Baotian Service Manual

4 STROKE ENGINE
SERVICE AND REPAIR MANUAL

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Tab|e cf Ccntents
Chapter Tcp|c Fage
CH/l1Lb : lntroduct|on Z
CH/l1Lb Z: Body Cover and LxHaust 3ystem Z
CH/l1Lb 3: 3cHedu|ed la|ntenance 33
CH/l1Lb 4: lubr|cat|n 3ystem 4b
CH/l1Lb b: lue| 3ystem bZ
CH/l1Lb b: Ln|ne bemova| and lnsta||at|on b/
CH/l1Lb /: Cy||nder Head Va|ve /
CH/l1Lb : Cy||nder and l|ston
CH/l1Lb 9: 0r|v|n Be|t 0ev|ce & 1He 3tart|n lever 9b
CH/l1Lb C: 1He l|na| 1ransm|ss|on /ssemb|y C
CH/l1Lb : 1He Crankcase and tHe CranksHalt b
CH/l1Lb Z: 1He lront wHee|, lront Brake, Z4
lront Buller and tHe lront lork
CH/l1Lb 3: 1He bear wHee|, tHe bear Brake & bear 3Hock 4C
CH/l1Lb 4: 1He Battery and tHe CHar|n 3ystem 4b
CH/l1Lb b: ln|t|on 3ystem bC
CH/l1Lb b: 3tarter 3ystem bb
CH/l1Lb /: leters, 3w|tcHes and l|Ht|n 3ystem /3
lN0L/ C
I. Genera| Infcrmat|cn
lb/lL N0lBLb C01 l03l1l0N
LN0lNL N0lBLb C01 l03l1l0N
Tcp|c Fage
Ln|ne and lrame Number los|t|ons
lroduct 3pec|hcat|ons Z
and 1ecHn|ca| 0ata
1ecHn|ca| 1|ps 3
1orque 3ett|ns
Tcp|c Fage
1oo|s Z
0|| and 0rease 3upp|y CHart 3
Contro| Cab|es and w|r|n 0|aram 4
la||ure 0|anost|cs Z
Lccat|cn fcr: Eng|ne Number,Frame Number
Frcduct Spec|hcat|cns and Techn|ca| Data
Scccter Mcde| JL50QT-18
JL50QT-X1/8
JL50QT-14
Length bbmm |bb.b |ncHes
W|dth bbCmm |Zb |ncHes
He|ght C/Cmm |4Z |ncHes
Whee| base 9bmm |4/ |ncHes
Eng|ne type 4stroke 0HC
D|sp|acement 49.bcc
Fue| requ|rements leadlree aso||ne
Dry we|ght
lront 3bks |// |bs
bear bbks |Z3 |bs
1ota| 9ks |ZCC |bs
Curb we|ght
lront 3/ks |.b |bs
bear bCks |3Z |bs
1ota| 9/ks |Z3.b |bs
T|re s|ze
lront 3.CC x C
bear 3.CC x C
Grcund c|earance Cmm |3.Zb |ncHes
3topp|n d|stance 4m lrom 3Ckm/Hr
b lt lrom mpH.
1urn|n rad|us .bbm |b.b lt
Eng|ne Specs
1ype 4stroke 3l
3tart|n L|ectr|c/k|ck start
Cy||nders 3|n|e
Combust|on cHamber Hem|spHer|ca|
Va|ve tra|n 3|n|e 0HC
Bore 39mm |3.34 |ncHes
3troke 4.4mm |.b3 |ncHes
0|sp|acement 49.bcc
Compress|on rat|o C.b:
Compress|on pressure bk/cm
Zbps|

lower Z.Z Hl @ CCC bll
1orque 4.b lt |bs @ bCCC bll
lntake t|m|n b` B10CZ` /10C
LxHaust t|m|n 3` BB0Cb` B10C
Va|ve |asH .Cbmm
ld|e speed bC9CCbll
0|| system lressure/sp|asH
0|| pump lnterna| ear
0|| h|ter lu||Now h|ter and screen
0|| capac|ty .l |3Z oz
Coo||n 0ucted lorced a|r
A|r c|eaner loam and paper
Carburetcr type CVb bC
Ventur| mm
Thrctt|e mechan|sm ButterNy type
Ign|t|cn system C0l type
3`B10C @ ZCCC bll
3park p|u N0b C/H3/ CHamp|on
Z9Y
0ap .b.bmm |.CZZ.CZ4 |ncH
Battery ZV 4/H
Dr|ve system
C|utcH 0ry mu|t| p|ate
1ransm|ss|on CV1
3H|lt|n /utomat|c
l|na| 0r|ve 0oub|e reduct|on
st step 3.Z:
Znd step 3.4:
Steer tube ang|e b4`
Steer|ng ang|e 4b`
T|re pressure frcnt ./bk/cm |Zbps|
T|re pressure rear Z.Zbk/cm |3bps|
Frcnt brake Hydrau||c d|sc
Rear brake lecHan|ca| drum
Suspens|cn frcnt 1e|escop|c
Suspens|cn rear 1ra|||n arm
Shcck abscrber frcnt Co|| spr|n/Hydrau||c
Shcck abscrber rear Co|| over Hydrau||c sHock
Frame type 1ubu|ar space lrame
bep|ace a|| askets, or|ns, c|rc||ps
and cotter p|ns wHen perlorm|n
ma|ntenance on tHe scooter. Nuts and
bo|ts on a|| en|ne covers sHou|d be
t|Htened |n a d|aona| pattern to
un|lorm|y d|str|bute c|amp
lorce.
0se |ubr|cants recommended |n tH|s
manua| at a|| t|mes to assure peak
perlormance lrom tHe scooter.
0se on|y enu|ne rep|acement parts
wHen perlorm|n repa|rs to tHe scooter.
3pec|a| serv|ce too|s may be requ|red
to perlorm ma|ntenance and repa|rs on
tH|s scooter. /|ways use tHe proper too|s
to prevent damae to tHe scooter.
C|ean and |ubr|cate a|| en|ne parts
dur|n tHe d|sassemb|y and reassemb|y
process to prevent damae to tHe
en|ne.
Techn|ca| T|ps
wHen perlorm|n ma|ntenance on tHe
scooter, make sure tHat a|| mov|n parts
and contro|s move lree|y and return to
tHe|r proper pos|t|on.
wHen connect|n tHe battery, a|ways
connect tHe pos|t|ve term|na| hrst.
wHen d|sconnect|n tHe battery, a|ways
d|sconnect tHe neat|ve term|na| hrst.
lake sure tHat too|s and serv|ce
equ|pment do not come |n contact w|tH
botH battery term|na|s.
Cover botH battery term|na|s w|tH a
||Ht coat ol rease to prevent
corros|on.
Techn|ca| T|ps (ccnt|nued)
wHen rep|ac|n luses, a|ways use an
exact rep|acement. 0o not use luses ol
a H|Her amp rat|n|
bep|ace a|| rubber caps on w|re
connectors alter perlorm|n
ma|ntenance.
wHen d|sconnect|n w|re connectors,
press hrm|y on tHe |ock|n tab and pu||
tHe body ol tHe connectors. Never pu||
on tHe w|res
wHen assemb||n w|re connectors,
press hrm|y to assure tHe |ock tab lu||y
enaes.
lake sure tHat a|| w|re term|na|s are
proper|y |n p|ace belore attempt|n to
assemb|e any w|re connector.
YL3
N0
lake sure tHat a|| w|r|n connectors are lu||y
seated and |ock tubs enaed.
CHeck |l a|muce ol connector |s covered and
hxat|on |s t|Ht.
lake sure tHat a|| protect|ve covers are
proper|y |n p|ace over tHe w|r|n connectors.
Never reuse damaed w|re term|na|s or
connectors.
Never reuse damaed w|re term|na|s or
connectors.
bep|ace a|| rubber covers on w|re connectors
to prevent water lrom ett|n |nto tHe
connector.
3tr|p ol ma|n w|re must be hxed on ass|ned
pos|t|on.
lnsu|ator ol a|um|num str|p must be alhxed to
w|res.
lake sure tHat a|| w|r|n Harness reta|ners are
proper|y p|aced.
0o not over t|Hten w|r|n t|es to prevent
p|ncH|n ol w|res.
0o not a||ow w|r|n Harness to Han |n |oose
|oops.
lake sure tHat a|| w|re c||ps are
proper|y attacHed.
lake sure tHat tHe w|r|n Harness and
a|| w|res do not contact mov|n or
rotat|n parts ol tHe scooter.
a|| w|res do not contact Hot components
or surlace parts ol tHe scooter.
a|| w|res do not contact sHarp edes or
parts ol tHe scooter. 0se tape to prevent
damae to w|res on sHarp edes.
YL3
YL3 YL3
N0
N0
N0
N0
0o not pu|| w|res too t|Ht|y.
0se tape to protect aa|nst sHarp edes.
lake sure tHat a|| rubber rommets are |n
p|ace to protect tHe w|r|n Harness.
0o not reuse broken or lrayed w|res.
bepa|r or rep|ace w|res as necessary.
0o not tw|st or knot w|res wHen
perlorm|n ma|ntenance on tHe scooter.
lake sure tHe w|r|n Harnesses to tHe
Hand|ebars are not too t|Ht or too |oose
by turn|n tHe Hand|ebars botH r|Ht and
|elt wH||e mak|n sure tHere |s no p|ncH|n
or pu|||n ol tHe w|res.
lake sure tHat you understand tHe proper
use ol test equ|pment to perlorm
ma|ntenance on tHe scooter. 1H|s w|||
prevent acc|denta| damae to tHe
e|ectr|ca| system ol tHe scooter.
0se e|ectr|ca| contact c|eaner and
abras|ve paper to c|ean corros|on lrom any
w|re term|na|s.
1ake care to prevent |nadvertent damae
to w|r|n and cab|es.
YL3
N0
N0
Dehn|t|cns cf d|agrams
1He lo||ow|n |cons are used to H|H||Ht |mportant
operat|ons |n tHe serv|ce ol tHe scooter.
lubr|cat|n o|| requ|red.

0rease requ|red.

Ln|ne o|| requ|red.

3pec|a| too|s requ|red.

3pec|a| attent|on requ|red.

0anerous and |mportant,
spec|a| care requ|red.
Tcrque Sett|ngs
1orque
Standard Tcrque Sett|ngs
bmm Cap 3crew
bmm Cap 3crew
mm Cap 3crew
Cmm Cap 3crew
Zmm Cap 3crew
.b k/cm
k/cm
Z.Z k/cm
3.b k/cm
b.b k/cm
1orque lastener 1ype lastener 1ype
bmm 3ocket Head 3crew
bmm 3ocket Head 3crew
mm l|ane Head 3crew
Cmm l|ane Head 3crew
Zmm l|ane Head 3crew
.4 k/cm
.9 k/cm
.Z k/cm
Z./ k/cm
4.C k/cm
0enera| 1orque bequ|rements lor 3tandard lasteners
Number
0sed
Spec|a| Tcrque Sett|ngs
Cy||nder Bo|t /
Cy||nder Bo|t B
0|| l||ter 3creen Cap
LxHaust l|pe l|ane Bo|t
l|ane 3crew Be|t lu||ey
Va|ve /djusters
Cam CHa|n /djuster
0u|de l|ate 3crew
/ 0|| l||| 3crew
C|utcH Cover 3crew
C|utcH 0r|ven 0n|t
lount|n 3crew
3tarter lotor lount|n 3crew
0|| lump lount|n 3crew
C|utcH 0r|ver lount|n 3crew
/C0 co|| lount|n 3crew
Cam CHa|n /djuster 3crew
3park l|u
Z
Z
Z
4
Z
Z
3
1orque
k m ||n. |bs
Comments
0|a.
|mm
lastener 1ype
3C
b
b
b
Z
Z
b
b
Z
b
b
C
.9
.9
.b
.9
Z.C
.9
.C
.3
b.b
b.b
.C
.Z
b.b
.C
.b
.Z
lubr|cate w|tH Ln|ne 0||
lubr|cate w|tH Ln|ne 0||
1orque bequ|rements lor Ln|ne lasteners
Number
0sed
Cy||nder Bo|t /
Cy||nder Bo|t B
0|| l||ter 3creen Cap
LxHaust l|pe l|ane Bo|t
l|ane 3crew Be|t lu||ey
Va|ve /djusters
1orque
k m ||n. |bs
Comments
0|a.
|mm
lastener 1ype
Zb.4
C
4
C
b
Z
4b
C
34
Z3
.b
0se 3olt 3et lock1|te
1orque bequ|rements lor lrame lasteners
epa|r ol tHe
scooter, a comp|ete bas|c set ol metr|c s|zed
too|s |s requ|red. 1H|s sHou|d |nc|ude; 0penend
wrencHes, sockets and ratcHet, Hex keys, stra|Ht
and lH|||ps screw dr|vers, standard p||ers,
need|enosed p||ers, w|re cutters, w|re str|ppers,
scraper, p|n puncH, Hammer and solt laced ma||et.
lor a more extens|ve tear down and rebu||d ol tHe
scooter, tHere are a var|ety ol spec|a| too|s tHat
w||| be requ|red. 1Hese |nc|ude tHe lo||ow|n:
Va|ve spr|n compressor
Va|ve u|de reamer
lee|er ae set
3||de Hammer bear|n and sea| remover
Bear|n press
1orque wrencH
b|n compressor
C|utcH spr|n compressor
l|y wHee| pu||er
L|ectron|c mu|t| meter
Tcc| Requ|rements
Lubr|cat|cn Requ|rements: Eng|ne
va|ve u|de va|ve stem mov|n part
cam sHalt |u surlace
va|ve rock|n arm lr|ct|on surlace
camsHalt dr|ve cHa|n
cy||nder hxed screw bo|ts and nuts
around p|ston and p|ston r|n roove
around p|ston p|n
cy||nder surlace
connect|n rod, p|ston p|n bore
connect|n rod b| end
cranksHalt b, l s|de o|| sea|
starter reduct|on rear ena|n |mat|n part
coundersHalt ear ena|n part
hna| ear ena|n part
eacH bear|n rotat|ona| part
or|n surlace
o|| sea| ||p
starter |d|e ear
lr|ct|on spr|n mov|n part, sHalt mov|n part
sHalt mov|n roove part
starter dr|ve ax|e
/Cenerator connector
Item Lccat|cn Reccmmended Lubr|cant
3/L bw 3C Ln|ne 0||
/ll30 0rade Ln|ne 0||
o||
rease
o||
o||
o||
o||
o||
o||
o||
o||
o||
rease
o||
o||
o||
rease
o||
rease
adHes|ve
LN0lNL 0ll:
3lLL00lL1Lb
0blVL
0bL/3L:
3lLL0 lL1Lb llL/lBlL 3H/l1
lb0N1 wHLLl BL/blN0
Bb/bL C/l
ll/L0 llN
lb0N1 3H0Cb /B30bBLb B/3L
0bL/3L:
CLN1Lb 31/N0 llV01
0bL/3L:
bL/b wHLLl BL/blN0
0bL/3L:
bL/b Bb/bL lLVLb llV01
0bL/3L:
3L/1 l/1CH
0bL/3L:
bL/b Bb/bL
00l0L llNL
0bL/3L:
Bb/bL C/l
/N0 llN
/pp|y o|| to tHe lo||ow|n parts.
0se rease |n tHe parts otHer tHan spec|hed
ones.
/pp|y en|ne o|| or rease to tHe mov|n parts to
prevent abnorma| no|se and to ra|se durab|||ty.
Chass|s
Cab|e Rcut|ng D|agram
/010l/1lC BYl/33
31/b1Lb bL3l31/NCL
ll/3HLb
H0bN
l/lN 3wl1CH
1Hb011lL C/BlL
lb0N1 Bb/bL
3wl1CH lL/0
lb0N1 Bb/bL C/BlL
bL/b Bb/bL 3wl1CH lL/0
3lLL00lL1Lb C/BlL
bL/b Bb/bL C/BlL
HL/0ll0H1 lL/0 C0NNLC10b
HL/0ll0H1 bL3l31/NCL
V0l1/0L bL00l/1l0N/bLC1lllLb
3lLL00lL1Lb C/BlL
lb0N1 0l3C Bb/bL H03L
bL/b Bb/bL C/BlL
1Hb011lL C/BlL
/010l/1lC
LNblCHlLN1
bL3l31/NCL
HL/0ll0H1
bL3l31/NCL
V0l1/0L bL00l/1l0N bLC1lllLb
l/lN H/bNL33
1Hb011lL C/BlL
bL0 B/11LbY C/BlL l03l1lVL
l03L
0bLLN B/11LbY C/BlL NL0/1lVL
l0Nl1l0N C0ll
l0Nl1l0N C/BlL
V/C00l llNL
b0CbLb C0VLb VLN1
Cb/NbC/3L VLN1
1Hb011lL
l0Ll llNL
l0Ll 3LN30b
1Hb011lL C/BlL
31/b1Lb LNblCHlLN1
V/C00l llNL
V/C00l llNL
l0Nl1l0N C0ll
Cb/NbC/3L
BbL/1HLb
Cb/NbC/3L BbL/1HLb
l0Ll l/33/0L
l0Ll V/l0b bL10bN lllL
31/b1Lb LNblCHlLN1
C/BlL
31/b1Lb l010b C/BlL
l/lN wlblN0 H/bNL33
l/lN wlblN0
H/bNL33
lVC |l0Ll
C0N1b0l V/lVL
3l/bb ll00
B
/
w
w
B
|
l
/
3
3
0
ll
l
L
b

3
w
l1
C
H
H
L
/
0

l
l0
H
1
l
0
L
l

l
L
1
L
b
l
b
0
N
1
1
0
b
N
l
L
l
1
l
l0
H
1
l
B
|
0
b
1
0
b
N

3
w
l1
C
H
B
l
0
H
0
b
N

B
0
1
1
0
N
b
L
/
b

B
b
/
b
L

3
w
l1
C
H
l
0
L
l

3
L
N
0
L
b
0
N
0
l
l
B
0
/
Y
0
N
0
l
l
B
b
B
/
w
0
l
/
lN

3
w
l1
C
H
B
l
Y
B
/
w
l
l0
H
1

3
w
l1
C
H
B
r
b
L
/
b

1
0
b
N
l
l0
H
1

|b
l0
H
1
1
/
ll
/
B
b
/
b
L
l
l0
H
1
b
L
/
b

1
0
b
N
l
l0
H
1

|l
L
l
1
H
l0
H

B
L
/
l

lN
0
lC
/
1
0
b

l
l0
H
1
l
L
1
L
b

l
l0
H
1
1
0
b
N

lN
0
lC
/
1
0
b

l
l0
H
1
l
b
0
N
1

1
0
b
N

b
l0
H
1

l
l0
H
1
H
0
b
N
0
N
0
l
l
0
l
b
0
N
1
3
1
/
b
1
lN
0

B
b
/
b
L

B
/
1
1
L
b
Y
l
l
/
3
H
L
b
b
L
l
/
Y
b
w
4
/
0
1
0
L
N
b
lC
H
L
b
B
0
1
1
0
N
b
/
Y
0
N
0
l
l
0
3
w
l1
C
H
0
/
Y
0
N
0
l
l
L
l
L
b
0
L
N
C
Y
3
1
0
l

3
w
l1
C
H
0
B
/
w
Y
0
/
B
B
0
0
B
r
0
/
Y
l
B
l
0
r
Z
V

4
/
H
+
3
C
w
/
.
b
0
l
0
B
l/
w
B
l/
w
0
b
Y
Y
0
B
3
1
/
b
1
L
b
b
L
l
/
Y
3
1
/
b
1
L
b
l
0
1
0
b
l
0
/
Y
l
0
3
L
b
L
C
1
ll
lL
b
l0
N
l1
L
b
C
0
ll
3 l / b b l l 0 0
C
0
l
B
/
Y
3
l
L
L
0

l
ll
l1
|3
L
l
L
C
1
/
B
l
L

0
N
l1
l
/
0
L
N
1
/
B
l/
Y
B
b
b
:

b
e
d

0
:
0
r
a
n
e

Y
:

Y
e
||o
w

B
|:
B
|u
e

l
:
l
|n
k

0
:

0
a
r
k

r
e
e
n

0
r
:

0
r
e
y

B
r
:

B
r
o
w
n

l
0
:

l
|
H
t

r
e
e
n

0
:

0
r
e
e
n

B
|/
Y
:

B
|u
e
/
y
e
||o
w

B
/
b
:

B
|a
c
k
/
b
e
d

w
/
b
:

w
H
|t
e
/
r
e
d
Y
/
B
:

Y
e
||o
w
/
b
|a
c
k

B
|/
w
:

b
|u
e
/
w
H
|t
e

0
/
b
:

0
r
e
e
n
/
r
e
d

B
r
/
b
:

b
r
o
w
n
/
r
e
d

B
/
w
:

b
|a
c
k

0
/
Y
:

0
r
e
e
n
/
y
e
||o
w

w
:

w
H
|t
e

B
/
Y
:

b
|a
c
k
/
y
e
||o
w

l
B
l:

l
|
H
t

b
|u
e
Trcub|e Shcct|ng Gu|de
Starter Fa||ure cr Hard Start|ng
Check Adjust Fau|ty Ccnd|t|cn Cause cf Trcub|e
3upp|y app|y
enouH lue|
1Here |s spark over |n spark p|u
1est compress|on pressure
1Here |s no spark or weak spark
No compress|on pressure
or compress|on pressure
too |ow
Norma| compress|on pressure
No lue| supp||ed to carburetor
loosen carburetor overNow screw
and cHeck |l tHere |s lue| |n |t
bemove spark p|u |nsta|| |t |n |ts
cap and connect |t to en|ne to
lor spark
3tart accord|n to operat|n metHod
No |n|t|on spark
3park p|u wet 3park p|u dry
|Ln|ne Hav|n |n|t|on
spark but not to start
bemove spark p|u aa|n and cHeck
No lue| |n tank
l|oat passae c|ocked
lassae lrom tank
to carburetor b|ocked
/|r Ho|e |n lue| tank cap b|ocked
lue| h|ter screen b|ocked
Vacuum sw|tcH lau|ty
lue| h|ter b|ocked
3park p|u bad
l|ckup co|| bad
3park p|u d|rty and broken
C.0.l. bad
ln|t|on co|| broken c|rcu|t
ln|t|on co|| broken w|re
or sHort c|rcu|t
la|n sw|tcH bad
or sHort c|rcu|t
3tarter c|utcH bad
Cy||nder p|ston or p|ston r|n bad
Va|ve too t|Ht
Va|ve set bad
Cy||nder asket |eak|n
Va|ve t|m|n |mproper
Va|ve burned
/utomat|c cHoke perlormance
Carburetor o|| quan|t|ty
/|r |n|et |mproper man|lo|d
ln|t|on t|me wron
reu|at|on screw bad
Carburetor o|| |eve| too H|H
1Hrott|e va|ve open|n too w|de
/utoenr|cH|n dev|ce start
enr|cHment lau|ty
Ln|ne bll 0b low Ln|ne bll
ln|t|on t|m|n correct ln|t|on t|m|n |ncorrect
3upp|y en|ne w|tH lue| and watcH
beu|ate |n|t|on t|me us|n t|m|n |amp
Va|ve reu|at|on la||ure
1est compress|on pressure determ|n|n
Va|ve ap correct Va|ve ap |ncorrect
/|r h|ter b|ocked
lue| tank cap a|r b|eeder
b|ocked
lue| cHoke
LxHaust p|pe b|ocked
Carburetor d|apHram broken
/utomat|c o|| cup bad
/uto cHoke bad
C.0.l. bad
ln|t|on co|| bad
C|ean
3park p|u Heat va|ue |mproper
Va|ve seat bad
C|ean
Va|ve t|m|n bad
Cy||nder or p|ston worn
0|| passae b|ocked
0|| pump de||very
Ln|ne o|| too mucH
Ln|ne o|| uncHaned
Ln|ne o|| too ||tt|e
Cy||nder asket |eak|n
Va|ve ap adjustment |mproper
Va|ve seat excess|ve|y worn
|va|ve out sHoot|n excess|ve|y
Compress|on pressure norma| Compress|on pressure too |ow
No b|ockae B|ocked
Not d|rty or d|sco|ored 0|rty or d|sco|ored
CHeck lor carburetor b|ockae
bemove spark p|u to cHeck
Norma| |eve| too mucH
CHeck en|ne o|| |eve| or qua||ty |n crank case
Norma| /bnorma|
CHeck cy||nder Head |ubr|cat|on
Not too Hot too Hot
CHeck en|ne Heat|n
No knock|n bnock|n
/cce|erat|on or run at a H|H speed cont|nuous
l|ston or cy||nder worn
depos|t too mucH
l|xture excess|ve|y tH|n lue| |mproper
Combust|on cHamber carbon
ln|t|on t|me too ear|y
Combust|on cHamber
C|utcH s||pp|n
Carbon depos|t too mucH
lue| bad
l|xture weak
ln|t|on t|m|n too ear|y
(under speed, nc pcwer)
Trcub|e Shcct|ng Gu|de (under speed, nc pcwer)
Norma| /bnorma|
0ood Bad
/djust |n|t|on t|me
/djust carbureator adjust|n screw
CHeck lor carburetor asket a|r |eakae
bemove spark p|u and |nsta|| |t |n |ts cap and
connect |t w|tH en|ne to cHeck lor spark over
No a|r /|r |ntaken
C.0.l. bad
1r|er co|| bad
l|xture |ean
1oo r|cH |to t|Hten screw
|to |oosen screw
l|xture
0ood Bad
0ood Bad
CHeck /.C.V.
Heat sH|e|d bad
Neat|ve pressure p|pe broken
Carburetor Ho|ddown nut |oose
Heat sH|e|d broken
3park p|u bad or d|rty
ln|t|on co|| bad
C0l bad
Battery d|scHared
|ead broken or sHort c|rcu|t
la|n sw|tcH bad spark p|u
/.C.V. bad
Neat|ve pressure p|pe damaed
/|r b|eeder b|ocked or damaed
(h|gh speed)
Norma| /bnorma|
Norma| /bnorma|
/djust |n|t|on t|m|n
/djust va|ve ap
CHeck lue| |n automat|c o|| cup
CHeck carburetor lor b|ockae
Norma| /bnorma|
C.0.l. bad
1r|er co|| bad
/djustment |mproper
CamsHalt worn
Va|ve sea| bad
No b|ock|n B|ocked
Correct wron
CHeck va|ve t|m|n adjustment
0ood 3pr|n broken or lat|ued
CHeck va|ve spr|n
1oo ||tt|e lue|
lue| h|ter b|ocked
Vacuum sw|tcH bad
C|ean
1|me ear marks not a||ned
3pr|n bad
Trcub|e Shcct|ng Gu|de-Imprcper attery Charg|ng
(attery cverd|scharge cr cvercharge)
Battery vo|tae uncHared Norma| |Z.b4V
Norma| 1est va|ve too H|H
3tart en|ne and measure battery term|na|s lor ||m|ted vo|tae
1est /C manetor co|| res|stance va|ue
CHeck reu|ated rect|her. 1est vo|tae by connect|n red w|re
to pos|t|ve term|na| wH||e neat|ve term|na| body
CHeck rect|her connector lor |oosen
Vo|tae No vo|tae
Battery serv|ce ||le over
Battery bad
lau|ty reu|ated rect|her
lau|ty connector
Co|| bad
Ye||ow w|re broken c|rcu|t
lau|ty connector
Norma| /bnorma|
Battery w|tH ma|n sw|tcH on Hav|n no vo|tae w|tH ma|n sw|tcH |n `on`
1est vo|tae by connect|n reen w|re to and to body.
Norma| 3pr|n broken or lat|ued
CHeck reu|ated rect|her connector lor poor contact
bed w|re broken
/C0 bad
0reen w|re broken
Connector contact poor
beu|ated rect|her bad
lmproper|y cHared |overcHared
(nc spark)
3park weak or spark|ess 3park stron
lroper loose
bep|ace spark p|u and cHeck aa|n
CHeck spark p|u cap and |n|t|on co|| lor |ooseness
CHeck C0l connector lor |ooseness
CHeck lor conduct|on between connector
term|na|s and test C0l res|stance
Norma| /bnorma|
lormer spark p|u bad
la|n sw|tcH bad
ln|t|on co|| bad
l|ckup co|| bad
C0l bad
la|n cab|e broken
Connector p|u poor contact
3park p|u cap |oose
loor Contact
Norma| /bnorma|
Norma|
Norma|
Norma|
/bnorma|
/bnorma|
/bnorma|
/bnorma|
CHeck re|ated parts
0se C0l tester to cHeck C0l
CHeck |n|t|on co|| us|n C0l tester
ln|t|on co|| bad
cdy Exp|cded V|ew
Z. cdy Ccver and Exhaust System
0o not use excess|ve lorce wHen remov|n body
pane|s. 0se a hrm, cons|stent lorce to d|senae
tHe tabs and remove tHe pane|s.
0o not pry or pound on tHe body pane|s. 1He
mount|n tabs are not des|ned to w|tHstand
pry|n, pound|n or tw|st|n.
larts to be removed and sequence ol remova|.
lront Head||Ht and meter cover.
Back Head||Ht and meter cover.
lront lender.
lront body cover.
lront body pane|.
3eat and He|met box.
bear HandHo|d and ta||||Ht assemb|y.
lootboard cover and battery cover.
lootboard and rear cover.
lront lrame cover.
Covers and body s|de pane|s.
Bottom cover.
1orque requ|rements
Body mount|n nuts and screws .Zkm
LxHaust p|pe bo|ts 3bkm
Tcp|c Fage
0enera| lnlormat|on Z
Body Cover bemova| ZZ
LxHaust 3ystem bemova| Z4
Genera| Infcrmat|cn
cdy Ccver Remcva|
Frcnt Fane| Remcva|
. bemove one lront cover
screw lrom lront ol pane|.
Z. bemove two screws on botH
|elt and r|Ht s|des. bemove
lront pane|. lnsta|| lront pane| |n
tHe reverse order.
Frcnt Ccver Remcva|
3. bemover rear cover, |elt and
r|Ht s|de covers and lront wHee|.
4. bemove two screws |n lront
cover |4a.
and remove two screws on eacH
s|de ||elt and r|Ht |4b. bemove
lront cover.
b. lnsta|| lront cover |n tHe
reverse remova| order.
b. lake sure to support tHe
scooter wH||e remov|n tHe lront
wHee| to prevent |t lrom
la|||n.
Frcnt and Rear Hand|ebar
Ccver Remcva|
/. bemove two screws on lront
ol Hand|ebar cover and remove
one screw |n botH r|Ht and |elt
s|des ol rear Hand|ebar cover.
. 0|sconnect Head||Ht |ead
and remove lront Hand|ebar
cover.
9. 0|sconnect speedometer
|ead, |elt and r|Ht sw|tcHes and
brake sw|tcH connector. bemove
one hx screw |n rear Hand|ebar
cover.
C. bemove tHe hx screw |n eacH
s|de ol rear Hand|ebar cover.
bemove rear Hand|ebar cover.
. bemove tHe remova| order
lor |nsta||at|on.
lb0N1 C0VLb
3CbLw3
4a
4b
/
lb0N1
H/N0lLB/b
C0VLb
9
3lLL00lL1Lb C/BlL
lb0N1 Bb/bL
3wl1CH lL/0
lb0N1 Bb/bL
C/BlL
bL/b Bb/bL
3wl1CH lL/0
bL/b Bb/bL C/BlL
cdy Ccver Remcva|
. bemove m|dd|e |uae
box alter open|n tHe seat
and remov|n tHe lour |ock
nuts.
Z. bemove two center cover
screws.
3. bemove center cover.
4. bemove |elt and r|Ht
cover. |Z3
b. bemove tHree rearrack
screws.
b. bemove rear rack.
/. bemove screws |n rear ol
body pane|.
. bemove tHe two screws |n
tHe lront ol tHe body
pane|.
9. 0|sconnect seat |ock |ead.
C. bemove tHe remova|
order lor |nsta||at|on.
lake sure to connect
seat |ock |ead wHen
|nsta|||n body cover.
3
/
3L/1
ll00lL l000/0L B0/
CLN1Lb
C0VLb
b
b
l000/0L b/Cb
R|ght and Left S|de Mc|d
Remcva|
. bemove two rear body screws.
Z. bemove tHree screws |n e|tHer
s|de ol mo|d.
3. bemove |elt and r|Ht s|de
pane|s.
cdy under Ccver Remcva|
b. bemove rear body pane|.
b. bemove |elt and r|Ht s|de
pane|s.
/. bemove two nuts |n e|tHer s|de
ol body under cover.
. bemove body cover.
F|ccr Fane| Remcva|
. bemove battery cover,
d|sconnect battery |ead and
d|smount battery.
Z. 0|sconnect C.0.l. w|re and take
|t out ol battery box.
3. bemove body cover.
4. bemove tHe speed||m|t|n
overnor.
b. bemove lour cHeck bo|ts |n tHe
Noor pane|.
b. bemove Noor pane|.
Z
7 /
ll00b C0VLb
b
B00Y 0N0Lb C0VLb
N013
Frcnt cx Remcva|
. bemove lront cover and lront pane|.
Z. bemove two catcH bo|ts |n tHe lront ol
tHe Noor pane|.
3. bemove tHe lront box catcH bo|t.
4. bemove ma|n sw|tcH outer r|n and tHen
remove lront box outward|y and upward|y.
Frcnt and Rear Fenders Remcva|
. bemove tHe two hx screws |n tHe lront
lender.
Z. 0|smount tHe lront lender.
3. bemove tHe two catcH bo|ts |n tHe
rear lender stay.
4. bemove tHe rear lender stay.
Exhaust F|pe Remcva|
. bemove tHe two nuts |n tHe p|pe jo|nt.
Z. bemove tHe two p|pe catcH bo|ts.
3. bemove tHe exHaust p|pe.
4. bemove tHe jo|nt r|n.
lns!all exhaus! pipe join! rin beore
ins!allin exhaus! pipe.
lns!all exhaus! pipe join! nu!s and as!en
!hem and !hen ins!all exhaus! pipe ca!ch
bol!s and as!en !hem.
!orque.
Lxhaus! pipe ca!ch bol! 3.bkm
Lxhaus! pipe join! jam nu! 1.2km
Use a new exhaus! pipe carrier rin when
reassemblin !he exhaus! sys!em.
Z
Z
4
lb0N1 B0/
lb0N1 lLN0Lb
Z
Z
3. Schedu|ed Ma|ntenance
Tcp|c Fage
lrame and 1|re 1ype 3Z
la|ntenance CHart 33
lue| l||ter 34
1Hrott|e 0perat|on lever 34
/|r h|ter 3b
bep|ac|n lrequency 3b
3park l|u 3b
Va|ve /djustment 3b
Carburetor ld|e 3peed 3b
ln|t|on 1|m|n 3/
Cy||nder lressure 3/
bemov|n tHe 3park l|u 3/
l|na| beduct|on 0ear Ln|ne 0|| 3
Tcp|c Fage
0r|ve Be|t 3
bear Brake /rm 39
Brake 3ystem lront Brake 39
bear Brake 39
lront lamp /djustment 3C
C|utcH Lnaement 3C
lront 3uspens|on 3C
bear 3uspens|on 3C
Nut and Bo|t 1|Htness 3
Co||ar b|m 1|re 3
/|r lressure 3
1|re 3tandards 3
3teer|n 3ystem 3Z
Genera| Infcrmat|cn
Warn|ng
/|ways make sure you are |n a we||
vent||ated area belore tHe en|ne
starts. Never start tHe en|ne |n an
enc|osed area. 0aso||ne powered
en|ne exHaust lumes are po|sonous
and can cause |oss ol consc|ousness
and deatH. 0o not smoke or a||ow
open Names or sparks |n or near tHe
area wHere relue||n |s perlormed or
wHere aso||ne |s stored.
Frame
lront brake |ever lree p|ay: CZCmm
bear brake |ever lree p|ay: CZCmm
T|re type
lront: 3.CC xC
bear: 3.CC xC
1orque:
lront wHee| ax|e nut 4.Cb.Ck/m
bear wHee| ax|e nut .CC.Ck/m
1|re un|t: k/cm
Z
lerson
lront
bear
.b, / ps|
Z.C, Z3 ps|
./b, 9 ps|
Z.Z, Z ps|
Z lersons
Ma|ntenance Chart
lerlorm reu|ar ma|ntenance, accord|n to
ma|ntenance Handbook.
l: lnspect, c|ean, |ubr|cate, add hx or rep|ace
wHen necessary.
/: /djust B: C|ean C: bep|ace 0: 1|Hten
3. lore lrequent rep|acement |s requ|red |l tHe
veH|c|e |s subjected to sever use, sucH as Heavy
|oad operat|on, |on tr|ps or operat|on |n ra|n.
lor salety reasons, |t |s recommended tHat
serv|ce be perlormed by a dea|er.
Ncte:
. lor m||eae H|Her tHan wHat |s spec|hed |n
tHe cHart, tHe ma|ntenance sHou|d be repeated
at tHe same |nterva| ||sted.
Z. lore lrequent ma|ntenance |s requ|red |l
tHe veH|c|e |s used |n dusty areas or |n ra|n.
Wh|chever
ccmes hrst
Note 3
Note Z, 3
C|ean every 3CCCbm bep|ace wHen necessary
Ln|ne o||
Ln|ne o|| h|ter
lue| h|ter screen
0ear o||
Va|ve ap
Carburetor
/|r h|ter
3park p|u
Brake system
0r|ve be|t
3uspens|on
3crews and nusts
1|re
3teer|n stem bear|n
Frequency
Item
km
CCC
/ / / /
l
l b b
l l
b b b b b b b
C C
b
b
b
b
b b b
l l l
l
l
l l
l l
l l
l
l
l
l l l l
l
l
l
M||eage (Km)
km
ZCCC
km
3CCC
km
4CCC
km
bCCC
km
bCCC
km
/CCC
km
CCC
km
9CCC
km
CCCC
km
CCC
km
ZCCC
m|
bZC
m|
Z4C
m|
bC
m|
Z4C
m|
3CC
m|
3/ZC
m|
434C
m|
49bC
m|
bbC
m|
bZCC
m|
bZC
m|
/44C
tHe hrst
3CCkm/
b m|
new b
3CCkm/
b m|
3CCkm/
b m|
Fue| F||ter
. bemove |uae box |ZZ
Z. CHeck lue| ||ne lor ae|n or damae.
3. bep|ace w|tH a new one |n case damaed
or |eak|n.
Thrctt|e Lever Dperat|cn
. CHeck tHrott|e lor proper operat|on.
Z. CHeck tHrott|e r|p lree p|ay.
lree p|ay: Zbmm |.C/ |n..Z3b |n..
3. /djust lree p|ay us|n tHe adjust|n nut |n
tHe tHrott|e cab|e and tHe adjuster at tHe
carburetor.
lajor adjustment sHou|d be made at
carburetor.
/djust |t by |oosen|n tHe jam nut and rotat|n
adjust|n nut.
l|ne adjustment sHou|d be made at tHe tHrott|e
r|p.
bemove outer cover, |oosen jam nut and
rotate adjust|n nut to adjust |t.
A|r F||ter
F||ter Rep|acement
. bemove a|r h|ter cap, hx
screw and remove tHe a|r h|ter
cap.
Z. CHeck h|ter lor d|rt or
damae. bep|ace as necessary.
0o not attempt to c|ean tHe
h|ter e|ement.
Rep|ac|ng Frequency
. lore lrequent rep|acement
|s requ|red |l veH|c|e |s dr|ven on
dusty roads or |n tHe ra|n.
Z. lake sure tHe a|r h|ter
cover |s secure|y |n p|ace.
Spark F|ug
. bemove spark p|u.
Z. CHeck spark p|u lor
burn|n, d|rt or depos|t.
3. C|ean |t w|tH a sparkp|u
c|eaner or stee| brusH |n case
ol d|rt or carbon depos|ts.
3pec|hed spark p|u:
N0b: C/H3/ CHamp|on
CHeck spark p|u ap
0ap: C.b.C/mm |.CZZ.CZ4 |n.
4. CHeck p|u lor d|rt, carbon
bu||dup or crack|n ol |nsu|ator.
C.b.C/mm
.CZZ.CZ4 |ncH
CYllN0Lb
HL/0 C0VLb
/lb lll1Lb C/l
/lb lll1Lb
3l/bb
ll00
lN30l/10b Cb/Cb
CHLCblN0
Z
0/l, 0lb1Y C/bB0N
B0ll00l CHLCblN0
l0lL 3CbLw
Va|ve Adjustment
/|ways cHeck and adjust w|tH
en|ne temperature |ower tHan
3b`C |9b`l
. bemove cy||nder Head cover.
Z. botate coo||n lan to camsHalt. locate
mark at center top, a||n|n maneto
Ny wHee| mark w|tH tHat on crankcase.
laneto "1' mark and box cranksHalt
mark.
Va|ve gap check|ng and
adjustment va|ve gap:
lN: C.Cbmm |.CC9/ |n.
L/: C.Cbmm |.CC9/ |n.
3. 1o adjust tHe va|ve ap, |oosen am nut
and rotate adjust|n nut.
Va|ve Adjustment Wrench
Be sure to cHeck va|ve ap aa|n,
alter |ock|n jam nut.
Carburetcr Id|e Speed
ld|e adjustment sHou|d be made
w|tH tHe en|ne warmed up.
. bemove cover.
Z. /lter tHe en|ne warms up, connect |t
to an en|ne revo|ut|on counter.
3. /djust |d|e screw unt|| spec|hed
revo|ut|on |s obta|ned.

Minimum idlin speed. 1900+190rpm
4. beadjust tHe screw |l tHe |d|e speed
|s not steady or lue| cannot be
proper|y app||ed.
Z
3
H0lL lN C/l 0L/b
/w/Y lb0l LN0lNL
C/l3H/l1
CH/lN 0L/b
`1` l/bb
CYllN0Lb
HL/0 C0VLb
3
Ign|t|cn T|me
Lqu|pped w|tH C0l, tHere |s no need
lor |n|t|on sett|n.
CHeck |n|t|on system |l |n|t|on t|me
|s |ncorrect.
. 0|smount r|Ht body cover.
Z. bemove |n|t|on t|m|n |nspect|on.
3. CHeck |n|t|on t|m|n us|n tHe t|m|n ||Ht.
Crankcase mark must be a||ned w|tH mark
"l' on NywHee| wH||e en|ne |s at |d|e
speed. 1He t|m|n sHou|d advance as tHe
bll |s |ncreased.

1He t|m|n mark sHou|d a||n w|tH tHe
crankcase mark at 3CCC bll.
Cy||nder Fressure
. leasure cy||nder pressure w|tH tHe en|ne
warmed up.
Z. 0|smount m|dd|e |uae box and m|dd|e
cover |ZZ.
Remcve spark p|ug.
. lnsta|| cy||nder pressure aue.
Z. w|tH tHrott|e va|ve lu||y open, start starter
motor to measure cy||nder pressure. |Z3ps|
3. Compress|on pressure: bk/cmZ
bCCrpm.
4. ll tHe pressure |s excess|ve|y |ow, cHeck lor
tHe lo||ow|n:
Va|ve |eakae
Va|ve ap too t|Ht
Cy||nder Head asket damaed
l|ston r|n worn
l|ston or cy||nder worn
b. CHeck combust|on cHamber and p|ston top
lor excess|ve depos|t |l compress|on pressure
|s too H|H.
l0Nl1l0N 1lllN0
lN3lLC1l0N
l/bb `l`
lb0lLblY /ll0NL0
3
Z
1b/N3ll33l0N BLl1
Z
0ll 0b/lN/0L B0l1
/N0 w/3HLb
0L/b 0ll lNlL1
H0lL/CHLCb H0lL
F|na| check cf gear eng|ne c|| reduct|cn
CHeck|n o|| vo|ume, bu||d up ma|n loot
rest so tHat bu||d up body becomes
vert|ca| on p|a|n round.
. 0|smount ear o|| adjust|n bo|t alter
stopp|n en|ne.
Z. 1He o|| |eve| sHou|d be just under tHe
reu|at|on screw bo|t Ho|e. /dd ear o|| wHen o||
|eve| |s too |ow.
0ear o|| recommended: 3/L 9Cw
3. Bu||d up ear o|| reu|ator screw bo|t.
4. Conhrm wHetHer or not tHe pack|n wasHer
|s broken.
Chang|ng Gear D||
. bemove ear o|| adjust|n bo|t and dra|n o||.
Z. Conhrm wHetHer or not pack|n wasHer |s
broken.
3. /dd recommended ear o||.
0ear o|| capac|ty: C.Z|4CL3
Bo|t torque: C.9km /C |bs.
4. CHeck |l tHere |s any |eakae alter work |s
perlormed.
Transm|ss|cn e|t
. 0etacH tHe |elt crankcase cover |9Z.
Z. CHeck wHetHer tHere |s wear and tear ol
transm|ss|on be|t.
3. CHane w|tH new one wHen necessary or
dur|n t|me|y ma|ntenance.
Rear rake Arm
. CHane new peda| wHen brake bar |s pu||ed
to stopp|n pos|t|on and tHe sparrow ol brake
arm |s |n a||nment w|tH tHe brake p|ate mark.
rake System-Frcnt rake
. CHeck lree ap ol lront brake bar.
lree ap: CZCmm |C.b |n..
Z. botate adjust|n nut to reu|ate lree ap ol
brake bar.
Rear rake
CHeck lree ap ol rear brake bar.
lree ap: CZCmm |C.b |n..
1
b01/1L N01
Frcnt Lamp Adjustment
. botate nut to adjust lree ap wHen |t
exceeds proper adjustment.
Z. 1urn ma|n sw|tcH to "on' and start
en|ne.
3. botate adjust|n screw ol lront |amp
to a|m tHe ||Ht.
C|utch Engagement
. 3tart en|ne and |ncrease bll s|ow|y
to cHeck perlormance ol c|utcH.
C|utcH sHou|d enae at ZZCC
bll.
3erv|ce and rep|ace c|utcH as
necessary sHou|d s||ppae occur.
Frcnt Suspens|cn
. lu|| lront brake bar t|Ht|y and
compress lront lor up and down to cHeck
|ts perlormance.
Z. CHeck lor |eakae ol lront lor and/or
solt spr|ns.
Rear Suspens|cn
. Compress rear sHocks up and down
to cHeck perlormance.
Z. CHeck lor |eakae ol rear sHock or
solt spr|ns.
3. 3uspend rear wHee| and pusH |t |elt
and r|Ht to cHeck en|ne suspens|on
s|eeve lor wear.
/0J031lLN1 3CbLw
UNDERSIDE DF CDVER
Z
1
Nut and c|t T|ghtness
. CHeck a|| nuts and bo|ts lor proper t|Htness.
Z. /djust torque as necessary.
Cc||ar R|m T|re
. CHeck t|re pressure.
leasure t|re pressure wHen t|re |s co|d.
A|r Fressure
T|re Standards
lront t|re: 3.CC x C
bear t|re: 3.CC x C
. CHeck |l lront wHee| ax|e Has s|ack.
Z. CHeck |l rear wHee| ax|e nut Has s|ack.
3. 1|Hten wHen necessary to st|pu|ated torque |l
tHere |s s|ack.
!orque.
lron! wheel axle nu! 4.0b.0 km 2832 ! lbs
Rear wheel axle nu! 8.010.0 km bb6b ! lbs
lront 1|re ./bk/cm /ps|
bear 1|re Z.CCk/cm Z3ps|
1
CHECK TlPE
PPESSUPE
Steer|ng
. 3w|n Hand|ebars |elt and r|Ht
to cHeck |l tHere |s |nterlerence
lrom tHe w|res.
Z. 0rasp Hand|ebars and rotate
lrom |elt to r|Ht wH||e Ho|d|n tHe
lront wHee| stra|Ht. 1Here sHou|d
be s||ppae.
3. CHeck steer|n bear|n
adjustment. lork sHou|d turn lree|y
w|tH p|ay |n bear|n.
1
4. Lubr|cat|ng System
Lubr|cat|ng System
Cb/Nb3H/l1
b0CbLb /bl
lll1Lb 3CbLLN
LN0lNL 0ll l0ll
Tcp|c Fage
0vera|| en|ne requ|rements 4Z
lrob|em d|anos|s 4Z
Ln|ne o||/h|ter screen 43
0|| Vo|ume 43
0|| CHaned 43
Tcp|c Fage
Ln|ne 0|| lump bemova| 44
0|| lump 0|sassemb|y 4b
CHeck|n 4b
/ssemb||n 4b
lnsta||at|on 4b
Dvera|| Eng|ne Requ|rements
Spec|a| Attent|cn
0se proper motor o|| 3/L Cw 3C.
0se on|y c|ean, lresH o||.
0o not rebu||d o|| pump. bep|ace w|tH a new pump wHen needed.
CHeck lor |eakae alter rep|ac|n pump.
Frcb|em D|agncs|s
Lcss cf eng|ne c||
Ln|ne o|| natura| consumpt|on.
Ln|ne o|| |eakae.
l|ston r|n wear, bad assemb|y.
Va|ve u|de o|| sea| |s worn.
Nc c|| pressure
lump worn.
0se ol wron o||.
0|| |eve| |ow.
Eng|ne burn|ng excess|ve c||
B|ocked o|| passae.
0se ol wron o||.
worn r|ns.
Va|ves worn or damaed.
as|c Mater|a|
Item
Ln|ne o|| pump
0ap between |nner rotator and externa| rotor
0ap between externa| rotor and pump body
0ap between and surlace ol rotor and pump body
C.Zmm .CCb|n
C.Zmm .CCb|n
C.Zmm .CC|n
Nunmu| va|ue Rep|ace at
C.CbC.Cmm
.CC.CC4|n
Eng|ne D||,F||ter Screen
D|| Vc|ume
. CHeck o|| w|tH scooter parked on |eve|
round on center stand.
3cooter must be on center stand
wHen o|| vo|ume |s cHecked.
bun en|ne lor two or tHree m|nutes
and tHen turn |t oll. /lter two to tHree
m|nutes, cHeck tHe o|| |eve|.
Z. CHeck tHe o|| |eve| wHen tHe o|| d|pst|ck |s
unscrewed and out.
3. /dd o|| to upper ||m|t |eve| on tHe d|pst|ck.
D|| Changed
lt |s eas|er to dra|n o|| wHen motor |s
warm.
. bemove dra|n bo|t to comp|ete|y dra|n o||.
Z. 0|sassemb|e tHe o|| h|ter screen cover
and take oll tHe o|| h|ter screen. 0se
H|Hpressure a|r to c|ean tHe h|ter screen.
wasH w|tH so|vent and dry belore re|nsta|||n.
3. CHeck or|n lor damae. bep|ace |l
necessary.
4. /ssemb|e en|ne o|| h|ter screen and h|ter
screen cover.
1ors|on va|ue: .4km
3CC lt |bs
b. /dd ass|ned o|| to determ|ned vo|ume.
Ln|ne o|| capac|ty: C.l
3ZCL3
b. CHeck lor o|| |eaks.
/. bun en|ne lor Z m|nutes at |d|e speed.
. 1urn en|ne oll and cHeck o|| |eve|. /dd
o|| |l needed.
0ll31lCb
Z
3
0b/lN B0l1
CblN0
Cll lll1Lb 3CbLLN
D|| Fump Remcva|
. bemove en|ne r|Ht outer
cover lan manetor.
Z. bemove a|ternator rotor.
3. bemove stator pu|es co||.
4. bemove e|Ht bo|ts ol
r|Ht cranksHalt case cover
and take oll cranksHalt case
cover.
b. bemove wasHer and hxed
p|n.
b. bemove tHe hxed nut ol
tHe ear |n tHe o|| pump.
/. 1ake oll tHe ear ol tHe o||
pump.
. bemove hxed bo|ts ol o||
pump modu|e body.
9. 1ake oll o|| pump.
C. 1ake oll two or|ns.
. CHeck or|ns lor
damae.
Z. bep|ace |l necessary.
/
b
b
0L/b
w/3HLb
ll/L0 N01
C
9
0ll l0ll
0blN03
D|| Fump D|sassemb|y
. bemove tHree hxed screws |n o|| pump
body.
Z. 0|sassemb|e o|| pump.
Check|ng
. CHeck tHe ap between tHe o|| pump modu|e
body and tHe externa| rotator.
0sed ||m|t: C.Zmm |.CCb |n..
Z. CHeck tHe ap between tHe surlace ol tHe
rotator and tHe body.
0sed ||m|t: C.Zmm |.CC |n..
0ll l0ll B00Y
0ll l0ll B00Y
ll/L0 3CbLw3
L/1LbN/l b010b
L/1LbN/l b010b
lN1LbN/l b010b
Assemb||ng
. /ssemb|e |nner and outer
rotators and o|| pump
sHalt.

Be carelu| ol
a||nment between
pump bear|n unh||ed
corner and |nner
rotator unh||ed corner.
Z. /ssemb|e pump cover
and t|Hten screws.
Insta||at|cn
. l|rst put two or|ns at
tHe o|| pump seat.
Z. lut o|| pump |n tHe
cranksHalt case.
l|rst add o|| to pump
and tHen assemb|e.
3. 1|Hten tHe tHree hxed
screws.
L/1LbN/l b010b
lN1LbN/l b010b
l0ll 3H/l1
3
0ll l0ll
0blN03
b
l0l3L C0ll
4. lnsta|| ear ol o|| pump and
tHen hx nut.
1ors|on va|ue: C..Zkm
/lt |bs
b. /ssemb|e r|Ht cranksHalt
case cover, screws and t|Hten.
b. /ssemb|e pu|se co||, stator
and rotor.
/. lnsta|| lan and cover.
/
/
b
l/0NL10b C0ll
l/N
l/N C0VLb
l0l3L C0ll
b010b
4
0L/b
w/3HLb
ll/L0 N01
b. Fue| System
w
bL00l/10b
bL3l310b
LNblCHlLN1
w wHl1L Y YLll0w 0/B 0bLLN/Bl/Cb
Y
0/B
b 0Hl
b w
b. Fue| System
Tcp|c Fage
0enera| |nlormat|on bZ
1roub|esHoot|n b3
0|sassemb|y ol Carburetor b4
CHeck|n /utocHoke b4
/|r cutoll va|ve bb
/ssemb||n bb
Vacuum CHamberBreak 0own b/
/ssemb|y ol Vacuum CHamber b/
l|oat bow| and 0|sassemb|y b
CHeck|n l|oat Va|ve b9
Tcp|c Fage
0|sassemb|y ol /cce|erator lump bC
CHeck|n /cce|erator lump bC
/ssemb|y ol carburetor b
0|sassemb||n lue| tank bZ
/ssemb|y ol lue| 1ank bZ
Carburetor /djustment b3
/utomat|c lue| Va|ve b4
lue| leter 3end|n 0n|t b4
/|r l||ter lnspect|on bb
Genera| Infcrmat|cn
Warn|ng|
work on tHe lue| system |n a
we||vent||ated area tHat |s lree ol
sparks or open Names. 0o not breatHe
tHe vapors lrom tHe aso||ne. wear
protect|ve |oves to prevent sk|n
|rr|tat|on.
0pen tHe bow| dra|n and a||ow a|| aso||ne |n
tHe carburetor to dra|n |nto an appropr|ate
conta|ner pr|or to remov|n or serv|c|n |t.
bemove contro| cab|es and w|res carelu||y to
prevent damae.
CHeck a|| or|ns lor damae. bep|ace as
necessary.
bemove carburetor lrom tHe scooter belore
attempt|n to serv|ce tHe lue| bow| or vacuum
can|ster.
wHen c|ean|n tHe carburetor, remove tHe
vacuum d|apHram belore us|n a|r or so|vents
lor c|ean|n. 1H|s w||| prevent damae to tHe
d|apHram.
wHen stor|n tHe scooter lor a per|od ol t|me
exceed|n one montH, use a qua||ty lue|
stab|||zer to prevent deter|orat|on ol tHe lue|
and damae to tHe carburetor.
Repa|r|ng mater|a|
Spec|hcat|cn
Constant ve|oc|tyCVb
/mm |.b/ |n.
mm
.Z/ mm |.Z |n.
bCC bll
bmm |.Zb |n.
3 turns out
Carburetor type
Ventur| Bore
lue| leve|
la|n jet
ld|e jet
ld|e speed
1Hrott|e lree p|ay
l|xture screw sett|n
Standard va|ve
b. Fue| System
Trcub|eshcct|ng
Eng|ne |s hard tc start
No spark
low compress|on
No lue| |n carburetor
B|ocked lue| ||ne
B|ocked lue| h|ter
B|ocked vacuum ||ne
leaky vacuum ||ne
0|rty Noat need|e
l|oat set too H|H
Tcc much fue| tc eng|ne
B|ocked a|r h|ter
lan|lo|d a|r |eak
Bad auto cHoke
B|ocked a|r passae |n carburetor
A|r,fue| m|xture tcc r|ch cr tcc |ean
Bad auto cHoke
l|ued |d|e jet
l|oat need|e stuck or d|rty
l|oat He|Ht too H|H or too |ow
B|ocked a|r passae |n carburetor
0|rty a|r h|ter
/|r |eak at carburetor or man|lo|d
M|shre under acce|erat|cn
loor spark
/|r m|xture screw too |ean
Bad acce|erator pump
Fccr dr|vab|||ty
weak spark/bad |n|t|on system
B|ocked lue| ||ne
B|ocked lue| h|ter
Bad lue|
water |n lue|
/|r |eak at carburetor or man|lo|d
lmproper Noat |eve|
Bad auto cHoke
0bstructed jet |n carburetor
Vacuum s||de stuck
0amaed vacuum d|apHram
0|rt |n carburetor
b. Fue| System
D|sassemb|y cf carburetcr
. bemove seat and He|met
storae tub.
Z. bemove r|Ht s|de body pane|.
3. 0|sconnect cab|e connector lor
auto cHoke.
4. loosen carburetor dra|n screw
and dra|n lue| lrom Noat bow|.
b. loosen c|umps |n |ntake tube
and ma|n lo|d.
b. loosen tHrott|e cab|e and
remove lrom support and lrom
tHrott|e contro| p|ate.
/. bemove lue| ||ne lrom
carburetor.
. bemove a|r |n|et tube lrom
carburetor and pu|| carburetor
stra|Ht back out ol |ntake man|lo|d.
9. bemove auto cHoke lrom
carburetor.
Check|ng Autc Chcke
. CHeck res|stance vo|ume.
Z. 3tandard va|ue be|ow b wHen
co|d.
3. Connect auto cHoke to ZV
battery.
4. l|uner sHou|d extend 3/ |ncH
|n b m|nutes.
/lb lNlL1 10BL
/010 CH0bL
1Hb011lL 3CbLw
/lb 3CbLw
9
3
4
/
b
1Hb011lL C/BlL
l0Ll llNL
C/bB0bL10b 0b/lN
3CbLw l0C/1L0
0N0LbNL/1H ll0/1 B0wl
b. Fue| System
b. CHeck p|n and seat lor
wear.
b. bep|ace |l necessary.
/. l|ace auto cHoke |n
mount|n |ocat|on and press
down hrm|y.
. lut |ock r|n |n pos|t|on and
lasten screw
/010 CH0bL
l00N1lN0 l0C/1l0N
b
/
ll/ ll/1L
l0Cb blN0
3CbLw
llN
b. Fue| System
Z
3
/lb C010ll
V/lVL C0VLb
0blN0
3lblN0
V/C00l ll/1L
A|r Cut Dff Va|ve
. 0|sassemb|e two screws |n lue|
u|de hxed p|ate and remove hxed
p|ate.
Z. 0|sassemb|e two screws |n a|r
cut oll va|ve.
3. 1ake oll spr|n and vacuum
p|ate.
4. CHeck lor wear on p|ate, rep|ace
|l necessary.
b. C|ean tHe passae way to
remove d|rt or varn|sH.
Assemb||ng
. lnsta|| p|ate to carburetor.
Z. lnsta|| spr|n and cover ol a|r
cutoll va|ve.
3. Bu||d up lue| u|de ||ne hxed p|ate
and t|Hten two screws.

Be sure tHat lurrow ol vacuum
p|ate |s a||ned w|tH tHe
carburetor |ove.

lake sure tHat cover t|Htens
|nto p|ace.
l0Ll 00l0L
ll/L0 ll/1L
b. Fue| System
Vacuum Chamber-reak dcwn
. bemove two screws and take oll
cover.
Z. bemove spr|n, d|apHram p|ston.
3. bemove lue| p|n and s||de.
1ake spec|a| care not to
damae d|apHram. bep|ace
|l damaed.
Check|ng
. CHeck p|n lor wear and rep|ace |l
necessary.
Assemb||ng
. lnsta|| p|ston or p|ate to body ol
carburetor.
Z. lusH tHe button ol tHe p|ston to
vacuum cHamber s|de and keep open
comp|ete|y. lnsta|| spr|n and cover.
3. lnsta|| screw.
Be sure to Ho|d s||de and
p|ston |n up pos|t|on wHen
|nsta|||n cover and t|Hten
screw.
C0VLb
3lblN0
l0Ll llN
0l/lHb/0l
ll310N
Z
3
Z
b. Fue| System
F|cat cw|
D|sassemb||ng
. 0|sassemb|e tHree screws and
take oll Noat bow|.
Z. bemove Noat p|n spr|n.
3. bemove H|Hspeed jet, |owspeed
jet and lue| vo|ume contro| screw.
Be carelu| not to break tHe
lue| jets and contro| screw.
Count tHe turns wHen remov|n
tHe lue| vo|ume contro| screw.
wHen re|nsta|||n jets and
screws, do not over t|Hten.
4. C|ean jets w|tH so|vent and
compressed a|r.
b. C|ean body ol carburetor by
b|ow|n a|r tHrouH a|| passaes.
ll0/1 B0wl
ll0/1 llN
ll0/1 /bL/
Z
3
l0Ll llN
l/lN l0Ll JL1
l0Ll llN
3lb/Y N0ZZlL
l0w 3lLL0
JL1
l0Ll V0l0lL
bL00l/1l0N
3CbLw
b. Fue| System
Check|ng
. CHeck Noat va|ve and va|ve seat
lor damae.
Z. CHeck Noat va|ve and va|ve seat
wear, p|tt|n or bu||dup ol d|rt.
3. /ny |eakae ol tHe va|ve or a
bu||dup ol d|rt w||| allect tHe lue| |eve|
|n tHe Noat bow| and cause dr|vab|||ty
prob|ems.
4. /ssemb|e tHe |ow speed jet, lue|
p|n spray nozz|e, lue| p|n spray seat
and ma|n jet |nto tHe bottom ol tHe
carburetor Hous|n.
b. 3et tHe lue| |eve| |n tHe bow| by
adjust|n tHe lue| reu|at|on screw. 1He
standard sett|n |s Z turns, p|us or
m|nus a /4 turn.
b. /ssemb|e tHe Noat va|ve, Noat and
Noat p|n to tHe bottom ol tHe
carburetor us|n tHe reta|ner p|n.
/. CHeck tHe operat|on ol tHe Noat
and va|ve. /|| parts sHou|d move lree|y
and not b|nd.
. /lter assemb||n tHe Noat, cHeck
lor proper lue| |eve| us|n a sma|| ru|er
or a Noat ae. 1He proper lue| |eve|
|s ZC.bmm |.C/ |n..
ll0/1 llN
b
ll0/1
ll0/1
V/lVL
4
l0Ll llN
l/lN l0Ll JL1
l0Ll llN
3lb/Y N0ZZlL
l0w 3lLL0
JL1
l0Ll V0l0lL
bL00l/1l0N
3CbLw
b. Fue| System
Z
C0VLb
0blN0
3lblN0
/CCLlLb/1l0N
l0ll ll/1L
Acce|eratcr Fump
. bemove two screws on pump
and take oll cover.
Z. 1ake oll spr|n and acce|erat|on
pump p|ate.
Check|ng
. CHeck acce|erat|on pump p|ate
lor cracks or Harden|n ol tHe rubber.
bep|ace as necessary.
Z. CHeck lor b|ocked lue| passaes.
3. C|ean by H|H pressure a|r.
4. beverse steps to reassemb|e.
b. 1ake spec|a| care w|tH tHe
acce|erator pump p|ate to avo|d
damae.
b. Fue| System
Assemb|y cf Carburetcr
. 3||de carburetor carelu||y
|nto tHe man|lo|d, mak|n sure to
a||n tHe tab on tHe man|lo|d w|tH
tHe notcH on tHe carburetor.
3ecure|y t|Hten tHe c|amp screw
to hx tHe carburetor |n p|ace. 0o
not over t|Hten tHe screws as
tH|s can cause damae to tHe
man|lo|d.
Z. /ttacH tHe |n|et p|pe to tHe
rear ol tHe carburetor and
t|Hten tHe c|amp screw.
3. /ttacH tHe tHrott|e cab|e to
tHe tHrott|e by |nsta|||n tHe cab|e
|u |nto tHe notcH on tHe tHrott|e
p|ae. lnsert tHe outer cas|n ol
tHe tHrott|e cab|e |nto tHe cab|e
support bracket. lake sure to
a||n tHe "0' sHape ol tHe
adjust|n s|eeve w|tH tHe '0'
sHape Ho|e ol tHe bracket.
4. 0se tHe adjust|n nut and
stop nut to set tHe cab|e tens|on.
Correct adjustment sHou|d a||ow
/4 |ncH ol lree p|ay |n tHe
cab|e.
b. /ttacH tHe lue| ||ne lrom tHe
tank to tHe |n|et on tHe
carburetor and c|amp secure|y.
b. Connect tHe w|r|n Harness
lrom tHe auto cHoke to tHe
proper connect|on on tHe ma|n
w|r|n Harness.
/. /lter start|n tHe en|ne, set
tHe |d|e speed us|n tHe |d|e
adjust|n screw.
/lb lNlL1 10BL
1Hb011lL 3CbLw
/lb 3CbLw
Z
b
3
1Hb011lL C/BlL
l0Ll llNL
b
b. Fue| System
D|sassemb||ng Fue| Tank
. 0|sassemb|e tHe body cover.
Z. 0|sconnect tHe w|r|n Harness
lrom tHe lue| |eve| send|n un|t.
3. 0|sconnect tHe lue| ||ne and
vacuum ||ne lrom tHe auto lue|
va|ve.
4. bemove tHree bo|ts and nuts
to |oosen tHe lue| tank.
b. bemove tHe lue| tank lrom tHe
lrame.
Assemb|y cf Fue| Tank
. beverse steps lor reassemb|y.
3
4
V/C00l llNL
l0Ll llNL
C0N1b0l V/lVL
l0Ll 1/Nb
AIR INLET TUBE
AIR SCREW
2
3
IDLING SPEED
ADJUSTMENT SCREW
3
Carburetcr Adjustment
lt |s enera||y not necessary
to adjust tHe m|xture screw
on tHe s|de ol tHe
carburetor. 1H|s screw |s
preset at tHe lactory and
w||| Have ||tt|e ellect on tHe
perlormance ol tHe
carburetor.
. ll tH|s screw Has been removed
lor c|ean|n ol tHe carburetor, |t
sHou|d be reset carelu||y. 1He
standard sett|n |s two turns out,
p|us or m|nus /4 turn.
Z. 1o set tH|s pos|t|on, run tHe
en|ne unt|| warm and a||ow |t to
|d|e. 1urn tHe screw |n or out a ||tt|e
at a t|me and measure tHe |d|e
bll. 1He correct sett|n |s
acH|eved wHen tHe |d|e speed |s
max|m|zed.
3. /djust tHe |d|e speed ol tHe
en|ne once tHe en|ne Has been
warmed up.
4. 3et tHe warm |d|e speed to
9CCbll, p|us or m|nus CCbll.
b. CHeck lor en|ne return to |d|e
speed alter runn|n at part tHrott|e.
b. lake sure tHat tHe tHrott|e
cab|e a||ows tHe tHrott|e contro|
p|ate to return to tHe stop screw.
/. ll needed, readjust tHe m|xture
screw to He|p stab|||ze |d|e
perlormance.
l0Ll V0l0lL
bL00l/1l0N
3CbLw
NDTE: 30lL C0ll0NLN13
bLl0VL0 l0b Cl/bl1Y.
b. Fue| System
b. Fue| System
Autcmat|c Fue| Va|ve
. 0|sconnect tHe lue| ||ne and tHe vacuum ||ne
lrom tHe contro| va|ve and lrom tHe carburetor
and |ntake man|lo|d. Carelu||y |nspect tHese
||nes. /ny b|ockae, deter|orat|on, damae, or
crack|n ol tHese ||nes can cause |mproper
lunct|on|n ol tHe lue| va|ve. bep|ace tHese
||nes as necessary.
Z. /|ways make sure tHat tHe c|amps work
proper|y wHen rep|ac|n tHese ||nes |n order to
assure a t|Ht sea| ol tHe ||nes at tHe htt|ns on
tHe va|ve, carburetor and man|lo|d.
3. 1o cHeck tHe operat|on ol tHe va|ve, app|y a
vacuum to tHe |nput htt|n ol tHe va|ve. lue|
sHou|d Now lree|y wHen tHe vacuum |s app||ed
and stop wHen |t |s removed.
4. Never attempt to c|ean tHe va|ve w|tH H|H
pressure a|r. 1H|s w||| damae tHe va|ve and
requ|re rep|acement.
Fue| Meter Send|ng Un|t
. 0|sconnect tHe send|n un|t w|r|n Harness.
Z. 0|sconnect lour mount|n screws.
3. l|lt and turn tHe send|n arm to a||ow tHe
Noat arm and Noat to be removed lrom tHe lue|
tank. 1ake care not to bend or damae tHe Noat
arm as tH|s can cause |mproper read|ns.
4. CHeck tHe movement ol tHe arm. lt sHou|d
move lree|y w|tHout b|nd|n or Hes|tat|on. CHeck
tHe cont|nu|ty ol tHe co||. ll |t |s open, tHe un|t
needs rep|acement. wHen reassemb||n tHe
send|n un|ts, make sure tHat tHe asket |s not
damaed to avo|d |eakae.
V/C00l llNL
l0Ll llNL
C0N1b0l V/lVL
3
b. Fue| System
A|r F||ter Inspect|cn
. bemove a|r h|ter cover
screws.
Z. bemove cover.
3. bemove a|r h|ter e|ement.
4. bemove c|amp on a|r |n|et
tube.
b. 0|sconnect a|r tube lrom
carburetor.
b. bemove a|r box. lake sure
tHat tHe e|ement |s c|ean and lree
ol d|rt and o||. Lxcess|ve d|rt and
o|| on tHe e|ement can reduce
en|ne perlormance.
/. 0ur|n reassemb|y, make sure
tHat tHe cover and tube
connect|ons are t|Ht and do not
|eak. /|r h|ter box |eakae can
reduce en|ne perlormance.
/lb lll1Lb C0VLb
/lb lllL
/lb lll1Lb
Z
3
b. Eng|ne Remcva| and Insta||at|cn
Tcp|c Fage
3pec|a| requ|rements b
Ln|ne remova| bZ
Ln|ne |nsta||at|on b4
Spec|a| Requ|rements
bemove a|| body pane|s carelu||y to prov|de
ease ol access to tHe en|ne.
0se care wHen d|sconnect|n tHe battery
cab|es and lue| ||nes.
0se protect|ve c|otH|n sucH as |oves and
salety |asses to protect your body.
Eng|ne Remcva|
. 0|sconnect tHe battery
round w|re.
Z. bemove body pane|s to
expose en|ne.
3. 0|sconnect tHe en|ne
round w|re.
4. bemove tHe spark p|u
cab|e lrom tHe spark p|u and
tHe |n|t|on co||.
b. 0|sconnect tHe auto cHoke
lrom tHe w|r|n Harness.
b. 0|sconnect tHe maneto
w|res and starter motor w|res.
/. 0|sconnect tHe lue| ||ne
lrom tHe carburetor and tHe
vacuum ||ne lrom tHe |ntake
man|lo|d.
. 0|sconnect tHe tHrott|e
cab|e lrom tHe carburetor.
9. bemove tHe a|r h|ter box.
b
1Hb011lL 3CbLw
V/C00l
llNL
/lb 3CbLw
1Hb011lL C/BlL
l0Ll llNL
/
/

C. 0|sassemb|e tHe brake
contro| cab|e lrom tHe
brake contro| arm.
. bemove tHe rear sHock
absorber.
Z. bemove tHe en|ne
support bo|t and move tHe
cHass|s up tHe lorwards.
3. 3upport tHe cHass|s |n
pos|t|on temporar||y.
4. bemove tHe s|de stand
spr|n and s|de stand.
b. bemove tHe lront
en|ne support bo|t to
d|sconnect tHe en|ne lrom
tHe cHass|s.
b. 3eparate tHe en|ne
lrom tHe cHass|s.
/. CHeck tHe cond|t|on ol
tHe en|ne support
|so|at|on mounts. ll tHey
are worn or damaed,
rep|ace tHem dur|n tHe
en|ne |nsta||at|on
process.
Z
LN0lNL
30ll0b1 B0l1
CH/3l3
UNDERSIDE DF SCDDTER
b
Eng|ne Insta||at|cn
. /ttacH lront en|ne support
bo|t |nto pos|t|on and t|Hten to
bkm |3b lt|bs.
Z. 3||de cHass|s to tHe rear to
a||n tHe rear mount and |nsta||
tHe mount|n bo|t. 1|Hten to b
km |3b lt|bs.
3. /ttacH tHe rear sHock
absorber and t|Hten to 4 km
|Z lt|bs.
4. Comp|ete tHe rema|nder ol
tHe assemb|y process |n reverse
order ol tHe d|sassemb|y.
b. wHen assemb|y |s comp|ete,
make sure to cHeck tHe tHrott|e
adjustment and brake
adjustment belore attempt|n to
r|de tHe scooter.
b
LN0lNL
30ll0b1 B0l1
CH/3l3
UNDERSIDE DF SCDDTER
a
7. Cy||nder Head Va|ve
Tcp|c Fage
lmportant |nlormat|on /Z
1roub|e d|anos|s /3
CamsHalt 0|sassemb|y /4
CHeck|n ol CamsHalt //
Bear|n bocker /rm
Cy||nder Head 0|sassemb|y //
Cy||nder Head Break 0own /9
CHeck|n Cy||nder Head /9
Va|ve and Va|ve 0u|de /C
Tcp|c Fage
Va|ve 3eat CHamler Cutt|n 1oo|s /Z
Va|ve 3eat Cutt|n /Z
Bu||d|n up ol Cy||nder Head /3
lnsta|||n Cy||nder Head /4
CamsHalt /ssemb|y /b
CamsHalt CHa|n beu|ator /ssemb||n /b
Impcrtant Infcrmat|cn
wHen work|n on tHe cy||nder Head and va|ve
tra|n, a|ways use en|ne o|| to |ubr|cate s||d|n
parts wHen assemb||n. Never assemb|e dry
parts |nto tHe va|ve tra|n.
1He camsHalt |s |ubr|cated by en|ne o||
supp||ed v|a an o|| passae |n tHe cy||nder
Head. lake sure tHat tH|s passae |s c|ean and
open wHen you reassemb|e tHe Head.
wHen measur|n parts to determ|ne wear,
wasH tHe parts w|tH so|vent and dry tHem |n
order to et accurate measurements.
wHen d|sassemb||n tHe va|ve components,
keep tHem |n order and re|nsta|| tHem |n tHe
reverse order.
Item
|C.C4 C.Cb
|C.C4 C.Cb
bk/cm
Z
bCCrpm
Zb,/b
Zb,bC4
C,CCCC.Cb
C,CCCC.Cb
9,9/Z9,9/
9,9/Z9,9/
.C
.C
4,9/b4,9CC
4.9bb4,9/C
b,CCCb,CZ
b,CCCb,CZ
C.CCC.C3/
C.C3CC.Cb/
Z9.
33.b
C.Cb
Zb.b
Zb.Z4
C.C
C.C
9.9
9.9
.
.
4.9
4.9
b.3
b.3
C.C
C.C
Zb.
3C.b
lN
L/
lN
L/
lN
L/
lN
L/
lN
L/
lN
L/
lN
L/
lN
L/
lnner spr|n
0uter spr|n
Va|ve ap |co|d
Cy||nder Head compressed pressure
Cy||nder Head surlace tw|st|n
CamsHalt cover an|e He|Ht
Va|ve rocker arm |nner d|ameter
Va|ve rocker arm bear|n outer d|ameter
Va|ve seat an|e
Va|ve bar outer d|ameter
Va|ve u|de p|pe |nner d|ameter
0ap between va|ve bar and u|de p|pe
Va|ve spr|n
Standard va|ve Used L|m|t
Tcrque Va|ue
CamsHalt bo|t b lt |bs
lubr|cate tHreads w|tH o||
Va|ve ap adjust|n screw cap / lt |bs
Genera| tcc|s
Va|ve spr|n compressor
4b derees lN/L/
Va|ve seat reamer Z4.bmm
l|ane reamer 3C derees lN
Va|ve seat reamerZbmm
l|ane reamer 3Z derees L/
Va|ve seat reamer ZZmm
l|ane reamer bC derees lN/L/
Va|ve seat reamer Zbmm
beamer damp|n hxture bmm
Spec|a| tcc|s
Va|ve spr|n compressor accessor|es
Va|ve ap reu|atory spanner
Va|ve u|de screwdr|ver
Va|ve u|de reamer
Trcub|e D|agncs|s
Conhrm poor operat|on ol cy||nder Head by
measur|n pressure or by no|se produced
by en|ne upper end.
S|cw Speed H|tch
Compress|on pressure too |ow
Bad va|ve ap
Burn|n or curv|n ol va|ve
Bad va|ve t|m|n
Broken va|ve spr|n
Bad va|ve seat
leakae ol cy||nder Head asket
warped cy||nder Head surlace or crack|n
Bad spark p|u
Ccmpress|cn Fressure Tcc H|gh
1oo mucH carbon bu||dup |n combust|on
cHamber
Wh|te Smcke frcm Exhaust F|pe
wear|n ol va|ve u|de
Broken o|| sea|
Abncrma| Nc|se
Bad va|ve ap
Broken or burn|n ol va|ve or va|ve spr|n
wear|n and break|n ol camsHalt
wear|n ol |nner cHa|n adjust|n p|ate
wear|n ol cam sHalt and va|ve rocker arm
D|sassemb||ng cf Camshaft
. 0|sassemb|e m|dd|e cover. |ZZ
Z. bemove lour bo|ts and two nuts, take oll
va|ve cover.
3. 0|sassemb|e cam cHa|r adjust|n bo|t and
spr|n.
4. 0se tHe k|ckstart |ever to s|ow|y turn en|ne
unt|| "1' mark on NywHee| ||nes up w|tH |nd|cator
on crankcase. CHeck pos|t|on ol camsHalt to
hnd |l botH va|ves are c|osed. 1He Ho|e |n tHe
cam ear sHou|d be away lrom tHe en|ne. ll
tH|s |s not correct, rotate tHe crank one
revo|ut|on to acH|eve tH|s a||nment.
b. bemove lour bo|ts and remove camsHalt
caps.
4
b
Z
3
3
H0lL lN C/l 0L/b
/w/Y lb0l LN0lNL
C/l3H/l1
CH/lN 0L/b
`1` l/bb
CYllN0Lb
HL/0 C0VLb
b. bemove rocker arms and p|vots.
/. bemove camsHalt ear lrom camsHalt
cHa|n.
. bemove camsHalt.
9. CHeck CamsHalt
C. CHeck cam ||lt.
0se ||m|t: lN: Zb.bmm be|ow cHane
L/: Zb.bZ4mm be|ow cHane
. CHeck surlace ol cam |obes lor weary
surlace breakdown, sculhn or crack|n.
Z. CHeck camsHalt and bear|n lor |oose ht or
damae.
3. ll any excess|ve wear or damae |s lound,
rep|ace tHe camsHalt.
ba
bb
9
b0CbLb /bl3
llV013
C/l3H/l1
C/l3H/l1
BL/blN0

Check|ng cf Camshaft ear|ng Rccker Arm
. CHeck |l camsHalt bear|n hxed seat and
camsHalt rocker arm and camsHalt rocker
bear|n |s worn or broken.
Z. leasure outer d|ameter ol camsHalt
bear|n hxed seat and camsHalt rocker arm.
0sed ||m|t: 9.9mm |.39C |n.. CHane |l worn
|arer.
lnner d|ameter ol camsHalt rocker arm.
0sed ||m|t: C.Cmm |.39 |n.. CHane |l
worn |arer.
0uter d|ameter ol camsHalt rocker arm
bear|n and camsHalt rocker arm.
0sed ||m|t: 9.9mm |.39C |n..CHane |l
worn |arer.
1He ap between camsHalt rocker arm
and camsHalt rocker arm bear|n.

0sed ||m|t: C.Cmm |.CC4 |n.. CHane |l
worn |arer.
D|sassemb|y cf Cy||nder Head
. bemove camsHalt bear|n. |/4
Z. bemove carburetor |b4
3. bemove exHaust p|pe. |Z4
3. bemove |n|et man|lo|d.
Z
C/l3H/l1
ll/L0 3L/1
C/l3H/l1 b0CbLb
/bl BL/blN0
4. bemove lan cover.
b. bemove bo|t and screw
ol en|ne cover.
b. 0|sassemb|e and
remove en|ne cover.
/. lu|| up on cy||nder Head
to break asket and s||de oll
cy||nder stands.
. 1ake oll |ocat|on p|n and
cy||nder Head asket.
9. 1ake oll camsHalt cHa|n
u|de bar.
/
CYllN0Lb HL/0
CYllN0Lb HL/0
0/3bL1
l0C/1lN0 llN
C/l3H/l1
CH/lN 00l0L B/b
reak|ng Dcwn cf Cy||nder Head
. 0se va|ve spr|n compressor to take oll
|ock c||p and supporter and va|ve spr|n, spr|n
seat va|ve.
l|ace parts |n sequence alter
d|sassemb||n and assemb|e |n reverse
order dur|n reassemb|y.
Z. C|ean carbon depos|ts lrom combust|on
cHamber.
3. bemove asket mater|a| on cy||nder Head
surlace.
0on't damae cy||nder Head sea||n
surlace.
Check|ng Cy||nder Head
. CHeck spark p|u Ho|e lor damae.
Z. CHeck va|ve spr|n seats lor a||nment.

0sed ||m|t: C.Cbmm |.CCZ |n. above a||n
leasure |entH ol |nner and outer spr|ns.

0sed ||m|t:
CHane |l |nner spr|n be|ow Zb.mm
|.C3 |n..
CHane |l outer spr|n |s be|ow 3C.bmm
|.Z |n..
Z
Z
3lblN0
V/lVL
C0llbL330b
C0lB031l0N
CH/lBLb
Va|ve and Va|ve Gu|de
. CHeck |l va|ve |s beat, burnt or broken.
Z. CHeck |l va|ve and va|ve u|de are b|ocked.
3. leasure every va|ve stem's outer d|ameter.
0sed ||m|t: CHane |l be|ow 4.9mm.

bemove carbon depos|ts lrom va|ve
u|de us|n a reamer.

botate reamer |n proper d|rect|on and
do not stop rotat|on to pusH |n or pu||
out.
4. leasure |nner d|ameter ol every va|ve
u|de.

0sed ||m|t:
lN: CHane |l above b.3mm.
L/: CHane |l above b.3mm.
Va|ve gu|de rep|acement
. 0perate cy||nder at tHe temperature ol
about CC
`
Cb
`
C ZZ
`
l.
Heat cy||nder Head qu|ck|y and even|y
to prevent warp|n.
Z. lress, cut or pry out tHe va|ve u|de.
Be carelu| to not damae cy||nder Head
surlace.
3
Z
V/lVL lllL bL/lLb

V/lVL 00l0L
3CbLw 0blVLb
10 lbY 001
00l0L
3. lress |n tHe new va|ve u|de. 3pread en|ne
o|| on new or|n and bu||d up new va|ve u|de
p|pe. lake sure cy||nder Head |s st||| warm
wHen press|n |n new u|des.
4. 3|ze va|ve u|de w|tH reamer alter |nsta|||n.
0se cutt|n o|| on reamer. botate
reamer |n proper d|rect|on and do not
stop rotat|on to puncH |n or pu|| out.
b. C|ean cy||nder Head and et r|d ol cut b|ts ol
meta| and dust.
3pec|a| too|s
Va|ve u|de p|pe reamer
Va|ve 3eat CHeck|n and Correct|n
Va|ve 3eat CHeck|n
b. bemove carbon depos|t lrom combust|on
cHamber va|ves.
/. 3pread emery on seat surlace between
va|ve and va|ve seat. 0se po||sH|n bar to wear
|n va|ve.
. 1ake out va|ve and cHeck va|ve seat surlace.
CHane |l va|ve surlace |s course or lac|a|
po||sHed.
\alve sea! surace wid!h checkin
Used limi!. above 1.8mm (.07 in.) correc!.
9. Correct va|ve seat w|tH cHamlered too| |l
surlace w|dtH |s not even, too w|de or too
narrow.
4
9
3
V/lVL lllL bL/lLb
V/lVL 00l0L
3CbLw 0blVLb
10 lbY 001
00l0L
.mm
|.C/ |n. max
V/lVL 3L/1
30bl/CL wl01H
Va|ve Seat Chamfer Cutt|ng Tcc|s
beler to va|ve cHamlered too| Handbook lor
deta||s.
. lress and rotate w|tH 4bk CZ |b lorce
to po||sH and cut wHen correct|n.
0se cHamlered too| alter spread|n
en|ne o|| on |t.
Va|ve Seat Cutt|ng
. 0o not po||sH or cut excess|ve|y.
Z. Cut pr|mary surlace w|tH 4bC cutt|n Head.
3. CHamler |nner ede w|tH 3ZC cutt|n Head.
4. Correct |nner surlace by s|xtyderee
cHamlered too|.
60
45
CORSE SURFACE
IN, EX: (30mm)
IN, EX: (32mm)
IN: (24.5mm)
EX: (27.5mm)
32
VALVE SEAT SURFACE WIDTH
VALVE SEAT SURFACE WIDTH
32
60
b. 1r|m va|ve seat to ass|ned
seat w|dtH and va|ve seat w|dtH
w|tH 4b deree cHamlered cutt|n
too|.
3tandard va|ve: .C mm |.393 |n.
CHeck contact p|ace ol va|ve
seat.
b. lo||sH w|tH 3Cderee
cHamlered cutt|n too| |l He
contact p|ace |s too H|H. 1r|m to
ass|ned w|dtH w|tH 4bderee
cHamlered cutt|n too|. lo||sH
va|ve contact surlace w|tH emery
and po||sH|n bar alter correct|n
bar.
/. wasH and c|ean cy||nder and
va|ve alter po||sH|n and r|nd|n.
botate and press solt|y
wHen po||sH|n. 0on't put
emery |nto va|ve and va|ve
u|de p|pe wHen po||sH|n.
. 3pread red |nk on 4bderee
seat surlace and conhrm |l tHe
center ol tHe contact surlace ol
tHe va|ve |s even alter correct|on.
u||d|ng Up cf Cy||nder Head
. Bu||d 0p 3pr|n 3eat
0se new o|| sea|s wHen
reassemb||n.
Z. 3pread en|ne o|| on va|ve
stem and put |nto va|ve u|de.
3. Bu||d up |nner and outer va|ve
spr|n and put |n va|ve co||ar
us|n spr|n compressor.
V/lVL 3L/1
30bl/CL wl01H
V/lVL 3L/1
30bl/CL wl01H
3Z`
.Zmm
|.C4/ |n.
4b`
bC`
3
ba
b
bb
3lblN0
V/lVL
C0llbL330b
CDNTACT FLACE
TDD HIGH
CDNTACT FLACE
TDD LDW
4. 0se va|ve spr|n compressor
accessory to make va|ve contact w|tH
va|ve co||ar. 1ap w|tH p|ast|c ma||et two or
tHree t|mes, solt|y, on tHe ends ol tHe
va|ve to seat co||ars.
wHen us|n ma||et, be carelu| to
not damae va|ves.
Insta|||ng Cy||nder Head
. lnsta|| |ocat|n p|n and asket.
Z. lnsta|| cam cHa|n adjuster p|ate.
3. 3||de cy||nder Head over studs and
|nto p|ace.
3
Z 3
3lblN0
V/lVL
C0llbL330b
CYllN0Lb HL/0
0/3bL1
l0C/1lN0 llN
CYllN0Lb HL/0
C/l3H/l1
CH/lN 00l0L B/b
Camshaft Assemb|y
. /ssemb|e rocker arm
and rocker sHalt.
lake a||nment
between sHalt end
and hxed screw
bo|t Ho|e ol
camsHalt seat
wHen va|ve rocker
sHalt |s assemb|ed.
Z. lnsta|| tHe camsHalt |nto
tHe cy||nder Head. 3eat tHe
camsHalt |nto tHe hxed
seat and cHeck a||nment.
3. lnsta|| camsHalt hxed
seat.
4. botate NywHee| and
a||n "1' mark on NywHee|
w|tH cranksHalt mark.
b. /||n tHe camsHalt
cHa|n ear round Ho|e away
lrom en|ne.
b. lnsta|| camsHalt cHa|n
on camsHalt ear.
/. /ssemb|e hxed studs.
. /ssemb|e camsHalt
seat, space and nut |nto
cy||nder Head. 1|Hten
cy||nder Head nut and bo|t
secure|y.
!orque valve.
Lamsha! xed nu!.
2.0km 1b ! lbs
Z
4
a
b0CbLb /bl3
C/l3H/l1
3
b
b0CbLb 3H/l1
C/l3H/l1
ll/L0 3L/1
H0lL lN C/l 0L/b
/w/Y lb0l LN0lNL
C/l3H/l1
CH/lN 0L/b
`1` l/bb
Camshaft Cha|n Regu|atcr
Assemb||ng
. l|rst, bu||d up camsHalt
cHa|n reu|ator and spacer.
3econd, |ock two hxed bo|ts.
1H|rd, put spr|n |nto camsHalt
cHa|n reu|ator. last, assemb|e
tHe or|n and hxed bo|t.
lress down reu|ator
master jaw and dr|ve
down dr|v|n bar
wHen camsHalt cHa|n
reu|ator |s
assemb|ed.
!orsion valve. 0.30.b km
Reula!e valve ap. (3b)
Z. CHane tHe r|n ol He
cy||nder Head cover and
assemb|e tHe cy||nder Head
cover.
lut or|n |nto lurrow.
Z
0N0Lb3l0L 0l
CYllN0Lb HL/0 C0VLb
0blN0
l0bb0w
C0VLb
3. lock hxed screw bo|t ol cy||nder
Head cover.
!orsion valve. 0.81.2 km
4. 3pread rease on tHread|n
pos|t|on ol camsHalt hxed seat
screw bo|t.
b. lock two or tHree t|mes at
d|aona| ol camsHalt hxed seat
screw cap.
3
CYllN0Lb
HL/0
C0VLb
. Cy||nder and F|stcn
Tcp|c Fage
later|a| Z
1roub|esHoot|n Z
bemov|n tHe cy||nder 3
CHeck|n tHe Cy||nder b
Tcp|c Fage
bemov|n tHe p|ston 3
/ssemb||n tHe p|ston /
/ssemb||n tHe cy||nder
Impcrtant Fc|nts
1He work on tHe cy||nder and p|ston can be done on tHe en|ne w|tHout comp|ete d|sassemb|y.
/lter tak|n tHem apart, c|ean and dry tHe cy||nder and p|ston w|tH tHe compressed a|r belore measur|n and test|n.
Trcub|eshcct|ng
ln case ol d|lhcu|ty start|n or unsteady runn|n at
|ow speeds, cHeck |l tHere |s wH|te smoke com|n
out ol tHe a|r Ho|e p|pe ol tHe crankcase. ll tHat |s
tHe case, tHe p|ston r|n |s worn, burnt or broken.
Lcw Ccmpress|cn Fressure
1He p|ston r|n |s worn, burnt or broken.
1He p|ston/cy||nder |s worn or damaed.
Ccmpress|cn Fressure |s Tcc H|gh
Carbon depos|ts on tHe p|ston and tHe combust|on
cHamber.
Wh|te Smcke Ccm|ng Dut cf the Exhaust F|pe
1He p|ston r|n |s worn or damaed.
1He p|ston/cy||nder |s worn or damaed.
bnock|n No|se by tHe l|ston
1He cy||nder, tHe p|ston or tHe p|ston r|n |s worn.
1He p|ston p|n and |ts Ho|e are worn.
ltem
|C.C4 C.Cb
C.CbC.Cbb
C.CbC.Cbb
C.CC.ZC
C.CbC.ZC
C.ZCC./C
3.9C3./C
9mm away lrom sk|rt
C.CCC.C4C
3.CCZ3.CC
Z.9943.CCC
C.CCZC.C4
3.Cb3.C34
39.C
C.Cb
C.Cb
C.Cb
C.C9
C.C9
C.4b
C.4b
3./
C.
3.C4
Z.9b
C.CZ
3.Cb
Cy||nder
l|ston
l|ston r|n
00 ol tHe p|ston p|n
C|earance between tHe p|ston p|n and tHe Ho|e
l0 ol tHe sma|| end ol tHe connect|n rod
l0
0|stort|on
Cy||ndr|c|ty
0utolroundness
C|earance between
tHe r|n and tHe r|n roove
00 ol p|ston
CHeck po|nt ol 00
C|earance between p|ston and cy||nder
l0 ol tHe p|ston p|n Ho|e
Compressed ap
Norma| s|ze lax. 3erv|ce
/||owance
un|t: mm
Remcv|ng the Cy||nder
. 0etacH tHe cy||nder Head |reler to /b.
Z. bemove tHe cHa|n u|de ol tHe cam
cHa|n.
3. bemove tHe cy||nder.
4. bemove tHe cy||nder asket and tHe
|ocat|n p|n lrom tHe top ol tHe cy||nder
and tHe base ol tHe cy||nder.
Remcv|ng the F|stcn
. bemove tHe p|ston p|n snap r|n.
Attent|cn:
0on't drop tHe snap r|n
|nto tHe crankcase.
Z. 1ake out tHe p|ston p|n and tHen tHe
p|ston.
3. lusH tHe p|ston p|n lrom tHe s|de
oppos|te tHe removed snap r|n.
4. 0se a sma|| puncH or dr|lt p|n |l
necessary and top ent|y w|tH a soltlaced
bummer.
0se caut|on to keep lrom
scratcH|n tHe p|ston surlaces.
Za
CYllN0Lb HL/0
0/3bL1
l0C/1lN0 llN
ll310N llN
ll310N
3N/l
blN0
Zb
N01L: CH/lN bLl0VL0 lb0l
lll031b/1l0N l0b Cl/bl1Y.
ll310N
ll310N llN
ll310N
3N/l
blN0
ll310N
b
ll310N
blN0 0/l
CHeck|n tHe p|ston, tHe p|ston p|n and tHe
p|ston r|n.
Attent|cn:
0on't damae or break tHe r|n.
. bemove a|| ol tHe carbon depos|ts
lrom tHe r|n roove.
Z. lount tHe r|n and measure tHe
c|earance ol tHe r|n roove.
lax|mum serv|ce a||owance:
1He top r|n: bep|ace wHen |t oes
beyond C.C9mm |.C3b |n..
1He second r|n: bep|ace wHen |t
oes beyond C.C9mm |.C3b |n..
3. bemove tHe p|ston r|ns.
lnsta|| tHe p|ston r|ns |nto tHe bottom ol
tHe cy||nder.
Attent|cn:
0se tHe p|ston Head to press tHe
r|ns |nto p|ace |n tHe cy||nder.
4. leasure tHe p|ston r|n ap |n bore.
bep|ace wHen |t oes beyond
C.4bmm |.C |n..
b. leasure tHe l0 ol tHe p|ston p|n Ho|e.
3.C4mm |.b |n..
b. leasure tHe 00 ol tHe p|ston p|n.

Maximum service allowance.
Replace when i! is below 12.96 mm, (.b1 in.).
/. leasure tHe 00 ol tHe p|ston.
Attent|cn:
leasure |t |n a pos|t|on wH|cH lorms 9C deree w|tH
tHe center ol tHe p|ston p|n and wH|cH |s 9mm away
lrom tHe sk|rt.

Replace when i! is below 38.7 mm (1.b2 in.).
. leasure tHe c|earance between tHe p|ston p|n and tHe p|n
Ho|e.

Replace when i! oes beyond 0.02 mm (.0008 in.).
Check|ng the Cy||nder
. CHeck wHetHer |t's scratcHed, worn or damaed |n |ts |nner
surlace.
Z. leasure |ts l0 |n tHree pos|t|ons |upper, m|dd|e and |ower
wH|cH lorm 9C derees |xy d|rect|on w|tH tHe p|ston Ho|e.

Repair or replace when i! oes beyond 0.1mm (.004 in.).
!he dierence be!ween X and Y direc!ions is
ou!oroundness.
1He cy||ndr|c|ty |s tHe l0 d|llerence |between / and Y
d|rect|ons, measur|n at tHree pos|t|ons |upper, m|dd|e and
|ower. 1He |arest measured va|ue w||| be cons|dered tHe
resu|t. 1H|s |nd|cates a taper ol tHe cy||nder.

Uu!oroundness.
Repair or replace when i! oes beyond 0.0bmm (.002 in.).
Lylindrici!y.
Repair or replace when i! oes beyond 0.0bmm (.002 in.).
ll00lL
0llLb
lN L/
l0wLb
Y
/
ll310N llN
b
/
Z
3. CHeck tHe d|stort|on ol tHe
cy||nder.
bepa|r or rep|ace wHen |t oes
beyond C.Cbmm |.CCZ |n..
4. leasure tHe l0 ol tHe sma|| end
ol tHe connect|n rod.
3.Cbmm |.b |n..
Attent|cn:
0on't scratcH tHe p|ston or
break tHe p|ston r|n.
wHen rep|ac|n tHe r|n,
keep tHe surlace w|tH tHe "1'
mark up.
/lter assemb||n, make sure
tHat tHe r|n can be turned
lree|y |n tHe r|n roove.
b. l|Ht|y coat tHe r|ns w|tH en|ne
o|| belore |nsta|||n tHem on tHe
p|ston.
b. lake sure to keep r|n end aps
rotated at ZC
`
|ncrements.
/. Cover p|ston and r|ns w|tH a
||Ht coat ol en|ne o||.
Z
4
b
ZC`
ZC` ZC`
ZCmm
|./9 |n.
ZCmm
|./9 |n.
10l blN0
ZN0 blN0
3l0L blN0
L/l/N0lN0 blN0
3l0L blN0
10l blN0
3LC0N0 blN0
0ll blN0
C0NNLC1lN0
b00
. lnsta|| tHe cHa|n u|de |ever ol tHe cam.
Attent|cn:
lake sure tHat tHe |u ol tHe u|de
|ever enters tHe notcH ol tHe cy||nder.
Assemb||ng the F|stcn
. 3crape away tHe asket adHer|n on tHe
surlace ol tHe crankcase.
Attent|cn:
Be sure not to |et any matter drop
|nto tHe crankcase.
Z. /ssemb|e tHe p|ston and tHe p|ston p|n.
Attent|cn:
wHen assemb||n, keep tHe mark "|n'
|on tHe top ol tHe p|ston toward tHe
|n|et va|ve.
Be sure not to |et tHe p|ston p|n snap
r|n la|| |nto tHe crankcase. 0se a
c|otH to keep debr|s out ol tHe
crankcase.
3a
Z
ll310N llN
ll310N
3N/l
blN0
3b
ll310N
Assemb||ng the Cy||nder
3. lnsta|| tHe |ocat|n p|n and tHe
asket to tHe crankcase.
4. Coat tHe |nner surlace ol tHe
cy||nder, tHe p|ston and tHe p|ston r|n
w|tH o||.
b. wHen assemb||n tHe p|ston r|ns,
tHey must be compressed |nto tHe
cy||nder.
Attent|cn:
0on't damae or break tHe
p|ston r|n.
Be sure not to make tHe
pos|t|on ol tHe r|n ap po|nt
to tHe |n|et and out|et va|ves
and para||e| w|tH tHe
p|ston r|n.
9. Dr|v|ng e|t Dev|ce & The Start|ng Lever
Tcp|c Fage
lmportant lo|nts 9Z
1roub|esHoot|n 9Z
0etacH|n tHe lelt Crankcase Cover 93
bemov|n tHe 3tart|n l|vot 93
CHeck|n tHe 3tart|n l|vot 94
lnsta|||n tHe 3tart|n /ssemb|y 94
/ssemb||n tHe lelt Crankcase Cover 9b
CHeck|n tHe 0r|v|n Be|t 9b
bep|ac|n tHe 0r|v|n Be|t 9b
/ssemb||n tHe 0r|v|n Be|t 9/
1He 0r|v|n lu||ey0|smount|n 9/
1ak|n tHe 0r|v|n lu||ey /part 9/
CHeck|n tHe 0r|v|n lu||ey 9
/ssemb||n tHe 0r|v|n lu||ey 99
1He 0verrunn|n C|utcH bemova| 99
CHeck|n and /ssemb||n 99
tHe 0verrunn|n C|utcH
Tcp|c Fage
1He C|utcH/1ransm|ss|on lu||ey 9C
bemov|n tHe C|utcH/
1ransm|ss|on lu||ey
0|sassemb||n tHe C|utcH/ 9C
1ransm|ss|on lu||ey
CHeck|n tHe C|utcH 9
1ransm|ss|on lu||ey
bep|ac|n tHe transm|ss|on pu||ey 9Z
and tHe bear|n
1He C|utcH/1ransm|ss|on 93
lu||ey /ssemb|y
/ssemb||n tHe C|utcH Hous|n 94
Impcrtant Fc|nts
1H|s cHapter |s about tHe dr|v|n un|t, tHe
c|utcH/dr|ven un|t and tHe start|n |ever.
1He work on tHem can be done on tHe en|ne,
w|tHout tHe d|sassemb|y.
1He surlace ol tHe dr|v|n be|t and tHe dr|ve un|ts
are not a||owed to Have o|| adHer|n to tHem. ll
tHere |s any, remove |t to m|n|m|ze tHe s||p
between tHe be|t and tHe dr|ve un|ts.
Tcrque
1He nut ol tHe dr|v|n p|ate
3.k/m Zlt |bs
1He nut ol tHe c|utcH Hous|n
b.bk/m 4Clt |bs
1He bo|t ol tHe dr|v|n p|ate
C.3k/m 4C|n |bs
1He nut ol tHe c|utcH/dr|v|n p|ate
C.4bk/m 4C|n |bs

0n|versa| stand
Trcub|eshcct|ng
1He motorcyc|e doesn't run alter tHe en|ne |s
started
1He dr|v|n be|t |s worn
1He dr|v|n p|ate |s broken
1He brake ||n|n |s worn or broken
1He spr|n ol tHe dr|ven p|ate |s lractured
Sudden breakdcwn dur|ng runn|ng
1He spr|n ol tHe brake ||n|n |s lractured
Fcwer can't deve|cp fu||y
1He dr|v|n be|t |s worn
0|stort|on ol tHe dr|ven be|t spr|n
1He ro||er |s worn
1He dr|v|n p|ate surlace |s d|rty
Tech Cr|ter|cn
l0 ol tHe s|eeve ol tHe s||d|n dr|v|n p|ate
00 ol tHe Hub ol tHe s||d|n dr|v|n p|ate
w|dtH ol tHe dr|v|n be|t
1H|ckness ol tHe c|utcH brake ||n|n
l0 ol tHe c|utcH Hous|n
lree |entH ol tHe dr|ven be|t spr|n
00 ol tHe dr|v|n p|ate
l0 ol tHe s||d|n dr|v|n p|ate
00 ol tHe ro||er
Item Ncrma| S|ze Max. Ser|ce A||cwab|e
Z3.99Z4.Cb
ZC.CCZZ.CZb
C/.CC/.ZZ
9.
33.9bb33.9b
34.C34.Zb
3.C
Z4.Z4
9.9/
/
Z.C
C/.b
C/.b
9Z.
34.Cb
Z.4
Compress|n dev|ce lor
c|utcH spr|n
3ocket |39mm lor
3ocket |39mm lor tHe hx nut
Bear|n dr|ver
31/b1lN0 lLVLb
31/b1lN0
llV01 0L/b
lblC1l0N
3lblN0
31/b1lN0 llV01
w/3HLb
Z
3
4
31/b1lN0
llV01
bL10bN
3lblN0
Detach|ng the Left
Crankcase Ccver
. 0n|ock tHe c||p lor tHe a|r
tube lor tHe dr|v|n be|t.
Z. bemove e|Ht bo|ts and tHen
take oll tHe |elt crankcase cover
and tHe |ocat|n p|n.
3. CHeck wHetHer tHe asket |s
damaed or lractured.
Remcv|ng the Start|ng F|vct
. bemove tHe start|n |ever
lrom tHe p|vot.
Z. bemove tHe reta|ner and tHe
wasHer lrom tHe start|n p|vot.
3. 1urn tHe start|n p|vot ent|y
and remove tHe dr|v|n ear and
tHe lr|ct|on spr|n toetHer.
4. bemove tHe start|n p|vot
and tHe return spr|n.
b. 0etacH tHe start|n p|vot
s|eeve.
Clll 0l 1HL /lb 10BL
PDF processed with CutePDF evaluation edition www.CutePDF.com
lblC1l0N 3lblN0
0blVLN 0L/b
31/b1lN0
llV01
bL10bN
3lblN0
llV01 3lLLVL
b0BBLb 3lLLVL
Z
3
BL/blN0 l/b1
0l 31/b1lN0
llV01
BL/blN0 l/b1 0l 1HL
3H/l1 0l 1HL 0blVLN 0L/b
Check|ng the Start|ng F|vct

. CHeck |l tHe p|vot and tHe
ear are worn. CHeck |l tHere |s
any soltness ol tHe start|n
return spr|n. CHeck |l tHere |s
any excess|ve wear on tHe p|vot
s|eeve.
Z. CHeck |l tHe dr|ven ear |s
worn or Has la||ed. CHeck |l tHe
lr|ct|on spr|n |s worn or
lractured.
3. CHeck |l tHere |s any
excess|ve wear on tHe bear|n
part ol tHe start|n p|vot and ol
tHe sHalt ol tHe dr|ven ear.
bep|ace any parts sHow|n
excess|ve or unusua| wear.
Insta|||ng the Start|ng
Assemb|y
. lnsta|| tHe start|n p|vot
s|eeve and tHe return spr|n to
tHe crankcase cover.
Z
0/3bL1
lLl1 Cb/Nb C0VLb
Z
31/b1lN0 lLVLb
w/3HLb
3a
3b
Z. /s sHown |n tHe
p|cture on tHe r|Ht,
assemb|e tHe dr|ven
ear and tHe lr|ct|on
spr|n. la|nta|n tHe
or|entat|on as sHown.
3. lnsta|| tHe starter
p|vot |3a. lnsta|| tHe
wasHer, tHen tHe
reta|ner |3b.
Assemb||ng the
Left Crankcase
Ccver
. l|rst, |nsta|| tHe
|ocat|n p|n, tHen tHe
asket.
Z. /ssemb|e tHe |elt
crankcase cover, and
tHen t|Hten tHe e|Ht
hx bo|ts d|aona||y.
lnsta|| tHe a|r tube
toetHer, and tHen
|nsta|| tHe reta|ner.
ZC
Z
Check|ng the Dr|v|ng e|t
. 0etacH tHe |elt crankcase
cover.
Z. CHeck |l tHe dr|v|n be|t |s
cracked, lrayed, or |l tHere |s
abnorma| wear. leasure tHe w|dtH
ol tHe be|t. lax|mum serv|ce
a||owance: /mm |./ |n..
Rep|ac|ng the Dr|v|ng e|t
. bemove tHe e|Ht hx bo|ts,
tHen remove He crankcase cover.
Z. bemove dr|v|n pu||ey. 0se a
reta|n|n dev|ce to Ho|d tHe dr|v|n
pu||ey and screw out ol tHe Cmm
|.39 |n. bo|t.
3. bemove tHe dr|v|n pu||ey.
4. bemove tHe dr|v|n be|t lrom
tHe c|utcH dr|v|n pu||ey.
Z
Cl01CH H003lN0
ll/ N01
bL1/lNlN0 0LVlCL
0b 3l/NNLb
wbLNCH
0blVlN0 BLl1
Cl01CH 0blVLN l0llLY
3
Assemb||ng the Dr|v|ng e|t
. 1urn tHe dr|v|n pu||ey c|ockw|se to keep
tHe notcHes ol tHe be|t |n expanded cond|t|on.
1Hen |nsta|| tHe new dr|v|n be|t.
Z. lnsta|| tHe dr|v|n be|t on tHe dr|v|n
pu||ey. lnsta|| tHe dr|v|n pu||ey, tHe start|n
ratcHet and Cmm |.39 |n. wasHer. 1Hen
|nsta|| and t|Hten tHe nut. 1orque: 3,k/m
Zlt |bs
Attent|cn:
0ur|n assemb|y, be sure to a||n tHe
sp||nts ol tHe dr|v|n un|t w|tH tHose
on tHe crank sHalt w|tH tHe ratcHet.
The Dr|v|ng Fu||ey-D|smcunt|ng
3. 0se a reta|n|n dev|ce or spanner wrencH
to Ho|d tHe dr|v|n pu||ey.
4. 3crew out tHe Cmm |.39 |n. nut, and
tHen remove tHe ratcHet, tHe Cmm |.39 |n.
nut and tHe dr|v|n pu||ey.
Tak|ng the Dr|v|ng Fu||ey Apart
b. bemove tHe dr|v|n pu||ey and tHe s|eeve
lrom tHe cranksHalt.
b
0blVlN0
l0llLY
0blVlN0
BLl1
31/b1lN0
l/1CHLb
0blVlN0
l0llLY
0blVlN0 l0llLY 3lLLVL
b. bemove tHe reta|ner.
/. bemove tHe ro||ers.
Check|ng the dr|v|ng pu||ey
. CHeck tHe wear ol tHe ro||ers.
leasure tHe 00 ol tHe ro||er.
Replace when i! is below 12.4mm
(.47 in.).
Z. CHeck tHe wear ol tHe dr|v|n pu||ey
s|eeve. leasure tHe 00 ol tHe mov|n
sect|on ol tHe s|eeve.
(1.37 in.).
bL1/lNLb
b0llLb
0blVlN0 l0llLY
3lLLVL
/
Z
e Dr|v|ng Fu||ey
lnsta|| tHe dr|v|n pu||ey s|eeve and tHe
dr|v|n pu||ey on tHe cranksHalt |a. lnsta|| tHe
dr|v|n be|t on tHe cranksHalt |b. lnsta|| tHe
dr|v|n pu||ey and tHe wasHer |c.
!ih!en 10mm (.39 in.) nu!.
!orque. 3.8km 28! lbs
Attent|cn:
1Here mustn't be any rease on tHe
surlace ol tHe dr|ven be|t and tHe dr|v|n
pu||ey.
The Dverrunn|ng C|utch (Starter F|n|cn)
Remcva|
Z. bemove tHe |elt crankcase cover .
3. bemove tHe dr|v|n pu||ey.
4. bemove tHe seat ol tHe overrunn|n c|utcH.
b. bemove tHe overrunn|n c|utcH.
Check|ng and Assemb||ng
b. CHeck |l tHe bear|n part ol tHe overrunn|n
c|utcH sHalt |s worn.
/. CHeck |l tHe c|utcH runs smootH|y.
. CHeck tHe wear ol tHe ear and tHe bear|n
part ol tHe sHalt.
9. Coat tHe bear|n part ol tHe c|utcH sHalt
w|tH a b|t ol rease.
C. /ssemb|e |t |n tHe oppos|te sequence ol
remova|.
a
0blVlN0 l0llLY
3lLLVL
b
b
BL/blN0 3LC1l0N
0l 3H/l1
0VLbb0NNlN0
Cl01CH
Dverrunn|ng C|utch
b
b
0blVlN0
l0llLY
0blVlN0
BLl1
SPANNLP
wPLNCH
l0mm
P|X NUT
SLAL COvLP|NG
OP SHAPT COLLAP
7
l
2
The C|utch,Transm|ss|cn Fu||ey
Remcv|ng the C|utch,Transm|ss|cn
Fu||ey
. bemove tHe dr|v|n pu||ey. 1Hen
use a spanner wrencH to Ho|d tHe
c|utcH Hous|n to screw out tHe Cmm
|.39 |n. nut.
Z. bemove tHe c|utcH Hous|n.
bemove tHe c|utcH/transm|ss|on pu||ey.
bemove tHe dr|v|n be|t lrom tHe
c|utcH/transm|ss|on pu||ey.
D|sassemb||ng the
C|utch,Transm|ss|cn Fu||ey
b. 0se a spr|n compressor lor tHe
c|utcH spr|n to press down tHe
transm|ss|on pu||ey spr|n to remove
tHe spec|a| nut |Zmm, .CZ |n..
b. bemove tHe c|utcH spr|n.
/. bemove tHe sea||n cover ol tHe
sHalt co||ar.
CLUTCH HOUS|NG
CLUTCH
HOUS|NG
CLUTCH TPANSM|SS|ON PULLL
DP|v|NG 8LLT
3
Z
. bemove tHe u|de ro|||n p|n lrom tHe
transm|ss|on pu||ey assemb|y, and tHen
take out tHe or|n and tHe o|| sea|.
Check|ng the C|utch
Transm|ss|cn Fu||ey
. CHeck tHe wear ol tHe c|utcH Hous|n.
leasure tHe l0 ol tHe c|utcH Hous|n.
Replace when i! oes beyond
107.bmm (4.23 in.).
Z. CHeck tHe wear ol tHe c|utcH ||n|n.
leasure tHe tH|ckness ol tHe ||n|n.
Replace, when i! is below 2.0mm
(.078 in.).
3. leasure tHe lree |entH ol tHe
transm|ss|on pu||ey spr|n.
Replace when i! below 92.8mm
(3.6b).
0blN0
0ll 3L/l
1b/N3ll33l0N
l0llLY
00l0lN0 llN
4
Za
Zb
4. CHeck tHe wear ol tHe transm|ss|on pu||ey.
leasure tHe 00 ol tHe pu||ey.
(.79 in.).
b. CHeck tHe wear ol tHe transm|ss|on pu||ey.
leasure tHe l0 ol tHe pu||ey.
Replace when i! oes beyond 24.24mm
(.9b in.).
b. CHeck |l tHe u|de ro|||n p|n |s excess|ve|y
worn or uneven|y worn.
Rep|ac|ng the transm|ss|cn pu||ey and the
bear|ng
. CHeck tHe need|e bear|n lor wear or
excess|ve lree p|ay, r|tty lee| or no|se.
Z. CHeck tHe Hous|n bear|n lor wear.
bemove tHe reta|ner and take out tHe Hous|n
bear|n.
3. 0r|ve |n tHe new Hous|n bear|n, keep|n
tHe ||d s|de up.
Attent|cn:
0rease new bear|ns wHen
|nsta|||n. 0rease ab|e to res|st
> Z3C
`
.
lNNLb BL/blN0
bL1/lNLb blN0
H003lN0 BL/blN0
BL/blN0 l0llLb
4
Z
3
4. 0r|ve |n tHe new need|e bear|n,
keep|n tHe "mark' s|de up.
The C|utch,Transm|ss|cn Fu||ey
Assemb|y
. /ssemb|e tHe transm|ss|on pu||ey
u|de p|n and o|| sea|.
Z. lnsta|| tHe sea||n cover ol tHe
co||ar.
3. /ssemb|e tHe transm|ss|on pu||ey
d|sk and tHe spr|n to tHe c|utcH
assemb|y, press|n down w|tH tHe
spr|n compressor lor tHe c|utcH
spr|n.
4. lnsta|| tHe Zmm hx nut and
t|Hten |t.
!orque. b.06.0km 3b40! lbs
3L/llN0 C0VLb 0l
1HL 3H/l1 C0ll/b
0blN0
00l0L b0lllN0 llN
00l0L lLVLb 0l
1HL l0llLb
3l/NNLb
wbLNCH
Cmm
ll/ N01
b
4
4. /ssemb||n tHe c|utcH/transm|ss|on
pu||ey, put tHe dr|v|n be|t onto tHe
c|utcH/transm|ss|on pu||ey, tHen onto tHe
dr|v|n sHalt.
Assemb||ng the C|utch Hcus|ng
b. 0se a spanner wrencH to Ho|d tHe
Hous|n, tHen |nsta|| tHe Cmm |.39 |n.
nut and t|Hten |t.
1orque: b.bk/m 3lt |bs
/ssemb|e tHe |elt crankcase cover.
Cl01CH H003lN0
Cl01CH
H003lN0
Cl01CH 1b/N3ll33l0N l0llLY
0blVlN0 BLl1
I0. The F|na| Transm|ss|cn Assemb|y
Tcp|c Fage
0enera| lnlormat|on CZ
0|smant||n tHe l|na| C3
1ransm|ss|on /ssemb|y
bep|ac|n Bear|n C4
|on tHe s|de ol tHe
transm|ss|on earbox cover
Tcp|c Fage
bep|ac|n tHe Bear|n Cb
|on tHe s|de ol tHe crankcase
/ssemb||n tHe l|na| 0ear 3et Cb
Genera| Infcrmat|cn
0es|nated o||: 3/L 9C# 0ear 0||
l||||n C.Zl 4 ounces
CHan|n C.Cl 3.b ounces
Bear|n pu|||n set Zmm
Bear|n pu|||n set bmm
3|eeve sHalt lor assemb||n tHe cranksHalt
3|eeve |ever lor assemb||n tHe cranksHalt
Bear|n outer race dr|ver 3/4Cmm
Bear|n outer race dr|ver 3Z3bmm
0u|de |ever lor tHe bear|n dr|ver /mm
0u|de |ever lor tHe bear|n dr|ver bmm
0u|de |ever lor tHe bear|n dr|ver Zmm
Bear|n dr|ver
Trcub|eshcct|ng
The scccter dcesn't run after the eng|ne |s
started
1He transm|ss|on ear la||ed
1He dr|v|n be|t |s worn or broken
1He c|utcH la||ed
Deve|cp|ng abncrma| nc|se when |t runs
1He ear |s worn, burnt or Has damaed teetH
1He bear|n |s worn and ett|n |oose
D|| |eakage
1oo mucH o||
1He o|| sea| |s broken
ll/ B0l1
llN/l
1b/N3ll33l0N
3H/l1
llN/l
1b/N3ll33l0N
3H/l1
0blVlN0 3H/l1
30B 3H/l1
30B 3H/l1
D|smant||ng the hna|
transm|ss|cn assemb|y
. bemove tHe rear brake cab|e.
Z. bemove tHe rear wHee|
|reler to 33.
3. bemove tHe |elt crankcase
cover |reler to 9Z.
4. bemove tHe dr|ven pu||ey ol tHe
c|utcH |reler to 9b.
b. 0ra|n tHe o|| out ol tHe hna|
transm|ss|on.
b. bemove tHe bo|ts ol tHe hna|
transm|ss|on earbox.
/. bemove tHe transm|ss|on
earbox cover.
. bemove tHe asket and tHe
|ocat|n p|n.
Detach the hna| transm|ss|cn
gearbcx ccver
. CHeck tHe hna| transm|ss|on
assemb|y.
Z. CHeck |l tHe sub sHalt ear |s
worn or damaed.
3. CHeck |l tHe hna| transm|ss|on
ear |s burnt or damaed.
Z
3
30B 3H/l1 BL/blN0
llN/l 1b/N3ll33l0N
3H/l1 BL/blN0
0blVlN0 3H/l1 BL/blN0
0ll 3L/l
4. CHeck |l tHe bear|n |n tHe |elt
crankcase and tHe o|| sea| are worn
or damaed.
b. CHeck |l tHe dr|v|n sHalt |tHe
ma|n c|utcH sHalt and tHe ear are
worn or damaed.
b. CHeck |l tHe o|| sea| |n tHe
bear|n ol tHe transm|ss|on earbox
cover and tHat ol tHe bear|n ol tHe
hna| ear sHalt are worn or Have
la||ed.
Attent|cn:
0on't d|smant|e tHe hna|
transm|ss|on earbox, except
tHat some parts Have to be
rep|aced. wH||e rep|ac|n
tHe dr|v|n sHalt, tHe o|| sea|
must be rep|aced by new
ones.
Rep|ac|ng ear|ng (cn the s|de
cf the transm|ss|cn gearbcx
ccver)
. 0se a bear|n pu||er to remove
tHe bear|n |n tHe hna| transm|ss|on
earbox.
Z. bemove tHe o|| sea| on tHe hna|
transm|ss|on sHalt.
3. 0r|ve |n tHe new bear|n to tHe
hna| transm|ss|on cover.
Rep|ac|ng the ear|ng (cn the
s|de cf the crankcase)
. bemove tHe dr|v|n sHalt |tHe
c|utcH ma|n sHalt.
1Hen remove tHe o|| sea| ol tHe
sHalt.
Z. 0se a bear|n pu||er to remove
tHe bear|n |n tHe hna| transm|ss|on
earbox.
3. 0r|ve tHe new bear|n |nto tHe
hna| transm|ss|on earbox. lnsta||
tHe new o|| sea| lro tHe dr|ve sHalt.
Assemb||ng the F|na| Gear Set
. l|rst, |nsta|| tHe dr|ve sHalt |nto
tHe hna| earbox. 1Hen |nsta|| tHe
hna| transm|ss|on ear sHalt
|output sHalt to tHe hna| earbox.
a
Z
b
0blVlN0 3H/l1
0blN0
BL/blN0
0ll 0b/lN/0L 3CbLw
0L/b 0ll lNlL1
H0lL/CHLCb H0lL
ll/ 3CbLw
l0C/1lN0 llN
0/3bL1
bL3lN
w/3HLb
30B 3H/l1
3. /ttacH tHe sub sHalt and tHe
wasHer to tHe hna| transm|ss|on
earbox. lnsta|| tHe res|n wasHer to
tHe sub sHalt; |nsta|| tHe |ocat|n p|n
and tHe new asket.
4. lut on tHe hna| earbox cover.
b. 1|Hten tHe bo|ts ol tHe hna|
earbox cover.
b. /ssemb|e tHe c|utcH/dr|v|n
pu||ey d|sk |reler to 9.
/. /lter assemb||n, h|| tHe ear box
w|tH 9Cw ear o|| |reler to 3/.
0es|nated ear o||: 3/L 9C#
Vo|ume ol tHe earbox:
l||||n: C.Zl 4 ounces
CHan|n: C.Cl 3.b ounces
. 3crew up tHe o|| screw and
t|Hten |t.
!orque. 1.01.4km 810! lbs
9. 3tart tHe en|ne to cHeck |l tHere
|s o|| |eakae.
C. CHeck tHe o|| |eve|. bep|en|sH |t
w|tH tHe des|nated ear o|| wHen tHe
o|| |s not sulhc|ent |tHrouH tHe o||
cHeck|n Ho|e.
3
C
II. The Crankcase and the Crankshaft
ltem
Tech Cr|ter|a
C.CC.3b C.bb
1He c|earance ol tHe botH s|des ol tHe
b| end ol tHe connect|n rod
CC.CC C.Cb
1He c|earance ol /Y d|rect|ons ol tHe
journa| ol tHe b| end ol tHe connect|n
rod
C.C bun out
CranksHalt
Norma| s|ze lax. 3erv|ce /||owance
Impcrtant Fc|nts
1He cHapter |ves |nstruct|ons re|ated to tHe
cranksHalt and d|smant||n tHe crankcase.
Belore str|k|n, |t's necessary to take tHe
en|ne apart.
Comp|ete tHe lo||ow|n work belore tak|n tHe
crankcase apart. bemove tHe lo||ow|n:
1He cy||nder Head |reler to CHapter /
1He cy||nder and tHe p|ston |reler to CHapter
1He dr|v|n p|ate and tHe dr|ven p|ate |reler to
CHapter 9
/C enerator |reler to CHapter 4
1He carburetor and tHe a|r h|ter |reler to CHapter
4
1He rear wHee| and tHe rear buller |reler to
CHapter 3
1He start|n motor |reler to CHapter b
1He o|| pump |reler to CHapter 4
1orque:
Crankcase bo|t C.9k/m /lt |bs
Bo|t lor tHe cHa|n adjust|n u|de |ever cam .Ck/m lt |bs
Trcub|eshcct|ng
Abncrma| nc|se frcm the eng|ne
1He cranksHalt bear|n |s ett|n s|ack
1He cranksHalt p|n bear|n |s becom|n |oose
Tcp|c Fage
lmportant po|nts
0|anos|s
0|smant||n tHe crankcase 3
1He cranksHalt 4
/ssemb||n tHe crankcase b
3
3
4
4
b
bL1/lNlN0 3CbLw
0l 1HL CH/lN
00l0L lLVLb
0/3bL1
Cb/Nb3H/l1
l0C/1lN0 llN
l0C/1lN0 llN
D|smant||ng the
Crankcase
. 0etacH tHe bo|t ol tHe
cHa|n adjust|n u|de |ever
ol tHe cam and remove tHe
|ever.
Z. bemove assemb|y
bo|ts ol tHe crankcase.
3. 0|smant|e tHe r|Ht and
|elt crankcases.

Attent|cn:
0on't damae tHe
asket surlace.
wHen separat|n
tHe crankcases,
don't use a
screwdr|ver to
pry tHem apart.
4. bemove tHe asket and
tHe |ocat|n p|n.
b. bemove tHe cranksHalt
lrom tHe crankcase.
0ll 3L/l
Cb/Nb3H/l1
/. 3crape tHe asket away lrom
tHe jo|nt surlaces.
Attent|cn: be sure not to
scratcH tHe jo|nt surlaces.
. bemove tHe o|| sea| lrom tHe
|elt crankcase.
9. bemove tHe o|| sea| lrom tHe
r|Ht crankcase.
The Crankshaft
. leasure tHe |elt and r|Ht
c|earance between botH s|des ol
tHe b| end ol tHe connect|n rod.
Replace when i! oes beyond
0.bbmm (.02 in.).
Z. CHeck tHe c|earance ol tHe journa| ol tHe
b| end ol tHe connect|n rod |n /Y d|rect|ons.
Replace when i! oes beyond 0.0bmm
(.002 in.).
3. leasure tHe runout ol tHe cranksHalt.
Maximum service allowance,
Replace when i! oes beyond 0.10mm
(.004 in.).
4. CHeck |l tHere |s any abnorma| no|se and
|ooseness wHen tHe cranksHalt bear|n
revo|ves. bep|ace tota||y |l any abnorma|
no|se/|ooseness |s detected.
Assemb||ng the Crankcase
. 0se tHe lo||ow|n too|s to |nsta|| tHe o|| sea|
ol tHe crankcase:
Bear|n outer race dr|ver
Bear|n outer race 3Zx3bmm
|.Zb |n. x .3 |n.
Z
3
Cb/Nb3H/l1
BL/blN0
Z. lnsta|| tHe cam cHa|n |nto tHe |elt
crankcase.
3. /ssemb|e tHe cranksHalt |nto tHe |elt
crankcase.

Attent|cn:
Be sure not to |et tHe cHa|n
damae tHe o|| sea|.
4. lut tHe new |ocat|n p|n and tHe
asket onto tHe |elt crankcase.
Attent|cn:
beep tHe |elt crankcase downward
to assemb|e w|tH tHe r|Ht
crankcase.
b. 1|Hten tHe bo|ts ol tHe crankcase.
4
4
3
0/3bL1
Cb/Nb3H/l1
l0C/1lN0 llN
l0C/1lN0 llN
0blN0
b. lnsta|| tHe cam cHa|n

adjust|n |ever.
/. lnsta|| tHe or|n onto tHe
bo|t ol tHe cHa|n adjust|n
|ever.
. Coat tHe or|n w|tH o||,
and tHen |ock |t.
/ttent|on:
Be sure to put tHe o
r|n |nto tHe roove.
bL1/lNlN0 3CbLw
0l 1HL CH/lN
00l0L lLVLb
IZ. The Frcnt Whee|, Frcnt rake,

lron! uer and !he lron! lork
Tcp|c Fage
lnstruct|ons ZZ
1roub|esHoot|n Z3
bemov|n tHe 3teer|n Hand|ebars Z4
/ssemb||n tHe 3teer|n Hand|ebars Z4
lront wHee| bemova| Zb
0|smant||n ol wHee| Zb
/ssemb|y ol wHee| Z/
/ssemb||n tHe lront wHee| Z
0|smount|n tHe lront 3Hock Z9
Tcp|c Fage
0|smant||n tHe lront 3Hock ZC
/ssemb||n 3equence Z
1He lront lork ZZ
bep|ac|n tHe Ba|| Cone bace ZZ
bep|ac|n tHe 0pper bace ZZ
/ssemb||n tHe 0pper bace Z3
CHeck|n tHe Brake l|n|n Z4
0|smant||n tHe lront Brake Z4
/ssemb||n tHe lront Brake Z4
Item
Tech Cr|ter|cn
C |4.33 |n.
4.C |.b/ |n.
ZCZ.b |/.9/ |n.
lon|tud|na| Hop
1ransversa| wobb|e
C.Z |.9/ |n.
Z.C |.C/9 |n.
Z.C |.C/9 |n.
|4.3b |n.
Z.C |.C/9 |n.
9 |/./ |n.
Bend|n ol tHe wHee| ax|e
l0 ol tHe lront brake Hub
1He tH|ckness ol tHe brake ||n|n
1He lree |entH ol tHe lront sHock spr|n
bunout ol tHe lront
wHee| r|m
Ncrma| S|ze L|m|t (mm)
Nctes:
wHen detacH|n tHe lront wHee|, use a jack at tHe bottom ol tHe lrame to support |t. lake sure
tHat tHe scooter won't overturn wHen tHe lront wHee| |s away lrom tHe round. 0ur|n operat|on,
be sure not to |et o|| et |nto tHe brake Hub or onto tHe brake ||n|n.
!he s!eerin lever 4.0b.0km 30! lbs

!he nu! o !he s!eerin lever 8.012.0km b060! lbs
!he !op race o !he s!eerin lever 0.b1.3km 4070in lbs
!he nu! o !he ron! buer 2.02.bkm 16! lbs
!he nu! o !he ron! wheel axle 4.bb.0km 30! lbs
!he bol! o !he brake rock arm 0.40.7km 30b0in lbs
D|agncs|s
1He steer|n |ever |s too Heavy
1He top race ol tHe |ever |s too t|Ht.
1He ba|| |s broken |n tHe steer|n
mecHan|sm.
low t|re pressure.
The steer|ng |ever |s uneven
1He r|Ht and |elt sHocks are uneven.
1He lront lork |s crooked.
1He lront ax|e |s bent.
Fccr brake funct|cn
lmproper brake adjustment.
worn brake ||n|n.
0|rty brake ||n|n.
worn camsHalt ol tHe brake ||n|n.
1He brake Hub |s worn.
loose brake actuator arm.
ad brake funct|cn (d|sk brake)
/|r |s enter|n tHe brake system.
Brake Nu|d |s deter|orated.
0|rty and la||ed brake d|sk ||ner and/or
brake d|sk.
worn brake pads.
1He o|| sea| and tHe p|ston are worn
|ol tHe ma|n cy||nder.
C|oed brake Nu|d passae.
0elormed brake d|sk.
0ne s|de ol tHe brake ca||per |s worn.
The frcnt whee| wcbb|es
0elormed r|m.
Bear|n ol tHe lront wHee| |s ett|n
s|ack.
0elormed wHee| r|b.
0neven t|re mount|n or wear.
loose ax|e.
The frcnt shcck |s tcc weak
3pr|n |s solt, worn or broken.
low o|| |eve| |n lork.
The frcnt shcck |s prcduc|ng
abncrma| nc|se
lork |s m|sa||ned.
Bo|t ol tHe lront lork |s ett|n |oose.
low o|| |eve| |n lork.
3panner wrencH
0uter race pu||er Zx3Cmm
Compressor lor tHe sHock
absorber
w|tHdrawa| too| lor tHe ba|| bow|
l||ers lor tHe |nner reta|ner r|n
0r|ve bar
0uter race dr|ver 3/x4Cmm
0|smant||n |ever Cmm
Bear|n pu||er
Bear|n pu||er bar Cmm
3pr|n compressor
Remcv|ng the Steer|ng
Hand|ebars
. 0etacH tHe lront and rear
covers ol tHe Hand|ebars.
Z. bemove tHe two bo|ts ol
tHe |elt brake |ever.
3. bemove tHe bo|ts ol tHe
r|Ht Hydrau||c brake drum.
1Hese parts may be one
assemb|y.
4. bemove tHe two bo|ts ol
tHe tHrott|e contro| and
remove tHe tHrott|e r|p and
tHe cab|e. l|na||y, remove tHe
tHrott|e r|p lrom tHe Hand|e.
b. bemove tHe Hand|ebar
c|amp bo|ts.
Assemb||ng the Steer|ng
Hand|ebars
. /||n tHe |u ol tHe
Hand|ebar c|amp to tHe
roove ol tHe steer|n |ever,
tHen |nsta|| and t|Hten tHe
bo|t.
!orque. 4.0b.0 km
283b! lbs
Z
3
B0l1
B0l1
RIGHT HANDLEAR
LEFT HANDLEAR
4
a
b
3. Coat tHe end ol tHe
tHrott|e r|p w|tH rease.
4. lnsta|| tHe tHrott|e r|p
and tHen tHe cab|e.
b. 1o assemb|e, reverse
order ol d|sassemb|y steps.
Frcnt Whee| Remcva|
. l|lt tHe lrame to make
sure tHe lront wHee| |s oll tHe
round. 3upport tHe scooter
|n tH|s pos|t|on.
Z. 0etacH tHe screw ol tHe
speedometer cab|e and
remove tHe cab|e.
3. bemove tHe nut ol tHe
lront wHee| ax|e; take out tHe
ax|e and tHe wHee|.
4. bemove tHe drum d|sk
and tHe co||ar.
Check|ng
b. CHeck tHe stra|Htness ol
tHe ax|e. 1He meter |nd|cates
/Z ol tHe tota| bend|n
va|ue.
C.Zmm |.CC |n..
3lLL00lL1Lb
C/BlL
lb0N1 0b0l
Bb/bL H03L
3
4
Z
wHLLl //lL
b
4
b. CHeck tHe runout ol tHe wHee| r|m.
Hoploni!udinal 2.0mm (.079 in.)
Wobble!ransversal 2.0mm (.079 in.)
/. bep|ace wHen |t oes beyond tHe
above va|ue.
. bep|ace tHe bear|n wHen |t produces
abnorma| no|se or ets |oose.
D|smant||ng cf Whee|
. bemove o|| sea|.
b
0ll 3L/l
3l/CbLNL0 0/l 3l/CbLNL0 0/l
TRANSVERSAL LDNGITUDINAL
Z. 0etacH tHe r|m bear|n
and tHe spacer.
Assemb|y
. l||| tHe bear|n w|tH
rease
Z. 0r|ve tHe |elt bear|n hrst.
3. lnsta|| tHe spacer, tHen
dr|ve |n tHe r|Ht bear|n.
Attent|cn:
beep tHe o|| |dust
sea| s|de ol tHe
bear|n outwards,
tHen dr|ve |t even|y.
BL/blN0 cf Whee|
b. Coat tHe o|| sea| w|tH rease, and
tHen |nsta|| |t.
/. /ttacH tHe co||ar.
Assemb||ng the frcnt whee|.
. lo|nt tHe |u ol tHe ear bank ol
tHe speedometer to tHe notcH ol tHe
lront lork |e. 1Hen assemb|e tHe lront
wHee|.
Z. lnsta|| tHe speedometer and adjust
|ts rout|n.
3. 1|Hten /x|e Nut
!orque.
b.07.0km 3b40! lbs
/ C0ll/b
0ll 3L/l
3lLL00lL1Lb
C/BlL
lb0N1 Bb/bL H03L
3
Z
wHLLl //lL
3
4
l0wLb Cl/ll B0l1
0llLb Cl/ll B0l1
D|smcunt|ng the Frcnt Shcck
. bemove tHe lront wHee| |reler
to Z4.
Z. bemove tHe |ower lront cover
|reler to Z.
3. bemove tHe upper c|amp bo|t.
4. loosen tHe |ower c|amp bo|t to
take out tHe lront sHock.
4
D|smant||ng the Frcnt Shcck
. bemove tHe o||/dust sea|.
Z. bemove tHe outer reta|ner.
0se a bencH v|se to Ho|d tHe lront
lork bottom tube to remove tHe
u|de |ever ol tHe damper, tHe
socket HexHead bo|t and tHe
copper wasHer.
0se a bencH v|se to Ho|d tHe lront
lork tube.
3. bemove tHe top nut, tHe spr|n,
tHe damper and tHe buller spr|n.
Attent|cn:
wHen hx|n tHe lront
lork tube, use a c|otH to
wrap |t and don't exert
too mucH lorce.
4. leasure tHe lree |entH ol tHe
spr|n.
Max. service allowance.
198mm (7.8 in.)
10l N01
10l B0llLb
3lblN0
B0110l
B0llLb
10BL
0/llLb
0031 3L/l
bL1/lNLb
0ll 3L/l
lb0N1 B0llLb
B0110l 10BL
B0110l
B0llLb
3lblN0
b. lnsta|| tHe buller spr|n on tHe u|de
|ever ol tHe damper, tHen |nto tHe lront lork
tube. 1Hen |nsta|| tHe buller spr|n and
|ock tHe nuts.
Attent|cn:
wHen |ay|n down tHe spr|n, keep
tHe co||t|Ht ol |t down.
b. 0se a bencH v|se to secure tHe sHock
bottom tube, and tHen t|Hten tHe socket
bo|t.
/. 3pread tHe tHread |ock|n compound to
tHe wasHer and tHe bo|t, and tHen t|Hten
tHem up toetHer.
!orque. 1.b3.0km 101b! lbs
0esina!ed. Special damper oil
\olume. 8bml (30 ounces)
. /ttacH tHe outer reta|ner and tHen tHe
dustprool cover.
Assemb||ng Sequence
. /ttacH tHe lront sHock.
Z. lnsta|| down tHe upper c|amp bo|t.
1|Hten tHe |ower and upper c|amp bo|ts.

Attent|cn:
lake sure tHat tHe jo|nt ol tHe
upper bo|t Ho|e and tHe roove ol
tHe lront lork tube |lront damper
are proper|y a||ned.
3. /ttacH tHe lront wHee| |reler to Z4.
Z
3lLL00lL1Lb
C/BlL
lb0N1 0l3C
Bb/bL H03L
3
The Frcnt Fcrk
Frcnt fcrk remcva|
. 0etacH tHe Hand|ebar |reler to
Z3.
Z. bemove tHe lront wHee| |reler to
Z4.
3. bemove tHe cab|e ol tHe
speedometer, tHe rear brake cab|e,
tHe lront brake Hose and tHe lront
brake ca||per.
4. bemove tHe top race ol tHe
steer|n |ever and s||de tHem out ol
tHe steer|n tube.
b. CHeck |l tHe ba|| race and tHe
ba||s on tHe cone race are worn or
la||ed. bep|ace as necessary.
Rep|ac|ng the a|| Ccne Race
. bemove tHe race w|tH a cH|se|
and Hammer.
Attent|cn:
0on't damae tHe steer|n
|ever and tHe lront lork.
Z. 0se a su|tab|e dr|ver to dr|ve |n
tHe new cone race |nto p|ace.
Rep|ac|ng the Upper Race
. bemove tHe upper race us|n a
pu||er or pry|n too|.
4
10l B/ll b/CL

B/ll C0NL
b/CL
Z. lress |n tHe new race.
Attent|cn:
Be sure to press tHe race a|| tHe way
|nto p|ace.
Assemb||ng the Upper Race
. Coat tHe race w|tH rease and set tHe
race |nto tHe s|eutH. 1Hen coat tHe race w|tH
rease.
Z. lnsta|| tHe lront lork.
3. Coat tHe top race w|tH rease and set |t
|n p|ace.
4. /lter t|Hten|n tHe top race, turn |t back
and lortH severa| t|mes to make tHe bear|n
set |nto p|ace.
b. lnsta|| tHe top race, and tHen t|Hten
tHe upper nut.
!orque. 8.012.0km b060! lbs
b. /ttacH tHe lront wHee| |reler to Z/.
/. /ttacH tHe Hand|e |reler to Z3.
. /ttacH tHe cab|es |reler to b.
Z
b/CL
b/CL
b/CL
Check|ng the rake L|n|ng
. leasure tHe tH|ckness ol tHe
brake ||n|n. bep|ace wHen |t |s
be|ow Z.Cmm |.C/9 |n.
/ttent|on:
0on't a||ow tHe o|| adHere to
tHe ||n|n surlace.
D|smant||ng the Frcnt rake
3. bemove tHe adjust|n nut
ol tHe lront brake.
4. bemove tHe brake ||n|n.
b. bemove tHe hx bo|t ol
tHe brake arm.
b. bemove tHe brake arm.
Assemb||ng the Frcnt rake
. 3pread rease on tHe mov|n
parts ol tHe ||n|n and ol tHe hx p|n
||ocat|n p|n.
9. 3pread rease on tHe mov|n
part ol tHe brake cam sHalt and
tHen assemb|e |t.
C. lnsta|| tHe brake ||n|n.
3
Bb/bL 0b0l
Bb/bL 0b0l llNlN0
b
llCb0lL1Lb
Bb/bL
I3. The Rear Whee|, the Rear rake & Rear Shcck
Impcrtant Fc|nts
0ur|n operat|on, |t's not a||owab|e to Have o|| adHere to tHe |nner surlace ol tHe brake Hub and tHe
surlace ol tHe ||n|n. 0se brake so|vent to remove o||.
Tcp|c Fage
lmportant po|nts 3Z
1roub|esHoot|n 3Z
0etacH|n tHe bear wHee| 33
CHeck|n tHe bear wHee| 33
/ssemb||n 1He bear wHee| 33
Tcp|c Fage
CHeck|n tHe bear Brake 34
0|smant||n tHe bear Brake 34
/ssemb||n tHe bear Brake 34
0|smount|n tHe bear 3Hock 3b
/ssemb||n tHe bear 3Hock 3b
Check Fcs|t|cn Item
Tech Cr|ter|cn
lon|tud|na| Hop
1ransversa| wobb|e
Z.C |.C/9 |n.
Z.C |.C/9 |n.
|4.3b |n.
Z.C |.C/9 |n.
9 |/./ |n.
bear wHee| bunout
lree |entH ol tHe rear sHock spr|n
l0 ol tHe rear brake Hub
1H|ckness ol tHe rear brake ||n|n
Ncrma| S|ze L|m|t (mm)
!orque
!he nu! o !he rear wheel axle 10.0km 7b! lbs
!he !op o !he rear buer 4.bkm 30! lbs
!he bo!!om bol! o !he rear buer 3.0km 20! lbs
!he connec!ion nu! o !he silencer 1.2km 10! lbs
!he x bol! o !he silencer 3.bkm 2b! lbs
D|agncs|s
1He rear wHee| wobb|es
0elormat|on ol tHe rear r|m
Bad t|re mount|n or bent
The rear shcck |s tcc weak
3pr|n bent or broken
M|sadjusted brake
wear ol tHe brake ||n|n
wear ol tHe brake ||n|n cam
Brake cam worn
Brake Hub worn
C |4.33 |n.
4.C |.b/ |n.
ZCZ.b |/.9/ |n.
Z
3
Detach|ng the Rear Whee|

. 0etacH tHe exHaust p|pe |reler to Z
Z. bemove tHe nut ol tHe rear wHee| ax|e.
3. bemove tHe rear wHee|.
Check|ng the Rear Whee|
. CHeck tHe runout ol tHe rear wHee|.
Loni!udinal. 2.0mm (.079 in.) Hop
!ransversal. 2.0mm (.079 in.) Wobble
bep|ace wHen |t oes beyond tHe above
va|ue.
Z. CHeck tHe rear brake Hub.
3. leasure tHe l0 ol tHe rear brake Hub.
111mm (4.37 in.)
bep|ace wHen |t oes beyond tHe above
va|ue.
Assemb||ng the Rear Whee|
. /ssemb|e |n tHe oppos|te sequence ol tHe
d|smant||n.
1he rear wheel axle.
!orque. 10.00km 7b! lbs
!orque o !he exhaus! pipe.
Lonnec!ion nu!. 1.2km 10! lbs
lix bol!. 3.bkm 2b! lbs
Attent|cn:
wHen assemb||n tHe exHaust p|pe, hrst
lasten tHe connect|on at tHe bend, and
tHen |nsta|| tHe support bo|t.
3
4
Bb/bL C/l
llNlN0
/0J031lN0 N01
Check|ng the rake L|n|ng
. leasure tHe tH|ckness ol tHe
brake ||n|n. bep|ace wHen |t |s
be|ow Z.Cmm |.C/9 |n..
Attent|cn:
0on't a||ow o|| adHere to
tHe ||n|n surlace.
D|smant||ng the Rear rake
3. bemove tHe adjust|n nut
ol tHe rear brake.
4. bemove tHe brake ||n|n.
b. bemove tHe hx bo|t ol
tHe brake arm.
b. bemove tHe brake arm.
/. bemove tHe brake cam.
Assemb||ng the Rear rake
. 3pread rease on tHe mov|n
parts ol tHe ||n|n and ol tHe hx p|n
||ocat|n p|n.
9. 3pread rease on tHe mov|n
part ol tHe brake cam sHalt and
tHen assemb|e |t.
C. lnsta|| tHe brake ||n|n.
Bb/bL C/l llNlN0
9 C
b
b
Bb/bL /bl
ll/ B0l1
. /ssemb|e tHe wear |nd|cat|on board
and tHe brake arm.
Z. /ssemb|e tHe brake arm and tHe brake
cam.
Attent|cn:
lo|nt tHe "u||et' mark ol tHe brake
arm to tHe "dot' mark ol tHe brake
cam, and tHen assemb|e tHem.
3. lnsta|| and t|Hten tHe bo|t ol tHe brake
arm.
4. lnsta|| and t|Hten tHe hx bo|t ol tHe set
arm.
b. lnsta|| tHe return spr|n ol tHe brake
arm.
b. lnsta|| tHe p|n ol tHe brake arm.
/. lnsta|| tHe adjust|n nut ol tHe brake
cab|e.
. /ssemb|e tHe rear wHee| |reler to
3Z.
9. /djust tHe c|earance ol tHe brake |ever
|reler to 3.
D|smcunt|ng the Rear Shcck
. bemove tHe ||d ol tHe body
|reler to ZZ.
Z. bemove tHe case ol tHe a|r h|ter
|reler to 34.
3. bemove tHe top bo|t ol tHe rear sHock.
4. bemove tHe bottom bo|t ol tHe rear
sHock.
b. bemove tHe rear sHock.
3
4
B0110l B0l1
10l B0l1
CH/33l3
Assemb||ng the Rear Shcck
. /ttacH tHe rear sHock.
Z. lnsta|| tHe top bo|t ol tHe sHock.
3. lnsta|| tHe bottom bo|t ol tHe sHock.
4. 1|Hten tHe nuts and tHe bo|ts.

!orque
!op bol!. 4.bkm 30! lbs
o!!om bol!. 3.0km 20! lbs

b. /ssemb|e tHe ||d ol tHe body.
3
4
B0110l B0l1
10l B0l1
CH/33l3
I4. The attery and the Charg|ng System

142
HL/0 l/ll
3wl1CH
b
L
3
l
3
1
0
b /.C. l/0NL10
/010
LNblCHLb
bLC1llYlN0
V0l1/0L
C.Z 0Hl
bw
31/BlllZLb
0/Y
0 Y w b b 0
0/Y 0bLLN/YLll0w 0 0bLLN Y YLll0w w wHl1L 0/Y bL0
+
B/11LbY
ZV4/H
bLC1llYlN0 V0l1/0L
31/BlllZLb
/.C. l/0NL10
l03L
bL3l310b B/11LbY
Tcp|c Fage
lnstruct|ons 4
0|anos|s 4Z
1He battery 43
1He cHar|n system 44
1He rect|ly|n vo|tae stab|||zer 4b
1He maneto cHar|n co|| 4b
CHeck|n tHe res|stor 4b
0|smant||n tHe maneto 4b
Tcp|c Fage
1He CHar|n 3ystem
1est|n sHort c|rcu|t 4/
/ssemb||n tHe manetor 4
1He laneto CHar|n Co|| 49
CHeck|n 1He maneto ||Ht|n co|| 49
CHeck|n tHe bes|stor 49
0|smount|n tHe laneto 49
/ssemb||n tHe laneto 4
Impcrtant Fc|nts
1He e|ectro|yte |d||uted su|lur|c ac|d |s very tox|c. 00 N01 a||ow ac|d to sp|asH onto c|otHes, tHe sk|n
or eyes to protect tHem lrom burn|n. Lye contact w|tH ac|d may cause b||ndness. ln case ol contact
w|tH tHe ac|d, use a |are amount ol c|ean water to NusH and r|nse tHe areas |n wH|cH tHe ac|d came
|nto contact. 3ee a lHys|c|an |mmed|ate|y. ll tHe e|ectro|yte ac|d ets |nto c|otHes, |t w||| permeate to
tHe sk|n. bemove ta|nted c|otHes |mmed|ate|y and tHen put tHem |n water to r|nse.
1He battery can w|tHstand numerous cyc|es ol cHar|n and d|scHar|n as |on as |t |s not |elt |n a
d|scHared cond|t|on lor a |on per|od ol t|me.
ll tHe battery |s overcHared, |t can be detected by c|ose |nspect|on ol tHe battery |tse|l. ll tHe
battery |s exposed to an extreme overcHared cond|t|on, |t can break down and sHort c|rcu|t
|nterna||y. ln tH|s cond|t|on, tHe battery w||| produce zero vo|tae under a|| |oad and cHare cond|t|ons.
/n overcHared battery can "bo|| oll' tHe e|ectro|yte so|ut|on. 1H|s prob|em can be due to excess|ve
t|me on a battery cHarer or a la||ed vo|tae reu|ator.
ll tHe scooter |s |elt to s|t lor a |on t|me or |s stored, tHe battery w||| s|ow|y d|scHare. lt |s
adv|sab|e to recHare tHe battery belore attempt|n to start tHe scooter alter a per|od ol storae.
wHen h|||n a new battery w|tH ac|d, a||ow |t to s|t and "breatH' lor hlteen m|nutes belore |nsta|||n |t
|nto tHe scooter or cHar|n |t. lt |s adv|sab|e to cHare a new battery alter h|||n w|tH ac|d even
tHouH |t may appear to Have sulhc|ent cHare.
wHen work|n on tHe scooter's e|ectr|ca| system, make sure tHat tHe ma|n sw|tcH |s turned oll
and/or tHe battery |s d|sconnected. 0|sconnect|n and reconnect|n ol ||ve c|rcu|ts can cause H|H
|nstantaneous currents tHat can damae tHe battery and cause |njury.
/ny sHortc|rcu|t|n ol tHe w|r|n can cause damae to tHe battery.
!he bol! o !he !rierin coil 0.bkm 40in lbs

!he x bol! o !he coil 0.9km 4! lbs
!he x bol! o !he ywheel 3.8km 2b! lbs
!he bol! o !he coolin an 0.9km 7! lbs
D|agncs|s
Nc pcwer supp|y
Battery overd|scHar|n
Battery w|r|n |mproper
Burnt luse
Broken e|ectro sw|tcH |ock
Unstab|e current
Bad battery w|r|n contact
Bad contact ol d|scHar|n system
loor contact/sHort c|rcu|t ol tHe ||Ht|n
system.
Tcc|
0n|versa| hx|n wrencH
l|y wHee| pu||er
lu|t|meter
Lcw vc|tage
lmproper battery cHar|n
Bad contact
loor cHar|n system
0amaed rect|ly|n vo|t stab|||zer
Fccr charg|ng system
Bad contact, break|n or sHort c|rcu|t
ol tHe w|r|n connector
loor rect|ly|n stab|||zer
0amaed maneto
Item
Z V4/H or ZVb/H
3.V
Z.3V
3tandard: C.4/; last: Z/
3tandard: bC Hrs; last Hr
C.44bw/bCCCrpm
Between ye||owc|ean
Between wH|tec|ean
Z4/bCCC rpm |mu|t|meter, bll meter
3.b +/ C.bV
4.b +/ C.bV/3CCCCCCrpm
bw/4 0Hl
3Cw//.b 0Hl
3|n|e pHase, Ha|lwave 3Cb cHar|n;
3Cb Ha|lwave sHort c|rcu|t mode
Capac|ty/1ype
C..C 0Hl
C.Z.Z 0Hl
bes|stance |ZC`C
bes|stance |ZC`C
1ype
l|m|ted vo|t
Battery
laneto
bes|stor
bect|hn Vo|t
3tab|||zer
lu||y cHar|n
low ||m|t
l|Ht|n
CHar|n
V0l1 |ZC`C
CHar|n C0b
CHar|n Hours
Capac|ty
bes|stance ol ||Ht|n co|| |ZC`C
bes|stance ol cHar|n co|| |ZC`C
Data
Tech Cr|ter|a
Detach|ng the attery
. bemove tHe screws ol tHe battery cover under
tHe Noor mat.
Z. 0pen tHe cover and remove tHe battery cab|e
attacHment screws.
Attent|cn:
l|rst detacH tHe neat|ve | term|na| w|re,
tHen tHe |+ term|na| w|re. wHen detacH|n
tHe pos|t|ve |+ term|na| w|re, make sure
tHat tHe too| does not contact tHe lrame.
3. wHen assemb||n, operate |n tHe oppos|te
sequence ol d|smount|n.
Attent|cn:
ln order to prevent sHort c|rcu|t|n, hrst
connect tHe |+ term|na| w|re, tHen tHe
neat|ve | term|na| w|re
Check|ng the charg|ng
ccnd|t|cn (cpen c|rcu|t vc|t)
. 0pen tHe battery cover and d|sconnect tHe
battery.
Z. leasure tHe vo|tae across tHe term|na|s ol
tHe battery.
lu||y cHared: 3.V
lnadequate|y cHared: Z.3V
Attent|cn:
0se a vo|t meter to cHeck tHe cHar|n
cond|t|on.
Charg|ng
. Connect tHe |+ term|na| po|e ol tHe cHarer
to tHe |+ term|na| po|e ol tHe battery and tHe
neat|ve | term|na| po|e ol tHe cHarer to tHe
neat|ve | term|na| po|e ol tHe battery.
Za
Zb
Attent|cn:
No sparks sHou|d be a||owed around tHe
battery.
1urn oll tHe cHarer hrst, e|tHer at tHe
be|nn|n or tHe end ol tHe cHar|n, to
prevent sparks, wH|cH can cause an
exp|os|on.
wHen cHar|n, operate at tHe current
and t|me marked on tHe battery.
0n|ess |n an emerency s|tuat|on, do not
use last cHar|n.
leasure tHe vo|tae on|y 3C m|nutes
alter cHar|n.
CHar|n current:
3tandard C.4/
last: Z/
CHar|n Hours:
3tandard: bCHrs
last: Hrs.
wHen cHar|n ends:
0penc|rcu|t vo|tae: above Z.V
Ncte: 0ur|n cHar|n, tHe temperature ol tHe
battery |s not a||owed to o beyond 4b`C |C`l.
The Charg|ng System
Test|ng shcrt c|rcu|t
. 0etacH tHe eartH w|re lrom tHe battery.
Z. Connect tHe ammeter between tHe `` term|na|
ol tHe battery and tHe eartH w|re, tHe ma|n sw|tcH
be|n |n tHe "oll' pos|t|on to cHeck wHetHer |t's
sHortc|rcu|ted.
Attent|cn:
1He |+ term|na| term|na| ol tHe mu|t|meter
|s connected to tHe `` po|e ol tHe battery,
wH||e neat|ve | term|na| w|re ol tHe
mu|t|meter |s connected to tHe eartH w|re.
3. wHen an abnorma| s|n appears, cHeck |l
tHere |s a sHort c|rcu|t |n tHe ma|n sw|tcH and tHe
ma|n cab|e.
CHeck|n tHe CHar|n Cond|t|on
. wHen tHe battery |s |n lu|| cHar|n cond|t|on,
use a mu|t|meter to test.
Z. /lter tHe en|ne |s warmed up, |nsta|| tHe
lu||ycHared battery. Connect tHe vo|tmeter
across tHe term|na|s ol tHe battery.
3. bemove tHe ma|n luse and connect tHe
ammeter between tHe term|na|s.
4. Connect tHe bll meter to tHe en|ne.
b. 3tart tHe en|ne, wHen tHe speed ol tHe
en|ne s|ow|y r|ses, measure tHe cHar|n vo|tae
and current.
l|m|t|n Vo|tae/Current:
Be|ow 4bVC.b/ |Be|ow bCCCrpm
wHen tHe ||m|t|n vo|tae oes beyond tHe above
scope, cHeck tHe rect|ly|n vo|tae stab|||zer
|reler to 4b.
3w|tcH los|t|on
bll
ZbCC
bCCC
0ll
>.C/
>.b/
l
>.C/
>.b/
H
>.C/
>.b/
The rect|fy|ng vc|tage stab|||zer
. CHeck|n tHe ma|n cab|e c|rcu|t.
Z. 0etacH tHe 4l p|u lrom tHe
rect|ly|n vo|tae stab|||zer.
3. CHeck tHe conduct|v|ty between
term|na|s ol tHe ma|n cab|e |n tHe
lo||ow|n way:
ltem |matcH|n co|or w|re
Check|ng the Rect|fy|ng
Vc|tage Regu|atcr
. /lter tHe ma|n cab|e Has been
tested and lound norma|, cHeck tHe p|u
ol tHe rect|ly|n vo|tae stab|||zer
contact we|| and measure tHe res|stance
amon tHe term|na|s ol tHe reu|ator.
Attent|cn:
lake sure tHat your hner
doesn't toucH tHe meta| part
ol tHe test bar ol tHe mu|t|meter
because tHe Human body Has
res|stance.
0se a mu|t|meter to test.
1est pos|t|ons per cHart.
Z. wHen tHe res|stance amon tHe
term|na|s |s abnorma|, rep|ace tHe
rect|ly|n vo|tae stab|||zer.
lu|t|meter
lu|t|
meter
wH|te
wH|te
Ye||ow
bed
0reen
3bbCb
bbCCb
bbCCb
Ye||ow bed 0reen
bLC1llYlN0
V0l1/0L
31/BlllZLb
Z
0bLLN
wHl1L
bL0
YLll0w
The Magnetc Charg|ng Cc||
Attent|cn:
1H|s operat|on ol tHe maneto cHar|n
co|| can be accessed w|tH|n tHe en|ne.
Check|ng
. 0etacH tHe connect|n p|u ol tHe maneto.
Z. 0se a mu|t|meter to measure tHe res|stance
between tHe wH|te w|re ol tHe maneto and tHe
round.
Cr|ter|on: C.Z.Z 0Hl |ZC"C
wHen tHe va|ue oes beyond tHe cr|ter|on,
rep|ace tHe maneto co||.
Check|ng The magnetc ||ght|ng cc||
Attent|cn:
1H|s operat|on ol tHe ||Ht|n co|| can be
accessed w|tH|n tHe en|ne.
. 0etacH tHe connect|n p|u ol tHe maneto.
Z. 0se a mu|t|meter to measure tHe res|stance
between tHe ye||ow w|re and tHe round.
Cr|ter|on: C..C0Hl |ZC"C
wHen tHe va|ue oes beyond tHe cr|ter|on,
rep|ace tHe maneto co||.
Check|ng the Res|stcr
. leasure tHe res|stance between tHe res|stor
w|re and tHe round.
Cr|ter|on: 3Cw/.b 0Hl : b.C9.C 0Hl
bw4 0Hl : 3b 0Hl
D|smcunt|ng the Magnetc
. 0etacH tHe r|Ht s|de u|de str|p |reler to Z3
bemove tHe lour bo|ts, lour screws and remove
tHe lan cover.
l/N C0VLb
a
l/0NL10
C0NNLC1lN0 ll00
0l l/0NL10

3. bemove tHe lour bo|ts and remove
tHe coo||n lan.
4. 0se a un|versa| so||d wrencH to
secure tHe NywHee|. 0etacH tHe hx nuts
ol tHe NywHee|.
b. 0se a spanner wrencH Ho|d NywHee|
wH||e remov|n tHe reta|n|n nut.
b. 0se a NywHee| pu||er to remove tHe
NywHee|.
/. bemove and save tHe key.
. 0etacH tHe connect|n w|re ol tHe
maneto.
3b
4 b
C00llN0
l/N
3a
llY wHLLl
0NlVLb3/l
wbLNCH
3l/NNLb wbLNCH
l/N C0VLb
C00llN0 l/N
llY wHLLl
1bl00LblN0
C0ll
l0C/1lN0 bLY
b
4
Z
1bl00LblN0 C0ll
1bl00LblN0 C0ll
3. 0etacH tHe stator ol tHe maneto.
4. bemove tHe bo|ts ol tHe tr|er|n
co||.
b. bemove tHe rubber s|eeve ol tHe
manetor w|re lrom tHe r|Ht
crankcase.
b. bemove tHe tr|er|n co||.
Assemb||ng the Magnetc
. /ttacH tHe tr|er|n co|| to tHe
r|Ht crankcase.
Z. lock tHe hx bo|ts ol tHe tr|er|n
co||.
!orque.
!he !rierin coil. 0.bkm
40in lbs
!he s!a!or. 0.9km 7! lbs
3. 3et up tHe rubber s|eeve ol tHe
maneto w|re.
4. Connect tHe connect|n
w|re ol tHe manetor.
b. C|ean tHe cone part ol tHe
cranksHalt and ol tHe NywHee|.
Be sure to |ay tHe |ocat|n key
ol tHe NywHee| |nto tHe keyway
on tHe cranksHalt prec|se|y.
lo|nt tHe roove ol tHe NywHee|
to tHe |ocat|n key on tHe
cranksHalt and tHen assemb|e
|t.
Attent|cn:
lake sure tHat tHere
|s no bo|t/nut |ns|de
tHe NywHee|, and tHen
assemb|e |t.
b. 0se a un|versa| so||d wrencH
to Ho|d tHe NywHee|, and tHen
|ock tHe nut.
!orque. 3.8m

/. 3et up tHe coo||n lan
!orque. 0.9km
b
4b
b
llY wHLLl
0NlVLb3/l
wbLNCH
3l/NNLb wbLNCH
/a
C00llN0
l/N
/b
l/0NL10
l0C/1lN0 bLY
C0NNLC1lN0 ll00
0ll/0NL10
4a
. lnsta|| tHe lan cover and secure|y
t|Hten lasteners.
l/N C0VLb
Ib. Ign|t|cn System

l03L
l/lN
3wl1CH
C0l
0Nl1
l0Nl1l0N
C0ll
3l/bb
ll00
B Bl/Y 0 B/Y
B Bl0L Bl/Y Bl0L/YLll0w BY Bl/Cb/YLll0w 0 0bLLN
+
B/11LbY
ZV4/H
l/lN 3wl1CH
C0l
/.C. l/0NL10
llCb0l C0ll
3l/bb ll00
Ib. Ign|t|cn System
Tcp|c Fage
0enera| lnlormat|on bZ
1roub|esHoot|n b3
C0l un|t |nspect|on b4
ln|t|on Co|| bemova| 3teps bb
laneto l|ckup Co|| lnspect|on bb
3park /dvance /n|e lnspect|on bb
Genera| Infcrmat|cn
CHeck |n|t|on system |n accordance w|tH tHe
troub|esHoot|n procedure |n 3ect|on bZ.
/s tHe |n|t|on system Has an e|ectr|c
automat|c spark contro| |n tHe C0l un|t, tHere |s
no need lor spark advance an|e adjustment.
C0l sHou|d not be d|sconnected or subjected
to |nput. 0amae or la||ure can occur.
loor contact may be tHe cause ol many lau|ty
|n|t|on system cases. CHeck a|| term|na|
connect|ons to be sure tHey are c|ean and t|Ht
wHenever troub|esHoot|n an e|ectr|ca| prob|em.
lake sure spark p|u Heat rane |s correct.
0s|n an |ncorrect spark p|u w||| resu|t |n
|mproper en|ne operat|on or spark p|u
damae.
leak vo|tae |s used as relerence po|nt |n
tests. becord co|| res|stance tests.
wHen |nspect|n spark p|u, reler to re|ated
|nstruct|ons |n CHapter 3.
wHen remov|n /C enerator and p|ckup co||,
reler to |nstruct|ons |n CHapter 4.
Item
Reference Standard
|N0bC/H3/ CHamp|on Z9Y
|N0bCbH3/
|N0bCH3/
C.bC./mm
3` +/ ` |ZCCCr/m|n
C..C 0Hl
/9b 0Hl
34b 0Hl
C 0Hl
0ver ZCV
0ver Z.V
3pec|hc spark p|u
ln|t|on co|| res|stance
3park p|u ap
3park advance an|e
3tandard
Hot
Co|d
w|tH cap
w|tHout cap
lax|mum advance |n `l` pos|t|on
lr|mary co||
3econdary co||
Standard va|ve
l|ckup co|| res|stance
lr|mary |n|t|on co|| peak vo|tae
l|ckup co|| peak vo|tae
Ib. Ign|t|cn System
Trcub|eshcct|ng
H|gh Tens|cn Vc|tage Tcc Lcw
CranksHalt revo|ut|on too s|ow or battery
vo|tae too |ow
ln|t|on system w|r|n |oose
lau|ty |n|t|on co||
lau|ty C0l un|t
lau|ty p|ckup co||
H|gh Tens|cn Vc|tage Interm|ttent
lau|ty ma|n sw|tcH
loor C0l term|na| connect|on
loor C0l round
lau|ty p|ckup co||
loor H|Htens|on |ead term|na| connect|on
lau|ty C0l un|t
H|gh Tens|cn Vc|tage Ncrma| but Nc Spark
lau|ty spark p|u
lau|ty spark p|u cap
No H|H 1ens|on Vo|tae
lau|ty ma|n sw|tcH
Battery d|scHared or lau|ty rect|hcat|on
system
lau|ty cHare system
lau|ty |n|t|on co||
lau|ty C0l 0n|ted Lqu|ne loundat|on No
Interm|ttent H|gh Tens|cn Vc|tage
lau|ty |n|t|on co||
Battery vo|tae too |ow
lau|ty cHare system
Ib. Ign|t|cn System
CDI Inspect|cn
. bemove tHe tHree screws lrom tHe
battery case cover.
Z. 0|sconnect tHe C0l modu|e lrom tHe w|re
Harness.
3. 1est res|stance ol tHe term|na|s w|tH a
mu|t|meter.
Attent|cn:
3|nce tHere |s a sem|conductor |n
return c|rcu|t, test|n resu|ts may be
s|n|hcant|y d|llerent |l d|llerent mu|t|
meters are used.
ll tHe po|nter on tHe d|a| N|ckers and
hna||y stops dur|n test|n, |t sHou|d
be rearded as norma|. Because tHe
capac|tor |n tHe C0l modu|e |s
cHared wH||e be|n tested, |t cannot
d|scHare.
Z
3
Bl0L/YLll0w
Bl/Cb/YLll0w
0bLLN
Bl/Cb/bL0
Bl/Cb/wHl1L
Ib. Ign|t|cn System
Ign|t|cn Cc|| Remcva| Steps
. bemove tHe m|dd|e box.
Z. bemove tHe spark p|u cap.
3. 0|sconnect tHe w|res, remove tHe |n|t|on
co|| jam nuts and remove tHe |n|t|on co||.
lnspect|on
4. CHeck tHe |n|t|on co|| c|rcu|t. 1He spark
advance an|e does not need to be adjusted.
ll tHe spark advance |s abnorma|, cHeck tHe
C0l, p|ckup co|| or maneto. bep|ace tHe
|n|t|on co|| |l necessary.
b. 1est tHe pr|mary co|| res|stance, tHe
standard va|ue ol wH|cH sHou|d be C..C.
b. 1est tHe secondary co|| res|stance lrom
spark p|u cap neat|ve term|na|s. 1He
standard va|ue sHou|d be /9k |w|tH cap
and 34k |w|tHout cap.
/. 1est co|| us|n altermarket spark tester.
. lerlorm tHe lo||ow|n |nspect|on |n
accordance w|tH tHe operat|n |nstruct|ons |n
tHe manua|.
a. 3et tHe |n|t|on co|| tester sw|tcH
to ZV and connect tHe tester to
tHe |n|t|on co||.
b. 1urn tHe sw|tcH to tHe 0N pos|t|on
to cHeck spark lrequency lrom tHe
|nspect|on door.
ln ood cond|t|on: 3park|n cont|nuous|y
ln lau|ty cond|t|on: 3park|n abnorma||y.
Ib. Ign|t|cn System
l/N C0VLb
Magnetc F|ckup Cc|| Inspect|cn
1H|s test |s to be conducted w|tH
tHe stator mounted |n tHe en|ne.
. bemove tHe lan cover.
Z. 0|sconnect tHe maneto.
3. 1est tHe p|ckup co|| res|stance between
tHe b|ue/ye||ow and reen |ead term|na|s
wHose standard va|ue |s CbC.
4. 0|smount|n tHe maneto |reler to
4b.
Charg|ng Cc|| Inspect|cn
. 1est tHe cHar|n co|| res|stance
between tHe b|ack/red and tHe reen |ead
term|na|s wHose standard va|ue |s bCCbCC .
Spark Advance Ang|e Inspect|cn
3|nce a C0l |s used, tHere |s no need
to adjust tHe t|m|n advance.
ll tHe spark advance |s abnorma|,
|nspect C0l, p|ckup co|| or maneto.
bep|ace |l necessary.
3. bemove t|m|n ||d.
4. /lter tHe en|ne |s warmed up, cHeck
tHe spark advance an|e by tHe spark t|m|n
|amp. lt |s proper lor "l' to a||n w|tH + Z`
w|tH tHe en|ne revo|v|n at a speed ol
/CCrpm.
1He spark advance an|e sHou|d be 3` +
` |ZCCCr/m|n.
l/0NL10
Z
Ib. Starter System
l03L
31/b1
l010b
B/11LbY
lb0N1
l/lN 3wl1CH
Bb/bL
3wl1CH
bL/b
Bb/bL
l/ll
B bL0 Y/b YLll0w/bL0 0/Y 0bLLN/YLll0w 0 0bLLN
0
b
bLl/Y
b
0/Y
Y/b
l03L |C/
0
0
31/b1 3wl1CH
Bb/bL 3wl1CH Bb/bL 3wl1CH
bLl/Y
31/b1Lb
Ib. Starter System
1He starter motor can be removed w|tHout
d|sassemb|y ol tHe en|ne.
Fastener Tcrque Spec|hcat|cn
3tarter motor c|utcH cover bo|t
.Zkm 9 lt |bs
3tarter motor c|utcH jam nut
9.bkm bbblt |bs
Hex key
0pen end wrencHes
Trcub|eshcct|ng
Starter Mctcr Dces Nct Turn
luse broken
Battery d|scHared
lau|ty ma|n sw|tcH
lau|ty starter c|utcH
lau|ty brake sw|tcH
Tcp|c Fage
0enera| lnlormat|on bZ
1roub|esHoot|n bZ
3tarter lotor bemova| b3
3tarter 0|sassemb|y b3
3tarter lnspect|on b3
lnspect|n tHe 3tarter be|ay bb
Tcp|c Fage
3tarter lotor lnspect|on bb
3tarter lotor lnsta||at|on bb
3tarter l|n|on bemova| b/
3tarter l|n|on lnspect|on b/
3tarter l|n|on lnsta||at|on b/
Genera| Infcrmat|cn
Item
Insta||at|cn Reference Standard
.b mm |.33b |n. b mm |.Z |n. 3tarter motor brusH |entH
Standard va|ve Wear L|m|t
Starter Mctcr Turns Dver S|cw|y
Battery d|scHared
loor or lau|ty cab|e connect|ons
3tarter motor ear se|zed by a lore|n object
Starter Mctcr Turns - Eng|ne Dces Nct Rctate
lau|ty starter c|utcH
3tarter motor reversa|
Battery d|scHared
Ib. Starter System
Starter Mctcr Remcva|
Never work on tHe starter
motor unt|| ma|n sw|tcH |s
turned oll and tHe battery
round w|re |s
d|sconnected to ensure
tHat tHe motor cannot
turn.
. bemove tHe starter motor
|ead c|amp.
Z. bemove tHe two bo|ts and
remove tHe starter motor.
3. bo|| up tHe waterprool rubber
cover to d|sconnect tHe starter
motor.
Starter D|sassemb|y
. bemove tHe two case bo|ts
and remove tHe motor Hous|n
lrom tHe |nterna| parts.
Starter Inspect|cn
Z. lnspect brusHes and
commutator lor wear, damae or
d|sco|orat|on. bep|ace |l
necessary.
3. C|ean attacHed meta| part|c|es
lrom tHe commutator surlaces.
4. leasure tHe res|stance
between eacH contact surlace ol
tHe components.
b. lake sure tHere |s no
conduct|on current between eacH
commutator sement and tHe
armature sHalt.
Z
3a
a b
31/b1Lb l010b
H003lN0
3b
Ib. Starter System
b. CHeck tHe starter motor
Hous|n conduct|v|ty. Be sure
tHere |s no conduct|on current
between tHe cab|e term|na| and
tHe starter motor Hous|n.
/. CHeck conduct|v|ty between
tHe |ead term|na| and tHe brusH.
bep|ace tHem |l necessary.
. leasure tHe brusH |entH. lts
serv|ce ||m|t |s bmm |.Z |n..
bep|ace |t |l necessary. CHeck
brusH Ho|der lor conduct|on
current. bep|ace |l necessary.
9. lnspect bear|n |n lront
bracket lor smootH rotat|on and
lor |ooseness wHen |nsta||ed.
bep|ace |t |l necessary. lnspect
dust cover lor wear or damae.
b
9
0ll 3L/l
BL/blN0
Ib. Starter System
C. /pp|y rease to tHe dust cover.
. lnsta|| spr|n brusH |n |ts Ho|der.
Z. /pp|y a ||Ht h|m ol rease to botH ends ol
tHe s||d|n surlaces ol tHe armature sHalt.
3. lnsta|| armature |n lront bracket.
lake sure tHe surlaces between tHe
brusH and tHe armature are not
damaed.
Be sure tHe dust cover ||p |s not
damaed by tHe armature mount sHalt.
4. lnsta|| a new or|n |n lront bracket.
b. Lnae motor Hous|n w|tH tHat ol lront
bracket. lnsta|| two Hous|n bo|ts.
wHen ena|n tHe Hous|n w|tH tHe
lront bracket, |nsta|| tHe armature hrst,
Ho|d tHe armature sHalt and tHen |nsta||
tHe Hous|n |n case tHe armature |s
drawn out by tHe manet.
Starter Re|ay Inspect|cn
. bemove r|Ht s|de body pane|.
Z. w|tH ma|n sw|tcH |n tHe "on'
pos|t|on, depress tHe starter button
to cHeck lor a c||ck, wH|cH |nd|cates
proper operat|on ol re|ay. ll starter
button |s depressed w|tHout a c||ck,
perlorm tHe lo||ow|n steps.
1est starter re|ay vo|tae.
lnspect starter re|ay round
return c|rcu|t.
lnspect starter re|ay.
C
Z
3
b
0031 C0VLb
/bl/10bL
3H/l1
/bl/10bL
3H/l1
lb0N1
Bb/CbL1
Ib. Starter System
3. 1o |nspect starter re|ay vo|tae: 3tand tHe
scooter on |s center stand, measure tHe vo|tae
between tHe starter re|ay neat|ve term|na|
|reen/ye||ow cab|e and tHe round.
1urn tHe ma|n sw|tcH to "on', pu|| tHe brake
|evers and make sure tHe battery vo|tae |s
ava||ab|e at tHe re|ay |Z vo|ts. ll tHere |s no
battery vo|tae, |nspect tHe brake sw|tcH
e|ectr|ca| conduct|v|ty and w|r|n.
Tc |nspect starter re|ay:
. bemove tHe r|Ht s|de body pane|.
Z. 0|sconnect tHe starter re|ay un|t coup|er
lrom tHe w|re Harness and remove |t. 0se oHm
meter or cont|nu|ty tester to cHeck co||.
3. Connect tHe meter to term|na|s card 0.
1H|s c|rcu|t sHou|d read c|osed. 0se oHm meter
or cont|nu|ty tester C.
4. CHeck contactor.
b. Connect tHe meter to term|na|s / and B.
1H|s c|rcu|t sHou|d read open w|tH term|na|s C
and 0 d|sconnected and read c|osed w|tH
term|na|s C and 0 app||ed to Z vo|t supp|y.
Starter Mctcr Insta||at|cn
. /pp|y rease to tHe starter motor or|n
and |nsta|| tHe starter motor.
Z. lnsta|| tHe two bo|ts.
3. Connect tHe starter motor term|na|s to tHe
Harness.
/
B
C
0
b
Z
Ib. Starter System
3. bemove tHe lour bo|ts and remove
tHe coo||n lan.
4. 0se a un|versa| so||d wrencH to
secure tHe NywHee|. 0etacH tHe hx nuts
ol tHe NywHee|.
b. 0se a spanner wrencH Ho|d NywHee|
wH||e remov|n tHe reta|n|n nut.
b. 0se a NywHee| pu||er to remove tHe
NywHee|.
/. bemove and save tHe key.
. 0etacH tHe connect|n w|re ol tHe
maneto.
3b
4 b
C00llN0
l/N
3a
llY wHLLl
0NlVLb3/l
wbLNCH
3l/NNLb wbLNCH
I7. Meters, Sw|tches and L|ght|ng System

Dperating Points
/|ways be sure tHat co|ors matcH wHen w|res are connected, tHat w|res are |nsta||ed |n Harness tube or
supported by |nsu|at|n tape alter connect|on and tHat connectors matcH w|re co|or |n assemb|y.
lake sure connectors ht proper|y to assure connect|on.
Be sure to a|ways test sw|tcH operat|on alter |nsta||at|on.
Tcp|c Fage
la|ntenance |nlormat|on /Z
1roub|esHoot|n /Z
lue| 3ensor bemova| /3
lue| 3ensor lnsta||at|on /3
lue| 3ensor 1est|n /3
lue| 0aue lnspect|on /3
Hand|ebar sw|tcH /Z
l|Ht 3w|tcH lnspect|on /4
3tarter 3w|tcH lnspect|on /4
0|mmer 3w|tcH lnspect|on /4
1urn l|Ht 3w|tcH lnspect|on /4
Ln|ne 3top 3w|tcH lnspect|on /4
Horn 3w|tcH /b
Tcp|c Fage
bep|ac|n tHe Horn 3w|tcH /b
la|n 3w|tcH lnspect|on /b
bep|ac|n tHe la|n 3w|tcH /b
Brake l|Ht 3w|tcH lnspect|on /b
Horn lnspect|on /b
bep|ac|n tHe Horn 3w|tcH /b
3peedometer bemova| and /b
be|nsta||at|on
Head||Ht bemova| and lnsta||at|on //
Bu|b bep|acement and lnsta||at|on //
1a||||Ht, brake ||Ht, rear //
pos|t|on ||Ht or ||cense ||Ht
Ma|ntenance
Trcub|eshcct|ng
ll tHe brake ||Ht or turn ||Ht la||s to come on
w|tH tHe |n|t|on sw|tcH "0N,' |t may be
caused by:
Bad bu|b
lau|ty sw|tcH
lead broken
luse b|own
Battery d|scHared
lau|ty w|re matcH|n
Bad NasHer
If the fue| |nd|catcr fa||s tc ccme cn:
lead d|sconnected
w|re broken
lmproper Noat operat|on
lau|ty lue| sensor
Bad meter
If ||ght |s d|m:
lau|ty maneto ||Ht|n co||
Lxcess|ve vo|tae at matcH|n w|re or
sw|tcH
lau|ty rect|her reu|ator
If the d|mmer sw|tch dces nct cperate
proper|y:
Bad bu|b
lau|ty sw|tcH
If fue| |nd|catcr pc|nter mcves
unstead||y:
loose |ead connect|on
lau|ty lue| sensor
lau|ty meter
Fue| Senscr Remcva|
/vo|d sparks and Names wHen work|n
on tHe lue| system.
. bemove tHe m|dd|e |uae box.
Z. bemove tHe r|Ht body pane|.
3. 0|sconnect tHe lue| sensor lrom tHe w|re
Harness.
4. bemove tHe bo|t ol tHe lue| sensor.
lake sure not to damae tHe lue|
sensor |ead.
b. bemove tHe lue| sensor.
Be sure tHat tHe lue| sensor Noat |s not
damaed.
Fue| Senscr Insta||at|cn
b. beverse tHe remova| procedure lor
|nsta||at|on.
/. Be sure to a||n tHe roove on tHe lue|
sensor w|tH tHe mark on tHe lue| tank.
. 1He mark on tHe sensor sHou|d be a||ned
w|tH tHat on tHe lue| tank.
Fue| Senscr Test|ng
. bemove tHe lue| sensor.
Z. leasure tHe res|stance ol eacH term|na|
w|tH tHe Noat |n eacH pos|t|on.
Fue| Gauge Inspect|cn
w|tH tHe |n|t|on sw|tcH "0N,' connect tHe |ead.
1urn on tHe turn s|na| to be sure tHe
batteryreturn c|rcu|t |s |ntact belore perlorm|n
tHe |nspect|on. CHeck tHe aue read|n by
cHan|n tHe Noat pos|t|on.
Lead Term|na|
/+/ Z 0Hl 9b+/ Z 0Hl 0reeB|ue/wH|te
F|cat Up F|cat Dcwn
l|oat los|t|on
l
L
0p
0own
bead|n
4
Hand|ebar Sw|tches Inspect|cn
. bemove tHe speedometer cover.
Z. 0|sconnect tHe Hand|ebar connector and
cHeck eacH term|na| lor conduct|on.
3. lnspect eacH sw|tcH |l abnorma|.
L|ghts Sw|tch
Co|or B|ue/wH|te Ye||ow Brown Brown/wH|te l|nk
Code Bl/w Y Br Br/w l
D|mmer Sw|tch
Co|or B|ue/wH|te B|ue wH|te
Code Bl/w B| w
Starter Sw|tch
Co|or Ye||ow/bed 0reen
Code Y/b 0
be|eased
0epressed
3et an 0Hm meter at / 0Hl wHen us|n |t.
H|
lo
Turn L|ght Sw|tch
Co|or B|ue/wH|te B|ue wH|te
Code
b
0ll
l
0r lB| 0
Eng|ne Stcp Sw|tch
B|ack B|ack Z
bun
3top
YLll0w
YLll0w/bL0
llNb
0bLLN
Bb0wN/wHl1L
Bb0wN
Bl0L/
wHl1L
YLll0w/bL0
0bLLN
ll0H1 Bl0L
0b/N0L
0b/Y
Bl/Cb
wHl1L
ll0H1 Bl0L Bl0L
Bl/Cb/
wHl1L
Rep|ac|ng the hcrn sw|tch:
. bemove tHe lront pane|.
Z. bemove tHe Hand|ebar cover.
3. 0|sconnect tHe w|re connector.
4. bemove sw|tcH lrom Hous|n.
b. beverse tHe remova| procedure lor
|nsta||at|on.
Ma|n Sw|tch Inspect|cn
Z. 0|sconnect tHe ma|n sw|tcH w|re
connector to cHeck tHe connect|on at eacH
term|na|.
Rep|ac|ng the ma|n sw|tch:
Z. 0|sconnect tHe ma|n sw|tcH w|re
connector.
3. bemove tHe two mount|n bo|ts and
remove tHe ma|n sw|tcH.
4. beverse tHe remova| procedure lor
|nsta||at|on.
Ma|n Sw|tch
Co|or
Code b B B/w 0
0n
0ll
bed B|ack B|ack/wH|te 0reen
Hcm Sw|tch
Co|or l|Ht 0reen Bl/Cb
Code l0 B
be|eased
0epressed
0bLLN
0bLLN
Bl/Cb
ll0H1 0bLLN
Bl/Cb
Bl/Cb/
wHl1L
bL0
rake L|ght Sw|tch Inspect|cn
Z. 0|sconnect tHe lront brake sw|tcH |ead.
3. 0perate tHe lront brake |ever to cHeck tHe sw|tcH
lor proper operat|on.
4. 0|sconnect tHe rear brake sw|tcH w|re connector.
b. 0perate tHe rear brake |ever to cHeck lor proper
operat|on.
b. 1He above tests can be conducted w|tH a
cont|nu|ty tester or oHm meter.
Hcrn Inspect|cn
Z. 0|sconnect tHe Horn w|re connector and connect
tHe term|na| to a battery |ZV.
3. 1He Horn |s ood |l |t sounds proper|y.
4. CHeck operat|on ol sw|tcH w|tH oHm meter or
cont|nu|ty tester.
Tc rep|ace the hcrn sw|tch:
b. 0|sconnect tHe Horn sw|tcH w|re connector.
b. bemove tHe mount|n bo|t.
/. bemove tHe Horn.
. beverse tHe procedure lor |nsta||at|on.
Speedcmeter Remcva| and Re|nsta||at|cn
. bemove lront and rear Hand|ebar covers |reler to ZZ.
Z. 0|sconnect a|| tHe w|r|n connectors.
3. bemove tHe tHree set screws and speedometer.
4. beverse tHe remova| procedure lor |nsta||at|on.
Head||ght Remcva| and Insta||at|cn
. bemove tHe speedometer cover |reler
to Z.
Z. bemove tHe Head||Ht adjustab|e bo|t.
3. bemove tHe a||nment p|n and
Head||Ht.
4. beverse tHe remova| procedure lor
|nsta||at|on.

Be sure to a||n tHe Head||Ht
tab w|tH roove |n odometer
cover.
1He Head||Ht beam sHou|d be
adjusted alter |nsta||at|on |3Z.
u|b Rep|acement and Insta||at|cn
Z. bemove tHe Head||Ht or lront marker
||Ht bu|b lor rep|acement.
3. beverse tHe procedure lor |nsta||at|on.
Ta||||ght, brake ||ght, rear pcs|t|cn
||ght cr ||cense ||ght
. bemove tHe two screws |n tHe rear
pane|.
Z. bemove tHe rear pane|, two set
screws |n rear ||Ht cover and ||Ht cover.
3. bemove tHe ||Ht bu|b lor rep|acement.
4. beverse tHe procedure lor |nsta||at|on.
HL/0ll0H1
/0J031/BlL B0l1
Z
/ll0NlLN1 llN
HL/0l/ll
3
UNDERSIDE DF CDVER
A. Electric Scooter Assembly
Topic Page Topic Page
Important Points
The electrolyte (diluted sulfuric acid) is very toxic. DO NOT allow acid to splash onto clothes, the skin
or eyes to protect them from burning. Eye contact with acid may cause blindness. In case of contact
with the acid, use a large amount of clean water to ush and rinse the areas in which the acid came
into contact. See a Physician immediately. If the electrolyte acid gets into clothes, it will permeate to
the skin. Remove tainted clothes immediately and then put them in water to rinse.
The batteries can withstand numerous cycles of charging and discharging as long as it is not left in a
discharged condition for a long period of time.
If one of the batteries are overcharged, it can be detected by close inspection of the battery itself.
If the battery is exposed to an extreme overcharged condition, it can break down and short circuit
internally. In this condition, the battery will produce zero voltage under all load and charge conditions.
An overcharged battery can boil off the electrolyte solution. This problem can be due to excessive
time on a battery charger or a failed voltage regulator.
If the scooter is left to sit for a long time or is stored, the battery will slowly discharge. It is
advisable to recharge the battery before attempting to start the scooter after a period of storage.
When lling a new battery with acid, allow it to sit and breath for fteen minutes before installing it
into the scooter or charging it. It is advisable to charge a new battery after lling with acid even
though it may appear to have sufcient charge.
When working on the scooters electrical system, make sure that the main switch is turned off
and/or the battery is disconnected. Disconnecting and reconnecting of live circuits can cause high
instantaneous currents that can damage the battery and cause injury.
Any short-circuiting of the wiring can cause damage to the battery.
Important points A-2
Scheduled Maintenance A-3
Specications A-4
Troubleshooting A-4
Rear Wheel Dismantling A-5
Rear Wheel Removal A-5
Electric Motor Removal A-8
Motor Dissasembly A-10
Recharging Batteries A-16
Torque
The nut of the rear wheel axle 10.0kgm 75ft lbs
The top of the rear buffer 4.5kgm 30ft lbs
The bottom bolt of the rear buffer 3.0kgm 20ft lbs
The connection nut of the silencer 1.2kgm 10ft lbs
The x bolt of the silencer 3.5kgm 25ft lbs
Torque Settings A-2
Motor Inspection A-12
Battery Access and Power A-13

Perform regular maintenance onthe foll owing parts as the chart indicates.
C = Clean
L = Lubricate
I = Inspect, check, fix, replace when necessary
Mil eage (km) Frequency
Item
124
( 200)
621
( 1000)
1864
( 3000)
3107
( 5000)
4972
( 8000)
6215
( 10000)
7458
( 12000)
Controll er C C
Charger I I
Front/rear detent I I I
Wheel bearing I I
Front/rear suspension I I
Front fork bearing I I
Tire I I
Major side kickstand L L I
All other body parts L L L I
All screws & nuts I I I I I
Motor bearing I I
I f riding the vehicle in dusty or rainy areas, perform maintenance more frequently.
Scheduled Maintenance

No. Description Specifi cations No. Description Specifi cations
1 Product Si ze
1700x760x1180mm
13 Speedchanging Automatic
2 Tread 1180 mm 14 Motor type
B l ushless motor
3
Mi nimum cl earance
from ground
110 mm 15 Rated power 750W
4 N. W 90 kg 16 Rated current 22A
5 L oad weight <80 kg 17 Rated voltage 48V
6 Maximum speed >40 kg 18
Worki ng effi ci ency
>72%
7 Mil eage per
charge
<40 kg 19 Battery
Seal ed, free
protective, l ead-
aci d battery
8 Brake distance <4.5 m 20 Battery capacity 12V 17Ahx4
9 Brake ways M/M 21 Charger American
10 Climbing ability >8 22 Tire 3.0-10-4PR
11 Max torque 20 N. M 23
Wheel Pr essure
( FR /R R )
175/225 (kpa)
12 Max noise 64dB(A)
Problem Cause Solution
Scooter does not start. No power Charge or replace
battery/batteries.
Battery connection poor Reconnect battery
terminals.
Scooter runs weak. Weak battery Recharge or replace
batteries.
Scooter starts but doesnot
move.
Motor inoperative Replace 750W motor.
Specifications
Troubleshooting

Dismantling and Removing Rear Wheel Assembly
1. Loosen and remove brake cable
mount from Brake Arm.

Attention:
Exercise caution when loosening
and removing cable tension spring
2. Loosen and remove brake cable
tension spring from Brake Arm.
3. Loosen and remove fasteners
securing anti-rotational bracket onto
frame and rear wheel axle.

Dismantling the Rear Brake
4. Remove the adjusting nut
of the rear brake.
5. Remove the x bolt of
the brake arm.
6. Remove the brake arm.
7. Remove the brake cam.
When Assembling the Rear Brake
A. Spread grease on the moving
parts of the lining and of the x pin
(locating pin).
B. Spread grease on the moving
part of the brake cam shaft and
then assemble it.
C. Install the brake lining.
8. Remove anti-rotational brackets.
9. Remove smaller restraining bracket
10. Remove restraining bolt.

11. Assemble the wear indication board
and the brake arm.
12. Assemble the brake arm and the brake
cam.
Attention:
Point the gullet mark of the brake
arm to the dot mark of the brake
cam, and then assemble them.
13. Install and tighten the bolt of the brake
arm.
14. Install and tighten the x bolt of the set
arm.
15. Install the return spring of the brake
arm.
16. Install the pin of the brake arm.
17. Install the adjusting nut of the brake
cable.
18. Assemble the rear wheel (refer to
13-2).
19. Adjust the clearance of the brake lever
(refer to 13-8).

20. Slide rear wheel away from frame
mounting slots.
21. Slowly remove rear wheel from
cam.

Attention:
Give particular attention to the power
cable, when removing rear wheel.
22.Carefully loosen all four mounting bolts
securing electric motor to rear wheel.

Attention:
The 750 watt electric motor is very
heavy. Exercise caution while
removing motor mounting bolts.
1. Loosen and remove four mounting
bolts securing 750 watt motor to rear
wheel.

Electric Motor Removal

2. Carefully place rear wheel onto ground with
electric motor facing upwards.
3. Using a flat-head screwdriver, cautiously pry
the electric motor from the rear wheel rim.
4. Lift and remove electric motor from wheel
assembly.
5. Loosen set screw securing collar to
motor spindle.
6. Remove and place collar set screw in
secure place for reuse.

1. Using the proper screwdriver or bit type
and size, carefully loosen each screw that is
securing the motor cover, .
2. Remove each screw and set aside for reuse.
3. Gently lift and remove the collar from the
motor spindle.
Attention:
Removing the screws in a diagonal pattern
is recommended to avoid stripping and
damaging the screws and the threads.
Attention:
Exercise caution with the power cable
when removing set collar.
Motor Disassembly

4. Once again, using a flat-head screwdriver,
carefully pry motor cover from the motor assembly.

Attention:
Use very mild and steady force when prying,
to avoid damaging motor housing and coils.
Attention:
Always exercise caution
when using any tool to pry
one surface from another.
5.Gently lift and remove the motor cover
from the motor assembly.

1. Carefully lift and remove motor coil sub-assembly
from motor housing.

Attention:
Once again, exercise caution when
removing motor sub-assembly to avoid
damaging motor coils.
2. Thoroughly inspect coils and coil wires for damage.

Motor Inspection
1. Loosen and remove fasteners securing left and
right side panels.
2. Loosen and remove fasteners securing floor panels
and panel beneath scooter seat.
3. Carefully remove body panels (as shown).

Attention:
Exercise caution when
removing body panels and
fasteners to avoid damage.
Battery Access and Power

4. Access battery power switch located in
rear storage compartment of scooter.
5. Remove power to motor by flipping the
power switch to the OFF position.
Attention:
Be sure not to sperate the ground wire
connections that are seperate for the
connector.
Attention:
Confirm that power is removed
from motor before beginning
work on vehicle
6. Once power has been removed, disconnect
power connection to motor by carefully unclipping
and seperating the wire connectors
Attention:
Confirm that power is removed from motor
before disconnecting and removing batteries
7. Loosen and remove fasteners securing battery
restraining bracket.
8. Remove bracket.
9 Disconnect battery terminals.
Battery Access and Removal
Attention:
Disconnect and reconnect
positive terminal first, followed
by the negative battery terminal.
10. Use a volt meter to check
battery voltage (as shown).
Recharging Batteries
1. Access charging input recepticle, located
inside scooter rear storage compartment.
3. Allow batteries to continue charging until
indicator shows that batteries are fully charged.

2. Plug charger into charging recepticle as well
as into wall outlet (standard AC).

B. Retro Model Scooter Panels
C. Scooter Panels

Baotian Service Manual

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4 STROKE ENGINE

SERVICE AND REPAIR MANUAL

b. Eng|ne Remcva| and Insta||at|cn

7. Cy||nder Head Va|ve

V/lVL lllL bL/lLb

Check|ng the Start|ng F|vct

b. lnsta|| tHe cam cHa|n

IZ. The Frcnt Whee|, Frcnt rake,

!he s!eerin lever 4.0b.0km 30! lbs

10l B/ll b/CL

Detach|ng the Rear Whee|

I4. The attery and the Charg|ng System

!he bol! o !he !rierin coil 0.bkm 40in lbs

I4. The attery and the Charg|ng System

I4. The attery and the Charg|ng System

Ib. Ign|t|cn System

I7. Meters, Sw|tches and L|ght|ng System

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