Generic XOR 50 ccm Service Manual

2

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.

3

GENERAL INFORMATION

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

CONTENT

4

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.

1

5

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.

6

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

0

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.

7

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

8

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 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

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

9

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

10

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.

11

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.

12

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.

3

13

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.

14

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.

15

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.

16

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.

17

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.

18

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

19

③

①

②

④

⑤

⑥

⑦

⑧

⑨

⑩

14

20

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

 A

③A

21

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

22

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

23

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

24

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

25

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

26

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.

27

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

28

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.

29

 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

30

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

31

ENGINE COMPONENTS INSPECTION AND SERVICING

BEARINGS

Clear bears with solvent and lubricate
with engine oil before inspecting.

T urn the inner ring and check to see that
the inner rieng turns smoothly. If it does
not turn lightly , quietly and smoothly , or if
noise is heard, the bearing is defective
and must be replaced with a new one.

OIL SEAL

Damage to the lip of the oil seal may result in leakage of the fuel-air mixture or oil.
Inspect for damage and be sure to replace the damaged seal if found.

CRANKSHAFT
CRANKSHAFT RUNOUT

Support crankshaft by“V” block, with the dial gauge
rigged to read the runout as shown.

Service limit：0.05mm(0.002in)

Excessive crankshaft runout is often responsible for
abnormal engine vibration. Such vibration shortens
engine life.

Condition of big end bearing

Turn the crankshaft with the connecting rod to feel the
smoothness of rotary motion in the big end. Move the
rod up and down while holding the crankshaft rigidly to
be sure that there is no rattle in the big end.
Wear on the big end of the connecting rod can be
estimated by checking the movement of the small end
of the rod. The method can also check the extent of
wear on the parts of the connecting rod ‘s big end. If
wear exceeds the limit, replace connecting rod, crank
pin and crank pin bearing.

Service limit：3.0mm(0.12in)

32

Connecting rod small end inside diameter

Measure the connecting rod small end diameter with
a caliper gauge.

Service limit：14.040mm

33

Automatic clutch inspection

The scooter is equipped with an automatic clutch
and variable ratio belt drive transmission. The
engagement of the clutch is governed by engine
RMPS and centrifugal mechanism located in the
clutch.
To insure proper performance and long lifespan of
the clutch, it is essentiall that the clutch engages
smoothly and gradually. Two inspection checks must
be performed to thoroughly check the operation o f
the drivetrain. Follow the procedures listed.

1．Inspect initial engagement

Warm up the scooter to normal operating
temperature.
Remove the right frame side cover.
Connect an electric tachmeter to the connecting
portion of the magneto lead wire (black with red
tracer).
Seated on the scooter with the scooter on level
ground, increase the engine RPMs slowly and note
the RPM at which the scooter begins to move
forward.

Tachometer

Standard 2900r/min

tolerance ±300r/min

2．Clutch “LOCK-UP” inspection

Perform the inspection to determine if the clutch is
engaging fully and not slipping.
Warm the engine to normal operating
temperatures.
Connect the electric tachomter to the magneto
lead wire.
Apply the rear brake as firm as possible.
Briefly open the throttle fully and note the
maximum engine RPMs sustained during the test
cycle.

CAUTION:

Do not apply full power for more than 10 seconds
or damage to the clutch or engine may occur.

LOCK-UP R/MIN

Standard 5800r/min

Tolerance ±400r/min

34

If the engine R/MIN doesn’t coincide with the specified r/min range, then

disassemble the clutch.

Clutch shoe---inspect the shoes visually for chips, cracking, uneven wear and burning,
and check the thickness of the shoes with vernier calipers. If the thickness is less than
the following service limit, replace them as a set.
Clutch springs -----visually inspect the clutch springs for strectched coils or broken
coils.

Service limit:：2.0mm(0.08in)

CAUTION ： clutch shoes or springs must be
changed as a set and never individually.

Clutch wheel—inspect visually the condition of the
inner clutch wheel surface for scrolling, cracks, or
uneven wear. Measure inside diameter of the clutch
wheel with inside calipers. Measure the diameter at
several points to check for an out-of-round condition
as well as wear.

Service limit:110.50mm(4.350in)

DRIVE BELT
Remove the drive belt and check for cracks, wear
and separation. Measure the drive belt width with a
vernier calipers. Replace it if the belt width is less
than the service limit or and defect has been found.

Service limit：16.0mm(0.630in)

CAUTION；Always keep the drive belt away
from any geasy matter.

Drive face
Inspect the belt contact surface of the dirve faces
for wear, scratches or any abnormality. If there is
something unusual, replace the drive face with a
new one.

35

Roller and sliding surface

Inspect each roller and sliding surface for wear or
damage.

Driving face spring
Measure the free distance of the driven face spring. If
the length is shoter than the service limit, replace the
spring with a new one.

service limit: 104.5mm(4.11in)

Driven face pin and oil seal
T urn the driven face and check to see that the driven
faces turn smoothly. If any stickiness or hitches are
found, visually inspect the lip of oil seal, driven face
sliding surface and sliding pins for wear or damage.

Driven face
inspect the belt contacting surface of bothdriven
faces for any scratches, wear and damage.
Replace driven face with a new one if there are
any abnormality.

Cylinder head

Decarbon the combusion chamber.
Check the surface of the clinder head as shown
in the illustration for distortion with a straightedge
and thickness gauge, taking a clearance reading
at several places.

service limit：0.05mm(0.002in)

36

If the largest reading at any portion of the
staightedge excees the limit, rework the surface by
rubbing it against emery paper laid flat on the
surface plate in a lapping manner. The surface must
ge smooth and perfectly falt in order to secure a tight
join: a leaky joint can be the cause of reduced power
output and increased fuel consumption.

CYLINDER

Decarbon exhaust port and upper part of the
cylinder, taking care not to damage the cylinder wall
surface. The wear of the cylinder wall is determined
from diameter reading taken at 20mm from the top
of the cylinder with a cylinder gauge. If the wear thus
determined exceeds the limit indicated below, rework
the bore to the next oversize by using a boring
machine or replace the cylinder with a new one.
Oversize pistions are available in two sizes: 0.5mm
and 1.0mm. (cylinder gauge)

service limit：40.075mm(1.5778in)

after reworking the bore to an oversize , be sure to
chamfer the edges of ports and smooth the
chamfered edges with emery paper. To chamfer,
use a scraper, taking care not to nick the wall
surface.

NOTE

：

Minor surface flaws on the cylinder wall durto seizure
or similar abnormalities can be corrected by grinding
the flaws off with fine-grain emery paper . If the flaws
are deep grooves or otherwise persist, the cyliner
must be reworked with a boring machine to the next
oversize.

PISTON
cylinder and piston clearance

cylinder –piston clearance is the difference between
piston diameter and cylinder bore diameter. Be sure
to take the maked diameter at right angles to the

piston pin. The value of elevation ,A is prescribed to
be 20mm from the skirt end.

(micrometer)
service limit：39.885mm(1.5703in)

As a result of the above measurement, if the
piston-to-cylinder clearance exceeds the following
limit, overhaul the cylinder and use an oversize piston,
replace both cylinder and piston. The measurement
for the bore diameter should be taken in the
intake-to-exhaust port direction and at 20mm from
the cylinder top surface.

37

Unit：mm

Piston pin bore

Use a caliper gauge to measure the piston pin bore inside diameter,. If reading
exceeds the following service limit, replace it with a new one.
(Dial caliper)
Limit service: 12.30mm(0.4736in)

Piston pin outside diameter：
Use a micrometer to measure the piston outside

diameter at three positions.
(Micrometer（0-25mm）)
service limit：11.980mm(0.4717in)

Piston rings

Check each ring for end gap, reading the gap with a
thickness gauge shown in the illustration. If the end gap
is found to exceed the limit, indicated below, replace it
with a new one.
The end gap of each ring is to be measued with the ring
fitted squarely into the cylidner bore and held at the
least worn part near the cylidner bottom, as shown in
the illustration.

Service limit：0.75mm(0.030in)

As the piston ring wears, its end gap increases reducing
reducing engine power output becaust of the resultant
blow by through the enlarged gap. Here lies the
importance of using piston rings with end gaps with the
limit. Measure the piston ring free end gap to check the
spring tension.

service limit：3.6mm(0.14in)

Fix the piston ring in the piston ring groove, measure the ring side clearance with the
thicknes gauge while matching the sliding surface of piston and ring.

Standard service

limit
Cylinde
r

40.005-40.0
20

40.075

Piston 39.94-39.955 39.885
Cylinder to
piston

0.06-0.07 0.120

38

Standard clearance

1st：0.04-0.06mm(0.0016-0.0024in)

2nd：0.02-0.04mm(0.0008-0.0016in)

Reed valve

Check the clearance A betw een reed valve and its
seat and the dimension B. If the clearance A is noted
to exceed 0.2mm, replace the reed valve assembly.
The dimension B is at least 1mm.

ENGINE Reassembly

Reassembly is generally performed in the reverse
order of disassembly, but there are a number of
reassembling steps that demand or deserve detailed
explanation or emphasis. These steps will be taken
up for respective parts and components.

Oil seals
fit the oil seals to the crankcase following the
procedure below. Replace removed oil seals with
new ones.

z Lubricate the edge of oil seal

z Install oil seal into crankcase

carefully with special tool.

Oil seal installation

Bearing

Install new bearing with
special tool

Install bearing

First heat up the cover and
cool down the bearing. The
install would be much easier
and better for the bearing.

39

shock absorber bushing

positon

install bearing in the cover. Don’t install
the bearings on the crankshaft.

Install shock absorber bushing

Install crankshaft (without bearings)

40

CRANKCASE

z Wipe the crankcase mating surfaces with

clraning solvent.

z Apply GENERIC NO.1215 evenly to the mating

surface of the right half of the crankcase

z Tighten the crankcase screws securely.

z Check if crankshaft rotates smoothly.

Install gearcase bearing

Install new bearing and oil seal into gearcase cover with special tool, and tighten
anchor pin.

41

z install output axle

z gearshift
z install middle gear , position pin by installing middle

gear axle, gasket and thrust gasket

z install gearcase cover into

crankcase and lock bolt.

z tighten each screw

z screw oil drain nut,11

tightening torque：4-7 N.m

(0.4-0.7kg-m,3.0-5.0 Ib-ft)

42

z install the bearing in the fixed driven face with the

special tool.

z install sliding bearing 。

43

z Install the bearing with special tool

z install the spacer and circlip:

z install the new oil seals and to the movable

driven face with the special tool.

z apply grease to the lip of oil seals and

groove of inside of movable driven face.

GENERIC special super grease

NOTE:
When reinstalling the movable face to the fixed
face, make sure that the oil seal is positoned
properly.

z install the pin at three places on the driven

face hub.

z Apply grease lightly to the cam part where the

pins are placed.

z Install two O-RINGs.

44

z Install the movable driven face seat.

z install the clutch shoe assembly and nut.

z tighten the nut to the specified torque with the

special tool.

tightening torque：40-60 Nm
(4.0-6.0kg.m 29.0-43.5Ib-ft)

z insert the V-belt between the driven faces as

deep inside possible while pulling the movable
driven face all the way outside to provide the
maximum ble clearance.

CAUTION:

the belt should be positioned so that the arrows
on the belt periphery point the normal turning
direction.
The V-belt contact face on the driven faces should
be thoroughly cleaned to be free from oil.

z Thoroughly clean the clutch housing to be free

from oil and position it over the clutch shoe
assembly.

z tighten the clutch housing nut to the specified

torque with the special tool.

Torque：40-60 Nm

(4.0-6.0kg.m 29.0-43.5Ib-ft)

45

z Apply grease to all the sliding and rolling surfaces

for six roller weights. For each weight,
approximately 1.5g of grease should be used.

GENERIC super grease

z Mount the three dampers on the movable drive

plate and install it on the movable drive face.

z Position the O-RING on the movable drive

face.

z Install the movable drive face cover.

NOTE:

1. Make sure that the mova ble drive plate is fully
positioned inside, or the weight roller may
come off.

46

z Insert the spacer
z Position the movable drive face

subassembly on the crankshaft as shown in
illustration.

NOTE

：

Thoroughly clean the belt contact to be
free from oil.

z Install the fixed drive fan.
z tighten the nut to the specified torque with

special tool.
Connecting rod fixer
Tightening torque：40-60Nm

(4.0-6.0kg-m, 29.0-43.5Ib-ft)

z fill grease in the groove provided inside sliding

surface of the kick driven gear and install  on the

end of the crankshaft. Wipe off excess grease.

QIANJIANG super grease

Install washer and spring.

NOTE:

When Installing washer，face the resin surface

of washer to outside.

z install the retainer.

z continue turning the fixed drive face by hand

until the belt is seated in and both the drive and

driven faces will move together smoothly with

slip.

fill the final gear box with engine oil up to the
level hole.

Oil capacity： 90ml
z tighten the oil level bolt to the specified torque.
Tightening torque：9-15Nm

47

Starter assy.

z Inject lubrication into start bearing and

lubrication in the end of starter shaft

GENERIC SPECIAL LUBRICATION

z Tighten starter shaft gasket

Install starter ratchet wheel and circlip

48

z Install the dowel pins
z install the new gaskets( and )

z apply GENERIC bond no. 1215 to the clutch

cover as shown in the illustration.

GENERIC bond no. 1215

NOTE: Install the kick starter lever as
shown in the illustration.

Tightening toque：8-12Nm

(0.8-1.2kg-m, 6.0-8.5Ib-ft)

PISTON

z install the piston rings on the piston.

The first and the second ring: keystone ring.

NOTE:

Position the ring so that the marking is on
upside.

z it is extremely important that, when the

piston is fed into the cylinder , each ring in

place should be so positioned as to hug

the locating pin as shown in illustration.

49

z apply oil for the piston and install the piston to

the connecting rod.

NOTE

：

The arrow mark  on the piston head should
point the exhaust side.

z The circlip should be mounted in such a

position that the mating ends of the circlip do
not coincide with the grovve portion of the
piston.

z apply oil on the position and cyoinder wall

surfaces and install the cylinder over the
piston carefully.

z tighten the cylinder head nut to the

specification.

tightening torque：18-28Nm

z install right crankcase oil seal press board

z install worm, and lubricater it with GENERIC

special lubrication.

Oil pump

z install oil pump into crankcase

torque：3-5Nm

(0.3-0.5kg-m, 2.3-3.7Ib-ft)

OUTSIDE

50

Reed valve

z install a new reed valve paper

gasket.

z Install reed valve
z Install oil hose

Intake pipe
z install intake pipe

Magneto

z clear crankshaft and magneto rotor
z install half circle key
z install paper gasket and stator coil, and fix them

z tighten to specified torque with special tool

specified torque：35-45Nm
(3.5-4.5kg.m,25.5-31.0Ib-ft)

51

z install cooling fan

z install guiding cover

z install fan guiding cover

z install pipe screw and screw for tightening muffler

to their specified torque.
：8-12Nm (0.8-1.2kg.m,6.0-8.5Ib-ft)
：18-28Nm (1.8-2.8kg.m,13.0-20.0Ib-ft)

z lubricate brake cam shaft with GENERIC grease.

52

CHAPTER 4 FUEL AND LUBRICATION SYSTEM

CONTENTS
FUEL SWITCH
CARBURETOR
OIL PUMP

53

FUEL SWITCH

When the engine has started, a negative pressure (vacuum) is generated at the intake
port. The negative pressure acts upon the diaphragm of the fuel switch and it pressed
down the spring which supports the diaphragm so that the fuel passageway is opened
and fuel is fed to the carburetor.

When the engine has stopped, the spring presses the valve, the fuel passageway is
closed, and no fuel flows to the engine.

Fuel switch

54

CARBURETOR

CARBURETOR

Carburetor
manufacturer/type
Identification code
Throat tube diameter
Main jet size
Idle needle jet size
Oil needle clamp position
Idle air adjusting screw
Float height

equal vacuum
PZ19JB

19mm
#80
#57.5
3

rd

groove

extrude 1

2

1

±

2

1

turnout

13±1mm

55

CARBURETION

Proper carburetion is determined according to the results of various tests, mainly
concerning engine poer , fuel consumption and cooling effect of feul on engine, and jet
settings ard made so as to satisfy and balance all of these conditions. Therefore, the
jet should not be replaced with a size other than the original. And the positions of
adjustable parts should not be changed except wh en compensation for the mixture
ratio due to altitude differences or other climatic conditions. When adjustment is
necessary, refer to the following.

OIL PUMP

OIL LEAKAGE throughout

Whenever evidence is noted of some air having leaked into the oil pipe from the oil
tannk in a machine brought in for servicing, be sure to carry out an air bleeding
operation with the oil pump in place before returning the machine to the user. T o bleed
air, hold the machine in standstill condition.

56

CHAPTER 5 ELECTRICAL SYSTEM

CONTENS

IGNITION SYSTEM
CHARGING AND LIGHTING SYSTEM
STARTER SYSTEM
FUEL GAUGE
OIL LEVEL CHECK LIGHT AND TURN SIGNAL INDICATOR
SWITCHS
BARTERY

57

IGNITION SYSTEM

The ignition system consists of a flywheel magneto, a CDI&Ignition coil unit and a

spark plug.

As the rotor tatates, an AC current is induced in the coil. Then current induced in the

,A direction charges up the capacitor.
As the rotor rotates further, the current is induced in the reverse direction (dirction,B).
the current causes a voltage applied through the ground to the gate of SCR.
As the SCR conducts, the energy which has been charged in the capacitor is
instantaneously discharged through the primary winding of the ignition coil.
CDI UNIT AND IGNITION COIL INSPECTION
CHECKING WITH ELECTRO TESTER
Connect the CDI test lead to the coil”s primary
connector.
Connect the high tension leads, red,+ lead to the
spark plug cord and the black,— lead to the black
lead of the test lead.

z Set the test selector knob to “P.E.I”.
z Connect the power lead to the appropriate AC source.
z Switch the power on.

Switch Black

red

CDI test lead

MAGNETO

CDI&Ignition coil unit

Spark plug

58

 Note the spark in the spark gap window. It should
be strong and continuous, not intermittent, acrossa
preset 8mm(0.32in) gap. Allow the spark to jump
the test gap for at least five minutes continuously.
To insure proper operation under the temperature
of actual riding.

Electronic tester
Ignition coil testing lead
Use portable tester to check it.

Test the resistance between i gntion ground wire and
spark plug cap.
Ignition coil second resistance：12-18 KQ

MAGNETO EXCITING COIL

z remove the right frame side cover
z disconnect the exciting coil lead wire(black with

red tracer).

z Using a pocket tester, measure the resistance

between the B/R lead wire and ground. If the
resistance checked is incorrect, re plac e the coil.

Exciting coil restance：140-220

59

CHARGING AND LIGHTING SYSTEM

The charging system uses the flywheel magnetoas shown in the figure. The charging
and lighting coils are mounted on the magneto stator and generate AC as the
flywheel rotor turns. AC generated in the charging coil flows to the regulator/recifier
which changes AC to DC. The DC Then charges the battery.
Charging output check
start the engine and keep it running at 5000r/min
with lighting switch turned on.

NOTE:

When making the test, be sure that the batteryis
in fully charged condition.

Tachometer
Standard charging output：13-16v at 5000r/min

Fuse

Battery

60

NO-LOAD PERFORMANCE

z Disconnect the magneto lead wire coupler.
z Start the engine and keep it running at 5000r/min.
z Using a pocket tester, mea sure the AC voltage between the white and red trace r

lead wire and ground. If the tester reading is as follows, magneto is in good
condition.

Standard no-load performance: more than

65v(AC)AT 5000R/MIN.

STATOR COILS
Inducing coils

Use procket tester to measure the resistance

between the lead wire and ground. If the resistance
checked is not correct, replace the coil.

Rregulator/rectifier

Disconnect the lead wire couple.
Using the pocket tester（ × 1KQ RANGE）, measurethe resistance between the
terminals as shown in the following table. If the resitance checked is incorrect, replace
the regulator/rectifier.

UNIT:
NOTES：

Including the components such as
transistor,capacitance, regulator
diode and so on, so tested
resistance may be different from
actual resistance.

Standard

resistance
W/R-GROUND 0.6-1.1Q
W/R-GROUND 0.5-0.8 Q

61

STARTER SYSTEM

DESCRIPTION
The starter system is shown in the diagram bel ow: namely, the starter motor, relay,

starter switch and battery. depressing the starter button while squeezing the front or
rear brake lever energizes the relay, causing the contact points to close which
connects the starter motor to the battery.

Starter motor removal and disassembly

Remove the starter motor
Disassemble the starter motor as shown in the
illustration

62

STARTER MOTOR INSPECITION

CARBON BRUSHES

When the brushes are worn, the motor will be
unable to produce sufficient torque, and the engine
will be difficult to turn over. To prevent the ,
periodically inspect the length of the brushes and
replace them when they are too short or chipping.

Service limit：3.5mm(0.14in)
Commutator

If the commutator surface is dirty, starting
performance will decrease. Polish the commutator
with #400 or similar fine emery paper when it is dirty.

Service limit：0.2mm(0.008in)
Armature coil

using the pocket tester , check the coil for open and
ground by plcing probe pins on each commutator
segment and rotor core and on any two segments
at various places. With the brushes lifted off the
commutator surface. If the coil is found to be
open-circuited or grounded, replace the armatrue.

Starter relay inspection

z Disconnect lead wire (R/W) of the starter motor.

T urn on the igniton switch and squeeze the front
or rear brake lever, then inspect the continuity
between the Red and Red/White lead wires at
the starter relay when pushing the starter
button.
If the starter relay is in sound condition,
continuity is found.

• Disconnect the starter relay lead wire couple.

Check the coil for “open”, “ground” and ohic
resistance. The coil is in good condition, if the
resistance is as follows:

STANDARD RESTANCE:：80-150Q

Segment

Mica

63

FUEL LEVEL METER/GAUGE

FUEL METER INSPECTION

T o test the Fuel Meter two different checks may be used. The first,and simplest test will
tell if the mete is operating but will not indicate the meters accuracy throughout the
range.To perform the test,lift the seat and remove the right frame cover,then
disconnect the B/W and Y/B lead connector of the fuel gauge sending unit.Connect a
jumper wire between B/M and Y/B wiers coming from the main wiring harness.With the
ignition switch tuined ON,the fuel meter should indicate“F”.

The second test will check the accuracy of the meter in
the full and empty positions.Connect a 90-ohm resistor
between the Y/B and B/W lead wires.The fuel meter is normal
if its pointer indicates the E(empty) position when the
specified voltage is applied to the circuit and if its
pointer indicates the F(full) position when the resistor is
changed to 10 ohms.If either one or both indications are
abnormal,replace the fuel meter with a new one.

FUEL GUAGE SENDING UNIT INSPECTION

Disconnect the lead wires coming out of the fuel
gauge and check resistance of eadn podition.
If the resistance measured is incorrect, erplace the
fuel gaue assembly with a new one.

The relation between the position of the fuel guage float and
resistance is shown in the following table.

FLOAT POSITION RESISTANCE

F（FULL）

APPROX.33

1/2 APPROX.200

E（EMPTY）

APPROX.566

CABLE ASSY.

33

64

SIGNAL SYSTEM

The same bulb is used tor both oil level check light and turn signal indicator light.The
circuitry is shown below.When the oil level has fallen to a certain level (the remaining
amount of oil has become approximately 160 ml,the oil level check light turns on and
remains lit.When the turn signal switch is turned on and the turn signal light flashes,the
turn signal indicator light (oil level check light)also flashes,both being not concurrently
but alternatively as one being lit white the other unit.

Fig. 7

OIL LEVEL SWITCH INSPECTION

Check the oil level switch for continuity between the lead wire.If the tester does not
show the value of 0-1 ohm when the switch ring is in bottom position,file the contact
surface or replace the unit.

65

SWITCH

DARK GREEN

OFF

ON

HORN SWITCH

RED/WITHE

OFF

OFF

ON

RED/SWITCH

LOCK

BREAK SWITCH

RED

ON

RED/WHITE

MA IN SWITCH

BROWN

TURN RIGHT

TURN LEFT

DIRECTION SWITCH

ORANGE

GREEN

/BLACK

GREEN/WHITE

PASSING LIGHT

YELLOW/RED

PURPLE

DIPPED
HEADLIGHT

HIGH BEAM

OFF

BULE AZURY

EXCHANGE LIGHT SWITCH

GREEN/RED

BLACK

HEAD LIGHT

YELLOW/RED

YELLOW

LIGHT CONTROL SWITCH

YELLOW

PINK

66

BATTERY

SPECIFICATIONS

Type designation YB4L-B

Capacity 12V 4Ah

Standard electrolyte 1.28(20)

INITIAL CHARGING

FILLNG ELECTROLYTE
Remove the aluminum tape  sealing the battery electrolyte filler holes.

Remove the caps .
NOTE：
* After filling the electrolyte completely ,use the removed cap

 as the sealed caps of battery-filler holes.
* Do not remove or pierce the sealed areas  of the
electrolyte container.

Insert the nozzles of the electrolyte container into the
battery`s electrolyte filler holes,holding the container
firmly so that it doer not fall.Take precaution not to
allow any of the fluid to spill.

Make sure air bubbles are coming up each electrolyte
container ,and leave in the positon for about more than 20
minutes.

Test the battery after the filling process. If
necessary charge the battery about 20 minutes
with the charger.

67

RECHARGING OPERATION

Apply multimeter to measure the voltage of battery. If the reading is below 12.0V，it
should be charged.

NOTE:
When recharging, remove the battery form the vehicle.
NOTE:
When recharging, don’t remove the sealing cap off battery top.

Recharging time：0.4A or for 5 hours or 4.0A for 1 hour.

NOTE:
The current should be not more than 4A at any time.

After recharging, wait for more than 30 minutes and apply multimeter to meas ure the
battery voltage.
If the battery voltage is less than12.5V，please rechare the battery again.

If battery voltage is still less than 12.5V，please replace the battery with a new one.
When the battery is left for a long term without using, it is subject to discharge. When th
scooter is not used for more than 1 month (especially dring the winter season),
recharge the battery once a month at least.

68

CHAPTER 6 CHASSIS

CONTENTS

LEG SHIELD AND FRAME SIDE COVERS

LEG SHIELD REMOVAL
LEG SHIELD REMOUNTING
FARME SIDE COVER REMOVAL
FARME SIDE COVER REMOUNTING

HANDLEBAR COVERS

REMOVAL
REMORNTING

FRONT WHEEL

REMORAL
INSPECTION AND DISASSEMBLY
REASSEMBLY AND REMOUNTING

FRONT BRAKE

BRAKE PAD REPLACEMENT
CALIPER REMOVAL AND DISASSEMBLY
CALIPER AND DISC INSPECTION

CALIPER REASSEMBLY
MASTER CYLINDER REMOVAL AND DISASSEMBLY
MASTER CYLINDER INSPECTION
MASTER CYLINDER REASSEMBLY AND REMOUNTING

STEERING STEM AND FRONT SUSPENSION

REMOVAL AND DISASSEMBLY
INSPECTION
REASSEMBLY AND REMOUNTING
IGNITION SWITCH

REAR WHEEL AND BRAKE

REMOVAL AND DISASSEMBLY
INSPECTION
REASSEMBLY AND REMOUNTING

69

Side cover removal

1. remove seat and helmet barrel by opening
seat and loosing tightening screw .

2. loose hexad screw  and remove decorating
cap , rear carrier and oil tank lock ，remove
side cover  by loosing side cover screw  ；

3. unlock oil pump cap and remove it, two
tapping screw are exposed, remove
them; remove tapping screw；then remove
side cover

side installation

4. the sequence of installation is the reverse of removal.

④

③

⑦

②

③

⑦

⑧

⑩ ⑩

⑨

70

under cover removal

1. unscrew screw  and bolt 

2. removing under cover by loosing the left and right tapping screws ；

under cover installation

3. The sequence if installation is ther reverse of removal.

front cover removal
1．Unscrew tapping screw , and remove front cover  by removing front cover screw

②

①

①

②

①

③

①

② ②

②

①

71

LEGSHIELD AND PEDAL REMOVAL

1. Remove power lock housing  by unscrewing bolt.

3. remove legshield and pedal by
unscrewing the four bolts

Legshield and pedal installation

4. the sequence of legshield and

pedal is the reverse of reomval；

②

③

①

72

HANDLE COVER REMOVAL

1． Remove front handle cover  by

unscrewing the six tapping screws 

2. Remove master cylinder by removing
the bolt ;

①③

①①

①①

①①

①②

73

3． Disconnect throttle cable and oil pump cable

4．Remove rear brake cable adjusting nut 

①③

①④

①⑤

74

Handle cover removal

5. remove all cables；

6．Remove handle cover by unscrewing bolt 

Handle cover unstallation

7. The sequence of removal is the reverse of reomval

⑥

75

Front wheel

1. front rim

2. middle bushing

3. oil seal

4. roller bearing GB6201-2RS

5. tire

6. valve mouth

7. nut GB6817

8. front shaft

9. front wheel left bushing

10. gearcase

11. valve mouth cap

remove

Remove the front brake caliper  by removing the
mounting
bolts.
NOTE： Do not operate the front brake lever while
dismounting caliper

∙remove mounting bolt

∙remove the left decorating cover  and right one .

∙remove under front fender 

∙support the scooter by jack or wood

shelf.

∙Remove front wheel by removing

front axle shaft.

① ②

③

⑤

④

⑥

76

INSPECTION AND DISASSEMBLY

WHEEL BEARING
Inspect the play of bearing inner ring by hand while
mounted in the wheel.
Rotate the inner ring by hand to inspect if any abnormal
noise occurs or rotating smoothly,
Replace the bearing if there is anything ucusual.
∙Remove the dust seal.
CAUTION:
The removed dust seal and bearing should be replaced with new ones.

AXLE SHAFT
Check the axle shaft runout with a micrometer and
replace it if the runout exceeds the limit.

Service limit:0.25mm (0.010in)

WHEEL RIM
Make sure that the wheel rim runout does not exceed
the service limit when checked as shown.
An excessive runout is usually due to worn or loose
wheel bearings and can be reduced by replacing the
bearings.If bearing replacement fails to reduce the
runout,replace the wheel.

Service Limit:2.0mm (0.08in)）

77

Reassembly and remounting

Reassemble and remount this front wheel in the reverse order of removal, and also
carry out the following steps:

install this wheel bearing with the special tools as shown in this illustration.
CAUTION: Install this wheel bearing for left side..

Install the brake disc as shown in photo.

When installing this speedometer gear box, align the
two driving pawls with the two recesses of the wheel
hub.
Tighten the nut with special tool.

78

FRONT BRAKE SYSTEM

RAKE PAD REPLACEMENT
Remove the calliper by removing the mounting bolts  .
NOTE:
Do not operate the front brake lever while dismounting the calliper.

1. disc brake assy.

2. disc brake handle

lever

3. tightening bolt

4. nut M6

5. master cylinder

6. tightening seat

7. bolt M6X23

8. brake hose assy.

9. brake caliper

10. connecting

board tightening
bolt

11. hose mounting

bolt

12. seal gasket

13. front gasket

14. rear gasket

15. brake pad 1

16. brake pad 2

17. master cylinder

rubber bushing

18. front brake

switch

①

79

∙Remove the brake pads.

CAUTION:
Replace the brake pads as a set,otherwise braking
performance will be adversely affected.

Reassemble and remount the calliper.

CALIPER REMOVAL AND DISASSEMBLY
Remove the brake hose and catch the brake fluid in a suitable
receptacle.
CAUTION:
Nevere re-use the brake fluid left over from the last
servicing and stored for long periods.

∙Remove the calliper.
∙Remove the brake pads.
∙Remove the spring and pad holder.

∙Place a rag over the piston to prevent popping up.Froce out the piston with a air gun.

CAUTION:
Do not use high pressure air to prevent piston damage.

∙Remove the dust seal  and piston seal .

80

CALIPER AND DISC INSPECTION

Inspect the calipe cylinder bore wall or
micks,scratches or other damage.
Inspect piston for damage and wear.

Inspect each rubber part for damage and wear.

Check the disc for wear with a micrometer.Its
thickness can be checked with disc and wheel in
place. Ralpace the dise if the thickness exceeds the
service limit.

Service Limit:3.5 mm (0.14 in)

With the disc mounted on the wheel, check the dids
for face runout with a dial gauge as shown.
Replace the disc if the runout exceeds the service
limit.
Service Limit:0.3 mm(0.012 in)

81

BRAKE CALIPER REASSEMBLY

Reassemble and remount the calliper in the reverse
order of removal and disassembly, and also carry out
the following steps.
CAUTION:
Wash the calliper components with fresh brake fluid
before reassembly. Never use cleaning solvent or
gasoline to wash them.Apply brake fluid to the calliper
bore and piston to be inserted into the bore.

Reassemble and remount the calliper. (refer to preceding bove pages)
WARNING:
Bleed air after remounting the calliper. (refer to above pages)

MASTER CYLINDER REMOVAL AND DISASSEMBLY

Remove the handlebar cover. (Refer to above page)
Disconnect the front brake light switch lead wires.

Place a cloth underneath the union bolt on the master
cylinder to catch spilled drops of brake fluid. Unscrew
the union bolt and disconnect the brake hose master
cylinder joint.

CAUTION:
Completely wipe off any brake fluid adhering to any part of motorcycle. The fluid reacts
chemically with paint, plastics, rubber materials, etc.

Remove the master cylinder.

82

Remove the brake lever and brake switch.

Remove the dust boot.

Remove the circlip with the special tool.

Remove the piston/primary cup with return spring.
Remove the reservoir cap and diaphragn.
Drain brake fluid.

MASTER CYLINDER INSPECTION
Inspect the master cylinder bore for any
scratches or other damage.

83

Inspect the piston surface for scratches or other damage.
Inspect the primary cup and dust boot for wear or damage.

MASTER CYLINDER REASSEMBLY AND
ERMOUNTING
Reassemble and remount the master cylinder in the
reverse order of removal and disassembly,and also
carry out the following steps.

CAUTION:
Wash the master cylinder components with fresh
brake fluis before reassembly. Never use cleaning solvent or gasoline to wash them.
Apply brake fluid to the cylinder bore and all the internals to be inserted into the bore.

Reassemble and remount the master cylinder, When remounting the master cylinder
on the handlebar, first tighten the clamp bolt for upside.

CAUTION:
Bleed air after remounting the master cylinder.

84

STEERING STEM AND FRONT SUSPENSION

REMOVAL AND DISASSEMBLY

（Refer to preceding page）
□ remove the handle cover（refer to preceding page）
□ remove under decorating cover（refer to the preceding page）
□ remove legshield（refer to preceding

page）

□ remove front wheel（refer to preceding

page）

□ disconnect the front and rear brake

light switch lead wires .

□ Remove the rear brake cable .

□ Remove throttle grip case .
□ Remove throttle cable .

1. handle jointing assy.

2. bolt GB5789

M10X1.25X45

3. nut GB6187 M10X1.25

4. left handlebar

5. throttle grip assy.

6. screw GB818 M5X10

7. rear brake cable assy.

8. throttle cable assy.

9. left switch comp.

10. right switch comp.

11. anti-dust cover

12. steel ball ￠5

13. lower outer steel bowl

14. connecting steel bowl

15. under connecting borad

assy.

16. lower inner steel bowl

17. bolt GB5789

M10X1.25X30

18. locknut

① ③

④

②

85

□ remove disc brake system by unscrewing tightening bolt.

□ remove handle by removing tightening bolt

□ unscrew locknut with special tool

□ remove fornt fork assy. by removing upper outer steel bowl

NOTE:
Not drop the steering stem balls.

□ remove front fork

□ remove bearing lower race by chisel.
□ Remove steel balls.

Number of steel balls：

Upper：21
lower：21

□ remove the upper and lower bearing inner races with a

appropriate bar

86

87

INSPECTION

□ inspect the removed parts for the following abnormalities.

 bearing race wear and brinelling.
 Worn and damaged steel balls
 Distortion of steering stem or handlebar.

□ Inspect the suspension for damage

88

Reassembly and remounting

reassemble and remount the steering stem, handlebar
and front fork in the reverse order of disassembly
andremoval, and also carry out the following steps.

Install the right left suspension arms.

Steel ball
Apply grease when installing the upper and lower
steel balls.
QTY：upper ：21

lower ：21

Tighten the steering outer race with special tool,
then extrude it 1/8-1/4round.
NOTE：adjustment will vary from scooter to scooter. B e
sure that the steering turns smoothly and easily, left to
right.

□ install a locknut by installing locknut and

anti-dust cover

□ screw locknut with special tool, and adjust

front fork bearing to get smooth turning.

89

install handlebar and tighten the screw and bolt

to the specified torque：37-44N.M



NOTE:
After performing the adjustment and installing the handlebar, rock the front wheel
forward and backward to ensure that there Is not play and that the procuder is
accomplished correctly. If play is noticeable, raadjust the steering outer race nut.

90

REAR WHEEL AND BRAKE

1. Tire 130/70-12

2. rear rim assy.

3. brake pad kit

assy.

4. brake pad kit

spring

5. rear brake

tension

6. rear indicator

7. anti-dust cover

8. rear brake

camshaft

9. bolt M6Χ30

10. valve

11. nut M16Χ1.5

12. rear brake arm

13. valve ca

p

91

REMOVE

□ Place the scooter on level ground.
□ Remove muffler.
□ Remove rear small fender.
□ Remove locknut and rear wheel.
□ Remove brake shoes.

INSPECTION
REAR RIM
Measure inner diameter of rear rim hub with
micrometer, if measured diameter exceeds 110.7,
replace it with a new one.

Brake shoes
Check the brake shoe and decide whether it should be replaced or not from the
thickness of the brake shoe lining.

Service limit：2.5mm(0.09in)

92

REASSEMBLY AND REMOUNTING

Reassemble and remount the rear wheel and
brake in the reverse of removal, and also
carry out the following steps:

□ Turn the punched mark  on the camshaft

to the rear axle shaft side.

□ Install the protrusion  of indicator plate to the

groove  of Camshaft.

□ When installing the brake cam shaft, aligh the groove 

of camshaft with the slit  of on cam shaft.

□ When installing brake shoes, be sure to daub

camshaft with adequate grease.

CAUTION:
Be careful not to daub the camshaft with too
much grease.
If grease gets on the lining, brake effectiveness will be lost.

93

SERVICING INFORAMTION

Troubleshooting
Battery
Vehicle
Wiring diagram
Wire, cable and brake hose routing
Special tools
Thread parts tightening torque
Service data

CONTENTS

94

TROUBLESHOOTING

ENGINE

Complaint Symptom and possible causes Remedy
Engine does
not start, or
is hard to
start.

Compression too low

Excessively worn cylinder or piston rings.
Stiff piston ring in place.
Gas leaks from the joint in crankcase, cylinder or

cylinder head.

Damaged reed valve.
Spark plug too loose.
Broken, cracked or otherwise failed piston.

Plug not sparking

Damaged spark plug or spark plug cap.
Dirty or wet spark plug.
Defective CDI & ignition coil unit or stator coil.
Open or short n high-tension cord.
Defective ignition switch.

No fuel reaching the carburetor

Clogged hole in the fuel tank cap.
Clogged or defective fuel cock.
Defective carburetor float valve.

Clogged fuel hose or defective vacuum hose.

Replace.
Repair or replace.
Repair or replace.

Replace.
Tig ht en
Replace.

Replace.
Clean and dry.
Replace.
Replace.
Replace.

Clean.
Clean or replace.
Replace.
Clean or replace.

Engine stalls
easily.

Carbon deposited on the spark plug.
Defective CDI & ignition coil unit.
Clogged fuel hose.
Clogged jets in carburetor.

Clogged exhaust pipe.

Clean.
Replace.
Clean.
Clean.
Clean.

Noisy engine. Noise appears to come from piston

Piston or cylinder worn down.
Combustion chamber fouled with carbon.
Piston pin, bearing or piston pin bore worn.

Piston rings or ring grooves worn.

Noise seems to come from crankshaft

Worn or burnt crankshaft bearings.
Worn or burnt conrod big-end bearings.

Noise seems to come from final gear box

Gears worn or rubbing.
Badly worn splines.

Worn or damaged bearing of drive shaft or rear axle

shaft.

Replace.
Clean.
Replace.
Replace.

Replace.
Replace.

Replace.
Replace.
Replace.

Slipping
clutch

Worn or damaged clutch shoes.

Worn clutch drum.

Replace.
Replace.

Engine idles
poorly.

Excessively worn cylinder or piston rings.
Stiff piston ring in place.
Gas leaks from crankshaft oil seal.
Spark plug gaps too wide.
Defective CDI & ignition coil unit.
Defective magneto stator coil.
Float-chamber fuel level out of adjustment in

carburetor.

Clogged jets in carburetor.

Broken or damaged reed valve.

Replace.
Replace.
Replace.
Adjust or replace.
Replace.
Replace.
Replace.
Clean or adjust.
Replace.

95

Complaint Symptom and possible causes Remedy
Engine runs
poorly in
high-speed
range.

Excessively worn cylinder or piston rings.
Stiff piston ring in place.
Spark plug gaps to narrow.
Ignition not advanced sufficiently due to poorly working

CDI & ignition coil unit.

Defective magneto stator coil.
Float-chamber fuel level too low.
Clogged air cleaner element.
Clogged fuel hose, resulting in inadequate fuel supply to

carburetor.

Clogged fuel cock vacuum pipe.

Replace.
Replace.
Adjust.
Replace.
Replace.
Adjust or replace.
Clean.
Clean and prime.
Clean.

Dirty or
heavy
exhaust
smoke.

Too much engine oil to the engine.
Use of incorrect engine oil.

Check oil pump.
Change.

Engine
lacks
power.

Excessively worn cylinder or piston rings.
Stiff piston rings in place.
Gas leaks from crankshaft oil seal.
Spark plug gaps incorrect.
Clogged air cleaner element.
Float-chamber fuel level out of adjustment.
Clogged air cleaner element.
Fouled spark plug,

Sucking air from intake pipe.
. Slipping or worn V-belt.
Damaged/worn rollers in the movable drive face.
. Weakened movable driven face spring.
. Too rich fuel/air mixture due to defective starter system.

Replace.
Replace.
Replace.
Adjust or replace.
Clean.
Adjust or replace.
Clean.
Clean or replace.
Retighten or replace.
Replace.
Replace.
Replace.
Replace.

Engine
overheats.

Heavy carbon deposit on piston crown.

Defective oil pump or clogged oil circuit.

Fuel level too low in float chamber.

Air leakage from intake pipe.

Use of incorrect engine oil.

Use lf improper spark plug.
Clogged exhaust pipe/muffler.

Clean.
Replace and clean.
Adjust or replace.
Retighten or replace.
Change.
Change.
Clean or replace.

96

CARBURETOR

Complaint Symptom and possible causes Remedy
Trouble

with
starting.

Starter jet is clogged.
Air leaking from a joint between starter body and

carburetor.

Air leaking from carburetors joint or vacuum hose joint.
Starter plunger is not operating properly.

Clean.
Check starter body and
carburetor for tightness,
and replace gasket.
Check and replace.
Check and replace.

Idling or
low-spee
d
troubles.

Pilot jet, pilot air jet are clogged or loose.
Air leaking from carburetors joint, vacuum pipe joint, or

starter.

Pilot outlet is clogged.
Starter plunger is not fully close.

Check and clean.
Check and replace.

Check and clean.
Check and replace.

Medium­or
high-spee
d trouble.

Main jet or main air jet is clogged.
Needle jet is clogged.
Fuel level is improperly set.
Throttle valve is not operating properly.
Fuel filter is clogged.

Check and clean.
Check and clean.
Check and replace.
Check throttle valve for
operation.
Check and clean.

Overflow
and fuel
level
fluctuatio
ns.

Needle valve is worn or damaged.
Spring in needle valve is broken.
Float is not working properly.
Foreign matter has adhered to needle valve.
Fuel level is too high or low.

Replace.
Replace.
Check and adjust.
Clean.
Adjust and replace.

97

ELECTRICAL

Complaint Symptom and possible causes Remedy
No sparking

or poor
sparking.

Defective CDI & ignition coil unit.
Defective spark plug.
Defective magneto stator coil.

Loose connection of lead wire.

Replace.
Replace.
Replace.
Connect/tighten.

Spark plug
soon
becomes
fouled with
carbon.

Mixture too rich.
Idling speed set too high.
Incorrect gasoline.
Dirty element in air cleaner.
Spark plug loose.
Incorrect engine oil.

Adjust carburetor.
Adjust carburetor.
Change.
Clean.
Replace by hot type plug.
Replace.

Spark plug
electrodes
overheat or
burn.

Spark plug too hot.
The engine overheats.
Spark plug loose.
Mixture too lean.
Not enough engine oil.

Replace by cold type plug,
Tune up.
Retighten.
Adjust carburetor.
Check oil pump.

Magneto
does not
charge.

Open or short in lead wires, or loose lead

connections.

Shorted, grounded or open magneto coil.
Shorted or open regulator/rectifier.

Repair or retighten.
Replace.

Replace.

Magneto
charge, but
charging
rate is
below the
specificatio
ns.

Lead wires tend to get shorted or

open-circuited or loosely connected at terminal.

Grounded or open-circuited stator coils of

magneto.

Defective regulator/rectifier.
Defective cell plates in the battery,

Repair or retighten.
Replace.
Replace.

Replace the battery.

Magneto
overcharge
s.

Internal short-circuit in the battery.
Resistor element in the regulator/rectifier

damaged or defective.

Regulator/rectifier unit poorly grounded.

Replace the battery.
Replace.

Clean and tighten ground
connection.

Unstable
charging.

Defective regulator/rectifier.
Lead wire insulation frayed due to vibration,

resulting in intermittent shorting.

Magneto coil internally shorted.

Repair or replace.
Replace.

Replace.

Starter
button is not
effective.

Battery run down.
Defective switch contacts.
Brushes not seating properly on commutator in

starter motor.

Defective starter relay.
Defective starter pinion gears
Defective front or rear brake light switch circuit.

Recharge and replace.
Replace.
Repair or replace.

Replace.
Replace.
Repair or replace.

98

BATTERY

Complaint

Symptom and possible causes Remedy

Battery runs
down
quickly.

The charging method is not

correct.

Cell plates have lost much of
their active material as a result of
over-charging.

A short-circuit condition exists
within the battery due to excessive
accumulation of sediments caused
by the incorrect electrolyte.

Battery is too old.

Check the magneto and regulator/rectifier
circuit connections, and make necessary
adjustments to obtain specified charging
operation.
Replace the battery, and correct the
charging system.

Replace the battery.
Replace the battery.

Reversed
battery
polarity.

The battery has been connected
the wrong way round in the system,
so that it is being charged in the
reverse direction.

Replace the battery and be sure to connect
the battery properly.

Battery
discharges
too rapidly.

Dirty container top and sides.

Battery is too old.

Clean.
Replace.

99

CHASSIS

Complaint Symptom and possible causes Remedy
Handling feels

too heavy.

Steering stem nut overtightened.
Broken bearing/race in steering

stem.

Distorted steering stem.
Not enough pressure in tires.

Adjust.
Replace.
Replace.
Adjust.

Wobbly
handle.

Loss of balance between right

and left front suspension.

Distorted front axle or crooked

tire.

Replace.
Replace.

Wobbly front
wheel.

Distorted wheel rim.
Worn front wheel bearings.
Defective or incorrect tire.
Loose nut on axle.
Loose nuts on the rear shock.
Worn engine mounting bushing.
Loose nuts or bolts for engine

mounting.

Replace.
Replace.
Replace.
Retighten.
Retighten.
Replace.
Tighten.

Front
suspension
too soft.

Weakened springs.
Oil leakage of shock absorber,

Replace.
Replace.

Front
suspension
too stiff.

Not enough grease,
Worn suspension arm spacer

Refill.
Replace.

Noisy front
suspension.

Not enough grease.
Loose nuts on suspension.

Refill.
Retighten.

Wobbly rear
wheel.

Distorted wheel rim.
Defective or incorrect tire.
Loose nuts on the rear shock

absorber.

Worn engine mounting bushing.
Loose nuts or bolts for engine

mounting.

Replace.
Replace.
Replace.
Replace.
Retighten.

Rear
suspension
too soft.

Weakened spring.
Oil leakage of rear shock

absorber.

Replace.
Add lubrication

Noisy rear
suspension.

Loose nuts on shock absorber,
lubrication leakage.

Adjust
Add lubrication.

100

BRAKES
Complaint Symptom and possible causes Remedy

Insufficient
brake
power.

Leakage of brake fluid from hydraulic

system.

Worn pad.
Oil adhesion on engaging surface of

pad.

Worn disc.
Air entered into hydraulic system.
Worn shoe.
Friction surfaces of shoes are dirty

with oil.

Excessively worn drum.

Too much brake lever play.

Repair or replace.
Replace.
Clean disc and pads.
Replace.
Bleed air.
Replace.
Replace.
Replace.
Adjust.

Brake
squeaking.

Carbon adhesion on pad surface.
Tilted pad.
Damaged wheel bearing.
Worn pad.
Foreign substance entered into brake

fluid.

Clogged return port of master

cylinder.

Brake shoe surface glazed.
Loose front-wheel axle or rear-wheel

axle nut.

Worn shoe.

Repair surface with sandpaper.
Modify and fitting.
Replace.
Replace.
Replace brake fluid.
Disassemble and clean master cylinder.
Repair surface with sandpaper,
Ti ghten to specified torque.
Replace.

Excessive
brake lever
stroke.

Air entered into hydraulic system.
Insufficient brake fluid.
Improper quality of brake fluid.
Worn brake cam lever.
Excessively worn shoes and/or

drum.

Adjust
Refill
Replace
Replace
Replace

Leakage of
brake fluid.

Insufficient tightening of connection

joints.

Cracked hose.
Worn piston seal.

Replace or repair
Replace.
Replace.

Brake
drags.

1. Rusty moving parts. replace