENGINE DOES NOT KNOCK ENGINE KNOCKS 3 INCORRECT FUEL 4 EXCESSIVE CARBON IN COMBUSTION CHAMBER 5 LGNITION TIMING TOO EARLY POOR PERFORMANCE AT IDLE AND LOW SPEEDS FLOW PATH BAD SITUATION PROBABLE CAUSE CHECK IGNITION TMING AND VALVE CLEARANCE CORRECT TIMING AND CLEARANCE INCORRECT TIMING AND 1 INCORRECT TIMING ADJUSTMENT CLEARANCE 2 INCORRECT VALVE CLEARANCE CHECK CARBURETOR PILOT SCREW ADJUSTMENT CORRECTLY ADJUSTED INCORRECTLY 1 MIXTURE TOO LEAN ADJUSTED 2 MIXTURE TOO RICH CHECK FOR AIR LEAKS 1 FAULTY CARBURETOR PACKING NO AIR LEAKS 2 CARBURETOR NOT SECURELY TIGHTENED 3 FAULTY INTAKE PIPE GASKET REMOVE SPARK PLUG AND WEAK OR 1 FAULTY OR FOULED PLUG TEST SPARK INTERMITTENT SPARK 2 FAULTY C D 3 MAGNET AT FAULT PDF created with pdfFactory Pro trial version www pdffactory com 2 TROUBLE SHOOTING _MINIATY ee ee ee ee ee ee ee ee ee ee ee Im m com
16. www pdffactory com ee oe nystan N N LZ BN gt 8 75 8 7 78 7 8 7 8 7 GEAR BOX ASSEMBLY Install drive shaft in the final transmission gear box Install final shaft in the final transmission gear box Install counter shaft and washer in the gear box Install resin washer on counter shaft Install fix pin on the gear box case Install gear box cover Tighten gear box cover with bolts Inject oil in the box Possess should be done on a flat surface Oil type SAE 90 Volume of gear box Disassembly 0 111 Exchange 0 09L Torque 1 0 1 5kg m start engine and check if oil 1 leaking Check the volume of oil Check oil volume from checking hole add oil if volume is low PDF created with pdfFactory Pro trial version www pdffactory com 11 amp Crankcase _MINIATV _ a ce Z8 78 7 8 gt DISASSEMBLY Remove the cam chain tensioned pivot Remove the cam chain tensioner Remove the crankcase setting bolts Separate the right crankcase and left crankcase Remove the gasket amp dowel pin Remove the crank from the crankcase Remove the cam chain Clean the crankcase connecting surface of any gasket material with scraper Do not damage the surface
17. 1 GENERAL INFORMATION MINI 1 1 SAFETY 1 If the engine must be kept running to service the unit make sure the area is well ventilated Never run the engine in a closed area 2 The battery generates hydrogen which can be highly explosive Do not smoke or allow flame and spark near the battery especially while charging 3 Gasoline is extremely flammable and 1 explosive under certain conditions Do not smoke or allow flames and sparks in working area 4 The battery electrolyte contains sulfuric acid Keep the acid away from your eyes skin and clothing In case of contact flush thoroughly with water and eek immediate medical attention 1 2 MODEL IDENTIFICATION ENGINE SERIAL NUMBER iu E a a The frame serial number is stamped The engine serial number is stamped on the forward part of the frame n the left bottom crankcase PDF created with pdfFactory Pro trial version www pdffactory com MINI ATV 1 3 Tightening Specifications for Fasteners ENGINE Thread It Quantit Diamet uantl lameter N m kg m ft Ib mm 8 12 0 8 1 2 Cam chain tensioner mounting bolt NE 6 81081 _ 8 28320832 6 820812 Valve adjusting screw lock nut 6 94230922 Starter motor mounting bolt 20 25 2 0 2 5 1 1 1 1 rj un En 9 Q 8 e 5 E EIE x 2a or CL o 9 je aq D 5 5 S e ga 2 z 2
18. C 0 1mm 0 1mm 5 10mm 3 16 3 8in 17001 00rpm l4ke cm 12mm 0 4in 10 20mm 0 37 0 75in 600mm 23 6in 617mm 24in N A 145 70 6 145 70 6 2 2psi 0 15kg cm 2 15kpa 5 10mm 0 2 0 4in PDF created with pdfFactory Pro trial version www pdffactory com 3 MAINTENANCE MINIATV m Lm Ll Lem Lr Lem Lem Lem Lr m WB LI a Lr LL WB LL WB L LL Ll a Y LL c 3 2 MAINTENANCE SCHEDULE Periodic Service Lubrication 1 3 6 6 1 Month Moths Months Months Year Check condition Adjust gap and clean Replace if necessary Air filter Clean Every 20 40 hours Replace if necessary more often in wet or dusty areas Check idle speed starter operation Adjust if necessary breather system Replace if necessary Exhaust system Check leakage Retighten if necessary Replace gasket if necessary Check fuel hose for cracks or damage Replace if necessary Replace Warm engine before draining Clean ra Correct if necessary Replace if damaged Check bearing assembly for looseness damage Replace if damaged Check operation Replace if damaged Check toe in Adjust if necessary Check specific gravity Check that the breather hose is positioned properly Check liquid height PDF created with pdfFactory Pro trial version www pdffactory com 3 MAINTENANCE Buh
19. D DRIVE CHAIN 4 WHEEL BEARING NOT LUBRICATED PROPERLY CHECK TIRE PRESSURE INCORRECT TIRE 1 PUNCTURED TIRE NORMAL PRESSURE PRESSURE 2 FAULTY TIRE VALVE PDF created with pdfFactory Pro trial version www pdffactory com 2 TROUBLE SHOOTING RAPIDLY ACCELERATE DOES NOT ACCELERATE 1 SLIPPING CLUTCH FROM LOW TO SECOND WITH ENGINE SPEED 2 WORN OR UNEVEN CLUTCH FACINGS ACCELERATES RAISED 3 CLUTCH PLATE WARPED REV UP GRADUALLY ENGINE SPEED DOES 1 CARBURETOR CHOKE CLOSED NOT INCREASE 2 CLOGGED AIR CLEANER ENGINE SPEED INCREASES 3 CLOGGED FUEL LINE 4 CLOGGED FUEL TANK CAP BREATHER HOLE 5 CLOGGED MUFFLER CHECK IGNITION TIMING INCORRECT TIMING CORRECT TIMING INCORRECT TIMING ADJUSTMENT CHECK VALVE CLEARANCE INCORRECT VALVE CORRECT VALVE CLEARANCE 1 INCORRECT VALVE CLEARANCE 2 WORN VALVE SEAT TEST CYLINDER LOSS OF COMPRESSION 1 VALVE STUCK OPEN COMPRESSION 2 WORN CYLINDER AND PISTON RINGS NORMAL COMPRESSION 3 BLOWN CYLINDER HEAD GASKET 4 INCORRECT VALVE TIMING 5 FLAWS IN CYLINDER HEAD OR CYLINDER CLOGGING CARBURETOR NOT CLOGGED 5 CARBURETOR FOR CLOGGED 1 CARBURETOR JETS CLOGGED REMOVE SPARK PLUG PLUG FOULED OR 1 FOULED PLUG DISCOLORED COLORED 2 INCORRECT HEAT RANGE PLUG CHECK OIL LEVEL AND CONDITION 10 CORRECT ENGINE OIL LEVEL OIL DIRTY OR LEVEL 1 LEVEL TOO LOW OR HIGH INCORRECT 2 CONTAMINATED OIL PDF created
20. DF created with pdfFactory Pro trial version www pdffactory com 9 TRANSMISSION SYSTEM _MINIATV m _ gt gt gt E a Disconnect the duct of L crankcase cover Remove the left crankcase cover Remove the driven face Warning fix the driven face by tool when loosening the fixing out Remove the drive belt DRIVEN BELT INSPECTION Inspect the belt for cracks wear or any damage Measure the width of the belt Service limit 17mm PDF created with pdfFactory Pro trial version www pdifactory com 9 TRANSMISSION SYSTEM Len LI WB LE Lr LL a WB MOVABLE DRIVEN FACE INSPECTION Measure the movable driven face inner diameter Service limit 24 06mm WEIGHT ROLLER INSPECTION Measure the weight roller of the outer diameter Service limit 12 4mm PIN OF DRIVEN FACE INSPECTION Measure the pin inner diameter Service limit 33 94mm Remove the clutch outer cover Remove the driven pulley CLUTCH OUTER INSPECTION Measure clutch outer cover inner diameter Service limit 107 5mm CLUTCH LINING INSPECTION Measure the lining thickness Service limit 2 0mm PDF created with pdfFactory Pro trial version www pdffactory com 9 TRANSMISSION SYSTEM
21. DISASSEMBLY REAR DRUM BRAKE Use an adjustable spanner to loose the nut on the axle Remove the brake shoes as the picture Check the brake pad If the surface of shoes is becoming worn or thin replace with new shoes ASSEMBLY BRAKE CALIPER Assemble the brake shoe Combine the drum and tight the nut on the axle Assemble the wheel and tight the nuts PDF created with pdfFactory Pro trial version www pdffactory com
22. SHOOTING _MINIATY SS ss se Im up pcm com POOR HANDLING FLOW PATH BAD SITUATION PROBABLE CAUSE IF STEELING IS HEAVY 1 STEERING HEAD ADJUSTER TOO TIGHT 2 DAMAGED STEERING CONES OR STEEL BALLS IF EITHER WHEEL IS 1 EXCESSIVE WHEEL BEARING PLAY WOBBLING 2 DISTORTED RIM 3 IMPROPERLY INSTALLED WHEEL HUB 4 SWING ARM PIVOT BUSHING EXCESSIVELY WORN 5 DISTORTED FRAME 6 IMPROPER DRIVE CHAIN TENSION OR ADJUSTMENT IF THE MOTORCYCLE 1 MISAPPLIED SHOCK ABSORBER PULLS TO ONE SIDE 2 FRONT AND REAR WHEELS NOT ALIGNED 3 BENT FRONT FORK 4 BENT SWING ARM CHECK TIRE PRESSURE PDF created with pdfFactory Pro trial version www pdffactory com _ J gt gt gt Z8 78 gt gt gt gt Z8 78 7 8 7 8 gt gt 7 8 7 8 3 1 SERVICE INFORMATION SPECIFICATIONS Ignition timing Spark plug Spark plug gap Recommended spark plugs Valve clearance cold Intake Exhaust Throttle lever free play Idle speed Cylinder compression Standard Brake lever free play Drive chain slack Drive chain length 52pins Standard Service limit Drive chain tensioner guide roller O D Standard Service limit Front rear rim size Front rear tire size Front rear tire pressure Front rear tire circumference Standard Toe in Bul E c e 13 BTDC 2000 100rpm 0 6 0 7mm 0 024 0 028in BP7S
23. e crankcase to the left crankcase amp connect with the cam chain Install the gasket amp dowel pin Install the right crankcase amp the setting bolts Install the cam chain tensioner amp the pivot Lubricate the o ring Tight the chain tension bolt PDF created with pdfFactory Pro trial version www pdffactory com _ _ REPLACING THE FRONT SHOCK ABSORBER 1 Lift up the frame 2 Remove the lug nuts 4 pieces from the wheel Remove the nut and bolt 2 pieces from the shock absorber Install a new shock absorber Lock up the fixed screws 2 pieces Install the tire and tighten the lug nuts Take off the lifter REPLACING THE REAR SHOCK ABSORBER Lift up the frame Take off the castle nut and the bolts 2 pieces Remove the shock absorber Install a new shock absorber Lock up the screws and the castle nut Take down the lift REPLACING TIE ROD 1 Lift up the frame 2 Remove the lug nuts 4 pieces from the tire PDF created with pdfFactory Pro trial version www pdffactory com ILU pu m _ ms a 2 3 Remove the screws from the Tie Rod Assy Tighten by the open end
24. e the rocker arms by using a 5mm bolt PDF created with pdfFactory Pro trial version www pdffactory com 7 CYLINDER HEAD VALVE MZ H gt 8 LL Z2 8 E 8 78 Z2 8 7 8 79 8 7 8 ZW ZB LZ E _ 2 Inspect the holder rocker arm shaft for wear and or damage Measure the rocker arm LD Service limits 10 10 mm Measure the rocker arm shaft O D Service limits 9 91 mm CYLINDER HEAD REMOVAL 1 Remove the two setting bolts 2 Remove the cylinder head 3 Remove the dowel pins amp the cylinder head gasket CYLINDER HEAD DISASSEMBLY Remove the valve cotter valve spring retainer valve spring and valve spring seat by using a compressor CYLINDER HEAD FLATNESS INSPECTION Service limits 0 05mm PDF created with pdfFactory Pro trial version www pdffactory com 7 CYLINDER HEAD VALVE ELM x MB N N gt gt 8 gt 7 8 7 8 7 8 79 VALVE SPRING INSPECTION Measure the uncompressed length of springs Service limit Outer 30 5mm Inner 26 1mm VALVE INSPECTION 1 Inspect the valve for during amp bending Measure the valve stem outer diameter Service limit IN 4 9mm EX 4 9mm Ream the guide to remove any carbon deposits with a reamer before checking th
25. e valve guide If the stem to guide clearance exceeds the service limit replace with a new guide and reface the valve seats Valve guide inspection Measure the valve guide inner diameter Service limit IN 5 3mm EX 5 3mm VALVE GUIDE REPLACEMENT Support the cylinder head and drive out the valve guide from the port with a guide remover PDF created with pdfFactory Pro trial version www pdffactory com 7 CYLINDER HEAD VALVE mra MB N N LLL NL LZ NL LZ BN LZ BN LZ 8 75 8 7 8 7 E _ _ VALVE SEAT GRINDING 1 Using a 45 degree cutter remove the roughness and irregularities from the seat Using a 32 degree cutter remove 1 4 of the existing valve seat material Using a 60 degree cutter remove the bottom 1 4 of the old seat Install a 45 degree finish cutter and cut the seat to proper width Standard 1 0mm INSPECT THE CONTACT AREA OF VALVE SEAT Apply a thin coating of Prussian blue to the valve seat Press the valve through the valve guide and on the contact area w the valve the seat must lowered using 45 degree flat gt cutter If the contact area 1 too low valve the seat must be raised using 60 degree inner cutter i X Note CH SLE o Refresh the seat to specifications using 45 degree finish poe
26. ed idle speed Idle speed 1 7007100 rpm NOTE Inspect and adjust the carburetor idle speed after all Other engine adjustments are within specification PDF created with pdfFactory Pro trial version www pdffactory com 3 MAINTENANCE e x gt gt gt SN 8 gt 7 8 7 gt _ 3 8 CYLINDER COMPRESSION Warm up the engine Stop the engine and remove the spark plug Connect a compression gauge Turn the throttle lever fully open and start the engine by push the electric starter switch for several times until the gauge reading stop rising Standard compression 14 kg cm 660rpm 3 9 DRIVE CHAIN Stop the engine and check the chain slack Standard 1 0 20mm Adjust the chain slack as below Loose the lock nut and adjusting nut Adjust the drive chain slack Tight the lock nut and adjusting nut Lubricate the drive chain with a commercial chain lubricant When the drive chain becomes very dirty it should be removed cleaned and lubricate with a commercial chain lubricant 1 Clean the drive chain with kerosene 2 Wipe it dry 3 Lubricate the drive chain 3 10 BRAKE SYSTEM Check the brake lever and cable for excessive play or damage Replace or adjust it if necessary Measure the free play of the front and rear brake lever at the end of the lever Standard free play 12
27. haust pipe Remove muffler and exhaust pipe PDF created with pdfFactory Pro trial version www pdffactory com 6 ENGINE REMOVAL x 8 78 Z8 7 8 7 NL _ Remove setting bolt of engine front side Remove the electric wire of starter motor PDF created with pdfFactory Pro trial version www pdffactory com 7 CYLINDER HEAD VALVE Ed LM ll CAMSHAFT REMOVAL 1 Remove the cylinder head cover 2 Remove the shroud grommet amp the pan screw Rotate the fly wheel clockwise and align the on the fly wheel with the index mark on the right crankcase cover Make sure the hole on the cam sprocket is on the top position Remove the setting nuts amp washers of the camshaft holder PDF created with pdfFactory Pro trial version www pdffactory com T CYLINDER HEAD VALVE Ed MB R J ZB ZB LLL LZ E aa 6 Remove the camshaft holder amp dowel pins 7 Remove the camshaft from cam chain CAMSHAFT INSPECTION 1 Measure the height of cam lobe Service limits IN 24 688mm EX 25 24mm 2 Inspect the bearing for loosening amp wear CAMSHAFT HOLDER DISASSEMBLY 1 Remov
28. ing cable 5 Remove fuel adjusting cable 6 Loosen the screw of the intake manifold clip and screw of air cleaner connecting pipe 7 Remove carburetor STARTER PLUNGER INSPECTION 1 Check the starter plunger wire for continuity Standard 5 check it when engine has cooled for 10 minutes If the value is over or under the standard replace with a new starter plunger Remove the carburetor and let it cool down for 30 minutes Blow air into the drain tube to check current air passage 4 Connect a fully charged battery to the starter plunger wire for five minutes Check the air current passage as shown Siarter pinger REMOVE STARTER PLUNGER 1 Remove screw to take off setting plate 2 Remove starter plunger from carburetor PDF created with pdfFactory Pro trial version www pdffactory com S FUEL SYSTEM x Z8 gt Z8 gt E 8 7 8 7 8 7 INSPECTION OF AUTO CHOKE 1 Check the valve amp needle for wear or any damage 2 If auto choke is defective replace with a new one INSTALL STARTER PLUNGER 1 Install inspected starter plunger on carburetor 2 Mount the fix plate and tighten the screws 3 Make sure the auto choke has been installed completely 4 Bottom side of fixing plate should face to ground when installed AIR CUTTING VALVE DASASSEMBLY 1
29. m x gt gt gt gt gt gt LZ BN gt E 8 7 E _ _ 3 3 Fuel Line amp Fuel Filter Check the fuel lines for deterioration damage or leakage and replace if necessary 3 4 Throttle Operation Check for smooth throttle lever operation and opening also ensure that it automatically fully closes in al steering positions Make sure there is no deterioration damage or kink in the throttle cable Replace any damaged parts Disconnect the throttle cable at the upper end and thoroughly lubricate the cable and pivot with cable lubricant to prevent premature wear Install the throttle cable in the reverse order of removal Make sure the throttle lever free play is 3 5mm 0 12 0 201n at the tip of the throttle lever 3 5 Spark plug Disconnect the spark plug cap and remove the spark plug Visually inspect the spark plug electrodes for wear The center electrode should have square edges and the side electrode should have a constant thickness Discard the spark plug if there 1 apparent wear or if the insulator is cracked or chipped Measure the gap with a feeler gauge and adjust by carefully bending the side electrode SPARK PLUG GAP 0 6 0 7mm 0 024 0 028 in RECOMMENDED SPARK PLUGS Standard BP7SC
30. m for defects or lack of elasticity Disassemble the oil pump Remove 3 setting screws Disassemble the oil pump OIL PUMP INSPECTION Measure the rotor to body clearance Service limit 0 12mm Measure the pump tip clearance Service limit 0 12mm Measure the pump end clearance Service limit 0 2mm PDF created with pdfFactory Pro trial version www pdffactory com 4 LUBRICATION SYSTEM N gt LZ K ZB ZZ BN LZ NL LLL ZZ 8 7 8 75 8 gt 7 8 7 8 7 8 gt ASSEMBLY OF THE OIL PUMP Install rotors and pump shaft into pump body Close pump by pump cap and tighten it by screws INSTALL OIL PUMP ON CRACK CASE Put 2 O rings back into pump circle hole Add oil into oil pump and mount back to crank case Tighten 3 bolts Install the pump driven gear and fix by nut Torque 0 8 1 2kg m Install right crank case cover and tighten it by bolts Install the A C Generator Coil amp pulsar Install the A C Generator Fly wheel PDF created with pdfFactory Pro trial version www pdffactory com S FUEL SYSTEM gt gt LZ BN gt E 8 7 8 7 8 7 REMOVE CARBURETOR 1 Release fuel drain screw 2 Drain out gasoline from the float chamber 3 Remove fuel tube and vacuum tube 4 Remove the nut of the fuel adjust
31. mm Adjust the free play of the brake lever by turning the adjusting nut on the brake arm 3 11 WHEELS TIRES Inspect the tire surfaces for cuts nails or other sharp objects Check the tire pressure at cold tire conditions Recommended tire pressure 2 2 psi 0 15kg cm 15 PDF created with pdfFactory Pro trial version www pdffactory com 3 MAINTENANCE A a gt gt gt gt gt gt gt gt gt gt gt _ 3 12 STEERING SYSTEM Check the free play of the steering shaft with the front wheels turned straight ahead When there is excessive play inspect the tie rod kingpin bushing and ball joint 3 13 TOE IN Place the vehicle on level ground with the front wheels facing straight ahead Mark the centers of the tires to indicate the axle center height Measure the distance between the marks Slowly move the vehicle back let the wheels turned 180 so the marks on the tires are aligned with the axle center height Measure the distance between the marks Calculate the difference in the front and rear measurements Toe in 5 10mm PDF created with pdfFactory Pro trial version www pdffactory com 4 LUBRICATION SYSTEM moo MZ N N gt gt gt LZ m 8 gt 8 7 gt _
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