TABLE OF CONTENTS - Mortch International Limited
Contents
1. Disconnect the negati pole first Measure the voltage between the two poles yy BATTERY OPEN CIRCUI VOL AG Disconnect the cable on the battery terr BATTERY CHARGING e Lift the battery out of the vehicle Connect the positive pole of the charger with the positive pole of the battery e Connect the negative pole of the charger with the negative pole of the battery e Charge the battery for the charging time marked on the battery Measure the voltage 30 minutes after charging is finished It should reach the specified value or recharging is needed Charging Current Charging Time Charging Result PRIMARY COIL The picture shows the structure of a common generator 1 Cooling Fan 2 Generator assembly 6 Bolt 3 Flywheel comp 7 Nut 4 Stator comp 8 Bolt o Washer 9 Bolt 52 PRIMARY COIL INSPECTION When the inspection work is done on the engine there is no need to remove the generator Remove the 4 core connector of the generator Measure the resistance value between the white wires of the generator and connecting wire of When the actual value is more the S alue the coil should be replaced 0 2 0 4 20 C J GENERATOR REMOVAL e Remove the cooling fan cover bolt and screw e Remove the cooling fan cover 4 dr e Remove the cooling fan bolt and remove the cooling fan e While holding the flywheel with a universal holding wrench gt AN remo2. Bp m mark X 4 Install the crankcase dowel pin and gasket Install the driven belt and the driving plate e Install the left crankcase cover and lock tightly Install the starting pedal 29 ELECTRICAL STARTING SYSTEM STARTER MOTOR The starter motor is actually a direct current DC motor and its structure is shown in the picture Outer Cover Motor Rotor Motor Base Carbon Brush Plate Positive Electrode Carbon Brush Positive Electrode DIIS S CS STARTER MOTOR REMOVAL Before removal first shut off the main switch and disconnect the battery connecting wire Then press the starting button at this time the starter motor should not run Do this to insure safety 2 av a Remove the starter motor lead wire clamp T ir e Remove the starter motor holding bolt and remove the starter motor E Carbon brush seat e Roll up the rubber wate resistance cover and remove the starter motor joint Remove the motor case bolt the carbon brush seat and the motor case etc Motor Motor case boit 30 ARMATURE INSPECTION Inspect the armature surface for uneven wear damage or burns changing color Armature e When there are metal fines attached to the gap of the armature surface use a cleaning cloth to remove them Ing condition of the armature coil according 2 4 iate right It should
3. changes big from big to small because the perimeter of the driven belt is con stant At this time the speed increases Conversely the speed decreases when the diameter of the driving belt pulley changes from big to small and the diameter of the driven belt pulley changes proportionally from small to big Ratio of tran smission small 36 The structure of the driving belt pulley is shown in the picture of DRIVE BELT PULLEY DRIVE BELT PULLEY REMOVAL Remove the left crankcase air pipe lock bolt e Remove the kick starter and remove the left crankcase fixing bolt ive plate with a universal wrench remove the on the drive plate shaft Remove the drive plate Remove the move e Remove the ramp plate e Remove the centrifugal rollers DRIVE BELT PULLEY INSPECTION Inspect for abrasion or damage to the centrifugal roller Measure the outer diameter of the centrifugal roller Service Limit 17 00mm 38 Measure the inner diameter of the movable drive plate Service Limit 24 06mm is any abrasion or damage of the drive plate hub diameter of the drive plate hub s movable Roller Install the ramp plate Ramp plate Put the drive plate hub into the drive plate ut lt N p I Movable drive plate hn GE Ee Install the movable drive plate on the crankshaft 39 Mount the other end of the driven belt o
4. f the contact position is too low then cut out some of the part of the valve seat with a 60 milling cutter to raise the face of the valve seat e Finally mill the working face of the valve seat to the speci NND width with a 45 milling cutter e f the valve seat still cannot contact evenly with the valve after trimming the valve should be revised or replaced 16 VALVE AND VALVE SEAT LAPPING After finishing the valve and seat should be lapped in order to make them seal properly Spread a thin layer of silicon carbide on the working bevel of the valve Using valve suction cup tool repeatedly After lapping th 5 spected Method Two evenly draw s Place the valve into the valve s impermeability is satisfactory is no leakage the valve is seated correctly LUBRICATION SYSTEM INSPECTION AND SERVICING GENERAL INTRODUCTION The picture shows the functional diagram of the lubrication system After the lubrication oil crosses the filter screen it is pumped by the rotator oil pump Some ofthe oil goes into the big end of the connecting rod and splashes on the cylinder wall and the small end of the connecting rod the rest rough some oil passages such as the shaft neck of the camshaft and splashes on the 18 OIL SYSTEM INSPECTION AND REPLACEMENT OIL REPLACEMENT Tighten the dipstick i Oil Level Disasse ling Replacing Noo AM ROTARY OIL PUMP The oil pump is the critical compon
5. of the reduction gear shaft It should be replaced when the diameter is more than 10 05mm Measure the outer diameter of the reduction gear shaft It should be replaced when the diameter is less than 9 94mm Reduction gear 33 ENGAGING MECHANISM Remove the st w STARTING CLUT NSPE Inspect the movement b The driving gear should sm should not move countercle Inspect the contact surface between the needle bearing for abrasion or other damage replaced if the surface is damaged Driving gear placed when the diameter is more than 32 06mm Inspect the condition of the needle bearing It should be there is any damage Inspect the contact surface between the outer clutch com and the roller for abrasion or other damage Inspect the roller for injury Inspect the spring for distortion e f the damage is serious it should be replaced Measure the inner diameter of the flange clutch It should be replaced when the diameter is more than 27 94mm 3 m 34 STARTING CLUTCH INSTALLATION e Install the spring the roller and the top on the body of the clutch Align the dowel pin on the flange clutch with the hole on the clutch then install lutch component on Vi of tre woodruf key on the crank and install Install the left crankcase cove CONTROL STARTER RELAY INSPECTION e Check the conductivity of the start button At
6. this time remove the starting rela green yellow line Connect the yellow red line with the ground wire and press the start button It should be conductive between the yellow red line and the ground wire If it is not conductive then the start button its wire or the wire connector is damaged 35 e Check the working condition of the starting relay At this time remove the starting relay Connect the C end and the D end of the starting relay with the battery and the A and B ends with the multimeter The battery voltage should be at 12 volts At this time the multimeter should indicate a conductive condition or the starting relay is not good BELT DRIVEN CVT MECHANISM INSPECTION AND SERVICING GENERAL INTRODUCTION The belt driven CVT mechanism is made up of two belt pulleys the drive belt pulley and the driven belt pulley whose diameter can be changed and a notched driven belt The driving belt pulley is mounted on the ngine crankshaft and the driven belt pulley connects with the rear driven mecha nism pes Priven plate Clutch weight Movabie drive plate Drive plate Its basic operational principle is to realize automatic CVT by the di Drive pulley Driven pulley ameter changes the transmission ratio changes of the driving and driven belt pulley ED When the diameter of the driving belt pulley changes from small to f Ratio of tran smission big proportionally the diameter of the driven belt pulley
7. 05 50 100 9 E GorG Wy 0 5 50 0 5 50 IGN BY B Black W White R Red G Green Y Yellow PC G R 10 1000 10 100 The CDI component can also be inspected and measured with the CDI testing instrument Please carefully read the instrument specification to know how to properly te Connect CDI component with the special wire of the testing instrument Observe the spark condition on the instrument when the switch is turned on different positions OFF P EXT ON1 ON2 58 IGNITION COIL IGNITION COIL REMOVAL e Remove the spark plug cap Remove the primary ignition coil wire e Remove the ignition coil positioning bolt and remove the ignition coil IGNITION COIL INSTALLATION Reverse the removal procedure for installation F in al J connect the black yellow wire of the primary ignition coil with the olack yellow connector of CDI and the green wire with the green connector of the ODI PRIMARY IGNITION COIL INSPECTION Standard Value 0 1 1 0KQ 20 C If the resistance value is it indicates the coil is bad and should be replaced SECONDARY IGNITION COIL INSPECTION Install the spark plug cap and measure the resistance value of the secondary ignition coil Standard Value 7 9KO 20 C If the resistance value is in the standard range it is good however indicates the coil is bad Remove the spark plug cap and measure the res
8. 18 54 28 21 20 21 19 19 19 PISTON SET 4 PISTON SET INSTALLATION 5 PRIMARY COIL PRIMARY COIL INSPECTION ANG N ROCKER ARM AND SPARK PLUG SPIRAL SPINE TRANSFERRING 87 STARING CLUTCH INSTALLATION STARTER MOTOR STARTER MOTOR INSTALLATION STARTER MOTOR REMOVAL STARTER REPLAY INSPECTION STARTING CLUTCH INSPECTION STARTING CLUTCH REMOVAL STARTING MECHANISM INSPECTION AND SERVIVING 64 TIGHTENING TORQUE CHART TRANSFERRING STYLE STARTING MECHANISM INSTALLATION TRANSMISSION BELT TRANSMISSION BELT INSPECTION TRANSMISSION CASE AT CASE GEAR INSPECTION TRANSMIS ASE OIL INSPECTION CASE OIL REPLACEMENT OIL REPLACEMENT EMOVAL CASE VACUUM SHAME EMC VALVE AND VALVE SI ABILITY INSPECTION VALVE AND VALVE SEA VALVE AND VALVE lt gt VALVE AND VALVE SPRING VALVE AND VALVE SPRI VALVE CLEARANCE VALVE CLEARANCE ADJUSTMEI VALVE GUIDE VALVE GUIDE INNER DIAMETER MEASUR VALVE GUIDE REPLACEMENT VALVE MECHANISM INSPECTION AND SER VALVE SEAT VALVE SEAT FINISHING VALVE SEAT TOUCHING POSITION INSPECTION VALVE SEAT WIDTH MEASUREMENT 65 28 44 44 26 26 45 45 55 57 2f 58 24 23 17 17 13 13 13 14 14 14
9. CTION AND SERVICING ENGINE COMPONENTS CYLINDER CYLINDER REMOVAL Then removal can be done on the vehicle body e Remove Cylinder head Remove cylinder Remove cylinder gasket bolts e Clean cylinder gasket and remove any debris CYLINDER INNER WALL WEAR INSPECTION Use bore diameter dial gauge to measure the oe 7 wear The measure point is divided into nr tional plandel in axial direction upper middle lower measure every plane each time on the mutually perpendicular directions X Y the mea sured least dimension is the cylinder bore at the most upper position measured is the largest diameter and the lowest position measured is the smallest diameter their difference is the cylin dricity of the cylinder At the same cross secti n measure the difference of diameter between two points mutually perpendicular which is the circularity of the cylinder number as the result In the situation without a dial gauge a feeler gauge can be used to mak relativity measufemient put a new piston into the cylinder and use the feeler gauge to measure the gap between the piston skirt and the cylinder wall T hen figure out the abrasion loss of the cylinder If the circu larity of the cylinder exceeds the limit then a cylinder reboring machine should used to rebore the cylinder and enlarge its diameter by 0 5mm or 1 00mm then fit the piston and piston ring which size are also enlarged If the we
10. T CHAMBER FLOAT CHAMBER REMOVAL Remove the carburetor Remove the clamp and remove the float chamber e Remove the O ring turn out the float chamber screw remove the float pin and remove the float and float valve e Remove the choke adjusting screw air adjusting screw 24 Before removing first tighten the two screws gently counting the number of turns Remove screws Do not use excessive force to avoid damaging the air adjusting screw head surface e Remove the main fuel injection nozzle and fuel injection needle seat FLOAT CHAMBER INSTALLATION Inspect the float for any damage and for fuel in the float Inspect the float valve and float valve seat for wear If there is wear it should be replaced Clear every fuel line and air line on the carburetor body with compressed air FLOAT CHAMBER INSTALLATION Install the main fuel injection nozzle and fuel injection needle seat Install the air adjusting screw and choke adjusting screw and turn them to the proper position ac cording to the noted number of turns while removing Mount the float valve the float and the float pin Tighten the float pin positioning screw FUEL LEVEL INSPECTION Measure the fuel level height Inspect the float for any damage and inspect the float valve for excess wear Fuel level height e Confirm that the up and down movement of the float is normal CARBURETOR INSTALLATION Inspect the float for
11. TABLE OF CONTENTS CHASSIS NUTS AND BOLTS ENGINE IGNITION SYSTE 18 22 27 30 36 40 45 50 56 CHASSIS NUTS AND BOLTS Note Inspect the first week and then every month thereafter Always pay attention to the unit s nuts and bolts Some loosening after use is normal Check to ensure that all nuts and bolts are tight Torque Tightening Chart Bolt Conventional Marked Bolt 8 8 Marked Bolt Ib ft D o 129 VS 0 50 50 N m 15 35 9 540 8 12 Kg m 0 15 0 3 03 06 0 8 1 2 Ib ft 1 0 2 0 2 0 4 5 6 0 8 5 18 20 16 0 25 5 40 60 25 5 40 70 100 110 160 250 200 280 1 8 2 8 4 0 6 0 es TOR 11 0 16 0 GeO eZ 97 20 28 0 200 29 0 43 5 ILS 25 2 5 115 5 123 0 181 0 144 5 202 5 94 137 5 FUEL SWITCH PETCOCK Periodically clean the petcock externally with grease remover and water Check for any leaks or seeping fuel Replace the petcock if there are any leaks found This vehicle has a manually operated fuel valve There are three positions ENE RES OF position The normal operating position for the fuel valve lever is the ON position In this position fuel will flow to the carburetor RES position If the fuel level in the fuel tank becomes too low for the engine to operate with the fuel valve lever in the ON position turn the lever to the RES position to use the reserve fuel supply and refu
12. TION CHARGING SYSTEM INSPECTION AND SERVICING CHASSIS CHASSIS NUTS AND BOLTS CLUTCH 61 CLUTCH DISASSEMBLING 40 CLUTCH INSPECTION 40 CLUTCH INSTALLATION 41 CLUTCH REMOVAL 40 CONNECTING ROD END INSPECTION 4 CONTROLING MECHANISM 36 4 5 6 7 T 22 3 TION J REMOVA DRIVE BELT PUL DRIVE BELT PULL NG ST DRIVE BELT PULLEY DRIVEN BELT PULLEY DRIVEN BELT PULLEY REMOVAL DRIVEN PLATE BEARING REPLACEME ELECTRIC LEAKGAE TESTING ELECTRIC SYSTEM ELECTRICAL STARTING MECHANISM ENGAGING MECHANISM ENGINE ENGINE COMPONENTS ENGINE COMPONENTS AND CRANK CONNECTING ROD ENGINE COMPONENTS INSPECTION AND SERVICING ENGINE OIL FINAL GEAR OIL FLOAT CHAMBER FLOAT CHAMBER INSPECTION FLOAT CHAMBER INSTALLATION FLOAT CHAMBER REMOVAL FOAM FILTER MAINTENANCE DRIVEN BELT PULLEY INSTALLAT aA IT 62 FUEL LEVEL INSPECTION FUEL SUPPLY SYSTEM INSPECTION AND SERVICING FUEL SWITCH PETCOCK GENERAL INTRODUCTION IGNITION CO IGNIT ON CO IGNITIO wW IGNITION SYSTE IGNITION TIME I MAIN WIRING SUB EL MECHANISM INSPECTION MECHANISM INSPECTION AN SERVIC OIL PUMP ASSEMBLING OIL PUMP INSPECTION OIL PUMP INSTALLATION OIL PUMP REMOVAL OIL REPLACEMENT OIL SYSTEM INSPECTION AND REPLACEMENT OIL SYSTEM INSPECTION AND SERVICEING PISTON PIN INSPECTION AND SERVICING PISTON RINGS INSPECTION AND SERVICING PISTON RINGS SET UP 63 25 22 18 36 o4 5 5 59 59 59 56 56 56 2f
13. am valve y again x gi n v Take out the feeler gauge tighten the lock nuts and then oometimes when tightening the lock nuts the cleara so it must be rechecked for the proper clearance Valve Clearance 0 08 0 12mm CAMSHAFT The camshaft is the main driving unit of the valve train The air inlet cam the exhaust cam and the cam journal are on the shaft It causes the intake and exhaust valve to open and close at the correct time Wear to the camshaft will affect engine performance and cause excessive noise CAMSHAFT REMOVAL am chain tensional bolt cap and remove the O ring ain tensioner by adjusting bolt clockwise Remove the cam chain wheel from the cam remove tk camshaft e ils CAMSHAFT INSPECTION Inspect the camshaft bearings for play If there is too much play reple Inspect cam surface for damage Measure the height of the cam Inlet Cam 25 96mm Exhaust Cam 25 815mm 10 CAMSHAFT INSTALLATION Rotate the flywheel to align the T mark on the flywheel with the camshaft mark The round hole on the cam chain wheel should be up and the left and right sit parallel with the cylinder head the lobes of the camshaft are down Then install the camshaft on the cylinder head e Mount the cam chain on the chain wheel 7 ar cover bolt The O ring must roc 2 yinfh grove Replace t
14. any damage and inspect the float valve for excess wear e Confirm that the up and down movement of the float is normal CARBURETOR INSTALLATION Reverse the removal procedure for installation e After installing confirm that all carburetor linkage and cables are in correct position Verify that carburetor is in idle position 25 AIR CUT VALVE ACV The air cut valve can avoid some abnormalities when the throttle closes too quickly The structure of the air cut valve is shown in the picture Air check valve s NN Yo Aacuum membrane l Air check valve Ar spring 5 A te Vacuum Membrane Vacuum membrane cover AIR CUT VALVE INSTA Mount the vacuum membr e Mount the spring the vacuum me bolt The bottom side of the vacuum membra OU be aligned with the carburetor The top side sh be aligned with the vacuum membrane w w i E Vacuum membrane cover AIR CHECK VALVE SN The air check valve starts working under 31mph 50 km h anc d open t reduce CO displacement AIR CHECK VALVE INSTALLATION Reverse the procedure for removal When installing make sure all the connecting pipes are connected prop and that they are not squeezed bent or clogged up 26 TRANSMISSION COMPONENTS STARTING MECHANISM INSPECTION AND SERVICING The starting mechanism can be divided into two types kick starting and electric
15. ar is too severe and cannot be reworked then a new oylin der should be installed Cylinder bore 57 4mm Cylindricity 0 05mm Circularity 0 05mm CRANK CONNECTING ROD MECHANISM PISTON SET PISTON PIN INSPECTION AND SERVICING Insert the piston pin horizontally into the piston pin hole and inspect the clearance between pis ton and piston pin Service Limit If the free play is too much the worn condition of piston pin and piston pin hole must be inspected respectively e Measure the external diameter of piston pin Service Limit 14 98mm If the result is less than the Service limit it should be replaced After replacement check the clearance between piston pin and piston pin hole and make sure it complies with the required measurement Measure the inner diameter of piston pin Service Limit 15 02mm If the result is more than the service limit it should replaced After replacement check the clearance between the holes of the piston pin and make sure it com plies with the required measurement PISTON RINGS INSPECTION AND SERVICING Inspect the piston ring for flaws serious wear or serious conglutination etc If there is it should be replaced e f the piston ring s lateral clearance and notch clearance are too large or too small it will cause malfunctions so it must be measured Measure the clearance of the piston ring in the piston ring groove This cleararice is the piston ring 5 lateral c
16. be conductive service limit Measure the insulating condition of the carbon brush bracket It should be non conductive if not it should be replaced _ Bearing Inspect the needle bearing in the carbon brush base it should be able to move smoothly with no play Inspect the dust seal for wear or damage f damaged it should be replaced 31 STARTER MOTOR INSTALLATION Apply some oil on the dust seal Install the carbon brush on the carbon brush base Apply a little oil on the moving part of the armature ends gt carbon brush base Install a not to d case making sure v age e Tighten motor Before installing the starter connect the lead wires and after assembling it first y unning normally Apply oil on the O ring and install the M 2 e Tighten holding bolts 3 Motor case i REDUCTION MECHANISM The picture shows the structure of the reduction mechanism 1 Starter red 12 Bolt 2 Starter redu 13 Nut 3 Starting clutct 2 14 Washer 4 Starting clutch oute 15 Dowel pin 5 Flange starting clutch 16 Key woodruff 6 Starting clutch roller sp 7 Roller 7 Spring holder Needle bearing 8 Starter motor ri nd Starter motor lead wire 10 Clamp 11 Clamp REDUCTION GEAR INSPECTION Remove the starting clutch Remove the reduction gear to inspect its wearing degree Measure the inner diameter
17. driving gear with the oil pump corner then mount the driving gear and chain NL afts unfillec EG 2 Mount the driving gear positioning nut and tighten it Install the partition board and tighten bolts Install the starting reduction gear and starting clutch Mount the gasket and dowel pins 21 Mount the right crankcase cover positioning bolt Mount the trigger winding and the stator coil e Tighten the right crankcase cover positioning bolt The bolt should be gradually diagonally tightened in to three steps After finishing the installation in Starting clutch TEM INSPECTION AND SERVICING 5 a constant vacuum carburetor The picture shows the structure of the CV 16 Needle jet holder 17 Plate clip Needle jet 18 Holder cap Float set 19 Tube Float chambe Screw set Screw set B Valve plate set Starter valve set 10 Air cut valve set 11 Compression coil spring 12 Screw 13 Carburetor assy 14 Top comp 15 Vacuum piston comp Li CR N e e 4 e 2 ET gt Kaas SN 2 JR NLA 0 0 ux P Eg SJ n Lir k m 7X 46 2 x 2 Fe P E T amp 4 cui 5 ES so 1 24126 15 58 7 em P P 4 3 xe pe 1 E 7 EE 29 6 e T Fi ic 5 w
18. e After applying oil on the valve stem mount it into the valve Mount the inner and outer valve springs e Mount the valve locker with a spring compressor When mounting the twisting direction of the inner and outer springs must b 0 posite Tap on the valve gently two or three times with a rubber hammer to make the b and the valve lock connect well Do not damage the valve VALVE GUIDE Carbon accumulation on the valve guide will make the valve move roughly causing the valve to not open or close properly Valve guide abrasion is one of the causes of white smoke from the exhaust pipe the inner diameter of the guide the outer diameter of the valve stem Inlet valve Exhaust valve Service Limit 0 08mm O40mm gt b VALVE GUIDE REPLACEMENT Heat the cylinder head to 212 302 F 100 150 C The cylinder head must be wholly and quickly heated to the specific degree and cannot be heated partly or it will cause the cylinder head to distort The tempera ture is very high two technicians are recommended Tap the valve guide out with a valve guide remover or similar tool Do not damage the cylinder joint face After tapping the valve guide you need to trim it with a reamer When using the reamer cutting oil must be used The reamer can only be turned right do not push in or out directly Clean the cylinder head and re
19. el as soon as possible OFF position The closing position for the fuel valve is the OFF position When the vehicle is not in use always make sure the petcock is in the OFF position FINAL GEAR OIL Note Inspect monthly and change quarterly Note 80 90 weight gear oil is recommended in the final drive case However in extreme cold weather conditions you may notice that the unit is hard to push If that is the case use lighter viscosity oil such as 75 weight or equivalent motor transmission fluid b o I drive capacity rur Boo wein ENGINE OIL 7 4 e Remove the drain plug from the W Drain into oil pan for disposal move the screen e Wash the screen with cleaning solvent and refit making O ring is still in good condition Refill the engine with 10W 40 engine oil and run for 5 min Check oil level on the filler cap stick to assure proper leve N 2 Screen 1 The cap needs to be screwed in for a proper reading y sg CHASSIS Grease chassis bushings and bearings with grease quarterly to assure smooth operation and extended lift of the bushings and the components If used in extreme wet and muddy conditions or dusty conditions greasing is recommended more often CARBURETOR Refer to Carburetor section VALVE CLEARANCE Refer to Engine section ENGINE ENGINE COMPONENTS INSPECTION AND SERVICING ENGINE COMPONENTS AND CRANK CONNECTING ROD MECHANISM INSPE
20. ent of tl periodically If damaged seriously replace orication sa unit nspect and maintain it OIL PUMP REMOVAL e Remove the flywheel of the magneto e Remove the stator coil and trigger winding e Remove the right crankcase cover bolts followed by removing the right crankcase cover Remove the gasket and dowel pins Remove the starting reduction gear and starting clutch e Remove the oil pump partition plate positioning bolts followed by removing the oil pump partition plate e Remove the oil pump driving gear nuts followed by removing the driving gear and chain semble the oil pump Inspect the clearance between the inner rotator e rotator Service Limit Inspect the clearance between the rotator plane and the oil pump Service Limit If the inspection result exceeds the above stated ser vice limit the whole set should be replaced 20 OIL PUMP ASSEMBLING Assemble the inner and outer rotators of the pump and mount the oil pump shaft When assembling align the unfilled corner of the oil pump shaft with the corner of the inner rotator and then mount he dowel pin you can install it after aligning the oil amp dowel pin plate bolts the oil pump shaft and make OIL PUMP INS Install the oil pump Before installing installing the arrow of tr pointing upwards Tighten the oil pump positioning bolts Align the oil pump
21. found while inspecting Measure the axial trend clearance of the big end of the connecting rod e When measuring put the large end of the connecting rod close to the crank and insert the feeler gauge between the other side and the crank for the correct end play Service Limit Measure the radial trend X Y clearance of the big end of the connecting rod Service Limit e ua the main shaft journal jump of the crankshaft If this measurement is too great it will cause the engine to shake abnormally shortening the life of the engine It must be examined carefully when inspecting EP 10mm A 90 0 10mm B 105 e Examine if theres is any loose or j sound when the crank journal bearing turns If there is the whole set should be changed After cleaning the sanke inspect if there i is damage Inspect whether the joint face of th crankcase is clean While reassembling notice if it will affect the sealing performance between the left and p case e After the above inspection if the ps some AR damage use oilstone to refinish it If damage is too severe replace the cover gt e Mount the crankcase oil seal Put the cam chain into the left crankcase Put the crankshaft into the left crankcase Pay attention to avoid damaging the oil seal with the cam chain Mount the new dowel pins and gasket on the left crankcase Then join the right crankcase and le
22. fre Servi e Inspect for any NM ge Inspect for any abrasion or damage of the movable driven plate Service Limit 34 06mm Inspect the groove of the guide pin for wear 42 DRIVEN PLATE BEARING REPLACEMENT If the driven plate needle bearing or the ball bearing are loose damaged or make unusual sounds they should be replaced e Remove the needle bearing from the driven plate he removed bearing cannot be reused Apply some grease on the new ball bee Drive the ball bearing into the driven plate wi Mount the circlip Apply grease evenly on the inner wall of the driven plate Use the prescribed grease Drive in the new needle bearing with its mark upwards Use the specific tool Apply grease around the bearing NY Roller 43 DRIVEN BELT PULLEY INSTALLATION e Remove the grease on the driven plate Mount the oil seal Apply a little grease on the O ring Mount the movable driven plate into the driven plate seal collar Transmission belt e Inspect the transmission belt for cr Measure the width of the belt Service Limit q e Replace the belt if its width is less than the above limit When replacing you must use the OEM part for correct fit See the drive pulley removal and installation procedure fo replacement REAR TRANSMISSION MECHANISM INSPECTION AND SERVICING The structure of the rear tran
23. ft crankcase together Tighten the crankcase positioning bolts LI La M PT D 1 99 Ibs m 2 driven gear t in tensioner 1g on the cam chain tensioner bolt must be mounted in VALVE MECHANISM INSPECTIC d The picture shows the common valve train train its intake port exhaust port cam ha over the combustion chamber 3 four ke This is a kind of overhead valve 2 1 cylinder head the valves bottom up GENERAL INTRODUCTION The four stroke engine completes its four stroke with one piston stro Intake stroke Compression stroke Expansion stroke e Exhaust stroke VALVE CLEARANCE ADJUSTMENT Valve clearance is an important technical parameter in the valve train In order to enable the engine to run properly especially when the engine is overheated or in cold conditions a certain clearance must be kept This clearance is called valve clearance When the engine is running the earance must not be too big or too small top dead center anc case mark qi The crankshaft should rc at N e When adjusting loosen the lock nuts st the bolts a valve adjusting wrench When turned ise the va clearance decreases When turned counterciock the valve clearance increases Put a feeler gauge wi cific sizes between the valve and rocket to check for correct clearance oort may not be adjusted Valve adjusting wrench Aa i
24. he valve cover E 74 valve cover gask F st be pro gt DET ed in the groove Adjusting bolt Tighten the valve cover positioning o ROCKER ARM AND ROCKSHAFT ROCKER ARM AND ROCKSHAFT REMOVAL e Remove the camshaft holder Take out the rockshaft by removing the bolt Remove the rocker arm ROCKER ARM AND ROCKSHAFT INSPECTION Inspect if there is any abrasion or damage on the rocker arm and rockshaft or if tl clogged If there is abrasion on the surface of the rocker arm the camshaft should also be inspected Measure the inner diameter of the rocker arm Service Limit 10 04mm Measure the outer diameter of the rockshaft Service Limit Cam chain tens on Cam chain tensioner Gasket Cam chain tensioner pivot Cam chain guide Bolt Nut O ring 0 O ring E T i As for the adjustment of the cam chain tensioner clockwise tightens and counterclockwise loosens VALVE AND VALVE SPRING VALVE AND VALVE SPRING REMOVAL e Remove cylinder head Remove valve cotter pin and compressor Valve spring compressor Remove upper spring race Remove valve spring Valve spring compressor accessory ust valve parts Inlet valve Exhaust valve Inner spring Outer spring VALVE AND VALVE SPRING INSTALLA e Mount the spring retainer valve guide oil seal It is recommended to replace the valve guide TN
25. ier plug contacts well Measure the resistance value between every regulate rectifier terminal e f the resistance value between the terminals is unusual replace the regulate rectifier RESISTOR RESISTOR RESISTANCE VALUE MEASUREMENT Measure the resistance value between the resistor wire and the vehicle body It is normal when the actual value is in the range of 10 value marked on the diagram or the resistor If not it should be replaced 55 IGNITION SYSTEM INSPECTION AND SERVICING The circuit working principle is shown in the picture B Black R Red Main switch Ignition switch Y Yellow ON pw W White G Green OFF C D I Unit Ignition coil JUR UU Ce BAU ESSI SS Capacitor Silicon i Controlled plug Trigger winding E rectifier inspecting ignition function is 5 to inspect ignition timing e Remove the ignition timing hole cover remove th fan cover Rotate the generator rotor and align the F mark on the rotor with the crankcase timing ignition mark p Clip the ignition timing indicator light wire AT on m high end of the ignition coil e Start the engine and let it idle At this time observe if the mark on the crankcase aligns with the F mark on the rotor A difference between 3 indicates correct ignition timing on the contrary if it is more than 3 the ti
26. istance value of the secondary ignition coil Standard Value 2 20 C If the resistance value is in the standard range indicates it is good however indicates the coil is bad The ignition coil also can be inspected and measured with the ignition testing instrument Please operate properly according to the instructi ons Set the measuring switch of the ignition coil on the 1 2V position and connect the ignition coil Turn the switch of the testing instrument to the ON position Observe the spark and inspect the spark situation of the ignition coil If it is a normal consistent spark It IS good if the spark does not flash consistently it is not good SPARK PLUG Clean the carbon around the spark plug to prevent it from dropping into the cylinder Remove the spark plug 59 e Clean the fith and carbon accumulation on the spark plug with steel brush or a blade e Inspect the spark plug gap in general it should be about 0 6 0 7mm 60 INDEX AIR ADJUSTING SCREW ADJUSTMENT 23 AIR CHECK VALVE 26 26 26 26 26 31 24 51 52 51 51 51 48 AN 47 BELT DRIVEN CVT MECHA 36 CAM CHAIN TENSIONER 12 CAMSHAFT 10 CAMSHAFT INSPECTION 10 CAMSHAFT INSTALLATIION 11 CAMSHAFT REMOVAL 10 CAPACITIES 31 2 CARBURETOR IDLING ADJUSTMENT CARBURETOR INSTALLATION CDI COMPONENT CDI COMPONENT CHAIN ADJUSTRMENT CHARGING STATUS INSPECTION CHARGING SYSTEM INSPEC
27. learance First Ring Second Ring CONNECTING ROD END INSPECTION Put the piston pin and bearing into the connecting rod end inspect the degree of tightness of the piston pin in connecting rod end Measure the inner diameter of the connecting rod end Service Limit 15 06mm When the abrasion of the bore exceeds the limitation it should be replaced PISTON RINGS SET UP Before setting up apply oil on each piston ring then enlarge piston rings at the same time put them on the piston and move downwards gradually until piston rings fall into the ring groove PISTON SET INSTALLATION e Remove the engine Remove the cylinder cover e Remove the cylinder e Remove the piston Remove the drive plate and the driven plate e Remove the AC generator Remove the starting motor e Remove the oil pump Then remove the cam chain tensioner bolt Remove the cam chain tensioner cm rivengenr Use special tools to remove the starting driven gear 5 Remove the crankcase positioning bolts cc vot MOR MN oe gt e Separate the right crankcase and the left crankcase Be careful not to damage the joint face Remove the gasket on the crankcase be careful to not damage the joint fac Remove the oil seal from the left crankcase e Remove the oil seal from the right crankcase CRANKSHAFT AND CRANKCASE INSPECTION Replace the whole set of the crankshaft if serious wear is
28. m is bad trigger winding IGNITION CHARGING COIL e Remove the connector of the ignition charging coil wire Measure the resistance value between the ignition charging coil black red wire and the body ground wire Standard Value 300 1000 Q 20 C When the actual value is more than the standard value it should be replaced 57 TRIGGER WINDING e Remove the connector of the trigger winding wire Measure the resistance value between the trigger winding green red wire and the body ground wire Standard Value 40 300 20 When the actual value is more than the standard value it should be replaced CDI COMPONENT entinspection is similar to the regular inspection The CDI on is also divided into two steps First inspect every wiring nnected with CDI then inspect the CDI component REMOVE THE CDI COMPONENT e Check the connector for looseness or erosion Inspect the conduction and the resistance value of the main switch the ignition charging coil the trigger winding and the ignition coil When the main switch is in OFF position it should be conducted The resistance value of every coil should be the standard value Inspect the resistance value between every CDI component terminal If the actual value is not in the range of the value in the chart then the CDI component is faulty CDI COMPONENT SW BW EXT B R PC G R E G or GW IGN B Y swem _ 10 2 soe 00 EXT B R
29. ming should be adjusted e Slowly increase the engine rpm when the 150 model increases to 5000 r min at this time if the mark on the crankcase aligns with the rotor ignition advance angle mark the advance angle device is good if not it should be adjusted or replaced 1 When adjusting the trigger winding can be loosened to adjust the eo between it nd igni tion charging coil to adjust the ignition time IGNITION SYSTEM INSPECTION When the spark plug does not spark first inspect the wires If the connecting part is loose or the contacts are bad etc follow the electric circuit and use the method of measuring the voltage of every point to determine the trouble Please refer to the previous picture for the following inspection e Remove the old spark plug Install a new one if plug is bad 56 It is important that every electric circuit wire connects correctly It is important that the cylinder compression pressure is normal Connect the negative end of the multimeter with the positive connecting iron of the primary igni tion coil black yellow wire Press the starting button or use the kick starter and read the voltage value on the multimeter The highest voltage value should be above 112V When measuring the voltage do not touch the metal part of the multimeter with finger or an electric shock can occur e Remove the 4 core and 2 core connectors of the CDI component Connect the
30. move the scraps generated while ramming VALVE SEAT relative position between the valve seat and the working surface of the valve is very important for the valve to seal D P VALVE S AT WIDTH MEASUREMENT e Clean the carbon accumulation in the combustion chamber EE MN Valve seat width Measure the a of the valve seat with a vernier caliper Standard Service Limit fA L N 60 When abrasion causes the valve seat width to be uneven too wide or LN too narrow it will result in poor contact between the valve and the valve seat and not seal tight At this time it must be reamed with a custom ized valve seat milling cutter N Y 32 The valve seat milling cutter is the customized trimming tool for the valve seat and it has three cutting angles 32 y and60 While trimming press the valve seat milling cater to make rotary n mo tion with 40 50 N force Some oil must be applied on the valve ing nate scraping when trimming lt VALVE SEAT FINISHING e Ream out the defects on the working surface with a 45 coarse tooth milling cutter Do not ream too much Valve seat surface e Ream the upper angles of the valve seat working surface with a 30 milling cutter ZN Oid valve seat width specific seat width with ace If the contact position is too tilling cutter to reduce the working face of the valve seat
31. n the drive plate hub Mount the drive plate the drive plate washer and nut e plate with a multiuse holder to make it unmovable and remove the nut Remove the clutch friction plate CLUTCH INSPECTION Inspect for any abrasion or damage on the cl Measure the inner diameter of the clutch friction plate Service Limit 125 5mm Inspect for any abrasion or damage of the clutch centrifug weigh friction piece Measure the thickness of the clutch centrifugal weight friction piece Service Limit CLUTCH DISASSEMBLING e f the centrifugal weight set needs to be replaced you must disassemble the clutch When the friction piece is worn replace it and the centrifugal weight set Wrench Remove the clutch friction plate Circlip e Remove the whole clutch driven plate set While compressing the driven pulley spring with the clutch spring compressor remove the nut on the shaft Connecting piece irclip and remove the connecting piece centrifugal weight set and the spring ubber onto the drive plate pin and spring on the drive plate irclip and the bottom plate To avoid you must use a cit 41 DRIVEN BELT PULLEY DRIVEN BELT PULLEY REMOVAL Guide pin e After removing the clutch friction plate remove the guide pin the roller and the movable driven plate eal on the movable driven plate C ien P amid spring Measure the
32. positive end of the multimeter with the ignition charging coil black red wire end of the 2 core connector and the negative end with the ground wire end green end of the 4 core connector Press the starting button or use the kick starter and measure the highest voltage of the ignition charging coil It Should be more than 122V e When the highest measured voltage of the ignition charging coil is not normal then disconnect the generator connector to take further measurements f it is measured that the CD component end is abnormal and however the terminal voltage of the generator is normal then there is a bad wire or bad Connection e When both are not normal then the problem is a bad ignition charging coil e Remove the 4 core and 2 core of the CDI component Connect the positive end of the multimeter with the trigger winding green red wire terminal on the 4 core connector and the negative end with the green wire terminal on the 4 core connector Press the starting button or kickstarter and measure the highest voltage of the trigger winding which should be more than 2 1V e When the highest measured voltage of the trigger winding is not normal then remove the gen erator connector and take further measurements e f the measured terminal voltage of the CDI component is not normal and the generator terminal volt age Is normal then there is a bad wire or bad connection e f both are not normal then the proble
33. river collar N Bearing driver collar uh PR S me Bearing driver es 48 e Install the driven belt pulley shaft on the transmission case cover Bearing driver collar Pulley assember r and the final gear shaft into e Mount the final gear on the 1 Install the new dowel pin and gasket Install the transmission case cover and bolt e Mount the driven pulley and the clutch set YEE Transmission y Ni and gt Y _ a amp vi 4 3 53 n Mount the drive pulley the transmission belt and the left crankcase cover Fill the transmission case with oil 49 Electrical System CHARGING SYSTEM INSPECTION AND SERVICING ELECTRIC LEAKAGE TESTING CHARGING Install the fully t the voltage regulator 50 BATTERY The battery is an important component of the electric system The battery used on the vehicle is a maintenance free battery For long periods of storage the battery will discharge It should be charged every 3 months After 2 3 years of regular usage the capacity of the battery will lessen and will need changing Replace with the same type of battery uch the body of the vehicle with the removal it and ignite gas that will damage the battery or it will short S BATTERY u ATION Connect the positive cable y a meet egative cable
34. smission mechanism is shown in the following picture Mount the transmission case oil level bolt and the washer Inspect the bolt oil seal to see if it is damaged TRANSMISSION CASE OIL REPLACEMENT Remove the transmission case oil level bolt Remove the oil drain bolt to drain the oil e Mount the drain bolt and its oil seal and fasten 45 e Supply the oil with the prescribed specification and oil level e Mount the level bolt e After replacing the oil inspect for any oil leaks TRANSMISSION CASE GEAR IN Check the sub shaft sub shaft gear for wear Check if the final gear and the final gear shaft for wear and other damage 46 BEARING ON THE TRANSMISSION CASE COVER REPLACEMENT e Remove the sub shaft bearing Drive in the new final gear shaft and bearing When driving in the final gear shaft bearing keep the bearing parallel The same is required when installinc sub shaft bearing and the driven pulley shaft bearing Drive in the new sub shaft bearing Drive in the driven pulley shaft bearing 47 BEARING ON THE LEFT CRANKCASE BODY REPLACEMENT When removing or installing the bearing on the left crankcase body you must use the specific tool Remove the driver e Drive in the new driven belt pulley sh Drive in the new sub shaft bearing Drive in the new final gear shaft bearing E 08 JP vs et Bearing d
35. starting KICK RETURN STARTING MECHANISM Drive face Drive face boss Movable drive face comp Weight roller set Ramp plate Slide piece Starting driver pulley Starter gear friction spring 10 Starter idle gear comp 11 Starter idle shaft 23 12 Starter idle spring driv 13 Kick starter spindle comp SPIRAL SPLINE TRANSFERRING STYLE STARTING MECHANISM REMO m r e Remove the left crankcase cover p e Remove the crankcase gasket and dowel pins e Remove the movable driving plate the whole set Remove the starting spindle washer 27 e Remove the return spring stopping plate and remove the return spring Remove the whole starting lever set Remove the starting idle shaft Inspect the starting spindle bushing and the shaft hole for abrasion or other damage 28 SPIRAL SPLINE Return spring spindle Where it is under stress e Align the idle shaft holding pin with the then insert of the rotary retaining spring on the idle shaft The rotary retaining spring should be aligned with the specific groove of the crankcase to install Align the scribing mark of the starting spindle with the mark of the idle shaft then mount the starting spindle e Hook on the two ends of the return spring Install the return spring stopping plate
36. ve the flywheel nut NG Remove the flywheel with a flywheel puller and remove the solid key 53 e Remove the generator wire connector Remove the generator wire holder Remove the generator coil bolt e Remove the generator wire rubber bushing from the right crankcase REGULATE RECTIFIER MAIN WIRING SUB ELECTRIC CIRCUIT CONDITION i a V d Perform the voltage regulate rectifier inspection procedure i two steps First inspect the main wiring sub electric condition and then inspect the voltage regulator Second inspect only 4 when engine is cold Remove the 4 core connector of the regulate rectifier Measure the conducting status between the main wiring terminals according to the previous wir ing diagram o4 Connecting type Normal condition Battery the red wire Vehicle body Battery voltage value Connecting wire the green wire Vehicle body Conductive Lighting wire the yellow wire Vehicle body re Generally is 0 1 0 8 move the resistor side auto starter plug and turn the lighting switch to OFF Charging wire the white wire Vehicle body Generally is 0 2 2 00 Loo W Whie Yellow R Red G Gren AL 9 3 9 L 2 5 10 u 1 29 Gleen 5 10000 9 REGULATE RECTIFIER INSPECTION sub electric circuit condition is normal Check that the regulate rectif
37. y 18 i Y 22 CARBURETOR IDLING ADJUSTMENT AIR ADJUSTING SCREW ADJUSTMENT Step one Turn on the air adjusting screw in the turn out by the prescribed number of turns Turn out number of turns 2 3 4 2 1 4 Adjust the throttle by adjusting the screw to the prescribed idle rpm Left and right adjust the air adjusting screw slightly to find the highest position e Remove the body cover lead wire Loosen the throttle cable adjusting remove the throttle cable Remove the vacuum cover bolt and remove the vacuu Notice move slowly to prevent the spring from ejecting Press down the holding clamp of the needle valve top and turn left to take out the clamp Take out the spring and needle valve Do not damage the vacuum membrane Inspect the needle valve for wear Inspect the vacuum membrane for damage Inspect the plunger for damage 23 VACUUM CHAMBER INSTALLATION e Mount the plunger and the vacuum membrane into the carburetor body Vacuum cover e Push the plunger upwards in the direction of the vacuum chamber cover to open the carburetor jet tube c value it should be replaced line and blow very gently If it is ob e Remove the auto side starter cover Remove its positioning bolts and pieces Remove the auto side starter Inspect the auto side starting valve and fuel injection ne Inspect the O ring for wear FLOA
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