TR3-50 SERVICE MANUAL
Contents
1. Oil Tank E Dismantling and assembling oil tank 1 Drain off the oil 2 Disconnect plug of oil gauge 3 Remove the oil tank 4 Clean the oil tank 5 To assemble the oil tank please follow the opposite procedures of dismantling 100 V Electric equipment 1 Troubleshooting 2 Battery 1 Check the cells of battery 2 recharging 3 Test the recharging performance 3 Recharge system 1 the wiring diagram of recharge system 2 check A C flywheel magneto 3 Check regulator rectifier 4 Ignition system 1 the wiring of ignition 2 check spark plug 3 check H T cable and H V coil 4 check C D I set 5 Starting system 1 the wiring of starting 2 checking the starter 3 dismantling the starting motor 4 checking the starting motor 101 1 Troubleshooting Currency is unstable A Recharge system 1 The wiring of batter connection is not good No power 2 I gnition system connection is not good 1 Battery over discharging 3 gnition system is short circuit ONo electrolyte in battery 4 Lamp system connection is not good or Battery is bleached short circuit Short circuit in the Battery e Abnormal recharge system Regulator malfunction 1 The plug connection is not good 2 The battery wires are disconnected wire broken or short circuit 3 Fuse is broken 2 Rectifier is out of order 4 Ignition switch is abnormal 3 A C flywheel magneto is abnormal e Voltage is too low D Engine running unsmoothly 1 Batt2. B Dismantling the Fender 1 Take off the screws of front inner cover And fender 2 Take off the screws between the front Fender and chassis 3 Separate the head light and signal lamp Cable 4 Take off the fender 34 C Dismantling the upper handle cover 1 Remove the left and right Back mirror 2 Remove the screws of upper And lower handle cover 3 Unplug the speedometer cable 4 Unplug each switch cables 5 Remove the upper handle cover 35 D Dismantling the step plates and lower D Dismantling the step plates and lower Mudguard 1 Take off the screws of the four step plates and take off the four step plates 2 Screwing out the screws of lower mudguard E Dismantling the step floor and front inner cover screwing out the screws of battery cover 2 Disconnect the negative then positive cable 3 Screwing out the screws between the step floor and front inner cover Take off the front inner cover 4 Pull out both the negative and Positive battery cables Take off The step floor 5 When assembling the procedures Will be reversed M6 0 7 1 1kgf m M5 0 35 0 5kgf m Note Avoid clamping and scraping the Cables or pipes by the plastic parts Sf M Checking and Adjustment 1 Regular checking table 2 Battery 3 Clean air cleaner 4 The final reduction mechanism oil 5 Spark plug 6 Compression pressure measurement 7 Ignition timing 8 Throttle cables a
3. lever A A AEA oe Easy to kick Difficult to kick Ocylinder burn out wire broken or shout circuit Starting motor can not stop after starting Check and adjust Trouble condition Main switch Turn off start gear can t stop start relay capacitor melted or short circuit 25 12 No sparking Check and adjust ug eee ns ae Plug then check again Trouble condition amp Good sparking 7 Fe an PNET And H V cable is Loose or not Check the CDI plug i Is loose or not GHG Reba aN G ER CAC E TERE eRe T Eee Sate e eee Sens ee E Gees esse eens Check the connection Between CDI plug and Each terminals check The resistivity of Each terminal Aes eee AES Check relative parts SO eae CNOA ana Ea TO AO Aa e a Ae AO Ae Check ignition cojl eee 26 Weak sparking Or no sparking The reason Spark plug faulty Spark plug cap is loose Plug is poor connection Omin switch faulty defective magneto coil pulse generator faulty defective ignition coil main cable broke poor connection of joints or sockets defective CDI Defective ignition coil 13 Charging abnormal battery over charging or over discharging Check and adjust Trouble condition Measure battery s oo mmmmcenntsinnninene Voltage then start engine ors E amen nese aan al To normal value Obattery is dead But after engine pee he voltage er peer Bee down acii Check
4. Fuel leakage Clean Carburetor Carburetor s Throttle and wsrueyoow uguJ Wass uoneonqnT wa s s Jon Choke function Carburetor Float height Carburetor Adjustment Change fuel pipe X every 4 years 40 Remark Checking period gen era first aa Item l mong everyl2 everyl every3 everyl2 udgement che cki _ months months months months standard Initial 5000km 10000km 1000km 2500km 10000km Lamp system Dirty or broken Horn signal f Function Lamp reflector Rear view Dirty or broken mirror Dirty or damaged ng Dashboard Function E3 Losseness or Damage on Ass y part Muffler silencer Function Loose or chassis Damaged The previous Confirm it does Not happen Abnormal case Again Chassis others Lubrication Decarbonate on Combustion room And muffler 4l 2 Battery Recharge when power is out 1 remove the floor mat 2 Screwing out the two screws on the battery cover Remove the battery cover 3 Remove the negative cable and then the positive cable take out the battery to recharge 4 To re assemble the battery please follow the opposite procedure of disassembling after Recharging Negative Pole Positive Pole Note A The battery 1s totally sealed do not remove seal bolts when recharging B It s no need to add any electrolyte for this re filling free battery Please recharging 12V by the following curren
5. b Engine idling RPM unsteady running not smoothly 1 Improper adjustment of the carburetor idling 2 Ignition disorder 3 Compression pressure is too low 4 Air mixture is too thick 5 Air mixture is too lean 6 Air cleaner is blocked 7 Air injection is not in good function 8 Fuel is dirty c Air mixture 1s too lean 1 Carburetor main jet is blocked 2 The ventilation hole of the fuel tank cover is blocked 3 Fuel filter is blocked 4 Fuel pipe bended squeezed or blocked 5 Float valve is abnormal 6 Fuel level is too low 7 Air pipe is blocked d Air mixture 1s too thick 1 Float valve is abnormal 2 Fuel level is too high 3 Air jet is blocked 82 D Dismantling carburetor 1 Remove the luggage box 2 Loose the hose clamp between the carburetor and the air cleaner Then remove the air cleaner 3 Unscrew the fuel draining screw of the carburetor Drain off the fuel inside the carburetor 4 Remove the fuel pipe and the vacuum pipe on the carburetor 5 Remove the oil pile on the carburetor 6 Remove the bolts on the intake manifold and carburetor E Dismantling float nozzle Note The auto choke has been properly adjusted already Please do not adjust it further When there is blockage in the carburetor please clean it by air compressor 83 F Reed valve 1 Dismantling reed valve 1 Take off the luggage box 2 Remove the air cleaner 3 Remove the carburetor 4 Unscrew the locking screw of t
6. 1 Measure at the skirt area where is 12 mm from the skirt lower end of skirt 2 Limit of use 50cc change if when below 39 895mm 3 Calculate the clearance between the cylinder and piston Limit of use change it when over 0 100mm 5 Inner diameter measurement of the piston pin hole Limit of use chang it when over 14 032mm 10 6 Outer diameter measurement of the piston pin limit of use change it when under 9 970mm T REX 50cc 7 Check piston ring Measure piston ring gap Limit of use change new ones when the first ring and second ring are over 0 4mm Push the piston ring into the cylinder By piston the measure the gap 8 Check connecting rod small end 1 Install piston pin bearing onto the connecting rod small end then check the looseness of the piston pin 2 Measure the inner diameter of the connecting rod small end H Installing cylinder and piston 1 Place the piston ring into the second ring ditch first then install the piston ring into the first ditch 2 a Piston ring should be installed into piston ring ditch by even force b After assembling be sure that the piston ring sliding surface is at the same height as the piston outer surface c If the piston ring can not fit into the ditch please clean up the carbon in the piston ring ditch or piston ring itself 3 a Piston ring must be installed in the correct location b After installing the piston ring it should be able to rotate f
7. Spark freguency witch CIRB i ja AL JN F plug C D I d Set the head lamp switch at OFF engine revolution is at 2000 rpm while testing Then increase the rpm slowly Head Lamp Switch Recharging rpm 2 900rpm 6 000prm OFF DAY Under2 000rpm 0 6A MIN 1 SACMIN ON NIGHT Under2 000rpm 0 6A MIN 1 SACMIN e If the testing result does not match the standard value check the regulator 105 3 Recharge system 1 Recharge system diagram regulator redwhite yellow Head lamp swi tch BA fuse Generator b 7 rear lamp ae Head lamp Head lamp Hi light indicator LOG 2 Check A C Generator a Open the seat cover and remove the luggage box b Measure the resistance value of terminals Yellow V S black 0 1 1 0 White V S black 0 2 2 0 ACG inside 3 Check regulator Measure the resistance value between each terminal It should be in the specified range otherwise change a new one 107 4 Ignition system 1 the wiring or ignition NO Blue Black OFF CDI Ignition condensor H T coi Black Red RED ou 0 Wd re je rT 4 sade Ignition coil Blue yellow z e spark PI nl ark a SGR alle Ea ts Pulse coil Hy p 7 Black 2 check spark plug 3 Check the H V cable and H V coil by using the CDI tester Please follow the instruction manual 4 CDI sets checking Check with the CDI tester and please follow the inst
8. add grease on each cable 88 E Front wheel 1 Remove the locking nut of the front wheel on the right side 2 Draw out the axle of front wheel remove the ring and take off the gear sets of speedometer 3 Remove the front wheel assy 4 Assemble the front wheel follows the opposite procedure of dismantling Locking Torque M10 3 0 4 0kg m Note 1 Put the lock block of speedometer gear assy upon the extrusion of the front fork 2 Put the grease onto the grease sets of speedometer before assembling 5 Checking the front wheel axle a Check the bending degree of the front axle b Take note of the bending degree on the middle of axle c Limit of use Change it when above 0 2mm 89 6 Front wheel bearing checking Turn the tire If the bearing is Loosen or any occurrence for noise Please change a new one Sway ing horizontal direction 7 Front wheel rim checking 1 Check the swing of the front wheel rim 2 Limit of use eHorizontal direction Change a new one when above 2 0mm e Vertical direction Change a new one when above 2 0mm 90 F Front brake 1 Disassembling and assembling of the front brake comp a Remove two bolts fixed on the front brake comp and the front fork b Remove the front brake comp c Assemble the front brake comp Follows the opposite procedure of dismantling Locking Torque M8 2 0 3 0kg m 0il hydraulic disk brake Fluid releasing valve
9. l i ui A Fill the enough een to the container Lg i Fluid Hose b Do not let the brake oil overflow fromthe Ar i Ox Z e NG 2 Air releasing of the front brake comp wane ee The procedure of air releasing master cylinder or container when assemble the master cylinder cover c Put the spanner upon the drain screw d Lock and unlock the screw several times to Release the bubbles all HL eet e Operate slowly the brake lever several en Bas times f Clamp the brake lever to the end g Loose the drain screw then open the lever completely h Locking the drain screw and then loose it when the lever 1s opened completely 1 Repeat above procedure until all the air in the brake system has been released Completely Locking torque of leaking screw 0 6 kg m 91 3 Front fork checking If it is bent or cracked please replace with a new one 4 Front shock absorber checking Check is there any unusual damage or worn out condition and whether the guide rod of the Front fork is crooked or not Fork oil type SAE 10W20 Capacity each side 84 CC NOTE If the guide rod is crooked it should be replaced by a new one or repaired Tube fixing screw Spring fixing bolt 92 5 Disassembling and assembling the front brake disk a Remove the front wheel b Remove three nuts on the disk c Remove the disk d Assemble the disk follows the disassembling procedure Locking torque M8 2 0 3 0kgm 6 C
10. of order ignition coil disconnect or short circuit ignition coil disconnect or short circuit main switch out of order defective magneto coil Ostarting clutch out of order piston ring stuck reed valve deteriorated cylinder piston piston ring worn out cylinder gasket leakage cylinder body has sand hole Obad action of auto choke air trapped in intake manifold wrong ignition timing bad adjustment of carburetor s fuel adjusting screw QOcarburetor fuel level too high malfunction of auto choke throttle valve open too largely 2 Weak acceleration Check and Adjust Start engine and open throttle Gradually check and inspect PAEA A E aaa Engine can rotate up Check ignition timing check With ignition timing lamp Check cylinder Compression pressure use cylinder compression fe pressure gauge Check carburetor see es Shed AR AA ARAS HORS Is blocked or not No dirty and no color change Trouble condition Oair cleaner blocked fuel supply system abnormal Engine can t rotate fuel tank cover blocked Up completely muffler blocked auto cock is malfunctioned auto chock is malfunctioned OCDI unit is out of order alternator flywheel magneto out of order Ocylinder piston ring worn out Pressure 1s cylinder gasket leakage Not normal cylinder body has sand hole Reed valve malfunction blocked Clean the carburetor Oclean the dirt Dirty color
11. off the left cover Sl 3 Remove the fixing nut of the clutch 4 Take off the ramp plate 5 Take off the belt and the rear clutch 6 Take off the driving plate e Take off the driving gear start set 52 7 Remove the start idle gear fixing plate 1 4 1 s a he 5 i aig a J E t R at 1 af oy Fa LET g ii r e a g A Fai he E i i hy a eee Da Si 8 Take off the idle gear 53 9 To assemble the driving pulley please reverse above procedure Locking torque 1 Nut of driving pulley M10 3 2 4 0kg m 2 Locking nut of clutch M10 3 5 4 0kg m 10 Checking the driving belt 1 check whether it is cracked or not or its rubber and fiber are loose or not check also if they are extraordinarily worn out 2 driving belt width limit of use change it below 17 0mm 11 Disassemble the slide driving plate set 1 Remove the bush of slide driving plate 2 Remove the screw and disassemble the cover of slide driving plate 3 Remove RAMP plate 4 Remove weight roller Belt width 12 Checking list 1 Check the wearing condition of the weight roller limit of use change it when below 15 5mm 2 Check inner dia of slide driving plate s gasket Limit of use 5O0cc Change it when above 20 123 mm 3 Check the wearing condition for driving pulley surface 4 Check the outer diameter of the driving plate s boss Check the wearing condition Limit of
12. then check The sparking Ospark plug dirty Good ki l CDI out of order Sparking abnormal AC magnet abnormal Or no sparking ignition coil faulty H V coil disconnect or short circuit main switch is abnormal A C generator malfanction hose is damaged air pipe is blocked or damaged 17 4 Engine running unsmoothly high speed Check and adjust Trouble condition _ Check ignition timing OCDI sets faulty AC generator faulty Check auto cock Fuel supply system ee ee ee A ee A Ofuel level is too low fuel pipe fuel filter unsmoothly is blocked auto cock faulty Check carburetor Is blocked or not PETEERE Pee rer Retr ven RO E E Menon DERE ent ENMU ITF No blocked blocked Mclean and wash it ls 5 Clutch drive and driven pulley Trouble condition Odriving belt worn out distortion Engine can start but can t driven plate worn out Movethe vehicle driven plate spring distorted driven lining worn out driving pulley shaft gear teeth cracked final gear damage driven lining spring cracked or Engine runs but it stops worn out Suddenly and seems to rush out weight rollers melt and stick to driving face shaft worn out rear wheel rotates while idling QOdriving belt worn out distorted or slipping weight roller worn out driving plate worn out driving plate spring distorted driving pulley shaft worn out Climbing is not smoothly QOdriving bel
13. use change it when below 19 911mm 54 2 13 Assemble the slide driving plate 1 Clean the inner surface of slide driving plate then assemble the roller 2 Assemble the ramp plate 3 Please reverse the procedures of disassembling to finish assembling 55 D Starter dismantling 1 Dismantle the left crankcase cover 2 Remove the hexagon nut then remove the starter lever 3 Remove five screws of isolating plate 4 Remove the stater spring from the start returning positioner 5 Remove the driven gear comp of kick starter 6 Remove the retaining c type clip 7 Remove the spindle comp Of kick starter 8 Checking the starter a Check the wearing condition of the outer diameter of the spindle comp and the inner diamter of bush and gear b Check the wearing condition of the shaft of driven gear comp gear sets and ratchet 9 Assembling the starter To assemble the starter please follow the opposite procedures of dismantling Locking torque M6 1 0 1 2kg m Note Make sure that on end of the torsion spring is hooked on the groove of driven gear and another end of the torsion spring 1s hooked on the poled inside the left crankcase Put some grease on shaft and gear sets before assembling 56 E Clutch driven pulley 1 Dismantle the clutch a Remove left crankcase cover b Remove driving plate c Remove driving belt d Remove the M10 locking nut then the clutch 2 Assembling the clutch please follow t
14. voltage rectifier a Plug is loose or not battery malfunction ee ee ee ee good loosen Opoor connection Check the voltage red cable disconnected Between chassis and eee eed Rees The red cable Gof Voltage rectifier Ovoltage rectifier malfunction white cable disconnect Check the resistivity i ee Rn een ee ree poor connection Of A C generator coil A C generator s charging abnormal over charging white cable disconnected defective coil Start engine connect i eect ets _ green cable to Chassis then measure Woltaze hichen Than specification e e COREE GI Witeeceeneee cece the voltage between Of the cable of Voltage normal of voltage of rectifier chassis O and red cable 2 Voltage rectifier Ocable poor connection poor connection of green cable an Ere ae Of the body of nearest Voltage rectifier Out of spec of spec Voltage rectifier faulty 21 4 Dismantling maintaining repairing and assembling operation 1 Lubrication system 2 Plastic parts 3 Engine dismantling 4 Drive pulley starter clutch 5 Cylinder and piston 6 AC Generator 7 Final transmission mechanism 8 Crankcase crankshaft 9 Carburetor reed valve and auto cock 10 Steering bar front wheel front brake comp front fork 11 Rear wheel rear brake rear damper 12 Fuel tank oil tank 28 1 Lubrication system and oil pump 1 Lubricat
15. 10mm Smm Smm 3 0 4 0 2 0 3 0 Smm 3 Other parts standard torque values kg m 10mm bolt and nut 3 0 4 0 6 Smmscrewo 035 05 8 6mm flange bolt and screw 10 14 9 7mm flange bolt and screw 1014 LO 3 Lubrication instruction A Engine Sliding part Premium 2 stroke Lubrication Sliding part Or SAE 30 B Replacement 90c c 4 Replacement 220c c Gasket of starter shaft 3 i idle gear sliding Clean grease 3 parts l B Chassis appearance C Wheel bearing 13 5 Trouble shooting difficult starting or can t start Check and adjust Loose carburetor draining Screw check 1f in side of Carburetor have fuel or not The fuel supply in carburetors Ts enough or smooth Remove spark plug insert Spark plug cover and touch i With engine check there is Any spark Measurement of Compression pressure Start engine follow the Instruction of starting engine Engine has no knocking i Remove spark plug And check again eee Trouble condition No fuel supply in carburetor No sparking or Weak sparking Insufficient or No Pressure Engine knocking But can t start 14 The reason check there is fuel or not pipe between ful tank and carburetor 1s blocked Float is blocked Fuel gauge is blocked auto cock is malfunctioned Ospark plug out of order dirty CDI unit out of order A C generator out
16. 2 Locking torque M8 2 0 3 0kg m M10 3 0 4 0kg m M12 5 0 6 0kg m 3 After installing please do the following checking and adjustment Checking and adjustment a Wiring connection b Throttle cable and oil control cable c Rear brake adjustment d Fuel and oil route 4 Drive pulley starter amp clutch A Troubleshooting a Engine starts but vehicle does not move 1 driving belt worn out 2 driven plate worn out 3 clutch lining worn out 4 driving plate s spring broken b The vehicle stops or trembles when running 1 clutch lining spring cracked or broken c Can t reach high speed no pick up 1 driving belt worn out 2 Driving plate spring distortion 3 Weight roller worn out 4 Driving plate abnormal Note No grease and oil allowed to stain on driving belt and driven plate B CVT parts measurement data Item Standard value mm Limit of use mm Model 50cc The inner dia of Slide driving plate 20 035 20 085 20 123 The outer dia of boss movable 19 960 19 974 ar Driving plate Belt width 18 0 19 0 Clutch lining thickness Clutch outer diameter 117 0 117 2 117 5 Driving plate spring free length 87 9 The outer diameter of driven 33 965 34 025 33 95 plate sets The inner diameter of slide 34 000 34 025 34 070 Driven plate The outer diameter of weight 15 992 16 008 15 50 Roller set 50 C Driving pulley 1 Take off the 10 screws of left Cover remove the left cover 2 Take
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18. TR3 50 SERVICE MANUAL Manufactured by PGO of Motive Power Industry Co Ltd PREFACE This manual provides every service specialist with professional techniques of maintenance and repairing for Tricycle T REX 50 It provides a detailed guide for those who may concern with how to maintain repair reassemble and change parts of their scooters At every section we illstrate each important point by assembling procedures explosive diagrams and photographs Although we have tried our best to make this manual as perfect as possible please kindly inform us if any fault needs to be corrected in this manual Thank you for purchasing our PGO scooters Motive Power Industry Co Ltd Service Department October 20 2004 CONTENTS Page I The specification of T REX 50 I Service information 1 The operation notice 2 Locking torque value 3 Lubrication instruction 4 Wiring diagram 5 Troubleshooting M Checking and adjustment 1 Regular checking table 2 Battery 3 Cleaning air cleaner 4 The final reduction mechanism oil 5 Spark plug 6 Compression pressure measurement 7 Ignition timing 8 Throttle cables adjustment 9 Idle adjustment 10 Front brake adjustment 11 Rear brake adjustment 12 Tire IV Dismantling maintaining repairing and assembling operation 1 Lubrication system 2 Plastic parts 3 Engine dismantling 4 Drive pulley starter clutch 5 Cylinder and piston 6 AC generator 7 Final transmission me
19. ached on brake lining Contact surface of the wheel hub becomes rough brake cable over stretching or moving unsmoothly brake contacting surface wi6h brake lining does not comtact 100 Q water or sand drop into brake mechanism some grease on brake lining surface 9 Oil indicator malfunction a The oil lamp doesn t light up when the main switch is at ON position Check and adjust Trouble condition Turn the signal lamp On Check wiring sete _ Of battey Lamp dims light does battery has no power Not flash no light main switch abnormal circuit plug dropped off main wiring disconnected Remove the oil lamp And connect with fag Battery directly Obulb burn out Lamp lights Lamp does not light up electric plug is loose Good condition 5 or disconnected main wiring disconnected wrong wiring connection Remove oil gauge PCheckine aiplioh Up or not by moving The float Float upward lamp Extinguishes Good No good Ofloat faulty Good oil gauge switch dis Float downward lamp turn on connected or short circuit b Oil is enough but the indicator turns on all the time when the main switch is ON Check and adjust Trouble condition plug Oelectric plug is loose or drop off Remove oil gauge main wiring disconnected Check the lamp by wrong wire connection Moving the floating aie faulty i Oll gauge Switc disconnected or short circuit Flo
20. ad and cylinder head gasket Ol 9 Remove the Cylinder and the gasket 10 Remove the c type clip on the piston and piston pins by the nipper eTake off piston 11 Dismatling of the piston ring Take off the first piston ring then the second ring 12 When assembling please reverse the procedures of dismantling Locking torque M7 1 0 1 4kg m Opening end of piston ring M6 1 0 1 2kg m 2nd Ring om Skirt 62 6 A C Generator Flyweel A Dismantling AC generator 1 Remove fan cowl 2 Remove the M6 screws 4 3 Remove Screws of flywheel magneto 4 Remove the AC flywheel magneto by special tool 63 5 Remove the flywheel 6 Remove the electric plug of AC Flywheel magneto Take out the magneto B Install AC generator To install please reverse the dismantling procedures Locking torgue M6 1 0 1 2kg m M10 3 2 4 0kg m 7 Final Transmission Mechanism A Trouble shooting Engine can be started but vehicle doesn t move 1 Gear worn out or cracked 2 Gear burnt out Noise occurs when running 1 Gear worn out burnt or gear surface damaged 2 Bearing worn out or loosen 0i leakage 1 Too much oil 2 Seal worn out or damaged B Disassemble the final transmission mechanism 1 Remove the rear wheel 2 Drain off the oil in the gear box 65 3 Remove the 6 bolt in gear box cover 4 Take off the gear box 5 Take out the final reduction gear and idle gear shaft 6 Cle
21. an up the gear box 66 C Check the final transmission mechanism 1 Check the wearing condition of the driving shaft and gears 2 Check the wearing condition of the idle gear shaft and idle gears 3 Check the wearing condition of the final reduction gear 4 Check the wearing condition of the oil seal and bearing D Assemble the final transmission mechanism please follow the opposite procedures Of disassembling After locking the drain bolt refill 90c c of gear oil SAE 85W 140 Locking torque M6 1 0 1 2 kg m M10 3 5 4 0 kg m Drain bolt Ms 1 8 kg m 67 E Check for the flatness of cylinder head amp cylinder Check the flatness of contact surface of cylinder head amp cylinder Limit of use If it exceeds 0 1mm Change a new one F Combustion chamber cleaning Clean out the carbon piled up in combustion chamber Do not scratch the combustion chamber and contact surface of the cylinder during cleaning operation 68 G Check cylinder and piston 1 Check the wearing and damage condition on the contact surface of the cylinder and piston 2 Clean out the carbon on the cylinder exhausting port Be careful not to scratch the inner Surface of cylinder 3 Cylinder bore measurement 1 Measure each point A B C orderly and in X Y axis to find the smallest value 2 Limit of use 50cc change it when over 40 050mm Cylinder gauge 69 4 Piston outer diameter measurement
22. and piston worn out 2 Piston pin hole or piston pin worn out 3 Connecting rod small end or bearing worn out d Abnormal piston or cylinder noise piston ring worn out or cracked 2 Cylinder worn out or cracked B The operation notice 1 clean before operation to avoid particles dropping into engine 2 The connect surface of gasket must be clean 3 Dismantle the cylinder and the cylinder head by screw driver Do not scratch the contact surface 4 Cylinder inner surface and piston outer surface can t be scratched The contact surface should be lubricated by specified oil C PISTON amp CYLINDER DATAS hoe Standard Value Limit of use Part name description mm mm Cylinderhead Platness 00 cylinder Piston ring ring piston and 2m ring Measuring location of piston outer dia a Te 12mm from the lower end of skirt Piston pin hole inner dia 9 994 10 000 9 970 Clearance between piston and piston pin 0 004 0 018 0 030 Connecting rod small end inner dia 13 996 14 007 14 025 59 D cylinder head cylinder and piston dismantling 1 Remove the engine 2 Screwing out the two M6 bolt of cooling cowl 3 Screwing out the two M6 blot of fan cover 4 Remove the cooling cowl and fan cover 60 5 Remove the spark plug 6 Remove the two M6 nuts on the muffler and cylinder Also remove the two M8 bolt of crankcase 7 Remove muffler 8 Remove the four M7 nut on the cylinder head then remove the cylinder he
23. ankcase change the brake lining 12 Tire 1 Check the tire air pressure when it s cold 2 Tire pressure Front tire 2 0 kg c mi Front tire 2 0 kg c m 3 Tire dimension Front tire 120 70 12 Rear tire 130 70 12 Note a check and adjust the tire pressure when it is too low The pressure is according to the carrier Driver passenger accessories and cruise Speed b Proper loading is very important for steering riding braking performance and safety c Never carry any parcel unfastened d Load the heaviest parcel on the center of vehicle balancing the weight on both sides e Beware of the weight loaded properly and check the tire pressure The total weight of carrier driver passenger and accessories cannot exceed the approved limit An overload vehicle is easy to cause tire damage and accident for rider 4 Check is there any sharp Object pierce the tire 5 Check the depth of tire Thread a Depth front amp rear According to mark of tire Ato change a new tire 43 3 Engine Dismantling A Dismantling engine 1 Take off the luggage compartment 2 Take off the left and right body covers 3 Take off the lower mudguard fender 4 Remove vacuum pipe fuel pipe auto choke cap of spark plug rear Brake cable carburetor pipe engine flywheel shelf s nut starter Motor cable plate and rear damper bolt 5 Remove the engine B Installing Engine 1 To install engine please reverse the above procedures
24. at upward lamp es Extinguishes Ooil tank distorted Float downward lamp some impure material Turns on dropping in 21 10 Fuel indication malfunction a wrong fuel level indication when the main switch is ON Check and adjust Trouble condition Turn the signal lamp On check wiring of battery normal Ofuse burn out battery has no power main switch abnormal circuit plug dropped off main wiring disconnected Lamp dims light Not flash not light Remove the fuel gauge Moving float up and Down to check The needle movement Do the short and opening Circuit test on the fuel Gauge plug which connect To wire harness Check the Needle movement Needle Needle on Fuel gauge abnormal u u moves motion oo Oelectric plug dropped off wrong connection abnormal wire broken or short circuit Float abnormal Needle no motion 22 b Fuel gauge needle is not steady and sometimes moves up and down when the main switch is ON Check and adjust Trouble condition Turn signal lamp on Check wiring of battery Ofuse burn out battery has no power i N main switch abnormal circuit plug dropped off or broken Remove the float main wiring disconnected Inside the tank peee Move up and down to Check the needle s movement Nes MONS Ofuel gauge contact 8 abnormal Move needle up and Down quickly 1 move Second check the Needle s movem
25. change specification is not correct 15 Check the oil level in crankcase Is too much or dirty Qoil level is too high oil level is too low Qoil does not interchange Oil level is Not normal Oil level is normal Check the lubrication of cylinder head Ooil route is blocked Abnormal insufficient oil pumping from oil pump Or not sass cadesesecesbcatecestessdeussesssesdtessseeseeuees Opiston and cylinder worn out mixture is too lean bad quality of the fuel too much carbon in the combustion room ignition timing is too early overheat Not overheat Running accelerately or _ High speed continuously No knocking Otoo much carbon in the combustion room bad quality of the fuel Qclutch slip mixture is too lean ignition timing is too early 16 3 Engine running unsmoothly low speed and idling Check and adjust Trouble condition OCDI faulty AC generator faulty Pere errr er rrrrrerrir rrr mixture too thick adjustment Not correct Omoto ln pradedo stonei tionde eieiei eniond esd aoai ainen ieninoiet tight the screw Check if there is air Leakage on carburetor gasket Oheat protector gasket broke carburetor locking nut loosen No leakage gasket crack hose ruptured Intake manifold gasket broken Remove spark plug insert To spark plug cover and E A E teeter Carburetor O ring distorted Connect with ground Start engine
26. chanism 8 Crankcase crank shaft 9 Carburetor reed valve auto cock 10 Steering column front wheel front brake comp front fork 11 Rear wheel rear brake rear damper 12 Fuel tank oil tank 13 Reverse Differential gear comp V Electric equipment 1 Troubleshooting 2 Battery 3 Recharge system 4 Ignition system 5 Starting system SPECIFICATIONS Model Overall Length 1930mm Primary reduction Direct Overall width 0mm Secondary ratio 52 13 44 13 1145mm 110CC Overall height eat height 710mm everse Drive Reverse 1385mm ifferential 250CC Wheelbase Dry weight 133kgs Steel pipe Engine Model P2 Telescopic 49CC Rear cushion Uni absorber O J T lt Cu say cS p O Cu ped NM So o AT Ci iston displacement ore 40 0mm 120 70 12 1 39 2mm 130 70 12 2 troke 6 8 1 Fuel Unleaded gas Capacity 6 7L ompression ratio gnition Clutch entrifugal CVT Drive Reverse Rearbrake Durm brake Auto seperated 12V 18W 2 hifting Tail light 12V 10W 3W Lubricant Signal light 12V 10W 4 41 Silencer iffusi alle o0 D x N pd g p sa oO N E II Service information 1 The operation notice 2 Locking torque value 1 For engine 2 For chassis 3 Others 3 Lubrication instruction a For engine b For chassis c Wheel bearing 4 Wiring diagram 5 Troubleshooting Difficult starting or starting 2 Weak acceleration 3 Engine running n
27. cking the rear brake hub a measure the inner diameter of rear brake hub b Limit of use change it when above 110 0mm 2 Checking the brake lining a measure the thickness of the rear brake lining b linit of use As the thickness is less than 2mm change it 96 F Rear damper 1 Rear damper disassembling diagram specified torque SA 2 0 3 0kg m specified torque 3 0 4 0kg m 84 97 12 Fuel tank A Troubleshooting 1 Engine can t start a No fuel in fuel tank b Fuel pipe is blocked c Auto cock and filter is blocked d The membrane of auto cock 1s over swell 2 The membrance of auto cock 1s over extended a Fuel tank cover s ventilation hole is blocked b Fuel pipe is crooked squeezed or blocked c Auto cock and fuel filter is dirty B Fuel tank disassembling diagram Intake Manifold Fuel Tank Carburetor 98 B Dismantling and assembling Fuel Tank 1 Remove the luggage box 2 Open the rear cover of the fuel Tank and take it off 3 Remove the left and right rear handle bars 4 Remove the left and right side covers 5 Remove the fuel pipe 6 Remove the connecting terminal of the fuel gauge 7 Remove the fuel gauge 8 Remove the fixing blot of the fuel tank 9 Take off the fuel tank 10 When re assembling please follow the opposite procedure of disassembling Locking torque M6 1 0 1 2kgf m 99 D Oil tank disassembling diagram Oil Gauge
28. cy Standard recharging 0 4A 5 10 hr or rapid recharging 4A 30min 50c c 42 3 Cleaning air cleaner 1 Remove air cleaner cover 2 Take out the air cleaner filter 3 clean the filter by the compressor air 4 Assemble the air cleaner by the opposite procedure f T eer rrereeeE Note Do not start the engine When the air cleaner is Not installed 43 4 The final reduction mechanism oil 1 Change the oil in the gear box a Turn off the engine after warm up b Put a bowl under the engine c Remove the draining bolt and Filler bolt to drain the gear oil off d Lock the draining bolt before refill 90c c gear oil and then lock the filling bolt Locking torque 1 8kg m 5 Spark plug 1 Remove spark plug 2 Check the spark plug electrode and check if it is Burnt out or not and carbonized or not 3 Clean the electrode whether it is dirty 4 Spark plug specification NGK BP7HS or same spec Gap of spark plug 0 6 0 7mm Spark plug Electrode Burn out Carbon piled up Washer 1s Distorted or not Procelain 1s Cracked or not 44 6 Compression pressure measurement 1 Measure it when the engine is warm 2 Remove the cover 3 Remove spark plug then place comp Ression pressure gauge 4 Fully open the throttle and kick to kickstarter 5 times continuously measure the compression Pressure 5 Compression pressure 50cc 6kg c m 600rpm 6 when the compression pressure is too low chec
29. djustment 9 Idle adjustment 10 Front brake adjustment 11 Rear brake adjustment 12 Tire 1 Regular checking table 1 O mark indicates periodical checking 2 X indicates changing the parts Checking period first every12 every3 everyl2 Judgement standard month or Initial Item Remark months months months months Handlebar Loose orswing O steering Operation O column Turning angle E Damaged tont ae 8 Shaft fixed condition 4 Shaft loose 4 f a clearance Lever Te novenenoftake O O O O_ Change brake cable O i PBrakecam wom i wane ane A E23 Eo and lining el eee and brake lining worn out shor Check from Check from Clearance Front 10 20mm Rear dia rear 110 0mm limit of use rear 111 0mm c wheel hub worn and damaged Front wheel axie damaged or distorsion Rear wheel ase damaged or distorsion Pressure tire Cracked or damaged tire thread worn out tire surface or other intruders unit kg c m 1 driver Change tire according to mark NM NM e e a 2 ya ge Q Q ie ie 5 Front axle nut torque 5 0 6 0kg m Nut Axle l rear axle nut torque location Tighten the bolt and nut 11 0 13 0kg m Swingness limit Vertical below 2 0mm Horizontal below 2 0mm i swingness and damage Rim 8 8 condition 5 a gos x z N n x Remark
30. ent Needle Needle no Insufficient J moves movement PSUTEE SOL NO CAMpPINg Oil inside the fuel gauge Check electric plug TENENTE esate Connecting condition Oelectric plug drop off or os wire broken or short circuit 23 11 The starting motor abnormal a Starting motor can not rotate Check and adjust Trouble condition Ofuse burn out Brake lamp Brake lamp battery has no power Lights up no light main switch abnormal circuit plug dropped off E E ta Omain wiring disconnected Turn signal lamp Noto check wiring Of battery ee eeedeeeeene Lamp dims no Obuttery has no power Flashing no light 3 Push starting switch aie seine E ETE T E D A E E And check the function Of start relay connetion relay wire broken or short circuit Ocircuit plug is loose normal No function Connect starting Motor boven To battery directly carbon brush worn out coil broken or short Starting Starting motor circuit Motor runs up Has no motion starting motor wire broken circuit plug is loose drop off main wiring broken 24 b Starting motor running slowly or no pick up Check and adjust Trouble condition rere ee On to check wi ring of battery l L l Flasi A Obattery has no power Starting Connect motor to the starting motor to E E daca sean E E Battery directly Delectric plug is loose Runing slowly Do start relay bad ete ge ee connection Kick the kickstarter
31. ery recharges insufficiently 1 Ignition primary circuit 2 The bad connection on wiring system Othe wire or plug of wiring connection is not good 3 Recharge system is abnormal main switch disconnects 4 Regulator malfunction 2 I gnition secondary circuit B Ignition system OIgnition coil is not in good function The sparking of spark plug is abnormal Spark plug is dead 1 Spark plug is dead QH V coil is not in good function 2 Wire connectsion is broken or short The spark plug cap is not in good function Circuit 3 Ignition timing Obetween A C generator and CDI sets A C generator is out of order between CDI sets and High Voltage coil A C coil is not in good function between CDI sets and main switch OC D I sets is out of order between main switch and spark plug eStarting motor runs weakly 3 Main switch is out of order 1 Battery recharges insufficiently 4 H V coil is not in good function 2 Wiring system disconnects 5 CDI sets is out of order 3 The alien objects drop in the motor or gear 6 A C generator is not in good function eStarting motor can rotate but C Starting system engine can t start up Starting motor can t rotated 1 Starting gear is abnormal 1 The fuse is broken 2 Starting motor is reversedly rotating 2 Battery recharges in sufficiently 3 Battery is out of order 3 Main switch is out of order 4 Starting motor switch is out of order 5 Front rear brake switch is out of order 6 Starte
32. gen era first Item l month every12 every3 every12 Judgement chec ki _ months months months months standard Initial 5000km 10000km 1000km 2500km 10000km Clearance on f Front axle Bearing Clearance on rear axle Sori Damage pong Condition Ass y part Loose or damaged condition loose or part loose or damage Bracket et 8 condition Looseness on Suspension Connecting Part ng Oil leakage O Damaged Absorber Condition Loose on ass y part Clutch and Fonction ooo Shift mec Gear oil hanism leakage Gear oil Change gear oil E arm LH crank case 90C C replace 220C C Reverse Clearance 0 6 0 7mm NCK BP7HS OR SAME Inspect cells When 20 C Specific gravity _ Start Starting motor Mechanism gear n Recharge rin Battery 1 270 1 290 Wire Looseness or Damage circuit jon connection plug Checking period id Item month every6 every12 every every3 every12 Ueeement Remark Or months months months months months standard Performance Noise L d i ow Pe Idling 1900 100rpm Acceleration Exhaustion Check the color of exhausting air Locking torque Cylinder head cold 1 0 1 2KG m inlet pipe cold Air cleaner Cylinder cy linder sued oursuyq head inlet pipe locking Condition 1 0 1 2kg m Using starting motor 6kg c m 600rpm Compression pressure Oil quantity blocked
33. he intake manifold 5 Remove the intake manifold 6 Remove the reed valve 2 checking for the reed valve chang a new one when the reed valve is worn out or distorted change a new one too when the base of the reed valve is cracked injured or distorted 84 G Check the auto cock 1 When the engine stop remove the fuel pipe from carburetor and check if there 1s fuel flow Out or not It means auto lock functions well 1f the residue fuel for the amount of 5 10cc flows out From the auto cock and fuel pipe However if it continues to flow out it means that the Vacuum pipe is blocked please clean it 2 Remove the vacuum pipe from the carburetor and suck it to produce a vacuum to have the Fuel flow out from the fuel pipe The fuel will stop flowing out if the vacuun disappear If the fuel does not flow out by the above operation please check the followings a Clean out blockage in the vacuum pipe b Blow air into the inlet pipe of the auto cock 3 Note Please remember to use a bowl to catch the flow out at the end of the fuel pipe Keep away from fire or even spark during operation 85 10 Handle bar front wheel front brake and front fork A Troubleshooting 1 steering handlebar is abnormal too tight a steering mechanism washer of conical bush locked too tightly b steering mechanism steel ball is cracked c steering mechanism steel ball base and washer of conical base is damaged d wheel pressure is t
34. he opposite procedure of dismantling Locking torque M10 3 5 4 0kg m 3 Checking the clutch Dismantling the clutch needs the special Tool please contact your dealers a Check the clutch driven face Check the clutch cover about its wearing Condition and inner diameter measurement Limit of use 5SOcc Change it when above 117 5mm b Check the clutch lining wearing condition and measure the lining thickness NY limit of use change it below 2 5mm 5T c Check driven spring free length standard 87 9mm Limit of use change it as it Is below 82 5mm 50cc d Check wearing condition of driving plate set Outer diameter measurement Limit of use change it as it Is above 33 950mm e Check wearing condition of slide driven plate Inner diameter measurement Limit of use change it as it Is above 34 070mm f Check is there any wearing occur to the ditch g Check wearing condition of seal location if necessary change a new one 58 5 Cylinder and piston A Troubleshooting a compression pressure is too low difficult to start engine and running unsmoothly 1 Cylinder head gasket cracked 2 Spark plug is not well locked 3 Piston ring worn out or cracked 4 Cylinder piston worn out 5 Reed valve is defective b compression pressure is too high engine overheating or abnormal noise 1 piston tip has too much carbon piled up c Abnormal piston noise 1 cylinder
35. hecking the front brake disk Standard thickness of disk 3 6mm Limit of usage change it when below 3 1mm 7 Checking the front brake lining a standard thickness 4 0mm limit of use As the thickness is below 2 0mm change it Note No grease on the lining 93 11 Rear wheel rear brake rear damper A Troubleshooting 1 Rear wheel swings a Wheel rim is distorted b Tire worn out c The wheel axle is improperly assembled 2 rear damper is too soft a Spring fatigue 3 Bad braking a The adjustment of brake is not proper b The brake lining 1s dirty c The brake lining worn out d The cam of brake lining 1s worn out e The brake cam lever worn out f The wheel hub worn out or damage g The operation on the brake arm tooth is not good B Data pa Limit af etm The swingness of rear wheel 0 Thickness of brake lining Wheel hub inner diameter 94 C Disassembling and assembling the rear wheel 1 Remove the rear mudguard and the exhaust pipe 2 Remove the locking nut of the rear wheel 3 Remove the rear wheel 4 To assemble the rear wheel please reverse the dismantling procedure Locking torque M6 0 7 1 1kg m M14 8 0 10 0kg m D Checking the rear wheel a check the swingness of rear wheel b vertical direction change it when above 2 0mm c horizontal direction change it when above 2 0mm 95 E Rear brake 1 Rear brake disassembling diagram 1 Che
36. ion system diagram Oil pump Oil tank F a Y ETa et B Engine over heating a The adjustment of oil pump is not properly lack of oil b The quality of oil is not good C Piston over burning a There is air in the oil pump system b Oil pump is out of order D The route from oil tank to oil pump is blocked a Ventilation hole on the tank cover is blocked Note 1 When removing oil pump do not drop any unexpected objects into the oil pipe 2 Please release the air if there is air trapped in the oil pipe 3 Locking torque of oil pump 0 8 1 2kg m 29 3 Removing the oil pump Clean the oil pump and Crank case before operation a Remove the luggage b Remove the input output oil pipe c Take out the oil pump by removing The locking screw on oil pump and Oil gauge cable 4 check the oil pump Remove oil pump and check a O ring is distorted or not b contact area of crankcase 1s injured or not d Oil pump body is damaged or not e The movement of control lever is free or not 110 cc model only f The gears are damaged or not g Check seal and see if there Is oil leakage or not h Never dismantle oil pump it can not function well after dismantling 30 5 Assemble the oil pump a Assemble the oil pump by reversing above procedure O ring of oil pump should be lubricated by grease or oil then place on crankcase The contact surface of oil pump and crankca
37. k the following a cylinder head gasket cracked b piston cylinder worn out c piston ring worn out 7 If the comperssion pressure is too high it may be due To the carbon piled up on combustion chamber and piston tip 45 7 Ignition timing This scooter is using CDI set it is no need to adjust ignition timing If ignition timing is not correct check the CDI sets AC magneto change it if it is abnormal checking ignition timing l remove seat the luggage compartment 2 Remove right body cover 3 Remove the fan case 4 Check with ignition timing lamp keep the engine running at 1 900 100 r p m the checking mark should lay in 3 apart From F mark 5 ignition timing B T D C 17 3 1900rpm 8 Throttle cables adjustment 1 check the clearance of throttle 2 Normal clearance 1 5 3 5mm 3 Adyjust it by rotating the adjust nut change it if the throttle cables can t be adjusted 46 9 Idle adjustment Note adjust it when the engine is warm 1 remove left body cover 2 start the engine and connect the tachometer 3 adjust the throttle valve screw to the specified revolution 1900 100rpm 4 if the idling rpm is still unsteady or fuel up is not smooth please adjust it by followings a Screw in the air adjust screw clockwise then screw out counterclockwise Recommended loop 1 3 8x1 2 b Rotate air adjust screw clockwise and counterclockwise to find out the highest revolution locatio
38. le simultaneously otherwise the engine will stop automatically for your safety 3 Use the brake lock device in the LH switch comp when stopping in inclined road 2 Locking Torque Value 1 Engine Thread Locking location is Gan Locking 1 0 1 4 When the engine is cold ylinder head lywheel outer ear brake lever riving pulley utch outer ight crankcase rive gear box cover eft crankcase raining and filler bolt nlet pipe ywheel magneto stator ooling fan uffler nut on cylinder head tarting motor racket between eng and ubber pad of central stand ark plug an cover ixed plate drive clutch ut of rear wheel axle Kick starter 10 4 0 3 2 1 0 1 2 3 2 4 0 3 5 4 0 1O 1 2 fo 10 10 p 1 0 1 2 1 0 1 2 When the engine is cold 1 0 1 2 O 1 0 1 2 1 0 1 2 When the engine is cold 1 0 1 4 When the engine is cold K YN NI m m p p p pd pd pa Wn BB GO N Z O CO NII ON N wINI D O rw e S ae OO NO AD KN LO 1 2 ge 1 0 1 11 13 U TYPE NUT A2 fo 14 NO N Q eS BIN oO 0 2 chassis 3 0 4 Lock nut 5 0 6 U type nut 5 0 6 U type nut 10mm 12mm 12mm teering stem nut ront axle nut Fixed nut fasten eng and chassis Rear shock absorber upper Rear shock absorber lower Lock nut faster frt brake disk and frt wheel rim Lock bolt between frt brake pump and frt absorber
39. n c Rotate the throttle valve screw to idling condition d Fuel up gradually until the idling running rpm is steady e If the rpm is still not steady please repeat above procedure 10 front brake adjustment 1 check the clearance of front brake lever Clearance 10 20mm 2 if the clearance is beyond standard check whether a The air mix into the pipe caliper b The oil brake system is leaking Note Try brake lever to see if it s loose Check the brake fluid Once air mixed in The fluid pipe which will reduce or Damage the brake efficiency or even its Function 3 check the fluid level a Refill the brake fluid when the level is under the LOWER line b Brake fluid specification SAE J 1703F DOT3 amp DOT4 Note a To prevent the fluid splitting onto the parts or clothes put a piece of cloth on the bottom when refilling b Be caution not to mix water or particles into the master cylinder when refilling c Never use the fluid not complied with spec d In case the fluid stains on the eyes wash with water at once and then ask for medical care immediately 4 amp 1 11 Rear brake adjustment 1 Check the clearance Of rear brake lever Clearance 10 20mm 2 If the clearance is beyond the above standard Adjust it by rotating the screw a Left handed rotation enlarge the clearance b Right handed rotation reduce the clearance Note When the arrow of rear brake indicator align with the arrow of left cr
40. n them with part 7 bolt Put rear brake wire x2 through the stopper of part 1 amp part 2 To the end of rear brake arm put into the spring amp stoppin fasten with nuts Put tires into the end of transmission shaft part 1 2 gt fasten the tires with nuts part 10 11 with torque 11 13kg m gt be sure the rotating direction of tires adjust the brake wire Faster rear Fenders part 12 with part 1 amp 17 with bolts amp washers of part 13 14 gt Put part 18 wire into and out of part 17 with the fixed points fasten the with part 19 and part 20 bolt Outlet is down for part 18 torque 0 9 1 1kg m Faster rear Fenders part 12 with part 21 amp 2 with bolts amp washers of part 13 14 Put part 22 wire into and out of part 21 with the fixed points fasten them with part 19 and part 20 bolt Outlet is down for part 22 torque 0 9 1 1kg m 9 Connect the wire of part 18 amp 21 with wire harness 10 Connect the wire of buzzer with wire harness gt fasten buzzer on part 3 with part16 bolt NOTE PART17 PART22 IS FOR TURN SIGNAL MODEL z a _ J i F a ra P 1 eA E i 2 E A C f aS s if Oe Sa ie A i t gt ra Fi a te J A 6 RE 7 Kore ae se LY oe Se g ri E FI Ei ie x J i eae 3 ty abe a L i pn m Fo al fe ea ime Oar f f f f A gt Sa e a y r i yas i Af ri S i SS j 7AA Fi aii ke i pek a UG A u IEn W ROSOV AY Es k alt I Lt A E Fa r
41. oo low 2 steering handlebar is aslant a left and right damper are not even b Front fork is crooked c The axle of front fork is crooked or the wheel is aslant 3 front wheel swings a wheel rim is distorted b bearing of front axle is loose c wheel spoke is distorted d Tire worn out e The wheel axle is improperly assembled 4 front damper is too soft or spring fatigue 5 Noise in front damper a noise comes form the shock absorber tube b locking screw of damper is loose B Data Standard value mm Limit of use mm Lining of frt pad 3 3 Disk of frt brake 3 0 wingness of frt rr wheel e ee The lining of rr Brake 86 C Change the speedometer cable 1 Remove the front handle cover 2 Remove the nut of the speedometer cable 3 Remove the fixed screw of the speedometer cable on the front wheel 4 Pull out the damaged speedometer cable 5 To assemble the new cable please follow the opposite of dismantling procedures Note Put some grease onto the inner cable before assembling ST D Steering handlebar 1 Remove the LH RH back mirrors 2 Remove the upper handle cover 3 Remove the nuts on front fork and handlebar 4 Take off the fixing bolt 5 Remove the nut and bolt of the front fork fixed on The handlebar 6 Take off the handle bar 7 When assembling please follow the opposite procedures Locking Torque M6 1 0 1 2kg m M10 3 0 4 0kg m 8 Before assembling please
42. ot smoothly low speed 4 Engine running not smoothly high speed 5 Clutch drive amp driven pulley 6 Handlebar steering was astray when running 7 Front and rear damper not balanced 8 Brake disorder 9 Oil indicator malfunction 10 Fuel indicafor malfunction 11 starting motor malfunction 12 No sparking 13 Charging abnormal 1 The operation notice 1 For parts like the gasket o ring clips and circlets please change a new part whenever re assembled 2 When trying to tighten screws or nuts please lock tightly according to each recommended locking torque and in the sequence of the X pattern 3 Please use PGO or PGO recommended parts 4 After dismantling please clean all parts involved or used for checking and grease all contact surfaces when reassembling 5 Use grease recommended by P G O 6 When removing the battery please disconnect the negative pole first However please connect the positive pole first when assembling 7 Before installing a new fuse please be sure that the specification 1s correct 8 After reassembling please re confirm that all connecting point locking parts circuits polar characteristics are functioning well befor selling out Operation Notice 1 Turn the shifting bar to right side to drive backward 2 Turn the shifting bar to left side to drive forward CAUTION Don t shift the gear until the vehicle is stopped When shifting to R you have to brake the vehic
43. r relay is out of order 7 Wire disconnects or broken 8 Starting motor is out of order 102 2 Battery 1 Check the cells of battery Always remove the battery negative Cable first then positive cable But connect the positive cable first then connect the Negative cable when assembling se i a i al ate i od ae E 4 a ia a te a I Fi yer E aed Fadi JER PA dF Pa ae a F z Ea Negative Pole Positive Pole 103 2 Recharge Connection procedure connect the positive cable of the negative cable of the battery and the negative cable of the recharge to the negative cable of the battery Recharging currency Please recharge 12V according to the following current and time Standard 0 4A 4 10Hr or Rapid 4A 30min 50cc Notice Keep away from fire when recharging The ON or OFF of recharging currency must be operated by the switch of recharge It will cause spark or explosive if plug or unplug the cable directly 104 3 Testing the recharging performance eThis test needs to be done when the battery is fully recharged This test needs to be done after engine is warm up a Disconnect the orange cable of regulator b Open the fuse box to remove the white cable c Connect currency meter between red white cable and fuse While testing the red wire cable must not touch the frame sae E ACLLOV Starting
44. rection to rod Limit of use Replace a new when above 0 71mm 2 check the looseness on X Y axis of the connecting rod big end Perpendicular directions to rod Limit of use Replace a new one when above 0 04mm 18 3 measure the swingness of crank shaft neck oe ee B Change it when Change it when Above 0 1mm Above 0 1mm 60 mm 4 check the slackness of crankshaft bearing Sway ing if itis slack change a new one C Swaying a Fil T i horizontal vertical direction direction _ _ F Assemble the crankcase 1 To assemble the crankcase please reverse the procedures of disaseembling 2 The locking torque value for bolts and nuts are all described in the previous chapters Please refer 19 9 Carburetor Reed Valve and Auto cock A Fuel system diagram Fuel Cap Fuel Gauge Fuel Tank Autocock Carburetor S0 B Carburetor dismantling diagram E9 1 XRSO kiebas CARBURETOR CARBURETOR ASSY HOLDER NEEDLE JET TOP SET MAIN JET SPG COMP FLOAT VALVE SET PLATE SET PIN ARM TUBE SET FLOAT SET JET NEEDLE FLOAT CHAMBER SET THROTTLE VALVE TUBE SET SCREW SET SCREW WASHER SCREW SET A S CAP HOLDER O RING AUTO BYSTARTER SET NEEDLE JEL SCREW WASHER SLOW JET PLATE SET Sl C Troubleshooting a Engine can not be started 1 No fuel in the fuel tank 2 Fuel pipe is blocked 3 There is too much fuel in the cylinder 4 Air cleaner is blocked
45. reely c If it is necessary to change the new piston ring it must change the whole set 4 a The location of the piston ring gap and the lock pin must be in opposite side b The mark gt on the piston tip must be pointing to the exhausting port c Lubricate the piston pin before installation 5 Please follow the opposite procedure of dismantling to install cylinder and cylinder head 12 8 Crankcase Crankshaft A Disassembling diagram 13 B Troubleshooting Engine noise 1 The bearing of final transmission mechanism is loose 2 Crank pin bearing is loose 3 The bearing of gear box is loose C Data Standard value Limit of use mm Clearance of connecting rod big end Parallel direction to rod vere ee Clearance of connecting rod big end 0 04 Perpendicular direction to rod l Swingness of the crank shaft neck 14 D Dismantle the crankcase and crankshaft please follow the following procedures 1 Remove the engine 2 Remove the left crank case the driving pulley driving plate clutch and belt 3 Remove the air cleaner TS 4 Remove the carburetor 5 Remove the intake manifold and reed valve 6 Remove the oil pump fan cowl and fan itself 16 7 Remove the AC flywheel magneto 8 Dismantle the right and left crankcase There are all together 7 bolts tf E Check the crankshaft 1 measure the clearance between crank shaft and co rod big end Parallel di
46. ruction manual If the CDI test failed please change a new one Ignition coil CDI 108 5 The starting system 1 The wiring of starting Starting relay Starting motor Teeme ENE TW Dl bb bet he nn EE E E E EE 1 de By He fn 2e frit at Ae il Sym she Bel H 4 G starting button Q2 safety switch 3 main switch 109 2 check the starter Connect green white cable to positive pole of battery connect black cable of negative pole of battery It means starter is function well if above connection and both Red Black cable of staring motor have currency passing through 3 Dismantling the starting motor a Remove 2 screws on starting motor b Remove starting motor cables 4 Checking the starting motor eCheck the function by connecting the starting motor to battery Check if it is rotating counter clockwise Note Do not operate starting motor for a long time lO INSTALL INSTRUCTION OF DIFFERENTIAL MECHANISM Put part 1 into the left hand s side of the differential gear box Be sure that the splint of the shaft be inserted into the splint hole The same procedure 1 gt Put part 2 into right hand side of differential gear box Put part 3 into the position of gear box as attached draw gt use part 4 through part 1 2 3 combine with engine And fasten the nut of part 5 torque 2 0 2 5 kg m Put part 6 with the fixed points of part 1 amp part 2 faste
47. se should be assembled firmly The gears of oil pump should be lubricated by grease b Be sure oil pump screw is tightened After assembling check the following a the adjustment of control cables b Is there air in oil pipe c oil leakage at any location 6 Releasing air in the oil pump a If there is air in the oil pipe it will cause engine lubrication trouble b Releasing air operation means the release of air trapped in the air pipe and oil pump Please firstly release air from the oil pipe a Fill up specific amount of oil to oil tank b Place dry cloth under the oil pump Remove oil pipe d Use injector to fill up the oil in the oil pipe and oil pump body Be sure the oil pipe and oil pump are full of oil before assembling e After assembling check if there is still air trapped in the oil pipe Sl 1 Plastic parts of Chassis A Dismantling the plastic parts 1 Removal of luggage compartment e Open the seat take off the screws of the luggage compartment 2 Removal of fuel tank e Open the lock cover of the fuel tank e Take off the fuel tank cover e Take off both the right and left handles by removing the screws off 32 3 Removal of left and right hand Side covers eTake off the screws of left and right side covers eRemove the left and right hand side COVer 4 Removal of front mudguard eRemove the screws of front fender e Take off the front mudguard 33
48. t worn out or slipping Can t reach high speed weight roller worn out driving pulley shaft worn out QMadherent grease on driving belt pulley phase Opa omen Wael driving belt worn out 8 driven plate spring distorted driving pulley shaft worn out 19 6 Handlebar steering astrayed when running 7 Front rear damper not in balanced Trouble condition Handlebar operates heavily Front and rear wheel swings Handlebar astrayed to one direction Trouble condition Damper is too soft Damper is too hard Damper has abnormal noise Brake disorder Trouble condition Brake plate mark points to mark Noise when brake Faulty performance 20 The reason front and rear wheel pressure are normal Osteering column lock screw locked too tightly steel ball cracked Orear front wheel bearing swings front rear wheel rim distorted Qollse front axle nut Ofront and rear wheel center not well digned front fork crooked The reason front and rear wheel pressure is normal Odamper spring is too soft carrying weight is too large damper oil leakage Ofront fork guide rod crooked damper and damper cover cracked problems in damper tube and spring damper and damper cover cracked The reason adjustment according to standard procedure QObrake lining worn out bake lining cam worn out brake cam worn out brake hub worn out Obrake lining worn out unknow matenals att
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