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150cc Service Manual 14589R4

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2. 15A Top Speed 20mph Speed Reduction Kit Available 35 39mph CHASSIS Rear Brake Hydraulic disc left foot control Tires Front Rear 17 x 7 0 8 15psi 18 X9 5 8 15psi Suspension Front Dual A arm with 1 8 45mm of travel Suspension Rear Spring over shock with 2 4 60mm of travel WEIGHT Dry Weight 198Kg 436lbs WARRANTY Components 30 days Frame 90 days Engine 1 year The specifications are subject to change without notice 5 14589R4 1 4 GENERAL INFORMATION SPECIFICATIONS 200 SERIES DIMENSIONS Overall length 2388mm 94 0 inch Overall width 1245mm 49 0inch Overall height 1784mm 70 25 inch Wheelba
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4. 1406mm 55 4inch Overall height 1458mm 57 4inch Wheelbase 1500mm 59 0inch Track Width Front Rear 1160mm 47 7inch 1000mm 39 4inch Ground 1 170mm 6 7inch ENGINE single cylinder oil amp cooled 4 stroke Engine capacity 150cc Bore x stroke 57 4 x 57 8 Corrected Compression Ratio 9 2 1 Carburetor KECB24J Output Power Torque N m r min 1 9 9 hp 7500rpm 13ft Ibs 5500rpm Starting keyed Electric Ignition CDI Lubrication Cooled Force amp Splash SAE 10W 40 Transmission CVT Automatic with Neutral and Reverse Spark P
5. 9 2 1 Carburetor KECB24J Output Power Torque N m r min 1 9 9 hp 7500rpm 13ft Ibs 5500rpm Starting keyed Electric Ignition CDI Lubrication Force amp Splash SAE 10W 40 Transmission CVT Automatic with Neutral and Reverse Final Drive Chain KMC 50 5 8 Pitch Spark Plug Gap C7HSA 0 6 0 7mm Fuel Type USE ONLY Mid Grade Unleaded 89 93 Octane CAPACITIES Maximum Load Driver Passenger amp Gear 400165 Climbing Angle 20 25 Fuel tank 2 64 Gal Engine 300z 12V 9Ah Fuse
6. Inlet cam 25 96mm Exhaust cam 25 815mm CAMSHAFT INSTALLATION Rotate the flywheel to align the T mark on the flywheel with camshaft mark and ensure that the round hole on the cam chain wheel is up and the left and right sit parallel with the cylinder head the lobes of the camshaft are down Then install the camshaft on the cylinder head e Mount the cam chain on the chain wheel Install the dowel pins e Mount the camshaft holder washer bolt cap on the cylinder head e Tighten the cylinder head bolt and nut While installing first apply some oil on the thread part of the camshaft holder bolt The camshaft nuts should be tightened diagonally in a 3 step process After installing adjust the valve clearance e Turn the cam chain tensioner adjusting bolt counter clockwise and release the lock e Apply oil on the new O ring e Mount and tighten the cam chain tensioner cover bolt The O ring must be mounted proper in the groove e Replace the valve cover gasket and mount the cover Adjusting bolt The valve cover gasket must be mounted properly in the groove e Tighten the valve cover positioning bolt ROCKER ARM AND ROCKSHAFT ROCKER ARM AND ROCKSHAFT REMOVAL Remove the camshaft holder e Take out the rockshaft by removing the bolt Remove the rocker arm ROCKER ARM AND ROCKSHAFT INSPECTION e Inspect if there is any abrasion
7. 237Kg 52216 WARRANTY Components 30 days Frame 90 days Engine 1 year The specifications are subject to change without notice 4 14589R4 1 3 GENERAL INFORMATION SPECIFICATIONS 6150 DIMENSIONS Overall length 2311mm 91 0inch Overall width 1200mm 47 3inch Overall height 1406mm 55 4inch Wheelbase 1500mm 59 0inch Track Front Rear 1040mm 41 0inch 920mm 36 3inch Ground Clearance 170mm 6 7inch ENGINE single cylinder oil amp cooled 4 stroke Engine capacity 150cc Bore x stroke 57 4 x 57 8 Corrected Compression Ratio
8. t ig DULIM laum pv PER ee E T i De ag ge HEX ung 22061 SSS SS SS SSeS SS SSS Se SSS Se SSS SSS SS SP ISR SSS SS SSS SSeS SSS Sees SSS eee Sea Ses ae w ME uada 5 NYIDI aG3IVIV 5 CHASSIS CONTENTS 5 1 5 2 5 3 5 4 CHASSIS CHASSIS SYSTEM INSPECTION AND SERVICING REAR AXLE REMOVAL REAR SWINGARM INSPECTION CHASSIS FRONT amp REAR SHOCKS INSPECTION FRONT amp REAR SHOCK ADJUSTMENT FRONT WHEEL REPLACEMENT FRONT HUB INSPECTION CHASSIS A ARM INSPECTION STEERING KNUCKLE SUPPORT INSPECTION TIE ROD INSPECTION FRONT AND REAR SHOCK ADJUSTMENT CHASSIS FRONT WHEEL ALIGNMENT CHAIN ADJUSTMENT 75 14589R4 76 76 76 76 77 77 77 77 77 78 78 78 78 78 79 79 79 5 1 CHASSIS CHASSIS SYSTEM INSPECTION AND SERVICING REAR AXLE REMOVAL e Disassemble the right rear RR Wheel e Remove the Cotter Pins on Axle Nut RR Wheel Remove the Axle Nut RR Wheel Block up rear end of the machine e Remove rear wheel and hub assembly by sliding off the splines of axle e Remove the chain Loosen nuts on bearing carrier and remove bolts e Remove axle and bearing carriers as a unit REAR SWINGARM INSPECTION Note Swingarm axle and motor can be removed as a unit if desired Remove Rear Shocks Remove rear brake calipers and set aside Do not remove brake hose Unplug brake light wiring from the electrical box Remove throttle cab
9. Dual A arm with 1 8 45mm of travel Suspension Rear Spring over shock with 2 0 60mm of travel WEIGHT Dry Weight 314Kg 6090155 The specifications are subject to change without notice 6 14589R4 2 MAINTENANCE AND TUNE UP PROCEDURES CONTENTS 2 1 2 2 2 3 2 4 2 5 2 6 MAINTENANCE AND TUNE UP PROCEDURES PERIODICAL CHECKS AND SERVICES PERIODIC MAINTENANCE AND TUNE UP PROCEDURES MAINTENANCE AND TUNE UP PROCEDUREs IDLE SPEED ADJUSTMENT SPARK PLUG TIRE PRESSURE WEAR BRAKE FLUID AND PERFORMANCE PERIODIC MAINTENANCE AND TUNE UP PROCEDURES AIR CLEANER PAPER FILTER MAINTENANCE FOAM FILTER MAINTENANCE CHASSIS NUTS AND BOLTS PERIODIC MAINTENANCE AND TUNE UP PROCEDURES TIGHTENING TORQUE CHART FUEL SWITCH PETCOCK FUEL FILTER FINAL GEAR OIL PERIODIC MAINTENANCE AND TUNE UP PROCEDURES ENGINE OIL PERIODIC MAINTENANCE AND TUNE UP PROCEDURES CHASSIS CARBURETOR VALVE CLEARANCE SHIFTER ADJUSTMENT CHAIN TENSION BATTERY NO NOD O 00S WO e e m Lc m oc om Re KF COO 2 Ss 14589 4 2 1 MAINTENANCE AND TUNE UP PROCEDURES PERIODICAL CHECKS AND SERVICES The maintenance intervals in the following table are based upon average riding conditions Riding in unusually dusty areas require more frequent servicing
10. DRIVE BELT PULLEY INSTALLATION e Apply some grease evenly in the movable drive plate e Put the centrifugal rollers into the movable drive plate Install the ramp plate Ramp plate Put the drive plate hub into the drive plate e Install the movable drive plate on the crankshaft Enlarge the driven plate belt groove and mount on the driven belt Mount the other end of the driven belt on the drive plate hub Mount the drive plate the drive plate washer and nut Hold the drive plate with a multiuse holder to make it unmovable same time fasten the nut on the shaft Do not allow any grease or oil on the surface of the movable drive plate and the driven belt 252 14589R4 3 36 ENGINE AND TRANSMISSION CLUTCH CLUTCH REMOVAL e Remove the left crankcase cover e Remove the drive plate and the driven belt e Hold the clutch friction plate with a multiuse holder and remove the nut Remove the clutch friction plate CLUTCH INSPECTION Inspect if there is any abrasion or damage on the clutch friction plate Measure the inner diameter of the clutch friction plate Service limit 125 5mm Inspect if there is any abrasion or damage of the clutch centrifugal weigh friction piece Measure the thickness of the clutch centrifugal weight friction piece Service limit 1 5mm h CLUTCH DISASSEMBLY Clutch Driven plate
11. If it is necessary to replace the centrifugal weight set then Sch sora you must disassemble the clutch 4 eee ae When the friction piece is worn it should be replaced with the centrifugal weight set Remove the clutch friction plate Remove the whole set of clutch driven plate Compress the driven pulley spring with the clutch spring compressor and at the same time remove the nut on the shaft 53 14589R4 3 37 ENGINE AND TRANSMISSION e Disassemble the clutch with the driven pulley Circlip Remove the circlip and remove the connecting piece Remove the clutch centrifugal weight set and the IN connecting piece spring CLUTCH INSTALLATION Mount the clutch damper rubber on the drive plate pin e Mount the new clutch weight set and spring on the drive plate e Install the connecting piece the circlip and the bottom plate e Finally reverse the removal procedure for installation When assembling the clutch and the driven plate you must use a clutch spring compressor or it will damage the spring No grease on the driven pulley DRIVEN BELT PULLEY DRIVEN BELT PULLEY REMOVAL After removing the clutch friction plate remove the guide Guide pin pin the roller and the movable driven plate Movable driven plate 54 14589R4 3 38 ENGINE AND TRANSMISSION Remove the oil seal on the movable driven plate DRIVEN BELT PULLEY I
12. Inspect the clearance between the oil pump body and the outer outer rotator rotator Service limit 0 12mm Oil pump body Inspect the clearance between the inner rotator and the outer rotator Service limit 0 12mm Inspect the clearance between the rotator plane and the oil pump Service limit 0 20mm If the inspection result exceeds the above stated service limit the whole set should be replaced OIL PUMP ASSEMBLY e Assemble the inner and outer rotators of the pump and z mount the oil pump shaft di pee When assembling align the unfilled corner of the oil pump shaft with the corner of the inner rotator and then mount Mount the dowel pin Dowel pin e After aligning the oil pump plate with the dowel pin it can be installed e Tighten the oil pump plate bolts e After assembling gently turn the oil pump shaft and make sure the oil pump can turn smoothly 36 14589R4 3 20 ENGINE AND TRANSMISSION OIL PUMP INSTALLATION e Install the oil pump on the crankcase Before installing fill the oil pump with oil When installing the arrow of the oil pump body must be upwards e Tighten the oil pump positioning bolts e Align the oil pump driving gear with the oil pump shaft unfilled corner then mount the driving gear chain e Mount the driving gear positioning nut and tighten it e Ins
13. results will very based on ambient temperature Colder temperatures negatively affect battery potential BATTERY CHARGING Connect the positive pole of the charger with the positive pole of the battery Connect the negative pole of the charger with the negative pole of the battery Charge the battery for the charging time marked on the battery Unless completely necessary do not use fast charging Fast charging reduces the life of the battery No smoking or open fire near the battery when charging At the beginning or the end of charging turn off the charger first in order to avoid the connecting part arcing Measure the voltage 30 minutes after charging is finished and it should reach the specified value or it needs to be recharged Normal 07A Charging current Fast 30A oTi Normal 5 10 hours Charging time Fast 30 minutes O circuit volt gt Charging result circuit voltage gt 12 8V 66 14589R4 4 3 ELECTRICAL SYSTEM PRIMARY COIL The picture shows the structure of a common generator 1 Cooling Fan 4 Stator comp 7 Nut 2 Generator assembly 5 Washer 8 Bolt 3 Flywheel comp 6 Bolt 9 Bolt PRIMARY COIL INSPECTION The inspection work can be done on the engine and there is no need to remove the generator Remove the 4 core connector of the generator Green 7 3 Regulate rectifier Red Battery Yellow Genera
14. 160 11 0 16 0 79 5 115 5 16 80 130 8 0 13 0 58 94 170 250 17 0 25 123 0 181 0 18 130 190 13 0 19 0 94 137 5 200 280 20 28 0 144 5 202 5 FUEL SWITCH PETCOCK This vehicle is equipped with an automatic fuel petcock There is no need to turn off the fuel since this happens when the engine is not running Check for any leaks or seeping fuel Replace the petcock if there are any leaks found FUEL FILTER Ensure the fuel filter is in an upright position so that no air can get pulled into the carburetor Also visually inspect the filter for debris damage or leaking Replace filter at specified interval FINAL GEAR OIL Inspect monthly and change quarterly To check level remove level screw on the right rear of engine case 11 14589R4 2 5 PERIODIC MAINTENANCE AND TUNE UP PROCEDURES To drain oil remove the drain plug at the rear bottom of the engine case It is recommended to warm the engine for 10 minutes or more before draining final drive oil la Drain Plug 80 90 wt Gear oil is recommended in the final drive case However in extreme cold weather conditions you may experience the vehicle to be hard to push In this case lighter viscosity oil may be used such as 75 wt or equivalent motorcycle transmission fluid Final drive capacity 750 80 90wt ENGINE OIL Inspect before riding every time Replace monthly Remove the drain plug from
15. 55 35 55 56 56 57 57 57 57 58 58 59 60 61 62 63 63 63 14589 4 3 1 ENGINE AND TRANSMISSION ENGINE AND TRANSMISSION COMPONENTS INSPECTION AND SERVICING CYLINDER CYLINDER REMOVAL NOTE The removal can be done with engine on the vehicle body e Remove cylinder head e Remove cylinder e Remove cylinder gasket bolts e Remove cylinder gasket CAUTION Do not damage the area of the cylinder Do not drop sundries such as cylinder gasket material into the crankcase CYLINDER INNER WALL WEAR INSPECTION Use a bore diameter dial gauge to measure the degree of wear The measure point is divided into three sectional planes in the axial direction upper middle lower measure every plane each time on the mutually perpendicular directions X Y the measured least dimension is the cylinder bore at the most upper position measured is largest diameter and at the most lower position measured is the smallest diameter their difference is the cylindricity of the cylinder At the same cross section measured the difference of diameter between two points mutually perpendicular which is the circularity of the cylinder 18 14589R4 3 2 ENGINE AND TRANSMISSION IN ORDER TO MAKE THE MEASURING POINT PERPENDICULAR WITH THE BORE AXIS OF THE CYLINDER AND TO ENSURE THE PRECISION OF THE MEASUREMENT THE BAR OF THE GAUGE CAN BE SLIGHTLY SWUNG IN THE DIRECTION OF THE GAUGE BAR AND
16. MEASUREMENT Measure the resistance value between the resistor wire and the vehicle body If the actual value is in the range of 12 of the value marked on the diagram or the resistor it is normal If not it should be replaced IGNITION SYSTEM The circuit working principle is shown in the picture B Black R Red i M tch Ignit itch Y Yellow BL Blue DN yeso gnition W White G Green D I Unit Amon coil gt f R grin SOS SS Silicon S e Controlled plug Trigger winding rectifier E 1 b Prim ide E Sec e coll T IGNITION TIMING INSPECTION The CDI ignition system has already been adjusted in the factory so there is no need to readjust it If inspecting ignition function is necessary take the following steps to inspect ignition timing Remove the ignition timing hole cover or remove the fan cover Rotate the generator rotor and align the F mark on the rotor with the crankcase timing ignition mark Clip the ignition timing indicator light wire clip on the high voltage end of the ignition coil Start the engine and let it run at idle At this time observe if the mark on the crankcase aligns with the mark on the rotor If there difference is between 3 it indicates correct ignition timing on the contrary if it is greater than 3 timing should be adjusted Slowly increase the engine speed to 5000rpm At this
17. Ream the upper angles of the valve seat working surface with a 30 milling cutter e Ream the lower angles of the valve seat working surface with a 60 milling cutter e Finally ream the valve seat to the specific seat width with a 45 milling cutter VALVE SEAT TOUCHING POSITION INSPECTION Valve seat Zh Surface Contact surface too high Old valve seat width Contact surface too low y ss Old valve seat width p DN 07 Apply a thin layer of oil on the valve seat and put the valve on the seat Rotate gently then take out the valve and observe the contact surface on the valve face If the contact position is too high cut out some of the upper part of the valve seat with a 32 milling cutter to reduce the working face of the valve seat If the contact position is too low then cut out some of the lower part of the valve seat with a 60 milling cutter to raise the working face of the valve seat Finally mill the working face of the valve seat to the specific width with a 45 milling cutter If the valve seat still cannot contact evenly with the valve after trimming the valve should be revised or replaced 32 14589R4 3 16 ENGINE AND TRANSMISSION VALVE AND VALVE SEAT LAPPING After finishing the valve seat the valve and seat should be lapped in order to make them seal properly Spread a thin layer of silicon carbide on the working level of the valve and use a valve suction cup
18. chain The lubrication oil that falls back into the oil groove can be recirculated 33 14589R4 3 17 ENGINE AND TRANSMISSION Rockershaft Crankshaft Filter screen OIL SYSTEM INSPECTION AND REPLACEMENT e Tighten the dipstick Remove the oil screen cap to let the oil flow out When oil and engine are cool remove the oil screen e Inspect if there is any damage of the screen and O ring if so it should be replaced Mount the oil screen and the screen covers and tighten the cover e oil and test according to Section 2 5 ENGINE OIL 24 14589R4 3 18 ENGINE AND TRANSMISSION ROTARY OIL PUMP The oil pump is the critical component of the lubrication system so it should be inspected maintained periodically and should be replaced as a unit when damaged seriously OIL PUMP REMOVAL Remove the flywheel of the magneto Remove the stator coil trigger winding Remove the right crankcase cover bolts and remove the right crankcase cover Remove the gasket dowel pins Remove the starting reduction gear starting clutch Remove the oil pump partition plate positioning bolts and remove the oil pump partition plate Remove the oil pump driving gear nuts and remove the driving gear chain Remove the oil pump positioning bolts and remove the oil pump assembly 35 14589R4 3 19 ENGINE AND TRANSMISSION OIL PUMP INSPECTION Remove the screws and disassemble the oil pump
19. is not good Replace if necessary e Remove the auto side starter cover e Remove its positioning bolts and pieces Remove the auto side starter e Inspect the auto side starting valve and fuel injection needle for wear e Inspect the O ring wear FLOAT CHAMBER FLOAT CHAMBER REMOVAL Remove the carburetor See Section 30 CARBURETOR REMOVAL e Remove the clamp and remove the float chamber e Remove the O ring and turn out the float chamber screw Remove the float pin float and float valve Remove the choke adjusting screw and air adjusting screw Before removing tighten the two screws gently counting the number of turns then remove the screws Do not use too much force or it will damage the air adjusting screw head surface e Remove the main fuel injection nozzle and fuel injection needle seat FLOAT CHAMBER INSPECTION Inspect the float for any damage and for no fuel in the float Inspect the float valve and float valve seat for wear If there is wear it should be replaced Clear every fuel line and air line on the carburetor body with compressed air FLOAT CHAMBER INSTALLATION e Install the main fuel injection nozzle and fuel injection needle seat e Install the air adjusting screw and choke adjusting screw and turn them into the proper position according to the noted number of turns while removing e Mount the float valve the float and the float pin e Tighten the float pin positioning s
20. make valve movement rough causing the valve to not open or close properly Valve guide abrasion is one of the causes of white smoke from the exhaust pipe CLEANING CARBON ACCUMULATION OF THE VALVE GUIDE e Remove the valve and springs etc e Clean the carbon accumulation with a valve guide reamer Generally only turn right when using the reamer and do not push in or out directly with the reamer Valve guide inner diameter measurement Service limit 5 03mm e Calculate the clearance between the valves stem and the valve guide The inner diameter of the guide subtracts the outer diameter of the valve stem Valve Inlet valve Exhaust valve Service limit 0 08mm 0 10mm When abrasion of the valve guide exceeds the use limit it should be replaced after replacing a new valve guide the valve retainer must be adjusted VALVE GUIDE REPLACEMENT Heat the cylinder head to 100 150 C The cylinder head must be wholly and quickly heated to the specific degree and cannot be heated partly or it ll cause the cylinder head to distort The temperature must be very high so two technicians are recommended for safety purposes the valve guide out with a valve guide remover or similar tool Do not damage the cylinder joint face 30 14589R4 3 14 ENGINE AND TRANSMISSION alve guide remover e After tapping the valve guide you ne
21. the left side bottom of the engine Drain into oil pan for disposal If the vehicle is equipped with an oil filter remove the filter and discard any existing oil in an approved container Replace oil drain plug Remove the large cap on the right bottom of the engine and remove the screen Wash the screen with cleaning solvent and refit making sure the O ring is still in good condition Re install the screen and cap Refill the engine with 300z of 10W 40 engine oil If your vehicle is equipped with an oil filter add additional new oil to the filter until the oil is 2mm or so from the top of the filter then install the filter See Section 3 46 OIL SYSTEM INSPECTION AND SERVICING W OIL FILTER Start and run engine for 5 minutes ensuring there are no oil leaks present Allow time for oil to return to oil pan then check oil level on the filler cap stick to assure proper level The cap needs to be screwed in to check 12 14589R4 2 6 PERIODIC MAINTENANCE AND TUNE UP PROCEDURES CHASSIS Grease chassis bushings and bearings with grease quarterly to assure smooth operation and extended lift of the bushings and the components If used in extreme wet and muddy conditions or dusty conditions it is recommended more often CARBURETOR Refer to Section 3 21 CV CARBURETOR VALVE CLEARANCE Refer to Section 3 7 VALVE CLEARANCE ADJUSTMENT SHIFTER ADJUSTMENT Your unit may require an occasional ad
22. time if the mark on the crankcase aligns with the rotor ignition advance angle mark the advance angle device is good if not it should be adjusted or replaced When adjusting the trigger winding can be loosened to adjust the angle between it and the ignition charging coil to adjust the ignition time 70 14589R4 4 7 ELECTRICAL SYSTEM IGNITION SYSTEM INSPECTION When the spark plug does not spark first inspect the wires and if the connections are loose or contacts are bad etc You can follow the electric circuit and take the method of measuring the voltage of every point to find out the trouble Please refer to the previous picture for the following inspection Remove the old spark plug and install a new one if plug is bad It is important that every electric circuit wire connects correctly It is important that the cylinder compression pressure is normal Remove the 4 core and 2 core of the CDI component Connect the negative end of the multimeter with the positive connecting iron of the primary ignition coil black yellow wire Turn the ignition key to START and read the voltage value on the multimeter the biggest voltage value should be above 12V This voltage will drop to when the CDI requests spark This drop may be so quick that a multimeter may not see the change When measuring the voltage do not touch the metal part of the multimeter with finger or an electric shock can occur Con
23. 0 degrees Turn out number of turns 2 3 4 2 1 4 Ensure the rear wheels are safely off the ground Start the engine and adjust the throttle adjusting screw to the prescribed idle rpm 1500 150rpm Left and right adjust the air adjusting screw slightly to find the highest position of the rpm Allow a few seconds after each adjustment Add throttle quickly and gently to full throttle and return throttle immediately Observe 10 to 15 minutes to ensure the idle speed remains the same CARBURETOR REMOVAL e Remove the body cover e Remove the automatic choke lead wire Loosen the fuel drain bolt and drain the fuel in the float chamber Remove the fuel line and the vacuum hose Loosen the throttle cable adjusting nut and positioning nut remove the throttle cable e Loosen the carburetor air inlet vent clip and the inlet manifold clip remove the carburetor CARBURETOR INSTALLATION Reverse the removal procedure for installation After installing make sure all carburetor linkage and cables are in correct position make sure carburetor is in idle position VACUUM CHAMBER The picture shows the structure of the vacuum chamber of the CV carburetor Vacuum chamber 39 14589R4 3 23 ENGINE AND TRANSMISSION VACUUM CHAMBER REMOVAL e Remove the vacuum cover bolt and remove the vacuum cover Remove slowly to prevent the spring from ejecting e Take out the spring the vacuum membrane a
24. 16 ENGINE AND TRANSMISSION VALVE AND VALVE SEAT LAPPING VALVE AND VALVE SEAT AIR IMPERMEABILITY INSPECTION LUBRICATION SYSTEM INSPECTION AND SERVICING GENERAL INTRODUCTION 3 17 ENGINE AND TRANSMISSION OIL SYSTEM INSPECTION AND REPLACEMENT 3 18 ENGINE AND TRANSMISSION ROTARY OIL PUMP OIL PUMP REMOVAL 3 19 ENGINE AND TRANSMISSION OIL PUMP INSPECTION OIL PUMP ASSEMBLY 3 20 ENGINE AND TRANSMISSION OIL PUMP INSTALLATION 3 21 ENGINE AND TRANSMISSION FUEL SYSTEM INSPECTION AND SERVICING CV CARBURETOR 3 22 ENGINE AND TRANSMISSION CARBURETOR IDLING ADJUSTMENT CARBURETOR REMOVAL CARBURETOR INSTALLATION VACUUM CHAMBER 3 23 ENGINE AND TRANSMISSION VACUUM CHAMBER REMOVAL VACUUM CHAMBER INSTALLATION AUTOMATIC SIDE STARTER CHOKE AUTOMATIC SIDE STARTER INSPECTION 3 24 ENGINE AND TRANSMISSION FLOAT CHAMBER FLOAT CHAMBER REMOVAL FLOAT CHAMBER INSPECTION FLOAT CHAMBER INSTALLATION FUEL LEVEL INSPECTION 15 30 30 30 30 31 31 31 32 32 32 33 33 39 33 33 34 34 35 35 35 36 36 36 37 37 38 38 38 39 39 39 39 39 40 40 40 40 40 41 41 41 41 41 41 14589 4 3 25 ENGINE AND TRANSMISSION AIR CHECK VALVE ACV AIR CHECK VALVE REMOVAL AIR CHECK VALVE INSTALLATION 3 26 ENGINE AND TRANSMISSION STARTING MECHANISM INSPECTION AND SERVICING STARTER MOTOR STARTER MOTOR REMOVAL 3 27 ENGINE AND TRANSMISSION ARMATURE INSPECTION CARBON BRUSH INSPECTION 3 28 ENGINE AND TRANSMISSION STARTER MOTOR INSTALLATION 3 29 ENG
25. 65 65 65 65 65 66 66 66 66 67 67 67 68 68 68 69 69 69 69 70 70 70 70 70 71 71 72 72 72 72 73 73 73 73 73 73 74 74 4 1 ELECTRICAL SYSTEM CHARGING SYSTEM INSPECTION AND SERVICING ELECTRICAL DRAIN TESTING Turn the main switch on the OFF position Disconnect the negative ground wire from the battery Connect the positive end of the ammeter with the negative end of the battery Connect the negative end of the ammeter with the ground wire Test the electric leakage In general it demands the number should be less than 1 m A if it is unusual inspect if there is short circuit of the main switch and the main wiring CHARGING STATUS INSPECTION Install a fully charged battery Connect the voltmeter between the binding posts of the battery Remove the fuse and connect the ammeter between the two ends of the fuse holder Connect the tachometer with the engine it s not needed when there is rpm indicator on the vehicle CAUTION Ensure the vehicle s rear wheels are off the ground Start the engine and accelerate slowly measure the charging voltage and current Charging voltage V 13 5 15 5 Typically 15V at idle Charging current A 0 5 Measuring condition 5000 rpm If the voltage is not in the range of the above specified value please inspect the voltage regulator BATTERY The battery used on the vehicle is a maintenance free battery For long periods of st
26. 93 Octane CAPACITIES Maximum Load Driver Passenger amp Gear 340Kg 750165 Maximum Bed Load 114 Kg 250165 Bed Capacity 0 127 cu m 4 5 cuft Under Seat Storage Capacity 0 09 cu m 3 25 cuft Maximum Towing Capacity Rolling Load 227 Kg 500Ibs Climbing Angle 15 20 Fuel tank 10 L 2 64 Gal Engine Oil with oil cooler 36 70z 12V 9Ah Head Light Tail Light Twin 12V 25W 12V 10W 5W Cargo Light 12V 25W Top Speed Speed Limited 45 48 kph 28 30mph CHASSIS Brakes Front and Rear Hydraulic disc Tires Front Rear 20 x 8 0 8 15psi 22 x 11 10 15psi Suspension Front
27. INE AND TRANSMISSION REDUCTION MECHANISM REDUCTION GEAR INSPECTION STARTING CLUTCH REMOVAL 3 30 ENGINE AND TRANSMISSION STARTING CLUTCH INSPECTION STARTING CLUTCH INSTALIATION 3 31 ENGINE AND TRANSMISSION STARTER RELAY INSPECTION 3 32 ENGINE AND TRANSMISSION BELT DRIVEN CVT MECHANISM INSPECTION AND SERVICING GENERAL INTRODUCTION 3 33 ENGINE AND TRANSMISSION DRIVE BELT PULLEY DRIVE BELT PULLEY REMOVAL 3 34 ENGINE AND TRANSMISSION DRIVE BELT PULLEY INSPECTION 3 35 ENGINE AND TRANSMISSION DRIVE BELT PULLEY INSTALLATION 3 36 ENGINE AND TRANSMISSION CLUTCH CLUTCH REMOVAL CLUTCH INSPECTION CLUTCH DISASSEMBLY 3 37 ENGINE AND TRANSMISSION CLUTCH INSTALLATION DRIVEN BELT PULLEY DRIVEN BELT PULLEY REMOVAL 16 42 42 42 42 43 43 43 43 44 44 44 45 45 46 46 46 46 47 47 47 48 48 49 49 49 50 50 50 51 51 52 52 53 53 53 53 53 54 54 54 54 14589R4 3 38 ENGINE AND TRANSMISSION DRIVEN BELT PULLEY INSPECTION DRIVEN PLATE BEARING REPLACEMENT 3 39 ENGINE AND TRANSMISSION DRIVEN BELT PULLEY INSTALLATION 3 40 ENGINE AND TRANSMISSION TRANSMISSION BELT TRANSMISSION BELT INSPECTION TRANSMISSION 3 41 ENGINE AND TRANSMISSION TRANSMISSION ASSEMBLY NGINE AND TRANSMISSION NGINE AND TRANSMISSION 3 44 ENGINE AND TRANSMISSION 3 45 ENGINE AND TRANSMISSION 3 46 ENGINE AND TRANSMISSION OIL SYSTEM INSPECTION AND SERVICING W OIL FILTER OIL FILTER REPLACEMENT 3 42 3 43 Ej Ej 17
28. Interval Initial service first week Monthly Quarterly Yearly IDLE SPEED ADJUSTMENT p 9 I I SPARK PLUG p 9 C A TIRE PRESSURE WEAR p 9 BRAKE FLUID AND PERFORMANCE p 9 AIR CLEANER p 10 CHASSIS NUTS AND BOLTS p 11 FUEL SWITCH PETCOCK FUEL FILTER p 11 C LR FINAL GEAR OIL p 11 I ENGINE OIL p 12 R 5hr R 10 hr CHASSIS p 13 C I CARBURETOR p 13 A VALVE CLEARANCE p 13 SHIFTER ADJUSTMENT p 13 CHAIN TENSION p 13 BATTERY p 13 A adjust C clean I inspect clean or replace if necessary L lubricate R replace 14589R4 2 2 PERIODIC MAINTENANCE AND TUNE UP PROCEDURES MAINTENANCE AND TUNE UP PROCEDURES This section describes the servicing procedures for each item in the Periodic Maintenance requirements IDLE SPEED ADJUSTMENT Over time engine idle speed may become too high or too low and hinder proper vehicle performance If this happens proper adjustments must be made to the components that affect the idle speed The three main components that directly affect idle speed are the Throttle Pedal Throttle Cable and Carburetor Indirectly the Fuel Line and Fuel Cock may also affect idle speed Set the idle speed to 1500 150rpm Ensure the belt is not engaging at idle SPARK PLUG Clean up the carbon around the spark plug to prevent it from d
29. N SET INSTALLATION Remove the gasket attached to the crankcase e Mount piston onto the small end of the connecting rod The top of the piston with IN mark should be mounted towards the direction of the inlet port if the mark is EX then it should be mounted towards the direction of the exhaust port Mounting piston pin and piston pin clip Apply oil on the piston pin to lubricate it Cover a piece of cloth on the crankcase port to avoid the piston pin clip from dropping into the crankcase 20 14589R4 3 4 ENGINE AND TRANSMISSION CRANK CONNECTING ROD SET The connecting rod is the component that links the piston and crankshaft The picture shows the structure and assembling relations of the crank connecting rod component FIGURE 1 CRANK CONNECTING ROD COMPONENTS CRANKCASE AND CRANKSHAFT REMOVAL Before removing the crankcase and crankshaft perform the following procedures e Remove the engine e Remove the cylinder cover e Remove the cylinder e Remove the piston e Remove the drive plate and the driven plate e Remove the AC generator e Remove the starting motor e Remove the oil pump Remove the cam chain tensioner bolt Starting 4 e Remove the cam chain tensioner Use special tools to remove the starting driven gear 21 14589R4 3 5 ENGINE AND TRANSMISSION Remove the crankcase positioning bolts e Separate the right crankcase and the left cr
30. NGINE AND TRANSMISSION GEAR SHIFTING SHAFT ASSY Assemble these parts according to the picture on the right in the order shown 59 14589R4 3 43 ENGINE AND TRANSMISSION e Put the gear shift fork sets into the gear shifting shaft assy and then use gear shift shaft to fit the gear shift fork in the right position Assemble the shift selector assy and fit one end of gear shift fork into the shift selector assy at the same time Revolve the shift selector in proper to ensure that the mark on shift camshaft set in the middle of 2 marks on the shift selector exactly That is the assembling of shift camshaft assy 60 14589R4 3 44 ENGINE AND TRANSMISSION e Fit the shift shaft s locating spring and small steel ball 29 5 into the shift shaft s locating bolt and locking the bolt with the washer Use the special tool to turn the shift camshaft to ensure each shift can turn the shaft freely Locating Spring Locating Bolt 61 14589R4 3 45 ENGINE AND TRANSMISSION Clip the circlip with caliper as in the picture on the right Put the circlip into the groove of shaft to prevent the lateral movement of bearing 62 14589R4 3 46 ENGINE AND TRANSMISSION OIL SYSTEM INSPECTION AND SERVICING W OIL FILTER Check all lines for leaks and cracks To replace an oil line first make sure the engine is cool and that the oil is not hot Loosen the bolt on both ends of the hose Then
31. NSPECTION Measure the free length of the driven belt pulley spring Service limit 163 7mm Inspect if there is any abrasion or damage on the driven plate Measure the outer diameter of the driven plate pulley hub Service limit 33 94mm Inspect of there is any abrasion or damage of the movable driven plate Service limit 34 06mm Inspect if the groove of the guide pin is worn DRIVEN PLATE BEARING REPLACEMENT some unusual sound they should be replaced If the driven plate needle bearing and the ball bearing are loose damaged or have e Remove the needle bearing from the driven plate The removed bearing cannot be reused 55 Bearing remover 14589R4 3 39 ENGINE AND TRANSMISSION e Remove the circlip from the driven plate e Drive the ball bearing out The removed bearing cannot be reused e Apply some grease on the new ball bearing e Drive the ball bearing into the driven plate with its front face upwards Mount the circlip e Apply grease evenly on the inner wall of the driven plate Use the prescribed grease e Drive in the new needle bearing with its mark upwards Use the specific tool e Apply grease around the bearing Movable driven plate DRIVEN BELT PULLEY INSTALLATION 1 e Remove the grease on the driven plate e Mount the oil seal e Apply a little grease o
32. R REMOVAL 18 CYLINDER INNER WALL WEAR INSPECTION 18 3 2 ENGINE AND TRANSMISSION 19 PISTON SET 19 PISTON PIN INSPECTION AND SERVICING 19 3 3 ENGINE AND TRANSMISSION 20 PISTON RINGS INSPECTION AND SERVICING 20 CONNECTING ROD END INSPECTION 20 PISTON RINGS SET UP 20 PISTON SET INSTALLATION 20 3 4 ENGINE AND TRANSMISSION 21 CRANK CONNECTING ROD SET 21 CRANKCASE AND CRANKSHAFT REMOVAL 21 3 5 ENGINE AND TRANSMISSION 22 3 6 ENGINE AND TRANSMISSION 23 CRANKSHAFT AND CRANKCASE INSPECTION 23 CRANKSHAFT AND CRANKCASE INSTALLATION 23 3 7 ENGINE AND TRANSMISSION 24 VALVE MECHANISM INSPECTION AND SERVICING 24 GENERAL INTRODUCTION 24 VALVE CLEARANCE ADJUSTMENT 24 3 8 ENGINE AND TRANSMISSION 25 3 9 ENGINE AND TRANSMISSION 26 CAMSHAFT 26 CAMSHAFT REMOVAL 26 3 10 ENGINE AND TRANSMISSION 27 CAMSHAFT INSPECTION 27 CAMSHAFT INSTALLATION 27 ROCKER ARM AND ROCKSHAFT 27 ROCKER ARM AND ROCKSHAFT REMOVAL 27 3 11 ENGINE AND TRANSMISSION 28 ROCKER ARM AND ROCKSHAFT INSTALLATION 28 CAM CHAIN TENSIONER 28 3 12 ENGINE AND TRANSMISSION 29 VALVE AND VALVE SPRING 29 VALVE AND VALVE SPRING REMOVAL 29 VALVE AND VALVE SPRING INSPECTION 29 VALVE AND VALVE SPRING INSTALLATION 29 14 14589R4 3 13 ENGINE AND TRANSMISSION VALVE GUIDE CLEANING CARBON ACCUMULATION OF THE VALVE GUIDE VALVE GUIDE REPLACEMENT 3 14 ENGINE AND TRANSMISSION VALVE SEAT VALVE SEAT WIDTH MEASUREMENT 3 15 ENGINE AND TRANSMISSION VALVE SEAT FINISHING VALVE SEAT TOUCHING POSITION INSPECTION 3
33. SHOWN IN THE PICTURE 9 10 y 1 Outer Cover Motor 5 Carbon Brush Positive 8 O ring 2 Rotor Motor Electrode 9 Bolt 3 Base Carbon Brush 6 Carbon Brush 10 Spring Washer 4 Plate Positive Negative Electrode 11 Washer Electrode 7 O ring 12 O ring STARTER MOTOR REMOVAL Before removing disconnect the negative battery terminal Then attempt to start the engine by turning the key switch At this time the starter motor should not run This must be done to ensure safety Starter motor lead wire e Remove the starter motor lead wire clamp e Remove the starter motor holding bolt and remove the starter motor 43 14589R4 3 277 ENGINE AND TRANSMISSION Roll up the rubber water resistance cover and remove the starter motor joint e Remove the motor case bolt the carbon brush seat and the motor case etc ARMATURE INSPECTION Inspect the armature surface for uneven wear or damage or burn changing color When there are metal shavings attached to the gap of the armature surface use a cleaning cloth to remove them Please do not use sandpaper to grind Also do not wash it in any solvent which can dissolve or damage its insulation Measure the conducting condition of the armature coil according to the picture It should be conductive Measure the conducting condition between the armature coil and the armature according to the right picture It should be non condu
34. Service Manual 150cc Product 6150 7150 200 Series G tIOM LtlOdsS G NZ DANZ FOREWORD This service manual has been specially prepared to provide all the necessary information for the proper maintenance and repair of the 6150 7150 Fun Karts and 200 Series Light Utility Vehicle The 6150 7150 fits the needs of a wide variety of kart users 13 years and older while the 200 Series vehicles fit the needs of drivers 16 and up Those who will be servicing this vehicle should carefully review this manual before performing any repair or services All information illustrations photographs and specifications contained in this manual are based on the latest product information available at the time of publication Due to improvements or other changes there may be some discrepancies in this manual Therefore if newest information is requested in the future please contact the local distributor or visit our website at www amsportworks com Distributor reserves the right to make production changes at any time without notice and without incurring any obligation to make same or similar changes to vehicles previously built or sold AMERICAN SPORTWORKS 4404 Engle Ridge Drive Fort Wayne IN 46804 Phone 800 643 7332 Fax 800 399 1399 GENERAL INFORMATION 2 MAINTENANCE AND TUNE UP PROCEDURES 7 ENGINE AND TRANSMISSION rrennnvvennnnnvnnnnnnnnnnnnnnvnnnnnnnnennnneennnnnnnnennenennnnnnnennnnnn
35. TAKE THE SMALLEST READING NUMBER AS THE RESULT In the situation without a dial gauge a feeler gauge can be used to make relativity measurement that is to put a new piston into the cylinder and use the feeler gauge to measure the gap between the piston skirt and the cylinder wall then figure out the abrasion loss of the cylinder If the circularity of the cylinder exceeds the limit then a cylinder reboring machine should be used to rebore the cylinder and enlarge its diameter by 0 5mm or 1 00mm then fit the piston and piston ring which size are also enlarged If the wear is too severe and cannot be reworked then a new cylinder should be installed Cylinder bore 57 4mm Cylindricity 0 05mm Circularity 0 05mm PISTON SET PISTON PIN INSPECTION AND SERVICING Insert the piston pin horizontally into the piston pinhole and inspect the clearance between piston and piston pin Service limit 0 02mm If the free play is too much the worn condition of piston pin and piston pinhole must be inspected respective Measuring the external diameter of piston pin Service limit 14 96mm If the result is less than Service limit it should be replaced After replacement the clearance between piston pin and piston pinhole must be assured to comply with the requirement Measuring the inner diameter of piston pin Service limit 15 04mm If the result is more than the Ser
36. UB ELECTRIC CIRCUIT INSPECTION Take the voltage regulator rectifier inspection procedure by two step First inspect the main wiring sub electric condition and then inspect the voltage regulator Inspect only when engine is cold Remove the 4 core connector of the regulator rectifier Measure the conducting status between the main wiring terminals according to the previous wiring diagram Connecting type Normal condition Battery the red wire Vehicle body Battery voltage value Connecting wire the green wire Vehicle body Conductive Lighting wire the yellow wire Vehicle body remove the resistor side auto starter plug and turn the lighting switch to OFF Generally is 0 1 0 8 0 Charging wire the white wire Vehicle body Generally is 0 2 2 00 W White Y Yellow R Red G Green W White 3 100K 2 Y Yellow 5 100K 2 R Red 5 100K 9 69 14589R4 4 6 ELECTRICAL SYSTEM REGULATOR RECTIFIER INSPECTION When the main wiring sub electric circuit condition is normal inspect the regulator rectifier Inspect if the regulator rectifier plug contacts well Measure the resistance value between every regulator rectifier terminal If the resistance value between the terminals is unusual replace the regulator rectifier RESISTOR RESISTANCE VALUE
37. ankcase The joint face cannot be damaged e Remove the gasket and the dowel pins e Remove the crankshaft from the crankcase Cam chain e Take out the cam chain e Remove the gasket on the crankcase joint face pay attention not to damage the joint face e Remove the oil seal from the left crankcase Remove the oil seal from the right crankcase 22 14589R4 3 6 ENGINE AND TRANSMISSION CRANKSHAFT AND CRANKCASE INSPECTION Replace the entire crankshaft assembly if serious wear is found while inspecting Measuring the axial trend clearance of the big end of the connecting rod When measuring place the larger side of the connecting rod close to the crank and insert the feeler gauge between the other side and the crank to measure the end play Service limit 0 55mm Measuring the radial trend X Y clearance of the big end of the conrod Service limit 0 05mm MEASURING THE MAIN SHAFT JOURNAL JUMP OF THE CRANKSHAFT If the crank journal jump is too much it will cause the engine to shake abnormally and shorten the life of the engine so it must be examined carefully when inspecting 0 10mm A 90 0 10mm B 105 Examine if there is any loose or unusual sound when the crank journal bearing turns If there is the Service limit whole set should be changed After cleaning the crankcase inspect if there is any damage Inspect if the joint face of the crankcas
38. ase bolts Make sure the starter motor case is free of metal particles because it is magnetic Before installing the starter motor on the vehicle after assembling it first connect the lead wires and inspect if the motor runs normally e Apply oil on the O ring and install the starter motor e Tighten holding bolts 45 14589R4 3 29 ENGINE AND TRANSMISSION REDUCTION MECHANISM The picture shows the structure of the reduction mechanism REDUCTION GEAR INSPECTION Remove the starting clutch Remove the reduction gear to inspect its wearing degree Measure the inner diameter of the reduction gear shaft It should be replaced when the diameter is more than 10 05mm Measure the outer diameter of the reduction gear shaft It should be replaced when the diameter is less than 9 94mm Reduction gear STARTING CLUTCH REMOVAL Remove the right crankcase cover Remove the left crankcase cover Hold the drive face with the universal set wrench Remove the starting clutch fixing nut Notice that the thread of the fixing nut should be left handed rotation Remove the starting clutch the whole set Fixing nut 46 14589R4 3 30 ENGINE AND TRANSMISSION STARTING CLUTCH INSPECTION Inspect the movement between the clutch and the driving gear for normality The driving gear should smoothly turn clockwise and should not move counterclockwise Inspect i
39. crew e Replace the carburetor See CARBURETOR INSTALLATION FUEL LEVEL INSPECTION Measure the fuel level height Fuel level height 18 5mm Inspect the float for any damage and inspect the float valve for excess wear Confirm the up and down movement of the float is normal 41 14589R4 3 25 ENGINE AND TRANSMISSION AIR CHECK VALVE ACV The air check valve can avoid some abnormity when the throttle closes too quickly such as that the mixed gases are too thin The structure of the air check valve is shown in the picture The air check valve starts working under 50 km h and impels the second air inlet to burn and reduce CO displacement AIR CHECK VALVE REMOVAL Remove the air inlet manifold of the cut valve e Remove the bolt and remove the vacuum membrane cover the spring and the vacuum membrane AIR CHECK VALVE INSTALLATION Mount the vacuum membrane on the carburetor e Mount the spring the vacuum membrane cover and the lock bolt The bottom side of the vacuum membrane should be aligned with the carburetor and the top side should be aligned with vacuum membrane When installing make sure every connecting pipe is connected properly and cannot be pinched bent or clogged up 42 14589R4 3 26 ENGINE AND TRANSMISSION STARTING MECHANISM INSPECTION AND SERVICING STARTER MOTOR THE STARTER MOTOR IS A DIRECT CURRENT DC MOTOR AND ITS STRUCTURE IS
40. ctive If not it should be replaced CARBON BRUSH INSPECTION Inspect the insulating condition between the connecting wire terminal and the starter motor case It should be nonconductive Inspect the conducting condition between the connecting wire terminal and the carbon brush It should be conductive Measure the length of the carbon brush Replace it if it exceeds service limit 44 Carbon brush seat Motor case Motor case boit Armature 14589R4 3 28 ENGINE AND TRANSMISSION Measure the insulating condition of the carbon brush bracket It should be non conductive If not it should be replaced Inspect the needle bearing in the carbon brush base It Bearing should be able to move smoothly with no play Inspect the dust seal for wear or damage If so it should be replaced Dust seal STARTER MOTOR INSTALLATION e Apply some oil on the dust seal e Install the carbon brush on the carbon brush base e Apply a little oil on the moving part of the armature Armature ends Put the carbon brush into the bracket and then install the carbon brush base Do not damage the contact area of the carbon brush and the armature Carbon brush base While installing do not damage the lip of the dust seal Mount the new O ring on the carbon brush base Motor case e Install armature into starter motor case marking sure to not damage the carbon brushes e Tighten motor c
41. e remove the starting relay Connect the C and D end of the starting relay with the battery and the A and B end with the multimeter The battery voltage should be at 12 volts At this time the multimeter should indicate a conductive condition or the staring relay is not good 48 14589R4 3 32 ENGINE AND TRANSMISSION BELT DRIVEN CVT MECHANISM INSPECTION AND SERVICING GENERAL INTRODUCTION The belt driven CVT mechanism is made up of two belt pulleys the drive belt pulley and the driven belt pulley whose diameter can be changed and a notched driven belt The driving belt pulley is mounted on the engine crankshaft and the driven belt pulley connects with the rear driven mechanism ES Driven plate Rotter Drive belt Movable drive plate i Drive plate Its basic operational principle is to realize automatic CVT by the Drive pulley Driven pulley diameter changes the transmission ratio changes of the driving and driven belt pulley When the diameter of the driving belt pulley changes from small Ratio of tran smission to big proportionally the diameter of the driven belt pulley big changes from big to small because the perimeter of the driven belt is constant at this time the speed increases On the contrary the speed decreases The structure of the driving belt pulley is shown in the picture Ratio of tran smission small 49 14589R4 3 33 ENGINE AND TRANSMISSION The picture s
42. e is smooth and clean and notice if it will affect the sealing performance between the left and right crankcase while reassembling After the above inspection use an oilstone to finish the crankcase if it has some surface damage Replace the cover if damage is too severe Because the right and left crankcase axle hole must be concentric so generally they must be replaced at the same time CRANKSHAFT AND CRANKCASE INSTALLATION Mount the crankcase oil seal e Put the cam chain into the left crankcase e Put the crankshaft into the left crankcase Pay attention to avoid the cam chain damaging the oil seal e Mount new dowel pins and gasket on the left crankcase Join the right crankcase and left crankcase together Gasket Dowel pin 23 14589R4 3 7 ENGINE AND TRANSMISSION e Tighten the crankcase positioning bolts Tightening torque 1 98 Ibs m Mount the starting driven gear e Mount the cam chain tensioner e Mount the new O ring on the cam chain tensioner bolt e Apply some oil on the O ring e Tighten the cam chain tensioner bolt The O ring must be mounted in the groove VALVE MECHANISM INSPECTION AND SERVICING The picture shows the common valve train of a four stroke engine This is one kind of overhead valve train Its intake port exhaust port camshaft are all located in the cylinder head the valves bottom up over the combustion cha
43. e lowest shortest setting LEFT ROTATE Shock stiffness adjustments should be made based on the overall Rex RN Ca weight of the rider and occupant 78 14589R4 5 4 CHASSIS FRONT WHEEL ALIGNMENT The front wheel should be toed in 1 8 to 1 4 To check alignment measure distance from A to B to the centerline CL of the tires with the wheels point straight ahead For the proper toe in dimension A should be 1 8 1 4 greater than dimension B Loosen the locknuts on both sides of Front Tie Rods To Make Dimension B smaller screw the rod left If B needs to be longer screw the rod right Tighten the jam nut tightly against the rod end Recheck the distance and repeat the above steps until the Dimensions are per paragraph 1 above FR Wheel tie rod Left rotate Right rotate Eo A E Right rotate Left rotate CHAIN ADJUSTMENT After the first two hours of operation check the chain adjustment and readjust if is has more than 1 2 flex Loosen Nut 1 Adjust Nut 2 Turn nut clockwise in 1 2 turn increments then turn Nut 1 clockwise until nut is tight Follow this procedure until chain is at proper tension Drive chain adjustment 1 79 14589R4
44. e of the secondary ignition coil Standard value 7 9KQ9 20 C The resistance value is in the standard range indicates it is good however indicates the coil is bad Remove the spark plug cap and measure the resistance value of the secondary ignition coil Standard value 2 4K Q 20 The resistance value is in the standard range indicates it is good however indicates the coil is bad THE IGNITION COIL ALSO CAN BE INSPECTED AND MEASURED WITH THE IGNITION TESTING INSTRUMENT Please operate properly according to the instruction Set the measuring switch of the ignition coil on the 1 2V position and connect the ignition coil Turn the switch of the testing instrument to ON position Observe the spark over window and inspect the spark over situation of the ignition coil If it is a normal consistent spark it is good If the spark does not flash consistently it is not good SPARK PLUG INSPECTION Clean the carbon around the spark plug to prevent it from dropping into the cylinder Remove the spark plug See Section 2 2 SPARK PLUG 73 14589R4 loz Arenuer pasay
45. ed to trim it with a reamer When using the reamer cutting oil must be used The reamer can only be turned right do not push in or out directly Clean the cylinder head and eliminate the scraps generated while ramming VALVE SEAT The relative position between the valve seat and the working surface of the valve is very important for the valve to seal properly VALVE SEAT WIDTH MEASUREMENT Clean the carbon accumulation in the combustion chamber Measure the width of the valve seat with a vernier caliper Standard 0 6 1 2mm 4 gt Valve seat width Service limit 1 8mm When abrasion causes the valve seat width to be uneven too wide or too narrow it will result in bad contact between the valve and the valve seat and the valve will not seal tightly At this time it must be reamed with a customized valve seat milling cutter The valve seat milling cutter is a customized trimming tool for the valve L yw seat and it has three cutting angles 32 45 and 60 While trimming press the valve seat milling cutter to make rotary motion with 40 50 N force a Some oil must be applied on the valve seat milling cutter to eliminate scrapping when trimming Je 31 14589R4 3 15 ENGINE AND TRANSMISSION VALVE SEAT FINISHING e Ream out the defects on the working surface with a 45 coarse tooth milling cutter Do not ream too much e
46. esnnnnn 14 SYSTEM eee E 64 CHASSIS 75 1 GENERAL INFORMATION CONTENTS 1 1 1 2 1 4 GENERAL INFORMATION MODEL IDENTIFICATION FRAME NUMBER ENGINE NUMBER FUEL AND OIL RECOMMENDATIONS FUEL ENGINE OIL BREAK IN PROCEDURE GENERAL INFORMATION SPECIFICATIONS 7150 GENERAL INFORMATION SPECIFICATIONS 6150 GENERAL INFORMATION Uu amp BWW WW WW Error Bookmark not defined LOCATION OF PARTS Error Bookmark not defined 14589R4 1 1 GENERAL INFORMATION MODEL IDENTIFICATION FRAME NUMBER The frame number or VIN can be found on a plate which is located on the crossbar behind the seats for fun karts or under the dump bed on 200 Series vehicles ENGINE NUMBER The engine number is located on the lower front left side of the engine cases FUEL AND OIL RECOMMENDATIONS Be sure to use the specified fuel and oil FUEL Only use midgrade unleaded gasoline 89 93 octane ENGINE OIL A high grade 10W 40 motor oil should be used BREAK IN PROCEDURE For the first 2 hours of riding do not exceed 2 3 throttle Vary engine speed for the first 5 hours Never hold engine at full throttle for long periods of time 3 14589R4 1 2 GENERAL INFORMATION SPECIFICATIONS 7150 DIMENSIONS Overall length 2160mm 85 0 inch Overall width
47. f there is any abrasion or damage on the contact surface between the driving gear and the needle bearing It should be replaced if the surface is damaged Measure the inner diameter of the driving gear It should be replaced when the diameter is more than 32 06mm Inspect the condition of the needle bearing It should be replaced if there is any damage Inspect if there is any abrasion or damage on the contact surface between the outer clutch component and the roller Inspect if there is any damage to the roller Inspect if there is any distortion of the spring If the damage is severe it should be replaced Measure the inner diameter of the flange clutch It should be replaced when the diameter is more than 27 94mm STARTING CLUTCH INSTALLATION e Install the spring the roller and the top pin on the body of the clutch e Align the dowel pin on the flange clutch with the hole on the clutch body the install e Apply some thread lock on the outer clutch component bolt and tighten e Apply some oil on the needle bearing and the driving gear and then put the outer clutch component on 47 Needle bearing Driving gear Outer clutch comp Spring p Flange clutch Dowel pin Flange clutch 14589R4 3 31 ENGINE AND TRANSMISSION e Align the groove of the woodruff key on the crank and install the staring clutch e Apply some oil on the reducti
48. hows the working theory of the driving belt pulley When rotating speed rises Movable drive plate The picture shows the structure of the driven belt pulley The clutch shown in this picture is the automatic dry centrifugal weight clutch DRIVE BELT PULLEY REMOVAL Remove the left crankcase air pipe lock bolt e Remove the kick starter and remove the left crankcase fixing bolt Remove the left crankcase cover Remove the gasket and the dowel pin e Hold the drive plate with a universal wrench and then remove the nuts and gasket on the drive plate shaft Remove the drive plate e Remove the driven belt from the drive plate Drive plate 50 14589R4 3 34 ENGINE AND TRANSMISSION e Remove the movable drive plate the whole set e Remove the ramp plate Remove the centrifugal rollers DRIVE BELT PULLEY INSPECTION Movable drive plate B Centrifugal roller Inspect if there is any abrasion or damage of the centrifugal roller Measure the outer diameter of the centrifugal roller Service limit 17 0mm Measure the inner diameter of the movable drive plate Service limit 24 06mm Inspect if there is any abrasion or damage of the drive plate hub 51 14589R4 3 35 ENGINE AND TRANSMISSION Measure the outer diameter of the drive plate hubs movable Roller surface Service limit 23 94mm
49. justment in the shift cables due to typical stretch found during normal operation of the vehicle To make shift adjustments refer to the following procedure Push the shift lever to the D position y Check the restriction control disc found just behind the i oil level dipstick to ensure that it has rotated forward all the way looking for any slack in control cable 1 Loosen adjustment nuts 1 and 2 pulling the housing to draw the cable tight Re tighten the nuts when the cable is properly tensioned e Shift the lever to the R position and check the control disc to ensure that it has rotated full towards the rear of the vehicle e Loosen adjustment nuts 3 and 4 pulling the cable housing to draw the 2 control cable tight Re tighten nuts 3 and 4 when the cable is properly tensioned CHAIN TENSION Refer to Section 5 4 CHAIN ADJUSTMENT BATTERY Inspect the battery for signs of leakage damage to the terminals or casing and loose connections Refer to Section 4 2 BATTERY CHARGING for details on charging Do not allow battery to drain completely as this causes damage to the battery and may prevent proper charging Only use a charger that meets the specifications described in Section 4 2 BATTERY CHARGING 13 14589R4 3 ENGINE AND TRANSMISSION CONTENTS 3 1 ENGINE AND TRANSMISSION 18 ENGINE AND TRANSMISSION COMPONENTS INSPECTION AND SERVICING 18 CYLINDER 18 CYLINDE
50. le Remove bolts from swingarm pivot Check Buffer Rubber Bushing for wear If wear is present on bushing it should be replaced 76 14589R4 5 2 CHASSIS FRONT amp REAR SHOCKS INSPECTION The Front and Rear Shocks are oil dampened units They are non rebuildable If any oil is noticed the shock should be replaced FRONT amp REAR SHOCK ADJUSTMENT There are 5 positions of choice on each shock the default position is set by the manufacture in the middle the third position Please use a round nut wrench to adjust the position The tension of shock spring would increase as you left screw and decrease as you right screw FRONT WHEEL REPLACEMENT Do not disassemble the castle nuts when you replace the front wheels It is only necessary to tighten the nuts so that the wheel turns freely on the axle with minimum endplay Please tighten the nuts after replacing the wheels FRONT HUB INSPECTION SC Lu Spring adjustment cam Check seals for rips or tears and replace if any exist Remove bearings with a punch from the opposite side Inspect bearings for ease of movement If dirt or mud has gotten to them wash them in cleaning solvent and spin with your finger Never spin them with compressed air Apply an ample amount of grease to the bearing and reinstall with a bearing tool making sure it goes in straight If the bearing is not straight damage to the hub can occur Install seals into hub It is recommended t
51. lug Gap C7HSA NGK 0 6 0 7mm Fuel Type USE ONLY Mid Grade Unleaded 89 93 Octane CAPACITIES Maximum Load Driver Passenger amp Gear 400165 Climbing Angle 20 25 Fuel tank 2 64 Gal Engine Oil 6150 without oil cooler 300z 7150 with oil cooler 36 70z 12V 9Ah Head Light 12V 35W Tail Light 12V 21W 5W Top Speed 20mph Speed Reduction Kit Available 35 39mph CHASSIS Brakes Front and Rear Hydraulic disc left foot control Tires Front Rear 19 x 7 0 8 15psi 21 X 10 10 15psi Suspension Front Dual A arm with 1 8 45mm of travel Suspension Rear Spring over shock with 2 4 60mm of travel WEIGHT Dry Weight
52. mber GENERAL INTRODUCTION The four stroke engine completes its four strokes with two piston strokes stroke Compression stroke e Expansion stroke e Exhaust stroke VALVE CLEARANCE ADJUSTMENT Valve clearance is an important technical parameter in the valve train in order to make sure that during any conditions especially when the engine is heated the valve can close tightly When the valve is in the cold condition there must be certain clearance kept This clearance is called valve clearance 24 14589R4 3 8 ENGINE AND TRANSMISSION When the engine is running the valve clearance is demanded neither too big nor too small So valve clearance adjustment is an important procedure in the valve train maintenance Inspection and adjustment must be with a cool engine below 35 C e Remove the cylinder head cover e Turn the cooling fan clockwise until the mark of the timing drive sprocket on the camshaft is in top dead center and the T symbol or other mark of the magneto flywheel aligns to the crankcase mark The crankshaft should co rotate or the exhaust port may not be adjusted When adjusting loosen the locknuts adjust the bolts with a valve adjusting wrench turn clockwise the valve clearance decreases and turn counterclockwise the valve clearance increases Then put a feeler gauge with specific size between valve and rocket to check for correct clearance Take
53. n the O ring Mount the movable driven plate into the driven plate Driven plate Driven plate e After applying some grease on the roller the guide pin mount them into the driven plate hole e nstall the oil seal collar UAI Oil seal collar e Remove the excessive grease No grease on the movable faces of the driven plate e Assemble with the clutch and install on the left crankcase 56 14589R4 3 40 ENGINE AND TRANSMISSION TRANSMISSION BELT TRANSMISSION BELT INSPECTION Remove the left crankcase cover Inspect if the transmission belt is chapped or worn Measure the width of the belt Service limit 19 0mm Replace the belt if its width is less than the above limitation When replacing you must use the OEM part for correct fit See the drive pulley removal and installation procedure for the replacement TRANSMISSION The picture shows an overview of the transmission Gear Shifting Shaft Assembly ASM Shift Selector Gear Shift Fork Reversing Shaft Gear Shift Shaft Shaft Shifter Cam 57 14589R4 3 41 ENGINE AND TRANSMISSION TRANSMISSION ASSEMBLY Put the reversing shaft into the hole of bearing 6203 in the left cover fit the adjusting washer 15 on the gear shifting shaft assy and put them into the hole of bearing 6202 Reversing Shaft 58 Gear Shifting Shaft Assembly 14589R4 3 42 E
54. nd the plunger e Press down the holding clamp of the needle valve top and turn left to take out the clamp e Take out the spring needle valve Do not damage the vacuum membrane e Inspect if the needle valve is worn or not e Inspect if there is damage on the vacuum membrane e Inspect if the plunger is damage VACUUM CHAMBER INSTALLATION e Mount the plunger vacuum membrane into the carburetor body Push the plunger upwards in the direction of the vacuum chamber cover to make the carburetor jet tube in the condition of completely open e Put the spring in e Align the bulge part of the vacuum membrane with the Vacuum cover fillister of the carburetor body and then mount the Vacuum Membrane vacuum chamber cover e Tighten the bolt AUTOMATIC SIDE STARTER CHOKE AUTOMATIC SIDE STARTER INSPECTION e Remove the fuel hose from the carburetor Loosen the carburetor float chamber drain screw and drain the fuel in the carburetor Remove the automatic side starter lead wire and remove the wore clip Remove the carburetor clamp and remove the carburetor Check the connection between the two lead wires The voltage should be below 10V If it exceeds the specific value it should be replaced 40 14589R4 3 24 ENGINE AND TRANSMISSION e While the engine is cold link a hose on the reserve supply fuel line and blow very gently to see if it is obstructed and if the auto side starter
55. nect the positive end of the multimeter with the ignition charging coil black red wire end and the negative end with a ground wire end green end This connection is not required for the CDI however this process can still be followed for diagnostic purposes Turn the ignition key to START and measure the highest voltage of the ignition charging coil it should be more than 12V When the measured highest voltage of the ignition charging coil is not normal then disconnect the generator connector to make further measurement If it is determined that the CDI component end is abnormal but the terminal voltage of the generator is normal then there is a bad wire or bad connection When both are not normal then it is a bad ignition charging coil Disconnect the connector of the trigger winding wire blue yellow where it connects to the blue white wire Connect the positive end of the multimeter with the trigger winding blue yellow wire terminal and the negative end with the green wire terminal on the 4 core connector Turn the ignition key to START and measure the highest voltage of the trigger winding which should be more than 2 1V When the measured highest voltage of the trigger winding is not normal then remove the generator connector and make further measurement If the measured terminal voltage of the CDI component is not normal the generator terminal voltage is normal then there is a bad wire or bad connection If both are no
56. ngine damage can occur Check and clean in the following manner PAPER FILTER MAINTENANCE Remove the air cleaner from its housing Tap filter on an object knocking dust from filter Replace the element if it is wrinkled torn FOAM FILTER MAINTENANCE Remove foam filter from steel cage Wash in non flammable cleaning solvent Submerge in oil and squeeze to remove excess oil Install the element back into the air box CAUTION Before and during cleaning inspect the element for tears A torn element must be replaced Make sure the element is seated properly and no foreign material can pass by it CHASSIS NUTS AND BOLTS Inspect first week and every month thereafter Always pay attention to the vehicles nuts and bolts Some loosening after use is normal and should not be left unchecked for an extended period of time 10 14589R4 2 4 PERIODIC MAINTENANCE AND TUNE UP PROCEDURES TIGHTENING TORQUE CHART Bolt Conventional marked bolt 8 8 marked bolt Diameter mm N m Kg m Ib ft N m Kg m Ib ft 4 1 2 0 1 0 2 0 7 1 5 1 5 3 0 15 0 3 1 0 2 0 5 1 4 0 2 0 4 1 5 3 0 3 6 0 3 0 6 2 0 4 5 6 4 7 0 4 0 7 3 0 5 0 8 12 0 8 1 2 6 0 8 5 8 10 16 1 0 1 6 7 0 411 5 18 28 1 8 2 8 13 0 20 0 10 22 35 2 2 3 5 16 0 25 5 40 60 4 0 6 0 29 0 43 5 12 35 50 3 5 5 5 25 5 40 70 100 7 0 10 0 50 5 72 5 14 50 80 5 0 8 0 36 5 58 110
57. o apply a small amount of grease to the lip of the seal If the retention spring is in bad shape replace the seal with a new one 77 14589R4 5 3 CHASSIS A ARM INSPECTION Grease the nipples of Upper amp Lower A Arm for Upper suspension arm 4 Grese periodically the front wheels periodically Remove Bolt of Upper amp Lower A Arm Fr Shock NE p nuckle Check the Nylon Bushing of Upper amp Lower gr se X aa Fr Braka caliper periodically A Arm for wear Replace them immediately if wear is present Fr Wheel Lower suspension arm STEERING KNUCKLE SUPPORT INSPECTION Remove Rubber Dust Cover of the knuckle Support Check the grease of Ball Joint clean it if it is dirty and fill with grease Replace the Steering Knuckle support if the Ball Joint is loose or steering isn t flexible TIE ROD INSPECTION Tie rods should be checked for ease of movement in their full rotation Remove protective boot and apply grease Check tie rod ends periodically for tightness at their adjusting nuts Always use a new cotter pin after removal FRONT AND REAR SHOCK ADJUSTMENT There are five adjustable positions on each shock The center notch is the default position as set by the manufacturer Ref Figure Use a round nut wrench to adjust the shock To INCREASE the shock stiffness rotate the ring to the highest longest setting To DECREASE the shock stiffness rotate the ring to th
58. on gear and the reduction gear shaft then install e Hold the drive face with the universal wrench at the same time fastens the clutch nut Notice that the thread of the nut should be left handed rotation e Install the right crankcase cover e Install the left crankcase cover Note The reduction mechanism and the engaging mechanism as a whole unit is called the starter STARTER RELAY INSPECTION Attempt to start the engine with the key switch and listen of there is a click sound If there is it is normal If there isn t follow the below procedures to inspect Inspect to see if the brake switch is conductive At this time turn the main switch ON and hold the brake lever The battery voltage should be at 12 volts Measure the voltage between the inlet line the green yellow wire starting relay and the ground wire of the body The voltmeter reading should be close to the magnitude of voltage between the two ends of the battery If not then the brake switch wire or the wire connector is bad Inspect if the key switch is conductive remove the starting relay inlet line the green yellow wire Connect the yellow red wire with the ground wire and turn the key switch to START It should be conductive between the yellow red wire and the ground wire or the key switch its wire or the wire connector is not good Inspect if the working condition of the starting relay At this tim
59. onent is faulty SW B W EXT B R PC G R E G or G W IGN B Y SW B W 100 50 100 EXT B R 0 5 50 100 G R 10 1000 10 1000 1 100 E GorG Wy 0 5 50 0 5 50 1 10 IGN B Y B Black W White R Red G Green Y Yellow The CDI component can also be inspected and measured with the CDI testing instrument Please carefully read the instrument specification so as to operate properly 72 14589R4 4 9 ELECTRICAL SYSTEM Connect CDI component with the special wire of the testing instrument Observe the spark condition on the instrument when the switch is turned on different positions OFF P EXT ONI ON2 IGNITION COIL REMOVAL Remove the spark plug cap e Remove the primary ignition coil wire Remove the ignition coil positioning bolt and remove the ignition coil IGNITION COIL INSTALLATION Reverse the removal procedure for installation When installing connect the black yellow wire of the primary ignition coil with the black yellow connector of CDI and the green wire the green connector of the CDI PRIMARY IGNITION COIL INSPECTION Standard value 0 1 1 0K Q 20 C If the resistance value is 22 it indicates the coil is bad and should be replaced SECONDARY IGNITION COIL INSPECTION Install the spark plug cap and measure the resistance valu
60. or damage on the rocker arm and rockshaft or if the oil hole is clogged 27 14589R4 3 11 ENGINE AND TRANSMISSION If there is abrasion on the surface of the rocker arm the camshaft should also be inspected Measuring the inner diameter of the rocker arm Service limit 10 04mm Measuring the outer diameter of the rockshaft Service limit 9 96mm ROCKER ARM AND ROCKSHAFT INSTALLATION Find the EX mark on the camshaft holder then mount the exhaust port rocker arm and the rockshaft After that mount the inlet port rocker arm and rockshaft Apply some oil on the rockshaft before mounting it on CAM CHAIN TENSIONER The chain tensioner must be in good working order for proper chain tension Cam chain Cam chain tensioner Cam chain tensioner lifter Gasket Cam chain tensioner pivot Cam chain guide Bolt Nut O ring 10 O ring Q9 OO Boc it The operational principle of the tensioner is Spring Inner lever Washer as shown in the picture Thread x Collar As for the adjustment of the cam chain tensioner clockwise is tightening and counterclockwise is loosening Adjusting bolt 28 14589R4 3 12 ENGINE AND TRANSMISSION VALVE AND VALVE SPRING VALVE AND VALVE SPRING REMOVAL Remove the cylinder head Remove the valve cotter with the valve compressor Valve spring e Remove the upper spring race valve s
61. orage the battery will discharge by itself so it should be charged every 3 months After 2 3 years of regular usage the capacity of the battery will descend so it may need charging between uses Replace when necessary with the same type of battery BATTERY REMOVAL Shut down the main switch to make sure no electric current goes through the vehicle e Disconnect the negative battery lead wire first e Disconnect the positive battery second The disconnecting order should not be reversed When disconnecting the positive cable do not touch the body of the vehicle with the removal tool or a short circuit may occur This can cause damage and may be harmful 65 14589R4 4 2 ELECTRICAL SYSTEM BATTERY INSTALLATION Connect the positive cable first and then connect the negative cable BATTERY OPEN CIRCUIT VOLTAGE INSPECTION Disconnect the cable on the battery terminals Disconnect the negative pole first then the positive pole Measure the voltage between the two poles of the battery Strong Battery Fully charged 13 1V Weak Battery Under charged 12 3V Refer to section 4 1 CHARGING SYSTEM INSPECTION AND SERVICING for electrical system testing procedure Fully charged a disconnected battery should never fall below 12 8V This condition indicates a failing battery The battery may still have enough power to start the engine but will need to be replaced very soon Note
62. out the feeler gauge tighten the locknuts and then inspect the valve clearance again Sometimes when tightening the locknuts the clearance will change so it must be rechecked for the proper clearance Top dead center 25 14589R4 3 9 ENGINE AND TRANSMISSION CAMSHAFT The camshaft is the main driving unit of the valve train There are the air inlet cam the exhaust cam and the cam journal on the shaft The camshaft controls the intake and exhaust valve to open and close at the correct time Camshaft wear will affect engine performance and cause excessive noise CAMSHAFT REMOVAL Loosen valve cover bolts and remove cover Remove the cam chain tensional bolt cap and remove the O ring Tighten the cam chain tensioner adjusting bolt clockwise Turn the flywheel counterclockwise to make the T mark on the flywheel align with the mark on the crankcase When the hole on the cam chain timing drive chain wheel is up it is the top dead center position Remove the cylinder head positioning bolt Remove the camshaft holder bolt cap washer Remove the camshaft holder and dowel pin Remove the cam chain wheel from the cam chain and remove the camshaft Cam chain 26 14589R4 3 10 ENGINE AND TRANSMISSION CAMSHAFT INSPECTION Inspect the camshaft bearings for play If there is play replace the whole set Inspect cam surface for damage Measure the height of the cam
63. pring lower spring race valve stem oil seal etc in turn e Remove the valve from the other side The removed parts should be placed properly in order 2 It s better to place intake valve parts and exhaust Valve spring compressor valve parts separately Er accessory VALVE AND VALVE SPRING INSPECTION Inspect to see if the valve is bent or burned Inspect if the action is smooth between the valve and the valve guide Measure the outer diameter of the valve stem Service limit 4 94mm Measure the free length of the inner and outer valve spring Valve Inlet valve Exhaust valve Inner spring 31 2mm 31 2mm Outer spring 34 1mm 34 1mm VALVE AND VALVE SPRING INSTALLATION e Mount the spring retainer valve guide oil seal It s recommended to replace the valve guide oil seal with a new one e After applying oil on the valve stem mount it into the valve guide e Mount the inner and outer valve springs e Mount the valve locker with a spring compressor When mounting the twisting direction of the inner and outer springs must be opposite and cannot be the same the valve gently two or three times with a rubber hammer to make the valve and the valve lock match well Do not damage the valve 29 14589R4 3 13 ENGINE AND TRANSMISSION VALVE GUIDE Carbon accumulation on the valve guide will
64. ropping into the cylinder when removing the spark plug Remove the spark plug In general this process should be performed after the engine has cooled If the spark plug is too tight to remove spray penetrating oil on the spark plug washer and the threads rotate the spark plug after soaking Clean up the filth and carbon accumulation on the spark plug with a steel brush or a blade t 06 0 7mm Inspect spark plug gap in general it should be about 0 6 0 7mm p When the carbon accumulation and wear of the spark plug are advanced replace the spark plug Replace with a spark plug of the same specification TIRE PRESSURE WEAR Check the tire pressure every time the vehicle is ridden The tire pressure is very important for the stability of the ride e For proper tire pressure ratings see sections 1 2 and 1 3 BRAKE FLUID AND PERFORMANCE Always check that there is plenty of brake fluid in the brake fluid reservoir Ensure brake fluid looks clean and brake hoses are in good condition Check that the front 7150 only and rear brake pads are in good condition Check the brake rotors for abnormal wear 9 14589R4 2 3 PERIODIC MAINTENANCE AND TUNE UP PROCEDURES AIR CLEANER Clean quarterly or more if the vehicle is driven in dusty conditions If the air cleaner is clogged with dust performance will be severely decreased and if left unserviced e
65. se 1588mm 62 5 inch Track Width Front Rear 1049mm 41 3 inch 1000mm 39 4 inch Ground Clearance 170mm 6 7 inch ENGINE Single cylinder oil amp cooled 4 stroke Engine displacement 150cc Bore x stroke 57 4 x 57 8 Corrected Compression Ratio 92 1 Carburetor DENLJB24J Output Power Torque N m r min 1 9 0 hp 7500rpm 13ft Ibs 5500rpm Starting Keyed Electric Ignition CDI Lubrication Cooled Force amp Splash SAE 10W 40 Transmission CVT Automatic with Neutral and Reverse Spark Plug Gap C7HSA 0 6 0 7mm Fuel Type ONLY USE Mid Grade Unleaded 89
66. t normal then it is a bad trigger winding 71 14589R4 4 8 ELECTRICAL SYSTEM IGNITION CHARGING COIL INSPECTION Measure the resistance value between the ignition charging coil black red wire and the body ground wire Standard value 300 1000 9 20 C When the actual value is more than the standard value it should be replaced TRIGGER WINDING INSPECTION Disconnect the connector of the trigger winding wire blue yellow where it connects to the blue white wire Measure the resistance value between the trigger winding blue yellow wire and the body ground wire When the actual value is more than the standard value it should be replaced Standard value 40 300 0 20 C CDI COMPONENT INSPECTION It is similar with the regular inspection the CDI component inspection is also divided into two steps First inspect every wiring winding or coil connected with CDI Then inspect the CDI component Remove the CDI component Inspect if the connector is loose or eroded Inspect the conduction and the resistance value of the main switch the ignition charging coil the trigger winding and the ignition coil When the main switch is in OFF position it should be conducted and the resistance value of every coil should be the standard value Inspect the resistance value between every CDI component terminal If the actual value is not in the range of the value in the chart then the CDI comp
67. take the hose out and replace with a new one Retighten bolts OIL FILTER REPLACEMENT The oil filter is removed by turning clockwise using an oil filter wrench Before installing the new filter fill it with oil 2 mm from the top and replace back on the oil cooler turning counterclockwise The engine manufacturer suggests that you change your oil and filter after 40hr of running 63 14589R4 4 ELECTRICAL SYSTEM CONTENTS 4 1 4 2 4 4 4 5 4 6 4 8 4 9 ELECTRICAL SYSTEM CHARGING SYSTEM INSPECTION AND SERVICING Electrical Drain Testing CHARGING STATUS INSPECTION BATTERY BATTERY REMOVAL ELECTRICAL SYSTEM BATTERY INSTALLATION BATTERY OPEN CIRCUIT VOLTAGE INSPECTION BATTERY CHARGING ELECTRICAL SYSTEM PRIMARY COIL PRIMARY COIL INSPECTION ELECTRICAL SYSTEM GENERATOR REMOVAL AND INSPECTION GENERATOR REMOVAL ELECTRICAL SYSTEM GENERATOR INSTALLATION REGULATOR RECTIFIER MAIN WIRING SUB ELECTRIC CIRCUIT INSPECTION ELECTRICAL SYSTEM REGULATOR RECTIFIER INSPECTION RESISTOR RESISTANCE VALUE MEASUREMENT IGNITION SYSTEM IGNITION TIMING INSPECTION ELECTRICAL SYSTEM IGNITION SYSTEM INSPECTION ELECTRICAL SYSTEM IGNITION CHARGING COIL INSPECTION TRIGGER WINDING INSPECTION CDI COMPONENT INSPECTION ELECTRICAL SYSTEM IGNITION COIL REMOVAL IGNITION COIL INSTALLATION PRIMARY IGNITION COIL INSPECTION SECONDARY IGNITION COIL INSPECTION SPARK PLUG INSPECTION 4 10 ELECTRICAL SYSTEM WIRING SCHEMATIC 64 14589R4 65
68. tall the partition board and tighten bolts e Install the starting reduction gear staring clutch Mount the gasket dowel pins Mount the right crankcase cover positioning bolt Mount the trigger winding and the stator coil e Tighten the right crankcase cover positioning bolt The bolt should be gradually diagonally tightened in two to three steps After finishing the installation inspect for any oil leaks 37 14589R4 3 21 ENGINE AND TRANSMISSION FUEL SYSTEM INSPECTION AND SERVICING CV CARBURETOR The CV carburetor is a constant vacuum carburetor The picture shows the structure of the CV carburetor Valve plate set Electric choke Auto choke 10 Air cut valve set 1 Gasket set 2 Float valve set 3 Needle jet set 4 Float set 5 Float chamber set 6 Screw set 7 Screw set B 8 9 11 12 13 14 15 16 17 18 19 20 Compression coil 21 spring 22 Screw 23 Carburetor assy 24 Top comp 25 Vacuum piston comp 26 Needle jet holder 27 Plate clip 28 Holder cap 29 Tube A 30 Tube B 38 Screw Screw Washer screw Washer screw Washer screw Clip Clip Tube Main jet Slow jet 14589R4 3 22 ENGINE AND TRANSMISSION CARBURETOR IDLING ADJUSTMENT AIR ADJUSTING SCREW ADJUSTMENT First turn the air adjusting screw all the way in Then turn the screw back out by the prescribed number of turns Each turn is one complete turn 36
69. tool Then repeatedly rotate the valve suction cup to lap the valve and valve seat evenly until they match tightly Before lapping clean the valve valve seat and valve guide When lapping do not use too much force During lapping do not drop any silicon carbide into the place between the valve lever and the valve guide VALVE AND VALVE SEAT AIR IMPERMEABILITY INSPECTION After lapping the valve and valve seat the air impermeability of the joint surface should be inspected Method one Same as the method of VALVE SEAT TOUCHING POSITION INSPECTION Method two Evenly draw several lines on the working surface of the valve with a pencil Put the valve into the valve seat If the lines are all broken after turning 1 8 1 4 then the air impermeability is good Method three Mount the valve on the cylinder head and fill the inlet and exhaust vent with nonflammable solvent and preserve for 5 minutes If there is no leaking the valve is seated correctly LUBRICATION SYSTEM INSPECTION AND SERVICING GENERAL INTRODUCTION The picture shows the functional diagram of the lubrication system After the lubrication oil crosses the filter screen the rotator oil pump pumps it Some of it goes into the big end of the connecting rod and splashes on the cylinder wall and the small end of the connecting rod The other goes through some oil passages such as the shaft neck of the camshaft and splashes on the cam rockshaft and cam
70. tor Auto side starter Resistor Measure the resistance value between the white wires of the generator and connecting wire of the vehicle body Standard value 0 2 0 4 2 20 When the actual value is more than the standard value the coil should be replaced 67 14589R4 4 4 ELECTRICAL SYSTEM GENERATOR REMOVAL AND INSPECTION Generator wire rubber clip GENERATOR REMOVAL Remove the cooling fan cover bolt and screw e Remove the cooling fan cover e Remove the cooling fan bolt and remove the cooling fan Hold the flywheel with a universal holding wrench at the same time remove the flywheel nut e Remove the flywheel with a flywheel puller and remove the solid key e Remove the generator wire connector e Remove the generator wire holder e Remove the generator coil bolt e Remove the generator wire rubber bushing from the right crankcase 68 _ Wrench TJ iywheel NO nnector bolt NW 14589R4 4 5 ELECTRICAL SYSTEM e Remove the coil set Do not damage the coil when removing GENERATOR INSTALLATION Reverse the removal procedure for installation When installing the flywheel make sure there are no metal pieces such as bolts or nuts attaching to the inner wall of the flywheel After the installation is finished start the engine to inspect and adjust the ignition timing REGULATOR RECTIFIER MAIN WIRING S
71. vice limit it should be replaced After replacement the clearance between the holes of piston pin must be assured to comply with the requirement 19 14589R4 3 3 ENGINE AND TRANSMISSION PISTON RINGS INSPECTION AND SERVICING Inspect if there is a flaw serious wear or serious conglutination etc on the piston ring If there is it should be replaced The piston ring s lateral clearance and notch clearance are too large or too small with both cause malfunctions so it must be measured Measure the clearance of piston ring in the piston ring groove This clearance is the piston ring s lateral clearance First ring 0 09mm Second ring 0 09mm CONNECTING ROD END INSPECTION Put the piston pin and bearing into the connecting rod end inspect the degree of tightness of the piston pin in connecting rod end Measure the inner diameter of the connecting rod end Service limit 15 06mm When the abrasion of the bore exceeds the limitation it should be replaced PISTON RINGS SET UP Before setting up first apply oil on every piston ring Then enlarge piston rings At the same time cover them on the piston and move downwards gradually until piston rings fall into the ring groove The ring gaps should be aligned at 90 degree intervals Ring order Top Barrel Ring slightly rounded edges Middle Square Taper Ring no rounding on edges Bottom Scraper Cutter Rings thin ring scraper thin ring PISTO

150cc Service Manual 14589R4

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