Explorer GT 50, Service And Maintenance Manual

Page 1: ...1 Service and Maintenance Manual 50ccm ...

Page 2: ...vicing 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 standar...

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Page 4: ...4 GENERAL INFORMATION TYPE IDENTIFICATION FUEL AND ENGINE OIL BREAK IN PROCEDURE PRECAUTIONS AND GENERAL INSTRUCTIONS SPECIFICATIONS CONTENTS ...

Page 5: ...ne number is 95 or more ENGINE OIL For GENERIC CCI SYSTEM we recommend special engine oil you can choose high quality two stroke engine oil without being diluted if without special oil GEAR OIL Use high quality all purpose SAE90 engine oil for scooter BREAK IN TIME General requirements are as follows Limit break in speed At the first 1000KMS 600 miles mileage play throttle less than 4 5 throttle A...

Page 6: ...ch other s safety when several persons do ႒ Inspect looseness and operating state of components after reassembling them ႒ Take high care of gasoline which is explosive and never use gasoline as lotion The words like warning notice note 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 t...

Page 7: ...ale stopper style Air cleaner dry Starting system electric and kicking start Lubricating system pressure lubricating ELECTRIC Ignition mode CDI Ignition timing 150 at 1500RPM Spark plug BP8HS Storage battery YTX5L BS Generator AC magneto Fuse 8A Headlight 12V 55W Turning light 12V 10W Taillight 12V 21 5W Meter light 12V 1 7W Oil level signal indicator light 12V 3W Turning signal indicator light 12...

Page 8: ...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 CONTENTTS ...

Page 9: ...xhaust pipe bolt T T T T T Cylinder head and cylinder change all 12000 km ಧ C R C R Spark plug ಧ R R R R Air cleaner Clean every 3000KM 2000 miles Idle speed rpm I I I I I Throttle cable play I I I I I Oil pump I I I I I Gear oil 75W90 R ಧ R ಧ R I I I I I Fuel line Replace every 4 years Brake I I I I I I I I I I Brake hose Replace every 4 years I I I I I Brake fluid Replace every 2 years Steering ...

Page 10: ...Inspect at initially 1000KM 600 miles 2 months and every 6000KM 4000 miles 12 months thereafter ႒ Uncover seat and then remove the battery box cap in the Middle of helmet barrel ႒ Disconnect negative pole line end positive end and then remove battery ႒ Measure the voltage between the two ends of battery with voltage gauge charge if the voltage is below 11 9V ...

Page 11: ...park plug cap 4 Tighten the nuts evenly one by one to the their specified torque 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 Remove carbon every 6000 km 4000 miles 12 months Carbon deposits in the combustion chamber and the cylinder head will raise the compression ratio and may cause preignition and over...

Page 12: ...ecified gap using a thickness 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 spark plug as indicated in the chart NGK TROCH REMARKS BPR7HS E8RTC If the standard plug is apt to get wet replace with the plug BPR8HS E7RTC Standard BPR9HS E6RTC If the standard plug is apt to overheat replace with the plug z Tighten the ...

Page 13: ...ter core in the reverse order of removal 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 Remember rapid wear of piston rings and cylinder bore is ofter caused by defective or poorly fitted filter core Ⱥ Non flammable cleaning solvent Ȼ CCI or CCI SUPER oil THROTTLE CA...

Page 14: ... controlled by amount of throttle opening Check the oil pump in the following manner to confirm correct operation for throttle valve full opening position Turn the throttle grip full open Check whether the red mark on the oil pump control lever Is aligned with the index mark when the throttle valve is positioned as above If the marks are not aligned loosen lock nuts and turn the adjuster in or out...

Page 15: ... 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 classification DOT4 WARNING The brake system of the scooter is filled with a ...

Page 16: ...rapped air exposes the machine and rider it is essential that after remounting the brake and restoring the brake system to the normal condition the brake fluid circuit be purged of air in the following manner Fill up the master cyliner reservoir to the upper end of the inspection window Replace the reservoir cap to prevent entry of dirt Attach a pipe to the caliper bleeder valve and insert the fre...

Page 17: ... with care the fluid reacts chemically with paint plastics rubber materials etc Rear brake Turn adjusting nut VR WKDW WKH WKH SOD ཱ RI UDNH OHYHU LV 15 25MM as shown in the illustration 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 brak...

Page 18: ...scooter with the excessively worn tires will decrease riding stability and consequently invite dangerous situation 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 handle...

Page 19: ... 6 2 Handle tightenging nut 37 44 3 7 4 4 3 Steering sterm locknut 37 44 3 7 4 4 4 Disc brake caliper fixing bolt 22 29 2 2 2 9 5 Disc brake master cylinder hose fixing bolt 22 29 2 2 2 9 6 Disc brake fixing bolt 5 9 0 5 0 9 7 Front shock absorber fixing bolt 37 44 3 7 4 4 8 Engine pivot fixing nut 55 60 5 5 6 9 Engine bracket fixing nut 37 44 3 7 4 4 10 Rear wheel fixing nut 100 130 10 13 11 Rear...

Page 20: ...21 ི ཱ ཱི ུ ཱུ ྲྀ ཷ ླྀ ཹ 14 ...

Page 21: ...re 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 VWHHULQJ VWHP EHDULQJ ཱIURQW ZKHHO EHDULQJ ིHQJLQH EUDFNHW ཱིUHDU EUDNH FDPVKDIW ུVLGH VWDQG ཱུUHDU EUDNH VKDIW DQG UHDU EUDNH FDOEH ྲྀVSHHGRPHWHU FDOEH DQG...

Page 22: ... inspection and servicing Bearings Oil seals crankshaft automatic clutch inspection cylinder head cylinder piston reed valve engine remounting oil seals bearings 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 ...

Page 23: ...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 ...

Page 24: ...er z Remove cooling fan cover z Remove cylinder cover z Remove cooling fan z Remove magneto nut with special tools z remove magneto rotor and half circle key with special tools z remove magneto stator and paper gasket z remove oil pump ...

Page 25: ...rd z remove cylinder head and cylinder z Place a cloth stopper beneath the piston and remove the circlip with a plier z remove the piston pin and piston z Remove the kick starter lever z Remove side cover z Remove movable ratchet wheel and clip ...

Page 26: ...move starting driven ratchet wheel by removing the nuts z Remove fanུ and V beltཱུ z Disassemble the movable drive faceྲྀ z Remove electric gear press board electric gear and super clutch z Remove starter motor ...

Page 27: ...e the clutch housing with the special tool Peg key z drain gear oil z remove rear axle nut z remove rear wheel z remove brake shoeུ and rear axleཱུᇭ z Remove the rear brake cam lever indicator plateཱ and camshaftི ...

Page 28: ...emove cotter pinུ and shaftཱུ z remove main standྲྀ z remove gearcase cover z Remove paper gasket and middle gear assy ཱ z Remove output gear assy ི z remove carburetor z remove intake pipe z remove reed valve and paper gasket ...

Page 29: ...fixing shaft z disassemble crankcase with special tools z first remove right crankcase cover z Remove crankcase with special tools z Remove crankshaft bearing with special tools SLIDING SHOAFT Warning use a new sliding shaft ...

Page 30: ...ressed down by hands to counter the clutch sparing load Releasing the hand suddenly may cause the following parts to fly apart nut ཱclutch shoe ིspring CAUTION Do not attempt to disassemble the clutch shoe assy Otherwise the clutch shoe may be damaged z Using a screwdriver or the like pry up the movable driven face spring guide Ⴠ Remove the pinsཱི movable driven faceུ and fixed driven faceཱུ ...

Page 31: ...e the removed bearing with a new one z Remove inner bearing with special tool CAUTION Replace the removed bearing with a new one z Remove the spacer Remove the oil seal from the gearcase cover with the speical tool CAUTION Replace the removed oil seal with a new one ᇭ ...

Page 32: ...th special tool warning use a new oil seal z remove left crankcase bearing with special tool warning use a new one z remove left crankcase shock absorber bushing with special tool warning use a new bushing wrap the oil seal with two appropriate size of sheet irons and clamp it shown as fig ...

Page 33: ...36 z Remove right crankcase oil seal with special tool Warning use a new oil seal z remove right crankcase bearing sliding bearing warning use a new bearing ...

Page 34: ...s with solvent and lubricate with engine oil before inspecting Turn the inner ring and check to see that the inner rieng turns smoothly If it does not turn lightly quietly and smoothly or if noise is heard the bearing is defective and must be replaced with a new one ...

Page 35: ...ng Turn the crankshaft with the connecting rod to feel the smoothness of rotary motion in the big end Move the rod up and down while holding the crankshaft rigidly to be sure that there is no rattle in the big end Wear on the big end of the connecting rod can be estimated by checking the movement of the small end of the rod The method can also check the extent of wear on the parts of the connectin...

Page 36: ... electric tachmeter to the connecting portion of the magneto lead wire black with red tracer Seated on the scooter with the scooter on level ground increase the engine RPMs slowly and note the RPM at which the scooter begins to move forward Tachometer Standard 2900r min tolerance s300r min 2 Clutch LOCK UP inspection Perform the inspection to determine if the clutch is engaging fully and not slipp...

Page 37: ...he condition of the inner clutch wheel surface for scrolling cracks or uneven wear Measure inside diameter of the clutch wheel with inside calipers Measure the diameter at several points to check for an out of round condition as well as wear Service limit 110 50mm 4 350in DRIVE BELT Remove the drive belt and check for cracks wear and separation Measure the drive belt width with a vernier calipers ...

Page 38: ... turn smoothly If any stickiness or hitches are found visually inspect the lip of oil seal driven face sliding surface and sliding pins for wear or damage Driven face inspect the belt contacting surface of bothdriven faces for any scratches wear and damage Replace driven face with a new one if there are any abnormality Cylinder head Decarbon the combusion chamber Check the surface of the clinder h...

Page 39: ...bore to an oversize be sure to chamfer the edges of ports and smooth the chamfered edges with emery paper To chamfer use a scraper taking care not to nick the wall surface 127 Minor surface flaws on the cylinder wall durto seizure or similar abnormalities can be corrected by grinding the flaws off with fine grain emery paper If the flaws are deep grooves or otherwise persist the cyliner must be re...

Page 40: ...ch ring is to be measued with the ring fitted squarely into the cylidner bore and held at the least worn part near the cylidner bottom as shown in the illustration Service limit 0 75mm 0 030in As the piston ring wears its end gap increases reducing reducing engine power output becaust of the resultant blow by through the enlarged gap Here lies the importance of using piston rings with end gaps wit...

Page 41: ...0 0016 0 0024in 2nd 0 02 0 04mm 0 0008 0 0016in Reed valve Check the clearance A between reed valve and its seat and the dimension B If the clearance A is noted to exceed 0 2mm replace the reed valve assembly The dimension B is at least 1mm ...

Page 42: ...ective parts and components Oil seals fit the oil seals to the crankcase following the procedure below Replace removed oil seals with new ones z Lubricate the edge of oil seal z Install oil seal into crankcase carefully with special tool Oil seal installation Bearing Install new bearing with special tool Install bearing First heat up the cover and cool down the bearing The install would be much ea...

Page 43: ...46 shock absorber bushing positon install bearing in the cover Don t install the bearings on the crankshaft Install shock absorber bushing Install crankshaft without bearings ...

Page 44: ...y GENERIC NO 1215 evenly to the mating surface of the right half of the crankcase z Tighten the crankcase screws securely z Check if crankshaft rotates smoothly Install gearcase bearing Install new bearing and oil seal into gearcase cover with special tool and tighten anchor pin ...

Page 45: ...nstall middle gear position pin by installing middle gear axle gasketཱ and thrust gasketི z install gearcase cover into crankcase and lock bolt z tighten each screw z screw oil drain nutႼ 11 tightening torque 4 7 N m 0 4 0 7kg m 3 0 5 0 Ib ft ...

Page 46: ...49 z install the bearingཱ in the fixed driven face with the special tool z install sliding bearing ིᇭ ...

Page 47: ...apply grease to the lip of oil seals and groove of inside of movable driven face GENERIC special super grease NOTE When reinstalling the movable face to the fixed face make sure that the oil seal is positoned properly z install the pin at three places on the driven face hub z Apply grease lightly to the cam part where the pins are placed z Install two O RINGs ...

Page 48: ... driven face all the way outside to provide the maximum ble clearance CAUTION the belt should be positioned so that the arrows on the belt periphery point the normal turning direction The V belt contact face on the driven faces should be thoroughly cleaned to be free from oil z Thoroughly clean the clutch housing to be free from oil and position it over the clutch shoe assembly z tighten the clutc...

Page 49: ... should be used GENERIC super grease z Mount the three dampers on the movable drive plate ཱ and install it on the movable drive face z Position the O RING on the movable drive face z Install the movable drive face coverི NOTE 1 Make sure that the movable drive plate is fully positioned inside or the weight roller may come off ...

Page 50: ...ed inside sliding surface of the kick driven gear and install ཱ on the end of the crankshaft Wipe off excess grease QIANJIANG super grease Install washerི DQG VSULQJཱི NOTE When Installing washerི face the resin surface of washer to outside z install the retainerུ z continue turning the fixed drive faceཱུ by hand until the belt is seated in and both the drive and driven facesྲྀ will move together smo...

Page 51: ...54 Starter assy z Inject lubrication into start bearing and lubrication in the end of starter shaft GENERIC SPECIAL LUBRICATION z Tighten starter shaft gasket Install starter ratchet wheel and circlip ...

Page 52: ...r as shown in the illustration Tightening toque 8 12Nm 0 8 1 2kg m 6 0 8 5Ib ft PISTON z install the piston rings on the piston The first and the second ring keystone ring NOTE Position the ring so that the marking is on upside z it is extremely important that when the piston is fed into the cylinder each ring in place should be so positioned as to hug the locating pin as shown in illustration ...

Page 53: ...ot coincide with the grovve portion of the piston z apply oil on the position and cyoinder wall surfaces and install the cylinder over the piston carefully z tighten the cylinder head nut to the specification tightening torque 18 28Nm z install right crankcase oil seal press board z install worm and lubricater it with GENERIC special lubrication Oil pump z install oil pump into crankcase torque 3 ...

Page 54: ... z Install oil hose Intake pipe z install intake pipe Magneto z clear crankshaft and magneto rotor z install half circle key z install paper gasket and stator coil and fix them z tighten to specified torque with special tool specified torque 35 45Nm 3 5 4 5kg m 25 5 31 0Ib ft ...

Page 55: ...uiding cover z install fan guiding cover z install pipe screw and screw for tightening muffler to their specified torque 8 12Nm 0 8 1 2kg m 6 0 8 5Ib ft ཱ 18 28Nm 1 8 2 8kg m 13 0 20 0Ib ft z lubricate brake cam shaft with GENERIC grease ...

Page 56: ...59 CHAPTER 4 FUEL AND LUBRICATION SYSTEM CONTENTS FUEL SWITCH CARBURETOR OIL PUMP ...

Page 57: ... 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 ...

Page 58: ...r manufacturer type Identification code Throat tube diameter Main jet size Idle needle jet size Oil needle clamp position Idle air adjusting screw Float height equal vacuum PZ19JB 19mm 80 57 5 3rd groove extrude 1 2 1 2 1 turnout 13 1mm ...

Page 59: ...e 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 OIL PUMP OIL LEAKAGE throughout Whenever evidence is noted of some air having leaked into the oil pipe from the oil tannk in a machine brought in for servicing be sure to carry out an air bl...

Page 60: ...63 CHAPTER 5 ELECTRICAL SYSTEM CONTENS IGNITION SYSTEM CHARGING AND LIGHTING SYSTEM STARTER SYSTEM FUEL GAUGE OIL LEVEL CHECK LIGHT AND TURN SIGNAL INDICATOR SWITCHS BARTERY ...

Page 61: ...te 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 coil s primary connector Connect the high tension leads redႼ lead to the spark plug cord and the blackႼ ಧ lead to the black lead of the tes...

Page 62: ...ctronic 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 z remove the right frame side cover z disconnect the exciting coil lead wire black with red tracer z Using a pocket tester measure the resistance between the B R lead wire and ground If the resist...

Page 63: ...lywheel 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 NOTE When making the test be sure that the batteryis in fully charged condition Tachometer Standard charging output 13 16v at 5000r min Fuse Battery ...

Page 64: ...cket tester to measure the resistance between the lead wire and ground If the resistance checked is not correct replace the coil Rregulator rectifier Disconnect the lead wire couple Using the pocket tester 1KQ RANGE measurethe resistance between the terminals as shown in the following table If the resitance checked is incorrect replace the regulator rectifier UNIT KQ NOTES Including the components...

Page 65: ...switch and battery depressing the starter button while squeezing the front or rear brake lever energizes the relay causing the contact points to close which connects the starter motor to the battery Starter motor removal and disassembly Remove the starter motor Disassemble the starter motor as shown in the illustration ...

Page 66: ...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 z 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 con...

Page 67: ...ll 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...

Page 68: ...n and remains lit When the turn signal switch is turned on and the turn signal light flashes the turn signal indicator light oil level check light also flashes both being not concurrently but alternatively as one being lit white the other unit LJ 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 swi...

Page 69: ...WITCH RED ON RED WHITE MAIN SWITCH BROWN TURN RIGHT TURN LEFT DIRECTION SWITCH ORANGE GREEN BLACK GREEN WHITE PASSING LIGHT YELLOW RED PURPLE DIPPED HEADLIGHT HIGH BEAM OFF BULE AZURY EXCHANGE LIGHT SWITCH GREEN RED BLACK HEAD LIGHT YELLOW RED YELLOW LIGHT CONTROL SWITCH YELLOW PINK ...

Page 70: ...ry filler holes Do not remove or pierce the sealed areas ི of the electrolyte container Insert the nozzles of the electrolyte container into the battery s electrolyte filler holes holding the container firmly so that it doer not fall Take precaution not to allow any of the fluid to spill Make sure air bubbles are coming up each electrolyte container and leave in the positon for about more than 20 ...

Page 71: ...current should be not more than 4A at any time 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 scoo...

Page 72: ...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 DISASSE...

Page 73: ...emove decorating cap ཱ rear carrier and oil tank lock ཱི remove side cover ཱུ by loosing side cover screw ུ ྲྀ 3 unlock oil pump cap and remove it two tapping screw are exposed remove them remove tapping screwླྀ then remove side coverཹ side installation 4 the sequence of installation is the reverse of removal ཱི ི ྲྀ ཱ ཱུ ི ྲྀ ཷ ཹ ཹ ླྀ ...

Page 74: ... 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 screwཱ ཱ ཱ ཱི ི ཱ ཱ ཱ ཱི ཱ ི ...

Page 75: ...DAL REMOVAL 1 Remove power lock housing ཱ by unscrewing bolt 3 remove legshield and pedal by unscrewing the four boltsི Legshield and pedal installation 4 the sequence of legshield and pedal is the reverse of reomval ཱ ི ...

Page 76: ...79 HANDLE COVER REMOVAL 1 Remove front handle cover ཱ by unscrewing the six tapping screws 2 Remove master cylinder by removing the bolt ི ི ཱ ...

Page 77: ...80 3 Disconnect throttle cableི and oil pump cableཱི 4 Remove rear brake cable adjusting nut ུ ི ཱི ུ ...

Page 78: ...81 Handle cover removal 5 remove all cables 6 Remove handle cover by unscrewing bolt ཱུ Handle cover unstallation 7 The sequence of removal is the reverse of reomval ཱུ ...

Page 79: ...arcase 11 valve mouth cap remove Remove the front brake caliper by removing the mounting bolts NOTE Do not operate the front brake lever while dismounting caliper remove mounting boltི remove the left decorating cover ཱི and right one ུ remove under front fender ཱུ support the scooter by jack or wood shelf yRemove front wheel by removing front axle shaft ཱ ི ུ ཱི ཱུ ...

Page 80: ...ed 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 bear...

Page 81: ...ollowing 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 ...

Page 82: ...the calliper 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 1 16 brake pad 2 17 master cylinder rubber bushing 18 front brake switch ...

Page 83: ... 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 and ...

Page 84: ...and wear Check the disc for wear with a micrometer Its thickness can be checked with disc and wheel in place Ralpace the dise if the thickness exceeds the service limit 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 Service Limit 0 3 mm 0 012 in ...

Page 85: ...liper refer to preceding bove pages WARNING Bleed air after remounting the calliper refer to above pages MASTER CYLINDER REMOVALAND 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 mast...

Page 86: ...he dust boot Remove the circlip with the special tool Remove the piston primary cup with return spring Remove the reservoir cap and diaphragn Drain brake fluid MASTER CYLINDER INSPECTION Inspect the master cylinder bore for any scratches or other damage ...

Page 87: ...d 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 ...

Page 88: ...rake light switch lead wires ႒ Remove the rear brake cable ཱ ႒ Remove throttle grip case ི ႒ Remove throttle cable ཱི 1 handle jointing assy 2 bolt GB5789 M10X1 25X45 3 nut GB6187 M10X1 25 4 left handlebar 5 throttle grip assy 6 screw GB818 M5X10 7 rear brake cable assy 8 throttle cable assy 9 left switch comp 10 right switch comp 11 anti dust cover 12 steel ball 5 13 lower outer steel bowl 14 conn...

Page 89: ... locknut with special tool ႒ remove fornt fork assy by removing upper outer steel bowl NOTE Not drop the steering stem balls ႒ remove front fork ႒ remove bearing lower race by chisel ႒ Remove steel balls Number of steel balls Upper 21 lower 21 ႒ remove the upper and lower bearing inner races with a appropriate bar ...

Page 90: ...SPECTION ႒ inspect the removed parts for the following abnormalities bearing race wear and brinelling Worn and damaged steel balls Distortion of steering stem or handlebar ႒ Inspect the suspension for damage ...

Page 91: ...all 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 ႒ install a locknut by installing locknut and anti dust cover ႒ screw locknut with special tool and adjust front fork ...

Page 92: ...ied torque 37 44N M NOTE After performing the adjustment and installing the handlebar rock the front wheel forward and backward to ensure that there Is not play and that the procuder is accomplished correctly If play is noticeable raadjust the steering outer race nut ...

Page 93: ... 1 Tire 130 70 12 2 rear rim assy 3 brake pad kit assy 4 brake pad kit spring 5 rear brake tension 6 rear indicator 7 anti dust cover 8 rear brake camshaft 9 bolt M6ȋ30 10 valve 11 nut M16ȋ1 5 12 rear brake arm 13 valve cap ...

Page 94: ...r wheel ႒ Remove brake shoes INSPECTION REAR RIM Measure inner diameter of rear rim hub with micrometer if measured diameter exceeds 110 7 replace it with a new one Brake shoes Check the brake shoe and decide whether it should be replaced or not from the thickness of the brake shoe lining Service limit 2 5mm 0 09in ...

Page 95: ... axle shaft side ႒ Install the protrusion ཱ of indicator plate to the groove ི of Camshaft ႒ When installing the brake cam shaft aligh the groove ཱི of camshaft with the slit ུ of on cam shaft ႒ 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 ...

Page 96: ...99 SERVICING INFORAMTION Troubleshooting Battery Vehicle Wiring diagram Wire cable and brake hose routing Special tools Thread parts tightening torque Service data CONTENTS ...

Page 97: ...ve CDI ignition coil unit 3 Clogged fuel hose 4 Clogged jets in carburetor 5 Clogged exhaust pipe Clean Replace Clean Clean Clean Noisy engine Noise appears to come from piston 1 Piston or cylinder worn down 2 Combustion chamber fouled with carbon 3 Piston pin bearing or piston pin bore worn 4 Piston rings or ring grooves worn Noise seems to come from crankshaft 1 Worn or burnt crankshaft bearings...

Page 98: ...ive face 12 Weakened movable driven face spring 13 Too rich fuel air mixture due to defective starter system Replace Replace Replace Adjust or replace Clean Adjust or replace Clean Clean or replace Retighten or replace Replace Replace Replace Replace Engine overheats 1 Heavy carbon deposit on piston crown 2 Defective oil pump or clogged oil circuit 3 Fuel level too low in float chamber 4 Air leaka...

Page 99: ...buretor Change Clean Replace by hot type plug Replace Spark plug electrodes overheat or burn 1 Spark plug too hot 2 The engine overheats 3 Spark plug loose 4 Mixture too lean 5 Not enough engine oil Replace by cold type plug Tune up Retighten Adjust carburetor Check oil pump Magneto does not charge 1 Open or short in lead wires or loose lead connections 2 Shorted grounded or open magneto coil 3 Sh...

Page 100: ...ttery polarity 1 The battery has been connected the wrong way round in the system so that it is being charged in the reverse direction Replace the battery and be sure to connect the battery properly Battery discharges too rapidly 1 Dirty container top and sides 2 Battery is too old Clean Replace CHASSIS Complaint Symptom and possible causes Reme dy Handling feels too heavy 1 Steering stem nut over...

Page 101: ...Excessively worn drum 9 Too much brake lever play Repair or replace Replace Clean disc and pads Replace Bleed air Replace Replace Replace Adjust Brake squeaking 1 Carbon adhesion on pad surface 2 Tilted pad 3 Damaged wheel bearing 4 Worn pad 5 Foreign substance entered into brake fluid 6 Clogged return port of master cylinder 7 Brake shoe surface glazed 8 Loose front wheel axle or rear wheel axle ...

Page 102: ......

Page 103: ...106 WIRE CABLE AND BRAKE HOSE ROUTING ...

Page 104: ...107 carburetor ...

Page 105: ...108 ...

Page 106: ...109 Ignition coil Starting relay CDI HORN POWER SWITCHH ...

Page 107: ... DESCRIPTION 1 2 3 4 5 6 7 8 9 10 T01 T02 T03 T04 T05 T07 T08 T09 T10 ಯTರshape of sleeve sleeve tools 7mm 8mm 10mm 12mm 13mm flywheel remover sleeve 18mm 24mm screw remover cylinder pressure gauge piston pin remover spark plug remover flywheel lockbolt remover clutch clamp ཱ ི ...

Page 108: ...111 ཱི ུ ཱུ ྲྀ ཷ ླྀ ཹ ...

Page 109: ...ump lock screw 5 9 Right crankcase lock bolt 10 12 Bearing press board lock bolt 10 12 Cylinder double head bolt 15 18 Motor tightening bolt 10 12 Left crankcase cover lock screw 10 12 Left crankcase cover lock bolt 10 12 Main drive wheel face locknut 35 38 Driven wheel face locknut 35 38 Driven wheel face clutch locknut 55 60 Exceeding clutch outside lock screw 10 12 Electrical start idle press b...

Page 110: ...arance 0 15 0 35 0 0059 0 0138 0 8 0 0315 1st ring 0 02 0 06 0 0008 0 0024 Piston ring to groove clearance 2en ring 0 02 0 06 0 0008 0 0024 Piston pin bore 10 002 10 008 0 3938 0 3940 10 030 0 3949 Piston pin outside diameter 9 994 10 000 0 3935 0 3937 9 98 0 3929 CONNECTING ROD CRANKSHAFT ITEM STANDARD LIMIT Conrod small end 13 995 14 006 0 5510 0 5514 14 040 0 5528 Conrod deflection 3 0 0 12 Con...

Page 111: ...NGUO flat inhale stopper type Identification code PZ19JB Throat tube diameter 19mm Main jet size 80 Pilot jet size 57 5 Oil needle clamp position 3nd groove Idle air adjusting screw Extrude 1 2 1 2 1 turnout Float height 13s1mm ELECTRICAL UNIT mm in ITEM SPECIFICATION NOTE Ignition timing 150 AT 1500RPM TYPE E7RTC NANJING Spark plug GAP 0 5 0 7mm 0 020 0 028 Spark performance Over 8 0 3 at 1 atm I...

Page 112: ... Rear 15 20mm Hub diamter Rear 110 mm 110 7 mm Brake shoe thickness Rear 4mm 2 5 mm Brake disc thickness front 4 0s0 2 3 mm Tire size Front rear 120 70 12 130 70 12 Tire surface thickness front rear 120 130 SUSPENSION Front shock absorber stroke 88 mm Rear shock absorber stroke 45 mm Tire air pressure Front tire air pressure 175kpa Rear tire air pressure 196kpa Fuel engine oil Item Specification R...