Motive Power PGO Specifications

PREFACE

This manual offers all service specialists with the technological procedures of maintenance, repairing for LIGERO-50 detailedly show those whom may concern how to maintain, repair, change parts, troubleshoot and reassemble, etc.

At every important section we illustrate by assembly, explosion diagrams and photographs, if necessary, please check the diagrams already shown.

Though we have tried our best, please kindly instruct us any faults found in this manual.

MOTIVE POWER INDUSTRY CO., LTD.

CONTENTS

1.

The specification 4

2.

Service information 5

(1)The operation notice 6

(2)Looking torque value 7

(3)Lubrication instruction 9

(4)Wiring diagram 12

(5)Troubleshooting 13

3.

Checking and adjustment 19

(1)Checking table 20

(2)Battery 24

(3)Clean the air cleaner 25

(4)Oil screen 26

(5)The final reduction mechanism oil 26

(6)Spark plug 27

(7)Compression pressure measurement 27

(8)Valve clearance 28

(9)Ignition timing 28

(10)

Idle Adjustment 29

(11)

Front brake adjustment 29

(12)

Rear brake adjustment 30

(13)

Tire 30

(14)

Throttle cables adjustment 31

4.

Dismantling, maintaining, repairing and assembling operation 32

(1)Lubrication system 33

(2)Plastic parts of chassis 37

(3)Engine dismantling 42

(4)Drive pulley, starter, clutch,driven pulley 44

(5)Cylinder head and valve 53

(6)Cylinder and piston 58

(7)AC generator flywheel 63

(8)Final transmission mechanism 66

(9)Crankcase, crank shaft 70

(10)

Carburetor 74

(11)

Steering stem, front wheel, front brake comp., front fork 78

(12)

Rear wheel, rear brake, rear damper 87

(13)

Fuel tank, oil tank 92

5.

Electric equipment 95

(1)Troubleshooting 96

(2)Battery 97

(3)Recharge system 99

(4)Ignition system 101

(5)Starting system 103

(6)Starting clutch 105

(7)Handle bar switch 107

SPECIFICATIONS

Model

Overall Length

Overall width

Overall height

Seat height

Wheelbase

LIGERO-50

1780mm

645mm

1060mm

770mm

1210mm

Transmission

Primary reduction

Secondary ratio

Direct

52/13*44/13

110CC

Dry weight

Engine Model

Piston displacement

Bore

Stroke

Compression ratio

Ignition

Clutch

Shifting

99kgs

P2

49CC

40.0mm

Frame

Front fork

Steel pipe

Telescopic

Rear cushion Uni-absorber

Front tire 3.50-10 *1

Rear tire 3.50-10 *1

CDI

39.2mm

6.8:1

Fuel

Capacity

Centrifugal / CVT Front brake

Unleaded gas

6.3L

Hydraulic disk brake

Drive Rear brake

Durm brake

Lubricant

Steering angel

Left

Right

Auto seperated

、

41

41

Reverse differential

Head light

Tail light

NA

12V-35W*1

12V-21W/5W

Vehicle model reorganization:

1. Movable model

2. Fixed model

2. Service information:

(1)The notice for operation-------------------------------------------------------------------- 6

(2)Locking torque value----------------------------------------------------------------------- 7 a. For engine b. For chassis c. Others

(3)Lubrication instruction--------------------------------------------------------------------- 9 a. For engine b. For chassis c. Wheel bearing -------------------------------------------------------------------------12

(4)Wiring diagram----------------------------------------------------------------------------13

(5)Troubleshooting

1. Hard starting or no starting

2. Not smooth rotation(weak acceleration; inefficient horse)

3. Engine running not smoothly(low speed)

4. Engine running not smoothly(high speed)

5. Charging abnormal(battery over charging or over discharging)

6. No Sparking, spark plug

(1) The operation notice:

1. Always replace gasket, O ring, cotter, pins and clip whenever reassembled.

2. When tighten screws or nuts, lock tightly as per specified locking torque, and in the sequence of cross direction.

3. Use PGO, or PGO Recommended parts.

4. After dismantling please wash all parts necessary for checking and grease all contact surface when reassembling.

5. Use grease recommended by P.G.O.

6.When removing battery, please dismantle the negative pole (-) first, when assembling please connect positive pole (+) first.

6. Before installing a new fuse, confirm the specification is correct or not.

7.After reassembling, please re-check that all connecting point, locking parts, circuits, polar characteristics are good, before selling out.

(2) TORQUE VALUE

No

1. Engine:

Locking location

1 Cylinder head

2 Flywheel outer

3 Rear brake lever

4 Driving pulley

5 Clutch outer

6 Right crankcase

7 Drive gear box cover

8 Left crankcase

9 Draining and filler bolt

10 Inlet pipe

11 Flywheel magneto stator

12 Cooling fan

13 Muffler nut on cylinder head

14 Starting motor

15 Bracket between eng. and

Rubber pad of central stand

16 Spark plug

17 Fan cover

18 Fixed plate, drive clutch

19 Nut of rear wheel axle

20 Kick starter

2. Chassis:

NO Locking location

Thread

Dia (mm)

7

10

6

10

8

6

6

6

6

10

6

6

6

6

6

Locking torque kg-m

Remarks

1.0~1.4 When the engine is cold

3.2~4.0

1.0~1.2

3.2~4.0

3.5~4.0

1.0~1.2

1.0~1.2

1.0~1.2

1.8 When the engine is cold

1.0~1.2

1.0~1.2

1.0~1.2

1.0~1.2 When the engine is cold

1.0~1.4 When the engine is cold

1.0~1.2

14

6

6

14

6

2.5~3.0

1.0~1.2

1.0~1.4

11~13 U TYPE NUT

1.0~1.2

1 Locking nut, steering stem

2 Front axle nut

Q’TY Thread dia. (mm) Locking torque (kg-m)

1

1

10

12

4.5

4.5 ~ 5.5

Remark

U type nut

3 Rear axle nut

4 Rear shock absorber bolt(upper)

5 Rear shock absorber bolt(lower)

6 Front brake caliper bolt

7 Chassis bolt, engine hanger bracket

8 Engine bolt, engine hanger bracket

9 Brake hose bolt

10 Air release valve

11 Front drum brake arm bolt

12 Rear drum brake arm bolt

2

1

1

1

2

2

1

1

1

1

10

6

6

6

8

10

10

16

10

8

11~ 13

4.0

2.4 ~ 3.0

2.0 ~ 3.0

3.5 ~ 4.5

3.0 ~ 4.0

3.0 ~ 3.5

0.6

1.0

1.0

U type nut

3.Other parts please refer the following table:

NO

Standard torque values:

Item

1 5mm bolt and nut

Torque (kgf- m)

0.45-0.6

2 6mm bolt and nut 0.8-1.2

3 8mm bolt and nut

4 10mm bolt and nut

5 12mm bolt and nut

6 5mm screw

7 6mm screw

8 6mm flange bolt and screw

9 7mm flange bolt and screw

10 8mm flange bolt and screw

11 10mm flange bolt and screw

1.8-2.5

3.4-4.0

5.0-6.0

0.35-0.5

0.7-1.1

1.0-1.4

1.0-1.4

2.0-3.0

3.0-4.0

(3)Lubrication instruction:

A. Engine

NO Lubrication location

1 Crankcase: rotating part,

Sliding part

2

3

Cylinder: rotating part,

Sliding part.

Drive gear box

Oil type

Premium 2 stroke

Motorcycle oil

Or SAE#30

Remarks

Auto-separated

Lubrication

SAE85-140

4 Gasket of starter shaft Clean grease

Total 110 c.c.

Replacement 90c.c

(#3)

5 Start idle gear sliding parts

Clean grease (#3)

B.CHASSIS

Steel ball, steering

Front brake cam

Front brake fluid

C.WHEEL BEARING

Motor oil

Final transmission mechanism gear oil

Speedometer gear-clean grease

Front wheel bearing-clean grease

(5)Trouble shooting:

1.Hard starting or can’t start:

Check and adjust Trouble condition The reason loosen carburetor draining screw, check if inside of carburetor have fuel or not

check there is fuel or not

No fuel supplies

pipe between fuel tank and carburetor carburetor is blocked

float is blocked

Fuel gauze is blocked

Auto cock is malfunctioned

Remove spark plug , insert spark plug cover , and touch

spark plug out of order with engine check there is

dirty any spark

CDI unit out of order

pulse generator out of order

ignition coil cable disconnect there is sparking in No sparking or or short circuit spark plug weak sparking

Ignition coil disconnect or short circuit

main switch out of order

defective magneto coil

starting clutch out of order unsufficient or no pressure

valve is too tight, no clearance

valve base out of orde r



Cylinder piston, piston ring out out of order start engine as the

cylinder gasket leakage instruction of starting

valve burns out engine

wrong valve timing engine knocking

bad action of auto choke knocking

air trapped in intake manifold

wrong ignition timing

bad adjustment of carburetor’s fuel adjusting screw check again

carburetor fuel level too high

malfunction of auto choke

throttle valve open too largely dry wet

2.Unsmooth rotation(Weak acceleration ; inefficient horsepower)

Check and Adjust Trouble condition start engine and open throttle gradually.

The reason

fuel supply system abnormal engine can rotate

up

fuel tank cover blocked engine can’t rot-

ate up completely

auto cock is malfunctioned

auto chock is malfunctioned

Check ignition timing, check with ignition timing lamp

CDI unit is out of order bad adjustment on valve

Timing is correct Timing is not correct.

alternator flywheel magneto is

out of order

Valve clearance adjustment is

Valve base is over worn out.

Check cylinder compression pressure

(use cylinder compre- ssion pressure gauge.

cylinder, piston worn out.

valve base is malfunctioned

Check carburetor

Is blocked or not

wrong valve timing

Remove spark

Plug and check it

clean the dirt.

No dirty and no

Color change

Dirty, color change

Check the oil level in crankcase

Is too much or dirty

oil level is too high.

Normal. Not normal.

Of cylinder head

oil does not interchange.

Check the lubrication

oil route is blocked.

Check engine overheat

Or not

oil pump.

piston and cylinder worn out.

bad quality of the fuel.

too much carbon in the combustion room.

ignition timing is too early

Running accelerately or

High sp eed continuously

bad quality of the fuel.

clutch slip

ignition timing is too early.

3.

Engine running not smoothly(low speed and idling):

Check and adjust Trouble condition

Check ignition timing

The reason

pulse generator faulty

Adjust carburetor oil screw

 mixture too lean.

(tighten the screw)

Check if there is air

Leakage on carburetor

broke leakage

loose

gasket crack

hose ruptured

spark plug is dirty

 CDI out of order

Sparking abnormal

Or no sparking

ignition coil faulty

H.T. coil faulty or

short circuit

 main switch is abnormal.

Check A.C.V

A.C.V. faulty

hose is damaged. good fault

air pipe is blocked or

damaged

4.Engine running unsmoothly(high speed)

Check and adjust Trouble condition The reason

Check ignition timing

CDI sets faulty correct not correct

pulse generator faulty

Adjust valve gap

valve base faulty

Check auto cock,

Fuel supply system

fuel level is too low good unsmoothly

fuel pipe or fuel filter

is blocked

auto cock faulty

Check carburetor

Is blocked or not

Check valve timing

the mark of cam’s timing correct Not correct

gear does not align

Check the valve’s

Reverse spring good Spring broke or fatigue

Spring faulty

5.Charging abnormal(battery over charing, or over discharging)

Check and adjust Trouble condition The reason

Measure batter’s

Voltage then start engine

Battery is dead

The Same

Voltage goes up

To normal value,

But after engine

Stop ,the Voltage

Check voltage rectifier

Plug is loose or not

poor connection good loose

red cable disconncet

Check the voltage

Between chassis Θand

The red cable♁ of

while cable disconnect

Check the resistivity

Of A .C . generator coil

defective coil charging abnormal(over charging) A.C. generator’s

white cable

Green cable to

disconnect

Voltage higher

The voltage between

Chassis Θand red cable

Than specification

Voltage normal

♁of voltage of rectifier.

Check the connection

Of the cable of good Poor connection

poor connection of

green cable

Check the resistivity

Of the body of

Voltage rectifier

Out of spec

Voltage rectifier

faulty

6.No sparking, spark plug

Check and adjust Trouble condition The reason

Replace new spark

Plug, then check again

Weak sparking

Or no sparking

Check spark plug, cap

And H.V. cable is

Loosen or not good loose

spark plug cap loosen

Check the CDI plug

Is loosen or not

connection

Check the connection

main switch faulty

Each terminals, check

The resistivity of

Each terminals

coil

pulse generator faulty

defective ignition

coil

Check relative parts

poor connection of

joints or sockets

Check ignition coil

defective ignition

By the CDI tester abnormal

coil

3.Checking and Adjustment:

(1)Periodical checking table

(2)Battery

(3)Clean air cleaner

(4)Oil screen

(5)The final reduction mechanism oil

(6)Spark plug

(7)Cylinder pressure

(8)Valve clearance

(9)Ignition timing

(10)

Idle adjustment

(11)

Front brake adjustment

(12)

Rear brake adjustment

(13)

Tire

(14)

Throttle cable adjustment

(1) Periodical checking table:

1.[○] mark indicates periodical checking

2.[＊] indicates changing the parts

Check item

A Suspension Loose,swing

Steering

Handlebar performance

Suspension: turning angle a.cracked

Front fork b.shaft fixed

condition c.shaft:loose

B: Brake a.clearance

○

○

Gen- eral che- cking

First

Month

Or

Initial

500km

○

○

Checking period

Home

Per 6 per12

Months months

Or or

5000km 1000km

Office

Per1 per3 per12

Months months months

Or or or

1000km 2500km 10000km

○ ○ ○ ○ ○

Judgement standard

Remark

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From steering column

○

○

Clearance:

Front:10-20mm

Rear : 10-20mm

Check from

Steering column

○

Brake lever b.movement of brake

Loose or damage brake Brake cables change

Brake cam Worn out

Brake drum

And brake shoe a.clearance between drum and plate b.brake shoe and br

ake plate worn out c.brake drum

worn and

damage front axle:dam- age or cracked rear axle:worn or damage

Wheel pressure

○ wheel

Wheel cracked

Or damage

Wheel gap and worn

Wheel surface

Or other metals

○

○

○

○

Axle nut screw

Pin tightness

Wheel rim swi-

Ngness and da-

Mage condition

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※per 2 years

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Standard dia:

Rear:130.0mm

Limit of use:

Rear:131mm mark type

○

○

○

○

Check rear

Unit:kg/c ㎡:ldriver U

1.5 1.75

Axle

○

Gaplimit:front wheel:

0.8mm rear wheel:0.8mm

Front axle screw torque

5.0-6.0kg-m rear axl e torque

11..0 -13.0kg-m

Swingness ofr front

Rear wheel rim.

Vertical swing:2mmbelow

Horizpmta;”:2mm b;epw

Nut location

Check item

Wheel Front

Bearing of axle,

Looseness

Rear

Damper Rear damper spring cracked ass’ part loose or damage

Connecting part

Loose

Bracket loose or

Damage

Suspen- sion

Connecting

Part loose

Oil leakage damper

Cracked assy's part,

Loose

Power

Transmi-

Ssion

Clutch and

Change

Speed mechanism

Supply grease

Electric

Install-

Ment

Ignition

Gen- eral che- cking

First

Month

Or

Initial

500km

○

○

Start mechanis m wiring

Starting

Motorpinion

Meshing

Recharge

Effect

Electroly-

Te quantit battery Electroly-

Te s. gra- vity wire circuit

Wire conn- ecting

Loose or cracked

Checking period

Home

Per6 per12

Months months

Or or

5000km 1000km

Office

Per1 per3 per12

Months months months

Or or or

1000km 2500km 10000km

Judgement standard

Remark

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※per 2 year

Clearance:

0.6~0.7mm

NGK:BP7HS

A

OR SAME

SPEC

Level between

“UPPER” AND

“LOWER”

WHEN 20℃

SPECIFIC

GRAVITY:

1.270-1.290

Check item

Engine Engine parts

Performance, noise

Low speed,

Accleration

Exhaustion

Air cleaner

Cylinder, cyl- inder head inlet

Pipe, locking

Condition

Compression pressure

Gen- eral che- cking

First

Month

Or

Initial

500km

○

Checking period

Home

Per6 per12

Months months

Or or

5000km 1000km

Office

Per1 per3 per12

Months months months

Or or or

1000km 2500km 10000km

Judgement standard

Remark

○ ○ ○ ○ ○

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○ Idling:1900±

100rpm

Check the clolr

Or exhausting

-air

○

○

○

Locking torque

Cylinder head:

(cold)

1.0-1.2kg/m

○

Lubr- icat-

Ion

Syst- em

Oil leakage

Oil quantity,

Dirty

Oil quantity,

Oil filter

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Using stating

Motor.

6.0kg/c ㎡

(750rpm)

○

○

Add if necessary fuel syst- em

Fuel quantity

Fuel leakage

Carburetor

Parts dirty

Carburetor thr- ottle and choke

Performance

Carburetor

Float height

Carburetor

Adjustment

Fuel pipe

Changing

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Change every

5000km

※per 4 years

Check item

Lamp system

Horn turn

Signal

Reflector lock

Rear view mirror

Gen- eral che- cking

First

Month

Or

Initial

500km

Performance ○

Dirty, cracked

Performance

Performance

Check the illumination

○

○

○

Checking period

Home

Per6 per12

Months months

Or or

5000km 1000km

Office

Per1 per3 per12

Months months months

Or or or

1000km 2500km 10000km

Judgement standard

○ ○ ○ ○ ○

Remark

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Horn

Turn signal

○ ○ ○ ○ ○

○ ○ ○ ○ ○

Blinker linc-

Nese plate nu-

Mber&mark

Instrument board

Dirty cracked performance

Muffler silencer

Ass’y part

Loose cracked performance

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○ ○ ○ chassis

The earlier

Abnormal condition loose or cracked

Confirm it does

Not happen again

○

○ ○ ○ others

Chassis

Lubrication

Decoking mixer

,muffler, silencer

○ ○

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○

(2)

Battery: Recharge when run out of it

1.Remove the floor mat.

2.Screwing out the two screws on the battery cover; remove the battery cover.

3.Remove the negative cable and then the positive cable, take out the battery to recharge.

4.Re-assembling the battery as the opposite procedure of disassembling after recharging.

Note:

A. Do not take out the sealed bolt when recharging.

B. Without refilling water fo r the battery.

Please recharging (12V) as the following current.

Time standard: 0.3A*5~10Hr or Rapid: 3A*1Hr

(3) Clean air cleaner

1. Remove air cleaner cover.

2. Take out the air cleaner filter.

3. Clean the filter by compressed air.

4. Assemble the air cleaner by the opposite procedure.

(4)MOTOR lubricant oil

 take off the cap of oil tank

 check the level of oil.

.

Attn: Do not start engine when air cleaner is not installed.

(5) The final reducing mechanism oil

1.Change the oil in the gear box: a. Turn off the engine after warm up. b. Put a bowl under the engine. c. Remove the draining bolt and filling bolt to drain the gear oil off. d. Lock the draining bolt before refill

110c.c. gear oil and then lock the filling bolt. e. Locking torque:1.8kg.m

Draining bolt Filling Bolt

(6)Spark plug

1.Remove spark plug.

2.Check the spark plug electrode and see whether it is burnt out/ carbonized or not.

3.Clean the electrode, if it is dirty.

 Spark plug specification

NGK: BP7HS or BPR7HS equivalent

Gap of spark plug:0.6~0.7mm spark plug

Electrode burnt out

Carbon piled up or not

Washer is distorted or not

Porcelain is cracked or not

(7) Cylinder Pressure

1.Measure it when the engine is warm.

2.Remove the cover at the right hand of the step floor.

3.Remove the spark plug then place cylinder pressure gauge. Then fully open the throttle and act on the starter motor to measure the compression pressure.

Compression pressure: 6.0kg/cm

2

at 750 rpm

＊When the compression pressure is too low, check the following: a. Gasket of the cylinder head is damaged. b. Piston ring worn-out c. Piston or cylinder worn-out

＊The cylinder compression pressure is usually too high when there is too much carbonization in the combustion chamber and the piston tip.

(8) Ignition Timing

Note: It is no need to adjust ignition timing and CDI set.

When ignition timing is not correct, just check the ignition system.

1.Remove the checking hole cover of ignition timing.

2.Using the ignition timing light to assure the ignition timing is correct.

3.Under idling, it means in good function when crankcase’s mark matches to the “F” on the flywheel.

4.Raise the engine revolution to 5000 rpm slowly, it means in good function, if the crankcase's mark matches with

Entering point of the flywheel.

(9) Idling Adjustment

Note: Adjust idling only when the engine is warm.

1.Remove the checking hole cover of carburetor.

2.Start the engine and connect the tachometer.

3.Adjust the throttle valve screw to the specified revolution.

4.Specified idling revolution: 1900

±

100rpm

 If rpm is still unsteady or fuel up is not smooth, please re-adjust the fuel intake screw.

(10) Front Brake Adjustment

1.Check the clearance of front brake lever

Clearance: 10-20mm.

2.If the clearance is beyond standard, check whether: a. The air mix into the pipe/caliper. b. The oil brake system is leaking.

Note: Try brake le ver to see if it’s loose. Check the brake oil.once air mixed in the oil pipe, which will reduce or damage the brake efficiency or even its function.

3.Check the oil level: a. Refill the brake oil when the level is under the LOWER line. b. Oil specification: SAE J-1703 or DOT3 orDOT4.

Note: a. To prevent the oil splitting onto the parts or clothes, put a piece of cloth on the bottom when refilling. b. Be caution not to mix water or particles into the master cylinder when refilling. c. Never use the oil that is not complied with spec. d. In case the oil stains on the eyes, wash with water at once and then ask for medical care immediately.

(11) Rear Brake Adjustment

1.Check the clearance of rear brake lever.

Clearance: 10~20mm

2.If the clearance is beyond the above

Standard, adjust it by rotation the screw. a. Left-handed rotation-Enlarge the clearance. b. Right-handed rotation-Reduce the clearance.

Note: When the arrow of rear brake indicator align with the arrow of left crankcase, cha nge the brake lining.

(12) Tire:

1.Check Tire air pressure.

2.Tire pressure:

Front tire: 1.50kg/cm

2

Rear tire:1.75kg/cm

2

3.Tire specification:

Front tire: 3.5-10

Rear tire: 3.5-10

Note:

1.Check and adjust the tire pressure when it is too low.

The pressure is according to the carrier, driver, passenger, accessories and cruise speed

2.Proper loading is very important for steering, riding, braking, performance and safety.

Never carry any parcel unfastened.

Load the heaviest parcel on the center of vehicle, balancing the weight on both sides.

Beware of the weight loaded properly and check the tire pressure. The total weight of carrier, driver, passenger, and accessories cannot exceed the approved limit. An overload vehicle is easy to cause tire damage and accident for rider

3.Check if there is any sharp object piece the tire.

4.Check the depth of wheel stripe.

 Depth (front and rear): According to the mark of tire” ” indicating the necessity to change a new tire.

(13) Throttle cables Adjustment

1.Check the clearance of throttle

2.Normal clearance: 1.5-3.5mm

Adjust it by rotating the adjust nut. Change it if the throttle cables can’t be adjusted.

4. Dismantling, Maintaining, Repairing and assembling operation

(1) Lubrication system

(2) Plastic parts of Chassis

(3) Engine dismantling

(4) Drive pulley, starter, clutch, driven pulley

(5) Cylinder head and valve

(6) Cylinder and piston

(7) AC generator

(8) Final transmission mechanism

(9) Crankcase, crank shaft

(10) Carburetor

(11) Steering stem, front wheel, frt brake comp., frt fork

(12) Rear wheel, rear brake, rear damper

(13) Fuel tank

(3)Engine Dismantling

A. Dismantling engine.

1.Take off the luggage compartment.

2.Take off the left and right body covers.

3.Take off the lower mudguard fender.

4.Remove vacuum pipe, fuel pipe, auto choke, cap of spark plug, rear

Brake cable carburetor pipe, engine flywheel shelf’s nut, starter

Motor cable plate and rear damper bolt.

5.Remove the engine.

B. Installing Engine.

1.To install engine, please reverse the above procedures.

2.Locking torque:

M8: 2.0~3.0kg- m

M10: 3.0~4.0kg- m

M12: 5.0~6.0kg- m

3.After installing, please do the following checking and adjustment:

Checking and adjustment: a. Wiring connection. b. Throttle cable and oil control cable. c. Rear brake adjustment. d. Fuel and oil route.

(4)Drive pulley, starter & clutch

A. Troubleshooting: a. Engine starts, but vehicle does not move.

1.driving belt worn out

2.driven plate worn out

3.clutch lining worn out

4.driving plate’s spring broken b. The vehicle stops or trembles when running,

1.clutch lining spring cracked or broken. c. Can’t reach high speed, no pick-up

1.driving belt worn out.

2.Driving plate spring distortion.

3.Weight roller worn out.

4.Driving plate abnormal.

Note:

No grease and oil allowed to stain on driving belt and driven plate.

B. CVT parts measurement data

Item

Model

The inner dia. of

Slide driving plate

The outer dia..of boss, movable

Driving plate

Belt width

Clutch lining thickness

Clutch outer diameter

Driving plate spring, free length

The outer diameter of driven plate sets

The inner diameter of slide

Driven plate

The outer diameter of weight

Roller set

Standard value(mm)

50cc

20.035-20.085

19.960-19.974

18.0-19.0

3

117.0~117.2

87.9

33.965~34.025

34.000~34.025

15.992~16.008

Limit of use(mm)

50cc

20.123

19.911

17.0

1.5

117.5

82.5

33.95

34.070

15.50

C. Driving pulley.

1.Take off the 8 screws of left

Cover, remove the left cover.

2.Take off the left cover.

3.Remove the fixing nut of the clutch.

4.Take off the ramp plate.

5.Take off the belt and the rear clutch.

6.Take off the driving plate.

• Take off the driving gear start set.

7.Remove the start idle gear fixing plate.

8.Take off the idle gear.

9.To assemble the driving pulley, please reverse above procedure.

Locking torque:

1.Nut of driving pulley:M10: 3.2~4.0kg- m

2.Locking nut of clutch:M10: 3.5~4.0kg- m

10.Checking the driving belt

(1)check whether it is cracked or not or its rubber and fiber are loose or not

check also if they are extraordinarily worn out.

(2)driving belt width:

limit of use : change it below 17.0mm.

11. Disassemble the slide driving plate set

(1)Remove the bush of slide driving plate

(2)Remove the screw, and disassemble the cover

of slide driving plate.

(3)Remove RAMP plate.

(4)Remove weight roller.

12.Checking list:

(1)Check the wearing condition of the weight roller. limit of use: change it when below 15.5mm.

(2)Check inner dia of slide driving plate’s gasket.

Limit of use:

50cc:Change it when above 20.123 mm

(3)Check the wearing condition for driving pulley surface.

(4)Check the outer diameter of the driving plate’s boss.

Limit of use: change it when below 19.911mm

13.Assemble the slide driving plate.

(1)Clean the inner surface of slide driving plate, then assemble the roller.

(2)Assemble the ramp plate.

(3)Please reverse the procedures of disassembling to finish assembling.

D. Starter dismantling

1.Dismantle the left crankcase cover

2.Remove the hexagon nut, then remove the starter lever.

3.Remove five screws of isolating plate.

4.Remove the starter spring from the start returning positioner.

5.Remove the driven gear comp of kick starter.

6.Remove the retaining c-type clip

7.Remove the spindle comp.

Of kick starter.

8.Checking the starter a. Check the wearing condition of the outer diameter of the spindle comp

and the inner diameter of bush and gear. b. Check the wearing condition of the shaft of driven gear comp, gear

sets and ratchet.

9.Assembling the starter

To assemble the starter, please follow the opposite procedures of dismantling.

Locking torque: M6:1.0~1.2kg- m

Note:

Make sure that on end of the torsion spring is hooked on the groove of driven gear, and another end of the torsion spring is hooked on the poled inside the left crankcase.

Put some grease on shaft and gear sets before assembling.

E. Clutch driven pulley

1.Dismantle the clutch a. Remove left crankcase cover. b. Remove driving plate. c. Remove driving belt. d. Remove the M10 locking nut, then the clutch.

2.Assembling the clutch: please follow the opposite procedure of dismantling.

Locking torque:

M10: 3.5~4.0kg- m

3.Checking the clutch:

Dismantling the clutch needs the special

Tool. please contact your dealers. a. Check the clutch driven face.

Check the clutch cover about its wearing

Condition and inner diameter measurement.

Limit of use:

50cc:Change it when above 117.5mm b. Check the clutch lining wearing condition

and measure the lining thickness

limit of use: change it below 2.5mm.

c. Check driven spring free

length: standard: 87.9mm

Limit of use: change it as it

Is below 82.5mm(50cc) d. Check wearing condition of

driving plate set.

Outer diameter measurement:

Limit of use: change it as it

Is above 33.950mm e. Check wearing condition of

slide driven plate.

Inner diameter measurement:

Limit of use: change it as it

Is above 34.070mm f. Check is there any wearing

occur to the ditch. g. Check wearing condition of

seal location, if necessary

change a new one.

(5)Cylinder and piston:

A. Troubleshooting.

a. compression pressure is too low, difficult to start engine and running unsmoothly.

1. Cylinder head gasket cracked.

2. Spark plug is not well- locked.

3. Piston ring worn out or cracked.

4. Cylinder, piston worn out.

5. Reed valve is defective. b. compression pressure is too high, engine overheating or abnormal noise.

1.piston tip has too much carbon piled up. c. Abnormal piston noise

1. cylinder and piston worn out.

2. Piston pin hole or piston pin worn out.

3. Connecting rod small-end or bearing worn out. d. Abnormal piston or cylinder noise

1.piston ring worn out or cracked.

2.Cylinder worn out or cracked.

B. The operation notice:

1.clean before operation to avoid particles dropping into engine.

2.The connect surface of gasket must be clean.

3.Dismantle the cylinder and the cylinder head by screw driver.

Do not scratch the contact surface.

4.Cylinder inner surface and piston outer surface can’t be scratched.

The contact surface should be lubricated by specified oil.

C. PISTON & CYLINDER DATAS:

Part name/description

Standard Value

(mm)

39.995~40.015

Cylinder head Flatness cylinder Bore

Piston/

Piston ring

Clearance b/w Piston ring piston and

Lst ring

2 nd

ring

Piston outer diameter

Measuring location of piston outer dia.

(12mm from the lower end of skirt)

Clearance b/w piston and cylinder

Piston pin hole inner dia

Piston pin hole inner diameter

Piston pin outer diamerer

Clearance between piston and piston pin

Connecting rod small end inner dia

0.05~0.06

0.05~0.06

39.950~39.970

0.045~0.065

13.022~13.013

10.002~10.008

9.994~10.000

0.004~0.018

13.996~14.007

Limit of use

(mm)

0.100

40.050

0.10

0.10

39.895

0.10

13.045

10.025

9.970

0.030

14.025

D. cylinder head, cylinder, and piston dismantling.

1.Remove the engine.

2.Screwing out the two M6-bolt of cooling cowl.

3.Screwing out the two M6-blot of fan cover.

4.Remove the cooling cowl and fan cover.

5.Remove the spark plug.

6.Remove the two M6 nuts on the muffler and cylinder.

Also remove the two M8-bolt of crankcase.

7.Remove muffler.

8.Remove the four M7-nut on the cylinder head, then remove the cylinder head

and cylinder head gasket.

9.Remove the Cylinder and the gasket.

10.Remove the c type clip on the piston and piston pins by the nipper.

•Take off piston.

11.Dismatling of the piston ring Take off the first piston ring then the second ring.

12.When assembling please reverse the procedures of dismantling.

Locking torque:

M7:1.0-1.4kg- m

M6:1.0-1.2kg- m

Opening end of piston ring

(6)A.C. Generator, Flyweel

A.Dismantling AC generator

1.Remove fan cowl.

2.Remove the M6 screws(4)

3.Remove Screws of flywheel magneto

4.Remove the AC flywheel magneto by special tool.

5.Remove the flywheel.

6.Remove the electric plug of AC Flywheel magneto.

Take out the magneto.

B. Install AC generator

To install, please reverse the dismantling procedures.

Locking torgue :

M6: 1.0~1.2kg- m

M10: 3.2~4.0kg- m

(7)Final Transmission Mechanism

A. Trouble shooting

Engine can be started, but vehicle doesn’t move.

1.Gear worn-out or cracked.

2.Gear burnt out.

Noise occurs when running.

1.Gear worn out, burnt or gear surface damaged.

2.Bearing worn out or loosen.

Oil leakage

1.Too much oil.

2.Seal worn out or damaged.

B. Disassemble the final transmission mechanism.

1.Remove the rear wheel.

2.Drain off the oil in the gear box.

3.Remove the 6 bolt in gear box cover

4.Take off the gear box.

5.Take out the final reduction gear and idle gear shaft.

6.Clean up the gear box

C. Check the final transmission mechanism

1.Check the wearing condition of the driving shaft and gears.

2.Check the wearing condition of the idle gear shaft and idle gears.

3.Check the wearing condition of the final reduction gear.

4.Check the wearing condition of the oil seal and bearing.

D. Assemble the final transmission mechanism:please follow the opposite procedures

Of disassembling. After locking the drain bolt, refill 90c.c of gear oil, SAE 85W/140.

Locking torque: M6: 1.0~1.2 kg- m

M10: 3.5~4.0 kg- m

Drain bolt: M8: 1.8 kg-m

E. Check for the flatness of cylinder head & cylinder.

Check the flatness of contact surface of cylinder head & cylinder.

Limit of use: If it exceeds 0.1mm

Change a new one.

F. Combustion chamber cleaning

Clean out the carbon piled up in combustion chamber.

Do not scratch the combustion chamber and contact surface of the cylinder during

cleaning operation

G. Check cylinder and piston:

1.Check the wearing and damage condition on the contact surface of the cylinder and piston.

2.Clean out the carbon on the cylinder exhausting port.

Be careful not to scratch the inner

Surface of cylinder.

3.Cylinder bore measurement:

(1)Measure each point (A)(B)(C) orderly, and in X.Y. axis to find the smallest value.

(2)Limit of use: 50cc-change it when over 40.050mm

4.Piston outer diameter measurement:

(1)Measure at the skirt area where is 12 mm from the skirt lower end of skirt.

(2)Limit of use: 50cc-change if when below

39.895mm

(3)Calculate the clearance between the cylinder and piston.

Limit of use: change it when over 0.100mm

5.Inner diameter measurement of the piston pin hole

Limit of use: change it when over 14.032mm

6.Outer diameter measurement of the piston pin

limit of use: change it when under 9.970mm(50cc ENGINE)

7.Check piston ring:

Measure piston ring gap:

Limit of use: change new ones when the first ring and second ring are over 0.4mm

Push the piston ring into the cylinder

By piston, the measure the gap

8.Check connecting rod small end

(1)lnstall piston pin, bearing onto the connecting rod small end, then check the looseness of the piston pin.

(2)Measure the inner diameter of the connecting rod small end.

Limit of use: replace a new one when over 14.025mm.(50cc ENGINE)

H. Installing cylinder and piston

1.Place the piston ring into the second ring ditch first, then install the

piston ring into the first ditch.

2 a. Piston ring should be installed into piston ring ditch by even force b. After assembling, be sure that the piston ring sliding surface is at the same height as

the piston outer surface. c. If the piston ring can not fit into the ditch, please clean up the carbon in the piston ring

ditch or piston ring itself.

3. a. Piston ring must be installed in the correct location. b. After installing the piston ring, it should be able to rotate freely. c. If it is necessary to change the new piston ring, it must change the whole set.

4. a. The location of the piston ring gap and the lock pin must be in opposite side. b. The mark”” on the piston tip must be pointing to the exhaus ting port. c. Lubricate the piston pin before installation.

5.Please follow the opposite procedure of dismantling to install cylinder and cylinder head.

(8)Crankcase, Crankshaft:

A. Disassembling diagram

B. Troubleshooting.

Engine noise:

1.The bearing of final transmission mechanism is loose.

2.Crank pin bearing is loose.

3.The bearing of gear box is loose.

C. Data

Measuring Item

Clearance of connecting rod big end

(Parallel direction to rod)

Clearance of connecting rod big end

(Perpendicular direction to rod)

Swingness of the crank shaft neck

Standard value

0.20-0.50

-

0.03

Limit of use.(mm)

0.71(50cc)

0.04

0.10

D. Dismantle the crankcase and crankshaft please follow the following procedures:

1.Remove the engine.

2.Remove the left crank case, the driving pulley (driving plate) clutch and belt.

3.Remove the air cleaner.

4.Remove the carburetor.

5.Remove the intake manifold and reed valve.

6.Remove the oil pump, fan cowl and fan itself.

7.Remove the AC flywheel magneto.

8.Dismantle the right and left crankcase.

There are all together 7 bolts.

9.Remove center stand, left and right crankcase and take out the crankshaft.

E. Check the crankshaft:

1.measure the clearance between crank shaft and co-rod big end.(Parallel direction to rod)

Limit of use: Replace a new when above 0.71mm

2.check the looseness on X.Y. axis of the connecting rod big end(Perpendicular directions to rod)

Limit of use: Replace a new one when above 0.04mm

3.measure the swingness of crank shaft neck.

A

Change it when

Above 0.1mm

Limit of use

B

Change it when

Above 0.1mm

A B

60mm

4.check the slackness of crankshaft bearing,

if it is slack, change a new one.

F. Assemble the crankcase.

1.To assemble the crankcase, please reverse the procedures of disaseembling.

2.The locking torque value for bolts and nuts are all described in the previous chapters

Please refer.

(9)Carburetor, Reed Valve and Auto cock

A. Fuel system diagram

Fuel Cap

Fuel Gauge

Fuel Tank

Carburetor

B: Carburetor dismantling diagram

01 CARBURETOR ASSY. 13 HOLDER, NEEDLE JET

02 TOP SET 14 MAIN JET

03 SPG., COMP. 15 FLOAT VALVE SET

04 PLATE SET 16 PIN, ARM

05 TUBE SET 17 FLOAT SET

06 JET NEEDLE 18 FLOAT CHAMBER SET

07 THROTTLE VALVE 19 TUBE SET

08 SCREW SET 20 "SCREW, WASHER"

09 SCREW SET（A.S） 21 CAP HOLDER

10 O RING 22 AUTO BYSTARTER SET

11 NEEDLE JET 23 SCREW, WASHER

12 SLOW JET 24 PLATE SET

C. Troubleshooting: a. Engine can not be started.

1.No fuel in the fuel tank.

2.Fuel pipe is blocked.

3.There is too much fuel in the cylinder.

4.Air cleaner is blocked. b. Engine idling(RPM)unsteady, running not smoothly

1.Improper adjustment of the carburetor idling.

2.Ignition disorder.

3.Compression pressure is too low.

4.Air mixture is too thick.

5.Air mixture is too lean.

6.Air cleaner is blocked.

7.Air injection is not in good function.

8.Fuel is dirty. c. Air mixture is too lean.

1.Carburetor main jet is blocked

2.The ventilation hole of the fuel tank cover is blocked.

3.Fuel filter is blocked.

4.Fuel pipe bended, squeezed or blocked.

5.Float valve is abnormal.

6.Fuel level is too low.

7.Air pipe is blocked. d. Air mixture is too thick

1.Float valve is abnormal.

2.Fuel level is too high.

3.Air jet is blocked.

D. Dismantling carburetor

1.Remove the luggage box.

2.Loose the hose clamp between the carburetor and the air cleaner.

Then remove the air cleaner.

3.Unscrew the fuel draining screw of the carburetor. Drain off the fuel inside the carburetor.

4.Remove the fuel pipe and the vacuum pipe on the carburetor.

5.Remove the oil pile on the carburetor.

6.Remove the bolts on the intake manifold and carburetor.

E. Dismantling float, nozzle

Note:

The auto choke has been properly adjusted already. Please do not adjust it further.

When there is blockage in the carburetor, please clean it by air compressor.

F. Reed valve

1.Dismantling reed valve.

(1)Take off the luggage box

(2)Remove the air cleaner

(3)Remove the carburetor.

(4)Unscrew the locking screw of the intake

manifold.

(5)Remove the intake manifold.

(6)Remove the reed valve.

2.checking for the reed valve.

chang a new one when the reed valve is worn out or distorted.

change a new one too when the base of the reed valve is cracked, injured or distorted.

G. Check the auto cock

1.When the engine stop, remove the fuel pipe from carburetor and check if there is fuel flow

Out or not.

It means auto lock functions well if the residue fuel(for the amount of 5-10cc)flows out

From the auto cock and fuel pipe. However, if it continues to flow out, it means that the

Vacuum pipe is blocked. please clean it.

2.Remove the vacuum pipe from the carburetor and suck it to produce a vacuum to have the

Fuel flow out from the fuel pipe. The fuel will stop flowing out if the vacuum disappear.

If the fuel does not flow out by the above operation, please check the followings:

(a) Clean out blockage in the vacuum pipe.

(b)Blow air into the inlet pipe of the auto cock.

3.Note:

Please remember to use a bowl to catch the flow-out at the end of the fuel pipe.

Keep away from fire or even spark during operation.

(11)Steering stem, front wheel, frt brake comp and front fork.

A. Troubleshooting

B. Data

C. Steering handlebar

E. Front wheel

F. Front brake

G. Front fork

A.Troubleshooting

1.steering handlebar is abnormal, too tight.

a. steering mechanism; washer of conical bush locked too tightly.

b. steering mechanism; steel ball is cracked.

c. steering mechanism; steel ball base and washer of conical base is damaged.

d. wheel pressure is too low.

2.steering handlebar is aslant. a. left and right damper is not even. b.Front fork is crooked. c. The axle of front fork is crooked, wheel is aslant.

3.front wheel swings.

a.wheel rim is distorted.

b.bearing of front axle too free. c.wheel rib is distorted. d.Wheel is not good. e. Front wheel axle locked improperly.

4.front damper is too soft, spring fatigue.

5.noise in front damper.

a.noise comes from damper box.

b.locking screw of damper is slackness.

B.Data

Item Standard value ( mm ) Limit of use ( mm )

Lining of frt brake 4.0 2.0

Disk of frt brake

Swingness of frt/rr wheel

3.6

-

3.1

2.0

C.Changing the speedometer cable

1.Remove the fixed screws of the front cover.

2.Remove the nut of speedometer cable.

3.Remove the front handle cover.

4.Remove the fixed screws of

speedometer cable on the

right of front wheel.

5.Draw out the damage

speedometer cable.

6.Assemble the new cable

follows the opposite

procedure of dismantling.

NOTE:Put the grease onto the

Inner cable before

Assembling.

(D)Steering handlebar

1.Remove the LH/RH back mirrors.

2.Remove the upper handle cover.

3.Remove the nuts on front fork and handlebar.

4.Take off the fixing bolt.

5.Remove the nut and bolt of the front fork fixed on

The handlebar.

6.Take off the handle bar.

7.When assembling, please follow the opposite procedures.

Locking Torque:

M6 :1.0-1.2kg- m

M10 :3.0-4.0kg- m

8.Before assembling, please add grease on each cable.

(E)Front wheel

1.Remove the locking nut of the front

wheel on the right side.

2.Draw out the axle of front wheel,

remove the ring and take off the

gear sets of speedometer.

3.Remove the front wheel assy.

4.Assemble the front wheel follows

the opposite procedure of

dismantling.

Locking Torque:

M10: 3.0-4.0kg- m

Note:

1.Put the lock block of speedometer gear assy upon the extrusion of the front fork.

2.Put the grease onto the grease sets of speedometer before assembling.

5.Checking the front wheel axle a. Check the bending degree of the front axle. b. Take note of the bending degree on the middle of axle. c. Limit of use: Change it when above 0.2mm.

6.Front wheel bearing checking

Turn the tire. If the bearing is

Loosen or any occurrence for noise,

Please change a new one.

7.Front wheel rim checking

(1)Check the swing of the front wheel rim.

(2)Limit of use:

 Horizontal direction:

Change a new one when above 2.0mm.

 Vertical direction:

Change a new one when above2.0mm.

(F)Front brake

1. Disassembling and assembling of the front

brake comp. a.Remove two bolts fixed on the front brake

comp and the front fork. b.Remove the front brake comp. c.Assemble the front brake comp.

Follows the opposite procedure of dismantling.

Locking Torque:

M8: 2.0~3.0kg- m

2.Air releasing of the front brake comp

The procedure of air releasing

a.Fill the enough brake oil to the container

b.Do not let the brake oil overflow from the

master cylinder or container when assemble

the master cylinder cover. c.Put the spanner upon the drain screw. d. Lock and unlock the screw several times to

Release the bubbles. e. Operate slowly the brake lever several times. f. Clamp the brake lever to the end. g. Loose the drain screw, then open the lever completely. h. Locking the drain screw and then loose it when the lever is opened completely. i. Repeat above procedure until all the air in the brake system has been released

Completely.

Locking torque of leaking screw: 0.6 kg-m

3.Front fork checking:

If it is bent or cracked, please replace with a new one.

4.Front shock absorber checking

Check is there any unusual damage or worn-out condition, and whether the guide rod of the

Front fork is crooked or not.

Front fork oil type: SAE 10W20

Capacity (each side): 70 CC

NOTE:

If the guide rod is crooked, it should be replaced by a new one or repaired.

5.Disassembling and assembling the front brake-disk. a. Remove the front wheel. b. Remove three nuts on the disk. c. Remove the disk. d. Assemble the disk follows the disassembling procedure.

Locking torque M8: 2.0~3.0kgm

6.Checking the front brake-disk.

Standard thickness of disk: 3.6mm

Limit of usage : change it when below 3.1mm

7.Checking the front brake-lining.

a.standard thickness: 4.0mm.

limit of use: As the thickness is below 2.0mm, change it.

Note: No grease on the lining.

(12)Rear wheel, rear brake, rear damper:

A.Troubleshooting.

B.Data.

C.Dismantling the rear wheel.

D.Checking the rear wheel.

E.Rear brake.

F.Rear damper.

A.Troubleshooting.

1.Rear wheel swings. a.wheel rim is distorted. b.wheel is abnormal. c.improperly assemble the wheel axle.

2.Rear damper is too soft

a.rear damper spring fatigue.

3.Bad braking

a.the adjustment of brake is not good.

b.the brake lining is dirty.

c.the brake lining is worn out.

d.the cam of brake lining is worn out

e.the brake cam lever is worn out.

f.the brake hub is worn out.

g.the assembling of brake lever gear trough is not good.

B.Data

Item Standard value(mm) Limit of use(mm)

The swings of rear wheel - 2.0

Brake hub inner diameter

Thickness of brake lining

110

4.0

111.0

2.0

C.Dismantling and assembling

The rear wheel.

1.Remove the fixed screws and

bolts of the exhaust pipe.

2.Remove the fixed screws of

the rear wheel drum.

3.Remove the bolts.

4.Remove the rear wheel.

5.To assemble the rear wheel,

please reverse the

dismantling procedures.

Locking torque : M6: 0.7-1.1kg.m

M14: 8.0-10.0kg.m

D.Checking the rear wheel.

 check the swings of rear wheel.

 radial direction:

change it as it is above 2.0mm

 horizontal direction:

change it as it is above 2.0mm.

E.Rear brake:

1.Rear brake disassembling diagram.

(1)Checking rear brake hub:

a.measure the inner diameter of rear brake

hub.

b.limit of use:change it as the diameter is

above 111.0mm

(2)Checking brake lining: a. measure the thickness of rear brake lining. b.Limit of use: As the thickness is less than

2mm, change it.

F.Rear damper

1.Rear damper disassembling diagram:

(13)Fuel tank

A. Troubleshooting:

1.Engine can’t start:

a. No fuel in fuel tank.

b. Fuel pipe is blocked.

c.. Auto cock and fuel filter is blocked.

d. The membrane of fuel cock over extended.

2.The mixture is too lean.

a. Ventilation hole is blocked.

b. Fuel pipe is crooked, squeezed, or blocked.

c. Auto cock and fuel filter is dirty.

B. Dismantling and assembling

Fuel Tank

1.Remove the luggage box.

2.Open the rear cover of the fuel

Tank and take it off.

3.Remove the left and right rear

handle bars.

4.Remove the left and right side

covers.

5.Remove the fuel pipe.

6.Remove the connecting terminal of

the fuel gauge.

7.Remove the fuel gauge.

8.Remove the fixing blot of the fuel tank.

9.Take off the fuel tank.

10.When re-assembling, please follow the

opposite procedure of disassembling.

Locking torque: M6: 1.0-1.2kgf- m

5.Electric equipment:

(1)Troubleshooting

(2)Battery

1.check specific gravity of eletrolyte

2.recharge

(3)Recharge system

1.the wiring diagram of recharge system

2.check A.C. flywheel magneto

3.check regulator/ rectifier.

(4)Ignition system

1.the wiring of ignition

2.check spark plug

3.check H.T. Cable and H.T. coil

4.check C.D.I. set

(5)Starting system

1.the wiring of starting

2.checking the starter

3.dismantling the starting motor

4.checking the starting motor

(6)Starting clutch

(7)Handle bar switch

(1)Troubleshooting: Currency is unstable.

A.Recharge system: 1.The wiring of battery connects

No power: improperly.

1.battery over charge 2.Ignition system connects abnormally.

No electrolyte in battery. 3.Ignition system is short circuit.

Battery becomes white. 4.Lamp system connects abnormally or

Short circuit in battery. Short circuit.

Regulator malfunction Abnormal recharge system:

2.the battery wires disconnected. 1.The plug part connects abnormally,

3.fuse is broken. Wire broken or short circuit.

4.Ignition lock is abnormal. 2.Rectifier is abnormal.

Voltage is too low: 3.A.C. flywheel magneto is abnormal.

1.Battery recharges insufficiently. D.Engine rotate unsmoothly:

2.The connecting is abnormal. 1.Ignition primary wiring

3.Recharge system is abnormal. the wire or plug of wiring connects

4.Regulator malfunction. Improperly.

B.Ignition system: main switch disconnects.

The sparking of spark plug is abnormal: 2.Ignition secondary wiring

1.Spark plug is abnormal. Ignition coil is abnormal.

2.Wire connects improperly, broken or short Spark plug is abnormal.

Circuit. H.T. coil is abnormal

between A.C. flywheel magneto and CDI Spark plug cover electricity leakage.

sets. 3.Ignition period

between CDI sets and H.T. coil. A.C. magneto is abnormal.

between CDI sets and main switch. A.C.G. coil disconnects.

between main switch and spark plug. C.D.I. set is abnormal.

3.Main switch is out of order.

4.H.T. coil is abnormal.

5.CDI sets is out of order.

6.A.C. flywheel magneto is abnormal.

C.Starting system: 8.Starting motor is out of order.

Starting motor can’t rotate:  Starting motor weak rotation:

1.The fuse is broken. 1.battery recharges insufficiently.

2.Battery recharges insufficiently. 2.wiring disconnect.

3.Main switch is abno rmal. 3.motor or gear some impure material drop

4.Switch of starting motor is out of order. in

5.Switch of front. rear brake is out of  Starting motor can rotate, but engine order. Can’t rotate:

6.Starter relay is out of order. 1.starting pinion is abnormal.

7.Wire disconnects or broken. 2.starting motor is reverse rotation.

3.battery is out of order.

(2)Battery:

Always, remove the battery negative

Cable(-), then remove positive cable

(+). But connect the positive cable

(+)first, then connect the negative cable(-) when assembling.

1.Recharging

Connection method:

Connect the positive cable(+)of the recharger to the positive cable(+)of the battery; and

The negative cable(-)of the recharger to the negative cable(-)of the battery.

Recharging currency:

Please recharge(12V) according to the following currency and time.

Standard: 0.3A * 5-10HR OR Rapid: 3A * 1Hr

NOTICE:

1.It is not necessary to refill the battery liquid into the battery.

2.Do not take off the sealed bolt while recharging.

NOTE:

 No fire near battery when recharging

 The “ON” or “OFF” of recharging

currency must be operated by the

switch of recharger. It will cause

spark or explosive if plug or unplug

the cable directly.

2.Testing the recharging performance

This test needs to be done under the

Battery has been recharged completely a. This test needs to be done after

engine is warm- up.

And take off the luggage case

Firstly. b. Disconnect the orange cable of

regulator. c. Open the fuse box to remove the

white cable d. Connect currency meter between red/

white cable fuse.

While testing, the red wire cable must not touch the frame. d. Set the headlamp switch at “OFF” , engine rotation is at 2000 rpm while testing.

Then increase the rpm slowly.

Head Lamp Switch Recharging rpm 2,500rpm 6,000rpm

OFF (DAY) Under2,000upm 0.6A(MIN) 1.5A(MIN)

ON (NIGHT) Under2,000upm 0.6A(MIN) e. If the testing result does not match standard value, check the regulator.

1.5A(MIN)

(3)Recharge system

1.Recharge system diagram

2.Check A.C. flywheel magneto. a. Remove the LH side strip and LH body cover. b. Measure the resistance value of terminals.

Yellow black 0.1-1.0

White black 0.2-2.0

3.Check regulator measure the resistance value

between each terminal, it should be in

specified range, otherwise change a new one.

Pocket tester range: * 1k range

Regulator

(4)Ignition system:

1.the wiring of ignition

2.CDI Resistance inspection

Pocket tester range: * 1k range

2.Check the spark plug.

3.Check the H.T. cable and H.T. coil

by using the CDI tester. Please

follow the instruction manual.

4.CDI sets checking.

Check with the CDI tester and

Please follow the instruction

Manual.

If the CDI is broken down, please

Change a new one.

Spark Plug

Coil

(5)Starting system

1.Starting wiring

2.Checking

 Other spare parts comp. Checking.

 Change a new one when there is any scratch,

damage or burnt on the surface.

 Any adherent metal powder in-between the

layers of the direction exchanger sho uld be

cleaned.

 The conductivity check among each contact

surfaces to other parts.

 The non-conductivity check between the

armature pivot and each layer of the

direction exchanger.

 The conductivity check of the outer cover of

the starter motor

 The non-conductivity check between the cable

ends and the outer cover of the starting motor.

 The conductivity check of the electric brush

and the cable ends. If there is anything

abnormal change a new one.

 The non-conductivity check of the brush

bracket.

If it is conductive, change a new one.

3.Start Relay

Starting check:

 Remove the body cover.

 When the main switch “ON” and press the

starting motor button, there should be a

“kata” sound.

 If there is not a “kata” sound:

a. Check the voltage of the start relay.

b. Check the start’s ground circuit.

c. Check the start reply starting system.

Voltage check for the start relay:



Put on the center stand. Measure the voltage

between the cable Green/Line(-) of the start

relay and the body’s ground circuit.



To switch “ON” for the main switch and clamp

the brake lever. The battery voltage has to

meet the requirement.



When there is no voltage at the start relay,

check the brake switch conductivity and the

cables.

(7)Handle bar switch

The colors for each switch cables:

Head Light Switch

Operation Dark green Yellow Yellow/black Blue

OFF ● ●

ON ● ● ●

Operation Green/White Black

/Color

FREE

PUSH ● ●

HI/LO bean Horn Switch

Operation Blue Brown/White Purple/White

/Color

HI ● ●

Operation Yellow/green Black

/Color

PUSH

FREE

● ●

LOW ● ●

Signal Light Switch Main Switch

Operation/Color Pink Blue/White Brown

L ● ●

Lock Off On

● Red/white

To L ● ●

N PUSH

● ● Blue/black

● Orange

● ● Black

To R ● ●

R ● ●