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minimocard 2.6

Blata minimocard 2.6 Service Manual For Use And Maintenance

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SAFETY WARNING
Always pay attention to the instructions and safety warnings below
This vehicle is not
allowed to be used on public roads!
Unsafe and careless use of the vehicle can result in serious injuries. The driver can minimize the potential risks by wearing safety equipment. The driver must wear a safety helmet, goggles, gloves, elbow pads, kneepads, and firm footwear. Avoid rough surfaces and obstacles. Always drive with both hands on the handlebars.
Fuel and fuel vapour are highly toxic and flamable. Always be careful when handling fuel – it can burn or poison you.
- stop the engine and turn off the fuel tap, keep naked flames and sparks away from your bike.
- do not smoke near your bike.
- refuel only outdoors in a well ventilated space
- clean up any excess fuel immediately
- keep children and pets away
Always ride within the limits of vehicle/ rider and weather conditions to avoid unnecessary accidents and injuries.
Check-ups Shut the engine off when performing maintenance check-ups otherwise You could be severely injured if your hands or clothing get caught by moving parts.
Make sure the engine and exhaust are cold before performing any inspection of this machine
Riding with a chain in poor condition or improperly adjusted can lead to serious injury. Always, Inspect, Adjust and Maintain the drive chain properly before each ride.
Failure to inspect and properly maintain the brakes increases the risk of having an accident. Before each ride check the brake cables and the brakes efficiency.
Riding with worn brake pads can reduce the braking performance and cause an accident. Check and replace brake pads according to the instructions in this manual.
Using worn, improperly inflated, or incorrect tyres will reduce stability and can cause an accident.
DISPOSAL OF UNUSABLE PRODUCT
Unusable product become a waste and it’s desposal should be in accordance with the law and any applicable local regulations. Don’t throw this product to municipal waste.
Always inspect the bike before each ride (refer to the article ‘INSPECTION AND MAINTENANCE’). Failure to inspect and maintain your bike properly increases the risk of an accident or damage to the vehicle.
MINIMOTARD 2,6
SERVICE MANUAL FOR USE AND MAINTENANCE AND SPARE PARTS LIST
OF MINIMOTARD
Before starting the operation of your Minimotard, read thoroughly these directions. For your own safety and the safety of others Follow these recommendations in order to use your Minimotard safely and correctly.
CONTENTS
PAGE
INTRODUCTION .............................................................................................................. 2
BASIC TECHNICAL DATA ...............................................................................................2
UNPACKING AND BASIC CONTROLS - FIG. 1 ............................................................3
SAFETY.............................................................................................................................3
BEFORE STARTING ....................................................................................................... 3
STARTING THE ENGINE - FIG. 2....................................................................................4
CARBURETOR - FIG. 3 ...................................................................................................4
RIDE ................................................................................................................................. 4
PERIODIC MAINTENANCE ..............................................................................................5
CHAIN SETTING ...............................................................................................................5
CLUTCH PADS REPLACEMENT .................................................................................... 5
ENGINE - EXPOSIVE VIEW..............................................................................................6
MINIMOTARD - EXPLOSIVE VIEW - FIG. 5.................................................................... 7
PART LIST .................................................................................................................... 8,9
FRONT AND REAR BRAKES - FIG. 7 ...........................................................................10
ADJUSTING THE BRAKES - FIG. 4 ............................................................................. 11
FRONT BRAKES PADS REPLACEMENT - FIG. 7 ....................................................... 11
REAR BRAKES PADS REPLACEMENT - FIG. 7 ......................................................... 11
DISMANTLING AND MOUNTING THE FRONT WHEEL - FIG. 5 ..................................11
DISMANTLING AND MOUNTING THE REAR WHEEL - FIG. 5 ....................................12
PINION EXCHANGE - FIG. 6 ..........................................................................................12
DISMANTLING AND ASSEMBLY OF AIR FILTER - FIG. 3 ..........................................12
STORAGE PROCEDURES .............................................................................................13
INTRODUCTION
Minimotard 2,5 is intended for a drive on closed tracks with even, smooth, and dust-free surface. Both growns - up and children can ride on the Minimotard. Children only under the supervision of a grown - up and responsible person. If the terms of a track are fulfilled, the Minimotards can be used for races. Minimotard is equipped with a single - cylinder, two - stroke, petrol combustion engine, with a front and rear disc brake, the rear one being controlled by a lever on the left side of handlebars and the front one by a lever on the right side of handlebars, when seeing in the ride direction. The fuel quantity controlled by a handle on the right side of handlebars. The engine is fitted with an air filter and an exhaust silencer. The driving moment transmission from engine to the driven rear wheel is carried out by a chain drive the ratio of which can be changed to a small extend by a sprocket wheel exchange on the rear wheel.
BASIC TECHNICAL DATA
ENGINE: TWO - STROKE ............................................................... AIR COOLED
DISPLACEMENT..................................................................... 39,9 ccm
POWER OUTPUT.................................................. 2,5 kW at 8 700 rpm
TORGUE ..............................................................3,5 Nm at 6 000 rpm
CARBURETOR .................................................................DELL’ORTO
IGNITION......................................................................... ELECTRONIC
STARTING ..............................................................................MANUAL
CLUTCH .....................................................CENTRIFUGAL, FRICTION
FRAME: WELDED ........................................ HIGH-STRENGTH STEEL TUBES
LINING: ........................................................................................ TWO PARTED
BRAKES: FRONT WHEEL.....................................MECHANICAL DISC BRAKES
REAR WHEEL.......................................MECHANICAL DISC BRAKES
WHEELS: FRONT WHEEL.....................................LIGHT ALLOY 2,1“ x 6,5“ - 90
REAR WHEEL.................................... LIGHT ALLOY 2,1“ x 6,5“ - 130
TIRES: FRONT ...................................................90/65 – 6,5“ WITH PATTERN
REAR.....................................................110/55 – 6,5” WITH PATTERN
FUEL: MIXTURE OF PETROL 91 OR HIGHER OCTANE + 2-STROKE SYNTHETIC OIL
MIXING RATIO.............................................................................. 50 : 1
TANK CAPACITY...................................................................... 1 LITRE
MAX. SPEED (depends on mounted sproket wheel):..... up to 28 mph ( 45 km/ h)
UNLOADED WEIGHT..........................................................................39,7 lb ( 18 kg)
CARRYING CAPACITY.....................................................................242 lb ( 110 kg )
BASIC DIMENSIONS:
LENGHT ....................................................................................925 mm
WIDTH ...................................................................................... 580 mm
HEIGHT .................................................................................... 570 mm
2
UNPACKING AND BASIC CONTROLS
The Minimotard is packed and delivered with demounted handlebars . After unpacking, set up the handlebars in a function position with two clamps and set up that will suit you best. However at maximum handlebars turning, the brake levers must not bump into the lining. After setting - up the handlebars, tighten the handlebars clamp bolts 1 on handlebars sleeves, the brake levers 2, and acceleration handle 3 acc. to Fig. 1.At tightening, don´t use an excessive force in order not to damage the parts or threads, or to distort the tubes, and the like. Verify the smooth and perfect movement of operating bowden cables of acceleration and both brakes. Fig. 1
Basic controls:
1. Handlebars clamp bolts
2. Brake lever bolts
3. Acceleration handle screws
4. Stop switch
5. Front brake lever
6. Rear brake lever
SAFETY Minimotard is not allowed to be used on public roads, as it doesn´t comply with valid Safety Standards. It is forbidden to ride even where the traffic of larger vehicles is possible. Minimotard is intended for a drive on closed tracks with even smooth and dust-free surface.For your own and other people´s safety keep all advices and recommandations, how to use your minimotard in a correct and thoughtful way. serious injuries can result from unsafe operation of this and other vehicles. You have to minimize the risk by wearing Safety Equipment e. g. : crach helmet, goggles, gloves, guards of elbow and knees, firm footwear.
BEFORE STARTING Regarding the engine life time it is important the minimotard to be well run - in as this fact will manifest itself by the power output and life of engine. The minimotard is considered to be run - in after consuming five full fuel tanks by riding. For brake-in period we use mixture of petrol and 2-stroke synthetic oil in the ratio 30 : 1. After brake-in the petrol octane no. 91 or higher and 2-stroke synthetic oil are mixed in ratio 50 : 1. Mix up throughly the mixture of fuel and oil before pouring it into the tank. During brake-in don´t increase the engine speed to maximum and don´t allow the overheating. Check the tire inflation which should correspond to the driver ´s weight. The pressure in one wheel has not to exceed 2,5 bar in the front and rear wheel.
3
5
3 1 1
2 2 4 6
STARTING THE ENGINE
To be done only on the starting stand - Fig. 2. After opening the tank filling hole, fill the tank with fuel and close it by screwing - in cap.Open the petrol supply cock by turning the small lever into position “ON”, Fig.3. Set the choke lever into position “C” , Fig. 3. Without turning the accelerating handle, pull gently twice the starting wire and by next quick pull start the engine. It is not allowed to pull the starting wire up to full winding off. After a short engine run, put the choke lever back to position “A” and let the engine run about 1 min. Let the Minimotard on the larking stand and, if need be, adjust the no - load speed to such a rate lest coupling should take along the no - load speed to such a rate lest coupling should take along the rear wheel. For adjustment use the adjustment screw No. 4 on the carburetor, Fig. 3.
Fig. 2
Fig. 3 CARBURETOR
ON OFF 1. Suction chamber
2. Sleeve screw
3. Carburetor body
4. Adjusting screw of no - load run
5. Float chamber
6. Fuel cock
A – choke lever for ride
B – choke lever for cold - starting
It is necessary to adhere to the following instructions for flange reassembling: always use a new plastic ring 110.078.00 which is inserted into the flange! Tighten up the screw with torque 5 Nm. Use of bigger torque can cause carburetor damage which is not covered by warranty !! Use of smaller torque can cause slackeing of the carburetor. Check up the screw tightness after every 5 hours of riding!
RIDE After mounting the Minimotard and slow turning the acceleration handle, you are starting your ride. Before braking, turn back the acceleration handle and depress slightly the front brake lever and then the rear brake lever. Beware of the wheels not to get them in skid.
4
The Minimotard engine will be switched off by pusching the red pusch ­buttom of the stop switch on handlerods. After the first half- hour ride it is necessary to check the tightening of screws and nuts, especially of the engine. Check also the brake setting.
PERIODIC MAINTENANCE
The periodic maintenance is the best way how to contribute to the machine life prolongation, ride safety, and cost decrease. In addition, you will be spared many worries, time and troubles. A - Before every ride:
1. Check the Cables and efficiency of brakes.
2. Check the lubrication and chain tension settings. The chain free play should be (5 mm) (.200in) After every ride clean the minimotard carefully and keep it clean. Do not use aggressive cleaning detergents.
3. After 1-hour of use, wash the air filter in air drying spirits and lubricate it with special oil for air filters. B. After every 5 hours of riding:
4. Check the tightness of all bolts and nuts. Tighten carefully to prevent damage to other parts.
5. Wash the air filter in gas and lubricate it with special oil for an air filters to better catch the dust.
6. Clean carefully the carburetor float chamber.
7. Check the brake pads, the thickness of brake lining cannot be less than 1 mm (.039 in). Review the basic brake adjustment.
8. Check the state of the clutch pads - the thickness cannot be less than 1 mm (.039in). C - Every time after 10 hours of riding:
9. Check the state of the clutch pads - the thickness cannot be less than 1 mm (.039in).
CHAIN SETTING: When setting up the chain attachment of the rear brake reaction catcher and the rear wheel axle nut 920.011.01. Then tighten uniformly the chain tighteners on both sides of rear wheel by means of nuts 920.009.01 , Fig. 5. When the chain is set - up to reguired sag 0,196” (5 mm), tighten the nut 920.011.01 of the rear wheel and the screw of If there is need to replace the chain, check also both chain wheels. In case they are worn-out, they must be replaced by new ones at the same time with the chain.
REPLACEMENT OF THE CENTRIFUGAL FRICTION CLUTCH PADS: Unscrew the fastening screws and remove the chain cover. Release the chain and dismantle it. Unscrew four screws 914.010.01 and 914.011.01 keeping the cover with drum of the clutch. Release the engine brace on the frame, shift it out, and remove the whole cover with clutch drum. By means of pliers draw off the clutch springs and loosen the pins holding the clutch levers. At the new clutch levers put the clutch pins and at assembly proceed in a revers sequence and, in the end, adjust the chain sag.
5
6
7
347.010.70
MINIMOTARD – 2,6
170.000.00
MINIMOTARD 2,6
510.002.00
STARTER COMPLETE
ENGINE
510.003.00
STARTER ROPE
110.001.00
ENGINE COMPLETE
510.004.00
HOLDER
110.001.01
ENGINE PROPER
510.005.00
HOLDER
110.002.00
CARBURETTER SHA 1412L
510.006.00
GUIDE BUSH
110.004.00
PISTON COMPLETE - A
510.007.00
STARTER CASE
110.004.01
PISTON COMPLETE - B
510.008.00
STARTER SPRING
110.004.02
PISTON COMPLETE - C
510.009.00
RATCHET WHEEL
110.004.03
PISTON COMPLETE - D
510.011.00
WASHER 4,5 x 16 x 1,5
110.005.00
PISTON RING
510.015.00
WASHER 8,1 x 16 x 1
110.006.00
PISTON - A
510.017.00
WASHER 6,1 x 16 x 1,5
110.006.01
PISTON - B
510.020.00
PINION 6Z
110.006.02
PISTON - C
510.020.01
PINION 7Z
110.006.03
PISTON - D
FRAME
110.008.00
WRIST - PIN
171.001.00
FRAME, VARNISHED
110.011.00
CRANK BALANCED
171.020.00
NUT HOLDER
110.015.00
CLUTCH DISC
BRAKES
110.017.00
CLUTCH LEVER - 2 PCS
112.004.00
LIFTER, RIGHT
110.019.00
CLUTCH SCREW COMPLETE
112.025.01
FRONT BRAKE DISC 2,5 x 119
110.020.00
CLUTCH SCREW SCREW
312.040.02
REAR BRAKE DISC 3,0 x 119
110.021.00
CLUTCH SPRING - SERIE 1,25 - 2PCS
112.050.02
BRAKE HOLDER
110.022.00
CLUTCH SPRING - RACING 1,4 - 2PCS
112.060.00
BRAKE COMPLETE
110.023.00
CLUTCH SPRING - RACING 1,6 - 2PCS
172.006.00
BOWDEN CABLE - FRONT BRAKE
110.024.00
CLUTCH DRUM
172.007.00
BOWDEN CABLE - REAR BRAKE
110.028.00
CLUTCH CASE
312.017.00
LIFTER LEVER
110.031.00
CLUTCH CASE COMPLETE
312.029.00
SPRING, LEFT
110.032.00
CLUTCH COMPLETE
312.035.00
WASHER 6,1 x 14 x 3
110.053.00
ENGINE COVERING
312.041.00
WASHER 10,5 x 18 x 3
110.055.00
ENGINE SEALING SET
332.020.00
NUT
110.056.00
FLANGE
512.004.00
HANDLE BAR LEVER, RIGHT
110.057.00
DIAPHRAGM SEALING - 2PCS
512.005.00
HANDLE BAR LEVER, LEFT
110.059.00
DIAPHRAGM
512.008.10
LIFTER, LEFT
110.060.00
DIAPHRAGM WASHER
512.016.50
TERM. CLAMP BOWDEN
110.063.00
SEALING ENGINE BLOCK
512.019.01
WASHER
110.065.00
ENGINE BLOCK
512.042.00
DISTANCE SLEEVE
110.067.00
DIAPHRAGM COMPLETE
512.043.00
BRAKE PIN
110.068.00
SEALING
512.044.00
LIFTER PIN
110.069.00
CYLINDER - A
512.045.00
BOWDEN HOLDER
110.069.01
CYLINDER - B
512.053.00
FRONT BRAKE CASE - 1 PAIR
110.069.02
CYLINDER - C
512.054.00
DISC BRAKE PADS - 2PCS
110.069.03
CYLINDER - D
512.055.00
BRAKE COMPLETE
110.070.00
CYLINDER + PISTON COMPLETE
512.058.00
REAR BRAKE CASE - 1 PAIR
110.072.00
EXHAUST SEALING
512.060.00
SPRING RIGHT
110.073.00
PLASTIC CONECT, FUEL COCK WHEELS
110.074.00
FUEL COCK
113.008.00
AXLE OF WHEEL
110.075.00
EXHAUST COMPLETE
113.009.00
AXLE OF WHEEL
110.076.00
EXHAUST SILENCER COMPLETE
113.015.00
DISTANCE SLEEVE, 14,5 mm
110.077.00
SILENCER MASS
133.002.20
TIRE W. PATTERN 90/65 – 6,5“
110.078.00
RING
133.010.20
TIRE W. PATTERN 100/55 – 6,5“
110.080.52
JET 52
153.033.00
CHAIN ADJUSTER, COMPLETE
110.097.00
FLOAT CHAMBER SEALING
193.001.00
BRAKE DISC WASHER
110.098.00
CARBURETOR SEALING 1
193.002.00
SPROCKET WASHER
110.099.00
ADJUSTING SCREW
193.003.00
BRAKE DISC WASHER
110.100.00
THROTTLE VALVE
193.020.00
WHEEL 2,1“ x 6,5“ – 90 without tire
110.101.00
CARBURETOR FILTER
193.021.00
WHEEL 2,3“ x 6,5“ – 130 without tire
110.102.00
NEEDLE VALVE
313.002.00
VALVE 90º - TUBLES
110.103.00
FLOAT
313.010.02
DISC 2,1“ x 6,5“ - 90
110.104.00
CARBURETOR SEALING 2
313.011.02
DISC 2,3“ x 6,5“ - 130
110.105.00
THROTTLE VALVE SEALING
513.011.04
DISTANCE SLEEVE 84,5 mm
110.185.00
JET SET
513.011.06
DISTANCE SLEEVE 117,3 mm
340.062.00
WASHER 5,5 x 15 x 4
513.011.09
DISTANCE SLEEVE 86,8 mm
8
LINING
119.011.00
RUBBER FOR FRAME
114.015.00
CHAIN COVER
119.013.00
HOSE CLAMP
114.016.00
CHAIN COVER, POLISHED
119.020.00
STAND
174.001.00
LINING COMPLETE, NON VARNISHED
119.035.00
WASHER 6,4 x 18 x 1
174.002.00
LINING COMPLETE, VARNISHED
129.008.00
HOSE CLAMP
174.004.00
SADDLE, NON VARNISHED
129.017.00
WASHER 6,4 x 16 x 1
174.005.00
FRONT FENDER, NON VARNISHED
199.002.00
LABEL COMPLETE, ONE MODEL
174.007.00
SADDLE VARNISHED
179.008.00
TANK WITH CAP
174.008.00
FRONT FENDER, VARNISHED
179.009.00
TANK
174.022.00
SADDLE
179.012.00
GAS TUBE
514.008.00
RUBBER WASHER 4 x 6,5 x 23,5
319.050.00
PINION KEY
CONTROL
329.001.01
FOOT REST, 2 PCS
195.001.00
FORK LEFT WITH BRAKE HOLDER
JOINING ELEMENTS
195.002.00
FORK RIGHT
911.007.01
SCREW M 10 x 140
115.018.01
CAP
912.005.02
SCREW M 5 x 16
175.005.00
HANDLE BAR TUBE
912.006.02
SCREW M 5 x 16
912.007.01
SCREW M 5 x 16
175.014.00
HANDLEBAR HOLDER - 1 PAIR
914.001.01
SCREW M 5 x 16
175.016.00
GAS BOWDEN CABLE
914.003.01
SCREW M 5 x 20
175.021.00
HOLDER ABOVE - COMPLETE
914.005.01
SCREW M 5 x 30
175.022.00
HOLDER BELOW - COMPLETE
914.007.01
SCREW M 6 x 16
175.025.00
HANDLEBAR BRACKET COVERING
914.008.01
SCREW M 6 x 20
175.026.00
PAD OF COVERING
914.011.01
SCREW M 6 x 30
515.002.00
HAND GRIPS - 2 PCS
914.015.01
SCREW M 8 x 45
515.006.00
THROTTLE GAS
914.021.01
SCREW M 6 x 12
515.007.00
BOWDEN DUST GUARD
914.026.01
SCREW M 5 x 12
515.008.00
ADJUSTING SCREW
914.080.01
SCREW M 6 x 14
915.001.01
SCREW M 4 x 8
TRANSMISSION
915.004.01
SCREW M 4 x 10
347.010.64
SPROCKET NO. TEETH 64
916.012.01
SCREW M 6 x 12
347.010.65
SPROCKET NO. TEETH 65
916.020.01
SCREW M 6 x 40
347.010.66
SPROCKET NO. TEETH 66
916.055.01
SCREW M 5 x 16
347.010.67
SPROCKET NO. TEETH 67
916.072.02
SCREW 5 x 20
347.010.68
SPROCKET NO. TEETH 68
917.010.01
SCREW 5 x 16
347.010.69
SPROCKET NO. TEETH 69
920.001.01
NUT M 5
347.010.70
SPROCKET NO. TEETH 70 - SERIE
920.006.01
NUT M 6
347.010.71
SPROCKET NO. TEETH 71
920.008.01
NUT M 5 SELFLOCKING
347.010.72
SPROCKET NO. TEETH 72
920.009.01
NUT M 6 SELFLOCKING
347.010.73
SPROCKET NO. TEETH 73
920.010.01
NUT M 8 SELFLOCKING
347.010.74
SPROCKET NO. TEETH 74
920.011.01
NUT M 10 SELFLOCKING
347.010.75
SPROCKET NO. TEETH 75
920.012.01
NUT M 8 LEFT
117.015.00
CHAIN CLASP
920.015.01
NUT M 6
117.015.01
CHAIN CLASP
930.003.01
WASHER 10,5
517.001.40
CHAIN 142
930.009.00
WASHER 6,4
517.001.44
CHAIN 144
930.010.00
WASHER 8,4
517.001.46
CHAIN 146 - SERIE
930.011.00
WASHER 8,1
517.001.48
CHAIN 148
940.006.00
ROLLER 6 x 6
EL. INSTALLATION
950.003.00
WOODRUFF KEY 3e7 x 3,7
118.001.00
SPARK COIL
950.005.00
WOODRUFF KEY 2e7 x 3,7
118.002.00
ROTOR COMPLETE
950.007.00
LOCK 15
118.003.00
SPARK PLUG
950.008.00
LOCK 35
118.005.00
SPARK PLUG CONNECTOR
950.010.00
PISTON PIN LOCK RING
118.010.00
ZIP TIES 3,6 x 140
960.003.00
BEARING 6000 ZR
518.001.00
KILL SWITCH
960.004.00
BEARING 6200 ZR
OTHER PARTS
960.006.00
BEARING 6202 C3
119.003.00
DISTANCE SLEEVE 25,8
960.007.00
BEARING 6202 2ZR
119.005.00
CHAIN ROLLER
960.108.00
CONNECTING ROD BEARING
119.006.00
HOLDER ENGINE
970.001.00
PACKUNG RING 12 x 22 x 7
119.010.00
SCREW CAP
970.002.00
PACKUNG RING 15 x 26 x 7
9
10
916.072.02
916.072.02
ADJUSTING THE BRAKES Fig. 4 Small incremental brake adjustment :
Free play at the handlebar lever is effected by turning the knurled end on the cable adjustor. This will allow the lever to be set at the nominal to ¼ inch of free lever movement.
Basic brake adjusting:
Screw in the knurled cable adjustor at the brake lever so the cable is in it’s most slack starting position.. At the caliper, loosen the nut, No. 3
and tighten the
adjustable bolt No. 4
, so the wheel cannot turn. Back off bolt No. 4 about ¼ to ½ of a turn and fix it with lock nut No. 3. Do not
use the cable retainer No. 5 for adjusting the brakes!
FRONT BRAKE PADS REPLACEMENT: FIG.7 At first, screw in the knurled cable adjustor at the brake lever on the handlebars. Unscrew two screws M5-914.003.01 that hold the brake body on fork and shift out the brake backwards. Take out from brake body two distance columns and two columns with coil. Do not loosen the cable retainer! Unscrew screws M6-914.010.01 and separate both halves of brake body and shift the worn-out brake plates out. Into the part with operating mechanism slide the brake plate with pin bore and unscrew completely the adjusting screw. Force on carefully the brake plate into the opposite piece. Before reassembly clean the whole brake. Assembly follows in reverse sequence.
REAR BRAKE PADS REPLACEMENT: FIG. 7 At first, screw in the knurled cable adjustor at the brake lever on the handlebars. Unscrew two screws M5-914.003.010 that hold the brake body on brake holder and shift out the rear brake backwards. Take out from brake body two distance columns and two columns with coil. Do not loosen the cable retainer ! Unscrew screws M5-914.003.01 and separate both halves of brake body and shift the worn-out brake plates out. Into the part with operating mechanism slide the brake plate with pin bore and unscrew completely the adjusting screw . Force on carefully the brake plate into the opposite piece. Before reassembly clean the whole brake. Assembly follows in reverse sequence.
DISMANTLING AND MOUNTING THE FRONT WHEEL, FIG. 5 Unscrew the nut M10 – 920.011.01 of the front axle and shift it out. By light pull shift downwards the wheel.For an easier mounting of the wheel dismantle left fork with freeing the screws M5 on the fork holders.At the first, for the mounting of the wheel carefully route the front brake and the wheel with brake disk to put inside the brake disk between the brake plates.Put the wheel on an axle, mount the right fork and tighten the nut M10 of wheel axle.
11
3
4
DISMANTLING AND MOUNTING THE REAR WHEEL, FIG. 5 Unscrew the rear axle nut 920.011.01 and loosen the nuts 920.009.01 on chain tighteners and the screw M6 on . Shift the wheel forward and remove the chain. At pulling out the wheel axle, secure the rear wheel two distance rollers fall out. The wheel mounting to be carried out in reverse sequence. It is necessary to see to the right location of distance rollers. Use the shorter roller on the site of chain wheel and the longer one at the brake disc. Don´t forget to tighten right the chain, tighten the wheel axle and check the rear brake function.
PINION EXCHANGE: FIG. 6
First dismantle the front
lining and chain guard. Loosen
the nut of rear wheel axle and
the nut of chain tightener,
remove chain. Insert carefully
a larger screwdriver or steel
rod into the hole of clutch
drum, Fig. 6, to avoid a turning
over the clutch drum at
releasing the pinion. Using the
pinion wrench P/ N 319.050.00,
release the new pinion to be
carried out by reverse way.
Fig. 6
REPLACEMENT OF TIRE – FIG. 5 Remove the wheel from the minimotard. For the front wheel unbolt the brake disk and for the rear wheel, the brake disk and sprocket. Deflate the tire, by removing the valve stem. Place the wheel on a hard surface and press the tire bead from the wheel rim in to the middle relief at centre of rim. Tire is ready to be removed from the rim at this time and is done in the conventional manner. After fitting new Tire and Tube (if necessary) to the rim, you can inflate 28 to 30 psi. Take care to check that the tire bead is fully seated in the rim bead edge. You can now refit the wheel to the bike in reverse order to removing it. Use Caution and recheck your work always.
DISMANTLING AND ASSEMBLY OF AIR FILTER, FIG. 3 Dismantling the air filter unscrew 2 and so ease the holder and put down the suction chamber 1. On this way you gain acces to the filter, that you can take off by means of screw driver. After cleaning and lubricating it with engine oil proceed the assembly on a reverse sequence.
12
NON USE AND STORAGE PROCEDURE
It is recommended to drain out all fuel from the tank and carburetor. Inflate the tires to the working pressure and put the minibike on the stand. During a *long storage period, unbolt the spark plug and insert a couple of drops of the motor oil into the cylinder. Pull the starting rope a couple of times so a film of oil covers and evenly coats the cylinder walls and piston rings. * Long period is 90 days and longer.
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The producer of the MINIBIKE is BLATA Company.
Manufacturing Number CZ …………………….........
Signature of the technical control: ………………………
This manual served also as a guarantee list. Please, after receiving the product check the manufacturing number and the date of sale. In the case of a claim it is necessary to submit this guarantee list.
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The entire construction solution for minimotard and used disc brakes are protected by industrial design. No part of this publication may be reproduced without an explicit consent of BLATA COMPANY !
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