I
MANUAL INSTRUCTION
Air
cooled engine
1
. -:3
-
.
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r-
i*
...
..
-
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'C
Pocket bike
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SERVICE
MANUAL
FOR
USE
AND
PflAINTENANCE AND
SPARE
PARTS
LIST
For your own
safety
and
lhe
safoty
01
01-ers
Follow
these
rccornmendat~ons
in
order
to
use
vour I~II~IISIKE s;:fely gild correctl? . Read
tbc Ins!ructions
CAREFULLY
.
failure
to
co
so
n?aY
blnce
yourself and ithers
In
extreme
and
or
ultimate
DANGER
.
I:
you do rot understand
th;
Instructions and Data tlien. you are not to
aCPmp:
to operate this Mlnibike under
any
circumstances
.
It
may
be
used
for
si;ow
purposes only!
CONTENTS
PAGE
..........................................................................................................
INTRODUCTION
2
TECHNICAL DATA
......................................................................................................
2
.....................................................
UNPACKING AND SETTING UP BEFORE RlGlNG
3
.......................................................................................................................
SAFETY
3
BEFORE STARTING
...................................................................................................
3
.
................................................................................
STARTING THE ENGINE - FIG
2
4
.
...........................................................................................
.
CARBURETOR FIG
3
4
RIDING
.......................................................................................................................
4
PERIODIC
MAINTENANCE
.........................................................................................
5
CHAIN SETTING At:D MAINTENAFICE
................................................................
5
CENTRIFUGAL CLUTCH REPAlR
0%
REPLACEMENT
......................................
'
.
5
.
.
....................................................................................
BRAKES ADJUSTING FIG
4
t
FRONT BRAKES PADS REPLACEMENT . FIG
.
7
..................................................
6
REAR BRAKES PADS REPLACEMENT . FIG
.
7
......................................................
6
REMOVE AND REFIT THE FRONT WHEEL-
FIG
.
6
............................
1
..................
7
REMOVE AND RFFlT THE REAR WHEEL . FIG
.
5
...................................................
7
REPLACEhlENT
OF
SPROCKET
-
FIG
.
9
..................................................................
7
MINIBIKE
..........................................................................................................
8-3
PARTS LIST
......
L
..............................................................................
10,
11
ENGINE
.........................................................................
12
CLUTCH COMPLETE- FIG
.
6
.............................................................................
13
FRONT AND
REAR
BRAKES .FIG
.
7
.................................................................
14
REPLACEMENT OFTIRE - FIG
.
6
15
..............................................................................
REMOVE AND REFIT AIR FILTER
..................................................................................
15
CLUTCH ADJUSTMENT - FIG
.
8
.............................
...........
.................................
15
MAINTENANCE OF COOLING SYSTEhl
...........................................................
16
TOXQUE SETTINGS
..................................................................................................
7
STORAGE PROCEEDURES
................................................................................
18
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Tlie fdinih~ke is designecl and built
for
use on a pavcc! cl00
).LI
circuil
track
The
trark
s!lollld'ile clcat, arid v~itnout obstacles of anv b..ntl. Qualifirtl
adi~its 2nd yot!n!)c: j~ersons cilrl drive the rliiriil~ike. Cliiidren c,?;, drive
the
min:blke only under the supervision
of
a respcrisible adu!t person. T!ie
niini!)ikc
is
corlstruc!ed especially for racing cornpctiii~tis cri sr?eciil[ rnci:~?
tracits.
Thc ~iiinlbike
uses
a singie-cylinder t\.:o-stroke, Gasoline co~r;b~~sti:n encine.
and has an air fiiter arid erhat~st silencer. Transfer of po:':er to the rear v:tie~.l
is
through a drive chain. The the
overall
rtrive ratio to the rear v:ilee! can tle
changer!
b:!
the repiacenlen! of c!lain sprockets. The front a?(] :car vdieel
IS
equipped with disk Drakzs. The rear brake is con!ro!lecl '::it11 t!le left lever 2nd
the front brake
is
control!ed with tb- rlght lever on the hanilleb,7rs.
BASIC TECHNICAL
DATA
ENGINE:
-
TWO-STROKE
NUPABER OF CYLINDERS
...................................................................
7
.........
CYLINDER CAPACITY
......................+..........
39,0
CC
................
ENGINE COOLING SYSTErL
...
.......
LIQUID COOLED
POWER OUTPUT
.................
....
...................
4.5
kW
at
11
530
rpm
-
..
TORQUE ................................................
4
Ntn
ar
1:
5'20
r?rn
CARBURETOR
....................................
-:
......
PHVA
17,s
DELL' ORTO
............
FUEL ADMlSlON
REED VALVE DIRECT TO CRAI'IXCfiSE
..........
IGNlTIOFJ
..
..........
..
................................
COP7ACT-LESS
.............................................................
SPARK PLUG
NGK
BSES
STARTING
..........................................
HAND
PULL TYPE, MAFJUAL
FRAME:
BRAKES:
.-
-
WHEELS:
TIRE:
-
W:
...
CLUTCH
.............................................
CENTRIFUGAL AUTOMATIC
.................
ENHANCED TRELLIS SUPPORTING STRUCTURES
MADE OF LIGHT ALLOYS
...
FRONT
WHEEL
DISC ERAKE- DISC DIAMETER 162rnn)
(
63")
........
REAR
WHEEL
DISC BRAKE-DISC DlAhlETER 119 mm
(
4,7")
FRONT
......................................
OF LIF,!T ALLOY
2,l
"X
6,6"-
99
...................................
REAR
OF
LIGH?
ALLOY 2,I"x 6.5"-
130
.
FRONT
.........................................................................
SIZE
90165
5;s"
...........................................................
REAR 110153 -6,5",
90!65
-6,s"
......
..MIXTURE
OF
PETROL
92
OR
HIGHER
OCTANE
+2
STROhE
SYNTHETIC OIL
........................................
hllXlNG ,RATIO (after break in periocl)
50: 1
.......................................
TANK CAPACITY
1.7
Litre ( 0,44
US
gal.
1
UNLOADED WEIGHT:
................................................................
25
kg
(
55
lb.
)
CARRYING CAPACITY:
................................-......................... 110
kg
(
242
lb.
)
BASIC DIMENSIONS:
LENGTH
...................................................................
1
100
mm
(
41"
WIDTH
...........................................................................
560
mm
122
"
)
......................................................................
HEIGHT
550
mm ( 21.6"
)
UNPACKING AND SETTING UP BEFORE RIDING
The
minibike
is
delivered in a cardboard carton
&cl
packedwith folded
handlebars
and
brake levers. After
unpacking,
set
up
the handlebars into the
position,
that suits the best for drlving. The maximum pulled brake lever
position should not touch on the handlebar grip. After setting
up,
tighten the
handlebar sleeve (clip-on) nuts
1;
tighten the
bra~e
lever bolts and the throttle
assembly
S.
See. Fig.1.
By
loosening the nut
M8
(PIN 920.010.01) on
the
foot
peo
bracke!. the rider can adjust the foot peg position in a forward or rear
direction. The foot rest can be
moved to
the
front or back position. It is
recommended to try and check the position of handlebars and
fwt rest's
individually.
Whlle tightening the bolts arld nuts, do not use an excessive force
as to not damage the threads, or distort the tubes and other parts. Verify the
sniooth and perfect function of the Eowden cables to throttle and botli brakes.
Fill the cooling system with coolant
anpvent the system [follow the
instructions
In chapter MAINTENANCE
OF
COOLER
SYSTEM), Fill the fuel
tank with
fuel
mlxture. Failure to usc the proper oil mix ratio will result in
Engine damage for which you
wi!l be responsible.
Fig.
1
3
75
1
Oweranq conlrofs:
1.
Handlebar bolts
2.
Brake lever bolts
3.
Throttle Assy. bolts
4.Stopswitch
5.
Front brake lever
6.
Rear brake lever
4
-/
1
Range of adjus!ing handlebars
functiori position
SAFETY
The minibike is unsuitable for public road use.
It
goes not cornply wilt1 valid
Safety
Standards.,Unsafe and careless use of a minibik.? ca,t resuit in serious
injuries. The
driver can minimize the potential risks
by
wearing the Safely
Equipment. The driver must wear safety helmet, goggles, gloves, elbow
pads,
kneepads, and firm footwear. The minibike cannot be used on wet, icy or oily
surfaces. Avoid uneven surfaces and obstacles. Drive with two hands on the
handlebars.
BEFORE STARTING
It
is strongly recommended to follow all the instructions about the break-in
period to promote engine reliability and long life. Break-in period
of
the
minibike is complete after
the
consumption of five full fuel tanks. It Is important
to use mixture of petrol
92
or higher Octane with 2-stroke synthetic oil in the
ratio
30:l
and after break-in period a ratio of
50:l.
Mix the petrol and oil
com~letelv before puttinn it into the fuel tank. During the break-in period do
not run the engine
at
maximum
RPM
and do not allow the englne to overheat.
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Check the tire inflation - 200 kPa (2 bars) or (28 to 30psij to be comlnensilrale
with the driver's weigh!. The Tyre pressure shoi~lcl never exceed
2.5
bars,
(38psi) in either the front or rear wheel.
IPAPORTANT NOTICE: If the coolant level rises in the balance tank, switch off
the engine immediately! Check the drive of the coolant pump and sealing of the
cooling system. After these steps, execute the ventilation of the Rad~ator. The
raised level of coolant is an indicator of
a
overheated engine, which can result
in seizing the piston in the cylinder.
STARTING THE ENGINE
Engine starting
shoulc be done only on the stand -Fig.
2.
Fill the fuel tank and
close it with the filler cap. Open the Gas
petcock. Set the petrol supply cock.
Set the choke lever
i
gjl)
position
"C",
Fig. 3. Without turning the accelerating
handle,
pill1 gently twlce the starting wire and by next guick puli start the
engine. It is not allowed
to pull the starting wire up to full winding off. The
choke lever
will turn back to the position
"A"
autornaticaly
by
t~~rning the
accelerating lever alter a short engine run . Let the engine run about
1
min.
Ltave the minibike on the stand with running englne and if necessary adjust
the revolutions so the rear wheel is not tt~rning. For adjtlstrnent tlse the
adjustment
screwNo.on the carburetor Fig.
3.
Fig.
3
l.
Air filter
2. Carburetor body
3. Idle speed adjusting screw
4.
Float chamber
A
-Cock position for riding
C - Cock position for cold starting
RlDlNG
Remove the minibike from the stand to sit on the seat. When seated, then
slowly rotate the throttle grip to start riding. Before braking, rotate the Throttle
grip to the off or idle position and lightly depress the rear brake lever with left
hand and then the front brake lever with right hand. Beware to not skid the
wheels. The
minibike engine is switched off
by
pushing the red button (Engine
stop switch) on the handlebars. It is necessary to check the tightness of bolts
and nuts, especially
of the englne, and the brake settings after the first ride and
often during the break in period.
PERIODIC MAINTENANCE
Periodic maintenance is the best way to help the machine perform well, give
'longevity and provide safety and low cost operation. In addition, you will be
spared from many worries
frorn self caused problems, resulting-from poor
malntinence or no malntinence.
A
-
Before everv ride:
1.
Check the Cables and efficiency of brakes.
2.
Check the lubrication and chain tension settings. The chain free playshor~ld
be (5 mm) (.200in) After every ride clean the minibike carefully and keep it
clean. Do not use aggressive cleaning detergents.
3.
After l-hour of use, wash the air filter in air drying spirits and lubricate it
with special oil for air filters.
4.
After
1-
hour of use, check the state of the clutch pads. Review the clutch
adluslnlent.
B.
&er everv 6 hours of ridlng:
Check the tightness of all bolts and nuts. Tiuhten with a uroperlv adiusted
torque wrench
only! For torque settinqs see tables on paqe
17.
5.
Wash tlie air filter in gas and lubricate it with special nit for an air filters
to
better catch the dust.
6.
Clean carefully the carburetor float chamber.
7.
Check the brake pads, the thickness of brnke lining cannot be less than
1
mm (.039 inj. Review the basic braheadjustment.
8.
Check the state of the clutch pads ;!he thickness cann~t be$s than 1 Inn,
(.039in). Review the clutch adjustmknl.
C - Everv time after 10 hours of rlding:
9.
Check the state of the clutch pads -the thickness cannot be less than 1 mm
(.039in).
CHAIN SEnlNQ
AND
MAINTENANCE
To set the chain tenslon, looserl the Nu! (920.011.01) of ?he axe1 thru the rear
wheel and
the
nui (914.021.01) of the rear Caliper anchor plate. The required
rhaln tension (chain free play ) is (6 mm] (.2OOin) and is performed by equal
movement of the Axel
adjustor plate (920.009.01) on the both sides of the rear
wheel. When the
ad,ustment is correct, tighten the Axel nuts and the Caliper
holding nut.
Tlghten the adjustor plate nuts both sides an extra nip, just to set
then1 firmly. It is important to lubricate the chaln regularly, to avoid excess
wear and prolong effective lifetime. The lubrication is Important after every ride
on
a
wet surface. It is recomlnended to
lubricate
the minibike with sp9cial
chain spray. If chain replacement is necessary, check both chain Sprockets
and If there is a need to change them do it together
with the chain.
CENTRIFUGAL
CLUTCH
PARTS. REPLACEMENT
Remove the chain guard by
loosing two bolts M6 (916.020.01), Fig.
5.
Loosen
the chain and remove it from the sprocket. Next, loosen three bolts holding the
alumlnum clutch housing. Remove it together with steel clutch basket, and
dismantle
it
Loosen the bolt lrom the carrier and remove
the
clutch from the
engine. Loosen and remove the adjustable bolts and springs. Then dismantle
the safety rings from pins. When all this is done, replace with new clutch
slipper shoes and springs (if required), at this time. During the reassembly
process follow these steps:
l.
put the plate with the springs on the slipper
shoes.
2. Put the plate against the carrier and mount iton the fixed plns.
Fit it with the safety rings and install the adjustable bolts.
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ADJUSTING
THE
BRAKE-?
Small incremental brake adiustment
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 notriinal to % inch of
free lever
movertierit.
Basic brake adiustinq:
Screw in the knurled cable
adjuslor at the brake lever so tlie cable is in it's
nlost slack starting position.. At the caliper, loosen the nut,
No.
and tighten
the
atljustable bolt=, so the wlteel cannot turn. Back off bolt
No.
about
%
to X of a turn and fix it with lock nut
Nu.
Do not use the cable retainer
No.
5
for aclil~stinc~ the brakes!
Fig.
4
FRONT BRAKE PADS REPLACEMENT
-
Fs.1
First screw
it1
the knurled cable adiustor at the riaht brake lever (122.002.001 on-
the handlebars to the
starling (slackened cabled). ioosen the 'nut
(920.001.01) and turrr the adj~cstable bolt (512.015.00) in the way that by
pressing the front brake lever, the lever (312.017.00)
will be over the bolt head
M5
(312.018.00), which protects bt-ake pads and spring of pads (312.020.00).
Unbolt tliis bolt and replace the old brake pac!s wilt) nev~ ones. When ~nounti~ig
the brake pads place the brake spriny against both pads, so they are pressed
into the front direction. While
replaiinq the brake pad~d_o~not loosen bolts
M5
~914.001.011 on tke drivinq pins and do not loosen t1:e cable retainer!
REAR
BRAKE
PADS
REPLACEMENT -FIG.
7
First screw in the knurled cable arliustor a1 the left brake lever (122.001.00) on
the
handlebars to the starting po;ition (slackended cable).
~oosen the'nut
,
(920.001.01) ancl turn the adjustable bolt (512.015.00) ali the way out. Unbolt the
nut M10 (920.001.01) of the back axel, push it out and disrnantle the rear wheel
frorn the
Swingarm. Push out the brakc from driving pins, that will loosen the
brake pads and replace the old ones at this time. While
replacinq the brake
pads do not loosen bolts M5 (914.001.01
)
on the drivinq pins and do not loosen
the cable retainer! During the
niounting follow all these instructions in the
reverse direction and then perform basic adjusting of the brakes.
REMOVE
AND REPLACE THE FRONT WHEEL - FIG. 5
Before
dismanlling the front wheel it is necessary to remove the front hrake
pads fron~ the front brake, so it is possible to move the brake caliper from the
wheel and be able to draw out the
v~hcel and tire. Remove the front axe1 nu:.
M1 0
(920.011.07 ) Draw out the axe1 front the fork and wheel. Remove
the
whee!
by an easy pull downwards frorn the forlts. CAUTION! Two 3mm spacers Wili
fall out when the wheel is being removed! Insert one spacer between the brake
rotor
ancl the brake mounting braclcct, ;~nd the other spacer belween the wheel
a~id thc rigltt fork(P1N
315.011.00~
when re-assemb1ing.Return the brake pads
with the spring and tighten up the
axe1 nut. Perform the basic brake adjusting.
Double
check your work. Tf~is is ilnportantl
..-p
REMOVE AND REPLACE THE
REAR
WHEEL
-FIG.
S
Loosen and remove nut M10 on the rear axle. Safelv (hold) keep the rear wheel
.,
.
frorn falling out while pulling out the nxc!. Caut~on, note the iocation
of
both
spacer tubes
ancl onc spacer washer (between caliper lnount plate ancl rotor)
while removing wheel. When refttting the wheel, ntake sure to slide the brake
rotor into
the caliper between the pads. Hold the wheel in olacc and fit the
wheel spacers in proper order.
.
Insert one 31ntn spacer between the brake
rotor and brake mounting bracket
an? than insert the
9.5fiirn
spacer betrveen
the brake and the rear swing arm.Adjust chain tension and tighten axe1 nut.
Tighten the caliper
liolcler plate nut and set and tighten both chain adjustor
plate
M6
nuts.
At this time check the brake operation.
Recheck all vour
vg&,
This is intportnntl
REPLACEMENT
OF
PINION
-
F=
First distnantle the front chain g~ra?d 2nd chain guard.Loosen the nut of rear
wheel
axle and tlie nut of cllain tightener .remove chain. Insert carefullv
a
larger screw drive or steel rod into the hole of clutch drum, Fig.
9,
to avoici
2
turning over the clutch drum at releasing the pinion. Using the pinion wrench
PIN
319.050.00, release the new pinion to be carried out by reverse way.
FIG.
9
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j]o
;52 03
s;~::?
1.-r
3?0.153.03 CI.CAiA+.CE
'i\'AS;iE2
.'>P.TCR !:L'.',!;.
3:O 155.01
KAifi;
FU!,!? SIiATT kSCE:.I?LY
?jO.l5901 DL'LI
CY
-LARGC
3i.>.050
01
d:I.F1ICF3 TTR!.'i:IAT
I?':
2LG.055
00 F:.:K;ST
f!R\CE
3dO 053.03 S!LEFIC?ii CC511:S
:60.OC.2.00
T;jGGEii
bYhC;,-El<
i?
:;p
0;;
r;:
:I.E:;JLI:
t,ir:C
3d?
075.CG kXlIAU5; CChl?Lt
ii
36:,105.00 EXHjUjl
8jH:tIGS
-
2FCC
510.005.CO STAiliER KOPE HAPI2
H7:C.i:
FRALf
341.001.00
fi;A<,iE
v,MrIISi.:Ec
341.005.FO S13t Fl!A%E Cfu7filER- L
341.C06.03
SIDE FRAPJE C;,iR;Er7
-
2
341.014.00 SPRCCKET COVEE
34:.100.@0 SW:NGARM
341.105.CC CHAIN
TENS1OI.!.!;7
311.200.00 UNDERSEAT FFAt:l<
341.?00.00 FRSNT TRELij
BRAKES
. -.
-
.
121.001.03
PiiAX\XS
LEES - LEFT
12i.00200
3EA'<t LEVER - RIGL*T
152.005.23 WAKE PACS - Phli!
312.010.20 RRA'KE COMFLETE
312.01501 DRAKE CASE
312016.00 CABLE REiWFIEA
312.017.00 LIFTER LEYEii
5l2.0ie.00 tv'0DIF:ED SCiiE'A'
312.019.tO SFHPIG-HIG;IT
?12.020.00 BRAKE
F:&
S?r71UG
312.021.00 SPAGE,i L-12
312.025.CO REAR BSA'KE >ADS-.=Alp
31:.028.0? €RAKE ti3LC'ER CO:.l;LEiE
312.0i9.00 S?R!PIS -?EF:
312030.03 BRAKE CASE
344.COl O'J
i44.002.00
344.003.00
3d4.004.00
3d4.0?5 CO
_OTHER
HARDYAqE
911.00201 SCREi9hlix45
912 005 02 SCREW h4
S
X
16
-
. .
. .
. - .
s14.001.01
siritx*
~rio
916.007.01 SC9W ht
6
X
;G
914.GO8.01 SCREW U
6
X
iCI
914.010 01 SC'iEPI
h4
6x
25
iAlRlNG PAINTED
SEAT-T4L ASSY PAliClED
REAR FElrClER PAINTED
WIIICStIIELD + RIVETS
FRONT FENDER.
UMPAISTEO
FRONT FENDER. PAlFlTEV
~~
9140q0: SCREWM
5x
l0
914.020.01 SCREWM
Sx
lO
914.021.01 SCQEI'I
:.l
6 r l?
914.070.01
SCREW H E % 125
815075.01 SCREWtAEX l40
914.080.01 .XRB'VM
6x
l4
916.08101 SCREW
tA
8
X
20
CAP
WII~.EBAR
S!
EtVE( CLIP-3Pl )LEFT
htAN?.EBA4 SLEEVE1 CLlv-
PI
IRIGYT
CASCARLEISLELVE ASSY
914.510.01
SCREW hl
G
X
33
~LAT HFW
916.003.01
SCREW M 6 X 10
916.00501
SCREW
h:
6 x 15
330.015.CO CLiTCH SV@EA+E
333.016.00 CYL'NDER HWDHOLDERSET
332017,CO CLUTCH ?HOE
3;j.o18.00 C-UTCII CASE
FORKR~CHT
TOEK
LEFI
1
RIFFLE TREE - UPPER. COUPLETE
TRI?PLL TREE- LOWER. COlvlPLElE
STEERING BOLT
mnfissgolr
SPiiCCYET
G8
IEiTH
CHAlt; 142 LINKS
918.031.01 SCREW M 6 X E
333.021.00 CLf!7CIi SFRNG
2.665
330.021.00 S?RNSFLAIE
330.C23.03
STAii'
ER LE'JER SPRi:i'G
3j0024.00 CLUTCH aASKiT
330.025.00 D:STANCE WASIIEF:
333.02801 CLIITCtl CASE
333.01900 PI:IION 6 TEE31
33C.G!0.00 CLUTC!i SIIGESCO;lPi.
ij
LEVE.?SI
330 (332.00 CLUTCH S0t:I'LLTk
330.039.00 SPACE? - PISTOY
330040.00 ST4Hi E3 CO!::'.E!E
315.tlS.CO Sih?TER CASE.
330.&$.00 GRCb!LiET
SCRE'NU
5x
10
SCRW
51
G
X
~A:LEN
SCREVJ h1
5
x
25ALLFN
NUT
1.4
5
SPARK PLUG CAP
NUT
M
10 SELF-LOCKIFIG
h1 6VWH COLLA4
FI2TMRx
I
NUTM !Ox!
WASIiEii
5.4
HtXt
CLAMP
;iJ/7
VIAStlFIR6:i
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16
J
1
CC!OLANT RESERV<)IR bYITli CAP
91s
cj;
0;
bW5kIf~ '$5
930 004.01
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B30 009 00
So;(
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WAFr4EII
6.4
230.8.11.00 S1:aTER S?iilPlG
330.0.11.00
S:A%TER
SAiCHET
VvUCE1
X3.Cji.CO SILENT BLO'!KiUBE
339.?5i.CO I!ITAKE GVSS,cKET
230.053.30 I1;TtUE GXANCH
?h'JA
17.6
330.056.30 IYTME BRAVCH CCMJLETE PHVA 17.5
330.05ti.CO E!A?i(RAG!vl COlII?LETE
330.C53.01 @;APHRAS!rl- ELACK(PAIR1
3j0.063.CO EI,lG;NE BLOCKtASGi SET
I!@.OSS.C.O EI,!G!NE FROFER
330.:66.01 EI,:JIS:E FRO?ER 04SKET SET
?3O.C67.CO C311 (VAC-tJCiO) HOLDER
350068.00 $PACER
330.669.20 CYLI?;DCR.A
33,2,063.2: CYLIFIDER.5
330.t63.21 CYLINDER-C
330.G69.23 CYLIN2ER-2
330.07020 CXlYCERt PISTON CO',tRETE
3;0.G72.20 CO::?USlI@N CHAM6ER
333.073.20 CYLINDES HEADCOYPLETE - WATER
330.083.01
AIH FILTER %I-
38
330.095.CO @EASING
CASE
?30.090.00 CYL!NOER SEALIGG SE:
330.C91.00 CYL'NDER GASKET
-
4
PCS
310.105.@2
EXHAUST SCRISGSPAI.?
?10.12J.W
%CSE
E3
335.150.00
WATER PUL'PTUSE
330.151.00
SPASER L=5
.
. - .
. . . . .
312.031.09 EihKE CS?.!?.J;ETE
I~~.OIS.~O
S?&:CER 6.1
X
!a
i3
312.036.CJ LIFTER - LEFT
312.03i.CJ LIFT3 - 'IG:%T
312.038.00 BSAKE SHAFT
332.003.20 BRAKE CAB!E/SLEEL'EASSY
342.001.00 i,iOhT
BRAKE
H9LCEk iOIrliLETE
U2.OOS.00 @RAKE CAD.LE!SLES8EASSY
342.026.00
BWKE ROTOR IDISK)
-
REW
342.040.CO
SRAYE ROTO? (ClSKI - FROPI:
511.016.50 CiFLE REW:hIER
512.013.01 WASHER
<?l?ill
ANi HESE2V~)lR CAP
~~~..
.
~~
P30.020.01 WASHER
5.'
940.006.00 CYLIN3ERF'iF
~O.OO~.~O
RIVEI
RUBCX
4
2x
~~.~vI!THcA~'
.-.-
~ ~
il5q.noa.00
SAFETY
~C::%dr
950.009.00 S4FEiY ILCCY l7
950.018.00
SAFETY
LOCK
1G
X
l
'001
PEGS FLAS iiC -FAIR
W:iE
(:L,%YJ'
Xi3
L!C::A?S SET ORIGALI' C1
.
-
8AFETY
LCLK
6
SPRING FIE1 10
X59
SALL
REAS:AZ
FKO.
? ZR
WHEELS
113.009.00 WHEEL
MLE
133.002.02
TIRE 90155-
6.5"
B- SLICK
BALL OiAlilblG
E203
-
2
ZR
BPL? BEARI:,!G
E003
-
2
LR
RAIL BLARII.IG 626
BALL BLANISG 6203 TN
9
C3
DALL tlEAHIElG 62i ZR
hEEDLE BEARING
+G
X
l? X 12
i
SEAL lix25r4
SEAL O-filtlGBx 13x18~4 1.8
O-RI1IG2212
O-RING27x3
O-RlNG41x1.73
0.
RiNG b6.4 x
!.78
COGGEDBE! i -WATER FUhiP
133 Oi0.02
ilEE l lO:5O
-6.:"
B-
SLICK
313
002.00
VALVE
97-
TUGELESS
313:010.20
RI:/I,WV@ ASSY 2.1.-
6.5'-
93
313.011.0i Rl'*lrHUBP,SSY 2.3--6.5'-130
313.G20.20
VU'HEiL CCMFLETE
V+.C
TIRE 2.1'-
5.5'-
99
313.021.02 VlHiE: C0:APLETEViDTIRE 2.3'- 5.5'-121)
Y3.CO5.00 WHEELPXLE
343.010.02 AXLESPACER 6.5X 1BX 23.3
TGE[
iAFiY CAP
ibCi
7AtdK'iVITtl
CAP
CARSCRETDR FUEL
BOSE
FUEL LIOS5
WHEEL RILE NUT
C;
rAldO
-
..
. .-
HOSES
SET +i;PIMDS
FLCEL COCK
IA$ASHC%
5
4
r
16 X 1
343.01004 AXLESPACE.? 10.5X
13X
9.5
343.010.05 AXLESPACEQ 10.5~ 16x 13.5
513.011.04 %LE SFACER L.24.5
513.011.06 AYLESDAZER ;=l173
513.011.07 AXLE SPACE8 L=B5?
10
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www.gbevolution.it
REPLACEMENT OF TIRE - FIG.
5
Renlove the wheel fromyhe rninibike. 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
converltionai 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
i!.
Use
Caution and recheck your work
always.
DISMANTLINr; AND MOUNTING
OFAJ?
FILTER - FIG.
3
Remove the bolt from the sleeve, which connects the rubber holder of the air
filter to the carburetor. When the air filter is loosened, take
if
out and very
carefully wash
it in air drying solvent, lubricate it when dry and spray with air
filter oil and reassemble, following the steps in the reverse
8rder.
CLUTCH .RDJUSTMENT - FIG.
8
After first hour
or
use, check the state of the clutch pads. Review the clutc:~
-adjustment - engaged with 8 000
-
8
500 rpm.
Basic adirrstinq:
After every clutch slipper shoe replacement it is necessary to adjust the clutch
springs. To increase
the revolutions, and feel the ciutch working, tighten up
the adjusting bolts
and to engage shoes at lower revolutions,loosen the bolt. It
-is important to adjust all the
sprinss to the same level, so the clutch lining
wearing is even. The
index fo: adjusting
is
the length of the spring, which
should be.21,00
mm.
The length is measured from the bearing surface
of
the
clutch shoe to the spring plate.
FIG.
1.
Lictirid Irllir~ct;
Place the nrirlihike on the stand. Disrnarillo the seat arrtf
very
carefully check all
the joirjts
OP
the Irose. For oicfer n,tnibikes
do
rlot forpet to check for lloles and
otller rlarnages to lI,e hose.
To fill
the cosler systcin.
0.5
litcrs ol the coolarlt
is
r,cedocl. In
cnse
rhr tr?init,ikc
~$11
I>+-
~rsccf c!ur.ir~r~ tlli: wirlterlirl,e.
do
tlol Forrlr-t
to use the itr?Li-freeze co0!;1111. Pol~r tI1e c001ar:t itrlu the halilnce till:l<, which is
pl;lced be:wcc;, thc hancllcbar'c. it:itrl it is fillecl to
>/,
<of capacity. Unbolt vent
bolt
M5
(PIPI
914,000.01).
rvhicl~ is
inscrlc.ci
in
1ha.trose
(PIPd
349.)
between the
I,r,tto~n p;+-t o! fllc rn;fiator ar>d 11112 ctlgi,ic block. Tiq::tc,i the bo:t or~ly after all
air has
beer? 1,terl ancl otrly coolntlt is c<,r~*iri<l out of the vent
lug
Itote. Always
Irold the 1,ose in order not to pull out the air escape valve. It is iniportant to
have inore 1l;;ln % capacity of the coolant in !he bal.?;%cc tank. Tlle s;tlne
proceclure applies to the velitilrg ho
;c
(PIN
340.)
betwee~r tllc cylincler tread JII~
11:- racliator. Oncc.
In01
r
Vellt the ByS1r:riI wIIII~? lo08ellili~j the air (~IeecI sCl.ew5
~rntil all alr 15 exl>cllecl.
Clone the fanh .~rrrl ~,&rll the start T'handle two or three times. This will circulrrto
ttie coolent
in
the systet~i. Once rnore venl tlre syste:ir vdliile loosenirlg tfic air
blcccl screw.
Only now ,t is (,ossit,!r to star1 rtre rni,iibil<c, arid leave it to rurt
on
the stabld lor
one
r;?inirlc. Tlortr of ttrc! rr,o!or.
and
vent it oqain. Then tllc vtitrihike is ready for
(ISC.
2.
~j-~?e~Ckh.gnof,cg&rsvs
ten?:
Before every ride ct)eck
thc
alllouIit 01 coolant in the bali~rlce tank1 After every
10
flours of
rirltrry,
ranlove the pull st;rrter cover and clleck tlte Gilrrler type
I,elt, v/hich runs llic coolant ~,ulirp.
iil,p~~Jal,ltjotice: If the coolznt
le_v.e~~~i~~e~ss;.jr!~f~~~~.~~.~l~~~~~~~~~~sv&l~fp_f_
ttie
<?,~~fin~iEI!lcLb3tcly! Check the rlrrue ofJhe cooIar>l
~ILIII~I>
iqrir! sealint1 of ttie
csoter svste!77. Aflcr
1t1e.r,r_s~~pP9svYer7t
tho
R?C
bleed screv,. T41r raised level of
coolnor
is
nrl rnrlicator nf n warrned
up
enoine. which
':an
result in seizinrl of
-
!hexiston
vn
the cyljn'!g!..
.
-
- -
---
-.
.-
3.
Qy,?i_nj!~glhc?
Coolal, t.;
Uisliiarlllr the hose 011 tlbc boltorr, of the cooler
system
allcl eli#ni!7;*te illrr
liqutcl. Unbolt :lie clrain plug
in
the bnlarice
tank.
TORQUE SETTINGS
(i
FT-LB
=
1
3558
1Jrlli
PART
NAME
QTY
TORQUE
SETTING
(FT-LD~-..
SECURED
BY
ENGINE
<':yltnder hea.:l, I:ql;~dcoo'~:I
--
MO
ti
Cyl~ntl~r
..
nuts
1,:s
4
lr~lekc
manifold
-
Xlf
Sl;l,!.;i
c:ovr.
.
Fjd
Iiatct.et
whce'
-&;l(
!.:E
hjtgnrlo
(rot3r);
rut
M76
Slar:er
prD..,:s
-
bo'ts
F115
lyn Iron
cn
I - bolts
!.?-8!:or
col norder - bolt
M6
Crankciise halves - htlj
Clulch base - nut
Ma
Clutch case - bolts
Mt
p#r:or;
oearlng
rase - 30115
M3
Wa:ar
purrlp
s:)af!
-
~tul bit3
Reeds - bolts
h13
Fioat
charnter
-
bclts M6
Slider $over (:arburelor> - k115
M1
c~el !:l!er cay. - odl
ME.
Plnion - 1dR
Impeller
(or
weter
pump
shaft)
-
M5
FRAIAE
Frorl wheel axle - nut
M10
Front brake mlor - M5
Ffonl brake bracket - ?A8
0r:ke
mount
--M5
Steer
nq
shaft
-
bllO
S9.F-LOCKING
LCCTlTE
LCCTI-F
LOCTI'E
SELF-LOCKlVG
L0CTl.E
LCCTITE
SELF.LOCKING
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