Académique Documents
Professionnel Documents
Culture Documents
1. REGULAR INSPECTION
1-1 Delivery Introduction ----------------------------------------------------3
1-2 Inspection Before Running --------------------------------------------4
1-3 Regular Inspection -------------------------------------------------------5
1-4 General Inspection -------------------------------------------------------6
1-5 Notes for Inspection -----------------------------------------------------6
2. MAINTENANCE INFORMATION
2-1 Specification Sheet -----------------------------------------------------7
2-2 Maintenance Date -------------------------------------------------------8
2-3 Special Tools --------------------------------------------------------------9
2-4 List of Grease & Oil Adopted ----------------------------------------12
2-5 Circuit Drawings --------------------------------------------------------13
2-6 Troubleshooting ---------------------------------------------------------20
2-7 Tighting Torque of Screws -------------------------------------------21
2-8 Troubleshooting ---------------------------------------------------------23
4. DISASSEMBLY REPAIRMENT
4-1 Notice for Disassembly Repairment -----------------------------48
4-2 Removal and lnstallation of Engine -------------------------------49
4-3 Disassembly and Assembly of Engine ---------------------------51
4-4 Removal and Assembly of Carburetor ---------------------------62
4-5 Removal and Inspection of Electric Parts -----------------------64
4-6 Removal and Inspection of Body Parts --------------------------90
4-7 Built-In Braking System ---------------------------------------------95
1
CHAPTER I
REGULAR INSPECTION
1. Starting:
A. Turn the power switch to "ON."
B. Hold the front or rear brake and press the "START" button.
C. If the scooter is not started, release the "START" button and try again after a few
minutes. Each start should be less than five seconds to avoid battery
consumption.
2. Fuel:
Inform customers to refill the fuel to no more than 80% of the tank capacity only.
2
1-1 Delivery Introduction
3 . Lubricant Adopted:
A. WARNING : TGB Supper Oil GA50400002 ( OR 2 STROKE OIL in accordance
with JASO FC ) will be adopted as two-stroke engine oil. The engine oil must be
refilled when the oil warning lamp lights, otherwise the engine will be burned-out
due to insufficient lubrication.
B. TGB Gear Oil GA50400004 ( OR SAE 85W-90 ) will be adopted as gear oil to be
changed on a periodical basis. Gear oil and engine oil are different in their nature.
Attention should be paid to avoid mistake when used.
3
1-2 Inspection Before Running
4
1-3 Regular Inspection
The chart below lists the recommended intervals for all the returned periodic service work
necessarily to keep the motorcycle operating at peak performance and utmost efficiency.
Mileages are expressed in terms of kilometers and months.
These intervals judged by odometer reading or month whichever comes first.
300 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000
Km
km km km km km km km km km km km km km
MONTHS New
1 2 3 4 5 6 7 8 9 10 11 12
Scooter
months months months months months months months months months months months months
ITEM period
Battery I I I I I I I I I I I I I
Tire I I I I I I I I I I I I I
Brake I I I I I I I I I I I I I
Brake fluid I I R I R
Spark plug I I I I I
Air cleaner I I I I
Steering system I I I
Suspension
I I I I I
system
Muffler I I I
Oil pump I I I I I
Fuel Filter R R
5
1-4 General Inspection General Inspection and Adjustment
* means adjustable.
Note: The ignition of this scooter by the use of crank-shaft which is 2 ignitions/revolution.
Special attention should be paid while setting the turning speed of Engine by
Tachometer.
6
CHAPTER 2
MAINTENANCE INFORMATION
2-1 Specification Sheet
ITEM NO. GA5 GF5 GI5 GE5 BH1 BR1 BK1 GF9 GI9 GE9 BH5
Exhaust Volume 49.3 cc 82.4 cc
Stroke 2T
Overall Length mm 1700 1670 1800 1780 1695 1830 1875 1670 1800 1780 1695
Overall Width mm 610 625 625 640 650 660 660 625 625 640 650
Overall Height mm 1030 1020 1080 1090 1075 1170 1170 1020 1080 1090 1070
Scooter
74 ㎏ 78 ㎏ 84 ㎏ 82 ㎏ 81 ㎏ 92 ㎏ 86 ㎏ 81 ㎏ 87 ㎏ 95 ㎏ 84 ㎏
Weight (Empty)
120/90-
10
120/70- 120/90-
120/90-10
3.00-10 120/90-10 120/90-10 12 10 120/90-10 120/90-10
Tire(tubeless) 90/90-10 120/70- 3.00-14 90/90-10
4PR 120/70-2I 120/70-12 130/70- 120/70- 120/70-12 120/70-12
12
12 12
130/90-
10
Cylinder Type Horizontally PlacedI
Max Horsepower 5.0ps/7500rpm 6.5ps/7000rpm
Gasoline 92 Unleaded Gasoline or Premium
Lubrication Method Oil Supplied Separately by Oil Pump
Cooling Type for
Air Cooled by Cooling Fan
Engine
Ignition Method C.D.I Ignition device w/o point.
MT2.5x10 MT2.5x10 MT2.5x10
MT3.5x10 MT3.5x10 MT3.5x10 MT3.5x10
Rim comp Size MT2.15x10 MT2.5x10 MT3.5x10 MT2.15x14 MT2.5x10 MT3.5x10 MT3.5x10
MT3.5x12 MT3.5x12 MT3.5x12 MT3.5x12
MT3.5x12 MT3.5x12 MT3.5x12
Turn Signal Flashing 80-85 Times/Minute.10W
Spark Plug BPR6HS,BPR7HS,BP6HS,BP7HS (NGK) Clearance: 0.6- 0.7mm BP7HS -10(NGK) Clearance :0.9-1.0mm
Battery 12V/4Ah
Rectifier AC 13V,DC14.5V
7
2.2 Maintenance Data
8
2-3 Special Tools
GA5000051F05/ GA5000051F19 /
Crank Case & Shaft Remover Bearing Remover
To Draw the Crank Shaft into the Right 1. Taking out LH Bearing of Drive Shaft
HandCrank Case on gear box cover.
2. Applicable Scope Ø17
9
2-3 Special Tools
1. Taking out LH Bearing of crank Shaft. 1. Left Hand Crank Shaft (Left Hand
2. Applicable Scope Ø25 Bearing of Drive Shaft.)
2. Applicable Scope Ø17 x Ø47
1. For Left Hand Crank Case 1. To press Right Hand Bearing of Drive
2. For Left Hand Crank Shaft Bearing Shaft
3. Applicable Scope Ø25 x Ø52 2. Applicable Scope Ø12 x Ø32
10
2-3 Special Tools
1. Oil Seal for Right Hand Crank Case & 1. To install Oil Seal for Rear Axle and
Gear box cover Crank Case
2. Applicable Scope Ø17 x Ø27 2. Applicable Scope Ø27 x Ø40
1. Left Hand Crank Case (Oil Seal for 1. To remove The Driving Pulley of C.V.T
Engine oil pump gear) 2. To remove Right Hand kickstarter
2. Applicable Scope Ø24 x Ø43
11
12
13
14
15
16
17
18
2-4 List of Grease & Oil Adopted:
GA55100001 GA50400003
TGB Supper Grease Supper Grease No.3
No.0 Apply in Axle Shaft,
Apply in Oil Seal. inside of Oil Seal.
GA50400001 GA50400004
1104 Sealing Three- TGB Gear Oil 85w/90
Bond Apply on Right Transmission Gear Oil
Hand Crank Surface. for Scooters.
GA50400002 GA55100002
TGB Supper Oil Three-Bond 1322
(JASO FC) Under M10 Screw
Apply in oil tank (For medium fixing) for
Flywheel Magneto.
GA50400005 GA55100003
TGB Supper Grease DOT-3 Brake Oil For
No. I Brake.
Apply in Oil Seal.
GA5040006 GA50400008
TGB Supper Grease TGB Supper Grease
No.2 No.4
Apply in Kick Starter. For Movable Drive Face Comp.
GA50400017
Cemedine 575
Apply in Handle Grip
19
2.6 Troubleshooting
20
2-7 Screw Torque
21
2-7 Screw Torque
General Torque
22
2-8 Troubleshooting
23
24
Check item:
○ No fuel
○ Dirty fuel filter
○ Obstructed ventilation tubing of th efuel tank
○ Poor carburector buoyant needle valve
○ Carburetor buoyant with impurities
○ Poor carburetor buoyant
○ No skip in spark plugs
○ Poor skip in spark plugs
○ Dirty spark plugs
○ Incorrect spark plugs gap
○ Dirty and wet spark plugs
○ Loose adjustment screws in the carburetor
○ Carburetor choke
○ Obstructed carburetor slow nozzle
○ Ailing carburetor threshold
○ Obstructed air filter grill
○ Leakage in cylinder washer
○ Seriously damaged cylinder, piston
○ Dead battery
○ Poor contact of battery pin and conductors
○ Starting switch with poor or failure
○ Starting relay with broken wire or short circuit
○ Loose contact and wiring
○ Starting gear and speeding clutch gear seriously worn
○ Starting gear and speeding clutch gear in poor engagement
○ Poor starting motor
25
2-8-2 Troubleshooting for poor skip of spark plugs
26
2-8-3 Troubleshooting for n0-skip of spak plugs
27
2-8-4 Troubleshooting for slow run (troubled engine)
28
2-8-5 Poor acceleration and horse power
29
30
CHAPTER 3 DESCRIPTION OF COMPONENTS AND ASSEMBLY
3-1 ENGINE
3-1-1 Combustion & Air In-Take & Exhaust System
3-1-2 Carburetor
3-1-3 Lubrication & Cooling System
3-4 BODY
3-4-1 Frame, Fuel and Oil System
3-4-2 Compartment and Seat
3-4-3 Front & Rear Suspension System
3-4-4 Brake System
31
3-1 ENGINE
32
3-1-2 Carburetor
I. idle Jet :
When scooter idling, gasoline will pass through idle jet and mix with air and go into the crank
case. When the throttle handle opens, the piston valve and needle jet are elevated to let
gasoline pass through the main jet and mix with air and go into the crank case
2 . Auto-Choke:
The body of Carburetor is equipped with PTC Heater to-start the Choke Plunger. Part of the
electricity made by Fly-wheel Magneto is used on PTC Heater, which heats the Ceramic plate.
The heat then expands the Thermo- Wax to start the Starter-Plunger to activate the Auto-
Choke in warm condition. The path is in closed condition then.
In cold condition, the Thermo-Wax will contract according to the temperature, so the Choke-
Plunger is in open condition.
33
3-1-3 Lubrication & Cooling System
1. Lubrication of Engine :
A. The Pump Gear is driven by the
Screw Crank Shaft to rotate
the Plunger valve of oil-Pump
and send the lubricating oil
into the Crank to completely
mix with the carburetted air
and then go into the Combustion
Chamber.
34
3-2 TRANSMISSION MECHANISM
35
3-2-2 Continuous Variable Transmission
I . V-Belt :
Made of rubber fiber, resistant
to heat, pressure and abrasion.
The inner side of the Belt is
toothed.
2 . Drive Pulley :
A. Due to the increasing revolution speed
of Engine, the Roller in the Movable
Drive Face is expanded by the
centrifugal force to move the Movable
Drive Face and squeeze and press
V-Belt to enlarge its turning radius.
3 . Driven Pulley :
A. Because the revolving radius of V-Belt
at the Drive End is enlarged, the Face
Comp Movable
Drive is squeezed out by the V-Belt at
the Driven End to shorten the revolving
radius.
36
3-2-2 Continuous Variable Transmission
4. Running Curve:
B. During quick speeding, because the torque cam begins to act,the quick transformation
can be achieved in high speed.
C. After the transmission,the scooter speed can also rise according to the ratio with the rise
of revolving speed of Engine.
37
3-2-3 Reducing Gear
The power received by the Drive Shaft will be transmitted by the
speed reduction of two sets of Gear to Rear Axle Shaft.
C. Starting Motor is
installed at the front
bottom of Crank Case .
E. Starter Switch is
installed on the Right-Hand
Handle. Starter Motor
revolves to activate
Pinion Gear Assy. to fly
out of the Pinion-Gear
and connect with the
Starter Gear.
38
3-2-4 Starting Mechanism:
2 . Kick starter :
A. To start the scooter by kicking,the center Stand has to be erected and the Brake-Lever
has to be under brake condition.
B. When the Kick-Starter Lever is kicked, the umbrella type gear of Starter Shaft will drive
the right hand kick starter to revolve the crank shaft to start the engine.
C. After the Engine is started, the Ratchet of the Left-kick Starter will stop the power
transmission to the Kick-Starter Driven Gear.
D. When the Kick-Starter Lever is released, the Kick Starter Gear will remove from Kick-
Starter Driven Gear and go back to its original place.
39
3-3 ELECTRIC SYSTEM
1. Ignition Device:
CDI Unit of two ignitions per revolution is adopted.
The ignition Lead is 18°±3°/4,000rpm (OLD)
15° ±3°/4,000rpm (NEW)
2. Charging Device:
Power is given by flywheel magneto. The voltage is controlled by voltage regulator.
Power is charged to battery.
A. Flywheel Magneto:
Flywheel (rotor) includes four poles, crossed N poles and S poles. The stator consists of
one high-tension ignition coil and three low-tension coils for charging and lighting to create
change of magnetic field by rotating the flywheel to generate electricity.
40
3-3-1 IGNITION CHARGING DEVICE FOR THE IGNITION
Note : The Battery is completely ready to use, thus do not remove the Aluminum
Seal on the closed filling hole until it is to be used. Electrolyte, except those
specified, is absolutely forbidden. While filling the electrolyte, only regulated
volume of electrolyte can be adopted. The seal plug should not be removed
after the electrolyte is added.
41
3. THE PROCEDURE OF USING NEW BATTERY
(FOR WATER-ADDING BATTERY )
6. Connect the black lead to the "-" pole of battery and red to "+" pole put the battery
to the location and clamp the rubber band.
7. For the connected plastics long tube to the air vent hole of battery , the other end of the tube
must be setted through into the square hole in the plastic leg shield rightly to discharge the
erosive air or sulfuric acid to avoid eroding the body. The tube must be without plugging or
straight bending to avoid exploding.
CAUTION:
It's important to use open long tube to instead of close short
tube to assure normal output of gas to prohibite of exploding.
42
4. BATTERY MAINTENANCE: (FOR WATER-ADDING BATTERY)
I . Frame :
A. steel pipe and steel sheet are adopted to
compose reinforced frame.
2 . Fuel Tank
A. Fuel Tank is made of plastic or steel
including electric Fuel-Level- guage.
B. When the Fuel Guage is in the E-Line,
there is about 1L of preserved fuel.
3 . Oil-Tank :
Oil Tank is made of plastic, including
electric Fuel-Level-guage, with the
capacity of 0.8L.
When the red indicating lamp of Oil Level
is lit, there is about 220 c.c. preserved oil.
4 . Fuel-Cock:
Automatic Cock of negative pressure
model.
44
3-4-2 Compartment and Seat
I . Compartment:
A. Located in the center of scooter body, there is a Personal Space for helmet and other, etc.
C. Please don't store precious or easy-to-break articles in the compartment without any
protection.
D. The Seat has to be locked. If the Seat is not locked during riding, it will affect the safety
and even cause injury.
E. Please pay attention not to let fuel or oil drop into the compartment.
2 . Helmet Holder:
There is a Helmet Holder at the position of Seat Hinge.
open the Seat to hook or unhook Helmet.
45
3-4.3 Front & Rear Suspension System
46
CHAPTER 4 . DISASSEMBLY REPAIRS
47
4-1 NOTICE FOR DISASSEMBLY lNSPECTION
1. In order to avoid mixing and loss of disassembled parts before reassembling, the
disassembled parts have to be arranged according to their function during the process.
2. The damage to Cover and Frame should be avoided while disassembling and assembling.
7. When important revolving and reciprocating parts, such as Cylinder Head, Cylinder, Piston,
Piston-Ring, and Crank, have been replaced, the vehicle can not go for full speed running
immediately. Preliminary running should be applied below 4000 rpm within 500km.
8 . While assembling, the main lip of oil seal should face inwards (oil chamber) and the antidust
sub-lip should face outwards.
Apply an even layer of specified grease onto the lip before it is pressed to its location with
balanced force by specified jigs.
9 . While pressing the bearing into the hole, apply balanced force to the outer ring of bearing
by specified jigs.
While pressing the bearing into the main shaft, apply balanced force to the inner ring of
bearing by specified jigs.
48
4-2-1 Removal of Engine
H . Lift Body
49
4-2-2 Installation of Engine
50
4-3-1 Disassembly Sequence of Engine
51
4-3-1 Disassembly Sequence of Engine
52
4-3-1 Disassembly of Engine:
( Muffler, Kick Starter Lever Assy, Drive Pulley Assy .)
1. Removal of Muffler block (14).
2. Removal of Kick Starter Lever
Assy:
A. Remove the hexagon bolt (15)of
kick starter lever assy (16) and
remove the kick starter lever assy.
B. Remove the fixed screw of clutch
cover.
C. Remove the Spring (17) of kick
starter shaft .
D. Remove the kick starter shaft (18).
E. Remove the bush (19) of kick
starter shaft
3. Removal of Drive Pulley:
A. Remove screw (1).
B. Remove spring seat (2).
C. Remove spring (3).
D. Remove washer (4).
E. Remove the left hand starter
assy (5).
F. Remove the RH starter (6).
WARNING
Because it is LH thread inside
the RH starter, it is necessary to
use deep bush while removing
(to avoid contact with the crank
shaft), and remove the RH
starter by using pneumatic
wrench turns to right hand. If it
turns to left hand, the wrong
direction, it will damage the
crank shaft easily.
Special Tool: GA5000051F36.
◎If manual wrench, instead of
pneumatic wrench, is adopted,
stop tool will be needed.
Special Tool: GA5000051F3.
G. Remove Movable Drive Face (7).
H. Remove V-Belt (8).
I. Remove Drive Pulley Assy (9) and
Spacer (10)
◎Press the Movable Drive Plate and
Drive Pulley Face while removing
the Drive Pulley Face Assy in
order to avoid the roller to stand
up.
J. Disassembly of Driven Pulley Face
Assy:
Remove screw (11), Movable Drive
Plate (12), roller (13) and guide
53
4-3-l Disassembly of Engine: (Removal of Driven Pulley Assy)
54
4-3-1 Disassembly of Engine: (Removal of Flywheel Magneto and Starter Motor)
55
4-3-1 Disassembly of Engine: (Removal of In-Take Pipe, Oil-Pump and Cylinder)
56
4-3-1 Disassembly of Engine: ( Removal of Reducing Gear)
11. Removal of Reducing Gear:
57
4-3-1 Disassembly of Engine: Removal of Rear Wheel
58
4-3-1 Disassembly of Engine: (Removal of Crank Case)
59
4-3-1 Disassembly of Engine: Removal of Crank Case
60
4-3-2 Inspection of Engine Components
Compression Pressure :
Standard 6 .8kg/cm2/500rpm
Limit 5.0gk/cm2
61
4-3-2 Inspection of Engine Components
62
4-3-2 Inspection of Engine Components
5. Inspection of Cylinder:
A. Check if any damage appears on the bore.
B. Check if any damage or crack appear on surface.
C. Excessive carbon deposit in the air outlet has to be cleaned.
D. Replace if the cylinder bore exceeds 41.07mm. (50C.C) 50.07 mm (90 C.C)
E. Repair will be needed if the flatness exceeds 0.1mm.
8. Inspection of Piston:
A. Check for unusual damage, crack or abrasion.
B. Measure the exterior diameter at 15m/m (50C.C), 20m/m (90C.C.) height above the
piston bottom and the perpendicular to the pin hole.
Replaced if it is less than 40.89mm. (50 C.C.) ,49.89 (90 C.C.)
C. Replaced when the piston pin hole exceeds 10.04mm (50.C.C), 12.04 mm (90 C.C.)
63
4-3-2 Inspection of Engine Components
B. Check for any break from the appearance. Replaced if the flatness of contact suface
exceeds 0.08mm.
64
4-3-3 Assembly Sequence of Engine
I. Assemble the Bearing of LH Crankcase.
Assemble the Oil Seal of LH Crankcase.
Assemble the Bush.
Assemble the Bearing of RH Crankcase.
Assemble the Oil Seal of RH Crankcase.
Assemble the Crank Shaft.
Assemble the RH Crankcase.
65
4-3-3 Assembly Sequence of Engine
9. Assemble the Pinion Gear Assy.
Assemble the Starting Gear.
Assemble the Cap Set of Starter Idler Gear.
Assemble the Starting Motor.
66
4-3-3 Assembly of Engine:
67
4-3-3 Assembly of Engine:
68
4-3-3 Assembly of Engine:
69
4-3-3 Assembly of Engine:
A. Apply a little gear oil (GA50400004) on the right hand bearing of rear axle, and then evenly
press into the reducing gear chamber. with fixture.
Special Tool: GA5000051F18.
B . Mount cir-clip (1) on the rear axle(2).
C. lnstall idle shaft washer(5).
D. Apply a little gear oil (GA50400004) on the bearing contact surface of idle shaft.
E. lnstall the final driven gear(4). lnstall cir-clip of rear axle.
F. lnstall idle shaft washer(5). Install idle shaft (3)
G. Assemble knock-pin(6) .
H. lnstall the gasket(7) of gear box cover.
I. Apply grease (GA50400005) on the lip of oil seal(8) of drive shaft and then press into the
gear box cover with special tool.
Avoid damage to the lip of oil seal. lnstall horizontally and slanting is not allowed.
Special Tool: GA5000051F30
J. Press in the LH bearing (9)of drive shaft with special tool.
Special Tool: GA5000051F17
K. Press the drive shaft(10) evenly into the gear box cover. .
L. lnstall the gear box cover and lock the bolt in sequence by diagonal step.
M. Lock the drain bolt(11 ).
Screw Torque : 90 - 150 kg cm
.
◎ The drain hole for engine is located on the gear box cover or outside the crank case, for we
have two designs.
N. Fill 90cc of TGB gear oil (GA50400004)
Q. Tighten the refilling bolt(12).
Screw Torque : 90 kg cm
.
◎ The refilling hole for engine is located on the gear box cover or outside the crank case,for
we have two designs.
70
4-3-3 Assembly of Engine
5. Assembly of Piston
A. Apply TGB oil (GA50400002) on
the needle roller bearing at the small
end of con-rod.
71
4-3-3 Assembly of Engine:
6. Assembly of Cylinder:
A. Apply a little TGB oil.
(GA50400002) to piston pin (3)
and then insert into the piston hole.
72
4-3-3 Assembly of Engine:
7. Assembly of Oil-Pump:
A. Apply a layer of grease (GA50400005) on the sliding part and gear tooth of oil-pump driven
gear (1) and then insert into the crank case.
B. Install the oil-pump (2).
OLD NEW
73
4-3-3 Assembly of Engine:
D. Install the starter gear(I) into the left hand crank shaft(2).
E. Install the starter motor and tight the bolt with cable clamp.
74
4-3-3 Assembly of Engine:
75
4-3-3 Assembly of Engine:
76
4-3-3 Assembly of Engine :
77
4-3-3 Assembly of Engine:
(Assembly of Movable Driven Pulley Assy)
M. Move the movable driven face (1) of movable driven pulley assy towards the clutch (2) by
hand. Install V-belt and then install to the drive shaft.
◎Wipe cleanly the grease on belt surface and the pulley surface.
O. Screw the nut (4) of clutch housing with tool to stop turning
or use pneumatic wrench.
screw Torque:400~600 kg . cm
special Tool: GA5000051F04
78
4-3-3 Assembly of Engine:
79
4-3-3 Assembly of Engine: (Assembly of Movable Driven Pulley Assy)
* WARNING *
Special deep socket sleeve should
be adopted while screwing.
* WARNING *
This component is left hand
threaded, thus turning
counterclockwise to screw will
be necessary when assemble.
Use general sleeve or trying too
hard to tighten will cause damage
to the thread of left hand crank
shaft which will cause to the
replacement of crank shaft assy.
80
4.3.3 Assembly of Engine:
81
4-4 REMOVAL AND ASSEMBLY OF CARBURETOR :
Removal of Carburetor :
I. Removal of Carburetor :
82
4-4 REMOVAL AND ASSEMBLY OF CARBURETOR:
Inspection and Assembly of Carburetor
2. Inspection of Carburetor:
A. Inspect and clean the jets and airway of
the carburetor.
Cleaning by compressed air.
B. Check if the float operates normally to its
position.
C. It is forbidden to use metal to remove dirt
appearing on the surface, or it will cause
damage to the surface. Blow the dirt off by
compressed air.
Replace it if necessary .
D. Idle Setting With An Air-Adjusting
Screw
Check that the throttle cable has about
1mm free play when the position valve (4)
is fully closed. Always adjust the idle
setting with the engine fully warm.
Screw in the idle-speed screw (2) to obtain
a slightly-higher idling speed than normal ;
then adjust the air-adjusting screw (1) to
obtain the most even running. Then
unscrew the idle-speed screw again
until you obtain the normal idling speed.
Finally, to obtain the best engine running,
it is worth rechecking by very carefully
readjusting the air-adjusting screw.
3. Assembly of Carburetor :
A. Install o-ring, washer and spring.
◎ Screwing too hard shall not be allowed,
or it will damage the seat.
B. Install the idle speed screw (2)and spring .
C. Install the auto-choke.
D. Place the needle clip(3) at the 3rd groove
of jet needle.
Put into the piston valve (4) with clamp (5),
and press into their positions.
E. Install the throttle cable and spring.
F. Install the piston valve into the carburetor
according to the position of groove and fix
the cap.
G. Install the carburetor into the engine.
H. Connect the negative pressure hose and
fuel-hose.
I. Insert the terminal of auto- choke to the
cable connector.
83
4-5 INSPECTION OF ELECTRIC ITEMS
84
4-5-1 Removal and Inspection of Ignition and Charging System
C. Inspection of Rectifier
a. Testing Range - X 1 KΩ
b. Terminals shall not connect with the rectifier surface.
c. Check the electric resistance value between each wire.
85
4-5-1 Removal and Inspection of Ignition and Charging System
50C.C.
NGK FUNCTION
86
4-5-2 Removal and Inspection of Starter Mechanism
87
4-5-3 Removal and Inspection of Fuel Meter and Fuel Level Gage
88
4-5-4 Removal and Inspection of Turn-Signal Indicator, Oil Warning Indicator and Level
Gage
89
4-6 REMOVAL AND INSPECTION OF BODY PARTS
Removal and Inspection of Front Fork
90
4-6 Disassembly and Inspection of Body Parts
Disassembly of Brake
91
4-6-3 Removal and Inspection of Brake
C. Inspection of the Return Spring of Brake Lining:
a. Testing the free length of the spring with a vernier caliper.
b. Check for any wear and crack on the spring.
Free Length of the Return Spring of Brake Lining (mm)
Standard 32.6-33.0 Limit Exchanged over35.0
D. Inspection of the Brake Cam:
a. Check for any rust or unusual wear on the brake cam.
b. Make sure the brake cam runs smoothly.
c. Make sure to apply sufficient grease to the brake cam and lining anchor-pin.
E. Inspection of Front Brake:
a. Check the gap between the ends of front brake lever.
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4-6 Disassembly and Inspection of Body Parts Assembly of Front
Brake and Wheel
B. Install the gear assy of speedometer (2) on the right hand side.
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4-6 Disassembly and Inspection of Body Parts
94
4-7 GE5 Built-in braking system:
95
4-7 GE5 Built-in braking system:
96