PREFACE The service manual has been specially prepared to
Contents
1. Check and adjust Clean Adjust and replace 85 ELECTRICAL Complaint No sparking or poor sparking Spark plug soon becomes fouled with carbon Spark electrodes overheat or burn plug Magneto does not charge Magneto charge but charging rate is below the specifications Magneto overcharges Unstable charging Starter button is not effective 86 Symptom and possible causes Defective CDI amp ignition coil unit Defective spark plug Defective magneto stator coil Loose connection of lead wire Mixture too rich Idling speed set too high Incorrect gasoline Dirty element in air cleaner Spark plug loose Incorrect engine oil Spark plug too hot The engine overheats Spark plug loose Mixture too lean Not enough engine oil TARWNAIOARWN 1 Open or short in lead wires or loose lead connections 2 Shorted grounded or open magneto coil 3 Shorted or open regulator rectifier T Lead wires tend to get shorted or open circuited or loosely connected at terminal 2 Grounded open circuited stator magneto 3 Defective regulator rectifier 4 Defective cell plates in the battery 1 Internal short circuit in the battery 2 Resistor element in the regulator rectifier damaged or defective 3 Regulator rectifier unit poorly grounded coils of 1 Defective regulator rectifier 2 Lead wire insulation frayed due to vibration resulting in interm2. SERVICE LIMIT 0 10 mm 4 MIDDLE Inspect the top of the cylinder for warpage SERVICE LIMIT 0 10 mm PISTON PISTON RING INSPECTION Measure the piston ring to groove clearance SERVICE LIMITS TOP 0 12 mm SECOND 0 12 mm 37 Inspect the piston for wear or damage Insert each piston ring into the cylinder and measure the ring end gap NOTE Push the rings into the cylinder with the top of the piston to be sure they are squarely set in the cylinder SERVICE LIMITS TOP 0 5 mm SECOND 0 5 mm Measure the piston pin O D SERVICE LIMIT 14 960 mm Measure the piston pin bore SERVICE LIMIT 15 04 mm 38 Calculate the piston to piston pin clearance SERVICE LIMIT 0 02 mm Measure the connecting rod small end I D SERVICE LIMIT 15 06 mm PISTON INSTALLTION PISTON RING INSTALLATION Clean the piston ring grooves thoroughly and install the piston rings with the marks facing up NOTE Don t interchange the top and second rings Avoid piston and piston ring damage during installation Space the piston ring end gaps 120 degrees apart Ai TOP ki t RAIL SPACER SISJDE 39 PISTON INSTALLATION Install the piston with it s IN mark on the intake valve side Install the piston pin with new pin clips Do not align the piston pin clip end gap with the piston cutout NOTE Do not allow the clip to fall into the crankcas
3. 17 master cylinder rubber bushing 18 front brake switch RAKE PAD REPLACEMENT Remove the calliper by removing the mounting bolts NOTE Do not operate the front brake lever while dismounting the calliper 68 Remove the brake pads CAUTION Replace the brake pads as a set otherwise braking performance will be 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 Remove the calliper Remove the brake pads Remove the spring and pad holder Place a rag over the piston to prevent popping up Froce out the piston with a air gun CAUTION Do not use high pressure air to prevent piston damage Remove the dust seal piston seal 69 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 lts thickness can be checked with disc and wheel in place Ralpace the dise if the thickness exceeds the service limit Service Limit 3 5 mm 0 14 in With the disc mounted on the wheel check the dids for face runout with a dial gauge as shown Replace the disc if the runout exceeds the service limit Servi
4. BA fA CAM CHAIN A Remove the nuts and washers CAMSHAFT HOLDER Remove the camshaft holder and dowel pins SUE Relax the camshaft gear from cam chain and remove the camshaft CAMSHAFT GEAR 26 INSPECTION Inspect the cam lobes surface and height of cam lobes for wear or damage Inspect the camshaft and bearings for wear or damage and replace them if necessary Screw a 5mm bolt into the rocker arm shaft threaded end Pull on the bolt to remove the shafts and rocker arms Inspect the camshaft holder rocker arms and rocker arm shafts for wear or damage BEARINGS 27 Measure the I D of each rocker arm SERVICE LIMIT 10 10 mm Measure the O D of each rocker arm shaft SERVICE LIMIT 9 91 mm CYLINDER HEAD REMOVAL Remove the flange bolts and cylinder head Remove the cylinder head gasket and dowel pins DOWEL PINS Remove the cam chain guide 28 CYLINDER HEAD DISASSEMBLY Remove the valve cotters spring retainers and valve springs with a valve spring compressor INSPECTION Clean off all carbon deposits from the combustion chamber Check the spark plug hole and valve area for cracks Measure the cylinder head diagonally for warpage with a straight edge and feeler gauge SERVICE LIMIT 0 05 mm 29 Inspect each valve for turning burning scratches or abnormal stems wear Check the valve movement in the guide Measure and record each valve s
5. Excessively worn cylinder or piston rings Replace poorly in 2 Stiff piston ring in place Replace high speed 3 Spark plug gaps to narrow Adjust range 4 ignition not advanced sufficiently due to poorly working CDI amp Replace ignition coil unit Replace 5 Defective magneto stator coil Adjust or replace 6 Float chamber fuel level too low Clean 7 Clogged air cleaner element Clean and prime 8 Clogged fuel hose resulting in inadequate fuel supply to Clean carburetor 9 Clogged fuel cock vacuum pipe Dirty or heavy 1 Too much engine oil to the engine Check oil pump exhaust 2 Use of incorrect engine oil Change smoke Engine lacks 1 Excessively worn cylinder or piston rings Replace power 2 50 piston rings in place Replace 3 Gas leaks from crankshaft oil seal Replace 4 Spark plug gaps incorrect Adjust or replace 5 Clogged air cleaner element Clean 6 Float chamber fuel level out of adjustment Adjust or replace 7 Clogged air cleaner element Clean 8 Fouled spark plug Clean or replace 9 Sucking air from intake pipe Retighten or replace Slipping or worn V belt Replace Damaged worn rollers in the movable drive face Replace Weakened movable driven face spring Replace Too rich fuel air mixture due to defective starter system Replace Heavy carbon deposit on piston crown Clean overheats Defective oil pump or clogged oil circuit Replace and clean Fuel level to
6. if necessary IMPORTANT If the front fork is too weak us 60 70 ml depends on the weight of the driver of W15 fork oil to improve the damping 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 a EN E E _ PAE 16 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 are 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 steering stem bearing front wheel bearing engine bracket rear brake camshaft side stand rear brake shaft and rear brake cable speedometer cable and gear box main stand AA lubrication A A A A 20 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 beari
7. induced in the direction charges up the capacitor As the rotor rotates further the current is induced in the reverse direction dirctiono B the current causes a voltage applied through the ground to the gate of SCR As the SCR conducts the energy which has been charged in the capacitor is instantaneously discharged through the primary winding of the ignition coil CDI UNIT AND IGNITION COIL INSPECTION CHECKING WITH ELECTRO TESTER Connect the CDI test lead to the coils primary connector Connect the high tension leads redo lead to the spark plug cord and the blacko lead to the black lead of the test lead Set the test selector knob to P E l Connect the power lead to the appropriate AC source Switch the power on 47 e 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 Test the resistance between igntion ground wire and spark plug cap Ignition coil second resistance 12 18 KQ MAGNETO EXCITING COIL remove the right frame side cover disconnect the exciting coil lead wire black with red tracer Using a pocket tester measure the resistance between the B R lead wire and ground If the resist
8. the electrolyte container into the battery s electrolyte filler holes holding the container firmly so that it doer not EU fall Take precaution not to allow any of the fluid to spill brede Make sure air bubbles are coming up each electrolyte container and leave in the positon for about more than 20 minutes Test the battery after the filling process If necessary charge the battery about 20 minutes with the charger 56 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 NOTE The current should be not more than 4A at any time insert 227 tightly After recharging wait for more than 30 minutes and apply multimeter to measure the battery voltage If the battery voltage is less than12 5V please rechare the battery again If battery voltage is still less than 12 5V please replace the battery with a new one When the battery is left for a long term without using it is subject to discharge When th scooter is not used for more than 1 month especially dring the winter season recharge the battery once a month at least 57 CHAPTER6 CHASSIS CONTENTS LEG SHIELD AND FRAME SIDE COVERS LEG SHIELD REMOVAL LEG SHIELD REMOUNTING FARME SIDE
9. wheel face clutch locknut Exceeding clutch outside lock screw 10 12 Electrical start idle press board screw 10 12 Gearcase lock bolt 10 12 Left crankcase discharging oil hole lock bolt 22 25 Left crankcase positioning pin shaft locknut 18 22 96
10. your motorcycle checked and adjusted periodically by your GENERIC Authorized Dealer to maintain the motorcycle at the optimum condition Code Inspection cleaning and adjustment R Replacement Cleaning replaced if necessary L Lubrication Remark 1 Clean or replace the air cleaner element more often when the motorcycle is operated on dusty roads or in the Heavily polluted environment Notes in the remarks are used to indicate the applicable models Maintenance and adjustment procedures The section describes the servicing procedures for each item of the Periodic Maintenance requirements Storage battery Inspect twice a year the contact Clean if any corrosion Remove the battery and charge before you store the vehicle for long time Uncover seat and then remove the battery box cap in the Middle of helmet barrel Disconnect negative pole line end positive end and then remove battery Measure the voltage between the two ends of battery with voltage gauge charge if the voltage is below 11 9V Cylinder head nuts and exhaust pipe bolts Tighten at each service If cylinder head nuts are not tightened to the specified torque may re in leakage of compressed fuel air mixture and reduce output tighten cylinder head nuts in the following procedures 1 Remove the frame lower covers 2 Remove the cylinder head cover bolt 3 Remove spark plug cap 4 Tighten the nuts evenly one by one to the their specifie
11. 00 5 012 STEM TO GUIDE CLEARANCE pest 0 030 0 057 040 VALVE SEAT WIDTH TORQUE VALUES Cylinder head bolts 8 12 0 8 1 2 kg m Camshaft holder flange nuts 20 24 2 0 2 4 kg m Tappet adjusting nut 9 12 0 9 1 2 kg m 24 TROUBLE SHOOTING Engine top end problems usually affect engine performance These problems can be diagnosed by a compression test or by tracing engine noise to the top end with a sounding rod or stethoscope LOW COMPRESSION Valve _Incorrect valve adjustment Worn or damaged valve seats Burned or bent valve Incorrect valve timing Weak valve spring Cylinder head Leaking or damaged head gasket Warped or cracked cylinder head Faulty cylinder or piston Excessive noise Incorrect valve adjustment Sticking valve or broken valve spring Worn or damaged rocker arm or camshaft Worn or damaged cam chain Worn or damaged cam chain tensioner Worn cam sprocket teeth Excessive smoke Damaged valve stem seal Faulty cylinder or piston rings CAMSHAFT COMPOSITION REMOVAL Remove the rubber tube of gas waste recovery Remove the cylinder head cover CYLINDER HEAD COVER 25 Remove the air cleaner and carburetor Remove the inlet pipe assy Remove the shroud compositions Relax the cam chain adjuster screw Remove the screw and O ring and tighten the cam chain adjusting bolt with clockwise direction 1 1
12. 17 1mm 44 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 And the positions of adjustable parts should not be changed except when compensation for the mixture ratio due to altitude differences or other climatic conditions When adjustment is necessary refer to the following fuel air mixtura ratio can ba changed 2 throttles opening heint of changim rakia pre eee ee pilot jet 1 larger number richer mixture zmallar mambar xi ghi leaner liar e jel needle fat laanar richer Sth meal i mo ri J re larger mumber richer mixture i smaller number height lean mixture 45 CHAPTER 5 ELECTRICAL SYSTEM CONTENS 46 IGNITION SYSTEM CHARGING AND LIGHTING SYSTEM STARTER SYSTEM FUEL GAUGE OIL LEVEL CHECK LIGHT AND TURN SIGNAL INDICATOR SWITCHS BATTERY IGNITION SYSTEM CDI amp lIgnition coil unit MAGNETO Spark plug The ignition system consists of a flywheel magneto a CDI amp lgnition coil unit and a spark plug As the rotor tatates an AC current is induced in the coil Then current
13. 7 2 Ibf ft 22 N m 16 Ibf ft 35 N m 25 Ibf ft 55 N m 40 Ibf ft 28 N m 20 7 Ibf ft 12 N m 8 9 Ibf ft 20 N m 14 8 Ibf ft 8 N m 5 9 Ibf ft 24 N m 17 7 Ibf ft 4 N m 2 9 Ibf ft 50 N m 36 9 Ibf ft 33 N m 24 Ibf ft 18 N m 13 3 Ibf ft 35 N m 25 8 Ibf ft 40 N m 29 Ibf ft 40 N m 29 5 Ibf ft 24 N m 17 7 Ibf ft 40 60 N m 30 45 Ibf ft 4 N m 3 0 Ibf ft 7 N m 5 2 Ibf ft 40 60 N m 30 45 Ibf ft 24 N m 17 7 Ibf ft 30 N m 22 1 Ibf ft 30 N m 22 Ibf ft 90 N m 65 Ibf ft 90 N m 65 Ibf ft 45 N m 33 Ibf ft CYLINDER HEAD VALVES SERVICE INFORMATION CYLINDER HEAD REMOVAL TROUBLESHOOTING CYLINDER HEAD INSTALLATION CAMSHAFT COMPOSITION REMOVAL SERVICE INFORMATION GENERAL This section describes cylinder head valves camshaft and the other parts maintenance The engine must be removed from the frame to service cylinder head Camshaft lubrication oil is fed to the cylinder head through an oil orifice in the engine case Before installing the cylinder head be sure the orifice is not clogged and the gasket O ring and dowel pins are in place SPECIFICATIONS ITEM STANDARD SERVICE LIMIT CAM LOBE HEIGHT 2 Ex 2950 29460 gt ROCKER ARM 10 000 10 018 1010 ROCKER ARM SHAFT O D 9972 9987 994 CYLINDER HEAD WARPAGE oom 0 VALVE SPRING FREE LENGTH NO x3 2000000 VALVE STEM O D LEN did 4955 4970 480 VALVE GUIDE IN EX 5 0
14. 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 MASTER CYLINDER REMOVAL AND DISASSEMBLY MASTER CYLINDER INSPECTION MASTER CYLINDER REASSEMBLY AND REMOUNTING STEERING STEM AND FRONT SUSPENSION REMOVAL AND DISASSEMBLY INSPECTION REASSEMBLY AND REMOUNTING IGNITION SWITCH REAR WHEEL AND BRAKE REMOVAL AND DISASSEMBLY INSPECTION REASSEMBLY AND REMOUNTING 58 Side cover removal 1 remove seat and helmet barrel by opening seat and loosing tightening screw 2 loose hexad screw remove decorating cap rear carrier and oil tank lock remove side cover by loosing cover SCrew 3 side 3 unlock oil pump cap and remove it two tapping screw are exposed remove them remove tapping screw then remove side cover side installation 4 the sequence of installation is the reverse of removal 59 under cover removal 1 unscrew screw bolt 2 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 60 LEGSHIELD AND PEDAL REMOVAL 1 Remove power lock housing by unscrewing bo
15. L When installing the brake cam shaft aligh the groove of camshaft the slit of on cam shaft When installing brake shoes be sure to daub camshaft with adequate grease CAUTION Be careful not to daub the camshaft with too much grease If grease gets on the lining brake effectiveness will be lost 81 SERVICING INFORAMTION 82 CONTENTS Troubleshooting Battery Vehicle Wiring diagram Wire cable and brake hose routing Special tools Thread parts tightening torque Service data TROUBLESHOOTING ENGINE Engine does not Compression too low start or is hard 1 Excessively worn cylinder or piston rings Replace to start 2 Stiff piston ring in place Repair or replace 3 Gas leaks from the joint in crankcase cylinder or Repair or replace Engine easily Engine poorly Noisy engine stalls idles cylinder head 4 Damaged reed valve 5 Spark plug too loose 6 Broken cracked or otherwise failed piston Plug not sparking 1 Damaged spark plug or spark plug cap Dirty or wet spark plug Open or short n high tension cord Defective ignition switch No fuel reaching the carburetor Clogged hole in the fuel tank cap Clogged or defective fuel cock Defective carburetor float valve Carbon deposited on the spark plug Defective CDI amp ignition coil unit Clogged fuel hose Clogged jets in carburetor Clogged exhaust pipe Noise appears to come from piston Pisto
16. 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 performing any repair or services Major modifications and changes incorporated later will be advised to GENERIC product distributor in each market Therefore if newest information is requested in the future please contact the local GENERIC distributor The scooters distributed in your country mignt differ in minor respects from the standard specification and if they do it is because some minor modifications had to be made to comply with the statutory requirements of your country GENERAL INFORMATION CONTENT TYPE IDENTIFICATION FUEL AND ENGINE OIL BREAK IN PROCEDURE PRECAUTIONS AND GENERAL INSTRUCTIONS SPECIFICATIONS TYPE IDENTIFICATION ENGINE NUMBER ENGINE NUMBER 01 is carved on rear crankcase as Shown in figure Both FRAME NUBER AND ENGINE NUMBER are designed spe 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 ENGINE OIL For GENERIC SYSTEM we recommend special engine oil you can cho
17. ance checked is incorrect replace the coil Exciting coil restance 140 220 48 B mm 10 32 in 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 The DC Then charges the battery Charging output check start the engine and keep it running at 5000r min with lighting switch turned on When making the test be sure that the batteryis in fully NOTE charged condition Tachometer Standard charging output 13 16v at 5000r min 49 NO LOAD PERFORMANCE Disconnect the magneto lead wire coupler e 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 Standard no load performance more than 65v AC AT 5000R MIN STATOR COILS Inducing coils Use procket tester to measure the resistance between the lead wire and ground If the resistance checked is not correct replace the coil Rregulator rectifier Standard resistance W R GROUND 0 6 1 1Q W R GROUND 0 5 0 8 Q sconnect the lead wire couple Using the pocket tester x 1KQ RANGE measurethe resistance between the termina
18. ator with 400 or similar fine emery paper when it is dirty Service limit 0 2mm 0 008in Armature coil using the pocket tester check the coil for open and ground by plcing probe pins on each commutator segment and rotor core and on any two segments at various places With the brushes lifted off the commutator surface If the coil is found to be open circuited or grounded replace the armatrue Starter relay inspection Disconnect lead wire R W of the starter motor Turn on the igniton switch and squeeze the front or rear brake lever then inspect the continuity between the Red and Red White lead wires at the starter relay when pushing the starter button If the starter relay is in sound condition continuity is found e Disconnect the starter relay lead wire couple Check the coil for open ground and ohic resistance The coil is in good condition if the resistance is as follows STANDARD RESTANCE 80 150Q 52 a I 7 Mica 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
19. ble cleaning solvent b CCI or CCI SUPER oil THROTTLE CABLE Adjust every 1000KM Loosen locknut and adjust throttle cable play by turning adjuster in or out to obtain the following cable play After adjusting the calbe play tighten the locknut Cable play 0 5 1 0MM 0 02 0 040 inch Engine idle speed Adjust every 1000KM e Adjust the throttle cable play e warm up the engine Note Warm up engine for 10 minutes Connect an electric tachometer to the connecting protion of the magneto lead wire as shown in the illustration Use the selector key C position 12 Tachometer Adjust the throttle stop screw to obtain the idle r min as follows Idle speed 1600 100r min Finally adjust the throttle cable play GEAR OIL Change as shown in the service schedule Inspect gear oil periodically as follows The transmission oil level can not be checked It must be replaced as listened in the manual 0 11 Lis required Tightening toque 9 15N m 0 9 1 5 kg m 6 5 11 0 Ib ft BRAKES Inspect at initially 500 km and every service replace brake fluid every 2 years replace brake hose every 4 years Front brake fluid level Keep the scooter upright and place the handlebar staight Check brake fluid level by observing the lower limit line on the brake fluid reservoir When the level is below the lower limit line replenish with brake fluid that meets the following specification Specification and class
20. ce Limit 0 3 mm 0 012 in 70 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 Reassemble and remount the calliper refer to preceding bove pages WARNING Bleed air after remounting the calliper refer to above pages MASTER CYLINDER REMOVAL AND DISASSEMBLY Remove the handlebar cover Refer to above page Disconnect the front brake light switch lead wires Place a cloth underneath the union bolt on the master cylinder to catch spilled drops of brake fluid Unscrew the union bolt and disconnect the brake hose master cylinder joint CAUTION Completely wipe off any brake fluid adhering to any part of motorcycle The fluid reacts chemically with paint plastics rubber materials etc Remove the master cylinder 71 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 12 Inspect the piston surface for scratches or other damage Inspect t
21. d adjust front fork bearing to get smooth turning 77 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 78 REAR WHEEL AND BRAKE Tire 130 70 12 2 rear rim assy brake pad kit assy brake pad kit spring rear brake tension rear indicator anti dust cover rear brake camshaft 9 bolt M6X30 10 valve 11 11 M16X1 5 12 rear brake arm 13 valve cap 79 REMOVE Place the scooter on level ground Remove muffler Remove rear small fender Remove locknut and rear wheel Remove brake shoes 11111111 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 Service limit 2 5mm 0 09in 80 REASSEMBLY AND REMOUNTING Reassemble and remount the rear wheel and brake in the reverse of removal and also carry out the following steps 1 Turn the punched mark the camshaft to the rear shaft side 1 Install the protrusion of indicator plate to the groove of Camshaft
22. d tor Tighten the nuts in the order indicated Tightening torque Cylinder head nut 15 18N m Exhaust pipe bolt 15 18N m Cylinder and cylinder head Clean carbon every 6000 km Carbon deposits in the combustion chamber and the cylinder head v raise the compression ratio and may cause preignition and overheatin Carbon deposited at the exhaust port of the cylinder will prevent the flc of exhaust gases reducing the output Remove carbon depos periodically 10 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 Carbon deposits on the spark plug will prevent good sparking al cause misfiring Clean the deposits periodically e If the center electrode is fairly worn down the plug should replaced and the plug gap set to the specified gap using a thickne gauge Thickness gauge Spark plug gap 0 6 0 7 mm 0 024 0 028 inch Check the spark plug for burnt condition If abnormal replace the spe plug as indicated in the chart BPR7HS E7RTC Standard Tighten the spark plug to the specified torque Spark plug Tightening torque 15 18N m NOTE To check the spark plug first make sure that the fuel used is unleaded gasol
23. e CYLINDER INSTALLATION Clean any gasket material from the crankcase surface NOTE Be careful not to damage the gasket surface Install the dowel pins and a new gasket 40 Coat the cylinder bore and piston rings with engine oil and install the cylinder NOTE Avoid piston rings damage cylinder bore during installation Do not allow the cam chain fall into the crankcase Install the cylinder head 41 CHAPTER 4 FUEL AND LUBRICATION SYSTEM CONTENTS FUEL SWITCH CARBURETOR 42 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 When the engine has stopped the spring presses the valve the fuel passageway is closed and no fuel flows to the engine Fuel switch 43 CARBURETOR gt e am C e a Mixture ratio adjusting ena amp orew t 2221 Cm mem t zi idle adjusting screw 4 ry IN ain float tube 1 AL M SE 2 needle jet main Jet CARBURETOR Carburetor manufacturer type Identification code Corundum or QJ Main jet size PD24J Idle needle jet size 158 37 5 Idle air adjusting screw 1 Float height extrude 1 2 turnout
24. er Modify and fitting Replace Replace Replace brake fluid Disassemble and clean master cylinder Repair surface with sandpaper Tighten to specified torque Replace Adjust Refill Replace Replace Replace Replace or repair Replace Replace Brake drags 1 Rusty moving parts replace 89 WIRE CABLE AND BRAKE HOSE ROUTING carburetor cable odometer _ cable n s d d Throttle cable clamp rear brake cable T carburetar cable front brake r hose oil pump cable odometer cable i 6 front brake hose o1l hose clamp 90 separatiing box throttle cable carburetor cable vacuum tube carburetro calbe fuel pipe o1l tube 5 carburetor discharge pipe 91 92 filter core FUEL tilter vacuum pipe fuel pipe I Starting relay Ignition coil 93 SPECIAL TOOLS LISTED BELOW FOR REMOVAL AND REINSTALLATION 94 NO TOOL NUMBER DESCRIPTION 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 95 TIGHTENTING TORQUE O F SCREW THREAD PARTS ENGINE Spark plug ee Motor tightening bolt Driven wheel face locknut Driven
25. he 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 CAUTION Wash the master cylinder components with fresh brake fluis before reassembly Never use cleaning solvent or gasoline to wash them Apply brake fluid to the cylinder bore and all the internals to be inserted into the bore Reassemble and remount the master cylinder When remounting the master cylinder on the handlebar first tighten the clamp bolt for upside CAUTION Bleed air after remounting the master cylinder 73 STEERING STEM AND FRONT SUSPENSION handle jointing assy bolt GB5789 M10X1 25X45 nut GB6187 M10X1 25 left handlebar throttle grip assy screw GB818 M5XIO rear brake cable assy throttle cable assy 9 left switch comp 10 right switch comp 11 anti dust cover 12 steel ball amp 5 13 lower outer steel bowl 14 connecting steel bowl 15 under connecting borad assy 16 lower inner steel bowl 17 bolt GB5789 M10X1 25X30 18 locknut REMOVAL AND DISASSEMBLY Refer to preceding page remove the handle cover refer to preceding page remove under decorating cover refer to the preceding page remove legshield refer to preceding page 8 D 6 remove front wheel refer to preceding page disconnect the front and rear brake light switch lead wires 1 Remove the
26. he tip of indicator is beyond the range the brake shoe assembly should be raplaced with anew set of shoe 16 Tire Inspect at initially 500km and every 2500km 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 Thereafter maintain the correct tire pressure for good roadability and to prolong tire life CAUTION The standard air pressure of tires is 2Bar the use of other than standard may cause handling instability Tire tread condition It is highly recommended to replace the tire when the remaining depth of tire tread reaches the following specification Front and rear 1 6MM 0 064IN Tire depth gauge Steering inspect at initially 500km and every service Steering should be adjusted properly for smooth turning of handlebars and safe running Too stiff steering prevents smooth turning of handlebars and too loose steering will cause poor stability Check that there is no play in the front fork assembly by supporting the machine so that the front wheel is off the ground with wheel staight ahead grasp lower shock absorber near the axle and pull forward If play is found perform steering bearing adjustment 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
27. ification DOT4 WARNING The brake system of the scooter is filled with a glycol based brake the lowest line Fluid Do not use or mix different types of fluid such as silicone based and petroleum based Do not use any brake fluid taken from old used or unsealed containers Never reuse the brake fluid left over from the last servicing and stored for long periods 14 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 When the wear exceeds the limit mark replace the pads with new ones Bleeding air from the brake fluid circuit Air trapped in the fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cylinder and interferes with the full braking performance of the brake caliper presence of air is indicated by sponginess of the brake lever also by lack of braking force Considering the danger to which trapped air exposes the machine and rider it is essential that remounting the brake and restoring the brake system to the normal condition the brake fluid circuit be purged of air in the following manner e Fill up the master cyliner reservoir to the upper end of the inspection window Replace the reservoir cap to prevent entry of e Attach a
28. ine and if plug is either sooty with carbon or burnt white replace it Confirm the thread size and reach when replacing the plug FUEL LINE Inspect at initially 500 km and every service replace every 4 years 11 AIR CLEANER Clean every 3000KM 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 O Remove screw 1 and screw 2 take down air cleaner O Unscrew tapping screw 3 remove air cleaner cap 4 Oo Fill a washing pan of a proper size with Non flammable cleaning solvent l Immerse the air Cleaner in the cleaning solvent and wash them clean O Squeeze the cleaning solvent out of the washed element By pressing it between the palms of both hands do not twist or wring the air cleaner filter core element or it will develop tears O Immerse cleaned filter core of air cleaner in CCI or CCI SUPER oil 7 squeeze the oil out of the core which may be slightly wet with oil 1 Install air cleaner filter core in the reverse order of removal 3 CAUTION Before and during the cleaning operation inspect the core for tears A tore core must be replaced Be sure to position the filter core so that no incoming air will bypass it C CY AB LT Remember rapid wear of piston rings and cylinder bore is ofter caused by um b defective or poorly fitted filter core A Non flamma
29. ittent shorting 3 Magneto coil internally shorted 1 Battery run down 2 Defective switch contacts 3 Brushes not seating properly on commutator starter motor 4 Defective starter relay 5 Defective starter pinion gears 6 Defective front or rear brake light switch circuit Remedy Replace Replace Replace Connect tighten Adjust carburetor Adjust carburetor Change Clean Replace by hot type plug Replace Replace by cold type plug Tune up Retighten Adjust carburetor Check oil pump Repair or retighten Replace Replace Repair or retighten Replace Replace Replace the battery Replace the battery Replace Clean and connection Repair or replace tighten ground Replace Replace Recharge and replace Replace Repair or replace Replace Replace Repair or replace BATTERY Complaint Symptom and possible causes Remedy Battery runs 1 charging method is not correct Check the magneto and regulator rectifier down quickly 2 Cell plates have lost much of their circuit connections and make necessary active material as a result of adjustments to obtain specified charging over charging operation 3 A short circuit condition exists Replace the battery and correct the charging within the battery due to excessive system accumulation of sediments caused by the incorrect electrolyte Replace the battery 4 Battery is too old Replace
30. ive smoke Worn cylinder piston or piston rings Improper installation of piston rings Scored or scratched piston or cylinder wall Damaged valve stem seal 34 CYLINDER REMOVAL Remove the cylinder head Li n WI Remove the cylinder Remove the cylinder gasket and dowel pins Clean off any gasket materials from the cylinder surface NOTE Be careful not to damage the gasket surface 35 PISTON REMOVAL Stuff a shop towel into the crankcase Remove the piston pin clip with needle nose pliers NOTE Do not allow the clip fall into the crankcase Remove the piston pin from the piston Remove the piston e 29 F PISTON PISTON PIN Spread each piston ring and remove it by lifting up at a point opposite the gap PISTON INSPECTION Inspect the cylinder walls for scratches or wear 36 Measure and record the cylinder 1 0 at three levels in both an X and Y axis Take the maximum reading to determine the cylinder wear SERVICE LIMIT 57 50 mm Calculate the piston to cylinder clearance Take the maximum reading to determine the clearance SERVICE LIMIT 0 10 mm Calculate cylinder taper at three levels in an X and Y axis Take the maximum reading to determine the taper a SERVICE LIMIT 0 10 mm DIN Calculate the cylinder out of round at three levels in STOP an X and Y axis Take the maximum reading to determine the out of round
31. ker arm and valve stem by applying a feeler gauge STANDARD VALVE 0 08 mm 32 Relax the cam chain adjusting bolt with counterclockwise direction and install the o ring and screw Install the cylinder head cover DV CYLINDER HEAD COVER 33 CYLINDER PISTON SERVICE INFORMATION PISTON REMOVAL TROUBLESHOOTING PISTON INSTALLATION CYLINDER REMOVAL CYLINDER INSTALLATION SERVICE INFORMATION GENERAL Camshaft lubrication oil is fed to the cylinder head through an oil orifice in the cylinder head and engine case Before installing the cylinder head make sure the orifice is not clogged and the gasket O ring and dowel pins are in place Cylinder ip 57400 540 _ 55600006 TAR 1 om OUT OF ROUND 100 WARPAGE ACROSS TOP Piston PISTON O D 57 3075 57 3095 Piston pin Piston rings PISTON PIN BORE 15 002 15 008 PISTON PIN O D 14 994 15 000 inm m 960 PISTON TO PIN CLEARANCE 0 002 0 014 PISTON TO PIN wc 015 0 050 CLEARANCE PISTON RING TO RING SECOND Bind 015 0 050 GROOVE CLEARANCE TOP SEC PISTON RING END GAP Ew CYLINDER TO PISTON CLEARANCE 0 0005 0 1025 01 CONNECTING ROD SMALL END I D 15 010 15 028 156 TROUBLESHOOTING Low or unstable compression Worn cylinder or piston rings Overheating Excessive carbon build up on piston or combustion chamber wall Knocking or abnormal noise Worn piston and cylinder Excessive carbon build up Excess
32. ls as shown in the following table If the resitance checked is incorrect replace the regulator rectifier UNIT NOTES Including the components such as transistor capacitance regulator diode and so on so tested resistance may be different from actual resistance 50 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 brake switch batt CE NONEM stop switch power starting CDI 1gnition lock rela coil f JA EF 08 P Fry F E alarm t3 start magneto theftproot starting 01 ar motor p Starter motor removal and disassembly m em UT B Remove the starter motor UG 7 Disassemble the starter motor as shown in the illustration px A Pena Nee j T fi vi bx z sp er 51 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 Service limit 3 5mm 0 14in Commutator If the commutator surface is dirty starting performance will decrease Polish the commut
33. lt 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 61 2 HANDLE COVER REMOVAL 1 Remove front handle cover by unscrewing the six Kk tapping screws 1 Remove master cylinder by removing the bolt 62 3 Disconnect throttle cable and oil pump cable 4 Remove rear brake cable adjusting nut 63 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 64 Front wheel front rim middle bushing tire valve mouth nut GB6817 front shaft front wheel left bushing gearcase valve mouth cap p eS wl remove D 2 Remove the front brake caliper removing the mounting bolts NOTE Do not operate the front brake lever while dismounting caliper remove mounting bolt remove the left decorating cover and right one remove under front fender Support the scooter by jack or wood shelf Remove front wheel by removing front axle shaft oil seal 10 es roller bearing GB6201 2RS 4 AR 65 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 smoo
34. main wiring harness With the ignition switch tuined ON the fuel meter should indicate F The second test will check the accuracy of the meter in the full and empty positions Connect a 90 ohm resistor between the Y B and B W lead wires The fuel meter is normal if its pointer indicates the E empty position when the specified voltage is applied to the circuit and if its pointer indicates the F full position when the resistor is changed to 10 ohms If either one or both indications are abnormal replace the fuel meter with a new one FUEL GUAGE SENDING UNIT INSPECTION Disconnect the lead wires coming out of the fuel gauge and check resistance of eadn podition If the resistance measured is incorrect erplace the fuel gaue assembly with a new one The relation between the position of the fuel guage float and resistance is shown in the following table FLOAT POSITION RESISTANCE F FULL APPROX 33 1 2 APPROX 200 E EMPTY APPROX 566 53 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
35. n or cylinder worn down Combustion chamber fouled with carbon Piston pin bearing or piston pin bore worn Piston rings or ring grooves worn Noise seems to come from crankshaft 1 Worn or burnt crankshaft bearings Worn or burnt conrod big end bearings Noise seems to come from final gear box Gears worn or rubbing Badly worn splines 2 3 5 1 3 1 2 3 4 5 1 3 2 1 2 3 shaft 1 Excessively worn cylinder or piston rings Stiff piston ring in place Gas leaks from crankshaft oil seal Spark plug gaps too wide Defective CDI amp ignition coil unit Defective magneto stator coil Float chamber fuel level out of adjustment in carburetor Clogged jets in carburetor Broken or damaged reed valve Defective CDI amp ignition coil unit or stator coil 4 2 4 Clogged fuel hose or defective vacuum hose 2 4 Worn or damaged bearing of drive shaft or rear axle Replace Replace Tighten Replace Replace Clean and dry Replace Replace Replace Clean Clean or replace Replace Clean or replace Clean Replace Clean Clean Clean Replace Clean Replace Replace Replace Replace Replace Replace Replace Slipping clutch Worn or damaged clutch shoes 2 Worn clutch drum Replace Replace Replace Replace Adjust or replace Replace Replace Replace Clean or adjust Replace 83 Complaint Symptom and possible causes Engine runs 1
36. ngs bushings crankshaft crankcase rear axle shaft transmission starter pinion and starter gear Movable driven and clutch Movable drive Kicking starter Piston Oil pump and oil pump driven gear Intake pipe Magneto 21 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 Engine center Carburetor Intake pipe Reed valve Oil pump Worm wheel Cylinder head Cylinder Piston Engine right side cooling fan Magneto Starter motor 22 TORQUE VALUES STANDARD e 5mm bolt and nut e 6 mm bolt and nut e 8 mm bolt and nut e10 mm bolt and nut e12 mm bolt and nut ENGINE e Cylinder head nut e Spark plug e Cylinder head bolt e Alternator bolt FRAME e Handlebar upper holder bolt e Throttle housing cover screw e Steering shaft nut e Steering shaft holder bolt e Wheel rim bolt e Tie rod lock nut e King pin nut e Handlebar lower holder nut e Front wheel bolt e Front axle castle nut e Front brake arm nut e Rear brake arm nut e Rear axle castle nut e Rear wheel bolt e Exhaust muffler mounting bolt e Engine hanger bolt e Rear axle holder bolt e Swing arm pivot nut e Rear shock absorber mounting nut 5 N m 3 5 Ibf ft 10 N m
37. o low in float chamber Adjust or replace Air leakage from intake pipe Retighten or replace Use of incorrect engine oil Change Use If improper spark plug Change Clogged exhaust pipe muffler Clean or replace 84 CARBURETOR Complaint Symptom and possible causes Starter jet is clogged Air leaking from a joint between starter body and carburetor Trouble with starting Idling or low speed troubles Medium or high speed trouble Overflow and fuel level fluctuations Air leaking from carburetor s joint or vacuum hose joint Starter plunger is not operating properly Pilot jet pilot air jet are clogged or loose Air leaking from carburetor s joint vacuum pipe joint or tarter Pilot outlet is clogged Starter plunger is not fully close Main jet or main air jet is clogged Needle jet is clogged Fuel level is improperly set Throttle valve is not operating properly Fuel filter is clogged Needle valve is worn or damaged Spring in needle valve is broken Float is not working properly Foreign matter has adhered to needle valve Fuel level is too high or low Clean Check starter body and carburetor for tightness and replace gasket Check and replace Check and replace Check and clean Check and replace Check and clean Check and replace Check and clean Check and clean Check and replace Check throttle valve for operation Check and clean Replace Replace
38. ose high quality Four stroke engine oil SHELL ULTRA 4 15W40 GEAR OIL Use high quality all purpose 80W90 engine oil for your vehicle BREAK IN TIME General requirements are as follows Limit break in speed At the first 100K MS mileage play throttle less than 4 5 throttle Don t run engine too long during break in time and try to change throttle position PRECAUTIONS AND GENERAL INSTRUCTIONS e Correctly abide by the following items when disassembling and assembling scooter e Don t run engine indoors without ventilation e Be sure to replace new bushings circlips O rings and cotter pins with new ones CAUTION e It is forbidden to use the circlip removed from shaft again only use new one e 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 Fix bigger diameter bolt first when tightening cylinder head or cylinder and tighten to specified torque gradually from inside to outside at diagonal order Use special tools for some special requirements Use original components and recommended engine oil e Keep each other s safety when several persons do e Inspect looseness and operating state of components after reassembling them E Take high care of gasoline which is explosive and never use gasoline as lotion The words like warning notice no
39. pipe to the caliper bleeder valve and insert the free end of the pipe into a receptacle nBleed air from the bleeder valve oqueeze and release the brake level several times in rapid succession And squeeze the lever fully without releasing it loosen the bleeder valve by turning it a quarter of a turn so that the brake fluid runs into the receptacles the will remove the tension of the brake lever causing it to touch the handlebar grip Then close the valve pump and squeeze the lever and open the valve Repeat the process until the fluid flowing into the receptacle no longer contains air bubbles thus The and such after dirt 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 valve disconnect the pipe Fill the reservoir with brake fluid to the upper end of the inspection window BLEEDER VALVE TIGHTENING TORQUE 6 9N m 0 6 0 9kg m 4 5 6 5lb ft CAUTION Handle brake fluid with care the fluid reacts chemically with Rear brake Turn adjusting nut so that the the play of the brake lever is 15 Brake shoe wear The vehicle is equipped with the brake lining limit Indicator on the rear brake Inspect brake lining limit as follows 1 First check if the brake system is properly adjusted 2 when operating the brake check to see that the tip of indicator is within the range 3 if t
40. r AC magneto Fuse 15A Headlight 12V 35 35W Turning light 12V 10W Taillight 12V 21 5W CAPACITY FUEL TANK 5 2L ENGINE OIL TANK 1L GEAR OIL 0 1L Transmission system Clutch system dry auto a centric Gearshift mechanism CVT stepless Operating mode of gears shift mechanism Automatic a centric Step less shift range 0 86 2 64 the above data may be modified without any notification Periodic maintenance and service CONTENTS 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 Steering Front shock absorber Rear shock absorber Vehicle bolts and nuts 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 PERIODICAL MAINTENANCE SCHEDULE Maintenance Item Kilometres 500KM 3500KM 6500KM 9500KM 12500KM 15500KM 18500KM 21500KM Remarks EN Transmission oil RO Replace all 6000Km or once a year Eg Engine oil OR Replace all 3000km The above maintenance schedule is established by taking the monthly 800 kilometers as a reference which ever comes first Have
41. rear brake cable 1 Remove throttle grip case 1 Remove throttle cable 74 1 remove disc brake system by unscrewing tightening bolt 1 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 L remove front fork remove bearing lower race by chisel 1 Remove steel balls Number of steel balls Upper 21 lower 21 1 remove the upper and lower bearing inner races with a appropriate bar 15 INSPECTION LI L 76 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 Reassembly and remounting reassemble and remount the steering stem handlebar and front fork in 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 QTY upper 21 lower 21 Tighten the steering outer race with special tool then extrude it 1 8 1 4round NOTE adjustment will vary from scooter to scooter Be sure that the steering turns smoothly and easily left to right install a locknut by installing locknut and anti dust cover L screw locknut with special tool an
42. se nuts on shock absorber lubrication leakage Replace Replace Replace Replace Replace Retighten Retighten Replace Tighten Replace Replace Refill Replace Refill Retighten Replace Replace Replace Replace Retighten Replace Add lubrication Adjust Add lubrication BRAKES Complaint Symptom and possible causes Insufficient 1 Leakage of brake fluid from hydraulic brake power system 2 Worn pad 3 Oil adhesion on engaging surface of pad Worn disc Air entered into hydraulic system Worn shoe Friction surfaces of shoes are dirty with up c Excessively worn drum Too much brake lever play Carbon adhesion on pad surface Tilted pad Damaged wheel bearing Worn pad Foreign substance entered into brake Brake squeaking Clogged return port of master cylinder Brake shoe surface glazed Loose front wheel axle or rear wheel nut Worn shoe 9 1 2 9 4 5 flui 6 T 8 a 9 Excessive brake lever stroke Air entered into hydraulic system Insufficient brake fluid Improper quality of brake fluid Worn brake cam lever Excessively worn shoes and or drum Leakage of 1 Insufficient tightening of connection brake fluid joints 2 Cracked hose 3 piston seal Remedy Repair or replace Replace Clean disc and pads Replace Bleed air Replace Replace Replace Adjust Repair surface with sandpap
43. te may turn out incessantly in the manual which means WARNING The personal safety of the rider may be involved Disregarding the information could result in injury to the rider CAUTION These instructions point out special service procedures or precautions that must be followed to avoid damaging the machine NOTE it provides some special information which keeps maintenance easier and important instructions clearer REPLACEMENT COMPONENTS Be sure to use genuine GENERIC components or their equivalent Genuine GENERIC components are high quality parts which are designed specially for your vehicle CAUTION Damage to the scooter may result from use of replacement components which are not Equivalent in quality to genuine GENERIC parts and it can lead to performance problems SPECIFICATIONS DIMENSION AND NET WEIGHT OVERALL LENGTH 1770 mm OVERALL WIDTH 702 mm OVERALL HEIGHT 1085 mm WHEELBASE 1280 mm NET WEIGHT 100 kg CHASSIS Front shock absorber spring oil damp Rear shock absorber spring oil damp Front wheel 120 70 12 Rear wheel 130 70 12 Front brake 190 Rear brake Drumqo110 ENGINE Type four stroke air cooled Intake system piston reed valve Cylinder QTY 1 Bore 02 4mm otroke 57 8mm Discharge 124 6ccm Compression ratio 9 5 1 Air cleaner dry Starting system electric and kicking start Lubricating systempressure lubricating ELECTRIC Ignition mode CDI opark plug CR7HSA Storage battery YTX7L BS Generato
44. tem O D SERVICE LIMITS 4 90 mm Measure and record the valve guide I D SERVICE LIMITS IN EX 5 30 mm Calculate the stem to guide clearance SERVICE LIMITS IN 0 08 mm EX 0 10 mm NOTE If the stem to quide clearance exceeds the service limits determine if a new quide with standard dimensions would bring the clearance within tolerance If so replace guides as necessary and ream to fit If the valve guide is replaced the valve quide is replaced the valve seat must be refaced CYLINDER HEAD ASSEMBLY Lubricate each valve stem with oil Insert the valves into guides Install the valve springs retainers and the cotters NOTE To prevent loss of tension don t compress the valve springs more than necessary 30 B INLET VALVE EXHAUST VALVE INSTALLATION Install the new gasket and dowel pins Install the cam chain guide Install the cylinder head CAMSHAFT COMPOSITION INSTALLATION Install the rocker arms and rocker arm shafts into the camshaft holder SA CYLINDER HEAD 31 Align the T mark on the flywheel with the index mark on the alternator cover by turning the flywheel counter clockwise Position the camshaft gear with cam chain so that its I mark aligns with the cylinder head surface and the circle hole forwards front Install the dowel pins and camshaft holder Tighten the washers and nuts TORQUE 20 n m 2 0 kg m Adjust the clearance between the roc
45. the battery Reversed 1 The battery has been connected the Replace the battery and be sure to connect the battery wrong way round in the system so that it battery properly polarity is being charged in the reverse direction Battery 1 Dirty container top and sides Clean discharges too 2 Battery is too old Replace rapidly 87 CHASSIS Handling feels too heavy Wobbly handle Wobbly wheel front Front suspension too soft Front suspension too stiff Noisy front suspension Wobbly wheel rear Rear suspension too soft Noisy rear suspension 88 1 Steering stem nut overtightened 2 Broken bearing race in steering stem 3 Distorted steering stem 4 Not enough pressure in tires 1 Loss of balance between right and left front suspension 2 Distorted front axle or crooked tire Distorted wheel rim Worn front wheel bearings Defective or incorrect tire Loose nut on axle Loose nuts on the rear shock Worn engine mounting bushing Loose nuts or bolts for engine mounting Weakened springs Oil leakage of shock absorber Not enough grease Worn suspension arm spacer Not enough grease Loose nuts on suspension Distorted wheel rim Defective or incorrect tire Loose nuts on the rear shock Worn engine mounting bushing Loose nuts or bolts for engine mounting 1 2 3 absorber A 5 Weakened spring Oil leakage of rear shock absorber Loo
46. thly Replace the bearing if there is anything ucusual Remove the dust seal CAUTION The removed dust seal and bearing should be replaced with new ones AXLE SHAFT Check the axle shaft runout with a micrometer and replace it if the runout exceeds the limit Service limit 0 25mm 0 010in WHEEL RIM Make sure that the wheel rim runout does not exceed the service limit when checked as shown An excessive runout is usually due to worn or loose wheel bearings and can be reduced by replacing the bearings If bearing replacement fails to reduce the runout replace the wheel Service Limit 2 0mm 0 08in 66 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 When installing this speedometer gear box align the two driving pawls with the two recesses of the wheel hub Tighten the nut with special tool 67 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 seal gasket 13 front gasket 14 rear gasket 15 brake pad I 16 brake pad 2
47. white the other unit RECTIFIER R REAR LIGHT EFT TURN LIGHT 6 P GJ G BeG B gt R W ALARM SYSTEM Fig 7 OIL LEVEL SWITCH INSPECTION Check the oil level switch for continuity between the lead wire If the tester does not show the value of 0 1 ohm when the switch ring is in bottom position file the contact surface or replace the unit 54 SWITCH MAIN SWITCH LIGHT CONTROL SWITCH RED RED WHITE DARK GREEN BLACK GREEN RED YELLOW RED YELLOW PINK YELLOW ON HEAD LIGHT e e e OFF e e PASSING LIGHT e e e LOCK e e oe e 6 BREAK SWITCH EXCHANGE LIGHT SWITCH RED SWITCH PURPLE YELLOW RED BULE AZURY ON o o HIGH BEAM e e OFF HEADLIGHT e 9 HORN SWITCH DIRECTION SWITCH RED WITHE BROWN ORANGE GREEN BLACK GREEN WHITE ON o 6 TURN LEFT e e OFF TURN RIGHT e e 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 as the sealed caps of battery filler holes Do not remove or pierce the sealed areas of the electrolyte container Insert the nozzles of
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