Service and Maintenance Manual (50ccm)
Contents
1. clearance 0 0059 0 0138 0 0315 Piston ring to groove 0 02 0 06 0 0008 0 0024 654 4 0 3938 0 3940 0 3949 diameter 0 3935 0 3937 0 3929 CONNECTING ROD CRANKSHAFT Si Conrod web to web width 38 38 1 1 496 1 500 55 OIL PUMP ITEM SPECIFICATION 30 00030 1 CCI pump ischarge 1 1 1 3ml 5min working pressure is 0 06Mpa and rotating speed ratio full open 1 18r min 113 CLUTCH Unit mm in ITEM STANDARD LIMIT Clutch wheel Inner diameter 112 00 112 15 4 410 4 415 112 5 4 429 Clutch shoe thickness 1 8 0 071 1 2 0 005 Clutch engagement 3000x300r min Clutch closedown 6000 300r min TRANSMISSION SYSTEM DRIVING CHAIN UNIT mm in EXCEPT RATIO CARBURETOR Oil needle clamp position Idle air adjusting screw Extrude 1 p sed gt turnout Float height 13t Imm ELECTRICAL UNIT mm in ITEM SPECIFICATION NOTE Spark plug TYPE E7RTC NANJING 05 0 7mm 0020 0028 Spark performance Over 8 0 3 at 1 atm Primary secondary 20 0 30 77 10 Plug cap ground ITEM SPECIFICATION NOTE Lighting lt 2 Gree Red GROUND Charging lt 20 White Ground Exciting 200 200 at 20 C Blure White or Gree White Ground Generator no load voltage More than 52v at 5000r min 114 Regulated voltage More than 12 14V at 5000r min WWW WATTAGE ITEM SPECIFICATION Headlight high beam 12 35W 35W Dipped headlight 12 35W Tailligh2. continue turning the fixed drive face by hand until the belt is seated in and both the drive and driven faces will move together smoothly with slip fill the final gear box with engine oil up to the level comm Z hole Oil capacity 90ml tighten the oil level bolt to the specified torque Tightening torque 9 15Nm Starter assy Inject lubrication into start bearing and lubrication In the end of starter shaft GENERIC SPECIAL LUBRICATION Tighten starter shaft gasket Install starter ratchet wheel and circlip 54 Install the dowel pins install the new gaskets and apply GENERIC bond no 1215 to the clutch cover as shown in the illustration GENERIC bond no 1215 NOTE Install the kick starter lever as shown in the illustration Tightening toque 8 12Nm 0 8 1 2kg m 6 0 8 5Ib ft PISTON install the piston rings on the piston The first and the second ring keystone ring NOTE Position the ring so that the marking is on upside itis 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 correct incorrect 55 apply oil for the piston and install the piston to the connecting rod NOTE The arrow mark 2 on the piston head should point the exhaust side The circlip should be mounted in such a position that
3. Before and during the cleaning operation inspect the core for tears A tore core must be replaced Besure 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 A Non flammable cleaning solvent b CCI or CCI SUPER oil THROTTLE CABLE Adjust at initially 1000KM 600 miles 2 months and every 6000 km 4000 miles 12 months O 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 at initially 1000KM 600 miles 2 months and every 6000 km 4000 miles 12 months thereafter O Adjust the throttle cable play O 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 position Adjust the throttle stop screw to obtain the idle r min as follows Tachometer B R lead wire Idle speed 1400 100r min Finally adjust the throttle cable play OIL PUMP Inspect at initially 500km and every year The engine oil is fed by the oil pump to the engine The amount of oil fed to it is regulated by engine speed and oil pump contro
4. 87 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 88 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 89 Inspect the piston surface for scratches or other damage Inspect the primary cup and dus
5. O screw locknut with special tool and adjust front fork bearing to get smooth turning 94 install handlebar and tighten the screw 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 95 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 bolt M6X30 10 valve ll nut M16X1 5 12 brake arm 13 valve cap 96 REMOVE Place the scooter on level ground Remove muffler Remove rear small fender Remove locknut and rear wheel ED GB Remove brake shoes INSPECTION Measure inner diameter of rear rim hub with micrometer 1f 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 97 REASSEMBLY AND REMOUNTING Reassemble and remount the rear wheel and brake reverse of removal and also carry out the following steps Turn the punched mark on the camshaft to the rear axle shaft side Install the protr
6. Throttle cable s clamp front brake F rear brake i hose cable carburetor cable oil pump cable odometer cable E E ORT brake hose uer oll hose clamp Zeie 106 separatiing box 011 pump cable Sec Zbrottle cable carburetor cable vacuum tube carburetro calbe fuel pipe oll tube carburetor i discharge pipe 107 FUEL filter vacuum pipe fuel pipe filter core 108 Starting relay Ignition coil POWER SWITCHF 109 SPECIAL TOOLS LISTED BELOW FOR REMOVALAND REINSTALLATION DESCRIPTION TOOL NUMBER T shape of sleeve sleeve tools 7mm 8mm 10mm 12mm 13mm flywheel remover sleeve 18mm 24mm screw remover cylinder pressure gauge piston pin remover spark plug remover flywheel lockbolt remover clutch clamp 110 111 TIGHTENTING TORQUE F SCREW THREAD PARTS ENGINE M 1 4 5 9 Cylinder guide covertappingserew L _ Right crankcase lock bolt 10 12 Bearing press board lock bolt 10 12 Exceeding clutch outside lock screw 10 12 Left crankcase positioning pin shaft locknut 112 SERVICE DATA CYLINDER PISTON PISTON RING Unit mm in ITEM clearance 0 0024 0 0028 0 0047 1 5750 1 5756 1 5778 Cylinder diameter 39 94 39 955 39 885 1 5724 1 5746 1 5703 Cylinder distortion 0 04 0 0016 0 0016 Pie ng oe coner
7. Worm wheel Cylinder head Cylinder Piston Engine right side cooling fan Magneto Starter motor 25 ENGINE ASSY Remove muffler Remove cooling fan cover Remove cylinder cover Remove cooling fan Remove magneto nut with special tools remove magneto rotor and half circle key with special tools remove magneto stator and paper gasket remove oil pump 26 Remove worm wheel and oil seal press board remove cylinder head and cylinder amp Place a cloth stopper beneath the piston Y Ez and remove the circlip with a plier NE remove the piston pin and piston Remove the kick starter lever Remove side cover 2 28 amp Remove starting driven ratchet wheel by removing the nuts Remove 5 and V belt 6 Disassemble the movable drive face Remove electric gear press board electric gear and super clutch Remove starter motor Remove the clutch housing with the special tool Peg key drain gear oil remove rear axle nut remove rear wheel remove brake shoe and rear 1 6 Remove the rear brake cam lever indicator plate and camshaft remove spring 4 remove cotter 5 and shaft amp remove main stand 2 remove gearcase cover Remove paper gasket and Remove output gear assy remove carburetor remove intake pipe r
8. Fuel level 15 too high or low ELECTRICAL No sparking 1 Defective CDI amp ignition coil unit Replace poor sparking 2 Defective spark plug Replace 3 Defective magneto stator coil Replace 4 Loose connection of lead wire Connect tighten Spark plug soon Mixture too rich Adjust carburetor becomes fouled Idling speed set too high Adjust carburetor with carbon Incorrect gasoline Change Dirty element in air cleaner Clean Spark plug loose Replace by hot type plug Incorrect engine oil Replace Spark plug Spark plug too hot Replace by cold type plug electrodes The engine overheats Tune up overheat or burn Spark plug loose Retighten Mixture too lean Adjust carburetor Not enough engine oil Check oil pump Magneto does not Open or short in lead wires or loose lead Repair or retighten charge connections Shorted grounded or open magneto coil Replace Shorted or open regulator rectifier Replace Magneto charge Lead wires tend to get shorted or open circuited or Repair or retighten but charging rate loosely connected at terminal is below the Grounded or open circuited stator coils of magneto Replace specifications Defective regulator rectifier Defective cell plates in the battery Replace Replace the battery Magneto Internal short circuit the battery Replace the battery overcharges Resistor element in the regulator rectifier damaged or Replace
9. 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 U attery 96 stop switch power starting 1gnition lock rela 11 f m mss je in o qe FL cb Gel F og Leef i Fre n E alarm zb Sud start magneto theftproot starting 7 inn motor ET Starter motor removal and disassembly Remove the starter motor Disassemble the starter motor as shown in the illustration 68 STARTER MOTOR INSPECITION CARBON BRUSHES When the brushes are worn the motor will be unable to i 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 a a Service limit 3 5mm 0 14in 7 r Commutator 1 If commutator surface 15 dirty starting performance will decrease Polish the commutator with 400 or similar fine emery paper when it 1s 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 co
10. cap to prevent entry of dirt O Attach a pipe to the caliper bleeder valve and insert the free end of The pipe into a receptacle O Bleed air from the bleeder valve Squeeze and release the brake level several times 1n 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 17 NOTE when bleeding the braking system replenish the brake fluid reservoir if necessary Make sure that there is always some fluid visible in the reservoir O Close the bleeder vavle 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 51b tt CAUTION Handle brake fluid with care the fluid reacts chemically with paint plastics rubber materials etc WT Rear brake Turn adjusting nut so that the the play of Brake lever is 15 25MM as shown in the illustration Brake shoe wear The vehicle 16 equipped with the brake lining limit Indicator on the rear brake Inspect brake lining limit as follows 1 First check if the brake system 15 proper
11. life Condition of big end bearing 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 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 connecting rod s big end If wear exceeds the limit replace connecting rod crank pin and crank pin bearing Service limit 3 0mm 0 12in Connecting rod small end inside diameter Measure the connecting rod small end diameter with a caliper gauge Service limit 14 040mm 38 Automatic clutch inspection scooter is equipped with an automatic clutch and variable ratio belt drive transmission The engagement of the clutch is governed by engine RMPS and centrifugal mechanism located in the clutch To insure proper performance and long lifespan of the clutch it 1s essentiall that the clutch engages smoothly and gradually Two inspection checks must be performed to thoroughly check the operation of the drivetrain Follow the procedures listed 1 Inspect initial engagement Warm up the scooter to normal operating temperature Remove the right frame side cover Connect an electric tachmeter to the connecting portion of the magneto lead wire black with red tracer seated on the scooter wit
12. octane number 15 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 1000K MS 600 miles mileage play throttle less than 4 5 throttle After mileage exceeds 1000KMS 600 miles play full throttle Don trun engine too long during break in time and try to change throttle position PRECAUTIONS AND GENERAL INSTRUCTIONS Correctly abide by the following items when disassembling and assembling scooter O Don t run engine indoors without ventilation Be sure to replace new bushings circlips O rings and cotter pins with new ones CAUTION It is forbidden to use the circlip removed from shaft only use new one Bevery 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 O Fix bigger diameter bolt first when tightening cylinder head or cylinder and tighten to specified torque gradually from inside to outside at diagonal order o Use special tools for some special requirements O Use original components and recommended engine oil 0 Keep each other s safety when s
13. often riding on bad road Periodic maintenance table Interval all Storage battery sr fr rate exhaust pipe bolt FPL change all 12000 km _ plug Throttle cable play Oil BD I Brake hose Replace every 4 years Replace x 2 years Brake fluid Vehicle body bootandmut T T T T T Note I inspect clean adjust lubricate or replace if necessary A adjust C clean R replace T tighten Maintenance and adjustment procedures The section describes the servicing procedures for each item of the Periodic Maintenance requirements Storage battery Inspect at initially 1000KM 600 miles 2 months and every 6000KM 4000 miles 12 months thereafter D 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 H Measure the voltage between the two ends of battery with voltage gauge charge if the voltage 1s below 11 9V Cylinder head nuts and exhaust pipe bolts Tighten at 500 km and each service If cylinder head nuts are not tightened to the specified torque may result in leakage of compressed fuel air mixture and reduce output tghten the cylinder head nuts in the following procedures l 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
14. or defective vacuum hose Clean or replace SH xa N Carbon deposited on the spark plug Clean Defective CDI amp ignition coil unit Replace Clogged fuel hose Clean Clogged jets in carburetor Clean Clogged exhaust pipe Clean Noisy engine Noise appears to come from piston 1 Piston or cylinder worn down Replace 2 Combustion chamber fouled with carbon Clean 3 Piston pin bearing or piston pin bore worn Replace 4 Piston rings or ring grooves worn Replace Noise seems to come from crankshaft 1 Worn or burnt crankshaft bearings Replace 2 Worn or burnt conrod big end bearings Replace Engine stalls easily D P Eg ae d Noise seems to come from final gear box Replace Replace 1 Gears worn or rubbing Replace 2 Badly worn splines 3 Worn or damaged bearing of drive shaft or rear axle shaft Slipping clutch 1 Worn or damaged clutch shoes Replace 2 Worn clutch drum Replace Excessively worn cylinder or piston rings Replace Stiff piston ring in place Replace Gas leaks from crankshaft oil seal Replace Spark plug gaps too wide Adjust or replace Defective CDI amp ignition coil unit Replace Defective magneto stator coil Replace Float chamber fuel level out of adjustment in carburetor Replace Clogged jets in carburetor Clean or adjust Broken or damaged reed valve Replace Engine idles poorly 1 2 3 4 6 7 9 100 Complaint Symp
15. the mating ends of the circlip do not coincide with the grovve portion of the piston apply oil on the position and cyoinder wall surfaces and install the cylinder over the piston carefully tighten the cylinder head nut to the specification tightening torque 18 28Nm install right crankcase oil seal press board install worm and lubricater it with GENERIC special lubrication Oil pump install oil pump into crankcase torque 3 5Nm 0 3 0 5kg m 2 3 3 7Ib ft 56 Reed valve install a new reed valve paper gasket Install reed valve Install oil hose Intake pipe install intake pipe Magneto clear crankshaft and magneto rotor install half circle key install paper gasket and stator coil and fix them tighten to specified torque with special tool specified torque 35 45Nm 3 5 4 5kg m 25 5 31 0Ib ft 57 install cooling fan install guiding cover install fan guiding cover install pipe screw and screw for tightening muffler to their specified torque CD 8 12Nm 0 8 1 2kg m 6 0 8 5Ib ft 18 28Nm 1 8 2 8kg m 13 0 20 0Ib ft lubricate brake cam shaft with GENERIC grease 58 CHAPTER4 FUEL AND LUBRICATION SYSTEM CONTENTS FUEL SWITCH CARBURETOR OIL PUMP 59 FUELSWITCH When the engine has started a negative pressure vacuum is generated at the intake port The negative
16. 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 overheating Carbon deposited at the exhaust port of the cylinder will prevent the flow of exhaust gases reducing the output Remove carbon deposits periodically SPARK PLUG Neglecting the spark plug maintenance eventually leads to difficult starting and poor performance If the spark plug is used for 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 and cause misfiring Clean the deposits periodically If the center electrode is fairly worn down the plug should be replaced and the plug gap set to the specified gap using a thickness gauge Thickness gauge 0 6 0 7 0 6 0 024 0 02 h Spark plug gap 0 6 0 7 mm 0 024 0 028 inch 0 024 0 028 in Check the spark plug for burnt condition If abnormal replace the spark plug as indicated in the chart TROCH If the standard plug 16 apt to get wet BPR7HS ESRTC
17. wires o Remove the rear brake cable Remove throttle grip case Remove throttle cable 91 O remove disc brake system by unscrewing tightening bolt remove handle by removing tightening bolt O unscrew locknut with special tool O remove fornt fork assy by removing upper outer steel bowl NOTE Not drop the steering stem balls O remove front fork remove bearing lower race by chisel Remove steel balls Number of steel balls Upper 21 lower 21 O remove the upper and lower bearing inner races with a appropriate bar 92 INSPECTION D inspect the removed parts for the following abnormalities bearing race wear and brinelling Worn and damaged steel balls Distortion of steering stem or handlebar O Inspect the for damage 93 Reassembly and remounting reassemble and remount the steering stem handlebar and front fork in the reverse order of disassembly andremoval and also carry out the following steps Install the right left suspension arms Steel ball Apply grease when installing the upper and lower steel balls 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
18. 0 12 Rear wheel 130 70 12 the above data may be modified without Front brake Disco 190 any notification Rear brake Drumo110 ENGINE Type two stroke atr cooled Intake system piston reed valve Cylinder QTY I Bore 40 0mm Stroke 39 6mm Discharge 49 8mL Compression ratio 6 9 1 Carburetor flat inhale stopper style Air cleaner dry Starting system electric and kicking start Lubricating system pressure lubricating ELECTRIC Ignition mode CDI Ignition timing 15 at 1500RPM Spark plug BP8HS Storage battery YTXSL 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 12V 3W CAPACITY FUEL TANK 5 21 ENGINE OIL TANK IL GEAR OIL 0 11 Periodic maintenance and service CONTENTTS Periodic maintenance ana sui VILT DULITUUIT Maintenance and service procedures Storage battery Spark plug Cylinder head nut and exhaust pipe bolt Cylinder head and cylinder Fuel level line Arr 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
19. 0 60 Nm 4 0 6 0kg m 29 0 43 5Ib ft 5 MOVABLE DRIVE movable drive face roller Mimoralbe drive plate LI damper GI O ring liimovable drive face cover E spacer fixed drive fan kicking starter Mitkick starter dirven gear lij xpring racket il etainer H V BELT Apply grease to all the sliding and rolling surfaces for six roller weights For each weight approximately 1 5g of grease should be used GENERIC super grease Mount the three dampers on the movable drive plate and install it on the movable drive face Position the O RING the movable drive face Install the movable drive face coverQ NOTE l Make sure that the movable drive plate is fully positioned inside or the weight roller may come off 32 Insert the spacer Position the movable drive face subassembly on the crankshaft as shown in illustration NOTE Thoroughly clean the belt contact to be free from oil Install the fixed drive fan tighten the nut to the specified torque with special tool Connecting rod fixer Tightening torque 40 60Nm 4 0 6 0kg m 29 0 43 51b ft fill grease in the groove provided inside sliding surface of the kick driven gear and install on the end of the crankshaft Wipe off excess grease QIANJIANG super grease Install washer 3 and spring NOTE When Installing washer face the resin surface of washer to outside install the retainer
20. BLY 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 Id Side cover removal 1 remove seat and helmet barrel by opening seat and loosing tightening screw 2 loose hexad screw and remove decorating cap rear carrier and oil tank lock remove side cover by loosing side cover screw 9 S 3 unlock oil pump cap and remove it two tapping screw exposed remove them remove tapping screw 9 then remove side cover side installation o 4 the sequence of installation 1s the yerse of removal 76 under cover removal 1 unscrew screw and bolt 2 removing under cover by loosing the left and right tapping screws under cover installation 3 The sequence 1f installation 15 ther reverse of removal front cover removal I Unscrew tapping screw and remove front cover 3 by removing front cover screwQ LEGSHIELD AND PEDAL REMOVAL 1 Remove power lock housing Q by unscrewing bolt 3 remove legshield and pedal by gt unscrewing th
21. L 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 7 SWITCH MAIN SWITCH RED RED WHITE DARK GREEN BLACK ON 8 OFF LOCK e BREAK SWITCH RED SWITCH PURPLE ON OFF HORN SWITCH RED WITHE BROWN ON e 72 LIGHT CONTROL SWITCH GREEN RED YELLOW YELLOW PINK YELLOW HEAD LIGHT o o o PASSING LIGHT o o o OFF LIGHT SWITCH YELLOW RED BULE AZURY HIGH BEAM Q DIPPED HEADLIGHT o DIRECTION SWITCH ORANGE GREEN BLACK GREEN WHITE TURN LEFT e TURN RIGHT e e SPECIFICATIONS Type designation YBAL B 2 4Ah Standard electrolyte 1 28 20 INITIAL CHARGING FILLNG ELECTROLYTE Remove the aluminum tape D sealing the battery electrolyte filler holes Remove the caps 2 NOTE After filling the electrolyte completely use the removed 2 as the sealed caps of battery filler holes Do not remove or pierce the sealed areas 3 ofthe electrolyte container Insert the nozzles of the electrolyte container into the battery s electrolyte filler holes holding the container firmly so that it electrolyte doer not fall Take precaut
22. Service and Maintenance 50ccm 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 your country mignt differ 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 CONTENTS TYPEIDENTIFICATION FUELAND ENGINE OIL BREAK IN PROCEDURE PRECAUTIONS AND GENERALINSTRUCTIONS SPECIFICATIONS IDENTIFICATION ENGINE NUMBER ENGINE NUMBER OD is carved on rear crankcase as Shown in figure Both FRAME NUBER AND ENGINE NUMBER are Designed specially for registering your scooter and ordering spare parts FUEL AND ENGINE OIL Be sure to use specified fuel and engine oil Some specifications are as follows FUEL Unleaded the minimum
23. T AND IGNITION COIL INSPECTION CHECKING WITH ELECTRO TESTER Connect the CDI test lead to the coils primary connector t Connect the high tension leads redo lead to the a spark plug cord the blacko lead to the black CDI test lead DL d lead of the test lead amp Set the test selector knob REI Connect the power lead to the appropriate AC source Switch the power on 64 Note the spark in the spark gap window It should be 8 mm 10 32 in 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 resistance checked 15 incorrect replace the coil Exciting coil restance 140 220 65 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 g
24. ace the bearing if there is anything ucusual Play 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 1f 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 83 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 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 84 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 hose mounting bolt seal gasket front gasket rear gasket brake pad 1 brake pad 2 master cylinder rubber b
25. al with special tool warning use a new oil seal remove left crankcase bearing with special tool warning use a new one remove left crankcase shock absorber bushing with special tool warning use a new bushing wrap the oil seal with two appropriate size of sheet irons and clamp it shown as fig bushing crankcase D i crankcase front side rear side 35 Remove right crankcase oil seal with special tool Warning use a new oil seal remove right crankcase bearing sliding bearing warning use a new bearing 36 ENGINE COMPONENTS INSPECTION AND SERVICING BEARINGS Clear bears with solvent and lubricate with engine oil before inspecting Turn the inner ring and check to see that the inner rieng turns smoothly If it does not turn lightly quietly and smoothly or if noise Is heard the bearing is defective and must be replaced with a new one d i dy m E e E Aa a 31 OIL SEAL Damage to the of the oil seal may result in leakage of the fuel air mixture or oil Inspect for damage and be sure to replace the damaged seal 1f found CRANKSHAFT CRANKSHAFT RUNOUT Support crankshaft by V block with the dial gauge rigged to read the runout as shown Service limit 0 05mm 0 002in Excessive crankshaft runout Is often responsible for abnormal engine vibration Such vibration shortens engine
26. arely 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 with the limit Measure the piston ring free end gap to check the spring tension service limit 3 6mm 0 14in Fix the piston ring in the piston ring groove measure the ring side clearance with the thicknes gauge while matching the sliding surface of piston and ring 43 Standard clearance Ist 0 04 0 06mm 0 0016 0 0024in 2nd 0 02 0 04mm 0 0008 0 00161n 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 Imm 44 ENGINE Reassembly Reassembly is generally performed in the reverse order of disassembly but there are a number of reassembling steps that demand or deserve detailed explanation or emphasis These steps will be taken up for respective parts and components Oil seals fit the oil seals to the crankcase following the procedure below Replace removed oil seals with new ones Lubricate the edge of oil seal Install oil seal into crankcase carefully with special tool Oil seal installation Beari
27. assification 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 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 trapped in the fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cylinder and thus interferes with the full braking performance of the brake caliper The presence of air is indicated by sponginess of the brake lever and also by lack of braking force Considering the danger to which such trapped 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 O Fill up the master cyliner reservoir to the upper end of the inspection window Replace the reservoir
28. defective Regulator rectifier unit poorly grounded Clean and tighten ground connection Complaint Symptom and possible causes Unstable l Defective regulator rectifier Repair or replace charging 2 Lead wire insulation frayed due to vibration resulting in intermittent shorting Replace 3 Magneto coil internally shorted Replace 102 Starter button is not effective Complaint Battery runs down quickly Reversed battery polarity Battery discharges rapidly too CHASSIS Complaint Handling feels too heavy Wobbly handle Wobbly front wheel Front suspension too soft Front suspension too stiff Battery run down Defective switch contacts Brushes not seating properly on commutator In starter motor Defective starter relay Defective starter pinion gears Defective front or rear brake light switch circuit Symptom and possible causes l The charging method is not correct Cell plates have lost much of their active material as a result of over charging A short circuit condition exists within the battery due to excessive accumulation of sediments caused by the incorrect electrolyte Battery 1s too old The battery has been connected the wrong way round in the system so that it is being charged in the reverse direction Dirty container top and sides Battery 15 too old Symptom and possible causes Steering stem nut overtightened Broke
29. e machine so that the front wheel 15 off the ground with wheel staight ahead grasp lower shock absorber near the axle and pull forward If play 15 found perform steering bearing adjustment 19 Front shock absorber Adjust at initially 500km and each service Inspect the front shock absorber for oil leakage or other damage and replace the defective parts 1f necessary Rear shock absorber Adjust at initially 500km and each service Inspect front shock absorber for oil leakage and other damage and replace the defective parts if necessary 205 Item 55 60 100 130 Front axle nut Handle tightenging nut Steering sterm locknut Disc brake caliper fixing bolt Disc brake master cylinder hose fixing bolt Disc brake fixing bolt Front shock absorber fixing bolt Engine pivot fixing nut Engine bracket fixing nut Rear wheel fixing nut Rear brake rocker arm fixing bolt Rear shock absorber under fixing bolt Start pedal mounting screw Rear shock absorber top fixing bolt To 8 _ ma LE d 22 5 LII l Apu RS ENE ee ae 20 21 LUBRICATION Proper lubrication is important for smooth operation and long life of each working part of the scooter The major lubrication points are indicated below NOTE 1 Lubricate exposed parts which aare subj
30. e F full position when the resistor 1s changed to 10 ohms If either one or both indications are abnormal replace the fuel meter with a new one ph au ince CABLE ASSY 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 FF 33 assembly with a new one The relation between the position of the fuel guage float and resistance is shown in the following table fp FYI mg FLOAT POSITION RESISTANCE F FULL APPROX 33 GUTES 565 FS 1 2 APPROX 200 E EMPTY APPROX 566 70 SIGNAL SYSTEM The same bulb is used tor both oil level check light and turn signal indicator light The circuitry 15 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 1s 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 ENGINE DIL ALARM INDICATUR DIRECTION LIGHI CLUCK EFT TURN LIGHT 5 Bea G ALARM SYSTEM Fig 7 OI
31. e four bolts Legshield and pedal installation 4 the sequence of legshield and pedal 15 the reverse of reomval 78 HANDLE COVER REMOVAL 1 Remove front handle cover unscrewing the six tapping screws 2 Remove master cylinder by removing the bolt 79 3 Disconnect throttle cable and oil pump cable imeem 4 Remove rear brake cable adjusting nut 80 Handle cover removal 5 remove all cables 6 Remove handle cover by unscrewing bolt 6 Handle cover unstallation 7 The sequence of removal is the reverse of reomval 81 Front wheel 1 front rim 2 middle bushing 3 oil seal 4 roller bearing GB6201 2RS 5 tire 6 valve mouth 7 nut GB6817 8 front shaft 9 front wheel left bushing 10 gearcase 1 1 valve mouth remove Remove the front brake caliper by 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 remove under front fender support the scooter by jack or wood shelf Remove front wheel by removing front axle shaft 82 INSPECTION AND DISASSEMBLY WHEEL BEARING Play Inspect the play of bearing inner ring by hand while mounted in the wheel Rotate the inner ring by hand to inspect if any abnormal noise Occurs or rotating smoothly Repl
32. ect 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 Crear brake camshaft side stand rear brake shaft and rear brake calbe speedometer calbe and gear box main stand Alubrication OA A A GA 22 ENGINE CONTENS Engine components removal with the engine 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 oll 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 24 Engine components removable with 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
33. emove reed valve and paper gasket 30 Remove crankcase fixing shaft disassemble crankcase with special tools first remove right crankcase cover Remove crankcase with special tools Remove crankshaft bearing with special tools SLIDING SHOAFT Warning use a new Sliding shaft 31 Unscrew clutch shoe nut with special tools Remove the nut while holding down clutch shoe assy by both hands as shown in the illustration WARNING Gradually back off the clutch shoe assy pressed down by hands to counter the clutch sparing load Releasing the hand suddenly may cause the following parts to fly apart GO nut clutch shoe sprine CAUTION Do not attempt to disassemble the clutch shoe assy Otherwise the clutch shoe may be damaged Using a screwdriver or the like pry up the movable driven face spring guide e Remove the pins amp movable driven 5 fixed driven 6 32 Remove circlip Remove bearing with special tool CAUTION Replace the removed bearing with a new one Remove inner bearing with special tool CAUTION Replace the removed bearing with a new one Fi 49442 i E Remove the spacer Remove the oil seal from the gearcase cover with the speical tool CAUTION Replace the removed oil seal with new one 34 Remove gearcase cover bearing with special tool Remove left crankcase oil se
34. enerated in the charging coil flows to the regulator recifier which changes AC to DC 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 66 NO LOAD PERFORMANCE Disconnect the magneto lead wire coupler start the engine and keep it running at 5000r min Using a pocket tester measure the AC voltage between the white and red tracer lead wire and ground If the tester reading is as follows magneto is in good condition Standard no load performance more than 65v AC AT 5000R MIN STATOR COILS Inducing coils Standard resistance W R GROUND 0 6 1 1Q 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 Disconnect the lead wire couple Using the pocket tester x IKO 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 such as transistor capacitance regulator diode and so on so tested resistance may be different from actual resistance 67 STARTER SYSTEM DESCRIPTION The starter system 15 shown in the diagram
35. ersize PISTON cylinder and piston clearance cylinder piston clearance is the difference between piston diameter and cylinder bore diameter Be sure to take the maked diameter at right angles to the piston pin The value of elevation is prescribed to be 20mm from the skirt end micrometer service limit 39 885mm 1 5703in As a result of the above measurement if the piston to cylinder clearance exceeds the following limit overhaul the cylinder and use an oversize piston replace both cylinder and piston The measurement for the bore diameter should be taken in the intake to exhaust port direction and at 20mm from the cylinder top surface 42 Unit mm sands Lenin Cylinder 40 005 40 020 40 075 x3439955 39885 Cylinder to piston 0 06 0 07 0 120 Piston pin bore Use a caliper gauge to measure the piston pin bore inside diameter If reading exceeds the following service limit replace it with a new one Dial caliper Limit service 12 30mm 0 47361n Piston pin outside diameter Use a micrometer to measure the piston outside diameter at three positions Micrometer 0 25mm service limit 11 980mm 0 47171n Piston rings Check each ring for end gap reading the gap with a thickness gauge shown in the illustration If the end gap 15 found to exceed the limit indicated below replace it with a new one The end gap of each ring 15 to be measued with the ring fitted squ
36. everal persons do O Inspect looseness and operating state of components after reassembling them 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 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 GENERIC 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 Transmission system OVERALL LENGTH 1830 mm Clutch system dry auto a centric OVERALL LENGTH 695 mm Gearshift mechanism CVT stepless OVERALL HEIGHT 1160 mm Operating mode of gears shift mechanism WHEELBASE 1295 mm Automatic a centric NET WEIGHT 92 kg Step less shift range 0 86 2 64 CHASSIS Front shock absorber spring no damp Rear shock absorber spring oil damp Turning angle 48 Front wheel 120 7
37. h the scooter on level ground increase the engine RPMs slowly and note the RPM at which the scooter begins to move forward Tachometer 2900r min tolerance 300r min 2 Clutch LOCK UP inspection Perform the inspection to determine 1f the clutch is engaging fully and not slipping Warm the engine to normal operating temperatures Connect the electric tachomter to the magneto lead wire Apply the rear brake as firm as possible Briefly open the throttle fully and note the maximum engine RPMs sustained during the test cycle CAUTION Do not apply full power for more than 10 seconds or damage to the clutch or engine may occur LOCK UP R MIN Tolerance 400r min 39 If the engine R MIN doesn t coincide with the specified r min range then disassemble the clutch Clutch shoe inspect the shoes visually for chips cracking uneven wear and burning and check the thickness of the shoes with vernier calipers If the thickness 1s less than the following service limit replace them as a set Clutch springs visually inspect the clutch springs for strectched coils or broken coils Service limit 2 0mm 0 08in CAUTION clutch shoes or springs must be changed as a set and never individually Clutch wheel inspect visually the 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
38. il 15 found to be open circuited or grounded replace the armatrue Starter relay inspection e 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 15 in good condition if the resistance 1s as follows SIANDARD RESTANCE 80 150Q 69 FUEL LEVEL METER GAUGE FUEL METER INSPECTION To test the Fuel Meter two different checks may be used The first and simplest test will tell if the mete is operating but will not indicate the meters accuracy throughout the range To perform the test lift the seat and remove the right frame cover then disconnect the B W and Y B lead connector of the fuel gauge sending unit Connect a jumper wire between B M and Y B wiers coming from the main wiring harness With the ignition switch ned 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 1s normal If its pointer indicates the E empty position when the specified voltage 1s applied to the circuit and if its pointer indicates th
39. il leakage of rear shock absorber Loose nuts on shock absorber lubrication leakage Refill Retighten Replace Replace Replace Replace Retighten Replace Add lubrication Adjust Add lubrication Insufficient brake power Brake squeaking Excessive brake lever stroke Leakage of brake fluid voe Ed M D Se nuo T SB S Leakage of brake fluid from hydraulic system Worn pad Oil adhesion on engaging surface of pad Worn disc Air entered into hydraulic system Worn shoe Friction surfaces of shoes are dirty with oil 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 fluid Clogged return port of master cylinder Brake shoe surface glazed Loose front wheel axle or rear wheel axle nut Worn shoe Air entered into hydraulic system Insufficient brake fluid Improper quality of brake fluid Worn brake cam lever Excessively worn shoes and or drum Insufficient tightening of connection joints Cracked hose Worn piston seal Repair or replace Replace Clean disc and pads Replace Bleed air Replace Replace Replace Adjust Repair surface with sandpaper Modify and fitting Replace Replace Replace brake fluid Disassemble and clean master cylinder Repair surface with sandpaper Tighten to specified torque Replace Adju
40. ion not to allow any of the fluid to ntarners spill 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 73 RECHARGING OPERATION Apply multimeter to measure the voltage of battery If the reading 1s 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 4 0A for 1 hour NOTE The current should be not more than AA at any time d insert mu tightly After recharging wait for more than 30 minutes and apply multimeter to measure the battery voltage If the battery voltage 1s less than12 5V please rechare the battery again If battery voltage 15 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 74 6 CHASSIS CONTENTS LEG SHIELD AND FRAME SIDE COVERS LEG SHIELD REMOVAL LEG SHIELD REMOUNTING FARME SIDE COVER REMOVAL FARME SIDE COVER REMOUNTING HANDLEBAR COVERS REMOVAL REMORNTING FRONT WHEEL REMORAL INSPECTION AND DISASSEM
41. l lever which is controlled by amount of throttle opening Check the oil pump in the following manner to confirm correct operation for throttle valve full opening position O Turn the throttle grip full open O 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 Ifthe marks are not aligned loosen lock nuts and turn the adjuster in or out to anu the marks O After align the marks tighten the locknuts Caution Oil pump calbe adjustment must be done after throttle cable adjustment 15 GEAR OIL Change as shown in the service schedule Inspect gear oil periodically as follows O Remove the cover and hose Remove the kicking starter lever Remove clutch cover Remove oil level bolt and inspect oil level 1f oil level 1s below oil hole add oil until oil flows from the level hole O Tighten oil level bolt to the specified torque Tightening toque 9 15N m 0 9 1 5 kg m 6 5 11 0 lb 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 O Check brake fluid level by observing the lower limit line on the brake fluid reservoir O When the level is below the lower limit line replenish with Brake fluid that meets the following specification Specification and cl
42. ly Adjusted 2 when operating the brake check to see that the tip of indicator is within the range 3 ifthe tip of indicator is beyond the range the brake shoe assembly should be raplaced with anew set of shoe Tire Inspect at initially 1000KM 600 miles 2 months and every 6000KM 4000 miles 12 months thereafter Tire pressure If the pressure is too high the scooter will tend to rede stiffly and have poor traction Conversely if tire pressure is too low stability will be adversely affected Thereafter maintain the correct tire pressure for good roadability and to prolong tire life CAUTION The standard air pressure of tires 1s 175 196K pa the use of other than standard may cause handling instability It is highly recommended to use a GENERIC genuine tire Tire tread condition Operating the 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 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 th
43. mp or clogged oil circuit Replace and clean Fuel level too low in float chamber Adjust or replace leakage from intake pipe Retighten or replace Use of incorrect engine oil Change Use lf improper spark plug Change Clogged exhaust pipe muffler Clean or replace CARBURETOR Trouble with 1 Starter jet is clogged Clean starting 2 Air leaking from a joint between starter body and carburetor Check starter body and carburetor for tightness and replace gasket Air leaking from carburetor s joint or vacuum hose joint Check and replace Starter plunger is not operating properly Check and replace Idling Pilot jet pilot air Jet are clogged or loose Check and clean low speed Air leaking from carburetor s joint vacuum pipe joint or starter Check and replace troubles Pilot outlet is clogged Starter plunger is not fully close Check and clean Check and replace 101 Medium Main jet or main air jet is clogged Check and clean high speed Needle jet is clogged Check and clean trouble Fuel level is improperly set Check and replace Throttle valve is not operating Check throttle valve for operation properly Check and clean Fuel filter is clogged Overflow and Needle valve is worn or damaged Replace fuel level Spring in needle valve is broken Replace fluctuations Float 15 not working properly Check and adjust Foreign matter has adhered to needle Clean valve Adjust and replace
44. n bearing race in steering stem Distorted steering stem Not enough pressure in tires Loss of balance between right and left front suspension 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 Recharge and replace Replace Repair or replace Replace Replace Repair or replace Check the and circuit connections and make necessary adjustments to obtain magneto regulator rectifier specified charging operation Replace the battery and correct the charging system Replace the battery Replace the battery Replace the battery and be sure to connect the battery properly Clean Replace Adjust Replace Replace Adjust Replace Replace Replace Replace Replace Retighten Retighten Replace Tighten Replace Replace Refill Replace 103 Noisy front suspension Wobbly wheel Rear suspension too soft Noisy suspension BRAKES Not enough grease Loose nuts on suspension Distorted wheel rim Defective or incorrect tire Loose nuts on the rear shock absorber Worn engine mounting bushing Loose nuts or bolts for engine mounting Weakened spring O
45. ng Install new bearing with special tool Install bearing First heat up the cover and cool down the bearing The install would be much easier and better for the bearing 45 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 46 CRANKCASE Wipe the crankcase mating surfaces with clraning solvent Apply GENERIC NO 1215 evenly to the mating surface of the right half of the crankcase Tighten the crankcase screws securely Check if crankshaft rotates smoothly Install gearcase bearing Install new bearing and oil seal into gearcase cover with special tool and tighten anchor pin 47 install output axle cearshift install middle gear position pin by installing middle gear axleCD gasket and thrust gasket install gearcase cover into crankcase and lock bolt tighten each screw screw oil drain nuto 11 tightening torque 4 7 N m 0 4 0 7kg m 3 0 5 0 Ib ft 48 Movable driven and clutch fixed drive face Zybushing IMO ring 14 needle roller bearing be ODisrping retainer hearing jspring akeirclip shoe SMmovable driven face Meluteh shoe nut 7011 seal d V belt Boil seal d peluteh drum Spin clutch drum nut install the 2 in the fixed driven Dee wi
46. pressure acts upon the diaphragm of the fuel switch and it pressed down the spring which supports the diaphragm so that the fuel passageway 1s opened and fuel 1s fed to the carburetor When the engine has stopped the spring presses the valve the fuel passageway 15 closed and no fuel flows to the engine Fuel switch 60 CARBURETOR CARBURETOR Carburetor manufacturer type Mixture ratio adjusting FRI 2 screw s idle adjusting screw AD L3 4 main float tube needle jet malin jet equal vacuum Identification code Throat tube diameter Main jet size Idle needle jet size Oil needle clamp position 3 groove Idle air adjusting screw STI j 2 1 sopa Float height 13 lmm 61 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 15 necessary refer to the following fuel air mixture ratio can be changed 25 follows throttle opening means of changin ratio standard setting pilot jet la
47. replace with the plug BPRSHS Standard If the standard plug 16 apt to BPR9HS E6RTC overheat replace with the plug 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 gasoline 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 AIR CLEANER Clean every 3000KM 2000 miles If the air cleaner Is clogged with dust intake resistance will be increased with a resultant decrease In power output and an increase in fuel consumption Check and clean the element in the following manner O Remove clamp 1 and screw 2 take down air cleaner Unscrew tapping screw 3 remove air cleaner cap 4 O Fill a washing pan of a proper size with Non flammable cleaning solvent 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 and squeeze the oil out of the core which may be slightly wet with oil O Install air cleaner filter core in the reverse order of removal CAUTION
48. rger number richer mixture zmaller number slight leaner mixture jet needle 151 leaner ES richer Sth ard groove medium 380 larger number richer mixture smaller mmber height lean mixture 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 bleeding operation with the oil pump in place before returning the machine to the user To bleed air hold the machine in standstill condition 62 CHAPTER 5 ELECTRICAL SYSTEM CONTENS IGNITION SYSTEM CHARGING AND LIGHTING SYSTEM SIARTER SYSTEM FUEL GAUGE OIL LEVEL CHECK LIGHT AND TURN SIGNAL INDICATOR SWITCHS BARTERY 63 IGNITION SYSTEM CDI amp lIgnition coil unit MAGNETO Spark plug The ignition system consists of a flywheel magneto a CDI amp Ignition coil unit and a spark plug DAs the rotor tatates an AC current is induced in the coil Then current induced in the A direction charges up the capacitor 2 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 UNI
49. st Refill Replace Replace Replace Replace or repair Replace Replace 104 in preys uroy 234211 saras re TH muayux auaq j31w35 aur ozriuc3 aypaq zez age a od isum HJJTET Ewe ER 0 H sasun rly 2 1 JET 8 1 awari WING 18 mem d 1 Dp A rJ uu ES g DO 4 wg e e ka JYBTT unrjsod pm HHH sik ss en a ke ZC ll UH Es e E H 1057 SRT IES ET LAdA 85 3 88 TE RE EE sn SEH A at AA Pigs Ha 2185 umy tt rar e d a a rt LL TER EN NE BCE HI SL e EUR AID lam vi d za Ie ESI bs 3p E A 2744019 ag Ki gala OM ra J d 4 m Kal q Ch T d T En qgiwdz Se Ej A G34 Tes LAKE Tal Lia indi i e iim m H 1 9 ucrirusI imTar 723450000 T3 RE serq Bu D LIO E 233285 Quat E Lm SUSE xukurni maq gx ro WIRE CABLE AND BRAKE HOSE ROUTING carburetor cable odometer d
50. t 12V 21W 5W Front turn light 12 10W Rear turn light 12 10W Turning signal 12V 3W indicator light High beam indicator 12V 1 7 W light Meter indicator light 12V 17W Alarm indicator light Light diode Brake and rim Brake lever play 15 20mm 9110 mm Tire surface thickness 120 130 SUSPENSION Front shock absorber stroke Rear shock absorber stroke Tire air pressure Front 175 Rear air 196kpa pressure pressure Fuel engine oil Fuel typre Gasoline applied should be graded 90 or high ocatane number unleaded gasoline is recommended Gera oil tank 0 11 capacity Brake fluid type DOT3 or DOT4 115
51. t 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 90 STEERING STEM AND FRONT SUSPENSION handle jointing assy bolt GB5789 10 1 25 45 nut GB6187 M10X1 25 left handlebar throttle grip assy screw GB818 M5XIO rear brake cable assy throttle cable assy left switch comp 10 right switch comp I l anti dust cover 12 steel ball 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 remove front wheel refer to preceding page o disconnect the front and rear brake light switch lead
52. th the special tool install sliding bearing 49 nstallthe bearing with special tool install the spacer and circlip install the new oil seals and to the movable driven face with the special tool apply grease to the lip of oil seals and groove of inside of movable driven face GENERIC special super grease NOTE When reinstalling the movable face to the fixed face make sure that the oil seal is positoned properly install the pin at three places on the driven face hub Apply grease lightly to the cam part where the pins are placed Install two O RINGs 50 Install the movable driven face seat D install the clutch shoe assembly and nut tighten the nut 3 to the specified torque with the special tool tightening torque 40 60 Nm 4 0 6 0kg m 29 0 43 5Ib ft insert the V belt between the driven faces as deep inside possible while pulling the movable driven face all the way outside to provide the maximum ble clearance 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 Thoroughly clean the clutch housing to be free from oil and position it over the clutch shoe assembly tighten the clutch housing nut to the specified torque with the special tool Torque 4
53. thickness gauge taking a clearance reading at several places service limit 0 05mm 0 002in 41 If the largest reading at any portion of the staightedge excees the limit rework the surface by rubbing it against emery paper laid flat on the surface plate a lapping manner The surface must ge smooth and perfectly falt in order to secure a tight join a leaky joint can be the cause of reduced power output and increased fuel consumption CYLINDER Decarbon exhaust port and upper part of the cylinder taking care not to damage the cylinder wall surface The wear of the cylinder wall 1s determined from diameter reading taken at 20mm from the top of the cylinder with a cylinder gauge If the wear thus determined exceeds the limit indicated below rework the bore to the next oversize by using a boring machine or replace the cylinder with a new one Oversize pistions are available In two sizes 0 5mm and 1 0mm cylinder gauge service limit 40 075mm 1 5778in after reworking the 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 NOTE 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 reworked with a boring machine to the next ov
54. to check for an out of round condition as well as wear Service limit 110 50mm 4 350in DRIVE BELI Remove the drive belt and check for cracks wear and separation Measure the drive belt width with a vernier calipers Replace it if the belt width is less than the service limit or and defect has been found Service limit 16 0mm 0 630in CAUTION Always keep the drive belt away from any geasy matter Drive face Inspect the belt contact surface of the dirve faces for wear scratches or any abnormality If there is something unusual replace the drive face with a new one 40 Roller and sliding surface Inspect each roller and sliding surface for wear or damage Driving face spring Measure the free distance of the driven face spring If the length 15 shoter than the service limit replace the spring with a new one service limit 104 5mm 4 11in Driven face pin and oil seal Turn the driven face and check to see that the driven faces 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 head as shown in the illustration for distortion with a straightedge and
55. tom and possible causes Engine 1 Excessively worn cylinder or piston rings Replace poorly 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 Defective magneto stator coil Adjust or replace Float chamber fuel level too low Clean 5 6 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 smoke 2 Use of incorrect engine oil Change Engine lacks 1 Excessively worn cylinder or piston rings Replace power 2 Stiff piston rings in place Replace 3 Gasleaks 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 10 Slipping or worn V belt Replace 11 Damaged worn rollers in the movable drive face Replace 12 Weakened movable driven face spring Replace 13 Too rich fuel air mixture due to defective starter system Replace Engine Heavy carbon deposit on piston crown Clean overheats Defective oil pu
56. ushing 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 85 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 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 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 piston seal 86 CALIPER AND DISC INSPECTION Inspect the calipe cylinder bore wall or micks scratches or other damage Inspect piston for damage and wear Inspect each rubber part for damage and wear Check the disc for wear with a micrometer Its thickness can be checked with disc and wheel in place Ralpace the dise if the thickness exceeds the service limit 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
57. usion 2 of indicator plate to the groove 3 of Camshaft When installing the brake cam shaft aligh the groove 4 of camshaft with the slit of on cam shaft O 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 98 SERVICING INFORAMTION CONTENTS Troubleshootine Battery Vehicle Wiring diagram Wire cable and brake hose routing Special tools Thread parts tightening torque Service data 99 TROUBLESHOOTING ENGINE Symptom and possible causes Engine does not start Compression too low or is hard to start Excessively worn cylinder or piston rings Stiff piston ring in place Gas leaks from the joint in crankcase cylinder or cylinder head Damaged reed valve Spark plug too loose 6 Broken cracked or otherwise failed piston Replace Repair or replace Repair or replace Replace Tighten Replace Plug not sparking 1 Damaged spark plug or spark plug cap Replace 2 Dirty or wet spark plug Clean and dry Defective CDI amp ignition coil unit or stator coil Replace Open or short n high tension cord Replace Defective ignition switch Replace fuel reaching the carburetor Clogged hole in the fuel tank cap Clean Clogged or defective fuel cock Clean or replace Defective carburetor float valve Replace Clogged fuel hose
Download Pdf Manuals
Related Search