Bintelli Breeze User`s manual

Contents
BINTELLI USER’S MANUAL
Instructions to Users
Precautions ........................................................................ 1
Vehicle Identification Number (VIN) and Engine Number ... 2
Brief Introduction to the Scooter ......................................... 3
Technical Specifications ..................................................... 6
Instrument Cluster .............................................................. 9
Left control switch ......................................................... 10
Right control switch ........................................................ 11
Ignition switch ................................................................... 12
Seat Cushion Lock/ Fuel tank .......................................... 13
Vehicle Operation ........................................................... 14
Motorcycle Load ............................................................... 15
Vehicle load/ tools included .............................................. 16
Operating Instructions
Basic vehicle information.................................................. 17
Kick starting the engine .................................................... 20
Electric starting the engine ............................................... 21
Parking the scooter .......................................................... 22
Service and Maintenance
Regular Service and Maintenance ................................... 24
New Vehicle Maintenance Procedure (500 mile Service)..25
Level 2 Service and Maintenance .................................... 26
Level 3 Service and Maintenance .................................... 26
Service and Maintenance for the Carburetor.................... 27
Checking and Changing the Engine Oil ........................... 28
Service and Maintenance of the Spark Plug..................... 29
Service and Maintenance of the Air Filter ......................... 30
Adjustment of the accelerator handgrip ............................ 31
Service and Maintenance for the Front Brake .................. 31
Service and Maintenance for the Rear Brake................... 32
Adjustment of the rear brake light .................................... 34
Adjustment of the idle speed ............................................ 34
Service and Maintenance for Front and Rear Tires .......... 35
Service and Maintenance for Battery ............................... 37
Service and Maintenance for the Fuse ............................. 38
Service and Maintenance for the Horn ............................. 38
Storage of the Vehicle ...................................................... 38
Service and Maintenance Interval Table........................... 40
Service and Maintenance Interval for Lubricated Parts .... 41
Common Faults and Troubleshooting............................... 42
USER’S MANUAL
Instructions to Users
Precautions
Please read the User’s Manual before operating the vehicle!
Warning
*
*
*
*
*
Always observe traffic laws and regulations.
All users’ must have a valid driver’s license.
Do not hang any items from the throttle grip as this will cause an unsafe driving condition.
Please wear a helmet and eye protection at all times.
Be aware the exhaust and muffler are extremely hot. Do not touch any part of the engine after riding to prevent burns.
Caution
*
After unpacking the vehicle from shipping, please check the accessories and various documents delivered according to the packing list.
*
Always follow the recommended weight limit. Any additional weight will cause premature wear to the engine and drive train.
*
Do not modify any part of the vehicle. Any attempt at modifying the vehicle could lead to a decrease in engine life, reliability and safety.
*
This high performance vehicle is designed to be run with premium fuel only (93 octane). Failure to use premium fuel will affect performance and
lead to premature engine failure due to detonation and pre-ignition. Any engine damage that has occurred from improper fuel grade is not covered
under warranty. It is the user’s responsibly to always ensure the correct fuel is used.
Suggestion
*
This manual provides important information regarding the vehicle. If ownership transfers, please include this manual.
*
All repairs must be completed at an authorized service center. The first 500 mile servicing which includes the valve adjustment must be completed
to maintain engine warranty. Failure to follow the servicing schedule outlined in this manual will void the warranty.
1
Instructions to Users
USER’S MANUAL
Vehicle Identification Number (VIN) and Engine Number
Vehicle Identification Number (VIN) and Engine Number
①Vehicle Identification Number (VIN) is
printed on the vertical tube of the frame,
behind this plastic cover.
②The product nameplate is
riveted on the right lower part of
the frame.
③The Engine Number is printed on
the lower left part of the crankcase.
Please fill in appropriate numbers for
future reference:
VIN:
Engine Number:
2
USER’S MANUAL
Brief Introduction to the Scooter
1.
Head Light
2.
Left front turn light
3.
Front storage box
4.
Seat cushion
5.
Rear carrier
6.
Disc brake
7.
Side support
8.
Main support
9.
Starting arm
10. Air filter
3
Instructions to Users
Instructions to Users
USER’S MANUAL
Brief Introduction to the Scooter
1.
Tail light
2.
Rear spoiler
3.
Helmet hook
4.
Steering column
5.
Right front turn signal
6.
Rear wheel
7.
Muffler
8.
Battery Compartment
9.
Front brake lever
10. Front wheel
4
USER’S MANUAL
Brief Introduction to the Scooter
5
1.
Rearview mirrors
2.
Left handgrip
3.
Left control switch
4.
Instrument cluster
5.
Ignition switch
6.
Right control switch
7.
Throttle grip
Instructions to Users
Instructions to Users
USER’S MANUAL
Technical Specifications
Sprint
Breeze
Edge
Scorch
Havoc
BN139QMB
BN139QMB
BN139QMB
BN139QMB
BN157QMJ
Cooling System
Air Cooled
Air Cooled
Air Cooled
Air Cooled
Air Cooled
Bore x Stroke
4
4 stroke
4 stroke
4
4
10.4:1
10.4:1
10.4:1
10.4:1
9.5:1
Horse Power
2.4kw/8000r/min
2.4kw/8000r/min
2.4kw/8000r/min
2.4kw/8000r/min
6.3kw/7500r/min
Max Torque N.m/(r/min)
2.8N.m/6500r/min
2.8N.m/6500r/min
2.8N.m/6500r/min
2.8N.m/6500r/min
8.8N.m/6000r/min
Ignition Type
CDI
CDI
CDI
CDI
CDI
Starter System
Electric/Kick
Electric/Kick
Electric/Kick
Electric/Kick
Electric/Kick
SJ10W-40
SJ10W-40
SJ10W-40
SJ10W-40
SJ10W-40
CVT
CVT
CVT
CVT
CVT
Spark Plug Model
NGK CR7HSA
NGK CR7HSA
NGK CR7HSA
NGK CR7HSA
NGK CR7HSA
Belt Model
Gates 669MM
Gates 669MM
Gates 669MM
Gates 669MM
Gates 835MM
Front Suspension
Straight
Straight
Straight
Straight
Straight
Rear Suspension
Single
Single
Single
Single
Double
Front Tire Size
3.50-10
3.00-10/3.50-10
3.50-10
120/70-12
130/60-13
Rear Tire Size
3.50-10
3.00-10/3.50-10
3.50-10
120/70-12
130/60-13
Disc / Drum
67.1" x 25.6"
x42.5"
Disc / Drum
68.3" x 25.8"
x42.9"
Disc / Drum
67.7" x 24.8" x
43.3"
Disc / Drum
73.4" x 27.8" x
46.1"
Disc / Disc
73.4" x 26.8" x
44.1"
28.9"
29.5"
29.5"
32"
32"
Rider Capacity
2
1
2
2
2
Fuel Capacity
1.4 G
1.3 G
1.3 G
1.6 G
1.5 G
Engine Type
Compression Ratio
Engine Oil
Transmission
Brakes (Front/Rear)
Scooter L x W x H
Seat Height
6
stroke
stroke
stroke
USER’S MANUAL
Max Load Capacity
400lb
400lb
400lb
400lb
400lb
Scooter Weight
170lb
172lb
190lb
190lb
225lb
Frame Material
Steel
Steel
Steel
Steel
Steel
Motobatt 12V,7A
Motobatt 12V,7A
Motobatt 12V,7A
Motobatt 12V,7A
Motobatt 12V,7A
Halogen
67.3" x 22.8"
x44.1"
Halogen
67.3" x 22.8"
x44.1"
Halogen
67.3" x 22.8" x
46.6"
Halogen
74.8" x 22.8" x
44.9"
Halogen
74.8" x 22.8" x
44.1"
Battery
Lights
Shipping Dimensions
(LxWxH)
7
Instructions to Users
Instructions to Users
USER’S MANUAL
Instrument Cluster
1.
Left turn indicator:
When the left turning indicator “
2.
” flashes, the left turn signal is on.
Tachometer:
Indicates the current engine speed in revolutions per minute.
3.
High beam indicator:
When the high beam indicator lamp “
beam lamp” is on.
4.
” is on, it indicates that the “High
Speedometer:
Indicates the current speed of the vehicle
5.
Odometer:
Records the traveled miles of the vehicle
6.
Fuel gauge:
Indicates how much fuel is left in the fuel tank
7.
Right turn indicator:
When the right turning indicator “
8.
Battery Meter (If equipped)
Indicates the charge of the battery
8
” flashes, the right turn signal is on
USER’S MANUAL
Instructions to Users
Left Control Switch
1.
High beam switch:
To use the High beam headlight setting, flip the switch up to the “
2.
Low beam switch:
To use the Low beam headlight setting, flip the switch down to “
3.
” position.
Horn button:
To use the horn, press the button labeled “
4.
” position.
”.
Turn signal switch:
When changing direction on the scooter, switch to “ ” or “ ” to turn left or right.
After completing the turn, press the center of the button to turn the signals off.
9
Instructions to Users
USER’S MANUAL
Right Control Switch
1.
Head Light switch: (When equipped)
On some models the headlights can be controlled from the right hand switch.
To use, turn the Head Light switch to the position “
on with the engine running.
2.
”, the headlight will turn
Electric Start button:
Pressing the “ ” button in combination with holding a brake lever and having
the ignition turned on will electrically start the scooter.
3.
Running light switch: (When equipped)
”, and the instrument panel
Turn the Head Light switch to the position“
and running lights will come on with the engine running.
4.
Main light switch: (When equipped)
To turn all the lights of the vehicle off, slide the button to the far right “”
position.
5.
Throttle Grip:
Turning the grip will increase the speed of the engine which allows the vehicle
to move forward. Always turn the grip slowly to provide smooth and safe
acceleration.
Caution:
Always use your turn signals and adhere to local traffic laws and regulations
10
USER’S MANUAL
Instructions to Users
Ignition Switch
Caution
When leaving the vehicle parked, using the “
11
” to lock the steering will help deter thefts and prevent the vehicle from being driven.
Ignition On:
Ignition Off:
Turn the ignition key right to the position “
”to turn
on the electrical system of the vehicle. The key cannot
be removed in this position. While in this position the
vehicle can be either electrical started with the push
button, or kick started with scooter on the rear kick
stand.
Turn the ignition key to the position “
” to
switch off the electrical system of the vehicle. In
this position the key can be removed. The
electrical system of the scooter will remain in the
off position.
Steering lock:
Turn the steering left to the outer most position,
then turn the ignition key to the position “ ”
to lock the steering. Remove the ignition key. In
this position the steering will not move. This is
recommended when storing the vehicle outside
to deter theft. To undo the steering lock, insert
the ignition key then rotate to the right while
gently moving the steering to disengage the
lock.
Instructions to Users
USER’S MANUAL
Fuel tank
Seat Cushion Lock
To open the under seat storage: Insert the ignition
key into the seat cushion lock and turn it 90º
clockwise to open the seat cushion. *Note* on some
scooters like the Breeze, the ignition switch opens
the seat. On those models, insert the key into the
ignition, and slowly turn to the left until the seat
pops open.
Check page 7 to see your models fuel tank capacity.
To gain access to the fuel tank, turn the fuel tank cap 90º
counter-clockwise and lift up. Always use 93 octane. Be
careful when adding fuel to prevent overfilling.
To close the fuel tank, place the cap on the tank paying
careful attention to line up the slots on the gas cap.
Turn clockwise to tighten.
12
USER’S MANUAL
Fuel petcock: The fuel petcock located in between the gas tank and the
carburetor controls the amount of fuel delivered. It uses the vacuum
created from engine movement to produce a steady supply of fuel. Some
units are mounted directly to the fuel tank while others are attached to the
frame.
Instructions to Users
Fuel Filter: The fuel filter located inline from the carburetor to the fuel tank
acts as a safeguard, keeping small particles and contamination from
entering the carburetor. Any blockage of the fuel filter can compromise the
fuel system.
Warning
*
*
*
Be careful not to overfill the fuel tank. Gasoline can damage the finish of the vehicle. Always remove spilled gas from painted surfaces and clean
with soap and water.
Gasoline is flammable. Only fill the vehicle with the engine turned off, and parked in a well ventilated area.
Do not smoke when filling the vehicle with gasoline. Do not expose gasoline to high heat, sparks, or fire.
Caution
*
13
Only use 93 octane fuel. Failure to use anything but premium fuel can cause engine damage and void the warranty.
Instructions to Users
USER’S MANUAL
Vehicle Operation
All Bintelli scooters use a dry-type automatic centrifugal clutch and belt driven CVT transmission. If there is ever an issue with
the transmission belt, variator, or clutch, please have the vehicle serviced at an authorized service center.
Front brake handle: When applied, the front brake will
engage and slow the vehicle.
Automatic clutch: The belt driven CVT transmission
allows for constant acceleration with no need for gear
changes. Simply turning the throttle will engage the
transmission.
14
Rear brake handle: When applied, the rear brake will
engage and slow the vehicle.
Kick start lever: Allows for manual starting of the
vehicle. Manual starting can only be used when the
vehicle is on the center kickstand.
USER’S MANUAL
Instructions to Users
Vehicle Load
Tools included with vehicle
The maximum load of the vehicle must be strictly observed. Failure to
do so will result in an unsafe driving condition, potential engine and/or
premature transmission wear.
Common service and maintenance tools included with the vehicle:
*
Articles in the rear storage box must be securely fixed.(If equipped)
*
Never hang items from the front steering.
*
The load of the rear carrier must not exceed 10lbs.
*
Check page 7 of this manual for your model specific vehicle load
limit
A tool kit under the seat features many of the tools
needed to perform routine tasks
Warning
Failure to follow the recommended vehicle load can cause
multiple issues with your scooter! Bintelli will not warranty damage or
wear that is the result of improper riding!
15
Operating Instructions
USER’S MANUAL
Basic vehicle information
In order to ensure optimal performance of the vehicle, regular service and
maintenance must be followed. Always check the vehicle is safe to
operate prior to driving.
1.
Start the engine and allow the vehicle to idle for a few minutes to let
the engine warm up.
2.
Check for any signs of leaks around and underneath the vehicle.
3.
Check all lights and scooter controls for functionality.
Prior to using the vehicle, please perform the following checks to ensure
proper safety and performance is met.
Turn the ignition key to
the right and verify the
controls are working.
Different levels of maintenance and service will be required at certain
odometer readings. Level 2 and 3 servicings include checking and
adjusting multiple areas of the scooter in addition to the required oil
changes. They are as follows:
500 Mile Servicing: Oil change and valve adjustment **must be
performed at authorized service center**
Level 1 Service and Maintenance: Odometer reading 1000-1500 miles.
Level 2 Service and Maintenance: Odometer reading every 3000 miles.
Level 3 Service and Maintenance: Odometer reading every 6000 miles.
16
Check the fuel gauge to
see if you need to add
fuel.
USER’S MANUAL
Check that the vehicle has an adequate level of
gasoline prior to riding. Verify the gas cap is secured.
Level the vehicle on the rear kick stand and check
the oil to verify the oil level is between the upper
and lower markings. If not, add oil and recheck.
Never drive the scooter with a low oil level, as
this will damage the engine.
17
Verify the steering is tight and moves freely.
There should be no binding and no play.
Verify the throttle grip turns easily. If the
throttle grip does not turn smoothly or binds,
do not drive the vehicle.
USER’S MANUAL
Check under the engine for leaks. Any signs of
Check the front tire pressure and inspect the
tread. Look for any signs of fluid leaks.
leaking should be addressed prior to riding.
Verify the connections on the battery
terminals are tight and free from damage
and corrosion.
Check the rear tire pressure and inspect the
tread. Look for any signs of fluid leaks.
Verify the rear brake cable engages and
disengages smoothly.
18
USER’S MANUAL
Operating Instructions
Kick Starting the Engine:
The scooter can be kick started by following these steps:
Turn the key to the “on” position with the vehicle on the
rear kick stand. The vehicle can only be kick started
while on the rear kick stand.
Verify the kill switch is in the open
“Run” position.
19
Pull the kick start lever out. Standing behind the vehicle, use
your foot to push down quickly on the lever until the engine
turns on. Pause shortly in between kicks to allow the engine
to stop spinning.
If the scooter has been sitting for a prolonged period of time,
turning the throttle 2-3 times will help with cold starts by
injecting extra fuel to aid in starting. During extremely cold
weather, it is sometimes helpful to slightly open the throttle
while kick starting to further aid in quick starting. Always
allow the engine to warm up for 2-3 minutes prior to
driving.
Operating Instructions
USER’S MANUAL
Electric Starting the Engine:
The duration of each electric start attempt should not exceed 5 seconds.
Always wait at least 10 seconds in between starting attempts to prevent
the starter from overheating. If 3 startup attempts fail consecutively, the
vehicle must be checked.
First, insert the key
into the ignition and
turn it to the position
“
”.
Verify the kill switch is
in the open “run”
position. The engine will
not run unless the kill
switch is in the correct
position. Always check
this prior to starting.
20
Hold a brake handle. A safety switch built into the handle
will prevent the engine from starting if you fail to do so.
Finally, press the electric start button with your right
thumb. The engine will start. Remove your thumb from
the button once the engine has started. In cold weather,
or if the scooter has been sitting, pulling slightly on the
throttle will aid in starting.
USER’S MANUAL
Operating Instructions
Parking the Scooter
Always park your vehicle in a safe place.
Use your turn
signals to warn
surrounding
vehicles and
pedestrians
when slowing.
Release the throttle and use the front brake lever
to slow the vehicle. Press both brakes steadily
and smoothly to reduce vehicle speed.
Always use both
brakes when
slowing the
vehicle down.
Once stopped, turn the ignition key left to
the off “
” position to turn off the
engine and shut off the electrical system.
21
Operating Instructions
USER’S MANUAL
Caution
*
When leaving the vehicle parked for an extended amount of time in
an unsupervised area, it is recommended to use the steering
column lock to deter thefts. Always make sure you remove the
ignition key from the vehicle after use.
After parking the vehicle, you have 2 choices to use for
kickstands. The side kick stand is great for quick use but is
not recommended if leaving the vehicle near high foot
traffic or unsupervised for a long period of time.
The rear kick stand is far more stable. To place the vehicle
on the rear kick stand, place a foot on the kick stand lever
and while pressing down shift the weight of the vehicle
backwards. The vehicle will reposition itself on the rear
kickstand as seen above.
22
Turn the ignition lock switch to the
position ”to lock the steering column. The
vehicle cannot be used in this position
USER’S MANUAL
Service and Maintenance
Regular Service and Maintenance
During normal operation of the vehicle it is possible for hardware to
loosen due to vibration. By regularly servicing and maintaining your
vehicle the reliability, fuel economy and performance will be maximized.
Failure to do so will result in decreased performance, safety, and shorten
the service life of the vehicle. Proper regular service and maintenance
can prevent issues from occuring, reduce the maintenance costs and
keep the vehicle in safe driving condition.
4.
The front and rear shock absorbers should be inspected prior to
riding. Always check the front and rear tire for correct air pressure
and inspect the tread. Do not drive the vehicle with low tire pressure
as this can cause the rubber tire to lose its seal and cause injury to
the driver.
5.
Verify there are no loose wires visible.
6.
Check the oil level prior to riding.
7.
Verify the battery connections are free of corrosion and tightly
secured.
Requirements for Service and Maintenance
The following items should be checked each servicing and prior to riding:
1.
Keep the engine clean and free from debris. The cooling shroud
around the engine should not be blocked off. Verify there is no gas or
oil leakage. When the engine starts check for abnormal noise.
2.
The throttle should turn easily without any binding. Any signs of
binding or issues with the throttle should be addressed prior to riding.
3.
Verify both front and rear brakes are engaging and adjusted to the
proper specificaitons. After releasing each brake lever, the brake
system should fully disenage. Any sign of brake issues should be
addressed prior to riding. Lubrication of all cables is recommend
regularly to prolong service life.
23
Service and Maintenance in the Run-in Period
During the first 500 miles of driving the new vehicle the speed should not
exceed 35mph. Running at constant or full speed for prolonged periods of
time must be avoided. It is highly recommended to alternate speeds
during the break in period to help the engine wear in properly. After the
first 500 mile servicing, the scooter can be driven normally. Proper driving
and servicing during the first 500 miles of the vehicle will lead to higher
performance and longer lasting engine life.
Service and Maintenance
USER’S MANUAL
New Vehicle Maintenance Procedure (500 mile Service)
Level 1 Service and Maintenance
1.
Drain and refill oil. Inspect and clean the oil filter screen.
2.
Drain and refill transmission fluid
Level 1 Service and Maintenance should be performed every time after
the vehicle runs 1000-1500 miles.:
3.
Check the travel of the front and rear brakes as well as the throttle
grip. Adjust them if necessary.
1.
Adjust the travel of the front brake to 1/4- 3/4 inches, and adjust the
rear brake to 3/4-1 inch.
4.
Inspect all hardware and tighten if necessary.
2.
5.
Inspect electrical controls. Verify all switches are working.
Adjust the travel of the throttle cable up to a 1/4 inch. Make sure the
throttle is closed at idle. Lubricate the throttle grip and the throttle
cable.
6. Adjust the valve clearance: set the intake valve to 0.003 inches and 3.
the exhaust valve to 0.003 inches. **NOTE** Valve clearance can only be
checked and adjusted with the engine cold. Allow the vehicle to sit for at 4.
least 2 hours after riding to ensure proper adjustment.
7. Check turn signal lights, headlight, taillight, and running lights.
5.
Inspect/clean the carburetor, fuel tank, oil filter screen and air filter if
necessary.
Failure to perform the oil change
and valve adjustment during the
first 500 miles will void the
warranty! It is important to have
this work done at an authorized
Bintelli service center!
24
Adjust the idle speed of the carburetor. With the vehicle on the
center kick stand and the engine running at normal operating
temperature, ensure the rear wheel is not spinning at idle.
Remove and inspect the spark plug. If there is any carbon deposits,
clean or replace and adjust the electrode gap spark plug to 0.025
inches.
6.
Inspect battery terminals. Clean off corrossion if needed and verify
tightness of connections.
7.
Check all body components for fit. Verify all hardware is secure and
in place.
8.
Verify the valve clearance: intake valve: 0.003 inches
exhaust valve: 0.003 inches
USER’S MANUAL
Service and Maintenance
Level 2 Service and Maintenance
Level 3 Service and Maintenance
Level 2 Service and Maintenance are additional items that need to be
checked at each 3000 mile interval. These items should be checked in
addition to the standard Level 1 servicing.
Level 3 Service and Maintenance are additional items that need to be
checked at each 6000 mile interval. These items should be checked in
addition to the standard level 1 and 2 servicing.
1. Check the condition of the transmission clutch. Excessive wear on
the clutch pad material indicates replacement is necessary.
1.
Inspect the frame for damage.
2.
Inspect the transmission gearbox for damage and wear to the gear
teeth.
3.
Ensure normal operation, of front and rear automatic clutches and
the drive system.
2.
Drain and replace brake fluid.
3.
Inspect and clean the carburetor, air filter, fuel tank, fuel filter.
4.
Clean and apply fresh grease to the upper and lower bearings of the
steering column.
4.
Check whether there is any crack, erosion, spalling or serious
stepped wear on each gear tooth of the rear transmission box.
5.
Check the front and rear tires for wear. Inspect for signs of damage.
5.
6.
Clean, inspect and lubricate all cables on the vehicle. Any signs of
fraying or damage indicate the need for replacement.
Ensure normal range of motion and rebound for the front and rear
shock absorbers.
6.
7.
Drain the transmission fluid and replace. Inspect and clean all
tranmission components, checking for wear of the variator and
tranmission belt. Replace as necessary.
Check entire fuel system. Verify all hoses and connections are
secure and no leaks are present.
7.
Check for damage to the front steering column. Any signs of the front
wheel not being properly aligned indicate damage. The steering
column must be replaced in the event of any signs of damage.
8.
25
Verify all electrical controls and switches function normally. Replace
any lightbulbs that are not working.
Service and Maintenance
USER’S MANUAL
Service and Maintenance for the Carburetor
For maximum performance and reliability it is important the carburetor is
adjusted properly. Failure to do so will affect starting,idle,as well as the
overall vehicles performance.
To ensure maximum performance, please do the following:
1.
Regularly check all connections and fittings on the carburetor. A poor
fit between the intake manifold and carburetor can result in hard
starting, poor performance and lower gas milage.
2.
Check the rubber fuel lines for signs of weathering. Any cracks or
deteroriation are cause for replacing.
3. Start and drive your vehicle often. The longer a vehicle sits the more
likely the carburetor is to to develop issues due to stale fuel
contamination.
4.
26
If the vehicle is to be stored for any period of time longer then 2
weeks, the carburetor must be drained to prevent the fuel from
contaminating in the bowl of the carburetor. Failure to do so can
result in hard starting, poor performance, and result in needing to
remove and throughly clean the carburetor.
USER’S MANUAL
Checking and Changing the Engine Oil
With the scooter on the center kick
stand, unscrew the oil dipstick and
wipe clean with a rag. Insert the
dipstick, pull out, and check the
level and color of the oil. The oil
level should always be between the
upper and lower oil level markings
on the dipstick
Service and Maintenance
Caution
Checking and Replacing Engine Oil
To ensure an accurate reading when checking the engine oil, place the
vehicle on the center kickstand. Only check the oil level after the engine
has been shut off for at least 5 minutes. Be aware the engine and engine
oil will be extremely hot if the engine has been running. It is
recommended you allow the engine to cool for at least 30 minutes after a
long drive before checking.
-Remove oil cap. Note if there is oil on the dipstick. A lack of oil on the
dipstick indicates a low oil level.
Following the service
intervals in this manual,
drain and replace the oil as
necessary. The 17mm bolt
on the bottom of the engine
needs to be removed to
drain the oil. Be sure to
clean the mesh filter screen
before reinstallation.
-Wipe the dipstick clean and insert into engine. Quickly withdraw the
dipstick and note the oil level. In between service intervals If there is no
oil on the dipstick, it will need to be added.
After the engine has drained
completely, reinstall the mesh screen
into the spring. Place the spring into
the drain plug and reattach to the
engine. Refill the engine with oil.
-Allow oil to drain completely. Not allowing all the oil to drain will result in
residual oil left in the crankcase which will alter the amount needed to fill
the engine.
Upper oil level marking
Lower oil level marking
-Note the color of the oil. Black oil indicates the oil must be drained and
replaced.
-To drain the engine oil, loosen the 17mm oil drain plug on the bottom
right hand side of the engine, directly underneath the black engine
shroud.
-Inspect oil filter and clean if necessary.
-Reattach oil drain plug with spring and filter installed.
-Fill with 750mL of 10W-40 engine oil through the oil dipstick opening.
-Insert dipstick and withdraw to verify correct oil level.
-Tighten dipstick and inspect for leaks.
27
Service and Maintenance
USER’S MANUAL
Service and Maintenance of the Spark Plug
Inspect for wear/
Side
electrode
Remove the spark plug from the engine. If the color of the insulator skirt
of the spark plug is brown it indicates that the carburetor is adjusted
properly. Any signs of buildup on the plug should be noted as this could
be a sign of an incorrect carburetor adjustment.
Cleaning the Spark Plug
Caution
Check the electrode gap of the
spark plug with a gauge and
adjust the gap to 0.025 inches
It is normal for the
spark plug to be
light brown. This
indicates a proper
air fuel mixture.
Inspect the spark plug for carbon buildup. If there are noticeable deposits
or wear on the spark plug, replace.
Correct spark plug gap helps fuel
economy and performance.
Incorrectly gapped spark plugs
can lead to hard starting and
poor performance. Always
replace the spark plug with the
original NGK replacement.
When removing and tightening
the spark plug, be sure to use the
correctly sized socket. Improper
removal can result in spark plug
damage that can result in costly
repairs.
28
USER’S MANUAL
Service and Maintenance
Service and Maintenance for the Air Filter
When the filter element of the air filter is blocked by dust, it may result in
increased resistance of the air intake system which leads to a rich gas
mixture that can reduce power and increase fuel consumption. It is
important the air filter be cleaned on a regular basis.
Take off the screws
for the air filter
cover, and remove
the air filter cover.
Check whether
there is dust and dirt
on the sponge foam
of the filter element.
Remove the air
filter.
*
It is forbidden to use the following cleaning agents to clean paper filter
elements, such as gasoline, low ignition-point solvent, acid, alkaline or
organic volatile oil.
Inspect the air filter. During normal operation the air filter
will accumulate dust and dirt. Excessive buildup in the air
filter indicates the need for replacement. Driving in dusty
conditions will lead to more frequent air filter replacements.
Wipe off excessive
dust inside the air
filter with a clean and
dry cloth.
29
Caution
Service and Maintenance
USER’S MANUAL
Adjustment of the accelerator handgrip
Service and Maintenance for the Front Brake
Check whether the free travel of the throttle grip is within the specified
range and adjust if necessary. Please follow the following steps to adjust
the throttle free travel:
Most models use a front disc brake, which features high heat dissipation
and increased performance.
1.
First, loosen the locking nut.
1.
Place the scooter on the rear kick stand.
2.
Spinning the regulator will extend or shorten the free travel of the
throttle.
2.
Adjust the regulating nut of the front brake to adjust the free travel of
the front braking handgrip to 1/4 -1/2 inch.
3.
When the desired setting is reached, tighten the locking nut and slide
the protective covering back over the regulator.
Adjustment of the front disc brake
The throttle grip should work
smoothly. Any signs of
sticking or binding should be
addressed prior to riding the
vehicle.
Locking nut
30
Regulator
Adjust the free travel of the front braking handgrip between ¼ and ½ inch
USER’S MANUAL
Service and Maintenance
Disc brake
*
31
Check the travel of the brake lever when applied. Excessive travel
could indicate worn pads or air in the brake fluid. Either of which
need to be addressed prior to riding.
*
Check for the wear on the front disc rotor. Any signs of warping or
irregularites in the surface of the brake rotor can cause vibration,
lower braking force, and increase the stopping distance. Replace if
needed.
Service and Maintenance
USER’S MANUAL
Service and Maintenance for the Rear Brake
Adjustment of the rear disc brake:
*
First, use the support to prop up the rear wheel of the motorcycle
and then adjust the free travel of the rear brake.
*
Apply the rear brake several times. Each time the brake should
release freely without binding or sticking. Rotate the rear wheel
assembly to check whether the wheel rotates freely.
When applying the rear brake, ensure the wheel stops spinning within the
recommend free travel. On rear brake cable equipped models, turn the
brake adjustment fitting at the bottom of the cable clockwise to tighten the
cable and reduce free travel. If the adjustment is maxed out, please take
your vehicle in to an authorized service center for servicing.
**Service Tip** Sometimes mud and dirt can collect around the rear
brake cable under transmission. Always keep the cable and fittings
clean of dirt and debris. Lubricate the cables often to improve service
life.
Use the support to prop up the motorcycle, and adjust the free
travel of the rear brake between ¼- ½ inch.
32
USER’S MANUAL
Service and Maintenance
Adjustment of the rear brake light
Adjustment of the idle speed
*
It is important to always check the vehicles lights are properly
functioning prior to using the vehicle. The brake light can be
inspected with the ignition turned to the on position, and the left
brake handle pressed.
If the vehicle stalls out during normal operation due to the engine speed
being too low, the idle speed of the can be adjusted as outlined in the
following steps:
*
When applying the front and rear brakes, each side should turn the
rear brake light on when pressed individually. Switches mounted to
the inside of the brake handles cause the brake light to turn on when
pressed.
In order to gain access to the brake switches the left and right side
controls must be removed as well as the brake handles. This can be
performed at your local authorized service center.
Rear brake
light switch
Front brake
light switch
33
*
*
*
Before adjusting the idle, make sure the engine has reached normal
operating temperature.( typically 5-10 minutes of driving )
Place vehicle on the center kickstand.
With the engine running, adjust the idle speed to the specified value.
*
If the engine dies .
Adjust the idle speed screw here. Turning clockwise will raise the
idle; counter clockwise will lower the idle.
Service and Maintenance
USER’S MANUAL
Service and Maintenance for Front and Rear Tires
Removal and Installation of Front Wheel
Prior to riding always inspect the tires. Make sure the front and rear tire
are filled to their recommend pressure. Proper tire inflation increases
riding comfort and stability of the driving of vehicle while prolonging the
service life of the tires.
*
With the engine off, place the vehicle on the center kickstand.
*
Remove the nut off the front wheel bolt. Slide the bolt out while
making sure to retain all hardware including wheel spacers, and
speedometer sending unit.
Tire Pressure
Front
wheel
Rear
wheel
30psi
32psi
Caution:
*
Do not use the front brake with the wheel removed.
*
Always retorque the front wheel nut to 80ft.lbs.
*
Check fluid level and top off if needed. Verify the wheel spins freely
with no brake drag.
Failure to
properly torque
the front wheel
nut can lead to
serious injury!
Check the air pressure of the tire and visually inspect the
rubber tire and rim for excessive wear or defects. If there are
any issues, the tire should be replaced at a local authorized
service center.
34
USER’S MANUAL
Removal and Installation of the Rear Wheel
Service and Maintenance
If the tread depth in the middle of the tire reaches the following limits the
tire must be replaced immediately.
*
Verify the engine is off.
*
Place vehicle on center kick stand and remove muffler.
*
Loosen the rear wheel nut, and remove the rear wheel.
Minimum limit of tread
depth
Front wheel
Rear wheel
5/64 inch
5/64 inch
Installation precautions:
*
Torque the rear wheel nut to 80ft.lbs. and reinstall muffer.
*
Verify the rear brake is adjusted properly.
Check the tread
wear depth of the
tire and inspect for
damage. If any
abnormality is
found, the tire must
be replaced
immediately.
Muffler
Rear Wheel Nut
Caution
35
*
Low tire pressure will increase the rolling resistance of vehicle,
increase fuel consumption and wear the tire prematurely. In more
severe cases it can lead to blow outs. Always check tire pressure
prior to riding.
*
Excessive tire pressure will cause uneven tire wear, increase the risk
for blow outs, and decrease vehicle stability.
Service and Maintenance
USER’S MANUAL
Service and Maintenance for Battery
All Bintelli scooters come standard with a MotoBatt Quadflex Sealed Maintenance
Free AGM Battery. These high performance batteries offer more cold cranking amps
and higher capacities then standard scooter batteries. In order to maintain and
prolong the life of your battery, please maintain the battery as follows:
1.
Keep terminals clean and free from corrosion.
2.
Ensure battery terminals and all connections are tight. Loose wires can lead to a
loss of the electric start.
3.
Always remove the battery from the scooter and place onto a trickle charger if the
vehicle is not going to be used for more then a 2 week period. Failure to maintain
the charge of the battery can lead to poor service life.
4.
MotoBatt batteries are sealed units, never remove any part of the battery to
replace fluids.
Ensure the battery terminals are clean and tightened
properly. Any signs of corrosion need to be cleaned
promptly to prevent damage to the battery and
cables.
36
When checking the voltage of the battery, a reading of less
than 12volts indicates the need for the battery to be charged.
You can also place the battery under a load test to verify the
strength.
Weak batteries will be unable to start the
scooter. Place the battery on a 12volt
trickle charger to maintain and prolong the
service life.
USER’S MANUAL
Service and Maintenance
Service and Maintenance for the Fuse
Service and Maintenance for the Horn
The fuse is connected in series to the battery. If there is a sudden power
Over time the horn may need to be adjusted due to road vibrations. By
removing the front panel you can gain access to the horn and the
adjustment screw.
surge or issue within the electrical system, the fuse will automatically break to
protect the battery and other electrical components. Bintelli recommends
using the OEM 15amp fuse.
If the entire electrical system of the scooter is not functioning,
check the fuse first. A blown fuse will cause all electrical
components including the electrical start to stop functioning.
Caution
*
37
A blown fuse can signify a problem with the battery, charging system,
or wiring harness. Always have your vehicle inspected at an
authorized Bintelli service center in the event of a blown fuse.
If the horn sound becomes weak or no longer works, remove the
front panel. Use a multi-meter to measure the output voltage of
the horn circuit. If the horn is receiving 12volts with the ignition
turned on, use the horn regulating screw to adjust the sound
volume of the horn to the desired level.
Service and Maintenance
USER’S MANUAL
Storage of the Vehicle
Long-time storage:
For vehicles that will be parked for longer then a month, the following
items need to be performed.
*
Increase the tire pressure to the normal specification if low.
*
Cover the vehicle and store it in a well-ventilated, waterproof area.
*
Drain all fuel from carburetor and fuel tank.
When removing from storage:
*
Remove spark plug. Pour a tablespoon of clean engine oil into the
cylinder. Using the kick start, turn the engine over 10-20 times to
evenly distribute oil inside the cylinder.
*
Clean the vehicle. Replace the engine oil if the vehicle has been
sitting for more than 4 months.
*
Remove the battery and place on a trickle charger.
*
Check the battery. Reinstall and verify all connections are secure.
*
Wash the vehicle and wipe dry with a soft cloth. Wax the painted
surfaces, and apply a film of anti-rust oil to the chrome surfaces.
*
Refill fuel tank.
*
Perform a visual inspection and check for leaks.
Caution
Failure to keep the battery on a trickle charger during prolonged periods of storage will result in electric start problems.
38
USER’S MANUAL
Service and Maintenance
Service and Maintenance Interval Table
Regular Service and Maintenance is generally based on the reading of the odometer. When the motorcycle is working under bad conditions or under
load operation for a long time, the service and maintenance interval should be appropriately shortened.
Item
Odometer
Times of service and maintenance
Items of service and maintenance
Interval
500 Miles
1500 Miles
3000 Miles
4500 Miles
Fuel system
C
C
C
C
Fuel filter
C
C
C
C
Throttle cable
A
A/C
A/C
A/C
※※
Carburetor
C
C
C
C
Air filter
C
C
C
C
Spark plug gap
A/C
A/C
A/C
A/C
※※
Valve lash
A
I
I
I
Engine oil
R
R
R
R
Oil Filter Screen
C
C
C
C
※※
Timing chain
I
A
A
A
Carburetor idling
A
A
A
A
※※
Transmission Belt
A
R
R
Battery
B
B
B
B
Brake shoe
I
A
A
R
※※
Braking system
A
A
A
R
Brake light switch
A
A
A
A
Lighting system
I
I
I
I
※※
Clutch
I
I
I
I
※※
Shock absorber
I
I
A
A
Nuts and bolts
G
G
G
G
Front and rear tire hardware
I
I
I
I
Throttle grip
I
A
A
R
A-Adjustment C-Cleaning I-Inspection R-Replacement G-Tightening B-Battery Charging
39
Remarks
Items marked “※※”
can only be performed
by an authorized
Bintelli service center.
When driving in a
highly dusty area the
service and
maintenance interval
should be appropriately
shortened.
Service and Maintenance
USER’S MANUAL
Service and Maintenance Interval for Lubricated Parts
Name
Engine Oil
Brake Cables
Brake Fluid
Lubricating oil for front
shock absorber
Tachometer gear
Steering gear
Bearings for front and rear
wheels
Rear braking swing arm
Model
SAE 10W-40
Multipurpose
lithium-based lubricating
grease)
DOT3 or DOT4
Lubricating grease for
shock absorber
Multipurpose
lithium-based lubricating
grease
Multipurpose
lithium-based lubricating
grease
Multipurpose
lithium-based lubricating
grease
Multipurpose
lithium-based lubricating
grease
Miles
-
1000
R
2000
R
-
-
R
Odometer reading
4000
8500
R
R
-
I
R
15000
R
20000
R
R
R
R
R
I
-
-
T
I
I
I
I
R
I
R
I
I
-
R
-
R
I
R
R
I
-
I
-
I
-
-
I
-
I-Inspection R-Replacement T-Addition
40
R
10500
R
Common Faults and Troubleshooting
Fault system
Fault
The engine is unable to be
started.
Fuel system
Incorrect air/fuel mixture;
The vehicle is difficult to start
or the fuel is excessively
consumed.
Air intake/exhaust
system
Causes
Fuel not entering the carburetor;
Fuel not flowing from fuel tank;
The vacuum line fitting leaks;
The fuel line is blocked;
The vacuum hose is blocked.
The carburetor is blocked;
The vehicle is hard to start
The carburetor leaks;
The fuel filter is blocked;
The throttle of the carburetor is worn;
The fuel is bad;
The air vent of the fuel tank is blocked;
Low fuel
The Air filter element is blocked;
The air filter leaks;
The air filter has too much dust;
The air filter housing leaks;
Excessive carbon buildup
The exhaust port leaks;
The muffler is blocked.
Troubleshooting
Check fuel lines for blockage
Check the fuel petcock
Replace the vacuum line fitting
Replace fuel line
Replace the vacuum hose
Clean or replace the carburetor
Readjust the mixing ratio and concentration of the
carburetor.
Clean the carburetor or replace the carburetor floater
Clean the fuel filter
Replace the throttle
Replace the fuel.
Remove blockage in air vent of the fuel tank
Add fuel to the fuel tank
Clean the air filter element
Replace the air filter
Clean the air filter element.
Repair or change the air filter housing.
Clean the carbon buildup
Replace cylinder head
Replace muffler
Service and Maintenance
USER’S MANUAL
Common Faults and Troubleshooting
Fault system
42
Fault
EPA Device
Emitted pollutants exceed
applicable standards
Ignition system
Weak or no spark
Engine Mechanical
The engine will not idle
Causes
Too much carbon is built up at the secondary air intake
port.
The air pump is blocked or damaged.
The air pump filter is blocked or damaged.
The intake rubber hose is leaking.
The clamp is loose or damaged
Excessive carbon buildup on the spark plug.
The spark plug is not gapped properly
The spark plug is damaged
Short-circuit of the ignition coil
C.D.I is faulty.
The stator is faulty.
The connection of the ignition system is loose.
The cylinder head is leaking
Valves are not adjusted properly .
Excessive blowby from piston rings
Troubleshooting
Clean the carbon buildup at the secondary air intake port.
Replace the air pump.
Replace the air pump filter.
Replace the intake rubber hose.
Replace the clamp.
Clean the carbon buildup and dirt on the spark plug .
Adjust the gap
Replace the spark plug
Replace the ignition coil
Replace C.D.I
Replace the stator
Check each connection.
Replace the cylinder head
Adjust the valves to specificed clearance.
Replace piston rings/hone or replace cylinder
Common Faults and Troubleshooting
Fault system
Fault
Compression ratio is too
high
Excessive noise from
engine.
Engine Mechanical
The cylinder compression is
low
Excessive smoke from
muffler
The cylinder head leaks.
The front wheel vibrates
Front Wheel
The front wheel has play in it
Causes
There is too much carbon buildup in the combustion
chamber and on the top of the piston.
Valves are incorrectly adjusted.
The air valve is broken
Internal engine damage from oil starvation
Troubleshooting
Clean the carbon buildup in the combustion chamber and
on the top of the piston.
Readjust the valve clearance
Replace the air valve
Replace damaged engine internals
Damage to cylinder, rings, valves, piston possible
Replace damaged parts
Worn/ damaged piston rings
Oil leaking past valve seals.
Wear on piston and piston rings
Valves not adjusted at 500 mile servicing
The front shock absorber is faulty
The triple tree is bent from a crash
The front wheel is damaged
Object in tire
The front wheel bearings are worn out or damaged.
The front wheel is damaged
The front wheel nut is loose
The tire pressure is too low.
The front wheel bolt is loose.
Replace the piston, rings, cylinder
Replace valve seals
Replace the piston, rings/ cylinder
Cylinder head needs to be replaced
Replace the front shock absorber
Replace triple tree
Replace front wheel
Replace tire
Replace the front wheel bearings.
Replace the front wheel
Torque the front wheel nut to the proper specification
Increase the tire pressure.
Torque the front wheel nut to the proper specification
Service and Maintenance
USER’S MANUAL
Common Faults and Troubleshooting
44
Fault system
Fault
Rear Wheel
The rear wheel vibrates.
Suspension system
The shock absorber no
longer rebounds
Brakes
Poor braking performance
Lights
The head light will not turn
on
Causes
The rear wheel is damaged.
The tire pressure is too low.
The rear wheel nut is loose.
The spring of the shock absorber is worn out
The shock absorber is improperly adjusted.
The master cylinder has air in it
The front brake pads are worn
The rear disc pads are worn
Contaminated or old brake fluid
The head light bulb is burnt out .
The headlight switch is faulty.
The connecting plug is loose.
The fuse is burnt out
The battery is dead
Stator issue
Troubleshooting
Replace the rear wheel.
Increase the tire pressure.
Torque the rear wheel nut to the proper specification
Replace the spring of the shock absorber
Re-adjust the shock absorber
Bleed the brake lines
Replace front brake pads/ bleed lines
Replace rear brakes/ adjust brake cable
Flush and bleed brake lines
Replace the head light bulb.
Inspect headlight switch wires/ replace
Check the plug connector
Replace the fuse.
Charge the battery
Check stator connections/ replace