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Kymco People 50 Service Manual

1. per LM one a TEER TE ee TL mm sr TF LP EN TR am Uu HIER MISKI WS BECH Dok vy Mya P mn k L Wi es mas m um ux 125 L juj FEE n EER m E mn HE B I a H x IE D LW un COLE 38 GA V COLORLAE 2 16 1 SPECIFICATIONS CABLE amp HARNESS ROUTING Front Brake Reservoir 5i Front Brake Fluid weed S a m Tube Throttle Cable Rear Brake Cable Ignition Switch peedometer Cable starter Relay Regulator Rectifier Ground Horn 2 17 2 GENERAL INFORMATION Speedometer Cable Wire Harness Starter Relay Front Brake Fluid Tube 2 18 1 SPECIFICATIONS Fuel Unit Left Crankcase Breather Oil Tube Ignition Coil h Fuel Filter Ignition Coil spark Plug 2 19 2 GENERAL INFORMATION Fuel Unit Fuel Tank Cap Oil Meter Oil Tank Cap Fuel Tube Fuel Filter Oe Bt Auto Bystarter Oil Filter Vacuum Tee Oil Tube Oil Pump Control Cable Ignition Coil Spark Plug Cap Throttle Cable 2 20 1 SPECIFICATIONS TROUBLESHOOTING ENGINE WILL NOT START OR IS HARD TO START Inspection Adjustment Probable Cause Check if fuel reaches carburetor by loosening drain screw Empty fuel tank
2. The model adopts krypton gas bulb When installing do not directly touch the bulb glass with fingers Use bulbs of the same specifications for replacement The installation sequence 15 the reverse of removal 16 8
3. Torque kg m 5mm screw 0 35 0 5 6mm screw SH bolt 0 7 1 6mm flange bolt nut 1 0 1 4 8mm flange bolt nut 2 4 3 0 10mm flange bolt nut 3 5 4 5 2 12 1 SPECIFICATIONS SPECIAL TOOLS Tool Name niversal bearing puller Lock nut wrench 39mm Lock nut socket wrench Lock nut wrench Crankcase puller Bearing remover set 12mm Spindle assy 15mm Remover weight Bearing remover set 15mm Spindle assy 15mm Remover head 15mm Remover shaft 15mm Flywheel puller Pilot 12mm Bearing outer driver 28x30mm Bearing remover Clutch spring compressor Crankcase assembly collar Crankcase assembly tool Rear shock absorber remover Ball race remover Rear shock absorber compressor Float level gauge Lock nut socket wrench 32mm niversal holder 2 Bearing outer driver 32x35mm 2 13 Tool No Remarks Crankshaft bearing removal Drive pulley disassembly assembly Top cone race holdine Stem lock nut tightening Crankcase disassembly Drive shaft bearing removal installation Drive shaft bearing removal installation Bearing installation Driven pulley outer bearing installation Driven pulley disassembly assembly Driven shaft crankshaft amp crankcase assembly Crankshaft amp crankcase assembly Front shock absorber disassembly assembly Steering stem bearing races Rear shock absorber disassembly assembly Carburetor fuel level check One way clutch lock nut removal
4. 7 vy b 3 Band m Bolt AC Generator Wire Connector Oil Pump Control Cable Spark Plug Cap 5 ENGINE REMOVAL INSTALLATION Remove the rear brake adjusting nut and Rear Shock Absorber Lower Mount Bolt disconnect the brake cable from the crankcase 2 Remove the rear brake cable clamp and rear brake cable Remove the cooling atr tube band on the left crankcase cover and disconnect the cooling air tube Remove the rear shock absorber lower mount bolt Remove the right and left engine mounting nuts Take out the right and left engine mounting bolts Lift the frame upward to separate it from the engine and be careful not to damage the rear fender Engine Mounting Nuts ENGINE HANGER BRACKET REMOVAL Remove the engine hanger bracket bolt and engine hanger bracket The installation sequence 15 the reserve of removal Torque 3 5 4 5kg m Engine Hanger Bracket Engine Hanger Bracket Bolt 5 ENGINE REMOVAL INSTALLATION ENGINE HANGER BRACKET Engine Hanger INSPECTION Inspect stopper rubbers and bushings for damage and replace with new ones if necessary Bushings Stopper Rubbers ENGINE INSTALLATION Install the engine in the reverse order of removal E Cables and wires should be routed properly Torque Values Engine mounting bolt 4 5 5 5kg m Rear shock absorber lower mount bolt 24 3 0kg m Perform the following inspections and adjustm
5. Connect the auto bystarter yellow wire to the battery positive terminal and green black wire to the battery negative terminal and wait 5 minutes Connect a hose to the fuel enriching circuit and blow the hose with mouth If air can be blown into the hose the auto bystarter is faulty and replace it with a new one AUTO BYSTARTER REMOVAL NN Auto Bystarter Remove the auto bystarter cover Remove the two auto bystarter set plate screws to remove the auto bystarter Screws Set Plate O ring Check the auto bystarter valve and needle for wear or damage Check the O ring for wear or damage Bystarter Bystarter Valve Needle 11 7 11 CARBURETOR AUTO BYSTARTER INSTALLATION Screws Auto Bystarter Install the auto bystarter into the carburetor body until it bottoms Install the set plate and then tighten the two screws FLOAT CHAMBER Remove the two float chamber screws and the float chamber O ring Remove the screw and O ring Remove the float pin float and float valve Float Pin 11 CARBURETOR Float Valve FLOAT FLOAT VALVE INSPECTION Inspect float for damage fuel Inside the float Check the float valve seat for wear or damage JETS SCREWS REMOVAL Before removing the throttle stop screw or air screw record the number of rotations until it seats lightly Then remove them Do not force the air screw against its seat to prevent damage Remove t
6. TROUBLESHOOTING Engine does not start Lean mixture No fuel in tank Clogged fuel jets Faulty float valve Too much fuel getting to cylinder Clogged fuel cap vent Float level too low Clogged fuel filter Clogged fuel filter Clogged air cleaner Clogged air cleaner Bent kinked or restricted fuel line Engine idles roughly stalls or runs poorly Rich mixture Incorrect idle speed Clogged air cleaner Faulty float valve Ignition malfunction Intake air leaks Float level too high Compression too low Fuel contaminated Clogged air jets Incorrectly adjusted air screw Faulty reed valve Incorrect float level Clogged fuel jets 11 2 11 CARBURETOR THROTTLE VALVE DIS ASSEMBLY Remove the rear carrier gt 12 5 Remove the met in box gt 12 4 Loosen the carburetor cap and remove the throttle valve Carburetor Cap Disconnect the throttle cable from the Throttle Valve throttle valve Remove the throttle valve spring carburetor cap and rubber seal 11 3 11 CARBURETOR Remove the jet needle by removing the R Jeedle Clip needle clip Check the jet needle and throttle valve for leedle Retainer wear or damage nd Notch STD Jet Needle Throttle Valve Rubber Seal Carburetor Ca THROTTLE VALVE INSTALLA TION Install the jet needle on the throttle valve and secure with the needle clip Install the rubber seal on the throttle cable and then install the carburetor cap and throttle valve spring Th
7. 22 00 2220 220 0101000 nen 10 4 CRANKSHAFT 8 2 2 20220 000 00000 25 10 5 CRANKCASE ASSEMBLY sese 10 7 10 0 10 CRANKCASE CRANKSHAFT Torque 0 8 1 2kg m 10 1 10 CRANKCASE CRANKSHAFT SERVICE INFORMATION GENERAL INSTRUCTIONS This section covers crankcase separation to service the crankshaft The following parts must be removed before separating the crankcase Engine gt Section 5 Driven pulley Section 9 Carburetor gt Section 11 A C generator Section 7 Oil pump Section 4 Cylinder head cylinder Section 6 Reed valve gt Section 11 When the left crankcase must be replaced remove the following part In addition to the above Final reduction removal Special tools must be used for crankshaft and crankcase assembly When separating the crankcase the bearing will remain in the crankcase and it should be removed When assembling drive a new bearing into the crankcase and install a new oil seal SPECIFICATIONS Item Connecting rod big end radial clearance Crankshaft runout A B SPECIAL TOOLS Crankcase puller Universal bearing puller Crankcase assembly collar Crankcase assembly tool TROUBLESHOOTING Abnormal engine noise Excessive crank journal bearing play Excessive crankpin bearing play Excessive transmission bearing play Standard mm Connecting rod big end side earn s 060 0 50 Service Lim
8. at the oil tank side must be locked from inside of the oil tube joint 5 ENGINE REMOVAL INSTALLATION ENGINE REMOVAL INSTALLATION SERVICE JINEOR VIAE ION uu i uyu u ua 5 1 GI PREPA IO V A L gt 5 2 ENGINE INS TALCEA MON uuu aun 5 4 5 0 5 ENGINE REMOVAL INSTALLATION SERVICE INFORMATION GENERAL INSTRUCTIONS Parts requiring engine removal for servicing Crankcase Crankshaft TORQUE VALUES Engine mounting bolt 45 5 5kg m Rear shock absorber lower mount bolt 2 4 3 0kg m Engine hanger bracket bolt 3 5 4 5kg m 5 1 5 ENGINE REMOVAL INSTALLATION ENGINE REMOVAL Remove the frame body cover 12 5 Remove the two bolts attaching the atr cleaner case Loosen the band between the atr cleaner and carburetor to remove the atr cleaner case Remove the carburetor cap Disconnect the oil pump control cable from the pump body Disconnect the oil inlet line from the oil pump After the oil inlet line is disconnected plug the oil line opening to prevent oil from flowing out Disconnect the auto bystarter A C generator and starter motor wire connectors Remove the spark plug cap Air Cleaner Case 4 Carburetor Cap Z gt 4 4 J a SZ oa lt Z gt 4 jj
9. 0 _ _ IGNITION SWITCH REPLACEMENT Remove the front cover gt 12 3 Disconnect the ignition switch wire couplers Remove the two mounting bolts and remove the ignition switch The installation sequence is the reverse of removal Bolts 16 4 16 INSTRUMENT SWITCHES LIGHTS HEADLIGHT SWITCH INSPECTION Remove handlebar front cover 5 12 3 Disconnect the headlight switch wire coupler and check for continuity between wire terminals Headlight Switch Blue White Brown Pink TL RE DIMMER SWITCH INSPECTION Check for continuity between wire terminals White Black LO H 0 0 LO O o PASSING o Dimmer Switch TURN SIGNAL SWITCH INSPECTION Check for continuity between the wire terminals Light Blue Orange Gray L WR R O Turn Signal Switch 16 5 16 INSTRUMENT SWITCHES LIGHTS STARTER SWITCH INSPECTION Check for continuity between wire terminals Push the starter button when measuring Starter Switch HORN SWITCH INSPECTION Check for continuity between wire terminals Push the horn button when measuring Horn Switch STOP SWITCH INSPECTION Remove the handlebar front cover gt 12 3 Disconnect the front and rear stop switch wire couplers Check for continuity between the wire terminals when the front rear brake lever 15 applied 16 6 16 INSTRUMENT SWITCHES LIGHTS HOR
10. 13 2 TROUBLESHOOTING ia a uu uuu 13 2 STEERING HANDLEBAR eene tren 13 3 FRONT 13 5 FRONT BRAKE DRUM BRAKE eene 13 9 FRONT BRAKE DISK BRAKE eee 13 12 FRONT SHOCK 5 6 13 20 FRONT FORK 13 23 13 0 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK 6 0kg m 13 1 13 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK SERVICE INFORMATION SPECIFICATIONS Standard mm Service Limit mm Axle shaft runout 0 2 Axial 2 0 ront shock absorber spring free length 182 8 rake disk thickness 35 3 8 3 0 rake disk runout 0 30 rake master cylinder I D 12 743 12 75 rake master cylinder piston O D 12 684 12 64 rake caliper piston O D 25 405 25 45 rake caliper piston I D 25 368 TORQUE VALUES Handlebar lock nut 4 0 5 0 Front damper nut 1 5_ 3 0kg m Steering stem lock nut 8 0 12 0kg m Front axle nut 50_ 7 0kg m Steering top cone race 0 5 3kg m Brake arm bolt 0 4 0 7kg m SPECIAL TOOLS Lock nut wrench Driver handle A Lock nut socket wrench Outer driver 37x40mm Outer driver 28x30mm Pilot 10mm Bearing puller snap ring pliers close Damper compressor Rear shock absorber remover Rear shock absorber compressor Ball race remover TROUBLESHOOTING Hard steering heavy Excessively tightened steering stem top co
11. 4 Remove the oil pump from the crankcase Bolt Control Cable Plate OIL PUMP INSPECTION Remove the oil pump and inspect the following items Weakened O ring Damage to crankcase mating surface Damage to pump body Control lever operation p epum 1 Oil leaks through seals c Hae Worn or damaged pump pinion UE O ring i y Jw was 441 Do not disassemble the oil pump which cannot be used after disassembly Control Lever m Pinion 4 LUBRICATION SYSTEM OIL PUMP INSTALLATION Lubricate the O ring with grease or engine oil before installation Make sure that the pump 15 inserted into the crankcase Apply molybdenum disulfide or grease to the pump pinion Install the oil pump onto the crankcase Install the oil pump control cable plate Connect the oil inlet line and oil outlet line properly Connect the oil pump control cable Bleed air from the oil pump Grease or Engine Oil Control Cable Plate l A Oil Outlet Line x i a Control Cable 4 LUBRICATION SYSTEM OIL PUMP BLEEDING Air in oil lines will block oil flow and result in severe engine damage Bleed air from the oil lines and oil pump whenever the oil lines or pump have been removed or there is air in the oil lines OILINLET LINE OIL PUMP BLEEDING Fill the oil tank with recommended oil Place a shop towel around the oil pump Disconnect the
12. Dead battery Disconnected battery cable Fuse burned out Faulty ignition switch Low power Weak battery Loose battery connection Charging system failure Faulty regulator rectifier 15 1 BAIOAB AC 12VAAH 1 0 13 2V 0 4A 5H 4A 0 5H BRSHSA 0 6 0 2 7 0 0 7mm 0 3 2 8 4KQ 2 5 3 2KQ 80 1600 8 14 15 BTDC2000rpm Intermittent power Loose battery cable connection Loose charging system connection Loose connection or short circuit m ignition system Loose connection or short circuit m lighting sy stem Charging system failure Loose broken or shorted wire or connector Faulty regulator rectifier Faulty A C generator 15 ELECTRICAL EQUIPMENT IGNITION SYSTEM No spark at plug Faulty spark plug Poorly connected broken or shorted wire Between A C generator and CDI unit Between CDI unit and ignition coil Between CDI unit and ignition switch Between ignition coil and spark plug Faulty ignition switch Faulty ignition coil Faulty CDI unit Faulty A C generator STARTING SYSTEM Starter motor won t turn Fuse burned out Weak battery Faulty ignition switch Faulty starter switch Faulty front or rear stop switch Faulty starter relay Poorly connected broken or shorted wire Faulty starter motor Engine starts but turns poorly Ignition primary circuit Faulty ignition coil Poorly connected wire or connector Ignition secondary circuit Faulty ignition coil Faulty spark plug Poo
13. FRAME BODY COVER REMOVAL Remove the rear carrier gt 12 5 Remove the rear fender gt 12 5 Remove the met in box gt 12 4 Remove the rear brake cable Remove the bolt attaching the front center cover of the frame body cover Remove the frame body cover The installation sequence 15 the reverse of removal Bolt frame body FRONT FENDER REMOVAL Bolts Remove the floor board gt 12 4 Remove the front tool box gt 12 4 Remove the handlebar gt 13 3 Remove front fork gt 13 19 Remove two bolts attaching each side of the front fender Remove the front fender The installation sequence 15 the reverse of removal Front Fender FRONT LOWER COVERS REMOVAL Remove the rear brake cable Remove the frame body cover 12 5 Remove front tool box gt 12 4 Remove the handlebar gt 13 3 Remove the front fork gt 13 19 First remove the front cover gt 12 3 Remove the right and left bottom cover removing the two screws for each rail Remove the two bolts attaching each of the right and left front lower covers Remove the front lower covers Bolts Front Lower Cover The installation sequence 15 the reverse of removal 12 6 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK SERVICE 000
14. G stator Faulty A C generator Check auto fuel valve for fuel supply D Empty fuel tank Fuel flows freely 2 Clogged fuel tube filter Clogged charcoal canister Check carburetor jets for clogging Mn Not clogged Clogged QD Clean and unclog Remove auto bystarter connecting wire and check if bypass fuel line is clogged Not clogged Clogged Broken auto bystarter wire Faulty auto bystarter Connect auto bystarter wire to battery Wait for 5 minutes then connect a hose to fuel enriching circuit and then blow the hose with mouth Glossed D Faulty auto bystarter Not clogged 2 26 1 SPECIFICATIONS CLUTCH DRIVE AND DRIVEN PULLEYS Engine starts but motor cycle does not move Motorcycle creeps or Probable Cause Qo Worn or slipping drive belt Broken ramp plate Broken driven face spring Separated clutch lining Damaged driven pulley shaft splines Damaged final gear Seized final gear engine starts but soon D Broken shoe spring stops or seems to rush 2 Clutch outer and clutch weight out Rear wheel rotates when engine GSeized pivot idles Worn slipping drive belt Engine lacks power at Worn weight rollers start of a grade poor Seized drive pulley bearings Slope performance Weak driven face spring Worn or seized driven pulley bearings Engine lacks power at D Worn or slipping drive belt high s
15. Service Limit 12 75mm Inspect the master cylinder for scratch or crack Measure the brake master cylinder piston O D Service Limit 12 6mm Before assembly inspect the Ist and 2nd rubber cups for wear Assembly Before assembly apply brake fluid to all removed parts Install the spring together with the Ist rubber cup During assembly the main piston spring must be installed as a unit without exchange When assembling the piston soak the cups in brake fluid for a while Install the cups with the cup lips facing the correct direction Install the main piston spring and snap ring Install the rubber cover Install the brake lever 13 11 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK Place the brake master cylinder on the Punch Mark Bolts handlebar and install the holder with up mark facing up Be sure to align the punch mark with the holder joint First tighten the upper bolt and then tighten the lower bolt Torque 1 0 1 4kg m Up Mark Install the brake fluid pipe with the attaching bolt and two sealing washers Install the handlebar covers gt 12 3 Fill the brake reservoir with recommended brake fluid to the upper limit and bleed air according to the method stated in 13 12 BRAKE CALIPER FRONT Removal Remove the brake caliper gt 13 13 Place a clean container under the brake caliper and disconnect the
16. When installing the drive face nut make sure that the tooth spaces of the drive pulley face and starting ratchet align with the teeth of the crankshaft 3 12mm Washer RRS Starting Ratchet 8 8 8 KICK STARTER DRIVE PULLEY CLUTCH DRIVEN PULLEY DRIVE PULLEY REMOVAL Hold the drive pulley with the holder and remove the 12mm drive face nut Remove the starting ratchet 12mm washer and drive pulley face MOVABLE DRIVE FACE DISASSEMBLY Remove the movable drive face and drive pulley collar from the crankshaft Movable Drive Face Remove the ramp plate Ramp Plate SiN US eT 1 xu ELS uj 1 i LT 1s J Te marie k DUE TP _ TE 8 KICK STARTER DRIVE PULLEY CLUTCH DRIVEN PULLEY Remove the weight rollers Weight Roller MOVABLE DRIVE FACE INSPECTION Check each weight roller for wear or damage Measure each roller O D Service Limit 50 12 4mm replace if below DRIVE PULLEY INSTALLATION Install the drive pulley collar and movable drive face onto the crankshaft Drive Pulley Collar 8 10 8 KICK STARTER DRIVE PULLEY CLUTCH DRIVEN PULLEY Install the drive belt on the crankshaft Drive Pulley Face Install the drive face starting ratchet and 3 washer then tighten the 12mm drive face nut Torque 3 5 4 0ke m Keep grease or oil off the dr
17. b M i x a Install the brake pads the reverse order of Front Brake Caliper removal Torque 1 5 2 0kg m Keep grease or oil off the brake pads to avoid brake failure Brake Disk Measure the brake disk thickness Service Limit 3 0mm Measure the brake disk runout Service Limit 0 3mm 13 9 13 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK Brake Master Cylinder Bolts BRAKE MASTER CYLINDER Removal First drain the brake fluid from the hydraulic brake system When servicing the brake system use shop towels to cover rubber and plastic parts and coated surfaces to avoid being contaminated by brake fluid When removing the brake fluid pipe bolt be sure to plug the pipe to avoid brake fluid leakage Disassembly Snap Ring Remove the piston rubber cover and snap d phe r TORTS EAR CREER ring from the brake master cylinder s r uto oe ome 1 AMIL d F EJ A eH 3 En T Snap Ring Pliers close Remove the washer main piston and spring Master Cylinder Spring Main Piston from the brake master cylinder Clean Inside of master cylinder and brake reservotr with brake fluid 2 J Washer Snap Ring 13 10 13 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK Inspection Measure the brake master cylinder I D
18. brake fluid pipe from the caliper Do not spill brake fluid on any coated surfaces 13 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK Disassembly Remove the brake caliper seat from the brake caliper Remove the piston from the brake caliper If necessary use compressed air to squeeze out the piston through the brake fluid inlet opening and place a shop towel under the caliper to avoid contamination caused by the removed piston Check the piston cylinder for scratch or wear and replace if necessary Push the piston oil seal outward to remove it Clean the oil seal groove with brake fluid careful not to damage the piston surface 13 13 Brake Caliper Seat DOE gaudes Ton tae ae h e ASW ee M 4 H crisi Compressed Air Piston Oil Seal 13 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK Check the piston for scratch or wear Measure the piston O D with a micrometer Service Limit 25 45mm Check the caliper cylinder for scratch or wear and measure the cylinder bore Service Limit 25 30mm Assembly Clean all removed parts Apply silicon grease to the piston and oil seal Lubricate the brake caliper cylinder inside wall with brake fluid Install the brake caliper piston with grooved side facing out Install the piston with its outer end 3_ 5mm protruding be
19. carburetor reach carburetor logged canister Clogged fuel filter Remove spark plug Faulty auto fuel valve Plug not fouled or Plug fouled or O Fouled spark plug discolored discolored 2 Incorrect heat range plug Remove spark plug and install it into spark plug cap to test spark by connecting it D Fouled spark plug to engine ground 2 Faulty CDI unit Weak or mice Faulty A C generator Good spark stent spa k Faulty ignition coil P Broken or shorted high tension wire Test cylinder Faulty ignition switch compression using a compression gauge Flaws in cylinder head Faulty reed valve Seized piston D Worn cylinder and piston rings Normal Abnormal 2 Blown cylinder head compression compression A gasket Check carburetor for clogging Not Clogged Clogged D Clogged carburetor jets Check ignition timing D Faulty CDI unit or A C 2 flywheel aligned Check carburetor atr screw adjustment D Mixture too rich turn Correctly adjusted screw out Mixture too lean turn screw in 1 SPECIFICATIONS Inspection Adjustment Probable Cause Check carburetor gasket for air leaks D Carburetor not securely tightened gasket Deformed or broken carburetor O rIng Remove auto bystarter connecting wire and check if bypass fuel line is clogged OO D Broken cable Not clogged Clogged Dirty auto b
20. coil Pulser coil resistance 20 C Ignition timing 2 11 10 without plug cap Service Limit mm BAIOAB AC 0 2 182 8 2 0 111 2 0 2 0 0 30 BAIOAB AC 12 4 13 0_ 13 2V 0 4 5 4A 0 5H BRSHSA 0 06 0 7mm 0 153 0 1870 6 99 10 21KQ 3 204 3 96KQ 80 1600 8 14 1 5 BTDC2000rpm 2 GENERAL INFORMATION TORQUE VALUES ENGINE Cylinder head bolt Clutch drive plate nut Clutch outer nut BF7x115 Engine mounting bolt Engine hanger bracket bolt Exhaust muffler Joint lock nut Exhaust muffler lock bolt Spark plug BF10x50 8 35 Handlebar lock nut Steering stem lock nut Steering top cone race Front axle nut Rear axle nut Rear brake arm bolt Front shock absorber upper mount bolt lower mount bolt hex bolt Front damper nut Front pivot arm bolt Rear shock absorber upper mount bolt lower mount bolt lower joint nut Thread dia mm Thread dia mm cold Flange bolt U nut Flange U nut Flange U nut Flange nut 11 0 130 Flange bolt U nut Cross head Apply locking agent Flange screw U nut Flange nut Torque specifications listed above are for important fasteners Others should be tightened to standard torque values below STANDARD TORQUE VALUES Torque kg m 5mm bolt nut 0 45 0 6 6mm bolt nut 0 8 1 2 8mm bolt nut 18 2 5 10mm bolt nut 3 0 4 0 12mm bolt nut 5 0 6 0 SH bolt 8mm Flange 6mm
21. combustion chamber Poor quality fuel Clutch slipping Mixture too lean 2 24 2 1 SPECIFICATIONS POOR PERFORMANCE ESPECIALLY AT IDLE AND LOW SPEEDS Inspection Adjustment Probable Cause Check ignition timing JE Faulty CDI unit Correct timing Faulty A C generator Check carburetor air screw adjustment Mixture too rich turn Correctly adjusted Incorrectly adjusted screw out Mixture too lean turn screw In Check carburetor gasket for air leaks Carburetor not securely D DII 2 Faulty intake manifold Remove spark plug gasket and e it into G Deformed carburetor spark plug cap to test O ring spark by connecting it to engine ground Faulty or fouled spark lug Faulty CDI unit Faulty A C generator Faulty ignition coil Broken or shorted high Weak or inter mood Spare mittent spark Remove auto bystarter tension wire connecting wire and Faulty ignition switch OOOO 3 check if bypass fuel line is clogged D Broken auto bystarter Not clogged Clogged wire Connect auto bystarter Faulty auto bystarter wire to battery Wait for 5 minutes then connect a hose to fuel enriching circuit and then blow the hose with mouth Clogged Not clogged 2 25 2 GENERAL INFORMATION POOR PERFORMANCE AT HIGH SPEED Inspection Adjustment Probable Cause Check ignition timing D Faulty CDI unit Correct timing Loose A C
22. down rapidly 1 round sec to check the operation of pointer Pointer moves in Pointer does not Insufficient d 7 accordance with move in accord el icient damping OI float ance with float tuel gauge Check connectors for proper connection connector Q Broken or shorted wire in fuel gauge 2 30 1 SPECIFICATIONS STARTER MOTOR 1 Starter motor won t turn Inspection Adiustment Probable Cause Check operation of stop switch b applying brake Burned out fuse Weak or dead battery Faulty stop switch Loose or disconnected connector Broken or shorted ignition switch wire Stoplight comes Stoplight does not come on GOOQ Check battery circuit by operating turn signals a Signals dim remain Faulty or weak battery Check operation of properly on or don t starter relay b depressing starter button Relay operates Relay does not aie i button operate ee 2 Faulty starter relay Connect starter Loose or disconnected motor directly to connector battery Starter motor Starter does not Faulty starter motor Faulty wire harness 2 Starter motor turns slowly or idles Inspection Adiustment Probable Cause Check battery circuit by operating turn signals Signals operate Signals dim remain properly QD Weak or dead battery Starter motor Starter motor disconnected turns slowly turns normally Faulty starter relay Rotate crankshaft D Broken or shorted sta
23. length TORQUE VALUES Rear axle nut Rear shock absorber upper mount bolt 3 5 Rear shock absorber lower mount bolt 2 4 Rear shock absorber lower joint nut 3 5 SPECIAL TOOL Rear shock absorber remover Rear shock absorber compressor TROUBLESHOOTING Rear wheel wobbling Bent rim Faulty tire Axle not tightened properly Soft rear shock absorber Weak shock absorber spring Poor brake performance Brake not adjusted properly Contaminated brake linings Worn brake linings Worn brake shoes at cam contacting area Worn brake cam Improper engagement between brake arm and wear indicator plate 11 0_ 13 0kg m 4 5kg m 3 0kg m 4 5kg m apply locking agent 14 2 14 REAR WHEEL REAR BRAKE REAR SHOCK ABSORBER REAR WHEEL Rear Axle Nut REMOVAL Remove the two exhaust muffler joint lock nuts Remove the two exhaust muffler lock bolts Remove the exhaust muffler Remove the rear axle nut to remove the rear wheel 52 2 70 ot EN d INSPECTION Measure the rear wheel rim runout Service Limits Radial 2 0mm replace if over Axial 2 0mm replace if over INSTALLATION meat Axle Nut Install the rear wheel and apply SAE30 engine oil to the axle threads Then tighten the rear axle nut Torque values Rear axle nut 1 0 13 0kg m 14 3 14 REAR WHEEL REAR BRAKE REAR SHOCK ABSORBER REAR BRAKE Remove the rear wheel gt 14 3 Inspect the rear brake drum Measure the rear brake dr
24. needle 3 57 will then remain at unless the Blue Yellow Black condenser is discharged Use the x KQ range for the Sanwa Tester Use the X 1000 range for Kowa Tester Unit KQ Probe Blue Black NEE E Blue ome eS Black 15 10 5 ELECTRICAL EQUIPMENT Ignition Switch Starter Button Starter Motor Starter Relay G Y uw R YR Ignition Switc IY Front QO Redr E Stoplight Batter 2 e e Stop Switch 15 ELECTRICAL EQUIPMENT Starter Relay STARTER RELAY INSPECTION Remove the front cover Disconnect the starter relay coupler and then remove the starter relay Connect the starter relay green yellow Red Yellow Red terminal to the 12V battery positive terminal and the relay yellow red terminal to the battery negative terminal Check for continuity between the starter relay red and red white terminals The relay 15 normal if there is continuity Red White LT Meseen STARTER MOTOR REMOVAL Bolts Disconnect the starter motor cable Remove the two bolts attaching the starter motor and remove the starter motor The installation sequence 1s the reverse of removal Starter Motor 15 12 15 ELECTRICAL EQUIPMENT STARTER MOTOR INSPECTION Starter Motor Battery Terminal Connect a battery across the starter motor and check for its operation 1 Do not turn the
25. oil inlet line from the oil pump and clip it Fill the oil pump with oil by squirting clean oil through the joint About 3cc Fill the oil line with oil and connect it to the oil pump Bleed air from the oil inlet line first then bleed air from the oil outlet line OIL OUTLET LINE BLEEDING 1 Disconnect the oil outlet line and bend it into U shape Force air out of the tube by filling it with oil 2 Start the engine and allow it to idle with the oil control lever In the fully open position Visually check the oil flow If there is no oil flowing out within 1 minute bleed air from the oil inlet line and oil pump 99 Never run the engine closed area Do not Increase the engine speed at will 4 5 Oil Outlet Line Oil Pump Oil Tube Intake Manifold Oil Outlet Line 4 LUBRICATION SYSTEM OIL TANK Oil Meter OIL TANK REMOVAL Remove the met in box gt 12 5 Remove the frame body cover gt 12 5 Remove the rear carrier gt 12 5 Remove the two bolts four nuts attaching the stay comp fuel tank Remove the oil meter connector Remove the two bolts attaching the oil tank Disconnect the oil inlet line Drain the oil inside the oil tank into a clean container Remove the oil tank The installation sequence 1s the reverse of removal Wire Connector Bolts Connect the oil line properly Bleed air from the oil pump after installation The oil tube clip
26. turning the throttle stop screw and air SCrew Idle Speed A BAIOAB AC 50 2000 100rpm Air Cleaner Screws Remove the air cleaner cover by removing the five bolts cleaner cover screws Remove the air cleaner element 3 INSPECTION ADJUSTMENT Wash the air cleaner element in detergent oil squeeze out and allow to dry Never use gasoline or organic vaporable oil with acid or alkali for washing After washing soak the element in clean engine oil SAE 15W 40 and squeeze out excess oil Reinstall the element Cylinder Compression Warm up the engine before compression test Remove the spark plug and Insert a compression gauge Open the throttle valve fully and push the starter button for 7 8 seconds to test the compression Compression 50 11 8 If the compression 15 low check for the following Leaking cylinder head gasket Worn piston cylinder If the compression 15 high 1 indicates that carbon deposits have accumulated on the combustion chamber and the piston head LUBRICATION SYSTEM Oil Filter Cleaning Disconnect the oil tube at the oil pump side and allow oil to drain into a clean container Remove the tube clip at the oil tank side and disconnect the oil tube Remove the oil filter Oil Filter 5 Squeeze out Soak In oll Squeeze out excess oil dry 3 10 3 INSPECTION ADJUSTMENT Clean the oil filter screen wi
27. unit with the flange on the fuel tank Groove OIL METER Oil Meter INSPECTION Remove the met in box gt 12 4 Remove the frame body cover gt 12 4 Disconnect the oil meter wire connectors and remove the oil meter Keep the oil meter float at the lower position Measure the resistances between the wire terminals as and Q shown in the left figure Wire Terminals Green Red _ Black Green _ Black NEM Before removing the oil meter be sure to drain the motor oil and do not allow sparks or flames near the working area Oil Meter Operation Inspection Connect the oil meter wire connectors and turn the ignition switch ON Measure the resistance between the wire terminals with the float at upper position Green Red _ Black About 3002 Light ON Before performing the following test operate the turn signals to determine that the battery circuit is normal 16 3 16 INSTRUMENT SWITCHES LIGHTS Move the oil meter float up and down to see if the oil indicator light will go out and come on If the oil indicator light does not light check for burned bulb loose wire or connector After correction check again according to the method mentioned above SWITCHES IGNITION SWITCH INSPECTION Remove the front cover gt 12 3 Disconnect the ignition switch wire couplers and check for continuity between the wire terminals 0 0 0
28. 0mm 13 20 13 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK INSTALLATION Apply grease to top and bottom ball races and install 26 steel balls on the top ball race and 29 steel balls on the bottom ball race Apply grease to the ball races again and then install the front fork Apply grease to the top cone race and install it Tighten the top cone race and then turn the steering stem right and left several times to make steel balls contact each other closely Check that the steering stem rotates freely without vertical play Top Cone Race Lock Nut Socket Wrench Install the steering stem lock nut and tighten it while holding the top cone race Torque 8 0 12 0kg m Install the handlebar gt 13 4 Install the speedometer cable Lock Nut Wrench 13 21 14 REAR WHEEL REAR BRAKE REAR SHOCK ABSORBER 18 REAR WHEEL REAR BRAKE REAR SHOCK ABSORBER SERVICE 2 42 7 14 2 TROUBLESHOOTING oseas tue 14 2 REAR WHEEL 14 3 REAR TRA eee ee g 14 4 REAR SHOCK 14 7 14 0 14 REAR WHEEL REAR BRAKE REAR SHOCK ABSORBER p BT 2 7kg m 422 11 0kg m 14 1 14 REAR WHEEL REAR BRAKE REAR SHOCK ABSORBER SERVICE INFORMATION SPECIFICATIONS Rear brake drum Rear brake lining thickness Standard mm Service Limit mm Rear shock absorber spring free
29. 1 SPECIFICATIONS TABLE OF CONTENTS SFECIFICALTIONS 1 CGENERALEINFEORNIA TION uu u uu u uu uu 2 INSPECTIONADJUSIMENT uu uuu 3 LUBRICATION SVS LEN un uu ias ene 4 ENGINE REMOVAL INSTALLATION 5 CYLINDER HEAD CYLINDER PISTON 6 ACO u u as 7 KICK STARTER DRIVE PULLEY CLUTCH DRIVEN PULLEY FINAC REDUCTION u i e umanuan aun mura 9 CRANKCASE CRANKSIIAET uu u l u suu isi 10 CARBURETOR Z i L uuu uu uzun uu 11 COV ERS 12 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FOR K A 13 REAR WHEEL REAR BRAKE REAR SHOCK ABSORBER 14 ELECTRICAL 15 INSTRUMENT SWITCHES LIGHTIS 16 1 0 1 SPECIFICATIONS SPECIFICATIONS 1850 685 1075 1270 Engine type Air cooled 2 stroke Displacement cc 49 5 cc Front wheel 37 et weight kg Rear wheel 58 5 Total 95 5 Seating capacity 2 riders 110kg Front wheel 79 Gross weight kg Rear wheel 126 5 Total 205 5 Ti Front wheel 70 90 16 42 Ires Rear wheel 90 90 16 54J Ground clearance mm 175 Braking distance m Initial speed Km h
30. 4 4m 30km h Min turning radius mm 1900 Starting motor amp kick starter Gasoline 2 stroke motor oil Cylinder arrangement Single cylinder flat ombustion chamber type Semi sphere Reed valve amp piston Bore x stroke mm 39 x 41 4 10 3 0 2 11 8kg cms 2 pm Max output kw r min 1 765 5400 kw r min Max torque kg m rpm 0 33 4600 kg m rpm Open Automatic controlled Intake Automatic controlled Port 252 Exhaust iming en Scavenge Close 2000 100 Separate type Idle speed rpm Lubrication type il pump type il filter type Plunger type Full flow filtration O IO pd 1 Lubrication oil capacity 1 1 liter Air cleaner type amp No Wet single 5 8 Plunger type Carburetor Piston dia mm Venturi dia mm 16 CDI electromagnetic Ignition Ignition system type Ignition timing F mark 8 14 1 5 BTDC 2000 rpm plug ND Spark plug gap mm 0 6 0 7 Battery capacity 12 4 Power transmission J ower to transmission gear Reduction ratio of power to ransmission Clutch type Dry multi disc clutch Transmission gear operation Automatic ype centrifugal type Transmission ratio 1 speed 1st reduction ratio Two stage reduction 3 113 0 895 2nd reduction 14 69 ratio Transmission gear type Non stage transmission 1 75 kg cms 2 0 kg cms Right amp left 45 Tire pressure Front kg cmS Rear wheel Turning an
31. 4 Grease Front Rear Brake Lever j Seat Lock Engine Oil Speedometer Cable Grease rk v Rear Wheel Speedometer Gear t Bearing Brake Cam Front Shock Absorber 4 Lower Mount Grease Brake Cam Anchor Pin Grease Engine Oil Main Stand Pivot Rear Brake Cable 2 15 2 GENERAL INFORMATION BA10AB AC WIRING DIAGRAM ITAET mecum TANTE a IS m Lt P wamani aec Iren aa cid uki set L m E m gt B E i s rm T H A tT T PASA L HI 8 uU ZG E cm u E mM miris ER um 18 Pa ac T zn Bi n T n um a 7 uf at E y vea Dm dn j PLOT LaF 7 8 LU Er FE DE re MI w C L E LENT d mmus bi rn TE 5 1 1 iaa TRE rum T oy ig Lt Im 1 g t m E m A i 1 L EE A arr E i tM VERITR ndi 2 am f 1 F Bs ER Cl Th F T R al H m Mack LOG HEE rl Aoi LA TES aT TT 11 HEP
32. 8 14 REAR WHEEL REAR BRAKE REAR SHOCK ABSORBER INSTALLATION Upper Mount Bolt u Install the rear shock absorber Install the rear shock absorber upper mount bolt and then install the lower mount bolt Torque Upper Mount Bolt 3 5 9 4 5kg m Lower Mount Bolt 24 3 0kg m Install the frame body cover gt 12 5 Lower Mount 14 9 15 ELECTRICAL EQUIPMENT Oooo 15 ELECTRICAL EQUIPMENT SERVICE 15 1 TROUBLESHOOTING 15 1 CHARGING S TEM DIU AMOR UIN sasam 15 3 Tl l 15 4 15 7 STARTIN 15 11 15 0 15 ELECTRICAL EQUIPMENT SERVICE INFORMATION GENERAL INSTRUCTIONS It is not necessary to check the battery electrolyte or fill with distilled water Remove the battery from the motorcycle for charging Do not remove the electrolyte cap Do not quick charge the battery Quick charging should only be done in an emergency Charge the battery according to the charging current and time specified on the battery When charging check the voltage open voltage with an electric tester When replacing the battery do not use a traditional battery SPECIFICATIONS Battery Charging current Spark plug gap Secondary coil with plug cap Secondary coil without plug cap Ignition coil resistance Pulser coil resistance 20 C Ignition timing TROUBLESHOOTING CHARGING SYSTEM No power
33. AB AC 0 10 38 90 0 10 1 2 03 11 98 Item Cylinder head warpage Piston O D 5mmfrombottomofpiston Cylinder to piston clearance 38 970 38 955 12 002 12 008 11 994 12 0 Piston pin hole I D Piston pin O D Piston to piston pin clearance 0 10 0 25 17005 17 017 39 0 39 025 18 20 01 20 025 20 035 20 085 13 0 107 107 2 87 9 0 40 17 03 39 05 Piston ring end gap top second Connecting rod small end I D Cylinder bore Drive belt width Drive pulley collar O D 19 97 12 4 107 5 Movable drive face ID eight roller O D Clutch outer I D Driven face spring free length Driven face O D Movable driven face I D Connecting rod big end side clearance Connecting rod big end radial clearance Crankshaft runout A B CARBURETOR BAIOAB AC enturi dia l4mm Identification number 058 Float level 8 6mm Main jet 85 Slow jet 35 Air screw opening Idle speed 2000 100rpm 2 6mm c oO yQ FI O lt Jet needle clip notch Ist notch 2 10 1 SPECIFICATIONS Axle shaft runout Rear wheel rim runout Brake drum I D Brake lining thickness Brake disk runout Rear shock absorber spring free length Front rear Front rear Front rear ELECTRICAL EQUIPMENT Voltage Batter Charging current Spark plug NGK Spark plug gap Secondary coil with plug cap Secondary
34. AL REDUCTION ASSEMBLY Install the drive shaft 1nto the left crankcase Install the final gear and final shaft into the left crankcase 9 6 9 FINAL REDUCTION Install the countershaft and gear into the left crankcase Install the resin washer onto the counter shaft Install the dowel pins and a new gasket Install the transmission case cover Install and tighten the transmission case cover bolts Install the clutch driven pulley c 8 20 Install other removed parts In the reverse order of removal Dowel Pins Resin Washer Bolts Countershaft 9 FINAL REDUCTION After installation fill the transmission case with the specified oil Place the motorcycle 116 main stand on level ground Check the sealing washer for wear or damage Specified Gear Oil SAE90 Oil Capacity at disassembly 0 12 liter at change 0 09 liter Install and tighten the oil check bolt Torque 1 0 1 5kg m Start the engine and check for oil leaks Check the oil level from the oil check bolt hole and add the specified oil to the proper level if the oil level 15 low Drain Bolt 9 8 10 CRANKCASE CRANKSHAFT CRANKCASE CRANKSHAFT SERVICE 10 2 TROUBLESHOOTING esee 10 2 CRANKCASE SEPARA TION 10 3 CRANKSHAFT REMOVAL cccscsceseseeseseseseeeeeeesesesteeaeeeeeeees 10 3 CRANKSHAFT 2 2
35. BAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK INSTALLATION Mount Bolts Install the front shock absorbers onto the steering stem Install and tighten the front shock absorber upper mount bolts Tighten the lower mount bolts Install the front fender Install the front wheel gt 13 8 Front Shock Absorber Mount Bolts FRONT FORK Lock Nut Socket Wrench REMOVAL Remove the steering handlebar gt 13 3 Disconnect the speedometer cable and front brake fluid pipe and remove the front brake caliper Remove the front wheel gt 13 5 Hold the steering stem top cone race and remove the steering stem lock nut Lock Nut Wrench Remove the top cone race and remove the front fork Be careful not to lose the steel balls 26 on top race and 19 on bottom race Inspect the ball races cone races and steel balls for wear or damage Replace if necessary Top Cone Race 13 19 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK BOTTOM CONE RACE REPLACEMENT Remove the bottom cone race using a chisel Drive a new bottom cone race into place with a proper driver Be careful not to damage the steering stem and front fork Bottom Cone Race BALL RACE REPLACEMENT Ball Race Drive out the ball races Drive in new ball races Driver Handle A Be sure to drive the ball races into place completely Outer Driver 37x4
36. E10W90 Install and tighten the oil check Torque 10 1 55 Start the engine and check for oil leaks Oil Check Bolt 3 INSPECTION ADJUSTMENT ELECTRICAL EQUIPMENT Gap Wear and m IGNITION APPARATUS Fouling Deposits 0 6 0 7mm Spark Plug Remove the frame center cover Remove the spark plug cap and spark plug Check the spark plug for wear fouling and carbon deposits Remove the fouling and carbon deposits with a spark plug cleaner or wire brush Specified Spark Plug Cracks NGK BAIOAB AC BRSHSA Spark Plug Gap 0 6_ 0 7mm Bolt Ignition Apparatus The CDI ignition timing 1s not adjust able If the timing 1s incorrect check the CDI unit ignition coil and A C generator and replace any faulty parts Remove right side rail gt 12 4 Remove the A C generator fan cover gt 7 3 Remove the four bolts attaching the fan and then remove the fan Warm up the engine and check the ignition timing with a timing light When the engine is running at the specified rpm the ignition timing 15 correct if the F mark on the flywheel aligns with the index mark on the crankcase within 1 5 Ignition Timing BAIOAB AC 8 14 1 5 BTDC 2000rpm Index Mark 3 INSPECTION ADJUSTMENT ENGINE Throttle Stop Screw BODY At High and Low Speeds The engine must be warm for accurate idle speed adjustment Adjust the idle speed to the specified range by
37. Electric Tester TH 5H The proper range for testing 1s listed below Range SP 10D TH 5H Resister A Bolt k Coupler Regulator Rectifier C Yellow A Red D Green B White 15 6 5 ELECTRICAL EQUIPMENT Ignition Coil Spark Plug M Ignition Switch Yo me A C Generator Exciter Coil Pulser Coil B Ignition witch A I Spark Plug 1es nq G x 2V4 15 20 Regulator A C Generator Rectifier 15 7 15 ELECTRICAL EQUIPMENT IGNITION COIL INSPECTION Continuity Test This test 1s to inspect the continuity of ignition coil Remove the met in box gt 12 4 Measure the resistance between the ignition coil primary coil terminals Resistance 20 0 153 0 1870 Measure the secondary coll resistance between the spark plug cap and the primary coll terminal as Figure A shown Resistance 20 C with plug cap 70 84KQ Figure A Measure the secondary coil resistance 9 between the ignition coil terminal the primary coll terminal as Figure shown Resistance 20 C without plug cap 2 5 3 2KQ O t s Wi FINE Black Ignition Coil 15 8 5 ELECTRICAL EQUIPMENT Performance Test Remove the ignition coll Ignition Coil Inspect the ignition coil with an ignition coil Ignition Coil Tester tester AC 110V 07508 0070100 Follow the ignition coil tester manufac tur
38. Fuel reaches Fuel does not 2 Clogged float valve carburetor reach carburetor Clogged charcoal canister m Clogged fuel filter Fault to fuel val Remove dius plug auto valve and install it Into spark pue cap to test spark by connecting it Fault k pl to engine ground AUY Fouled spark plug Faulty CDI unit Faulty A C generator Broken or shorted ignition coil Broken or shorted exciter coil Test cylinder Faulty ignition switch compression Burned or worn D cylinder piston compression compression Blown cylinder head Spark Jumps Weak or no spark ODONO gasket Leaking crankcase Faulty crankcase oil Start engine by follow seal ing normal starting procedure D Incorrectly adjusted idle Engine does not Engine fires but speed fire does not start 2 Air leaking through intake pipe 1 Incorrect ignition timing Remove spark plug and inspect again Wait for 30 minutes and then remove the carbu retor auto choke Flooded carburetor Dry spark plug Wet spark plug Throttle valve excessively open circuit hose and blow the hose with mouth Not clogged Clogged Faulty auto bystarter 2 21 2 GENERAL INFORMATION ENGINE STOPS IMMEDIATELY AFTER IT STARTS Inspection Adjustment Probable Cause Check if fuel reaches carburetor by loosening drain screw Empty fuel tank Fuel reaches Fuel does not a
39. N INSPECTION Horn Terminal Remove the frame front cover gt 12 3 Disconnect the horn wire couplers The horn is normal if it sounds when a 12V battery Is connected across the horn wire terminals Battery FRONT TURN SIGNAL LIGHT REPLACEMENT Remove the met in box gt 12 5 Remove the floor board gt 12 4 Remove the front tool box gt 12 4 Remove two screws attaching the turn signal light shell and the bulb Replace with new ones Replace with new bulbs of the same specifications Turn Signal Light Bulb TAILIIGHT S TO PUGHT REAR TURN S IGNAL LIGHT BULB REPLACEMENT Taillight Shell Removal Remove two screws attaching the taillight shell Remove the taillight shell and stop light bulb Remove screws attaching the rear turn signal light Remove the rear turn signal light bulbs The installation sequence 1s the reverse of removal Screws 16 7 16 INSTRUMENT SWITCHES LIGHTS INSTRUMENT Instrument Bulbs Replacement Remove the handlebar rear cover 5 12 3 Remove the bulbs and replace with new ones SPEEDOMETER REMOVAL Disconnect the speedometer cable Disconnect the speedometer wire connector Remove the three screws attaching the speedometer Remove the speedometer The installation sequence 15 the reverse of removal Screws HEADLIGHT Bulb Sockets REMOVAL BULB REPLACEMENT Remove handlebar front cover gt 12 3 Remove the bulb sockets and bulbs
40. RANKSHAFT The distance between the left crankcase oil Oil Seal seal and crankcase surface is about 1 0mm 1 0mm uv v Install and tighten the crankcase attaching bolts After assembly check the crankshaft for smooth operation 10 8 11 CARBURETOR CARBURETOR SERVICE INFORMATION uu uyu ua 11 2 TROUBLESHOOTING 11 2 THROTTLE VALVE DISASSEMBLY 11 3 THROTTLE VALVE INSTALLATION 11 4 CARBURETOR 11 5 AUTO BYSTARTER uu uu a 11 6 uu quis 11 8 FEOATLEVEC INSPECTION Ju unuy 11 10 CARBURETOR INSTALLATION 11 11 ATIS SCREW AD 11 11 11 12 POE LEANE 11 13 11 CARBURETOR 11 1 11 CARBURETOR SERVICE INFORMATION GENERAL INSTRUCTIONS i When working with gasoline keep away from sparks and flames Note the locations of O rings when disassembling and replace them with new ones during assembly i All cables fuel lines and wires must be routed and secured at correct locations i Bleed air from the oil lines whenever they are disconnected SPECIFICATIONS BAIOAB AC l4mm 8 6mm 85 35 1 0 2000 100rpm 2_ Identification number 058 SPECIAL TOOL Float level gauge
41. _ 13 0kg m Rim runout at rim end Front Axial 2 0mm Radial 2 0mm Rear Axial 2 0mm Radial 2 0mm Rear wheel transmis sion case u 3 2 level Oil check bolt hole at lower hole edge Plug gap 0 6 0 7mm 3 INSPECTION ADJUSTMENT Fre Ist Every 6 month months months Q uenc 2 Judement Standards Remarks Inspection amp Maintenance Item Preride Performance and abnormal noise Conditions at low and high Body speeds Exhaust smoke Air cleaner O Oil level indicator Indicator light comes on when oil is insufficient O Oil quality and quantity O Engine O Check oil filter for clogging Fuel leakage Carburetor throttle valve and auto bystarter System eck Tue liter for Fuel level Fuel tube replacement Operation Lights amp Winke Winking action dirt and Buzzer amp Gace Steering Lock da Rearview Mirror xx Retlector Rearview mirror position O Reflector amp License Plate Dirt and damage Exhaust Joint looseness and damage uffler Exhaust muffler performance Body amp Frame Looseness and damage Every 4 years C yQ ga O O E AE ga C ge Mirror O aon 09 C Check if the abnormal O O conditions occur again Lubrication points Remove carbon deposits on Others combustion chamber O es lt 3 lt NO brea
42. any loose wire S B Before connecting a terminal check for damaged terminal cover or loose negative terminal Check the double connector cover for proper coverage and installation B Insert the terminal completely Check the terminal cover for proper coverage B Do not make the terminal cover opening face up Secure wire harnesses to the frame with their respective wire bands at the designated locations Tighten the bands so that only the insulated surfaces contact the wire harnesses 2 5 2 GENERAL INFORMATION B After clamping check each wire to make sure it is secure x A Z not squeeze wires against the weld or its clamp om B After clanping check each harness to make sure that it is not interfering with any moving or sliding parts ae N gt m When fixing the wire harnesses do not No Contac if make it contact the parts which will fy generate high heat Route wire harnesses to avoid sharp edges or corners Avoid the projected ends of bolts and screws Route wire harnesses passing through side of bolts and screws Avoid the projected ends of bolts and screws 2 6 2 GENERAL INFORMATION Route harnesses so they are neither pulled tight nor have excessive slack Protect wires and harnesses with electrical tape or tube if they contact a sharp edge or corner B When rubber protecting cover is used to protect the wire
43. ar for wear or damage Inspect the return spring for weakness or damage Inspect the kick starter spindle bushing for wear or damage Plastic Bushing Spindle Bushing Friction Spring Check the kick starter driven gear for wear or damage Check the friction spring for wear or damage Kick Starter Driven Gear 8 KICK STARTER DRIVE PULLEY CLUTCH DRIVEN PULLEY Inspect the kick starter spindle and driven Kick Starter Spindle Forcing Part gear forcing parts for wear or damage BEES SIN eae KICK STARTER INSTALLATION Install the kick starter spindle bushing and return spring onto the left crankcase cover If the hooks of the return spring can not be installed properly use a screw driver k ELVIS lt to press them into their locations respectively Kick Starter Spindle Friction Spring Kick Starter Gear Properly Install the kick starter driven gear I and friction spring as the figure shown Friction Spring 8 KICK STARTER DRIVE PULLEY CLUTCH DRIVEN PULLEY First install the washer and then the circlip onto the kick starter spindle Install the kick lever Washer Circlip LEFT CRANKCASE COVER Dowel Ems INSTALLATION First install the dowel pins and then the seal rubber Install the left crankcase cover and tighten the ten bolts diagonally Connect the drive belt cooling air tube and install the circlip For drum brake note the l
44. arger negative cable to the battery negative cable Front tool box Cover Keep flames and sparks away from a charging battery Turn power ON OFF at the charger not at the battery terminals to prevent sparks near the battery Charge the battery according to the current specified on the battery surface Charging current Standard 0 4A Quick 4 Charging time Standard 5 hours Quick 0 5 HOUR After chargng Open arcut voltage 12 8V min Power Charging Lamp Lamp Green Red Quick charging should only be done an emergency During quick charging the battery temperature should not exceed 45C Measure the voltage 30 minutes after the battery 15 charged 15 4 15 ELECTRICAL EQUIPMENT PERFORMANCE TEST Warm up the engine Remove the floor mat and front tool box cover Use a fully charged battery to check the charging system output Stop the engine and open the fuse box Disconnect the wire lead from the fuse terminal Connect an ammeter between the wire lead and fuse terminal as shown Connect the battery positive terminal to the voltmeter positive probe and battery negative terminal to the voltmeter negative probe Start the engine gradually increase engine speed to test the output 2500 1 0 min 6000 2 0A min Charging Limit Voltage 14 5 0 5 V 8000rpm If the limit voltage is not within the specified range check the regulator rect
45. as a unit Reed Valve Seat INSTALLATION Install the reed valve in the reverse order of removal Install a new gasket with the gasket Indentation aligned with the reed valve After installation check for intake air leaks 11 12 11 CARBURETOR FUEL TANK Fuel Tank Cap REMOVAL Fuel Unit e Remove the met in box gt 12 4 Remove frame body cover gt 12 5 b kece Remove the rear carrier gt 12 5 Disconnect the fuel tube and vacuum tube at the auto fuel valve Disconnect the fuel unit wire connector Remove the fuel tank mounting bolts and fuel tank Inspect the fuel unit gt 16 2 Replace the fuel unit if necessary gt 16 2 Fuel Tube Vacuum Tube TD e s gt gt l 12 FRAME COVERS FRAME COVERS SERVICE INFORMATION 12 2 FRAME COVERS 12 3 12 0 12 FRAME COVERS ASSEMBLY DRAWING 12 1 12 FRAME COVERS SERVICE INFORMATION When removing frame covers use care not to pull them by force because the cover joint claws may be damaged Items Related for Removal Handlebar front cover Headlight wire Front cover Speedometer cable and instrument light wlre connectors etc Handlebar rear cover Frame body cover Met in box rear carrier rear fender Floor board Front tool box frame body cover Front cover battery floor b
46. bearing into the driven face with the sealed end facing up Seat the snap ring in its groove Pack all bearing cavities with 5 0 5 6g grease Specified grease 230 Heat resistant grease m 8 15 8 KICK STARTER DRIVE PULLEY CLUTCH DRIVEN PULLEY Bearing Driver Pilot Drive in a new needle bearing into the driven face with the mark facing up Outer Driver 24x26mm Driven Pulley Oil Seal CLUTCH DRIVEN PULLEY ASSEMBLY First install the movable driven face onto the driven face Then install the guide roller pins O rings and a new oil seal Install the seal collar 8 16 8 KICK STARTER DRIVE PULLEY CLUTCH DRIVEN PULLEY Set the driven pulley driven face spring and clutch assembly onto the clutch spring compressor Compress the tool and install the 28mm drive plate nut Tighten the 28mm nut to the specified torque Torque 5 0 6 0kg m CLUTCH DRIVEN PULLEY INSTALLATION Install the drive belt on the clutch driven pulley and then install the clutch driven pulley onto the drive shaft Install the clutch outer Universal Holder Hold the clutch outer with the universal aaa holder Install and tighten the 10mm clutch outer nut Torque 3 5 4 5kg m Install the left crankcase cover gt 8 7 EN we W Clutch 8 17 9 FINAL REDUCTION FINAL REDUCTION SERVICE INFORMATION 9 2 TROUBLESHOOTING be pe puss
47. ccur Excessive white smoke or hard starting due to pump control lever excessively open Seized piston due to pump control lever insufficiently open 3 11 3 INSPECTION ADJUSTMENT FUEL SYSTEM Throttle Grip Free Play Measure the throttle grip free play Free Play 2_ 6mm Lock Nut If the throttle grip free play does not fall within the specified range adjust by loosening the lock nut and turning the adjusting nut Adjusting Nut OTHERS LIGHTS Headlight Adjust the headlight beam by loosening the headlight adjusting bolt and moving the adjusting bolt forward and backward to a proper position Tighten the adjusting bolt Headlight Adjusting Bolt 3 12 4 LUBRICATION SYSTEM KRE LUBRICATIONSYSTEM SERVICE INFORMATION 4 2 TROUBLESHOOTING sasecspssincasaranshoasaeduaswoseatecesnians bota uio 4 2 QILPUMDRINOVALu uuu Rasu aaa 4 3 OIL PUMP INSPECTION 4 3 OIL PUMP INSTADDATION E 4 4 OIL PUMP BLEEDING 4 5 SIEUT C 4 6 4 0 4 LUBRICATION SYSTEM LUBRICATION SYSTEM 4 1 4 LUBRICATION SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS Use care when removing and installing the oil pump not to allow dust and dirt to enter the engine and oil line Do not attempt to disassemble the oil pump Bleed air from the oil pump if there is air between the oil pump and oil line If the oil is disconnected refill the
48. ch spring compressor Bearing outer driver 37x40mm One way clutch puller TROUBLESHOOTING Engine starts but motorcycle won t move Worn drive belt Broken ramp plate Worn or damaged clutch lining Engine stalls or motorcycle creeps Broken clutch weight spring Universal holder Lock nut socket wrench 32mm Bearing driver pilot 17mm Outer driver 24x26mm Poor performance at high speed or lack of power Worn drive belt Weak driven face spring Worn weight roller Faulty driven face 6 2 8 KICK STARTER DRIVE PULLEY CLUTCH DRIVEN PULLEY KICK STARTER LEFT CRAN KCAS E CO VER REMO VAL Remove the drive belt cooling air tube connector circlip Remove the nine left crankcase cover bolts left crankcase cover and dowel pins Inspect the left crankcase cover seal rubber for damage or deterioration KICK STARTER SPINDLE REMOVAL Remove the kick lever from the kick starter spindle Remove the circlip and washer from the kick starter spindle Washer Circlip Slightly rotate the kick starter spindle to remove the kick starter driven gear together with the friction spring Kick Starter Driven Gear Friction Spring 8 KICK STARTER DRIVE PULLEY CLUTCH DRIVEN PULLEY Remove the kick starter spindle and return Kick Starter Spindle spring from the left crankcase cover Remove the kick starter spindle bushing Spindle Return Spring KICK STARTER SPINDLE INS PECTION LU Inspect the kick starter spindle and ge
49. d battery Faulty ignition switch Faulty instrument Faulty oil meter Motor oil indicator light winks Loose wire connection Broken wire Faulty oil meter Fuel gauge pointer does not register correctly Disconnected wire or connector Broken wire Faulty float Faulty fuel unit Faulty instrument Fuel gauge pointer fluctuates or swings Loose wire connection Faulty fuel unit Faulty instrument 16 INSTRUMENT SWITCHES LIGHTS Fuel Unit FUEL UNIT No Smoking REMOVAL Remove the frame body cover 12 5 Disconnect the fuel unit wire connectors Remove the three bolts attaching from the fuel unit retainer Do not damage the fuel unit wire Remove the fuel unit Fuel Unit Wire Be careful not to bend or damage the fuel unit float arm INSPECTION Remove the fuel unit Measure the resistance between the fuel unit wire terminals with the float at upper and lower Y W L W FUEL GAUGE INSPECTION Connect the fuel unit wire connectors and turn the ignition switch ON Before performing the following test operate the turn signals to determine that the battery circuit is normal Check the fuel gauge needle for correct indication by moving the fuel unit float up and down Position Pull Lower E Empty 16 2 16 INSTRUMENT SWITCHES LIGHTS INSTALLATION The installation sequence 1s the reverse of removal Align the groove on the fuel
50. e the floor board gt 12 4 Open the front tool box and remove the battery Remove the switch covers Remove the nut attaching and six screws the front tool box Remove the front tool box The installation sequence 15 the reverse of removal When removing the battery first disconnect the battery negative cable Front Tool Box and then the positive cable When taking the front tool box pull them up and backward from downside not to damage the claws BOTTOM COVER REMOVAL Screws Remove the flood board gt 12 4 Remove the three screws each side of the bottom cover Remove the bolt attaching the side stand Remove the bottom cover The installation sequence 15 the reverse of removal Bottom Cover Bolt 12 FRAME COVERS MET IN BOX REMOVAL Met in Box Rubber Packing Oil Tank Cap Open the seat Remove the two bolts two nuts attaching the met in box Remove the oil tank cap rubber packing and fuel tank cap Remove the met in box The installation sequence 1s the reverse of removal Nuts fuel tank cap Bolts Bolts REAR CARRIER REMOVAL Remove the three bolts attaching the rear carrier Remove the rear carrier The installation sequence 15 the reverse of removal Rear Carrier REAR FENDER REMOVAL Remove the two screws the rear fender Remove the rear fender The installation sequence 15 the reverse of removal Screws Rear Fender 12 5 12 FRAME COVERS
51. ear brake lever free play 53 4 Brake Arm Pin Adjusting Nut 14 6 14 REAR WHEEL REAR BRAKE REAR SHOCK ABSORBER REAR SHOCK ABSORBER Upper Mount Bolt Rear Shock Absorber REMOVAL _ Remove the front cover gt 12 6 Remove met in box 12 5 Remove air cleaner case 5 2 Remove the rear shock absorber upper and lower mount bolts to remove the rear shock absorber Lower Mount Bolt Rear Shock Absorber Compressor DISASSEMBLY Install the rear shock absorber compressor as the figure shown Install the rear shock absorber lower joint into the rear shock absorber compressor Compress the rear shock absorber spring Rear Shock Absorber Remover Loosen the lower joint lock nut Lock Nut Remove the lower joint Remove the lock nut rubber and damper 14 7 G 14 REAR WHEEL REAR BRAKE REAR SHOCK ABSORBER INSPECTION Inspect the damper rod for bending or damage Inspect the damper for oil leaks Inspect the damper rubber for deterioration or damage Measure the rear shock absorber spring free length Service Limit 232mm replace if below m ASSEMBLY Assemble the rear shock absorber in the reverse order of disassembly Install the shock absorber spring with loosely wound coils facing down Apply locking agent to the lock nut thread and then install and tighten the lock nut Tighten the lock nut Torque 3 5 4 5kg m 14
52. ents after installation Throttle cable Oil pump control cable 3 11 Rear brake cable 3 5 Oil pump bleeding 73 11 5 4 6 CYLINDER HEAD CYLINDER PISTON CYLINDER HEAD CYLINDER PISTON DER VICE INFORMATION uu i uyu yere os vob ades 6 2 TROUBLESHOOTING eceran 6 2 6 3 CXLINDER PISTODNN 6 6 6 0 6 CYLINDER HEAD CYLINDER PISTON Torque 0 8 1 2kg m Torque 1 1 7kg m 1_ Sy cold Torque 1 5 1 7kg m 6 1 6 CYLINDER HEAD CYLINDER PISTON SERVICE INFORMATION GENERAL INSTRUCTIONS The cylinder head cylinder and piston can be serviced with the engine installed in the frame Before disassembly clean the engine to prevent dust from entering the engine Remove all gasket material from the mating surfaces Do not use a driver to pry between the cylinder and cylinder head cylinder and crankcase Do not damage the cylinder inside and the piston surface After disassembly clean the removed parts before inspection When assembling apply the specified engine oil to movable parts SPECIFICATIONS Item Cylinder head warpage Piston O D 5mm from bottom of piston Cylinder to piston clearance Piston pin hole I D Piston to piston pin clearance Piston ring end gap top second Connecting rod small end I D 5 lt gt MN Cylinder bore Cylinder head bolt 15 1 7k
53. er s instructions 1 Turn the changeover switch to 12V and connect the ignition coil to the tester 2 Turn the power switch ON and check the spark from the watch window Good Normal and continuous spark _Faulty Weak or intermittent spark lt 5 2 The test is performed at both conditions Black Red that the ignition coil 1s cold and hot A C GENERATOR Exciter Coil Pulser Coil Inspection This test 1s performed with the stator installed in the engine Remove the met in box gt 12 4 Disconnect the A C generator wire connector Measure the pulser coil resistance between the blue yellow wire and ground Resistance 20 100_ 1500 Blue Yellow 15 9 15 ELECTRICAL EQUIPMENT CDI UNIT INSPECTION Remove the battery cover Disconnect the CDI coupler and remove the CDI unit Coupler r CDI Unit CDI CIRCUIT INSPECTION Measure the resistance between the terminals Replace the CDI unit if the readings are not within the specifications in the table below Black Yellow Green Due to the semiconductor In circuit it 1s necessary to use a specified tester for accurate testing Use of an improper tester in an improper range may give false readings Use a Sanwa Electric Tester or Kowa Electric Tester TH 5H In this table Needle swings then returns indicates that there is a charging current app lied to a condenser The
54. er hole in the flywheel off any burrs and dirt Install the woodruff key in the crankshaft keyway Install the flywheel onto the crankshaft with the flywheel groove aligned with the crankshaft woodruff key Hold the flywheel with the universal holder and install the 10mm flywheel flange nut Torque 3 5 4 0kg m start the engine and check the ignition timing 3 8 Install other removed parts in the reserve order of removal 9 KICK STARTER DRIVE PULLEY CLUTCH DRIVEN PULLEY KICK STARTER DRIVE PULLEY CLUTCH DRIVEN PULLEY 8 SERVICE 1 22022 0 000000000004 8 3 TROUBLESHOOTING atis toti eee 8 3 ere M 8 4 LIYE D LI T 8 8 DRIVE PULLEY a 8 10 STARTER ONE WAY CLUTCH DRIVE 8 12 CLUTCH DRIVEN PULLEY sees 8 15 8 0 8 KICK STARTER DRIVE PULLEY CLUTCH DRIVEN PULLEY MODEL BAI0AB AC Torque Torque 3 5 4 5kg m 8 1 9 KICK STARTER DRIVE PULLEY CLUTCH DRIVEN PULLEY SERVICE INFORMATION GENERAL INSTRUCTIONS Avoid getting grease and oil on the drive belt and pulley faces SPECIFICATIONS BAIOAB AC 50 Savio Limit mm 24 24 19 97 12 4 107 5 82 6 33 94 34 06 L TORQUE VALUES Drive face nut 3 5 4 0kg m Clutch outer nut 3 5 4 5 Clutch drive plate nut 5 0 6 0kg m SPECIAL TOOLS Lock nut wrench 39mm Clut
55. g m Exhaust muffler joint lock nut 1 0 1 4 Exhaust muffler lock bolt 30 3 6kg m Spark plug l 1 7 TROUBLESHOOTING Compression too low hard starting or poor performance at low speed Leaking cylinder head gasket Loose spark plug Worn stuck or broken piston and piston rings Worn or damaged cylinder and piston Compression too high overheating or knocking Excessive carbon build up cylinder head or on piston head Standard mm 50 39 0 service Limit mm BAIOAB AC 50 38 90 12 03 11 98 1 7 03 39 025 39 05 Abnormal noisy piston Worn cylinder and piston Worn piston pin or piston pin hole Worn connecting rod small end bearing Abnormal noisy piston rings Worn stuck or broken piston rings Worn or damaged cylinder 6 2 6 CYLINDER HEAD CYLINDER PISTON CYLINDER HEAD REMOVAL Remove the rear carrier Remove frame body cover 12 5 Remove the spark plug cap Remove the three bolts attaching the fan cover to remove the fan cover Remove the two joint lock nuts on the front of the exhaust muffler and then remove the two exhaust muffler lock bolts Remove the bolt attaching the engine hood to remove the engine hood The installation sequence 15 the reverse of removal When installing the exhaust muffler first tighten the two nuts on the front Bolt and then tighten the two bolts um Remove the spark plug Cylinder Head Cyl
56. gle Brake svstem Front Expanding hydraulic ype Rear wheel Expanding Suspension Front Telescope ype Rear wheel Unit swing Shock absorber Front Telescope ype Rear wheel Unit swing rame type Pipe under bone 2 GENERAL INFORMATION gt GENERAL INFORMATION ENGINE SERIAL NUMBER IDENTIFICATION e 2 1 SERVICE PRECAUTIONS nennen annern 25 9 SERVICE 1 2 10 TORQUE 7 6 2 12 SPECIAL TOOLS U Uu uuu susunan uqaqa 2 13 LUBRICATION POINTS Uu uu uu 2 15 WIRING uu uu 2 16 CABLE amp HARNESS ROUTING eene 2 18 TROUBLESHOOTING ccccccccsseseessesseesecssessecsecsecssesssessesseeseens 2 22 2 0 2 GENERAL INFORMATION ENGINE SERIAL NUMBER IDENTIFICATION a s J _ 8 Location of Engine Serial Number 2 1 2 GENERAL INFORMATION SERVICE PRECAUTIONS Make sure to install new gaskets O rings circlips cotter pins etc when reassembling B When tightening bolts or nuts begin with larger diameter to smaller ones at several times and tighten to the specified torque diagonally Use genuine parts and lubricants s When servicing the motorcycle be sure to use special tools for removal and installation After disassembly clean removed parts Lubricate sliding surfaces with engine o
57. h the crankshaft in cleaning solvent and then check for cracks or other faults After check apply clean engine oil to all moving and sliding parts Remove all gasket material from the crankcase mating surfaces Dress any roughness or irregularities with an oil stone 10 5 10 CRANKCASE CRANKSHAFT Drive a new crankshaft bearing into the right crankcase Drive a new crankshaft bearing into the left crankcase Install the crankshaft into the left crankcase Apply ULTRA motor oll or molybdenum disulfide to the crank shaft bearings and connecting rod big end Apply grease to the lip of the oil seal and then install it Bearing Outer Driver Handle A Bearing Outer Driver 37x40mm Bearing Driver Pilot 17mm Bearing Outer Driver Handle A Bearing Outer Driver 42x47mm Pilot 20mm Crankcase Assembly Tool K Crankcase Assembly Collar 10 6 10 CRANKCASE CRANKSHAFT CRANKCASE ASSEMBLY m Dowel Pins ym m quce Fi Install the dowel pins and a new gasket to the crankcase mating surface Assemble the crankcase halves mE oe Crankcase Assembly Tool The distance between the right crankcase oil Crankcase Assembly Collar seal and crankcase surface 1s about 12 5 0 5 mm When installing the oil seal be careful to press it with even force Crankcase Assembly Tool 10 7 10 CRANKCASE C
58. harnesses it shall be installed securely B Do not break the sheath of wire B fa wire or harness is with a broken sheath repair by wrapping it with protective tape or replace it B When installing other parts do not press or squeeze the wires 2 7 Do not press or squeeze the 2 GENERAL INFORMATION B After routing check that the wire harnesses are not twisted or kinked C Wire harnesses routed along with handlebar should not be pulled tight have excessive slack or interfere with adjacent or surrounding parts in all steering positions sre Do you understand m When a testing device is used make sure to the instrument Is understand the operating methods the instrument set thoroughly and operate according to the correctly operating instructions Be careful not to drop any parts When rust is found on a terminal remove the rust with sand paper or equivalent aus uae before connecting 2 GENERAL INFORMATION Symbols The following symbols represent the servicing methods and cautions included in this service manual Apply engine oil to the specified points Use designated engine oil for lubrication Engine Oil Apply grease for lubrication Grease Use special tool Special x Caution V Warning 2 9 2 GENERAL INFORMATION SERVICE INFORMATION ENGINE Standard mm BAIOAB AC service Limit mm BAIO
59. he main jet and needle jet holder x Air Screw CARBURETOR PASS AGES CLEANING Blow compressed air through all passages of the carburetor body with an air gun 11 9 11 CARBURETOR FLOAT CHAMBER ASSEMBLY Main Jet Needle Jet holder Install the main jet and needle jet holder T Install air screw and throttle stop screw according to the rotations recorded If the air screw must be replaced be sure to perform the air screw adjustment again Throttle Stop Screw Air Screw Install the float valve float and float pin Tighten the float screw securely FLOAT LEVEL INSPECTION Slightly tilt the carburetor and measure the float level with the float valve just connecting the float arm Float Level 8 6mm Replace the float if the level is out of the specified level range Install the O ring Check the operation of the float and install the float chamber Tighten the screws 11 10 11 CARBURETOR CARBURETOR INSTALLATION When installation do not allow foreign particles to enter the carburetor Check the carburetor insulator and O ring for wear or damage Install the carburetor and insulator onto the intake manifold and tighten the two lock nuts Connect the fuel tube and auto bystarter wire connector e if k Route the auto bystarter wire correctly Insulator and properly Install the carburetor cap gt 11 4 Install the air cleane
60. ifier A C GENERATOR CHARGING COIL INSPECTION Inspect with the engine installed Remove the met in box gt 12 4 Disconnect the A C generator connector Measure the resistances between the charging coil terminals whitefigreen and lighting coil terminals yellowfgreen Resistances 0 2_ 1 2 9 Lighting vellowrigreen 0 3 1 0 Q Refer to 7 3 for A C generator removal 15 5 Generator Connector we TW ml T L e y h gt 15 ELECTRICAL EQUIPMENT RESISTOR INSPECTION Remove the frame front cover gt 12 3 Measure the resistance between the resistor B pink wire and ground Measure the resistance between the resistor A green black wire and ground Resistances Resistor A 9 9 12 00 Resistor B 5 6 720 Faulty resistor 18 the cause of faulty operation of the auto bystarter REGULATOR RECTIFIER INSPECTION Remove the front cover gt 12 3 Disconnect the regulator rectifier wire coupler and remove the bolt to remove the regulator rectifier Measure the resistances between the terminals Replace the regulator rectifier if the readings are not within the specifications in the table below Due to the semiconductor In circuit it is necessary to use a specified tester for accurate testing Use of an improper tester In an improper range may give false readings Use a Sanwa Electric Tester 07208 0020000 or Kowa
61. il before reassembly 2 2 2 GENERAL INFORMATION Apply or add designated greases lubricants to the specified lubrication points B After reassembly check all parts for proper tightening and operation When two persons work together attention to the mutual working safety Disconnect the battery negative terminal before operation When using a spanner or other tools make sure not to damage the motorcycle surface B After operation check all connecting points fasteners and lines for proper connection and installation When connecting the battery the positive terminal must be connected first After connection apply grease to the battery terminals B Terminal caps shall be installed securely 2 3 2 GENERAL INFORMATION B f the fuse is burned out find the cause and repair it Replace it with a new one according to the specified capacity After operation terminal caps shall be installed securely B When taking out the connector the lock on the connector shall be released before operation Hold the connector body when connecting or disconnecting it B Do not pull the connector wire Check if any connector terminal is bending protruding or loose 2 GENERAL INFORMATION B The connector shall be inserted completely E If the double connector has a lock lock x Snapping it at the correct position Check if there is
62. inder head Bolts Remove the cylinder head bolts and the me 7 8474 ER cylinder head Loosen the bolts diagonally in 2 or 3 times Remove the cylinder head gasket Spark Plug 6 CYLINDER HEAD CYLINDER PISTON Combustion Chamber COMBUSTION CHAMBER DECABONIZING Remove the carbon deposits from the combustion chamber Avoid damaging the combustion cham ber wall and cylinder mating surface Mating Surface CYLINDER HEAD INSPECTION Check the cylinder head for warpage with a straight edge and feeler gauge Service Limit 50 0 10mm replace if over CYLINDER HEAD INSTALLATION Install the cylinder head on the cylinder properly careful not to damage the matine surfaces Install a new cylinder head gasket onto the cylinder 6 CYLINDER HEAD CYLINDER PISTON Cylinder Head Bolts Installation Install and tighten the cylinder head bolts diagonally in 2 or 3 times Torque 1 5 1 7kg m Install the spark plug Torque l 1 7kg m 3 f Cylinder Head Spark Plug Engine Hood Installation Spark Plug Engine Hood Install the engine hood gt 6 3 Install the spark plug cap gt 6 3 Perform the following inspections after installation Compression test Abnormal engine noise Cylinder air leaks Bolt Bolts 6 CYLINDER HEAD CYLINDER PISTON CYLINDER PISTON CYLINDER REMOVAL Remove the met in box and seat Remove the frame body cove
63. installation Flywheel holding Flywheel removal Drive shaft bearing installation Drive shaft bearing installation Final shaft bearing installation 2 GENERAL INFORMATION Tool Name Tool No Remarks Drive shaft bearing installation Final shaft Bearing outer driver 37x40mm bearing installation Crankshaft bearing installation Outer driver 24x26mm Driven pulley bearing installation Front wheel bearing installation Bearing driver pilot 17mm Drive shaft bearing installation Snap ring pliers close Circlip removal installation Bearing outer driver 42x47mm Crankshaft bearing installation Crankshaft bearing installation Bearing installation Drive in ball race Bearing outer driver handle A Bearing puller head 10mm Front wheel bearing removal niversal bearing puller Crankshaft bearing removal Bearing puller Front wheel bearing removal Pressure tester set Cylinder compression gauge gt Y O o e e NO c 3 3 3 3 2 14 1 SPECIFICATIONS LUBRICATION POINTS ENGINE Lubricant Remarks 1 Crankease sliding amp movable parts JASO FC or API TC 2 Cylindermovableparts 3 Transmission gear final gear SAE 908 7 4 Kick starter spindle bushing 6 Starter pinion movable parts Grease Apply clean engine oil or grease to cables and movable parts not specified This will avoid abnormal noise and rise the durability of the motorcycle Engine Oil Throttle Cable bey
64. it mm 0 04 0 15 0 10 Bearing outer driver handle A Bearing outer driver 42x47mm Bearing driver pilot 20mm Bearing outer driver 37x40mm Bearing driver pilot 17mm 10 2 10 CRANKCASE CRANKSHAFT CRANKCASE SEPARATION Remove the crankcase attaching bolts Attach the crankcase puller on the right Crankcase Puller crankcase and remove the right crankcase from the left crankcase CRANKSHAFT REMOVAL Crankcase Puller Attach the crankcase puller on the left crankcase and remove the crankshaft from the left crankcase When removing the crankshaft do it slowly and gently 10 3 10 CRANKCASE CRANKSHAFT Remove the remaining bearing on the crankshaft side using the universal bearing puller When separating the crankcase the oil seals must be removed Replace the oil seals with new ones CRANKSHAFT INSPECTION Measure the connecting rod big end side clearance Service Limit 0 6mm replace if over pe AM i E 1 vir Measure the connecting rod big end radial clearance at two points in the X and Y directions Service Limit 0 04mm replace if over 0 CRANKCASE CRANKSHAFT Measure the crankshaft runout Service Limit 0 150mm 0 100mm replace if over replace if over Check the crankshaft bearings for excessive play The bearings must be replaced if they are noisy or have excessive play Axial Radial CRANKSHAFT INSTALLATION Was
65. ive belt and drive pulley faces STARTER PINION REMOVAL Remove the left crankcase cover 5 8 4 Remove the drive pulley gt 8 8 Remove the starter pinion Starter Pinion Inspect the starter pinion seat for wear Inspect the starter pinion for smooth ali operation Inspect the starter pinion shaft forcing parts for wear and damage INSPECTION Shaft Forcing Parts INSTALLATION Apply a small amount of grease to the starter pinion teeth Install the starter pinion in the reverse order of removal Starter Pinion 9 11 8 KICK STARTER DRIVE PULLEY CLUTCH DRIVEN PULLEY CLUTCH DRIVEN PULLEY ee CLUTCH DRIVEN PULLEY REMOVAL Remove the drive pulley gt 8 8 Hold the clutch outer with the universal holder and remove the 10mm clutch outer nut Remove the clutch outer 10mm Clutch Outer Nut Remove the clutch driven pulley Clutch Driven Pulley Remove the drive belt from the clutch driven pulley CLUTCH DRIVEN PULLEY DIS Lock Nut Wrench 39mm ASSEMBLY Compress the clutch driven pulley spring with the clutch spring compressor and remove the 28mm drive plate nut Remove the driven face spring Clutch Spring Compressor 8 12 8 KICK STARTER DRIVE PULLEY CLUTCH DRIVEN PULLEY Remove the seal collar 3 is Seal Collar Driven Pulley Oil Seal Pull out the guide roller pins from the driven pulley and then remove the O
66. ke system use shop towels to cover plastic parts and coated surfaces to avoid damage caused by spill of brake fluid Brake Fluid Bleeding In order to avoid spill of brake fluid connect Lower Limit a transparent hose to the bleed valve Brake fluid spilled on brake pads or brake disk will reduce the braking effect Clean the brake pads and brake disk with a high quality brake degreaser Fully apply the brake lever and then loosen the brake caliper bleed valve to drain the brake fluid until there is no air bubbles in the brake fluid Then tighten the bleed valve Repeat these steps until the brake system is free of atr Brake Fluid Refilling Add DOT 3 brake fluid to the brake reservoir When bleeding be careful not to allow air in the brake reservoir flowing into the brake system When using a brake bleeder follow the manufacturer s instructions Never use dirty or unspecified brake fluid or mix different brake fluids be cause it will damage the brake system Make sure to bleed air from the brake system 13 8 13 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK Brake Pad Disk Replacement The brake pads must be replaced as a set to ensure the balance of the brake disk Remove the two bolts attaching the brake caliper Remove the brake caliper Remove the brake pads gt po na gt gy Fs Front Brake Caliper
67. le Remove the handlebar lock nut to remove Handlebar the handlebar Nut Bolt 13 3 13 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK INSTALLATION Install the handlebar aligning the tabs of the handlebar with the grooves in the steering stem Install and tighten the handlebar lock nut Torque 4 5 5 0 Lubricate the throttle pipe front end with grease Install the throttle grip and connect the throttle cable The installation sequence 15 the reverse of removal Install the rear brake lever holder Install the front brake master cylinder disk brake Tab Groove 97 A a s gt F T ta F Throttle Cable Brake Master Cylinder Holders 13 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK FRONT WHEEL Speedometer Cable REMOVAL DISK BRAKE Jack the motorcycle front wheel off the ground Remove the speedometer cable set screw and disconnect the speedometer cable Remove the front axle nut and pull out the axle Remove the front wheel Remove the brake panel side collar Axle Nut INSPECTION Set the axle in V blocks and measure the runout The actual runout is _ of the total indicator reading Service Limit 0 2mm replace if over Check the wheel rim runout Service Limits Radial 2 0mm replace if over Axial 2 0mm replace if
68. m 7 A C GENERATOR SERVICE INFORMATION GENERAL INSTRUCTIONS All A C generator maintenance and inspection can be made with the engine installed Refer to Section 15 for A C generator inspection TORQUE VALUE Flywheel nut 3 5 4 0kg m SPECIAL TOOLS Flywheel puller Universal holder 7 2 7 A C GENERATOR A C GENERATOR REMOVAL Remove the three bolts attaching the fan cover to remove the fan cover Fan Cover Bolts Remove the cooling fan by removing the Bolt four bolts Cooling Fan Hold the flywheel with an universal holder and then remove the 10mm flywheel nut 2 PAIN De q k40000 5x 72 7 A C GENERATOR Remove the A C generator flywheel using Lock Nut Wrench the flywheel puller Flywheel Puller Remove the A C generator wire connector A C Generator Wire Connector 7 Remove two pulser coil bolts and pulser coil from the right crankcase Remove the pulser coil wire clamp from the right crankcase Remove the two bolts attaching the A C generator stator Be careful not to damage the discon nected wire A C GENERATOR INSTALLATION Install the A C generator stator and pulser Pulser coil wire clamp onto the right crankcase and then install the pulser coil Stator Wire Clamp 7 4 7 A C GENERATOR Connect the A C generator wire connector A C Generator Wire Connector iw RE Clean the tap
69. m Water and mud in brake system Oil or grease on brake linings Brake performance is Expanding poor Brake Hydraulic Brake Faulty brake master cylinder Faulty brake caliper Oil or grease on brake disk Deformed brake disk Leaking brake fluid tube ONONO 2 28 1 SPECIFICATIONS OIL METER 1 Motor oil indicator light does not come on when there 15 no motor oil Ignition switch ON Inspection Adjustment Probable Cause Check battery circuit by operating turn signals Burned out fuse Weak or dead battery Faulty ignition switch Loose or disconnected connector Signals operate Signals dim remain properly on or don t Broken wire harness Bulb lights Bulb does not light Burned out bulb OOO Connect indicator light bulb to battery for bulb inspection Loose wire connector Faulty Broken wire harness Check connectors for proper operation Incorrectly connected Remove oil meter and wire check operation of indicator light by moving float Faulty float Broken or shorted wire in meter Float up Light off Float down Light on N 2 Motor oil is sufficient but the indicator light remains on Ignition switch ON Inspection Adjustment Probable Cause Loose or disconnected Check connectors for proper connection Good y Broken wire harness Remove oil meter and Incorrectly connected check operation of wire indicator light by moving floa
70. nder has an A mark or no mark on it When replacing the cylinder with a new one use a cylinder having the same mark as the old one Measure the piston O D at a point 5mm from the bottom of the piston skirt Service Limit 50 38 90mm replace if below Measure the piston to cylinder clearance Service Limit 50 0 10mm replace if over Measure the piston pin hole I D Service Limit 50 12 03mm replace if over Measure the piston pin O D Service Limit 50 11 98mm replace if below Measure the piston to piston pin clearance Service Limit 50 0 03mm replace if over 6 CYLINDER HEAD CYLINDER PISTON PISTON RING INSPECTION Measure each piston ring end gap Bs ix AE eas Service Limits Top Second iig ts 50 0 40mm replace if over i 1 T D E E s Set each piston ring squarely into the cylinder using the piston and measure the end gap CONNECTING ROD SMALL END INSPECTION Install the piston pin and bearing in the connecting rod small end and check for excessive play Measure the connecting road small end I D Service Limit 50 17 03mm replace if over PISTON CYLINDER INSTALLATION Piston First install the expander in the second ring L Top Ring Ist Ring groove Then install the top and second
71. ne race Broken steering balls Insufficient tire pressure Steers to one side or does not track straight Broken clutch weight spring Bent front fork Bent front axle or uneven tire Poor brake performance Incorrectly adjusted brake Worn brake linings Contaminated brake lining surface Worn brake cam Worn brake drum Poorly connected brake arm Poor brake performance disk brake Air in brake system Deteriorated brake fluid Contaminated brake disk or disk pad Worn brake bushing Worn brake master cylinder piston oil seal Clogged brake fluid line Deformed brake disk Unevenly worn brake caliper Front wheel wobbling Bent rim Loose front axle Bent spoke plate Faulty tire Improperly tightened axle nut Soft front shock absorber Weak shock springs Insufficient damper oil Front shock absorber noise Slider bending Loose fork fasteners Lack of lubrication 13 2 13 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK STEERING HANDLEBAR REMOVAL Brake Master Cylinder Remove the handlebar front and rear covers gt 12 3 Remove two bolts attaching the left brake lever holder Remove two bolts attaching the brake master cylinder disk brake to the right brake lever Bolts Bolts Remove the two right handlebar switch housing bolts and separate the housing Bolts Throttle Pipe Disconnect the throttle cable and then remove the throttle pipe from the handlebar Throttle Cab
72. oard 12 2 12 FRAME COVERS FRAME COVERS REMOVAL Front Cover Screws FRONT COVER REMOVAL 7A Remove the screw the front cover Remove the two screws on the back of the front cover Push the two inside claws of the downside front cover to float the front cover Remove the front cover downward The installation sequence 1s the reverse of removal Ty k During removal be careful not to pull sa the joint claws forcibly Screw Front Tool Box HANDLEBAR FRONT REAR COVER Screws Handlebar Rear Cover REMOVAL First remove the one screws attaching the handlebar front cover Remove the handlebar front cover Disconnect the headlight wire connector Remove the handlebar rear cover Remove the four screws and bolt attaching the handlebar rear cover Disconnect the speedometer cable and instrument light wire connectors Remove the handlebar rear cover The installation sequence 15 the reverse of removal Screws Screws 12 3 12 FRAME COVERS FLOOR BOARD REMOVAL Remove the rear carrier gt 12 5 Remove frame body cover gt 12 6 Remove the front cover gt 12 3 Remove the four bolts attaching and six screws the floor board to remove the floor board The installation sequence 1s the reverse of removal Floor Board SCICWS FRONT TOOL BOX REMOVAL Remove the rear carrier gt 12 5 Nut Battery Remove frame body cover gt 12 6 Remov
73. ocation of the brake cable clamp and install the rear brake cable In place with the clamp Rear Brake Cable Clamp 9 KICK STARTER DRIVE PULLEY CLUTCH DRIVEN PULLEY DRIVE BELT Remove the left crankcase cover INSPECTION Check drive belt for cracks separation or abnormal or excessive wear Measure the drive belt width Service Limit 50 16 5mm replace if below Use specified genuine parts for replace ment REPLACEMENT Cay Remove the ten left crankcase cover bolts 2 and left crankcase cover 8 4 Hold the clutch outer with the universal y AM holder and remove the 10mm clutch outer nut and clutch outer Universdl Holder Hold the drive pulley with the holder and Ratchet Drive Face remove the 12mm drive face nut 5 Remove the starting ratchet Remove the drive pulley face Drive Face Nut 8 KICK STARTER DRIVE PULLEY CLUTCH DRIVEN PULLEY Remove the drive belt from the clutch Clutch Driven Pulley driven pulley wa wasa Drive Belt DRIVE BELT INSTALLATION Drive Belt Turn the driven pulley clockwise and lift it up to expand the drive belt groove and Install a new drive belt Set the drive belt on the drive pulley Install the drive pulley face starting ratchet and 12mm washer then tighten the drive face nut Torque 3 5 4 0kg m Drive Face Nut Drive Pulley Face Drive Belt NE
74. oil line with motor oil before connecting it SPECIFICATIONS Recommended Motor Oil SAE20W20 2 stroke Motor Oil Oil Capacity 1 1 liter Light comes 0 5 liter TROUBLESHOOTING Excessive white smoke or carbon deposits on spark plug Oil pump not properly synchronized excessive oil Poor quality oil Engine overheating Oil pump not properly adjusted insufficient oiling Poor quality oil Seized piston No oil in tank or clogged oil line Oil pump not properly adjusted insufficient oiling Air in oil line Faulty oil pump Oil not flowing out of tank to engine Clogged oil tank cap breather hole Clogged oil filter 4 2 4 LUBRICATION SYSTEM OIL PUMP REMOVAL Oil Pum Oil Outlet Line Do not allow foreign matters to enter the _ crankcase Before removing the pump clean the oil pump and crankcase surfaces Remove the met in box gt 12 4 Disconnect the oil pump control cable from the pump body Disconnect the oil inlet line from the oil pump Then disconnect the oil outlet line Before disconnecting the oil line clip the oil line to avoid oil flowing out and then plug the oil line after it is disconnected 2 gt gt 1 M ot Y i 4 7 lt E lt 5 iJ lt 4 4 7 4 F E 4 b x I P 4 M Remove the oil pump control cable plate
75. orber tube When holding the shock absorber tube place a shop towel under it and do not apply too much force MES VI m gt aal A Lu E E Te E i xz Tn eis i e o 8 Z ss Aj und Beto coctis MR dii m tepsi Se 29 J SF E ip Oa 2m ata naha c Ea SA ant ui a s 7 I P ue kar 3 mer Tus FTU RATE Paz a s d Measure the front shock absorber spring free length Service Limit Right 200mm Left 200mm FRONTSHOCK ana Seal ABSORBER irclip AS SEMBLY o Nut 1 4 Damping Spring 13 17 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK Install the damping spring to the damper and then install them into the front shock absorber tube Install the front shock absorber spring and tighten the damper nut Install the front shock absorber spring with the loosely wound coils facing up Damper Nut Front Shock Absorber Use a vise to hold the front shock absorber Tighten the hex bolt Apply locking agent to the washer and socket hex bolt and install them together Torque 15 3 0kg m Specified Oil ss 8 Oil Capacity Bolt Washer Circlips Install the circlip w TE Install the dust boot Dust Boot 13 18 13 STEERING HANDLE
76. over 13 5 13 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK Turn the wheel bearings and replace them if Play Play they have excessive play or noise Axial Radial Dust Seal DISASSEMBLY Remove the dust seal 49 a e 99 k t N 2 4 N gt a m 7 E I N W XL A Hd K wheel bearings and distance Bearing Puller 13 6 13 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK ASSEMBLY 20 Grease Pack all bearing cavities with grease Drive in the left bearing Install the distance collar Drive in the right bearing Drive the bearing squarely with the sealed end facing out Apply grease to the dust seal lip and install Side Collar the dust seal Install the side collar 13 7 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK FRONT WHEEL INSTALLATION Disk Brake Install the front wheel aligning the speedometer gear tab with the front fork groove Connect the speedometer cable Torque 5 0 7 Okg m HYDRAULIC BRAKE FRONT BRAKE Brake Fluid Replacement Air Bleeding Check the brake fluid level on level ground Groove Tab Axle Nut Upper Limit When operating the brake lever the brake reservoir cap must be tightened securely to avoid spill of brake fluid When servicing the bra
77. peed 2 Worn weight rollers 3 Worn or seized driven pulley There 1s abnormal noise or smell while running bearings Oil or grease fouled drive belt Worn drive belt Weak driven face spring Worn or seized driven pulley bearings STEERING HANDLEBAR DOES NOT TRACK STRAIGHT Probable Cause Front and rear tire pressures are normal Steering is heav Steering stem nut too tight 5 2 Broken steering steel balls Excessive wheel bearing play Bent rim Loose axle nut Front or rear wheel is wobbling a 5 3 Misaligned front and rear wheels Bent front fork 2 GENERAL INFORMATION POOR SUSPENSION PERFORMANCE Symptom Probable Cause ee ert erent Front and rear tire pressures are normal Weak shock spring Shock damper oil leaking cd D Bent fork tube or shock rod Pe 2 Fork slider and tube binding Fork tube and spring binding Fork slider and tube binding N POOR BRAKE PERFORMANCE nennen Adjust brake according to standards QD Worn brake linings Index mark on brake Q2 Worn brake cam contacting area panel aligns with wear on indicator arrow brake shoes Worn brake cam 4 Worn brake drum Worn brake linings 2 Foreign matter on brake linings Rough brake drum contacting area Sluggish or elongated brake cables Brake shoes improperly contact brake dru
78. r Remove the cylinder head Remove the two exhaust muffler joint lock nuts and two exhaust muffler lock bolts Remove the exhaust muffler Remove the cylinder Remove the cylinder gasket Do not pry between the cylinder and crankcase or strike the fins Exhaust Muffler Lock Joint Lock Nuts Bolts PISTON REMOVAL Piston Piston Pin Remove the piston pin clip to remove the dc jw cuan piston pin and piston Do not damage scratch the piston Do not apply side force to the connect Ing rod when removing the piston pin 4 LJ Place clean shop towels in the crank case to keep the piston pin clip from falling into the crankcase Piston Pin Clip Spread each piston ring and remove by lifting it up at a point just opposite the gap Remove the expander 6 CYLINDER HEAD CYLINDER PISTON CYLINDER PISTON INSPECTION Check the cylinder and piston for wear or damage Clean carbon depostts from the exhaust port area careful not to damage the cylinder Inside wall Measure the cylinder bore at three levels of A B and C in both X and Y directions Avoid the port area Take the maximum figure measured to determine the cylinder bore Service Limit 50 39 05mm replace if over Inspect the top of the cylinder for warpage Service Limit 50 0 10mm replace if over 6 CYLINDER HEAD CYLINDER PISTON The cyli
79. r brake lever free play Inspection amp Maintenance Item O O Free play 10 20mm Brake Lever Brake lever operation O Brake performance Lever Looseness abnormal Cable noise and damage Brake Drum to lining O System clearance Brake Brake shoe and lining Pr Wear type shoe Standard Brake drum wear and damage Tire Tire pressure O O O gi X E FO Rear 110 mm Service Limits Rear 111 mm 1 1 50 1 75 rider kg cm kg cm Tire 70 90 16 90 80 16 Size 3 INSPECTION ADJUSTMENT Frequency Inspection amp Maintenance Item Preride month months Tire crack and damage O O Tire groove and abnormal wear O O Imbedded objects i O O gravel etc Axle nut looseness O Check wheel rim rim edge and spoke plate for damage Check front wheel bear ing for excessive play and abnormal noise Check front wheel bear ing for excessive play and abnormal noise Damage Connecting parts loose ness and arm damage Suspen sion arm Oil leakage and damage Assembly parts loose ness abnormal noise Operation Transmis sion case Oil leakage and oil level O es lt 3 lt NO O O Spark plug condition Battery Terminal connection Loose connection and Wires damage Remarks Judgment Standards months Groove Depth Front 0 8mm Rear 0 8mm Torque Values Front axle nut 5 0 7 0kg m Rear axle nut 11 0
80. r damage Countershaft 9 3 9 FINAL REDUCTION Inspect the final gear and final shaft for m wear damage or seizure Check the left crankcase bearings for excessive play and inspect the oil seal for wee wear damage cnn 32 WE Drive Shaft Bearing NT p ail NAN Final Shaft Bearing m Countershaft Bearing Inspect the drive shaft and gear for wear or damage Check the transmission case cover bearings for excessive play and inspect the final shaft bearing oil seal for wear or damage 3 Do not remove the transmission case cover except for necessary part replace ment When replacing the drive shaft also replace the bearing and oil seal Drive Shaft Bearing Oil Seal 9 4 9 FINAL REDUCTION PARIN sai Drive Shaft Bearing Transmission Case Cover Remove the transmission case cover bearings using the bearing remover Remove the final shaft oil seal Bearing Remover Set Drive new bearings into the transmission case cover Bearing Outer Driver Handle A BEARING REPLACEMENT Left Crankcase Cover Remove the drive shaft Remove the drive shaft oil seal Remove the left crankcase bearings using the bearing remover Bearing Remover Set 12mm 9 5 9 FINAL REDUCTION Drive new bearings into the left crankcase Install a new drive shaft oil seal FIN
81. r onto the carburetor and tighten the band screw Install the met in box gt 12 4 Carburetor Cap Band Air Cleaner Case AIR SCREW ADJUSTMENT Remove the met in box gt 12 4 Warm up the engine before air screw adjustment Turn air screw clockwise until it seats lightly and back it to the specification given Air Screw Opening BAIOAB AC 50 1 Q turns Start the engine and turn the air screw in or out slowly to obtain the highest engine speed Do not force the air screw against its seat to prevent damage Turn the throttle stop screw to obtain the specified idle speed Idle Speed BAIOAB AC 50 2000x100rpm Slightly increase the engine speed and make sure that the engine does not miss or run erratic If the adjustment of the air screw within the range of 0 turn makes no difference to the engine performance check other related items 11 11 11 CARBURETOR REED VALVE REMOVAL Remove the rear carrier Remove the frame body cover Remove the four intake manifold bolts and gasket Remove the reed valve and gasket INSPECTION Check the reed valve for damaged or weak reeds Check the reed valve seat for cracks damage or clearance between the seat and reed Replace the valve if necessary not disassemble or bend the reed stopper To do so can cause loss of engine power and engine damage If any of the stopper reed or valve seat is faulty replace them
82. rings and oil seal from the driven pulley E J 12 94 LI E ta k TER W m uiis k ft E welt bier Ix TEE r LT TP h O rings Guide Roller Pin CLUTCH DRIVEN PULLEY INSPECTION Inspect the clutch outer for wear or damage Measure the clutch outer I D Service Limit 50 107 5mm replace if below 8 13 8 KICK STARTER DRIVE PULLEY CLUTCH DRIVEN PULLEY Check the clutch shoes for wear or damage Measure the clutch lining thickness Service Limit 2 0mm replace if below Measure the driven face spring free length Service Limit 50 82 6mm replace if below Check the driven face assembly for wear or damage Measure the driven face O D Service Limit 33 94mm replace if below Check the movable driven face for wear or damage Measure the movable driven face I D Service Limit 34 06mm replace if below Check the guide roller pins for stepped wear 9 14 8 KICK STARTER DRIVE PULLEY CLUTCH DRIVEN PULLEY DRIVEN PULLEY FACE BEARING inner Bearing REPLACEMENT Check the needle bearings in the driven face and replace them 1f they have excessive play damage or abnormal noise Drive the inner bearing out of the driven pulley face Remove the snap ring and drive the outer bearing out of the driven face Outer Bearing Bearing Outer Driver 37x40mm Drive a new outer
83. rings in their respective ring grooves The piston rings should be pressed into the grooves with even force After Installation check and make sure that each ring is flush with the piston at several points around the ring A ring that will not compress means that the ring groove has carbon deposits in it and should be cleaned Second Ring 6 CYLINDER HEAD CYLINDER PISTON Install a new cylinder gasket on the mating Cylinder Gasket surface between the cylinder and crankcase oo N 1 Make sure that the ring end gaps are aligned ane doni with the piston ring pins in the ring grooves Lubricate the cylinder Inside and piston rings with engine oil and install the piston into the cylinder while compressing the piston rings Be careful not to damage the piston Install the cylinder head Torque 1 5 1 7kg m Install the exhaust muffler and tighten the exhaust muffler joint lock nuts Torque 10 1 4kg m Tighten the exhaust muffler lock bolts Torque 3 0 3 6kg m Install the frame covers Install the met in box The installation sequence 1s the reverse of removal 6 10 7 A C GENERATOR A C GENERATOR 7 SERVICE INFORMATION uuu i uyu y ens os Vb ades 7 2 IC OGENERATOR 7 3 GENERATOR INSTALLATION 7 4 7 A C GENERATOR 0 8 1 2kg m 0 6 1 0kg m 0 8 l 2kg
84. rly insulated plug cap Improper ignition timing Battery voltage too low 6V max Faulty CDI unit Lack of power Weak battery Loose wire or connection Foreign matter stuck in starter motor Or pinion Starter motor rotates but engine does not start Faulty starter pinion Starter motor rotates reversely Faulty starter clutch Weak battery 15 2 15 ELECTRICAL EQUIPMENT CHARGING SYSTEM Dimmer Switch Headlight Switch Resistor Ignition Switch A C Generator Wire Harne amp 1984 Bystarter 1O1SIS Rectifier 103239090 1081594 5 2 5 ELECTRICAL EQUIPMENT BATTERY id a BATTERY REMOVAL b Remove the front tool box cover Disconnect the battery cables First disconnect the battery negative cable and then the positive cable Remove the bolt and battery bracket Remove the battery The installation sequence 15 the reverse of removal BATTERY CHARGING OPEN CIRCUIT VOLTAGE INSPECTION Remove the battery cover and disconnect the battery cables Battery Measure the voltage between the battery terminals Fully charged 13 0V_ 13 2V Undercharged 12 3V max Battery charging inspection must be performed with an electric tester CHARGING METHOD Connect the charger positive cable to the battery positive cable Connect the ch
85. rottle Valve Spring Throttle Valve Connect the throttle cable to the throttle valve Q EC T zm x Throttle Cable 11 4 11 CARBURETOR Install the throttle valve by aligning the Groove groove in the throttle valve with the throttle Stop screw Throttle Stop Screw Tighten the carburetor cap Carburetor Cap After installation perform the following adjustments and inspections Throttle cable free play 43 12 Idle speed adjustment gt 3 11 Install the met in box CARBURETOR REMOVAL Auto Bystarter Throttle Cable Fuel Tube Remove the met in box gt 12 4 Remove the air cleaner by removing the air cleaner band screw and attaching bolts Disconnect the fuel tube Loosen the drain bolt to drain fuel from the carburetor Disconnect the auto bystarter wire connector Remove the two carburetor lock nuts Drain Bolt Band 11 5 11 CARBURETOR Remove the carburetor AUTO BYSTARTER AUTO BYSTARTER INSPECTION Measure the resistance between the auto bystarter wire terminals Resistance 502 10 minutes minimum after stopping the engine If the resistance exceeds 5 2 replace the auto bystarter with a new one After the engine stops for 30 minutes connect a hose to the fuel enriching circuit and blow the hose with mouth If air cannot be blown into the hose clogged the auto bystarter is faulty Replace it with a new one 11 6 11 CARBURETOR
86. rter motor cable 2 Faulty starter pinion Probable Cause Connect starter motor directly to battery 3 Starter motor does not stop turning Inspection Adjustment Turn ignition switch OFF Not stopped Stopped Faulty starter pinion Starter shorted stuck closed 2 31 3 INSPECTION ADJUSTMENT A INSPECTION ADJUSTMENT INSPECTION AND MAINTENANCE SCHEDULE 3 BRAKE 5Y5 IPNI inen a en 3 4 MOVING DEVICE eel alan Gat es 3 6 3 7 POWER DRIVE Sy STEM 3 7 EEBCTRICALT EOUIPNIEINL atii Tob ed 3 8 re 3 9 e 3 12 3 INSPECTION ADJUSTMENT INSPECTION AND MAINTENANCE SCHEDULE Note 1 means time for inspection 2 means regular replacement for the specified parts This inspection and maintenance schedule is based upon average riding conditions Machines subjected to serve use or ridden In unusually dusty areas require more frequent servicing Frequency Judgment Standards Remarks 156 Every 6 Preride month months months Check for looseness Steering 4 vertical play handlebar Operating performance turning angle Susp ension Damage Check for front fork Front pivot installation fork Check front fork pivot for looseness and abnormal noise Front rea
87. starter motor for long time 2 This inspection should be done with a fully charged battery 15 13 16 INSTRUMENT SWITCHES LIGHTS INSTRUMENT SWITCHES LIGHTS SERVICE INFORMATION uu yn u TROUBLESHOOTING C HE ee er E rr STOP SWITCH INSPECTION HORN BULB REE RACE MEN uu uuu mun a INSTRUMEN TAPE ADIGE uu u uzanan 16 0 16 INSTRUMENT SWITCHES LIGHTS SERVICE INFORMATION GENERAL INSTRUCTIONS Wires should be connected to other wires of the same color Couplers must be connected to other couplers of the same color All plastic plugs have locking tabs that must be released before disconnecting and must be aligned when reconnecting After installation of each switch a continuity check must be performed TROUBLESHOOTING Lights do not come on when ignition switch is ON Burned bulb Faulty switch Broken or shorted wire Fuse burned out Weak battery Poorly connected wire Faulty winker Light dims Faulty ignition coil Wire or switch resistance too high Faulty regulator rectifier Headlight does not change when dimmer switch is turn to Hi or Lo Faulty or burned bulb Faulty dimmer switch 16 1 Motor oil indicator light does not come on when motor oil is insufficient Fuse burned out Dea
88. t Float down Light on in meter Damaged oil tank Foreign matters in oil tank 2 29 2 GENERAL INFORMATION FUEL GAUGE 1 Pointer does not register correctly Ignition switch ON Inspection Adjustment Probable Cause Check battery circuit by operating turn signals D Burned out fuse Weak or dead battery Signals operate Signals dim remain Faulty ignition switch on or don t Loose or disconnected Remove fuel unit and connector check operation of pointer by moving float up and down Broken wire harness Pointer does not D Faulty float move Check operation of pointer by opening and shorting fuel unit terminal on wire harness side Pointer does not Pointer moves D Broken or shorted fuel move unit wire Check connectors for proper connection Q Loose or disconnected d 2 Incorrectly connected connector f oF Broken or shorted wire in fuel gauge 2 Pointer fluctuates or swings Ignition switch ON Inspection Adjustment Probable Cause Check battery circuit by operating turn signals and horn Burned out fuse Weak or dead battery Faulty ignition switch Loose or disconnected connector Broken wire harness Signals dim remain on or don t Remove fuel unit and check operation of Signals operate properly pointer by moving float up and down Pointer does not move D Poor contact in fuel unit Move float up and
89. t brake master cylinder check hole Brake Master Cylinder 3 INSPECTION ADJUSTMENT MOVING DEVICE TIRES Tire Pressure Check the tire pressure Tire pressure should be checked when tires are cold Tire Pressure one rider Front 1 50 kg cm _ Rear 1 75 kg cm __ Tire Size ETE 90 80 16 Axle Nut Axle Shaft Looseness Check the front and rear axle nuts for looseness If the axle nuts are loose tighten them to the specified torques lorques Front 5 0 7 0kg m Rear 1 0 13 0kg m Wheel Rim Spoke Plate Damage Check the wheel rim and spoke plate for wear or damage and measure the rim runout Axle Nut 3 INSPECTION ADJUSTMENT DAMPING DEVICE SHOCK ABSORBERS Oil Leak Damage Fully apply the front brake and check the action of the front shock absorber by compressing it several times Check the entire shock absorber assembly for looseness or damage Check the action of the rear shock absorber by compressing it several times Check the entire shock absorber assembly for looseness or damage POWER DRIVE SYSTEM TRANSMISSION CASE Check the rear wheel transmission case surrounding area for oil leaks Stop the engine and remove the oil check bolt Place the motorcycle on its main stand on level ground The gear oil level shall be at the oil check bolt hole Ifthe oil level is low add the specified oil to the proper level Specified Gear Oil SA
90. th compressed air Install the oil filter 1n the reverse order of removal and fill the oil tank with specified oil up to the proper level Bleed air from the oil pump and oil lines Connect the oil tubes securely Install the tube clip at the oil tank side and also install the clip to the lower oil tube that goes to the oil pump Check for oil leaks Filter Screen Oil Pump Condition Lock Nut Control Lever Aligning Mark Adjust oil pump control cable after the throttle grip free play is adjusted Open the throttle valve fully and check that the index mark on the pump body aligns with the aligning mark on the oil pump control lever Reference tip alignment within 1mm of index mark on open side Is acceptable Start and idle the engine then slowly open the throttle to increase engine rpm and check the operation of the oil pump control Au x lever Adjusting Nut ON Pump Body Index If adjustment is necessary adjust the oil Mark pump control cable by loosening the control cable lock nut and turning the adjusting nut After adjustment tighten the lock nut Reference tip alignment within 1mm of index mark on open side 15 acceptable However the aligning mark on the control lever must never be on the closed side of the index mark otherwise engine damage will occur because of insufficient lubrication If the oil pump is not synchronized properly the following will o
91. ther hole and exhaust muffler gt S 3 3 3 INSPECTION ADJUSTMENT BRAKESYSTEM BRAKE LEVER Free Play Measure the front and rear brake lever free plays Free Play Front 10 20mm Rear 10 20mm If the free plays do not fall within the limits turn the right and left adjusting nuts for adjustment Front 10 20mm Rear 10 20mm HE 0 MUSS Li A p 4 gt LI Rear A Marks Adjusting Nuts 3 4 3 INSPECTION ADJUSTMENT BRAKE DRUM SHOE lt Rear gt Brake Shoe Wear Replace the brake shoes if the arrow on the brake arm aligns with reference mark A on the brake panel when the brake is fully applied Brake Drum Wear Damage Check the brake drum appearance for damage Check if the brake lining wear 1s within the specified service limit Check the brake operation for abnormal noise and brake drum inside for wear or damage BRAKE DISK LINING Brake Disk Surface and Brake Pad Wear Check the brake disk surface for scratch Check if the brake pad wear is within the specified service limit Brake Disk Runout Inspection Jack the motorcycle wheels off the ground and check if the brake disk runout is within the specified service limit BRAKE FLUID LEVEL INSPECTION Brake Master Cylinder Fluid Level Inspection Turn the steering handlebar upright and check if the front brake fluid level is within the specified limits through the fron
92. tsr ettam bot d uiid 9 2 FINAL REDUCTION DISASSEMBLY eene 9 3 FINAL REDUCTION INSPECTION 9 3 FINAL REDUCTION ASSEMBLY 9 6 9 0 9 FINAL REDUCTION 9 1 9 FINAL REDUCTION SERVICE INFORMATION Specified Oil SAE907 At disassembly 0 12 liter At change 0 1 liter SPECIAL TOOLS Bearing remover set 12mm Bearing remover set 15mm Crankcase assembly collar Crankcase assembly shaft Bearing outer driver 37x40mm Bearing outer driver 32x35mm Bearing driver pilot 17mm Bearing driver pilot 15mm Bearing driver pilot 12mm Bearing outer driver handle A TROUBLESHOOTING Engine starts but motorcycle won t move Damaged transmission Seized or burnt transmission Abnormal noise Worn seized or chipped gears Worn bearing Oil leaks Oil level too high Worn or damaged oil seal 9 2 9 FINAL REDUCTION FINAL REDUCTION DISAS SEMBLY Remove the rear wheel gt 14 3 Remove the left crankcase cover c 8 4 Remove clutch driven pulley 48 15 Drain the transmission gear oil into a clean container Remove the transmission case cover attaching bolts Remove the transmission case cover Remove the gasket and dowel pins Driver shift Remove the final gear and countershaft Dowel Pin Final Gear Driver shift 7 3 Aka ae T m Final Shaft Countershaft Dowel Pin FINAL REDUCTION INSPECTION Inspect countershaft and gear for wear o
93. um I D Service Limit 95 5mm replace if over BRAKE LINING INSPECTION Measure the brake lining thickness Service Limit 2 0mm replace if below Keep oil or grease off the brake linings REAR BRAKE DISASSEMBLY Brake Arm Brake Shoes Remove the rear brake adjusting nut and disconnect the rear brake cable Remove the rear brake shoes Adjusting Nut 14 4 14 REAR WHEEL REAR BRAKE REAR SHOCK ABSORBER Remove the brake cam bolt to remove the brake arm wear indicator plate and felt seal Remove the brake arm REAR BRAKE ASSEMBLY Apply grease to the anchor pin and brake shoe moving parts Apply grease to the brake cam and install it Apply engine oil to the felt seal and install it to the brake cam stall the wear Indicator plate Align the wide tooth of the wear Indicator plate with the wide groove on the brake cam stall the brake arm onto the brake cam Align the punch mark on the brake arm with the scribed line on the brake cam Install and tighten the brake arm Install the brake arm return spring Install the brake shoes 14 5 Brake Arm Bolt Wear Indicator Plate Brake Arm Brake Cam Grease Wear Indicator Plate Punch Mark que Brake Arm 14 REAR WHEEL REAR BRAKE REAR SHOCK ABSORBER Install the brake arm pin Brake Cable Brake Arm Connect the brake cable and install the L adjusting nut Install the rear wheel gt 14 3 Adjust the r
94. yond the brake caliper Wipe off excessive brake fluid with a clean shop towel Apply silicon grease to the brake caliper seat pin and caliper inside Install the brake caliper seat 13 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK Installation Install the brake caliper and tighten the two bolts Torque 2 9 3 5kg m Connect the brake fluid pipe to the brake caliper and tighten the fluid pipe bolt Torque 3 0 4 0kg m Fill the brake reservoir with recommended brake fluid and bleed air from the brake system gt 13 12 Bolt 13 15 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK FRONT SHOCK ABSORBER REMOVAL Remove the front wheel gt 13 5 Remove the front fender gt 12 6 Remove the front shock absorber upper mount bolts Loosen the lower mount bolts to remove the front shock absorbers Front Shock Absorber Mount Bolt Circlip LEFT FRONT SHOCK ABSORBER ak DISASSEMBLY Remove the dust boot Remove the circlip um m 12844 a Dust Boot Use a vise to hold the front shock absorber and remove the shock absorber tube hex bolt and copper washer from the front shock absorber Bolt Washer Front Shock Absorber 13 16 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK Use a vise to hold the front shock absorber tube and remove the damper from the shock abs
95. ystarter Faulty auto bystarter Connect auto bystarter wire to battery Wait for 5 minutes then connect a hose to fuel enriching circuit and then blow the hose with mouth Faulty auto bystarter Clogged Not Clogged N 2 23 2 GENERAL INFORMATION ENGINE LACKS POWER Inspection Adjustment Start engine and accelerate Hghtly for observation Engine speed does not Increase sufficiently Engine speed Increases Correct timing Incorrect timing Test cylinder compression using a compression gauge Normal Abnormal compression compression Check carburetor for clogging Not Clogged Clogged Remove spark plug and inspect Plug not fouled or Plug fouled or discolored discolored Check if engine overheats Engine does not Engine overheats overheats accelerate or Rapidl speed run at Engine does not Probable Cause Clogged atr cleaner Clogged fuel filter Clogged exhaust muffler Faulty auto bystarter Faulty charcoal canister 2 5 Faulty CDI unit 2 Faulty A C generator Worn cylinder and piston rings Blown cylinder head gasket Faulty reed valve D Clogged carburetor jets D Fouled spark plug 2 Incorrect heat range plug Mixture too lean Poor quality fuel Excessive carbon build up in combustion chamber Ignition timing too early OQO 9 Excessive carbon build up in

Kymco People 50 Service Manual

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