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1
Preface
Preface
Thank you for choosing the Royal Alloy GT125/GT150 scooter.
Royal Alloy products embody high technology with reliability and
have been designed utilising RA Engineering Co. Ltd and its partners’
many years of experience in manufacturing motorcycles and scooter
for travel, commuting, leisure and sporting activities.
This is why this model takes a leading position in the market sector.
This manual explains the use, operation, basic inspection and
maintenance etc for your scooter. If you have any further questions
about the operation and maintenance, please contact your dealer.
The scooter is designed to fully meet the exhaust emissions standards
prevailing on the date of manufacture.
To keep the compliance to the exhaust emissions standards, please
carry out the maintenance schedule and instructions in this manual in
cooperation with your dealer.
The following important information will appear in this manual:
Caution
Refers to procedures that must be followed. Otherwise, your personal
safety may be endangered.
Note
Refers to procedures that must be followed to avoid damaging the
scooter.
Warning
Refers to procedures that must be followed to avoid injury to you, or
other persons or the scooter.
Note
This manual should be regarded as part of the scooter and should be always
with the scooter, even when it is resold.
Note
Our company is working hard in improvement of product design and quality.
This manual contains the latest product information at the time when it is printed.
However, it is possible that the manual may have slight differences with your
scooter. If you have any question, please contact your dealer.
Warning
Read this manual carefully before riding the scooter.
2
Contents
Contents
Contents ·········································································· 3
Precautions for Safe Riding ················································ 5
Names of different parts ····················································· 6
The Serial Number····························································· 8
Functions of Controllers ···················································· 9
Instrument Panel Indications
9
Ignition switch
11
Switches on the Handlebars
12
Throttle Grip
13
Brake Levers
13
Main Stand
14
Fuel Tank Cap
15
Seat Lock
15
Front Luggage Box
16
Fuel and Oil Recommendations ········································· 17
Running-in of New Scooter················································ 18
Inspection before Riding ··················································· 20
Battery connection
20
Inspection of Braking effect and free play
20
Inspection of the Tyre
21
Inspecting the Quantity of Fuel
21
Inspecting the Quantity of Engine Oil
22
Inspecting the Transmission Oil Level
23
Inspection of the Ignition Unit and the Lights
23
Inspecting the Rear View Mirrors
23
Inspecting the Reflectors and the License Plate
24
Riding Tips ······································································ 25
Start the Engine
25
Setting off
25
3
Contents
Inspection and Maintenance ·············································· 28
The First Service
28
Maintenance Schedule
29
Battery
31
Spark Plug
32
Fuel Hose
33
Air Filter
33
Throttle Cable Adjustment
34
Hydraulic brake fluid
34
Tyres
35
Fuse
36
Troubleshooting ······························································· 37
Storage Procedures ·························································· 37
Specifications ·································································· 39
Warranty ···········································································
4
Precautions for Safe Riding
Precautions for Safe Riding
Please obey all local traffic regulations and consider safety prior to
riding. It is advised to control your speed to stay within safe limits.
Practice before Riding
Before riding the scooter in traffic, it is advised to practice your riding
at a spacious and traffic-free place so that you are skilled enough to
ride safely and are familiar with the scooter’s controls. Practice is
essential to safety. Please observe any special training and or
government test required before using your scooter on public
highways.
Knowing Your Safety Speed Limit
Safety speed limit varies in accordance with the road conditions,
riding skill and the weather. To be aware of speed limits is helpful to
avoid traffic accidents.
Be Careful on Rainy Days
It is dangerous to ride on damp or wet roads. Therefore, high speed
should be avoided and special care should be taken when turning.
Bear this in mind, the braking distance on rainy days can be twice as
much as on dry days.
Correct Wearing of Safety Helmet
Always wear a safety helmet whenever you ride, and make sure you
fasten the strap securely whenever you wear the helmet.
Safety clothing Recommendation
Bright-coloured and well-fitting clothes are recommended. Fitted with
EC protection. Always wear gloves.
Indispensable Maintenance and inspection
The following items are indispensable:




Make safety checks before every journey.
Half-yearly thorough inspection.
One-year thorough serving.
Those listed in the Maintenance Schedule.
Caution High Temperature
The high temperature of the muffler may cause burns. Please park
your scooter to prevent the accidental chance of persons coming into
contact with the muffler.
No modifications allowable
Modification to the unit is prohibited as it may compromise safety
of riding.
5
Names of different parts
Names of different parts
Familiarise yourself with the following parts carefully before using the
scooter.
1 Exhaust / Muffler
○
4 Seat
○
7 Front turning lamps
○
2 Rear light / brake light
3 Rear rack
○
○
5 Acceleration grip & right switch ○
6 Head lamp
○
8 Front right shock absorber
○
⑥
①
② ③
⑤
④
⑦
⑧
Warning
Rear rack has a maximum payload of 5 kgs
6
Names of different parts
1 Rear brake lever
○
4 Glove box
○
7 Rear disc brake
○
10 Main stand
○
2 Rear-view mirrors
○
5 Rear shock absorber
○
8 Air filter
○
11 Front disc brake
○
⑤
④
①
②
12
○
3 Left grip switch
○
6 Rear turning lamps
○
9 Rear Drive
○
12 Front left shock absorber
○
⑥
③
11
○
⑩
7
⑧ ⑨ ⑦
The Serial Number
The Serial Number
Engine number
Engine number is stamped on the rear of the crankcase assembly.
Note:
Quote your chassis number for convenience in purchasing correct spare
parts from your dealer.
Chassis number
Chassis number is stamped on the frame right side frame rail.
Engine number
Chassis number
Please write down the serial numbers below for future reference.
Chassis Serial No. :
Engine Serial No. :
8
Function of Controllers
Functions of Controllers
Instrument Panel Indications
⑩
①
⑨
②
⑧
③
⑦
④ ⑤
①
⑥
Engine RPM Indicator
The indicator will show the engine RPM.
②
Fuel gauge
Indicate the fuel volume remaining in the fuel tank. When the pointer
points to “F”, the fuel tank is full. When the pointer moves to “E” or
lower, it means the fuel level is low and urgent refilling is necessary.
③/⑦ Lh Direction Indicator & Rh Direction Indicator Lamps
When the left hand indicator is operated the l/h direction indicator
lamp will flash. When the right hand indicator is operated the r/h
direction lamp will flash.
9
Function of Controllers
④
High beam/ Low beam indicator.
⑤
“MODE” button, function see below.
a.
ODOMETER and TRIP METER change:
Insert the key and turn the ignition “ON” to display the ODO
press “MODE” once to change to the TRIP function.
b. Km/h and mph change:
Depress the “MODE” button for 3 seconds to change between km/h
and mph.
c.
Clearing the trip counter history:
Press and hold for 5 seconds release when zero is displayed.
⑥
MI Indicator
If this warning light appears during riding, please consult your
dealer.
⑧
Battery Indicator
Indicates the battery voltage. When the pointer points to “H”, the
battery is full. When the pointer moves to “L” or lower, it means the
battery voltage is low and charging is necessary.
⑨
Display ODO, Trip
Displays the distance - total or single that the scooter has been ridden.
⑩ Speedometer
The speedometer shows the speed at which you are riding in mph or
km/h.
Warning
Before turning the ignition on for the first time, please ensure
that the battery is fully charged and that the battery terminal
connectors are secure.
10
③
Function of Controllers
Ignition switch
Rotate the key to turn power ON or OFF.
ON
OFF
LOCK
The engine can be started
Possible to drive
Not possible to pull out the key.
The engine cannot be started.
The engine is stopped
The key can be inserted or removed
The steering bars can be locked to one direction.
The key can be inserted or pulled out.
When you leave the scooter, you may lock the steering handlebars to help prevent your
scooter from being stolen.
1.
Turn the handlebars to the left.
2.
Insert the key. Press the key in and turn it anti-clockwise to LOCK position.
3.
Pull out the key.
To unlock the handlebars, insert the key from LOCK position, and
turn it (without pressing) clockwise to OFF position.


Note
Swing the handlebars to check if they are locked.
Tip, you may turn the handlebars slightly rightward and try again.
11
Function of Controllers
Switches on the Handlebars
①
③
②
① Beam Switch
This switch is used to change the headlamp beam. When you turn the
switch to:
HIGH
LOW
The high beam is turned on.
The low beam is turned on.
(Low beam is for normal riding)
② Turning Signal Lamp Switch
This switch is used to turn on and off the left or right signal lamps to
show the other vehicles that you want to turn left or right. When you
turn the lever to:
Right
The right signal lamps flash.
Left
The left signal lamps flash.
Push in the switch at the centre position to
Centre
cancel the turn-signal operation.
Please turn off the lamps when they are no longer necessary, otherwise
you may cause problems to other road users
③
Horn Button
Press this button to sound the horn. The horn is used as a warning.
12
Function of Controllers
④
Starter Button
This button is used to start the engine. Turn the ignition key to ON,
squeeze the rear brake lever and press the button.
The rear brake lever must be applied to allow the starter motor to
engage as a safety function
⑥
⑤
④
5
Throttle Grip ○
Throttle grip is used to control engine speed. Turn it towards
(anticlockwise) you to increase engine speed; Turn it away from you
to decrease the engine speed.
Brake Levers ⑥
By operating the brake levers, you can control the speed of the scooter
to slow down or stop. The brake is applied by squeezing the brake
lever gently towards the grip. The rear brake light will be illuminated
when the front or rear brake lever is squeezed inwards.
13
Function of Controllers
⑧
Main Stand ⑧
To use the main stand, depress it by foot until the stand is touching the
floor and lift the rear of the scooter backwards until the stand is
securely in place with the rear wheel off the ground. Use the rear rack
to assist in lifting the scooter upwards and backwards.
Always ensure that the scooter is on level ground or pointing uphill on
hard standing before putting the scooter on the main stand.
Never put the scooter on the stand if the machine is pointing downhill
or the floor is uneven or on soft or loose ground.
Please Note
The main stand is designed to support the weight of the scooter only. It is
not designed to support the weight of the scooter and a rider or passenger.
This may damage the scooter and/or the main stand.
14
Function of Controllers
Fuel Tank Cap
To open the fuel cap, insert the ignition key into the cap and turn it
clockwise.
Seat Lock
To open and close the seat as follows:
1.
The seat release button is located on the left hand side and to the rear of the
seat, push the button in and the seat will open.
2.
To close the seat gently lower the seat down onto the locking pin.
Please Note
Please do not drop the seat to close it as this will damage the seat catch.
15
Function of Controllers
Front Luggage Box







Caution
Do not keep breakables in the luggage box.
Do not keep valuable item in the luggage box.
Do not place fuel and oil in the luggage box.
Only store water proof items in luggage box
Never forget to lock the luggage box.
Maximum payload is 5 Kgs in the luggage box.
Maximum payload is 5 Kgs for the rear luggage rack.
16
Function of Controllers
Fuel and Oil Recommendations
Fuel
Only use unleaded fuel with an octane number 90 or higher. Unleaded
fuel can extend spark plug life and exhaust component life.
Use of leaded fuel or lead additive will damage the catalytic convertor
in the exhaust.
Engine Oil
Use only a high quality 4-stroke semi-synthetic engine oil, this will
extend the longevity of the engine. Grade SE or SD engine oil in API
method are recommended with a viscosity of SAE10W-40. If this oil
is not available, please purchase appropriate substitutes according to
the data listed below.
Transmission Oil
Use good quality EP 80w-90 gear oil.
17
Running-in of New Scooter
Running-in of New Scooter
The first 500 miles are the most important in the life of your scooter.
Proper running-in operation during this period will help ensure
maximum life and performance from your new scooter. The parts are
manufactured of high quality materials, and machined parts are
finished to close tolerances. Correct running-in procedure allows the
machined surfaces to bed in and run smoothly. Freeing up of the
internal parts is achieved after approximately 60 running hours, and
during this running-in period the engine will loosen up and
performance will improve.
Maximum Throttle Operation Recommendation
This table shows the maximum recommended throttle operation
during the running-in period.
Initial 500 miles
Initial 1000 miles
Less than 1/2 throttle
Less than 3/4 throttle
Vary the engine Speed
The engine speed should be varied and not held at a constant speed.
This allows the parts to be “loaded” with pressure, and then unloaded,
allowing the parts to cool. This aids the running-in process of the parts.
It is essential that some load should be placed on the engine
components during running-in. Keep the engine spinning but do not
place excessive loads on the engine.
Avoiding Constant Low Speed
It is not beneficial when running in the engine to operate it at a
constant low speed. Allow the engine to accelerate freely within the
recommended maximum limits. Do not, however, use full throttle for
the first 1000 miles.
18
Running-in of New Scooter
Allow the Engine Oil to Circulate before Riding
Allow sufficient idling time after warm or cold engine start up before
applying load or revving up the engine. This allows time for the
lubricating oil to reach all critical engine components. Failure to do
this will shorten the life of your engine.
Performing the First Service
The first 500Km service is the most important service your scooter
will receive. During running-in all of the engine components will have
bedded in and all the other parts will have seated in. All adjustments
will be restored, all fasteners will be tightened, and the old oil will be
replaced.
Timely performance of the 500Km service will ensure optimum
service life and performance from the engine.
Caution
The 500Km service should be performed as outlined in the inspection and
maintenance section in this manual. Pay attention to the caution and
warning in that section.
Failure to have your Royal Alloy scooter serviced will void the warranty.
19
Inspection before Riding
Inspection before Riding
Before riding the scooter, be sure to check the following items. Never
underestimate the importance of these checks. Perform all of them
before riding the machine.
Warning
Ensure that the battery is fully charged and that the
battery is secure and the battery terminals/connectors are
secure. A battery with loose connections will damage electrical
components including the ECU.
WHAT TO CHECK
Steering
Brakes
Tyres
Fuel
Lighting
Indicators
Horn
Engine oil
Throttle
CHECK FOR
1) Smoothness
2) No restriction of movement
3) No play or excessive movement
1) Correct brake lever free play
2) No obstruction in braking.
1) Correct pressure
2) Adequate tread depth
3) No cracks or cuts
Enough fuel for the planned distance of the
journey
Operate all lights —headlamp, tail lamp, brake
lamp, turning lamps
Oil indicator (if fitted) and turning indicators
Correct function
Correct level
1) Correct play in the throttle cable
2) Smooth operation and positive return of the
throttle grip to the closed position when
released
Inspection of braking effect and free play
Hold the brake levers until feeling resistance, measure the moved
distances at the lever ends. The distances should be 10~20mm.
20
Inspection before Riding
Inspection of the Tyre
1.Tyre Pressure
Observe the wear condition of the tyre and check the tyre pressures. If
the tyre pressure is abnormal, check it with a tyre pressure gauge and
adjust it to the correct value.
Recommended Tyre Pressure
Front Wheel
Rear Wheel
32psi
34psi
2. Crack, Damage, Foreign Object and Abnormal Wear
Check the surface of the tyre:

Is there any obvious damage?

Are there any nails, stones, glass etc. in the
tyre or in the tread?

Is there any abnormal wear?
Inspecting the Quantity of Fuel
Make sure that there is enough fuel to reach your destination. Turn the
ignition switch to ON position, if the fuel gauge hands points to the
red region, the fuel should be refilled as soon as possible.
21
Inspection before Riding
Inspecting the Quantity of Engine Oil
Caution! Always ensure the oil level is kept at the upper level mark
“B”. Never allow the oil level to exceed the upper mark or fall below
the lower mark “C” this will cause severe engine damage. It is the
rider’s responsibility to ensure that the engine has enough oil.
A
B. Max Oil Level
C. Min Oil Level
1. Keep the vehicle in an upright and level position on the main
stand.
2. Start the engine, let it idle for a few minutes to allow the oil to
circulate and then switch it off.
3. Wait for five minutes to allow the oil to return to the crankcase
and settle.
4. Loosen the refilling oil cap/dipstick and remove.
5. Clean the dipstick of oil residues, insert the oil filler cap but don’t
screw it in, otherwise there will be a wrong measurement which
may lead to engine damage. Remove again and check for the
correct oil level it must be between the reference marks “B” and
“C”.
6. If necessary, fill to the “B” level, taking into account that it should
not exceed the “B” mark.
7. Refit the dipstick securely
22
Inspection before Riding
Inspecting the Transmission Oil Level
1.
2.
3.
4.
5.
Start the engine, let it idle for a few minutes to allow the oil to
circulate and then switch it off. Wait for 5 minutes before
checking the oil level.
Remove the oil filler screw (A) and check that the oil level is just
below the oil-filler opening.
If required, replenish transmission oil Hypoid EP 80W - 90 via
the oil-filler opening.
When changing transmission oil, open the drain plug (B) until all
transmission oil flows out then tighten the plug (B) and add new
oil via the oil-filler opening.
Tighten the oil filler screw (A).
Inspection of the Ignition Unit and the Lights
Start the engine, check if the headlight and the rear light are on.
Operate the front and rear brake separately, and check if the brake
light is activated.
Operate turning signal lamp switch, and check if the turn signal lights
work normally.
Inspecting the Rear View Mirrors
Check if the back and side objects can be seen clearly from the rear
view mirrors when seated in the rider's position.
Check if the rear mirror is clean and free from damaged check
tightness on the handlebar mounting.
23
Inspection before Riding
Inspecting the Reflectors and the License Plate
Check that the license plate and the reflectors are not dirty or
damaged.
Check that the license plate is fixed securely and that the registration
number is clearly visible.
24
Riding Tips
Riding Tips
Caution
Before starting, you must
1. Check the quantity of fuel and engine oil.
2. Place the scooter onto the main stand.
3. Ensure that the machine is on flat, hard ground.
4. Apply brakes
Start the Engine
Insert the ignition key into the ignition switch and turn it to ON
When the engine is cold:
5.
Squeeze the rear or front brake lever and hold the throttle 1/8-1/4 turn
open.
6.
Push the starter button until the engine fires.
7.
Hold the throttle at 1/8-1/4 open for 30 seconds to help the engine
warm and to prevent the engine from stalling.
When the engine is warm:
8.
Squeeze the rear or front brake lever.
9.
Open the throttle 1/8~1/4.
10.
Push the starter button until the engine fires.
Caution
Release the starter button soon after the engine is started. Otherwise
damage may result to the starter motor and gear wheels.
Setting off
a)
Take the scooter off the main stand.
b)
Mount the scooter.
While holding the handlebars with both hands, and both brakes
applied mount the scooter from left side and sit on the seat. Support
yourself with your left foot.
25
Riding Tips
Caution
No turning of the throttle grip is advised before you are ready to set off.
c)
Look around to see if it’s safe to set off.
Activate your turning indicator. Look around to judge the conditions
are safe to set off. Keeping the rear brake lever squeezed lever until
you are ready to set off.
Caution
Special attention should be paid to the traffic approaching you from behind.
d)
Setting off
Release the rear brake lever and gradually rotate the throttle grip to let
the scooter build up speed.
Caution
Excessive rotation of the grip can lead to the danger of sudden acceleration.
e)
Adjust Speed
The speed of your scooter can be adjusted by turning the throttle grip.
Rotate the grip towards you to speed up (anti clockwise). Gradual
rotation is recommended. Close the throttle to slow down.
f)
Applying the Brakes and Stopping
Combined application of both brakes is always recommended.
Quickly release the throttle grip or rotate backwards (clockwise) to the
minimum position and squeeze the brake levers simultaneously.
It is advisable to reduce the speed by gradual application of the brakes.
Take extra care when riding on damp or wet roads.
Caution
Heavy single braking of the front or rear wheel may cause the danger of a
skid.
Harsh braking or sharp turning are one of the major causes for loss of
traction or crashes, and should therefore be avoided.
26
Riding Tips
Special care should be taken in rainy and wintery conditions.
Damp or wet road surfaces may reduce the level of grip. Sharp turning
during acceleration should be avoided. An appropriate distance should
be kept from the vehicles ahead. Please be mindful that the braking
distance on rainy days can be twice as much as on dry days.
Skidding may occur on wet or frozen roads, therefore concentrate and
be ready to apply the brakes cautiously at any time.
Check the brakes after washing the scooter or riding through water.
After washing the scooter or riding through standing water, the
braking effect may be reduced. If this occurs, slow riding and gentle
braking should be observed to allow time for the brakes to restore to
their normal function.
Caution
To prevent your scooter from falling off the main stand never park your
scooter facing downhill or on a loose or soft surface.
Always park the scooter on a hard flat surface or facing uphill.
Lock the handle bar
When you park the scooter, lock the handle bar to help protect your
scooter from theft.
27
Inspection and Maintenance
Inspection and Maintenance
The maintenance schedule indicates the intervals between periodic
services in KMs and months. At the end of each interval, be sure to
inspect, check, lubricate and service as instructed. If your scooter is
used under heavy load conditions such as continuous full throttle
operation or is operated in a dusty climate, certain services should be
performed more often to ensure reliability of the machine as explained
in the maintenance section. The dealer can provide you with further
guidelines. Steering components, suspension and wheel components
are key items and require very special and careful servicing. For
maximum safety we suggest that you have these items inspected and
serviced by your dealer or a qualified service mechanic.
The First Service
The maintenance after the first 500 KMs is the most important.
During running in, all engine parts will have been matched to each
other, bedding in will have occurred with other parts. All parts should
be re-adjusted; all fasteners re-tightened and contaminated engine oil
and filters replaced.
To ensure the engine a long service life and optimum performance,
carry out the 500 KMs service as soon as it is due.
Caution
We suggest you use genuine replacement parts. We recommend that those
items on the maintenance schedule marked with an asterisk (*), be
performed by the authorized dealer. You may perform the unmarked items
easily by referring to the instructions in this section.
Failure to have your Royal Alloy scooter serviced in accordance with the
manufacturers stipulations will void your warranty cover.
28
Inspection and Maintenance
Maintenance Schedule
The table below indicates the most inportant aspects which should be carried out per service.
Intervals
KMs
500
3000
6000
9000
12000
which ever
Months
comes first
Nuts at cylinder head and
exhaust pipe
Cylinder head
6
12
18
24
30
T
T
T
T
T
I
C
C
C
C
Exhaust system
T
T
T
T
T
Spark plug
I
I
R
I
R
Fuel hoses
I
I
I
R
I
Transmission oil
R
R
R
R
R
Brake fluid
I
I
I
R
I
Engine oil
R
R
R
R
R
Engine oil pump
I
I
I
I
I
V-belt
I
I
R
I
R
Brakes
I
I
I
I
I
Front fork
I
I
I
I
I
Handlebars
I
I
I
I
I
Rear suspension
I
I
I
I
I
Tyres
I
I
I
I
I
Nuts and bolts
T
T
T
T
T
Lubrication of cables
I
I
I
I
I
Air filter - Clean every 1000 kms replace when necessary or every 6000 kms.
NOTE:
I=Inspect, clean, adjust, lubricate or replace if necessary
C=Clean,
R=Replace,
29
T=Tighten
Inspection and Maintenance
Bolts and nuts on frame body
Tighten the bolts and nuts to specified torque after initial 500 kms and every 3000 kms
(6 months).
Specified torque settings
No.
Item
N·m
kg·m
Ft-lbs
1
Front axle nut
53
5.3
40
2
Handlebar mounting bolt
49
4.9
36
3
Steering stem lock nut
30
3.0
22
4
Handlebar locating bolt
25
2.5
18
5
Front fork mounting bolt
45
4.5
33
6
Master cylinder mounting bolt
10
1.0
7.5
7
Brake hose union bolt
23
2.3
17
8
Brake caliper mounting bolt
26
2.6
19
9
Brake bleed nipple
7.5
0.75
5.5
10
Front panel bolt
23
2.3
17
11
Rear axle nut
120
12.0
88
12
Rear shock bolt
29
2.9
21
13
Rear brake lever nut
11
1.1
8
14
Engine bracket mounting bolt/nut
98
9.8
72
15
Engine mounting bolt/nut
80
8.0
59
30
Inspection and Maintenance
Battery
The battery is located inside the removable cover on the body centre
cover beneath the front of the seat. This battery is a sealed type and
requires no maintenance such as fluid level and gravity.
Caution
If the machine is not being used for 2 weeks or longer – ensure the battery
is kept fully charged by connecting the battery to a trickle charger.
31
Inspection and Maintenance
Spark Plug
NGK
CR7HSA
Plug Gap
Use a small brass brush or cleaner to remove the carbon deposits at the
first 500 KMs or every 3000 KMs. Re-adjust the spark plug gap with a
spark plug gap thickness gauge to keep it 0.6~0.8mm. After every
6000 KMs, the spark plug should be replaced.
Whenever removing the carbon deposits, be sure to observe the colour
of the spark plug porcelain tip. The colour of the tip can tell you
whether or not the standard spark plug is suitable for your type of
usage - this is assuming that everything else is running correctly. If the
standard spark plug is very black, usage may be due to very short trips
where the engine does not reach full operating temperature, you are
better using a hotter heat range of spark plug. A normal operating
spark plug should be light brown or tan in colour. If the colour is
white, it then it may be due to overheating or a lean fuel mixture
condition and should be checked as soon as possible by an authorised
dealer.
32
Inspection and Maintenance
Caution
Don’t over tighten the spark plug or cross thread it. In order not to damage
the cylinder head, do not allow the contamination to enter the engine
through spark plug hole.
The standard spark plug for this scooter has been carefully selected to meet
the vast majority of all operation ranges. If the spark plug colour indicates
that other than standard spark plug should be used, it is best to consult the
dealer before selecting an alternate plug or heat range. The selection of an
improper spark plug can lead to severe engine damage.
Fuel Hose
Replace the fuel hoses every two years.
Air Filter
The air filter element used in this scooter is a paper element type with
a foam outer jacket. If the filter element has become clogged with dust,
intake resistance will increase with a resultant decrease in power
output and increase in fuel consumption due to the richer mixture.
Check and clean the air filter element according to the following
procedure.
1. Remove the screws.
2. Remove the two fixing slippers by sliding them rearward.
3. Remove the air filter cover.
4. Remove the filter element.
5. Clean the filter element by blowing it through with compressed air.
Clean every 1000 KMs and replace every 6000 KMs
Caution
1. Before and during the cleaning operation, carefully examine the air filter
element for any tears in the material. A torn filter element must be replaced
with a new one.
2.If driving under dusty conditions, the filter element must be cleaned
more frequently.
3. NEVER OPERATE ENGINE WITHOUT THE FILTER ELEMENT.
4. Always be sure that the filter element is in excellent
operational condition at all times. The life of the engine depends largely
on this very important individual component.
33
Inspection and Maintenance
Throttle Cable Adjustment
1. Loosen the lock nut.
2. Adjust the cable slack by turning adjuster in or out to obtain the correct
amount of free play 0.5~1.0mm.
3. After adjusting the free play, re-tighten the lock nut.
Hydraulic brake fluid
For front and rear disk brake model
Grade: DOT4.1
Note:
Only DOT4.1 glycol-based hydraulic brake fluid must be used
in this scooter.
Do Not mix with silicon-based or mineral oil-based fluid.
Otherwise the hydraulic brake system will be damaged and the
performance of the braking system seriously reduced.
Don’t use residual fluid from an opened container from previous
maintenance, brake fluid is hygroscopic, it can absorb moisture
from the atmosphere.
Caution
Do not over fill the master cylinder reservoirs or spill brake fluid onto any
painted surfaces.
Brake fluid will damage your paint work.
34
Inspection and Maintenance
Tyres
Before every ride check the tyre inflation pressure and tyre tread
condition. For maximum safety and optimum tyre life, the tyre
pressures should be inspected on a regular basis particularly before
long journeys or with passengers.
Tyre Pressure
Insufficient air pressure in the tyres not only increases tyre wear but
also seriously affects the stability of the scooter. Under inflated tyres
make smooth cornering difficult and over inflated tyres decrease the
amount of tyre in contact with the ground, which can lead to skids and
loss of control. Be sure that the tyre pressure is within the specified
limits at all times.
Tyre pressure should only be adjusted when the tyres are cold.
Cold Inflation Tyre Pressure
Front Wheel
32psi
Rear Wheel
34psi
Caution
Tyre pressures and the condition of your tyres are extremely important to
the proper performance and safety of your scooter. Check your tyres
frequently for both wear and correct inflation pressures.
35
Inspection and Maintenance
Tyre Tread Condition
Operating the scooter with excessively worn tyres will decrease riding
stability and can lead to loss of control. It is recommended that a tyre
be replaced when the remaining depth of tyre tread becomes 1.6mm or
less.
Caution
The standard tyres on your scooter are 110/70/12 front and 120/70/12 rear.
The use of a larger tyre other than standard may result in clearance issues
and may void your warranty.
Fuse
The fuse is located next to the battery. If there is any electrical system
failure, first check the fuse. In case the fuse blows, there is a 10A
spare fuse supplied in the fuse holder.
Caution
Always be sure to replace the blown fuse with the correct amperage fuse.
Never use a substitute, for example aluminium foil or wire, to replace a
blown fuse. If the spare fuse installed blows in a short period of time, it
means that you could have a major electrical problem. You should consult
the dealer or a qualified service mechanic immediately.
36
Troubleshooting
Troubleshooting
Caution
It is best to consult the dealer before attempting to troubleshoot any
problem. If the machine is still within the warranty, then the dealer should
definitely be consulted before you attempt any repairs on the machine.
Tampering with the machine by yourself while in warranty may affect
warranty consideration and void your warranty cover.
Storage Procedures
If the motorcycle is to be left unused for an extended period of time
for winter storage or any other reason, the machine needs special
servicing requiring appropriate materials, equipment and skill.
For this reason, we recommend that you trust this maintenance work
to the dealer. If you need to service the machine for storage yourself,
follow the general guidelines below.
Scooter
Place the motorcycle on its main stand and thoroughly clean the entire
scooter.
Fuel
Drain the fuel tank and run the engine for a few minutes until the
remaining fuel has been consumed.
Battery
Remove the battery from the scooter.
Clean the outside of the battery with mild detergent and remove any
corrosion from the terminals and wiring harness connections.
Store the battery in a room above freezing and connect it to a suitable
battery trickle charger / conditioner.
37
Storage Procedures
Tyres
Inflate the tyres to the normal specifications. See page 35
External
Spray all vinyl and rubber parts (Not Tyres) with rubber preservative.
Spray the unpainted surfaces with a rust preventative spray such as
WD40, GT85 or ACF-50 etc. (Not Brake Discs or Calipers)
Protect the painted surfaces with a good quality car wax.
Procedure for Returning to Service
Clean the entire scooter.
Re-fuel with unleaded fuel.
Re-install the fully charged battery.
Adjust the pressure of tyres as described in the TYRE section. Page 35
Lubricate all places as instructed in this manual.
Do the INSPECTION as listed in this manual before starting or riding
the machine.
38
Specifications
Specifications
Model
GT125
GT150
Overall size (mm)
Wheel base (mm)
Kerb/dry weight (Kg)
Max loading weight(kg)
Fuel tank capability (L)
Engine model
Engine idle speed
Engine type
Bore × stroke (mm)
Total displacement (ml)
Compression ration
Max net power, rate
(kW/r/min)
Max net torque, rate
(Nm/r/min)
Start mode
Engine oil(950ml)
Lubrication type
Transmission oil 170ml
Fuel type
(Unleaded Only)
Tyre type
Front tyre size
Rear tyre size
Inflation:
Front
Rear
Front brake
Rear brake
Spark plug
Head lamp
Turning lamp
Tail lamp/ Brake lamp
Instrument indicator
Battery capacity
Fuse
Horn
Max noise
1845×670×1115
1390
130
280
10.5
1P52QMI
1600 ±100 rpm
1 cylinder, horizontal,
52.4×57.8
124.6
10.5:1
7.2/7500
9.2/7000
376
1845×670×1115
1390
130
280
10.5
1P57QMJ
1800 ±100 rpm
1 cylinder, horizontal,
57.4×57.8
149.6
10.5:1
8.0/8000
10.0/6000
376
Electric
SAE 10W/40 Semi
Pressure/splash
EP 80w-90
Octane rating of 94 or
higher
Electric
SAE 10W/40 Semi
Pressure/splash
EP 80w-90
Octane rating of 94 or
higher
110/70-12
120/70-12
110/70-12
120/70-12
32 PSI
34 PSI
Disc brake
Disc brake
NGK CR7HSA
12V 35/35W
12V LED
12V LED
12V 3W
12V 9Ah
10A
12V 1.5A, 90-100dB(A)
≤7m ≤82dB(A)
32 PSI
34 PSI
Disc brake
Disc brake
NGK CR7HSA
12V 35/35W
12V LED
12V LED
12V 3W
12V 9Ah
10A
12V 1.5A, 90-100dB(A)
≤7m ≤82dB(A)
39
Warranty Terms and Conditions
Warranty
Warranty Terms and Conditions
All Royal Alloy scooters are supplied with a 2 year / 30,000 KMs warranty from
the date of registration. Normal wear and tear plus parts required for servicing are
excluded.
All service and repair work must use genuine Royal Alloy parts.
It is the end user’s responsibility to ensure that the servicing and maintenance
schedule is complied with – it may be a matter of importance to book your
machine into your dealer for a service well in advance in order to guarantee an
appropriate ‘slot’ for the work to be completed.
The Dealer has a responsibility to record work done to your machine via the Royal
Alloy UK online service portal. Your dealer should issue a completed
Pre-Delivery Inspection sheet at the time of handing your machine over. Your
servicing dealer can also issue you with a copy of the work recorded on the Royal
Alloy UK Service Portal – this is your copy of your service history.
The servicing schedule for Royal Alloy scooters is the first service at 500KMs or 6
months and then every 3000KMs or 6 months whichever comes first.
None Warranty – Excluded Items (except manufacturing Error)
Spark Plug, Fuel Strainers, Oil Filters, Drive Chains, Air Cleaner Elements, Brake
Pads, Clutch Disc/Centrifugal Clutch, Light Bulbs, Fuses, Gaskets, Tyres,
Grommets, Rubber Hoses, Rubber Cushions, Step Rubber and Drive Belts,
40
Warranty Terms and Conditions
Breakdown Recovery, Accidental or Negligent Damage, Oil, Petrol. Corrosion
and / or cosmetic deterioration of all components also excluded .
Six Month Limited Warranty Items
Batteries, Side Stand, Main Stand, Seat, Wheel Rim (Distortion), Painted/plated
Parts (including Exhaust), Stickers and Emblems.
Twelve Month Limited Warranty Items
Exhaust System Structural failure only (Paint/Rust NOT Included) LED’s.
ALL OTHER COMPONENTS AND ASSEMBLIES are covered for the full
duration against faulty materials or workmanship, this does not include normal
wear and tear, misuse, negligence, accidental damage. If a part or assembly has
exceeded its normal lifespan and has simply 'worn out' then this is deemed as a
part requiring replacement during normal servicing.
Dealer Responsibility
In order to maintain your Royal Alloy warranty, the supplying dealer must:
1.1: Register the bike for warranty on the dealer portal system.
1.2: Use genuine Royal Alloy parts for maintaining the vehicle.
1.3: Enter the service details carried out, along with observations of the
vehicle on the dealer portal system.
41
Warranty Terms and Conditions
Failure to adhere to these conditions may make the servicing dealer
responsible for any subsequent warranty claims for the remaining period of
the warranty term.
2. Servicing, in order to make a warranty claim, the vehicle must be
maintained according to the prescribed maintenance intervals and only
genuine Royal Alloy parts may be used. The owner is expected to ensure the
execution of the necessary work, and is responsible for the cost of the work
and the parts being replaced during periodic maintenance. It is also the
owner’s responsibility to ensure routine maintenance is carried out in
accordance with the maintenance schedule. Failure to service the vehicle at
the specified intervals will invalidate the warranty.
3. The warranty is limited to the free replacement or repair of any defective
part. This replacement or repair under warranty can only be done with the
express permission of Royal Alloy UK.
4. The liability of the manufacturer or importer is limited solely to the
warranty as defined in article 3 The buyer can in no way claim or apply for
compensation for material or physical damage, consumables or loss of
income, transport or accommodation, or vehicle recovery.
5. The warranty is void if: a) The product was not used or maintained
according to prescribed maintenance intervals specified in the instructions
for the related vehicle. b) The product was repaired or serviced outside the
authorised dealer network, or using none original parts. c) Other fuels,
lubricants or cleaning products were used than those which were
recommended by the manufacturer. d) The product has been rented out or
used for commercial purposes. e) A conversion or modification was carried
42
Warranty Terms and Conditions
out on the product or if the vehicle has been involved in an accident. f) The
product was used for sporting events on closed circuit, off-road, free style, or
for purposes for which it was not designed. g) Any alterations to the
specification of your machine or the fitting of none standard parts .
6. Normal wear and damage caused by the use of the vehicle and not due to a
material or manufacturing fault, are not covered by the warranty:
replacement of tyres and tubes, lighting, spark plugs, fuses, rubber parts,
brake pads and clutch linings, brake cables, clutch cables, speedometer
cables, oil seals, brake discs or drive belts, filters, fluids such as engine oil,
coolant, are expressly excluded from warranty coverage. Corrosion or
deterioration of all components is also excluded .
7. On plastic parts and body panels they will be guaranteed only if their
workmanship or manufacturing defects are detected prior to handover of the
new vehicle to the customer.
8. Warranty on batteries is limited to 6 months.
9. Royal Alloy UK reserves the right to make the final decision on any
Warranty Claim.
10. Royal Alloy UK reserves the right that the images and colours shown are
for illustrative purposes only. Details, prices and specifications are subject to
change without prior notice. E & OE.
43
Warranty Terms and Conditions
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44
Warranty Terms and Conditions
Owner’s Manual
45