SERVICE MANUAL
Contents
1. ees 2 Drain off the oil in the gear box 3 Remove the 6 bolt in gear box cover 4 Take off the gear box 5 Take out the final reduction gear and idle gear shaft 6 Clean up the gear box C Check the final transmission mechanism 1 Check the wearing condition of the driving shaft and gears 2 Check the wearing condition of the idle gear shaft and idle gears 3 Check the wearing condition of the final reduction gear 4 Check the wearing condition of the oil seal and bearing D Assemble the final transmission mechanism please follow the opposite procedures Of disassembling After locking the drain bolt refill 90c c of gear oil SAE 85W 140 Locking torque M6 1 0 1 2 kg m M10 3 5 4 0 kg m Drain bolt M8 1 8 kg m E Check for the flatness of cylinder head amp cylinder Check the flatness of contact surface of cylinder head amp cylinder Limit of use If it exceeds 0 1mm Change a new one l i l Clean out the carbon piled up in combustion chamber Do not scratch the combustion chamber and contact surface of the cylinder during cleaning operation G Check cylinder and piston 1 Check the wearing and damage condition on the contact surface of the cylinder and piston 2 Clean out the carbon on the cylinder exhausting port Be careful not to scratch the inner Surface of cylinder 3 Cylinder bore measurement 1 Measure each point A B C orderly and in X Y axis to find2. the smallest value 2 Limit of use 50cc change it when over 40 050mm Cylinder gauge 4 Piston outer diameter measurement 1 Measure at the skirt area where is 12 mm from the skirt lower end of skirt 2 Limit of use 50cc change if when below 39 895mm 3 Calculate the clearance between the cylinder and piston Limit of use change it when over 0 100mm 5 Inner diameter measurement of the piston pin hole Limit of use change it when over 14 032mm
3. 5 Remove the spark plug 6 Remove the two M6 nuts on the muffler and cylinder Also remove the two M8 bolt of crankcase 7 Remove muffler 8 Remove the four M7 nut on the cylinder head then remove the cylinder head and cylinder head gasket 9 Remove the Cylinder and the gasket 10 Remove the c ty eTake off piston 11 Dismatling of the prsto 9 oa 12 When assembling please reverse the procedures of RGAE Locking torque M7 1 0 1 4kg m Opening end of piston ring M6 1 0 1 2kg m 6 A C Generator Flyweel A Dismantling AC generator 1 Remove fan cowl 2 Remove the M6 screws 4 3 Remove Screws of flywheel magneto 4 Remove the AC flywheel magneto by special tool MTT ili i Wily ual N ve na Wy Ny 5 Remove the flywheel 6 Remove the electric plug of AC Flywheel magneto Take out the magneto B Install AC generator To install please reverse the dismantling procedures Locking torgue M6 1 0 1 2kg m M10 3 2 4 0kg m NO gy V U l E pow D raa 7 Final Transmission Mechanism A Trouble shooting Engine can be started but vehicle doesn t move 1 Gear worn out or cracked 2 Gear burnt out Noise occurs when running 1 Gear worn out burnt or gear surface damaged 2 Bearing worn out or loosen 0Oil leakage 1 Too much oil 2 Seal worn out or damaged B Disassemble the final transmission mechanism 1 Remove the rear wheel wA i Viet saan es
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