Generic XOR 50 ccm Service Manual

PREFACE

The service manual has been specially prepared to provide all the necessary information for the proper maintenance and servicing. You have now a new type of scooter that has many techinal features such as: V-belt drive automatic transmission Forced air-cooling system CDI ignition system Electric starter system

Those who will be servicing the scooter should carefully review the manual before performing any repair or services. Major modifications and changes incorporated later will be advised to GENERIC product distributor in each market. Therefore, if newest information is requested in the future, please contact the local GENERIC distributor. The scooters distributed in your country mignt differ in minor respects from the standard specification and, if they do, it is because some minor modifications had to be made to comply with the statutory requirements of your country.

GENERAL INFORMATION

TYPE IDENTIFICATION FUEL AND ENGINE OIL BREAK-IN PROCEDURE PRECAUTIONS AND GENERAL INSTRUCTIONS SPECIFICATIONS

CONTENT

TYPE IDENTIFICATION



ENGINE NUMBER

ENGINE NUMBER ① is carved on rear crankcase as Shown in figure.

Both FRAME NUBER AND ENGINE NUMBER are designed specially for registering your scooter and ordering spare parts.

FUEL AND ENGINE OIL

Be sure to use specified fuel and engine oil. Some specifications are as follows:

FUEL

Unleaded, the minimum octane number is 95 or more.

ENGINE OIL

For GENERIC CCI SYSTEM, we recommend special engine oil, you can choose high quality two-stroke engine oil (without being diluted) if without special oil.

GEAR OIL

Use high quality, all-purpose SAE90 engine oil for scooter.

BREAK-IN TIME

General requirements are as follows：  Limit break-in speed：

At the first 1000KMS（600 miles）mileage，play throttle less than 4/5 throttle；

After mileage exceeds 1000KMS（600 miles），play full throttle；

 Don’t run engine too long during break-in time, and try to change throttle

position.

PRECAUTIONS AND GENERAL INSTRUCTIONS

Correctly abide by the following items when disassembling and assembling scooter:

□ Don’t run engine indoors without ventilation; □ Be sure to replace new bushings, circlips, O-rings and cotter pins with new ones；

CAUTION

 It is forbidden to use the circlip removed from shaft, only use new one；  Be very carefull to install new circlip for fear that the end hatch of circlip exceeds

required sliding surface for shaft；

 After installing circlip, inspect whether it has been completely clipped into the

groove.

□ Fix bigger diameter bolt first when tightening cylinder head or cylinder, and tighten

to specified torque gradually from inside to outside at diagonal order.

□ Use special tools for some special requirements； □ Use original components and recommended engine oil； □ Keep each other’s safety when several persons do； □ Inspect looseness and operating state of components after reassembling them.； □ Take high care of gasoline, which is explosive, and never use gasoline as lotion.

The words like warning, notice, note may turn out incessantly in the manual, which means:

WARNING The personal safety of the rider may be involved. Disregarding the

information could result in injury to the rider.

CAUTION These instructions point out special service procedures or

precautions that must be followed to avoid damaging the machine.

NOTE it provides some special information, which keeps maintenance

easier and important instructions clearer..

REPLACEMENT COMPONENTS

Be sure to use genuine GENERIC components or their equivalent.. Genuine GENERIC components are high quality parts which are designed specially for GENERIC vehicle.

CAUTION

Damage to the scooter may result from use of replacement components which are not Equivalent in quality to genuine GENERIC parts, and it can lead to performance problems.

SPECIFICATIONS DIMENSION AND NET WEIGHT

OVERALL LENGTH 1830 mm OVERALL LENGTH 695 mm OVERALL HEIGHT 1160 mm WHEELBASE 1295 mm NET WEIGHT 92 kg

CHASSIS

Front shock absorber spring, no damp Rear shock absorber spring, oil damp Turning angle 48º Front wheel 120/70-12 Rear wheel 130/70-12 Front brake Discφ190 Rear brake Drumφ110

ENGINE

Type two-stroke, air cooled Intake system piston-reed valve Cylinder QTY. 1 Bore 40.0mm Stroke 39.6mm Discharge 49.8mL Compression ratio 6.9:1 Carburetor flat inhale stopper style Air cleaner dry Starting system electric and kicking start Lubricating system pressure lubricating

ELECTRIC

Ignition mode CDI Ignition timing 15

at 1500RPM Spark plug BP8HS Storage battery YTX5L-BS Generator AC magneto Fuse 8A Headlight 12V—55W Turning light 12V/10W Taillight 12V—21/5W Meter light 12V/1.7W Oil level signal indicator light 12V/3W Turning signal indicator light 12V/3W

CAPACITY

FUEL TANK 5.2L ENGINE OIL TANK 1L GEAR OIL 0.1L

Transmission system

Clutch system dry auto a centric Gearshift mechanism CVT stepless Operating mode of gears shift mechanism Automatic a centric Step less shift range 0.86~2.64

*the above data may be modified without any notification.

Periodic maintenance and service

Periodic maintenance and service schedule Maintenance and service procedures

Storage battery Spark plug Cylinder head nut and exhaust pipe bolt

Cylinder head and cylinder Fuel level line Air cleaner Throttle cable Engine idle speed Oil pump Gear oil Braking Tire Steering Front shock absorber Rear shock absorber

Vehicle bolts and nuts

CONTENTS

Periodic maintenance and service schedule

The following table lists all required intervals for maintenance and service，following which, you are assured to have your scooter perform in the best way.

Note

Do more frequent maintenance when often riding on bad road

Periodic maintenance table

Interval (first 500 than all 3000km)

Kilometer 500 3500 6500 9500 12500

Storage battery I

I I I I

Cylinder head nut and exhaust pipe bolt

T T T T

Cylinder head and cylinder (change all 12000 km)

—

C R C R

Spark plug —

R R R R Air cleaner Clean every 3000KM(2000 miles) Idle speed rpm

I I I I I

Throttle cable play

I I I I I

Oil pump

I I I I I

Gear oil (75W90) R — R — R

I I I I

Fuel line

Replace every 4 years

Brake

I I I I I I I I I I

Brake hose

Replace every 4 years

I I I I I

Brake fluid

Replace every 2 years

Steering

I I I I I

Front fork

I I I I I

Rear shock absorber

I I I I I

Tire

I I I I I

Vehicle body boot and nut T

T T T T

Note  I=inspect，clean，adjust，lubricate，or replace if necessary；

A=adjust； C=clean； R=replace； T=tighten

Maintenance and adjustment procedures

The section describes the servicing procedures for each item of the Periodic Maintenance requirements.

Storage battery

Inspect at initially 1000KM（600 miles，2 months），and every 6000KM（4000 miles， 12 months）thereafter

□ Uncover seat, and then remove the battery box cap in the

Middle of helmet barrel.

□ Disconnect negative pole line end, positive end, and then remove battery；

□ Measure the voltage between the two ends of

battery with voltage gauge，charge if the voltage is below

11,9V

Cylinder head nuts and exhaust pipe bolts

Tighten at 500 km, and each service.

If cylinder head nuts are not tightened to the specified torque, may result in leakage of compressed fuel-air mixture and reduce output, tighten the cylinder head nuts in the

following procedures:： 1． Remove the frame lower covers. 2． Remove the cylinder head cover bolt. 3． Remove spark plug cap. 4． Tighten the nuts evenly one by one to the their

specified torque. Tighten the nuts in the order

indicated.

Tightening torque：

Cylinder head nut：15-18N.m

Exhaust pipe bolt：15-18N.m

Cylinder and cylinder head

Remove carbon every 6000 km（4000 miles，12 months）

Carbon deposits in the combustion chamber and the cylinder head will raise the compression ratio and may cause preignition and overheating. Carbon deposited at the exhaust port of the cylinder will prevent the flow of exhaust gases, reducing the output. Remove carbon deposits periodically.

SPARK PLUG

Neglecting the spark plug maintenance eventually leads to difficult starting and poor performance. If the spark plug is used for a long time, the electrode gradually burns away and carbon builds up along the inside part. In accordance with the periodic table, the plug should be removed for inspection, cleaning and to reset the gap. z Carbon deposits on the spark plug will prevent

good sparking and cause misfiring. Clean the

deposits periodically. z If the center electrode is fairly worn down, the

plug should be replaced and the plug gap set to

the specified gap using a thickness gauge.

Thickness gauge

Spark plug gap：0.6-0.7 mm (0.024-0.028 inch) Check the spark plug for burnt condition. If abnormal replace the spark plug as indicated in the chart.

NGK TROCH REMARKS

BPR7HS E8RTC If the standard plug is apt to get wet, replace with the plug.

BPR8HS E7RTC Standard

BPR9HS E6RTC

If the standard plug is apt to overheat, replace with the

plug.

z Tighten the spark plug to the specified torque.

Spark plug Tightening torque:15-18N.m NOTE:

z To check the spark plug, first make sure that the fuel used is unleaded gasoline,

and if plug is either sooty with carbon or burnt white, replace it. z Confirm the thread size and reach when replacing the plug.

FUEL LINE

Inspect at initially 500 km and every service, replace every 4 years.

AIR CLEANER

Clean every 3000KM（2000 miles）

If the air cleaner is clogged with dust, intake resistance will, be increased with a resultant decrease in power output and an increase in fuel consumption. Check and clean the element in the following manner.

 Remove screw 1 and screw 2，take down air cleaner  Unscrew tapping screw 3，remove air cleaner cap 4  Fill a washing pan of a proper size with Non-flammable

cleaning solvent. Immerse the air Cleaner in the cleaning

solvent and wash them clean.

 Squeeze the cleaning solvent out of the washed element

By pressing it between the palms of both hands: do not

twist

or wring the air cleaner filter core element or it will

develop tears.，

 Immerse cleaned filter core of air cleaner in CCI or CCI

SUPER oil, and squeeze the oil out of the core，which

may be slightly wet with oil.

 Install air cleaner filter core in the reverse order of

removal. CAUTION：

 Before and during the cleaning operation, inspect the core

for tears. A tore core must be replaced  Be sure to position the filter core, so that no incoming air will

bypass it. Remember, rapid wear of piston rings and

cylinder bore is ofter caused by defective or poorly fitted

filter core.

А Non-flammable cleaning solvent

Б CCI or CCI SUPER oil

THROTTLE CABLE

Adjust at initially 1000KM（600 miles，2 months），and every 6000 km（4000 miles，12 months）

 Loosen locknut ，and adjust throttle cable play by turning

adjuster in or out to obtain the following cable play. After

adjusting the calbe play，tighten the locknut.

Cable play：0.5-1.0MM（0.02.-0.040 inch）

Engine idle speed

Adjust at initially 1000KM（600 mil es，2 months） and every 6000 km（4000 miles，12 months）thereafter.

 Adjust the throttle cable play.  warm up the engine.

Note：

Warm up engine for 10 minutes.

Connect an electric tachometer to the connecting protion of the magneto lead wire as shown in the illustration. Use the selector key “C’ position.

Tachometer

Adjust the throttle stop screw to obtain the idle

r/min as follows:

Idle speed：1400±100r/min

 Finally adjust the throttle cable play.

OIL PUMP

Inspect at initially 500km and every year.

The engine oil is fed by the oil pump to the engine. The amount of oil fed to it is regulated by engine speed and oil pump control lever which is controlled by amount of throttle opening. Check the oil pump in the following manner to confirm correct operation for throttle valve full opening position.

 Turn the throttle grip full open.  Check whether the red mark on the oil pump control lever

Is aligned with the index mark when the throttle valve is positioned as above.

 If the marks are not aligned, loosen lock nuts and turn the adjuster in or out to

align the marks.

 After align the marks, tighten the locknuts.

Caution：

Oil pump calbe adjustment must be done after throttle cable adjustment.

GEAR OIL

Change as shown in the

service schedule.

Inspect gear oil periodically as follows:

 Remove the cover and hose  Remove the kicking starter lever  Remove clutch cover  Remove oil level bolt and inspect oil level,

if oil level is below oil hole, add oil until oil

flows from the level hole.

 Tighten oil level bolt to the specified torque.

Tightening toque：9-15N.m （0.9-1.5 kg-m ，6.5-11.0 lb-ft）

BRAKES

Inspect at initially 500 km and every service, replace brake fluid every 2 years, replace brake hose every 4 years.

Front brake fluid level

 Keep the scooter upright and place the

handlebar staight.

 Check brake fluid level by observing the

lower limit line on the brake fluid reservoir.

 When the level is below the lower limit line,

replenish with brake fluid that meets the

following specification.

Specification and classification：DOT4

WARNING：

The brake system of the scooter is filled with a glycol-based brake the lowest line Fluid. Do not use or mix different types of fluid such as silicone-based and petroleum-based. Do not use any brake fluid taken from old, used or unsealed containers. Never reuse the brake fluid left over from the last servicing and stored for long periods.

WARNING：

Brake fluid, if it leaks, will interfere with safe running and immediately discolor painted surfaces. Check the brake hoses for cracks and hose joints for leakage before riding.

Brake pads

Wearing condition of brake pads can be checked by observing the limit line  marked on the pad. When the wear exceeds the limit mark, replace the pads with new ones.

Bleeding air from the brake fluid circuit

Air trapped in the fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cylinder and thus interferes with the full braking performance of the brake caliper. The presence of air is indicated by “sponginess” of the brake lever and also by lack of braking force. Considering the danger to which such trapped air exposes the machine and rider, it is essential that, after remounting the brake and restoring the brake system to the normal condition, the brake fluid circuit be purged of air in the following manner:

 Fill up the master cyliner reservoir to the upper end

of the inspection window. Replace the reservoir cap

to prevent entry of dirt.

 Attach a pipe to the caliper bleeder valve, and insert

the free end of the pipe into a receptacle. Bleed air from the bleeder valve.

Squeeze and release the brake level several times

in rapid succession. And squeeze the lever fully

without releasing it. loosen the bleeder valve by

turning it a quarter of a turn so that the brake fluid

runs into the receptacles: the will remove the

tension of the brake lever causing it to touch the

handlebar grip. Then, close the valve, pump and

squeeze the lever, and open the valve. Repeat the

process until the fluid flowing into the receptacle no

longer contains air bubbles.

NOTE：when bleeding the braking system, replenish the brake fluid reservoir if necessary. Make sure that there is always some fluid visible in the reservoir.

 Close the bleeder vavle, disconnect the pipe. Fill the reservoir with brake fluid to

the upper end of the inspection window.

BLEEDER VALVE TIGHTENING TORQUE: 6-9N.m(0.6-0.9kg-m,4.5-6.5lb-ft)

CAUTION：

Handle brake fluid with care: the fluid

reacts chemically with paint, plastics,

rubber materials, etc.

Rear brake

T urn adjusting nut so that the the play of the

brake lever is 15-25MM as shown in the

illustration.

Brake shoe wear：

The vehicle is equipped with the brake

lining limit Indicator on the rear brake.

Inspect brake lining limit as follows：

1. First check if the brake system is properly adjusted.

2. when operating the brake, check to see that the tip of indicator is within the range.

3. if the tip of indicator is beyond the range, the brake shoe assembly should be raplaced with anew set of shoe.

Tire

Inspect at initially 1000KM （ 600 miles ， 2 months） and every 6000KM（4000 miles，12 months）thereafter

Tire pressure：

If the pressure is too high, the scooter will tend to rede stiffly and have poor traction. Conversely, if tire pressure is too low, stability will be adversely affected. Thereafter , maintain the correct tire pressure for good roadability and to prolong tire life.

CAUTION： The standard air pressure of tires is 175/196Kpa, the use of other than standard may cause handling instability . It is highly recommended to use a GENERIC genuine tire.

Tire tread condition：

Operating the scooter with the excessively worn tires will decrease riding stability and consequently invite dangerous situation. It is highly recommended to replace the tire when the remaining depth of tire tread reaches the following specification. Front and rear：1.6MM（0.064IN） Tire depth gauge

Steering

inspect at initially 500km and every service.

Steering should be adjusted properly for smooth turning of handlebars and safe running. Too stiff steering prevents smooth turning of handlebars and too loose steering will cause poor stability. Check that there is no play in the front fork assembly by supporting the machine so that the front wheel is off the ground, with wheel staight ahead, grasp lower shock absorber near the axle and pull forward. If play i s found, perform steering bearing adjustment.

Front shock absorber

Adjust at initially 500km and each service.

Inspect the front shock absorber for oil leakage or other damage, and replace the defective parts, if necessary.

Rear shock absorber

Adjust at initially 500km and each service.

Inspect front shock absorber for oil leakage and other damage, and replace the defective parts if necessary.

No. Item N•m Kg-m

1 Front axle nut 55-60 5.5-6 2 Handle tightenging nut 37-44 3.7-4.4 3 Steering sterm locknut 37-44 3.7-4.4 4 Disc brake caliper fixing bolt 22-29 2.2-2.9 5

Disc brake master cylinder hose fixing

bolt

22-29 2.2-2.9 6 Disc brake fixing bolt 5-9 0.5-0.9 7 Front shock absorber fixing bolt 37-44 3.7-4.4 8 Engine pivot fixing nut 55-60 5.5-6 9 Engine bracket fixing nut 37-44 3.7-4.4

10 Rear wheel fixing nut 100-130 10-13

11 Rear brake rocker arm fixing bolt 5-9 0.5-0.9 12 Rear shock absorber under fixing bolt 22-29 2.2-2.9 13 Start pedal mounting screw 15-20 1.5-2 14 Rear shock absorber top fixing bolt 37-44 3.7-4.4

③

①

②

④

⑤

⑥

⑦

⑧

⑨

⑩

LUBRICATION

Proper lubrication is important for smooth operation and long life of each working part of the scooter. The major lubrication points are indicated below： NOTE：

1. Lubricate exposed parts which aare subject to ruse with engine oil.

2. Before lubricating each part, clean off any rusty spots and wipe off any grease, oil dirt of grime.

WARNING：Be careful not to apply too much grease to the rear brake camshaft, otherwise brake slippage will result from the presence of grease in brake drum.

steering stem bearing front wheel bearing engine bracket rear brake camshaft side stand rear brake shaft and rear brake cable speedometer cable and gear box main stand

A: lubrication

A

A

A

 A

③A

ENGINE

CONTENS

Engine components removal with the engine in place Engine removal and remounting Engine removal Engine remounting Engine disassembly Engine components inspection and servicing Bearings Oil seals crankshaft automatic clutch inspection cylinder head cylinder piston reed valve engine remounting oil seals bearings bushings crankshaft crankcase rear axle shaft transmission starter pinion and starter gear Movable driven and clutch Movable drive Kicking starter Piston Oil pump and oil pump driven gear Intake pipe Magneto

Engine components removable with the engine in place

The parts listed below can be removed and reinstalled without removing the engine from the frame.

Engine left side

Kicking starter lever Clutch brake pad kit Driver left face V-belt Driver belt right face Electric starter gear Super clutch Driven face

Engine center

Carburetor Intake pipe Reed valve Oil pump Worm wheel Cylinder head Cylinder Piston

Engine right side

cooling fan Magneto Starter motor

ENGINE ASSY.

z Remove the muffler z Remove cooling fan cover z Remove cylinder cover z Remove cooling fan

z Remove magneto nut with special tools.

z remove magneto rotor and half circle key with

special tools.

z remove magneto stator and paper gasket

z remove oil pump

Remove worm wheel and oil seal press board

z remove cylinder head and

cylinder

z Place a cloth stopper beneath the piston

and remove the circlip with a plier.

z remove the piston pin and piston.

z Remove the kick starter lever. z Remove side cover

z Remove movable ratchet wheel and clip

z Remove starting driven ratchet wheel by removing the nuts.

z Remove fan and V-belt. z Disassemble the movable drive

face.

z Remove electric gear press board, electric

gear and super clutch

z Remove starter motor

z Remove the clutch housing with the special tool.

(Peg key)

z drain gear oil

z remove rear axle nut z remove rear wheel

z remove brake shoe and rear axle。

z Remove the rear brake cam lever，indicator

plate and camshaft.

z remove spring z remove cotter pin and shaft z remove main stand

z remove gearcase cover

z Remove paper gasket and middle

gear assy.,

z Remove output gear assy.

z remove carburetor

z remove intake pipe

z remove reed valve and paper gasket.

z Remove crankcase fixing shaft

z disassemble crankcase with special tools z first remove right crankcase cover.

z Remove crankcase with special tools

z Remove crankshaft bearing with special tools

SLIDING SHAFT Warning use a new sliding shaft.

Unscrew clutch shoe nut with special tools.

z Remove the nut while holding down clutch

shoe assy. by both hands as shown in the illustration.

WARNING：Gradually back off the clutch shoe assy, pressed down by hands to counter the clutch sparing load. Releasing the hand suddenly may cause the following parts to fly apart.

nut clutch shoe spring

CAUTION：

Do not attempt to disassemble the clutch shoe assy. Otherwise the clutch shoe may be damaged.

z Using a screwdriver or the like, pry up the

movable driven face spring guide.

 Remove the pins, movable driven face and

fixed driven face.

Remove circlip z Remove bearing with special tool.

CAUTION：Replace the removed bearing with a new one.

z Remove inner bearing with special tool.

CAUTION：Replace the removed bearing with a new one.

z Remove the spacer

Remove the oil seal from the gearcase cover with the speical tool.

CAUTION： Replace the removed oil seal with a new one.

z Remove gearcase cover bearing with special

tool

Remove left crankcase oil seal z with special tool

warning：use a new oil seal

z remove left crankcase bearing with special tool

warning：use a new one

z remove left crankcase shock absorber bushing

with special tool

warning：use a new bushing

wrap the oil seal with two appropriate size of sheet irons and clamp it, shown as fig.

z Remove right crankcase oil seal with special tool

Warning：use a new oil seal

z remove right crankcase bearing sliding bearing warning：use a new bearing

+ 80 hidden pages

Generic XOR 50 ccm Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual