Stella Owners Manual

Stella Owners Manual
*.1035"/5*/'03."5*0/'035)&
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Dear Customer,
This is IMPORTANT INFORMATION
1. Name : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. Your
Stella
Address : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.........................................
: ........................
Colour
City : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
State :. . . . . . . . . . . . . . . Zip Code : . . . . . . . . . . . . . .
Engine No.
E 1 7
3
Licence No : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. Your Genuine Dealer. . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Chassis No.
M
7
C
G
8
4
A
3
Name : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Address : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D
Key No.
: . . . . . . . . . . . . . . . . . . . . .
Date of purchase
: . . . . . . . . . . . . . . . . . . . . .
Date of Registration
: . . . . . . . . . . . . . . . . . . . . .
.........................................
City : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
State :. . . . . . . . . . . . . . . Zip Code : . . . . . . . . . . . . . .
Tel. No. : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C-4727090 : STELLA-USA. : 01: 500 :1002
We at Genuine Scooter Company thank you for choosing
scooter.
(E)
as your new
Stella's classic frame is instantly recognizable, and the manual transmission
always keeps you in control. Stella offers the comfort of a new scooter, the
security of time-tested engineering, and is collectable "right out of the box."
With the turn of a key, Stella's auto thumb-start gets you going instantly. The
5-port Automatic Oil Mixing (AOM), 150cc Engine with Catalytic Converter
and Reed Valve Induction, has the power to deliver 8+/-0.3 BHP at 5500+/-200
RPM.
Stella is sure to offer smooth performance and years of comfortable riding. It's
style, performance, and metallic colors are impossible to ignore.
This owner's manual has been designed to help you understand Stella. To
optimize her performance and life, please go through this manual thoroughly.
CAUTION : Removal of the catalytic converter is a violation of Federal law
and will render the warranty null and void.
CONTENTS
DESCRIPTION
Reporting Safety Defects
General specifications
Identification data
Performance & Specifications
Specifications (Auto start)
Fuel supply
General Instructions
Locking System
Glove compartment
Saddle lock
Instrument panel
Control switches
Catalytic Converter
Operating the vehicle
Engine Running-in
Electrical equipments
Battery
Wiring diagram (auto start)
PAGE NO.
4
5
7
8
12
13
17
17
18
18
19
20
21
23
25
26
26
27
DESCRIPTION
PAGE NO.
Recommended oil & Lubricants
28
Maintenance
29
Removal of cowls
29
Tuning of carburettor
30
Dismantling air cleaner & air filter
30
Spark plug cleaning
31
Changing oil in gear case
32
Dismantling cooling hood & cyl. head 32
Changing wheels & tyres
33
Removal & refitting of spare wheel
34
Brake adjustment
35
Front disc brake
36
Replacing bulbs
37
Head lamp setting
38
Periodical maintenance
39
Cleaning & polishing
41
Care of your vehicle when not in use 42
Trouble shooting
43
2
Genuine Scooter Company always recommends that you wear a helmet
and protective eyewear when riding your scooter. BE SAFE!
3
CONSUMER INFORMATION
49 CFR 575.6
Genuine Scooter Company
5400 Damen Avenue
Chicago, Illinois 60625
Reporting Safety Defects
If you believe that your vehicle has a defect that could cause an accident, or could cause
injury or death, you should immediately inform the National Highway Safety Administration
(NHTSA) in addition to notifying Genuine Scooter Company, LLC.
If NHTSA receives similar complaints, it may open an investigation, and if it finds that a
safety defect exists in a group of vehicles, it may order a recall and remedy campaign.
However, NHTSA cannot become involved in any individual problems between you, your
dealer, or Genuine Scooter Company, LLC. To contact NHTSA you may either call the Auto
Safety Hotline toll-free at 1-800-424-9393 (366-0123 in Washington, DC area) or write to :
NHTSA
U.S. DEPARTMENT of TRANSPORTATION
400 7th Street SW, (NSA-11)
Washington, DC 20590
You can also obtain other information about motor vehicle safety from the Hotline mentioned
above.
4
GENERAL SPECIFICATIONS
Engine: A new generation energy saving and
the cleaner burning engine is connected to
the vehicle chassis through the crankcase
swinging arm on the clutch side. The rear wheel
(drive-wheel) is fitted on the outer side of the
drive shaft.
Lubrication: Engine (piston, cylinder, crank
shaft, main bearings flywheel side) is lubricated
by an automatic oil mixer device (AOM).
Fuel supply: Gravity fed petrol and oil. Oil is
mixed in petrol with automatic oil mixer device.
Carburettor has a throttle slide, and the air intake
is located under the seat.
Ignition: An electronic ignition device (CDI)
feeds the current to a high voltage transformer
(HT coil) to generate the spark.
Starting: For self start, push button on right hand
side of handlebar below head light switch. For
manual start, a kick start padel is located on the
right side of the scooter.
Cooling: Forced air provided by a centrifugal fan.
Clutch: A heavy duty, multi-plate oil bath type.
The unit is cable operated by a lever located on
the left side of the handlebar and is adjustable.
Gear box: Four speed forward drive with constant
mesh gears immersed in oil bath are operated by
hand on the left hand side of the handlebar which
functions in conjunction with the clutch control
lever.
Integral Chassis: Pressed steel sheet.
Monocoque structure.
Wheels: Interchangeable and made out of
pressed steel rim with 3.5 x 10 (89 x 254 mm)
tires.
Handlebar: Aluminium casting base with
headlamp, instrument panel and indicator lights.
All transmission cables are concealed within the
casting.
Steering column and suspension: The steering
column is connected to the front wheel swinging
hub. Front and rear suspensions are provided with
helical spring and hydraulic dampers.
5
Security lock: On the steering column and
operated by a key.
Saddle: Dual saddle, tip up type with push button
control and key security lock.
Brakes: Cable operated drum brakes with dual
expanding shoes.
Front Brake: Operated by hand lever placed
on right hand side of handle bar.
Rear Brake: Operated by pedal on the right hand
side footboard.
Fig. 1
Rear view mirror: Stylish rear view mirrors on
both side of handle bar.
Glove compartment: A sleek & spacious glove
compartment for keeping personal belongings
etc. secured with a lock.
Hook for Bag : Hook under the seat for hanging
a bag or helmet.
5. Tool kit:
Pouch containing:
Box wrench (13 X 21mm) and lever
Foot mat: Moulded centre mat & floor channel,
which protect entire foot rest area.
Double sided screwdriver
Battery : 12 Volt 9Ah battery.
(7 x 8 mm and 8 x 11 mm)
2 double ended wrenches
6
VEHICLE IDENTIFICATION
The vehicle is identified by two numbers: one
number is on the chassis and another is on the
engine.
The chassis identification number is stamped
on the right side of rear portion of the
chassis frame (fig. 2). The first row of this number
will being.
MD7CG84A--, and the second row will have 8
charecters.
The engine number is stamped on the crank
case (fig. 3) and will have the prefix E17-followed by 8 characters.
scooter comes with one set of
Each
duplicate keys; both keys are stamped with
identification number. Remember where you
place your duplicate key.
7
PERFORMANCE & SPECIFICATIONS
Dimensions
Overall length
Overall width
Wheel base
Maximum road clearance
Seat height
Weights
Vehicle dry weight
Maximum technically permissible mass
Engine
5.77
2.28
4.05
0.52
2.69
feet 1760 mm
feet 695 mm
feet 1235 mm
feet 160 mm
feet 820 mm
Displacement
Bore
Stroke
Compression ratio
Maximum output/Power
Maximum torque
Ignition system
240 lbs 109 kg
595 lbs 270 kg
Single cylinder, two stroke, forced air cooled with
rotary distribution with 5 transfer ports and reed valve
induction with catalytic converter.
149.56 cc
2.27 inch 57.8 mm
2.24 inch 57.0 mm
9.0 + 0.5 : 1
8 + 0.3 bhp @ 5500 + 200 RPM
13.5 Nm @ 3500 RPM
Capacitor Discharge Ignition (CDI) Electronic
Ignition timing
200 + 20 before TDC
8
Fuel
Un-leaded 87 octane Petrol
with automatic mixing of 2T oil
Fuel tank capacity
2.1 US Gallon (inclusive of 0.26 gallon in reserve.)
Oil tank capacity
0.26 gallon
Fuel cock
Three way tap.
Open (ON); Close (OFF), Reserve (RES).
Carburettor
SPACO–20/20D, Downdraft, 20mm venturi
Spark plug
RN9YC- Champion, B6ES- NGK, WR6DC- Bosch
Spark plug gap
0.7-0.8 mm
Starting
Push button for auto start & kick pedal for manual start.
Clutch
Multiplate, oil bath type.
Transmission
4 speed constant mesh
Overall Gear Ratio
1st Gear
15.38:1
2nd Gear
10.46:1
3rd Gear
7.24:1
4th Gear
5.39:1
9
Chassis
Steering column and suspension
Front & rear suspension
Brakes
Front brake
Rear brake
Tires
Front and rear tires
Tire pressure
Front wheel
Rear wheel
Controls
Steering
Accelerator
Gears
Clutch
Front brake
Rear brake
Pressed steel sheet, monocoque structure
The steering column is connected at the front lwheel
swinging hub.
Front and rear suspension with helical spring and
hydraulic dampers.
Disc brake
Drum brake, mechanical expanding shoe type
3.50 x 10" (89 x 254 mm) 4 Ply rating, interchangeable
22 psi
29 psi
*varies with
temperature
By Handlebar
Twist grip type on right hand side of the handlebar
By hand on left hand side of the handlebar
Lever operated on left hand side of the handlebar
Lever operated by right hand
Pedal operated by right foot
10
Electricals
Generator system
12 Volt 96 Watt flywheel magneto
Head lamp
12 Volt 35/35 Watt
Front position lamp
12 Volt 5 Watt
Tail light
12 Volt 5 Watt
Stop light bulb
12 Volt 10 Watt
Speedolight bulb
12 Volt 1.2 Watt x 2
Turn signal light bulb
12 Volt 21 Watt
Tell tale lamp
12 Volt 1.2 Watt x 6
Horn
12 Volt DC Horn
Battery
12 Volt 9 Ah
Fuse
8 Amp
Maximum speed
53 mph in 4th Gear
11
SPECIFICATIONS
(Auto start)
has an auto push button start located
just below the turn signal light switch (fig.5), as
well as an optional kick-start. The auto start
circuit is operated by a 12 volt-9Ah battery.
A PRD relay (Prevention of Restarting
Device) is provided to avoid use of the
self-starter when the engine is running.
A declutch switch has been provided to prevent
starting of scooter when the clutch is engaged.
An 8 Amp fuse (Near spare wheel bracket, rear
side fig. 6 & 7) is provided to avoid any damage
due to short circuiting in auto start system.
A powerful 12 volt-96 watt magneto charges
the battery through a regulator with a built in
charger.
12
Fuel supply: Both the fuel tank and oil tank are
located under the saddle (fig. 8) and are
accessible only when the saddle is unlocked
and lifted.
scooters are produced with AOM
(Automatic Oil Mixer) for engine lubrication, and
therefore have two separate tanks, one for petrol
'A' and the other for 2T oil 'B' (fig. 9).
Do not fill tank 'A' with "petrol oil mixture". Only
pure petrol is to be filled in tank 'A'. The oil tank
'B' should only be filled with 2T motor oil.
*Ask your dealer for recommendations about brands.
13
The petrol is fed to the carburetor by a normal
gravity system. The oil is supplied in the suction
pipe by means of an AOM device 'M' (fig. 10)
comprising of a piston pump with variable stroke.
This is controlled by crank shaft through a gear
transmission.
The oil tank is provided with a transparent cup
'C' (fig. 11) for checking oil level, which normally
remains full of oil. When oil level lowers to
reserve value, air bubbles will appears in the
cup. Refill recommended 2T Motor Oil.
Note: Take care that the oil inlet pipe 'T' (fig. 10) from
oil tank to the 'AOM' device is completely full of oil.
If air bubbles are present, take off the pipe 'T' from
the 'AOM' device, let some oil flow out so that the
air bubbles are eliminated. Reconnect the pipe.
14
Petrol control (fig. 12): The fuel cock below the
saddle has 3 positions. Use (ON) for regular flow
of petrol from tank to the engine; (OFF) for
stopping the petrol supply to engine; and (RES)
i.e. Reserve, to access the one litre of pertol kept in
reserve in your tank for emergencies.
Choke knob (fig. 13): Located below the seat. To
be used for starting the engine when it is cold.
Pull the choke knob outwards for operation. It
should be pressed back when the engine has
started running.
Caution: If the choke knob remains pulled out during
running, it will lead to the flooding of petrol in the
carburetor causing erratic running and high fuel
consumption.
1. Hook for bag
2. Fuel cock
3. Choke knob
4. Oil level indicator
15
Fuel Supply and Distribution
Fig. 14
1.
2.
3.
Petrol tank cap
Oil tank cap
Oil level indicator
4.
5.
6.
'AOM' Device
Oil inlet pipe
Oil supply pipe
7.
Oil supply valve
A. Suction period
B. Delivery period
16
LOCKING SYSTEM
The same key that starts
, also locks the
steering column, glove compartment and
saddle.
Locking the Handlebar: First turn the handlebar
to the extreme left and then turn the key
anticlockwise to lock position. Pull out the key
after locking (fig. 15).
Un-locking the Handlebar: To unlock, insert key
in lthe ignition, and turn clockwise.
To switch on the ignition: Turn the key further
clockwise to 'ON' position (fig. 16).
Caution:
As soon as ignition key is switched 'ON', the tail lamp
and position lamp is turned 'ON' and brake lamp,
flasher and horn are operable. These loads are
operable on battery. Battery would be discharged
considerably if ignition key kept 'ON' for more than 5
minutes when vehicle is in static condition (without
engine running).
17
Glove compartment lock: To open the glove
compartment, insert the key into the lock, turn
it completely counterclockwise, and then press
it downwards (fig. 17).
To lock, press lid and turn the key clockwise.
Saddle Lock: To unlock, Insert the key and turn
it clockwise to end.
To open, push lock in with thumb, and lift the
saddle from the back.
To close, press the saddle to its normal position:
turn the dey counterclockwise to lock.
18
INSTRUMENT PANEL
An elegantly designed instrument panel with
the following indicators.
1.
Head light high beam indicator
2.
LH turn signal indicator
3.
Neutral indicator
4.
Speed indicator needle
5.
Odometer
6.
Stop indicator
7.
RH turn signal indicator
8.
Head light low beam indicator
9.
Fuel-gauge
19
CONTROL SWITCHES: Control switches are
located on the left and right hand sides of the
handlebar.
Horn : Press button '1' (fig. 20).
Right hand side of the handlebar (fig. 21).
Left hand side of the handlebar (fig. 20) :
Turn indicator switch : Press left end of switch
'2' for turning left, and right end for turning right.
Headlight : Headlight becomes operative while
starting the engine.
For auto start : First press in clutch lever, then
press the start button '3'.
For high beam press top end of switch '2', and
for low beam press bottom end.
Left & right turn indicator is shown on the instrument
panel.
Headlight high & low beam positions are indicated on
the instrument panel.
Engine kill switch : To stop engine press
switch '1'.
Stop light : Becomes operative when foot brake
pedal or hand brake lever is pressed.
Neutral Switch : Is provided in gear control
bracket & neutral indicator is shown on the
instrument panel.
Stop light indicator is shown on the instrument panel.
20
CATALYTIC CONVERTER
The Catalytic converter is an emission control device used to convert toxic gases (Carbon
Monoxide, Hydrocarbons and oxides of Nitrogen) into Eco-friendly gases (Carbon dioxide,
water vapour and Nitrogen) so as to reduce the air pollution from the exhaust gases.
These vehicles are identified with an rectangular sticker near the
fuel tank mouth as a reminder to 'USE UNLEADED PETROL
ONLY'.
Caution : Removal of the catalytic converter is a violation of
Federal law, and will render the warranty null and void.
To make your Catalytic converter last longer.
1.
Use ONLY UNLEADED PETROL in the fuel tank.
2.
Use ONLY quality 2T OIL (Two Stroke).
USE RECOMMENDED
OIL ONLY
A rectangular sticker 'USE RECOMMENDED OIL ONLY' is pasted
on the fuel tank.
21
2.
To get best out of your vehicle fitted with Catelytic Converter.
2.1 Keep the engine properly tuned.
2.2 Do not switch off the engine abruptly when the transmission is engaged and vehicle is in
motion.
2.3 Do not drive the vehicle with choke knob pulled.
Precautions :
Since the silencer fitted with Catalytic converter can be extremely hot during running of vehicle.
do not tuch the silencer to avoid serious burns.
22
OPERATING THE VEHICLE
Warning: Before driving your scooter make
yourself thoroughly familiar with all operating
controls and their functions.
Starting the engine (fig. 22)
Before starting the engine:
Turn "ON" the Ignition switch.
Check if tires are properly inflated.
Put gear control in neutral position & ensure
indicator on instrument panel is ON.
Check for correct play in the clutch lever and
make sure that it operates properly.
Check for correct play in the foot brake pedal
and hand brake lever.
Check if the accelerator throttle is operating
properly and if the play is normal.
Ensure that 2T oil is available in the oil tank,
taking the reference of oil level indicator.
Open fuel cock to "ON" position.
Pull out the choke knob (for cold engine start
only.)
Bring the throttle to idiling position
If you are starting engine for the first time in the
day, press the clutch lever and, keeping it
pressed, kick the starter pedal a couple of times.
For starting the engine press clutch lever and
then press the push button start switch.
When the engine is running normally, press the
choke knob back to its normal position.
23
Caution:
1.
Do not use electric starter for more than 5 seconds at a time. Release the push button start
switch for approximately ten seconds before
pressing it again. If the engine fails to start after
repeated attempts hold the throttle 1/8-1/4 open
and use kick start option.
2.
Before using the auto start switch ensure that
you press the clutch lever.
A- Open fuel cock
B- Switch on ignition
C- Put gear in neutral position & check neutral
indicator is ON.
D- Pull the choke knob (with cold engine only).
E- Bring accelerator throttle to idling position
F- De-clutch
G - Kick starter pedal or push auto button
(for auto start).
24
ENGINE RUNNING-IN
Operation: The most important period in the life
of your vehicle is its first 1250 miles. The engine
is brand new and different moving parts of the
engine need to be set to their correct operating
tolerances. This ensures a longer life for your
vehicle. It is, therefore, necessary to take some
precautions so as not to overload the engine.
Vary the speed from time to time.
Keep to the following speed limits
*Allow a cooling off period of 5-10 minutes after
each hour of use.
1st Gear
:
0 to 6.2 miles/hr.
2nd Gear
:
6.2 to 12.5 miles/hr.
3rd Gear
:
12.5 to 21.8 miles/hr.
4th Gear
:
21.8 miles/hr. and above.
*Do not drive with half, or partially engaged clutch.
this will not only damage the clutch, but will also
cause the engine to overheat.
*Avoid running the scooter on full throttle for long
periods.
*Maintain oil level in gear box up to
recommended level.
25
BATTERY CHECKING :
Battery requires periodic and thorough
maintenance as advised below : The level of
electrolyte must always be in between the upper
and lower levels marked on the battery.
Normally a constant level in the specified range
is maintained for about two months or
approximately 1250 miles (fig. 23).
Caution:
Battery should be removed if the vehicle is to be
washed lying on its side.
Use only 8 Amp. fuse to prevent serious damage to
the wiring harness & battery. Ignition switch should be
in 'off' position while replacing fuse.
The level of electrolyte should be checked once
in a month. In case of a normal decrease
(0.5 cm) put in distilled water only so as to reach
the upper level indicated on the battery. In case
of a marked decrease (1 cm or more), please
get the battery checked at an authorised Service
Station.
26
WIRING DIAGRAM
27
RECOMMENDED OILS AND LUBRICANTS
S.No.
DESCRIPTION OF
PARTS
APPLICABLE
LUBRICANTS
RECOMMENDED BRAND OF LUBRICANTS
1.
Clutch & Brake levers
Grease
2.
3.
4.
5.
6.
Steering Column Bearing
Front Wheel Bearings
Speedo Drive Gear
Front Suspension
Control Cables
"
"
"
"
Grease &
7.
Gear Control Assy.
Grease
8.
8.
Disc Brake
Gear Box *
Brake fluid
Oil
Automotive/Bearing Grease
"
"
"
"
"
"
"
"
"
"
DOT 4, Mobil Super Heavy Duty
SAE 30 Engine Oil
9.
Petrol oil mixture
Oil
Motorcycle-Formulated Two Stroke Oil
* Recommended quantity of oil to be filled in Gear Box is 250 ml + 0ml
- 5 ml
28
REMOVAL AND REFITTING OF COWLS:
The levers for opening the cowls are located
under the saddle and can be operated only with
the saddle is unlocked and lifted.
For removal of cowls, lift the saddle (as explained
on page 18). Pull lever '1' for engine cowl & '2'
for spare wheel cowl so that the hook '3' is free
from the cowl anchoring. Swing the cowl
outwards so that the front locating pin '4' is free
from its housing.
Next, lift the cowl upwards from the front pivoting
onto its rear section so that the clasp '5' releases
from the chassis bracket. Last, pull the cowl
outward on pin '6' so that the latter clears it's
housing, thus releasing the cowl.
For refitting the cowls follow the reverse
procedure.
Fig. 25
1. Lever for engine cowl
2. Lever for LH cowl
3. Hook for locking
4. Front locating pin
5. Clasp securing cowl to chassis
6. Rear hooked pivot pin
29
TUNING OF CARBURETOR :
The idle setting screw controls the engine's idling
speed.
On the rear side of the carburetor a spring
loaded screw is provided to adjust the air fuel
mixture. To ensure optimum performance, it is
recommended that this screw should only be
adjusted by an authorized service station.
On the carburetor body a set screw is applied
for adjusting the throttle cable play; this screw is
to be reset only if necessary or on dismantling
and reassembly operations.
AIR
CLEANER
AND AIR FILTER :
AIR CLEANER : For removing the air cleaner
'A' (fig. 26) remove the engine cowl (fig. 25) and
air cleaner case cap. Unscrew the two screws
'B' and take out the air cleaner.
Air filter: Air filter is fitted over air in-take hole
on chassis below dual seat and requires
cleaning during each periodical service (fig.27)
& more frequently when riding in dusty areas.
Note: When air cleaner case is taken off, the carburetor
is accessible.
For cleaning and washing air cleaner use fuel oil
mixture.
30
Procedure for cleaning :
l Lift the seat and take out the air filter by
unscrewing it from the support plate.
l Rinse the filter in kerosene or petrol only till
same is fully cleaned.
l Blow dry the filter with low air pressure.
l Replace the filter ensuring proper positioning
of its gasket.
SPARK PLUG CLEANING:
Disconnect the high-tension (HT) lead cable by
removing the suppressor cap from the spark
plug.
Wipe & clean the area around the spark plug
than remove it with wrench (fig. 28)
Clean the elctrodes with a wire brush in pure
gasoline (petrol)
Check porcelain insulation, if cracked or broken
change plug. Palce spark plug back into position.
0.7 - 0.8mm
Adjust the gap 0.7 - 0.8 mm.
Fig. 29
31
CHANGING OIL IN GEAR CASE: Drain off the crank
case by unscrewing the drain plug '2' (fig. 30).
Then introduce a small quantity of oil to flush case,
run the engine for few minutes and drain off again.
Next, put 8.5 oz (250 ml) of new motor oil in gear box
up to level of filling hole by removing level plug '1' The
engine should be warm when the oil is changed.
COOLING HOOD AND
CYLINDER HEAD:
Remove the engine cowl, (fig. 25) and disconnect
the HT lead, dismantle the 'cooling hood' (fastening
'A'-'B'-'C' fig.31) and unscrew the 4 nuts using the
tool kit wrench.
When refitting, tighten the securing nuts alternately.
32
CHANGING WHEELS & TIRES:
For dismantling the wheels, remove the wheel
covers and then the securing nuts (fig. 33 & 34).
On reassembly tighten the securing nuts
alternately & progressively.
For removing the tires: first deflate them and then
remove the nuts joining the two wheel rims.
Check that tires are at the recommended level
(page 10) at the nearest service station.
33
REMOVING AND REFIXING THE SPARE
WHEEL: To remove the spare wheel, first remove
the wheel cowl (procedure on page 27.)
Next, unscrew the bolt securing the spare wheel
protection cover (fig. 35).
Last, remove the two nuts 'A' which secure the
wheel to the upper part of the bracket (fig. 36).
To replace the spare wheel, follow the above
procedure in reverse order.
34
BRAKE ADJUSTMENT:
Adjust the screws as indicated with arrow
in fig. 37. Ensure that the wheels should rotate
freely when the brake lever or pedal are in their
resting position.
Note: The braking action should begin immediately
on operating the respective controls.
35
FRONT DISC BRAKE
scooters are produced with a Disc brake
in front wheel (Fig. 38). The disc brake functions
on hydraulic system. Proper functioning of the
brake depends on maintaining the correct level
of brake fluid in the 'Master Cylinder Assy.'
Check the level of brake fluid in the Master
Cylinder which is located on the RH side of the
handle bar (Fig. 39). The transparent level
indicator provided in Master Cylinder should
never be lower than the 'MIN' mark.
If the fluid level is found low, then add the
appropriate brake fluid to the correct level.
Under normal conditions, it is advisable to
change the brake fluid every 10,000 miles or
every 2 years.
36
REPLACING BULBS (fig. 40) :
To access the headlamp bulbs, first remove the
four screws 'A' from the lower part of the
handlebar.
Next. push the speedometer cable upwards &
disconnect from the speedometer.
Then, lift cover 'B', disconnect the harness
sockets, and remove the handle bar top cover.
Last, take out the buld holder and replace the
bulb.
To reassemble, follow the reverse proceddure.
37
HEAD LAMP SETTING: Place the unloaded
vehicle on a level floor at 10 meters from a twilight
white screen and take care that the vehicle axis
is perpendicular to the screen.
Draw a horizontal line 'b-b' at a height of 'B' from
the ground corresponds to 0.9xC with the
headlamp switched on the low beam position,
the horizontal line of demarcation between the
dark zone and the lighted one should not be
over the horizontal line.
Note: The operation of headlamp setting can be carried
out also with the driver only sitting on the machine. In
this case, of course, the beam alignment should be
altered whenever the scooter is being ridden by both
driver and passenger.
B=Cx0.9-C = Height from the ground to headlamp centre.
B=Cx0.95 when the setting of the headlamp is carried out
with the vehicle at 5 meters from the screen.
38
PERIODICAL MAINTENANCE
Preventive maintenance:
In order to optimize Stella's performance, it is important to carry out periodic maintenance. Refer to the following
table for suggested action and scheduling for different maintenance matters.
Code of suggested action is:
C - Check
I - Inspect, check and adjust
F - Drain and refill with fresh oil
S.No.
ITEM
L - Lubricate
T - Check and top up if necessary
D - Carry out.
2500
Miles
1.
Washing and cleaning
D
2.
Gear oil
F
3.
Tightening of all
external nuts and bolts
(Also cylinder head)
5000
Miles
D
S.No.
ITEM
2500
Miles
6.
Air filter (outer)
washing in kerosene
or petrol only
D
7.
Carburetor tuning
I
8.
Carburetor cleaning
D
5000
Miles
4.
Spark plug
I
9.
D
5.
Air cleaner (cleaning
and washing in fuel oilmixture
De-coke of engine
and silencer neck
D
10.
Ignition timing
C
39
2500
Miles
S.No.
ITEM
11.
Functioning of electrical
electronic systems
C
12.
Battery (Top up, check sp.
Gravity and bleeder tube)
13.
5000
Miles
S.No.
ITEM
2500
Miles
5000
Miles
16.
Front and rear shocker
C
D
17.
Tire rotation
D
Control cable adjustment
I
18.
14.
Brakes
C
Lubricate:
Gear control assembly
Speedo drive gear
Front wheel bearing
Steering column bearings
15.
Clutch
C
Caution :
L
L
L
L
Clean Air Filter (located below saddle) more frequently when riding in dusty areas for better
performance and longer life of engine. Replace the filter after 6250 miles or earlier, if required.
40
CLEANING & POLISHING:
Painted surfaces should first be wet down using
a low-pressure hose to loosen any dirt.
Spots : Possible spots caused by tar, grease,
oil etc. can be removed by rubbing gently with
a soft cloth or cotton-wool dipped in oil or
turpentine.
Next, use a car type shampoo (water solution
3-5% weight) and sponge down the surface.
Rinse the area immediately with a solution of a
car type shampoo and plenty of water.
Dry off using a clean chamois leather to eliminate
water marks.
Any insect remnants on the windshield or
headlamp can be removed with a combination
of warm water and car shampoo.
BODY WASHING
Note : For cleaning the exposed surfaces of the engine
use paraffin (for drying up the vehicle use a brush and
soft cloth or chamois leather).
41
Polishing : In addition to regular cleaning,
periodic polishing helps to minimize the effects
of sun, rain or dust on the paint.
To Polish your scooter : first apply a thin coat of
good quality wax, then polish and shine with a
soft cloth. Gently rub the surfaces to be polished
in a side to side manner.
Note: Washing and polishing operations should not
be carried out in the sun, particularly during the summer
when the bodywork is warm. Under no circumstances
should petrol or Diesel oil be used for washing painted
surfaces or plastic material as they will deteriorate.
CARE OF YOUR VEHICLE WHEN NOT IN USE
FOR LONG PERIODS :
Store
properly if you are not going to use
her for more than two months.
First, remove (i.e. siphon) the petrol from the fuel
tank. Start the engine for some time and burn
the remaining petrol.
Next, remove the spark plug (explained on page
29), and put a few drops of 2T oil in the spark
plug hole. Press the kick lever a couple of times.
Replace the spark plug.
Clean the vehicle thoroughly and apply antirust
grease on all unpainted metallic parts.
Remove the battery.
Finally, raise the wheels off the ground using
wooden planks, and deflate the tires so that they
do not touch the floor. And last, cover the scooter.
42
TROUBLE SHOOTING
Engine fails to start or stops immediately after starting
Remedy
Possible Cause
Fuel
Fuel cock in OFF position
No petrol in fuel tank
Irregular flow of petrol to the carburettor
Air lock in fuel tank
Dirty carburettor
Carburettor flooded
(presence of unvapourised fuel in the
engine cylinder)
Electrical
Ignition off
Spark plug terminal disconnected
Dirty spark plug
Weak spark
Engine Misfires
Irregular flow of fuel to the carburettor
Bring the fuel cock to ON position
Refill
Clean fuel lines, fuel cock and filters
Check and clean fuel tank cap air vent hole
Clean carburettor
Close fuel cock, open throttle and kick over the
engine several times, or remove the spark plug,
clean, kick over the engine several times, refit
spark plug and start
Switch on ignition
Connect the terminal properly
Clean and re-set gap
Contact authorised dealer
Check and clean, fuel lines, fuel cock and filters
If the suggested remedies are not sufficient in eliminating the trouble please contact the nearest dealer.
43
TIRE REGISTRATION
Registration form for Independent distributors and dealers-tire identification number
I M P O R TA N T
Approved through 5-31-85
OMB No. 2127-0050
In case of a recall, we can reach you only if
w
e
have your name and address. You MUST send
in this card to be on our recall list.
Do it today.
A
SHADED AREA MUST
BE FILLED IN BY SELLER
TIRE IDENTIFICATION NUMBERS
QTY
1
2
3
4
5
6
7
8
9
10
CUSTOMER'S NAME (Please print)
CUSTOMER'S ADDRESS
CITY
STATE
ZIP CODE
NAME OF DEALER WHICH SOLD TIRE
DEALER'S ADDRESS
CITY
STATE
ZIP CODE
Genuine Scooter Company and LML Limited have joined forces to produce a worldclass Motor scooter specifically for the North American Marketplace. LML Limited is
a well-known manufacturer, based in India, of "everyday mobility" that we have been
fortunate enough to have as our valued partner. We are proud to present this product,
Stella, which they have skillfully manufactured for our customers. We wish you years
of pleasurable scootering.
The descriptions and illustrations in this manual are not to be taken as binding on the
manufacturer. The essential features of the model described herein remain unaltered,
though Genuine Scooters and LML Limited reserve the right to carry out, at any moment,
without modifying this booklet, modifications to the machine and its parts or accessories,
that the companies deem necessary for improving the machine or satisfying
manufacturing standards.
C-4727090 : STELLA-USA. : 01 : 500 : 1002
(E)
11
www.genuinescooters.com
Chicago, Illinois USA
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