GENUINE Blur 150, Blur 220i Service Manual

Blur 150 & 220i Service Manual

PERIODICAL MAINTENANCE TABLE

(on

In order to achieve safe riding, good performance and reduce pollution, please execute the recommended
maintenance accordingly.

Item

Engine oil* 4T BLUR-150:800cc, total 1000cc

Oil Filter BLUR -150

Coarse oil filter*
oil draining bolt)
Air cleaner 4T Crack and blockage check. I I I I I I

Air filter 4T Clean or replace it if required I I I R I I

Model

4T

BLUR -220

4T

Checking Content

BLUR-220: 1,000CC, total1,200cc

Replace R replace it per 6000km

Clean or replace it if necessary C

MONTHS/DISTANCE(IN KM)FOR CHECKING

1 or

190

mile

3 or

1865

mile

R Replace it initially 300km,

6 or

3730

mile

and then replace it per 3000 km

and then replace it per 6000 km if necessary

9 or

12 or

5595

7460k

mile

clean it initially 300km,

mile

15 or

9320k

mile

18 or

11185

mile

Gear oil* 4T BLUR -150: 90cc, total 110 cc

BLUR -220: 90cc, total 110 cc

Disk & drum brake 4T Leaking and function check I I I I I I
Clutch shoes* 4T Check or replace it if necessary I R I

Tires 4T Worn-out check or replace it if

necessary

Wheel bearing* 4T Fasten tightly if loosen I I I I I I
Front fork* 4T Leaking and function check I I I I

Steering head bearing*
Rear absorber* 4T Leaking and function check I I I

Main/Side Stand 4T Function check or replace it if
Nuts, bolts, fasteners 4T Tighten it if required I I I I I I

Battery 4T Recharge the battery it required.
Valve gap* 4T BLUR -150: 0.08mm/ IN&EX
Spark plug* 4T Clear or replace if required I R I R I R

V belt* 4T Worn out check or replace if

Fuel feeding system* EXCEPT

Fuel feeding system * EMS ONLY
Engine idle speed* 4T 4T engine: 1700±100 rpm A A A A A A A

Carburetor idle A/F
Adjustment*
EMS function check* EMS ONLY

4T

4T Check looseness. Adjust it if

EMS

(Injection)

4T Check and adjust referring to

(Injection)

1 or

required

required

Clear the poles.

BLUR 220: 0.08mm/ IN&EX

necessary.
Crack and blockage check.
Replace it if necessary.
Inspect hose, clamp, and replace
the filter per 15,000km

CO/HC Percentage.
Inspect EMS function, and clear
the defect memory if necessary

R R R R

I I I I I I

3 or

190

mile

A A A

1865

mile

I L I L I L

A A A

I I R

A A A A A A A

I I I I I I

6 or

3730

mile

I C I C I C

Adjust it when necessary

9 or

12 or

5595

7460k

mile

I R

mile

15 or

9320k

mile

18 or

11185

mile

REMARKS：：：：

1. A: adjust C: clean I: inspect, or replace if necessary L: lubricate R: replace

2. Items with “*” mark indicate our recommendation to have it done by Genuine dealer.

NOTE 1：：：：

For 4T engine, the engine oil shall be changed completely after run-in period 300km or one month later.
This can make sure the engine runs smoothly.

NOTE 2：：：：

The exchange of brake fluid

1. After disassembling of brake main cylinder or caliper, do change the new fluid.

2. Check the fluid level often, Refill if necessary.

I

3. Change the oil seal of main cylinder and caliper every two years.

4. Change the brake fluid hose every four years.

Exhaust control system (only be valid for the bike equipped catalyst):

Catalyster will not be possible to be withdrawn individual, the only you have to do is to maintain fuel,
ignition, intake/exhaust system periodically.

1. Maintenance procedure of air clearer (see page 33).

2. Spark plug’s checking: please repair or replace if spark plug is dirty.

3. Fuel system’s checking: please repair or replace if fuel pipe is jammed or broken.

4. Muffler’s checking: please fix tightly once or renew a gasket if it is leaking.

5. Idle rpm’s checking: please fix tightly once or renew a gasket if throttle cable.

6. Exhaust density checking while idle: please left the job to any service center of anti-pollution inspection

for carburetor adjusting.

PREFACE

This manual provides every service specialist with professional

techniques of maintenance and repairing for BLUR . It provides a detailed

guide for those who may concern with how to maintain, repair, reassemble, and
change parts of their scooters.

This manual includes 2 kinds of engine displacement:

 BLUR 150 : abbreviated as “BLUR-150” is 4 stroke engine

(4T), 150cc displacement.

 BLUR SS220i: abbreviated as “BLUR SS220” is 4 stroke

engine (4T), 220cc displacement.

At every section, we illustrate each important point by assembling
procedures, explosive diagrams and photographs.

Although we have tried our best to make this manual as perfect as
possible, please kindly inform us if any fault needs to be corrected
in this manual.

Thank you for purchasing our Genuine scooters.

FACTORY

Motive Power Industry Co.,Ltd.

CONTENTS：

ⅠⅠⅠⅠ.

.The specification of BLUR (ALLORO)

..

Ⅱ

Ⅱ.Service information

ⅡⅡ

(1)The operation notice
(2)Locking torque value
(3)Lubrication instruction
(4)Periodical maintenance table
(5)Troubleshooting

Ⅲ

Ⅲ.Checking and adjustment

ⅢⅢ

(1)Regular checking table
(2)Battery
(3)Cleaning air cleaner
(4)The final reduction mechanism oil
(5)Spark plug
(6)Compression pressure measurement
(7)Ignition timing
(8)Throttle cables adjustment
(9)Idle adjustment
(10)Front brake adjustment
(11)Rear brake adjustment
(12)Tire

Ⅳ

Ⅳ.Dismantling, maintaining, repairing and assembling operation

ⅣⅣ

(A). Plastic parts

(B). BLUR 150 Engine dismantling

(1) Lubrication system
(2) Engine dismantling
(3) Install Engine
(4) Drive pulley, starter, clutch, driven pulley
(5) Cylinder head and valve
(6) Cylinder and piston
(7) AC generator
(8) Final transmission mechanism
(9) Crankcase, crank shaft
(10) Carburetor

(C)Steering column, front wheel, front brake comp, front fork

(D)Rear wheel, rear brake, rear damper

(E)Fuel supply`

Ⅴ

Ⅴ.Electric equipment

ⅤⅤ

(1)Troubleshooting
(2)Battery
(3)Recharge system
(4)Ignition system
(5)Starting system
(6)Switch operation
(7)Wiring diagram

ⅤⅤⅤⅤI

I. BLUR-220 characteristics , dismantle & inspection

II

(1) Engine dismantling
(2) engine inspection
(3) Electric system

(4) Maintenance
(5)Engine Management System(EMS)
(6)EMS diagnostic
(7)EMS system Repairing tool
(8)EMS General Electric units

ENGINE MODEL

1.1 BLUR 150

BRAND Genuine FRAME STEEL PIPE
MODEL BLUR-150 FRONT TELESCOPE

LENGTH 1885 mm

WIDTH 730 mm PRIMARY DIRECT

HEIGHT 1170 mm 2ND 42/15*42/13

DIMENSION

AXLE DISTANCE

SPECIFICATION

ON

ENSI

SUSP

1365 mm CLUTCH CENTRIGUAL

REAR SWING

FRONT 55 KG

REAR 77 KG FRONT 120/60-13

GROSS

TOTAL 132 KG

PASSENGER 2 (110KG) FRONT DISK

WEIGHT

CONSUMPTION

PERFORMAN

FRONT 95 KG

REAR 147 KG SPEEDOMETER 140 km/hr

TOTAL

TOTAL 242 KG HEAD(HI、LO)

TOP SPEED 87 km/hr REAR 12V-5W

FUEL

GRADIENT 24°

FUEL 92 UNLEADED SILENCER DIFFUSER

STROKE 4T AIR FORCED PARTICLE BELOW 15 %

BORE φ57.5 mm CO BELOW 4.5%

STROKE 58.6 mm

40 km/l BRAKE 12V-21W

C5M HORN DC 12V

TRANSMISSI

TIRE

BRA

LIGGHT

EXHAUS

SHIFTING V-BELT C.V.T

REAR 130/60-13

KE

REAR DISK

SIGNAL 12V-10W*4

HC BELOW 7000 ppm

12V-35W/35W

CYLINDE

CYLINDER

DISPLACEMENT

ENGINE

C.R. 9.4：1 & SPLASH

MAX H..P. 7.7kw/7250rpm FUEL TANK 7.5 L

MAX TORQUE 10.6N-M/6250rpm

LAYOUR HORIZONAL

IGNITION CDI

STARTING ELECTRIC & KICK

SINGLE EXHAUST LAYOUT RIGHT

152.1 cc LUBRICATE SEPARATE PUMP

1.2 BLUR220

SCOOTER SPECIFICATION

BRAND
MODEL BLUR

LENGTH 1885 mm

SCALE

MASS

PERFORMA

NCE

WIDTH 730 mm 1ST REDUCTION 0.81~2.43

HEIGHT 1170 mm 2ND REDUCTION

WHEEL BASE 1365 mm CLUTCH CENTRIFUGAL

MASS OF

VEHICLE

MASS

FUEL CONSUMPTION

FRONT 57 KG

REAR 87 KG FRONT 120/60-13

TOTAL 144 KG

RIDER 2 (150KG) FRONT DISK

FRONT 115 KG

TOTAL

REAR 179 KG SPEEDOMETER 199 km/hr

TOTAL 294 KG HEAD LAMP 12V-60W/55W

TOP SPEED 110 km/hr TAIL LAMP 12V-5W

Genuine FRAME STEEL TUBE

BLUR----SS

BLURBLUR

SS22

220000IIII FRONT TELESCOPE

SSSS

2222

SUSPENSION

TRANSMISSIO

TYRE

BRAKE

LIGHT

33 km/l BREAKING LAMP

REAR UNI-ABSORBER

8.077

GEARBOX C.V.T.

REAR 130/60-13

REAR DISK

12V-21W

HILL CLIMB 30°↑

TYPE C8E5 HORN DC 12V

FUEL 92 UNLEADED MUFFLER C-D ABSORPTION

CYCLE/COOLING

CYLINDER

ENGINE

DISPLACEMENT

COMPRESSION RATIO

MAX POWER 11.0kw/7000rpm P. C. V. YES

MAX TORQUE 16.5N-M/5500rpm CATALYST YES

ARRANGEMENT

IGNITION TRANSISTOR
STARTER ELECTRIC

TURNING LIGHT

4T/FORCE AIR&OIL COOL PARTICLE BELOW 15 %

BORE φ67.5 mm CO BELOW 3.0%

STROKE 61.5 mm

NUMBER SINGLE EXHAUST DIRECTION

220 cc LUBRICATION

10.0：1 E. E. C. NO

HORIZONTAL S. A. I. YES

EMISSION

IDLE

HC BELOW 1600 ppm

12V-16W*4

RIGHT HAND SIDE&

BACKWARD

COMPRESS &

SPLASH

RREMARK

1. FUEL SUPPLY：INJECTION

Ⅱ.Service information：

(1)The operation notice
(2)Locking torque value

1.For engine

2. For chassis

3. Others

(3) Lubrication instruction

a.For engine
b. For chassis

c. Wheel bearing
(4)Periodical Maintenance Table
(5)Troubleshooting

1.Difficult starting or starting

2.Weak acceleration

3.Engine running not smoothly (low speed)

4.Engine running not smoothly(high speed)

5.Clutch, drive & driven pulley

6.Handlebar steering was astray when running

7.Front and rear damper not balanced

8.Brake disorder

9.Oil indicator malfunction

10. Fuel indicator malfunction

11. Starting motor malfunction

12.No sparking

13.Charging abnormal

(1) The operation notice：

1.For parts like the gasket, o-ring, clips and circlets, please change a new
part whenever re-assembled.

2.When trying to tighten screws or nuts, please lock tightly according to each
recommended locking torque and in the sequence of the ”X” pattern.

3.Please use PGO or PGO recommended parts.

4.After dismantling, please clean all parts involved or used for checking and
grease all contact surfaces when reassembling.

5.Use grease recommended by PGO.

6.When removing the battery, please disconnect the negative pole(-) first.
However, please connect the positive pole(+) first when assembling.

7.Before installing a new fuse, please be sure that the specification is correct.

8.After reassembling, please re-confirm that all connecting point, locking parts,
circuits, polar characteristics are functioning well before selling out.

：

：：

Thread dia.

(2) L

ocking Torque Value:

1. 4T Engine (150/220CC)

NO

1 Fixing nut (Tappet screw nut) 2 5 0.7~0.8
2 Nut of oil pump sprocket 1 6 0.7~1.0

3 Cylinder head bolt A (intake) 2 6 0.9~1.1
4 Guiding pin bolt, chain extensioner 1 6 0.4~0.6
5 Screw, chain extensioner 2 6 0.9~1.1
6 Cylinder head bolt B (Exhaust) 2 8 2.0~2.3
7 Flange nut, cam shaft holder 4 8 2.0~2.3
8 Gear oil drain bolt 1 8 1.7~2.0

9 Spark plug 1 10 1.2~1.3
10 Nut of fly wheel 1 12 5.0~6.0
11 Fixing nut, clutch outer 1 12 5.0~6.0
12 Nut, driving plate 1 12 5.0~6.0
13 Bolt of engine oil drain 1 12 2.5~3.0

Locking location Q’ty

(mm)

Locking torque

(kg-m)

14 Bolt of 2nd oil filter 1 12 0.8
15 Nut (LH thread), one-way clutch 1 22 9.0~10.0
16 Cap, coarse oil filter 1 30 1.5~2.0

2. Chassis

NO Locking location Q’TY

1 Air bleed bolt of caliper 1 6 0.6
2 Brake arm bolt, front drum 1 6 0.8~1.0
3 Brake arm bolt , rear drum 1 6 0.8~1.0
4 Nut of starter relay 2 6 0.5~0.6
5 Front brake caliper bolt 2 8 2.0 ~ 3.0
6 Bolt of disk 3 8 2.5~3.0
7 Locking nut, steering stem 1 10 3.5~4.5
8 Rear shock absorber bolt(lower) 1 10 3.5 ~ 4.5

9 Rear shock absorber bolt(upper) 1 10 3.5~4.5
10 Chassis bolt, engine hanger bracket 2 10 4.5 ~ 5.0
11 Engine bolt, engine hanger bracket
12 Hose bolt, master cyl. & caliper 2 10 2.5 ~ 3.0
13 Front axle nut 1 12 4.5 ~ 5.5

1 10 3.0 ~ 4.0

Thread dia.

(mm)

Locking torque

(kg-m)

14 Nut, swing arm & connecting rod 1 14 4.5 ~ 5.5
14 Rear axle nut 1 16 10.0~11.0

3. Other parts standard torque values:

No

Item Torque

kg-m

1 5mm bolt and nut 0.45-0.6
2 6mm bolt and nut 0.8-1.2
3 8mm bolt and nut 1.8-2.5
4 10mm bolt and nut 3.0-4.0
5 12mm bolt and nut 5.0-6.0
6 5mm screw 0.35-0.5
7 6mm screw 0.7-1.4
8 6mm flange bolt and screw 1.0-1.4

9 7mm flange bolt and screw 1.0-1.4
10 8mm flange bolt and screw 2.0-3.0
11 10mm flange bolt and screw 3.0-4.0

(3) Lubrication instruction

A. 4T Engine (150 /220cc)

NO Lubrication location Oil type Remarks

1 Crankcase: rotating part,

Sliding part

2 Cylinder: rotating part,

Sliding part.

premium 4 stroke

motorcycle oil

Auto-Separated
Lubrication

 BLUR-150

Total 900 c.c.
Replacement 800c.c

 BLUR220

or SAE15W40

3-1 Drive gear box(BLUR-150) SAE85-140 Total 110 c.c.

3-2 Drive gear box(BLUR-220) SAE85-140 Total 130 c.c.

4 Gasket of starter shaft Clean grease (#3)

Total 1400 c.c.
Replacement 1000c.c

Replacement 90c.c

Replacement 110c.c

5 Start idle gear sliding

parts

Clean grease (#3)

C. Chassis appearance

1. Apply oil : #1, #2

1 2

3 4 5 6 7 8

2. Apply grease (#3, #4, #5. #6 ,#7, #8)

D.Wheel bearing

錯誤!

錯誤

誤錯誤

錯

Final transmission mechanism gear oil

Speedometer gear: clean grease

(4) PERIODICAL MAINTENANCE TABLE

(on

Item

Engine oil* 4T BLUR 150:800cc, total 1000cc

Oil Filter BLUE-150 Replace R replace it per 5000km
Coarse oil filter*
oil draining bolt)
Air cleaner 4T Crack and blockage check. I
Air filter 4T Clean or replace it if required I I I I I I

Model

4T

4T

Checking Content

BLUR 220: 1,400CC, total 1,000cc

Clean or replace it if necessary C

MONTHS/DISTANCE(IN KM)FOR CHECKING

1 or

190

mile

3 or
1865
mile

R Replace it initially 300km,

6 or

3730

mile

and then replace it per 1,000 km

and then replace it per 3,000 km if necessary

9 or

12 or

5595

7460k

mile

clean it initially 300km,

mile

15 or

9320k

mile

18 or

11185

mile

Gear oil* 4T BLUR-150: 90cc, total 110 cc

BLUR-220: 110cc, total 130 cc

Disk & drum brake 4T Leaking and function check I I I R I I
Clutch shoes* 4T Check or replace it if necessary I I I I I
Tires 4T Worn-out check or replace it if

necessary

Wheel bearing* 4T Fasten tightly if loosen I I I I I I
Front fork* 4T Leaking and function check I I I I I I
Steering head bearing*

Rear absorber* 4T Leaking and function check A A A
Main/Side Stand 4T Function check or replace it if

Nuts, bolts, fasteners 4T Tighten it if required I L I L I L
Battery 4T Recharge the battery it required.

Valve gap* 4T BLUR150: 0.08mm/ IN&EX

Spark plug* 4T Clear or replace if required I A A A
V belt* 4T Worn out check or replace if

Fuel feeding system* EXCEPT

Fuel feeding system * EMS ONLY
Engine idle speed* 4T 4T engine: 1700±100 rpm A A I I R

Carburetor idle A/F
Adjustment*
EMS function check* EMS ONLY

4T Check looseness. Adjust it if

required

required

Clear the poles.

BLUR220: 0.08mm/ IN&EX

necessary.
Crack and blockage check.

EMS

(Injection)

4T Check and adjust referring to

(Injection)

Replace it if necessary.
Inspect hose, clamp, and replace
the filter per 15,000km

CO/HC Percentage.
Inspect EMS function, and clear
the defect memory if necessary

R R I I R I I

I I I I

I I I

I I I I

Adjust
it when
necessa

ry

A A A A A A A

I

I

I I I I I

C I C I C

R I R I R

I R

A A A A A

REMARKS：：：：

I

1. A: adjust C: clean I: inspect, or replace if necessary L: lubricate R: replace

2. Items with “*” mark indicate our recommendation to h

ave it done by Genuine dealer.

NOTE 1：：：：

For 4T engine, the engine oil shall be changed completely after run-in period 300km or one
month later. This can make sure the engine runs smoothly.

NOTE 2：：：：

The exchange of brake fluid

1. After disassembling of brake main cylinder or caliper, do change the new fluid.

2. Check the fluid level often, Refill if necessary.

3. Change the oil seal of main cylinder and caliper eve

ry two years.

4. Change the brake fluid hose every four years.

(5)Trouble shooting:

Loose carburetor dr

aining

The fuel supply in carburetors

No fuel supply in

Remove spark plug, insert

Measurement of

Pressure is

Insufficient or

Start engine: follow the

Engine has no

knocking

Engine knocking

dry wet

1.difficult starting or can’t start:

Check and adjust

Screw, check if in side of
Carburetor have fuel or not

c

pipe between ful tank and
carburetor is blocked
Float is blocked
Fuel gauge is blocked
fuel pump is malfunctioned

spark plug out of order

Spark plug cover, and touch

dirty

With engine check there is

CDI unit out of order

Any spark

A.C. generator out of order
ignition coil disconnect or
short circuit
ignition coil disconnect or

There is sparking

short circuit

In spark plug

main switch out of order
defective magneto coil

Compression pressure

starting clutch out of order
piston ring stuck
reed valve deteriorated
cylinder, piston, piston
ring worn out
cylinder gasket leakage
cylinder body has sand hole

Instruction of starting

engine

bad action of auto choke
air trapped in intake manifold
wrong ignition timing
bad adjustment of carburetor’s
fuel adjusting screw

Remove spark plug

And check again

carburetor fuel level too high
malfunction of auto choke
throttle valve open too largely

Trouble condition The reason

heck there is fuel or not

No sparking or
Weak sparking

2.Weak acceleration:

Check and Adjust

Trouble condition

The reason

Start engine and open throttle

Engine can

’

t rotate

Check ignition timing, check

With ignition timing lam

p

Timing is correct

Timing is not correct

Check cylinder

Pressure is normal

Pressure is

Check carburetor

Is blocked or not

No blocked

blocked

Remove spark plug and Check it

air cleaner blocked

fuel supply system abnormal
fuel tank cover blocked
muffler blocked
fuel pump is malfunctioned
auto chock is malfunctioned

CDI unit is out of order
alternator flywheel magneto
out of order

Engine can rotate up

Compression pressure
(use cylinder compression
pressure gauge)

Up completely

cylinder, piston ring worn out

cylinder gasket leakage
cylinder body has sand hole
Reed valve malfunction(2T engine)

Not normal

Clean the carburetor

clean the dirt

specification is not correct

No dirty and no color change

Dirty, color change

Oil level is normal

Oil level is

Normal

Abnormal

Check engine overheat

Or not

Not overheat

overheat

Running accelerately or

knocking

For 4T engine only:

oil level is too low

oil does not interchange

Check the oil level in crankcase
Is too much or dirty

Not normal

oil level is too high

Check the lubrication
of cylinder head

oil route is blocked

insufficient oil pumping from

oil pump

piston and cylinder worn out
mixture is too lean
bad quality of the fuel
too much carbon in the combustion room
ignition timing is too early

High speed continuously

too much carbon in the combustion room
bad quality of the fuel
clutch slip
mixture is too lean

ignition timing is too early

No knocking

3.Engine running unsmoothly (low speed and idling)

Check and adjust

Trouble condition

The reason

Correct

Not correct

Good

Faulty

Check if ther

e is air

Good sparking

Or no sparking

Check generator

good

fault

Remove spark plug, insert

Check ignition timing

CDI faulty
AC generator faulty

Adjust carburetor air screw

mixture too thick
( loose the screw)
mixture too lean
( tight the screw)

adjustment

Not correct

Leakage on carburetor
gasket




 gasket crack
 hose leakage
 I

To spark plug cover and

 Carburetor O ring distorted

Connect with ground
Start engine, then check
The sparking

No leakage

leakage

heat protector gasket broke

carburetor locking nut loosen

ntake manifold gasket broken

spark plug dirty
CDI out of order
AC magnet abnormal

Sparking abnormal

ignition coil faulty

H.V. coil disconnect or
short circuit

main switch is abnormal

A.C. generator malfanction

hose is damaged
air pipe is blocked or
damaged

△

4.Engine running unsmoothly (high speed)

Check and adjust

Trouble condition

The reason

timing

correct

Not correct

Check

fuel pump

,

good

unsmoothly

Check carburetor

No blocked

blocked

Check ignition

CDI sets faulty
AC generator faulty

Fuel supply system

fuel level is too low
fuel pipe, fuel filter
is blocked
fuel pump faulty

Is blocked or not

clean and wash it

5.Clutch, drive and driven pulley

Trouble condition

The reason

Move the vehicle

Engine runs, but it stops

Climbing is not smoothly

Can’

t reach high speed

Noise, or bad smell when

running

driving belt worn out, distortion
driven plate worn-out

Engine can start but can’t

driven plate spring distorted

 driven lining worn-out

d
cracked
final gear damage

 driven lining spring cracked or

worn out

weight rollers melt and stick to

driving face

Suddenly and seems to rush out

shaft worn-out
(rear wheel rotates while idling)

driving belt worn-out, distorted,
or slipping
weight roller worn-out
driving plate worn-out
driving plate spring distorted
driving pulley shaft worn-out

weight roller worn-out
driving pulley shaft worn-out

driving belt worn-out or slipping

adherent grease on driving belt,
pulley
driving belt worn-out
driven plate spring distorted
driving pulley shaft worn-out

riving pulley shaft gear teeth

6.Handlebar steering astrayed when running.

Trouble condition

The reason

Handlebar operates heavily

Front and rear wheel swings

Handlebar astrayed to one direction

Trouble condition

Damper is too soft

Damper is too hard

Damper has abno

rmal noise

The reason

Trouble condition

The reason

points to

“△”

mark

(front and rear wheel pressure are normal)
steering column lock screw locked too
tightly
steel ball cracked

rear, front wheel bearing swings
front, rear wheel rim distorted
loosen front axle nut

front and rear wheel center not well­ allined
front fork crooked

7.Front, rear damper not in balanced

(front and rear wheel pressure is normal)
damper spring is too soft

carrying weight is too large
damper oil leakage

front fork guide rod crooked
damper and damper cover cracked

problems in damper tube and spring
damper and damper cover cracked

8.Brake disorder.

brake lining worn-out
bake lining cam worn-out
brake cam worn-out
brake hub worn-out

brake lining worn-out


rough


unsmoothly
brake contacting surface with brake lining does
not contact 100%
water or sand drop into brake mechanism
some grease on brake lining surface

Brake plate”△”mark

Noise when brake

Faulty performance

(adjustment according to standard procedure)

unknown materials attached on brake lining
Contact surface of the wheel hub becomes

brake cable over stretching or moving

9.Oil indicator malfunction (Only available for 2T engine)

Check and adjust

Trouble condition

The reason

Turn the signal lamp

Normal

Lamp dims, light does

Remove the oil lamp,

Battery directly

Lamp lights

Lamp does not light up

Check electric plug

Good condition

No good

Remove oil gauge,

The float

Good

No good

Check and adjust

Trouble condition

The reason

Check all elect

ric

Good

Disorder

Remove oil gauge,

Good

Disorder

(a)The oil lamp doesn’t light up, (when the main switch is at “ON”position)

On. Check wiring
Of battey

fuse burn-out
battery has no power
main switch abnormal
circuit plug dropped off
main wiring disconnected

And connect with

bulb burn out

electric plug is loose
or disconnected
main wiring disconnected
wrong wiring connection

Check the lamp light
Up or not by moving

Float upward: lamp Extinguishes float faulty
oil gauge switch dis­Float downward: lamp turn on connected or short circuit

(b)Oil is enough but the indicator turns on all the time (when the main switch is “ON”)

plug

electric plug is loose
or drop-off
main wiring disconnected
wrong wire connection

Check the lamp by
Moving the floating

float faulty
oil gauge switch
disconnected or short circuit

Float upward: lamp
Extinguishes oil tank distorted
Float downward: lamp some impure material
Turns on dropping in

Not flash, no light

10.Fuel indication malfunction

Check and adjust

Trouble condition

The reason

battery

normal

Lamp dims, light

Remove the

fuel gauge

The needle movement

Indicator

moves

Indicator

no motion

Do the short and opening

Indicator

Indicator

on

motion

Check electric plug

good

(a)wrong fuel level indication(when the main switch is “ON”)

Turn the signal lamp
On; check wiring of

fuse burn-out
battery has no power
main switch abnormal
circuit plug dropped off
main wiring disconnected

Moving float up and
Down to check

Float abnormal

Circuit test on the fuel
Gauge plug which connect
To wire harness. Check the
indicator movement

Fuel gauge abnormal

electric plug dropped off
wrong connection
wire broken or short
circuit

moves

Not flash, not light

abnormal

Check and adjust

Trouble condition

The reason

Turn signal lamp on,

normal

No motion

Indicator

moves

good

No

movement

Move needle up and

Check electric plug

Connecting condition

good

abnormal

Remove the float

movement

Indicator

moves

Indicator

no

movement

(b)Fuel gauge needle is not steady and sometimes moves up and down (when the main switch is “ON”)

Check wiring of

fuse burn-out

battery

battery has no power
main switch abnormal
circuit plug dropped off or
broken
main wiring disconnected

Inside the tank,
Move up and down to
Check the needle’s

fuel gauge contact
abnormal

Down quickly(I move/
Second), check the
Needle’s movement

Insufficient or no damping
Oil inside the fuel gauge

electric plug drop-off or
loose
wire broken or short
circuit

11.The starting motor abnormal

Check and adjust

Trouble condition

The reason

Check bra

ke switch

Turn signal lamp

Brake lamp

Brake lamp

normal

Lamp d

oes not

Flashing no light

Push starting switch

normal

No function

Connect starting motor

To batte

ry directly

Starting

Motor runs up

Starting motor

Has no motion

(a)Starting motor can not rotate

fuse burn-out
battery has no power
main switch abnormal
circuit plug dropped off
main wiring disconnected

No to check wiring
Of battery

battery has no power

start switch bad

And check the function

connetion

Of start relay

relay wire broken or
short circuit
circuit plug is loose

carbon brush worn out
coil broken or short
circuit
starting motor wire
broken
circuit plug is loose,
drop-off
main wiring broken

Lights up

no light

(b)Starting motor running slowly or no pick-up

Check and adjust

Trouble condition

The reason

Turn signal lamp

r

ing of battery

normal

Lamp dims, no

Flashing, no light

Starting Connect motor

Running

normal

Runing slowly

Kick the kickstarter

lever

Easy to kick

Check and adjust

Trouble condition

The reason

Main switch,

Turn off

Motor can

’t

stop

Motor stops

battery has no power

electric; plug is loose
or drop off
start relay bad
connection

cylinder burn out
wire broken or shout

circuit

On, to check wi-

to the starting motor to
Battery directly

Difficult to kick

©Starting motor can not stop after starting

start gear can’t
return
start relay capacitor
melted or short circuit

12.No sparking

Check and

adjust

Trouble condition

The reason

Replace new spark

again

Good sparking

Weak sparking

Or no sparking

Check spark plug, cap

Check the CDI plug

good

loosen

Check the connection

Each terminals

good

abnormal

Check relative parts

good

abnormal

good

abnormal

Check ignition coil

By the

CDI tester

abnormal

good

loosen

Plug, then check

Spark plug faulty

And H.V. cable is
Loose or not

Spark plug cap is loose

Is loose or not

Plug is poor
connection

Between CDI plug and
Each terminals, check
The resistivity of

min switch faulty
defective magneto
coil
pulse generator faulty
defective ignition
coil

main cable broke
poor connection of
joints or sockets

defective CDI

Defective ignition
coil

13.Charging abnormal(battery over charging or over discharging)

Check and adjust

Trouble condition

The reason

Measure battery

’s

Voltage remain

The same

Voltage goes up

Goes down again

Check voltage rectifier

Plug

is loose or not

good

loosen

Check the voltage

good

No voltage

Check the resistivity

Of A.C. generator coil

normal

abnormal

Start engine, connect

rectifier

Voltag

e higher

Check the connection

Voltage rectifier

Check the resistivity

Voltage rectifier

good

Poor connection

Out of spec

Voltage then start
engine

battery is dead
battery malfunction

poor connection
red cable disconnected

Between chassisΘand
The red cable⊕of
Voltage rectifier

voltage rectifier
malfunction
white cable disconnect

defective coil
poor connection
A.C. generator’s
charging abnormal (over charging) white cable
disconnected

green cable to
Chassis, then measure
the voltage between
chassisΘand red cable⊕
of voltage of

Of the cable of

cable poor connection
poor connection of
green cable

Of the body of

Voltage rectifier
faulty

Than specification

To normal value,
But after engine
Stop, the voltage

Voltage normal

3

3. Checking and Adjustment:

33

(1)Regular checking table
(2)Battery
(3)Clean air cleaner
(4)The final reduction mechanism oil
(5)Spark plug
(6)Compression pressure measurement
(7)Ignition timing
(8)Throttle cables adjustment
(9)Idle adjustment
(10)Front brake adjustment
(11)Rear brake adjustment
(12)Tire

(1)Regular checking table:

hub

Front wheel

1.【O】mark indicates periodical checking

2.【※】indicates changing the parts

Item

Handlebar

steering

Suspension

column

front fork

Lever

Brake

Brake cable

Brake cam

Wheel hub

and brake

shor

axle

Rear wheel

axle

tire

Wheel

Axle Tighten the bolt and nut

Rim

Shaft fixed condition

b. movement of brake

Change brake cable

a. clearance between

b. brake shoe and brake

damaged or distorsion
damaged or distorsion

Cracked or damaged

tire thread worn out
tire surface or other

swingness and damage

Loose or swing

Operation

Turning angle

Damaged

Shaft:loose

a. clearance

loose or damage

worn out

and lining

lining worn-out

Pressure

intruders

condition

ge

neral

checking

first

month

or

Initial

190
mile

home office

every6

months

or

1865

mile

every12

months

3730

or

mile

every1

months

or

5595

mile

every3

months

or

7460

mile

every12

months

or

9320 mile

Judgement

standard

○ ○ ○ ○ ○ ○

Checking period

○ ○ ○ ○ ○ ○

○ ○
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○

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○ ○ ○ ○ ○

○ ○ ○ ○ ○

Front:10~20mm
Rear : 10~20mm

unit: kg/c ㎡;1 driver
front tire rear tire

2.0 2.0

Change tire
according to △mark

Front axle nut torque

5.0-6.0kg-m
rear axle nut torque

11.0-13.0kg-m
Swingness limit
Vertical: below

2.0mm
Horizontal: below

2.0mm

Clearance:

※every 2 years

Remark

Check from

Stering column

Check from

Stering column

Nut

location

Loose or damaged

wheel

Rear Damper

Transmission

Bearing

Spring

Ass’y part

Connecting

part

Bracket

Suspension

arm

Absorber

Clutch and

Shift mec-

hanism

Item

Clearance on
Front axle

Clearance on
rear axle
Damage
Condition

condition
loose or
loose or damage

condition
Looseness on
Connecting
Part

Oil leakage
Damaged

Condition
Loose on ass’y
part

Function
Gear oil

leakage

general

checking

first

month

or

Initial

190
mile

home office

every6

months

or

1865

mile

every12

months

3730

or

mile

every1

months

or

5595

mile

every3

months

or

7460

mile

every12

months

or

9320 mile

Judgement

standard

○ ○ ○ ○ ○ ○

Checking period

○

○
○ ○ ○ ○ ○

○ ○ ○ ○ ○
○ ○
○ ○

○ ○ ○ ○ ○
○ ○ ○ ○ ○

○
○

○
○

○ ○
○ ○

○ ○

○

○

Remark

LH crank
case

Gear oil

Ignition Spark plug

Start

Mechanism

Wiring

Electric

Battery

Wire

circuit

Change gear oil

Starting motor
gear
Recharge
Function

Electrolyte
level

Electrolyte
gravity

Looseness or Damage
on connection plug

○ ○ ○ ○ ○

○ ○ ○ ○ ○

○

○ ○

○ ○ ○ ○ ○

○ ○ ○ ○ ○

○

○ ○

○ ○ ○ ○ ○

BLUR 220:
110C.C. / replace
130C.C/ total

Clearance:

0.6~0.7mm
NGK:CR7E

Level between
“UPPER” and
“LOWER”

When 20℃
Specific gravity:

1.270-1.290

BLUR 150:
90C.C. / replace
110C.C/ total

BLUR-150
BLUR-220

general

checking

Item

Performance,
Noise

Low speed,
Acceleration

Exhaustion

Engine parts

Air cleaner

Cylinder, cy1inder
head, inlet pipe, locking
Condition

Engine mechanism

Lubrication system

Compression
Pressure
BLUE 150/220

Oil leakage
Oil quantity,
Dirty
Oil quantity,
Oil filter
blocked

○

first

month

or

Initial

190
mile

○ ○ ○ ○ ○

○ ○ ○ ○ ○ ○

○ ○ ○ ○ ○

Checking period

home office

every6

months

or

1865

mile

every12

months

3730

or

mile

every1

months

or

5595

mile

every3

months

or

7460

mile

every12

9320 mile

○ ○ ○ ○ ○

○

○ ○ ○ ○ ○

○ ○ ○ ○ ○

○ ○ ○ ○

months

or

Idling: 1600±100rpm

Locking torque
Cylinder head:
(cold)

○

1.0-1.2KG-m
Cam holder nut:

2.0-2.3kg-m
.

○

11kg/c ㎡
@ 650rpm

Judgement

standard

Remark

BLUR 150
BLUR 220

Check the
color of
exhausting-air

BLUE150&

220

Using
starting
motor

Fuel system

Fuel quantity

Fuel leakage
Clean

Carburetor
Carburetor’s
Throttle and
Choke function
Carburetor
Float height
Carburetor
Adjustment
Change fuel pipe

○

○ ○ ○ ○ ○
○ ○ ○ ○ ○

○ ○ ○ ○ ○

○ ○ ○ ○ ○

○ ○ ○ ○ ○

※every 4 years

Item

Function

Lamp system

Horn, signal

Lamp, reflector

lock

Rear view

mirror

License plate Dirty or damaged

Dirty or broken

Function

Function

Dirty or broken

general

checking

○

first

month

or

Initial

190

mile

home office

every6

months

or

1865

mile

every12
months

3730

mile

or

every1

months

or
5595
mile

every3

months

or

7460

mile

○ ○ ○ ○ ○

○ ○ ○ ○ ○ ○

○ ○ ○ ○ ○ ○

○ ○ ○ ○ ○

Checking period

○

○

○ ○ ○ ○ ○

every12

months

or
9320
mile

Judgement

standard

Remark

Dashboard

Muffler

silencer

chassis

The previous

Abnormal case

others

Function

Losseness or

Damage on

Ass’y part

Function

Loose or

Damaged

Confirm it does

Not happen

Again

Chassis

Lubrication

Decarbonate on

Combustion room

And muffler

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○

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○ ○

○ ○ ○ ○ ○

○

○

(2)Battery: Recharge when power is out

1.Remove the rear luggage cover by hand.

2.Screwing out the two screws on the battery cover. Remove the battery cover. (BLUR150/220)

3.Remove the negative cable and then the positive cable,→take out the battery to recharge.

4.To re-assemble the battery, please follow the opposite procedure of disassembling after
recharging.

Note:

A. The battery is totally sealed, do not remove seal bolts when recharging
B. It’s no need to add any electrolyte for this re-filling free battery
Please recharging (12V) by the following currency

Positive Pole Negative Pole

BLUR 150: Standard recharging:0.7A* 5-10 hr or rapid recharging:3A* 60min.
BLUR 220: Standard recharging:0.9A* 5-10 hr or rapid recharging:3A*60min.

(3) Air clearance

1.Remove air cleaner cover

2.Take out the air cleance filter

3.Clean the filter by the compressor air.

4.Assemble the air cleance by the opposite procedure.

BLUR 150

BLUR 220

Note: Do not start the engine when the air

cleaner is Not installed

(4)The final reduction mechanism oil

1.

Change the oil in the gear box:
a. Turn off the engine after warm up.
b. Put a bowl under the engine.
c. Remove the draining bolt and
Filler bolt to drain the gear
oil off.
d. Lock the draining bolt before
refill gear oil and
then lock the filling bolt.
e. Locking torque: 1.8kg-m

Note: Be sure the crankcase, tire or wheel are cleaned if there is grease/oil on it

Draining Filling Bolt

(5)Spark plug

Remove spark plug

1.

2.Check the spark plug electrode and check if it is
Burnt out or not and carbonized or not

3.Clean the electrode, whether it is dirty

4.Spark plug specification

BLUR 150/220: CR7E (NGK) or equivalent spec.

Gap of spark plug :0.6~0.7mm(general)

Electrode burn out/

Carbon piled up

Washer is

Distorted or not

Procelain is

Cracked or not

(6)Compression pressure measurement:

1.Measure it when the engine is warm.

2.Remove the cover.

3.Remove spark plug then place compression pressure gauge.

4.Fully open the throttle, and using starting motor 5 seconds continuously, measure the
compression pressure.

5.Compression pressure:

150/220 cc: 11 kg/c ㎡㎡㎡㎡ @650rpm

6.when the compression pressure is too low, check the following:

a. cylinder head gasket cracked.
b. piston cylinder worn out.
c. piston ring worn out.

7.If the compression pressure is too high it may be due to the carbon piled up on combustion
chamber and piston tip.

(7)Throttle cables adjustment:

1.check the clearance of throttle.

2.Normal clearance:1.5~3.5mm

3.Adjust it by rotating the adjust nut ; change it if the throttle cables can’t be adjusted.

BLUR150/220

(9) Idle adjustment:

Note:

Function.

Note: adjust it when the engine is warm.

1.remove left body cover

2.start the engine and connect the tachometer

3.adjust the throttle valve screw
to the specified revolution 1600±100rpm. (BLUE150&220)
if the idling rpm is still unsteady or
fuel up is not smooth, please adjust it by
followings.
a. Screw in the air adjust screw clockwise,
then screw out counterclockwise.
Recommended loop: 1 3/8×1/2
b. Rotate air adjust screw clockwise and counterclockwise to find out the highest
revolution location.
c. Rotate the throttle valve screw to idling condition.
d. Fuel up gradually until the idling running rpm is steady.
e. If the rpm is still not steady please repeat above procedure.

(10)front brake adjustment:

check the clearance of front brake lever.

1.
Clearance:10~20mm

2.if the clearance is beyond, standard check whether:
a. The air mix into the pipe/caliper.
b. The oil brake system is leaking.

Try brake lever to see if it’s loose.
Check the brake fluid. Once air mixed in
The fluid pipe, which will reduce or
Damage the brake efficiency or even its

3.check the fluid level:
a. Refill the brake fluid when the level is under the LOWER line.
b. Brake fluid specification: SAE J-1703F-DOT3&DOT4.

Note:

a. To prevent the fluid splitting onto the parts or clothes, put a piece of cloth on
the bottom when refilling.
b. Be caution not to mix water or particles into the master cylinder when refilling.
c. Never use the fluid not complied with spec.
d. In case the fluid stains on the eyes, wash with water at once and then ask for
medical care immediately

(11)Tire:

1.Check the tire air pressure(when it’s cold)

2.Tire pressure:
Front tire: 2.0 kg/c ㎡

Rear tire: 2.0 kg/c ㎡

3.Tire dimension:

BLUR 150/220:

Front tire: 120/60-13
Rear tire: 130/60-13

Note:
a. Check and adjust the tire pressure when it is too low.
The pressure is according to the carrier, Driver, passenger, accessories and cruise Speed.
b. Proper loading is very important for steering, riding, braking, performance and safety.
c. Never carry any parcel unfastened.
d. Load the heaviest parcel on the center of vehicle, balancing the weight on both sides.
e. Beware of the weight loaded properly and check the tire pressure. The total weight
of carrier, driver, passenger, and accessories cannot exceed the approved
limit, An overload vehicle is easy to cause tire damage and accident for rider.

4.Check is there any sharp Object pierce the tire.

5.Check the depth of tire Thread.

a. Depth(front & rear):
According to mark of tire “▲”to change a new tire

4. BLUR 150 engine Dismantling, Maintaining, Repairing and assembling
operation

(1) L

ubrication system

(2) Engine dismantling
(3) Install Engine
(4) Drive pulley, starter, clutch, driven pulley
(5) Cylinder head and valve
(6) Cylinder and piston
(7) AC generator
(8) Final transmission mechanism
(9) Crankcase, crank shaft
(10) Carburetor

(1) Lubrication System

 Oil Pump Dismantling

1.

Remove the rear section of muffler.

2.Remove the AC flywheel magneto.

3.Remove the AC generator coil.

4.Tale off the locking bolts of the

right crankcase cover.

5.Remove the crankcase cover

6.Remove the washer, lock pin

7.Remove starter reduction gear and

the starting clutch.

8.Remove oil pump separate plate by

Note:

With the notch of the

inner gear.

t

aking off the 2 bolts.

9.Remove the bolts from oil pump

driving gear

10.Take off the driving gear and chain.

11.Remove the oil pump by taking off

the locking bolt of the oil pump.

 Oil pump Assembly

1.Install the inner and outer of the oil pump.

2.Install the oil pump shaft.

The notch of the oil pump shaft should comply

3.Install the lock pin.

4.Match the lock pin hole to the pump cover

and install the oil pump cover.

5.Put on the screws and tighten them.

6.After installing, turn the shaft lightly

to assure installation.

7.Place the oil pump into the crankcase.

Note:
When installing, the arrow on the oil pump
body should be pointed upwards. Then fill in
the recommended oil before the installation.

8.Tighten the oil pump after installation.

Measurement data

i

tem

Clearance between the inner gear

Oil

pump

And outer gear
Clearance between the outer gear

And oil pump body
Clearance between gear end and

Oil pump body

Standard Value

( mm )

_ 0.12

0.045-0.10 0.12

0.045-0.10 0.12

Limit of use

( mm )

Troubleshooting

Reduction in fuel oil volume
a. Natural consumption
b Leakage of fuel
c.Piston loop seizes, or improperly install-
ation
d.Worn out of valve’s oil seal

Engine burning-out
a. Zero or too low oil pressure
b. Blockage in oil route
c. Did not use the fuel oil recommended

(2) Engine dismantling

1.Take off the luggage compartment.

2.Take off the left and right body
covers.

3.Take off the air cleaner fixing screws.

4.Loosen 2 nuts of intake manifold, withdraw
intake system assembly.

5.Remove vacuum pipe, fuel pipe ,auto
choke, cap of spark plug, rear
brake cable carburetor pipe, starter motor cable.

6.Remove the rear section of muffler, dismantle
the 2 bolts of rear brake caliper, then remove the
rear brake system assembly away from rear fork.

7.Loosen bolts of upper & lower engine hanger.

8.Remove the engine.

(3).Installing Engine

1.To install engine, please reverse the
Above procedures.

2.Locking torque:
M8: 2.0-3.0kgf.m
M10: 3.0-4.0kgf.m
M12: 5.0-6.0kgf.m

3.After installing, pleas do the following
Checking and adjustment:

a. Wiring for each circuit.
b. Throttle cable
c. Rear brake check.
d. fuel and oil route

(4) Drive pulley, starter clutch. driven p

A. Troubleshooting
B. Measurement data
C. Driving pulley
D .Starter
E. Clutch driven pulley

ulley

A.Troubleshooting:

a

.Engine starts, but vehicle don’t move.

1.driving belt worn out

2.driving plate worn out

3.clutch lining worn out

4.driving plate’s spring broken

b.the vehicle stops or tremble when running.

1.clutch lining spring cracked or broken.

c.Can’t reach high speed, no pick-up

1.driving belt worn out.

2.Driving plate spring distortion.

3.Weight roller worn out

4.Driving plate dirty.

Note:
No grease and oil should be distributed over
driving belt and driving plate.

B. Measurement data

Standard value ( mm ) Limit of use

Item

The inner dia. Of slide driving

24.011~24.052

plate
The outer dia. Of boss, movable

23.960.~23.974 23.940

Driving plate
Belt width
Clutch lining thickness

20.0~21.0

3

Clutch outer inner diameter 125.0~125.2
Driven plate spring, free length 151
The outer diameter of driven

33.965~34.025 33.95

Plate sets
The inner diameter of slide

34.000~34.025 34.06

Driven plate

( mm )

24.10

19.0

1.5

125.5
127

The outer diameter of weight
Roller set

17.920~18.080 17.40

(C)Driving Pulley

1.

Take off the screws of
left cover, remove the left cover.

2.Remove the lock nuts of driving
Plate and the nuts of Starter gear
And clutch.

3.Take off the ramp plate,
Belt and clutch.

4.Take off the boss and driving plate.

5.

Continuous Various Transmission engagement
speed inspection

 Connect an electric tachometer.
 Seated on the motorcycle with on level ground,

increase the engine’s speed slowly and notice the
RPM at which the motorcycle begins to move
forward.

Specified Engagement RPM : 3100 ± 300 rpm

6.Clutch “LOCK-UP” inspection

 Apply the rear brake as firm as possible
 Briefly open the throttle fully and notice the

maximum engine RPM sustained during the test
cycle.

Specified Clutch “LOCK-UP” RPM : 5200 ±
400 rpm

5.To assemble the driving pulley, reverse the whole

pr

ocdeure.

Locking torque:

1.Nut of driving pulley M12: 4.0-5.5kg/m.

2.Locking nut of clutch M12: 4.0-5.5kg/m

6.Checking driving belt

(1)check driving belt is cracked or not
rubber and fiber is loosened or not
also check if they are extraordinary
worn out.
(2)driving belt width:
limit of use :change it below 19mm

7.Disassemble slide driving plate set.

(1)Remove bush of slide driving plate.
(2)Remove screw, and disassemble the

cover of slide driving plate.
(3)Remove ramp plate.
(4)Remove weight roller.

8.Checlomg

(1)Check the wearing condition of

weight roller.

Limit of use : change it below 17.4mm

(2)Check gasket inner dia of

slide driving plate: limit

of use : change it over 24.1mm.

(3)Check the driving pulley

surface wearing condition.

(4)Check the outer diameter of the

contact surface of the movable

driving plate.

limit of use : change it

below 23.94mm.

9.Assemble the slide driving plate.

(1)Clean up the inside surface of slide

driving plate, then assemble the

roller.

(2)Assemble the ramp plate.

(3)Other procedure refers to the

opposite procedure of

disassembling.

D.Starter dismantle

1.Dismantle left crankcase cover

2.Remove hexagon nut, then remove the starter lever.

3.Remove five screw of separated plate.

4.Remove start spring from
start returning position.

5.Remove driven gear comp. of
kick starter.

6.Remove the retaining C-type
Ring.

7.Remove spindle comp.
of kick starter.

8.Checking starter
a. Check the wearing condition of the outer diameter of spindle comp and the inner
diameter of bush and gear.
b. Check the wearing condition of shaft of driven gear comp. Gear sets and
ratchet.

9.Assembling the starter
Assemble the starter follows the.
Opposite procedure of dismantling.
Locking torque : M6: 1.0~1.2kg/m.

Note:
Make sure one end of the torsion spring is
hooked on the groove of driven gear, and
another end of torsion spring is hooked on
the pole of inside of left crankcase.
Put some grease in every shaft and gear sets
before assembly.

E. Clutch driven pulley

M1

2:

4.0~5.5kg.m

1.Dismantling the clutch
a. Remove left crankcase cover.
b. Remove driving plate.
c. Remove driving belt.
d. Remove locking nut, then remove clutch.

2.Assemble the clutch : follows the opposite procedure of dismantling.

Locking torque:

3.Checking clutch:
dismantling tool

a.Check clutch driving face.
Check clutch cover about its wearing condition
And inner diameter measurement.
limit of use: change it above 125.5mm

b.Check clutch lining wearing condition and
Measure the lining thickness.
limit of use : change it below 1.5mm.

c.Check driving spring free length.

Standard: 151mm
Limit of usage:

Change it below 127 mm
d. Check wearing condition of
driving plate sets. And measure outer
diameter.
limit of use: change it above 33.95mm.

e.Check wearing condition of slide driven plate.
And measure its Inner diameter.
limit of use : change it above 34.00mm.

f.Check is there any wearing occur to the ditch

g.Check wearing condition of oil seal, if necessary,
change a new one.

(5)Cylinder head and valve

A.Trouble shooting
B.The operation data information
C.Dismantling and installing

1 HEAD COMP. CYLINDER 19 "CAM,SHAFT ASSY."
2 "GUIDE,EXH VALVE " 20 "SHAFT,EX.ROCKER ARM"
3 O-RING 21 VALVE RXKER ARM
4 "GUIDE,IN VALVE " 22 SCREW TOPPED ADJUSTER

5 VALVE EXHAUST 23 HEXAGON NUT
6 VALVE INLET 24 "SHAFT,EX.ROCKER ARM "

7 GASKET HEAD CYL. 25 LOCK PIN
8 LOCK PIN （D10*14L） 26 CAMSHAFT HOLDER
9 HEXAGON FLANGE BOLT 27 PLAIN WASHER
10 STUD BOLT 28 HEXAGON FLANGE NUT
11 STUD BOLT 29 CYL.HEAD COVER COMP.
12 INSULATOR CARB GASKET 30 CYL.HEAD COVER
13 INSULATOR CARB 31 "PACKING,CYL. HEAD COVER "

14 IGNITION PLUG (CR7HSA) 32 HEXAGON FLANGE BOLT
15 PLAIN WASHER 33 VALVE SEAL
16 "SPRING,VALVE " 34 CLIP
17 RETAIER VALVE SPRING 35 TUBE CYL. COMP.

A.Troubleshooting.
If the cylinder head is malfunctioned, usually it can tell fr

Compression pressure or from the noise that comes from the upper part of the engine.

1.Unsmooth idle speed

om the measurement of the

-Compression pressure is too low.

2.Insufficient compression pressure. 5.Abnormal noise

-Poor adjustment of valve clearance -Poor adjustment of valve clearance

-Valve being burned out or bent -Valve burned or damaged spring

-Valve timing is not correct -Camshaft is worn out.

-Valve spring is damaged. –Chain adjuster is worn out.

-Poor sealing of valve base. –Camshaft, valve rocker arm is worn out.

-Leakage in Cylinder head gasket.

-Cylinder head twisted or cracked.

-Spark plug is not properly installed.

3.Compression pressure is too high.

-There is too much carbon accumulated in the combustion chamber.

4.There is white fume coming out from the exhaust pipe.

-The valve stem or valve guide pipe is worn out.

-Valve stem’s oil seal is damaged.
B.The operation data information

Description

Clearance between adjuster tapped
Screw and valve stem
(Before warm up)

Compression pressure(throttle open
full)

Height of the cam’s convex part

Inner diameter of rocker arm shaft

Outer diameter of rocker arm shaft

Valve base angle

Outer diameter of valve stem

Inner diameter of valve guide
Clearance between valve stem and

Valve guide

IN/EX

Standard Value

(mm)

IN 0.08

EX 0.08

Limit of use

(mm)

－

－

－－

－

－

－－

11kg/650rpm (150CC)

IN 26.625(150CC) 26.23(150CC)

EX 26.53(150CC) 26.13(150CC)

IN 10.00~10.015 10.10

EX 10.00~10.015 10.10

IN 9.972~9.987 9.91

EX 9.972~9.987 9.91

IN&EX

1.0 1.8

IN 4.975~4.900 4.90

EX 4.955~4.970 4.90

IN 5.000~5.012 5.30

EX 5.000~5.012 5.30

IN 0.010~0.037 0.08

EX 0.030~0.057 0.10

C.Dismantling and installing the

Cam shaft

1.Take off the left cover.

2.Remove the intake pipe from the
Cylinder head cover.

3.Take off the 4 bolts of the

cylinder head cover and take off
the cylinder head cover.

4.Turn the flywheel counterclockwise and let
the ”T”

mark on the flywheel point to the crankcase
mark and
make the round hole on the cam chain gear point
upwards.
This is the upper dead point of compression.

5.Take off the cam shaft holder, the nut and the

locking pin.

6.Remove the cam gear from the cam chain.

7.Remove the cam shaft.

Check cam shaft

Limit of Use:

NOTICE:

Sliding surface.

Limit of use : replace it above 10.10mm.

Limit of use : replace it above 10.10mm.

NOTICE:

NOTICE:

C

heck the convex surface and the height and see whether it has

Been damaged.

IN :replace it below 26.23mm(150CC)
EX :replace it below 26.13mm(150CC)

Check camshaft. If the bearing is loosen or worn out, change the whole set if necessary.

Check cam shaft holder

1.Check the cam shaft holder, cam rocker arm, and cam

Rocker arm shaft and see whether it is loosen or worn
out.

Do check if there is any damage on the cam rocker arm

2.Cam shaft holder and cam rocker arm outer dia

measurement:

3.Cam rocker arm inner dia measurement:

4.Cam rocker arm shaft and rocker arm outer dia measurement:

5.Clearance between the Cam rocker arm and rocker arm shaft.

Limit of use : replace it above 0.10mm.

WHEN INSTALLING:

The mark “EX” on the cam shaft holder is the exhaust rocker arm, one-way stopper.

1.

Install the exhaust rocker arm, the inlet rocker arm, and the rocket arm shaft.

a.The tangen angle of the heat side of intake valve’s rocker arm shaft is to match
with the bolt of the cam holder.
b.The tangent angle of the exhaust valve’s rocker arm shaft is to match with the bolt
of the cam holder.

2.Turn the flywheel to make the T mark pin correctly. The hole on the cam chain gear

should point upwards. Both the left and right concave points and the cylinder head are at
parallel position (convex part of cam shaft points upwards), then install the cam shaft on
the cylinder head.

3.Install the cam chain onto the cam shaft gear.

4.Install the locking pin.

5.Install the camshaft holder, washer and nuts on the cylinder head.

6.Lock tightly the cylinder head nuts.

Locking torque: Cam shaft holder nuts:2.0kg-m

a.Put some grease on the bolt thread of cam shaft holder
b.Lock the nuts of the cam shaft bracket in “cross” sequence for 2-3 times.

7.Adjust the valves clearance.

Dismantling the cylinder head:

1.

Remove the carburetor.

2.Remove the muffler.

3.Remove the fan cover.

4.Remove the bolts on the engine cover.

5.Remove the camshaft.

6.Remove the cylinder head

7.Remove the lock pin, cylinder head gasket.

8.Remove cam chain guide

Notice:

Not to injure the contact

Surface of the cylinder.

Avoid any object dropping info the engine.

Further dismantling

se the valve contracting tool to remove valve pin,

U

supporter, the vlave spring collar, valve spring
and valve stem oil seal.

Notice:

Valve Spring has to be operated by the valve spring contractor.
To assemble the cylinder head, please follow the opposite procedure as above.

(6)Cylinder and piston

A.Trouble shooting
B.The Operation notice
C.Data
D.Dismaniling cylinder, piston
E.Installing cylinder, piston

C.Data (150CC)

Part name /description

Bore

Cylinder

Curve
Cylindrility
Roundness
Clearance b/w Piston

and
Piston ring

Clearance of cutting

Piston/

Piston ring

Piston pin outer diameter
Clearance between piston and piston pin
Connecting rod small end inner dia

section
Piston outer diameter

Measuring location of piston outer dia.
Clearance b/w piston and cylinder

Piston pin hole inner dia

tandard value

S

( mm )

57.490~57.510

Limit of use

( mm )

57.600

- 0.005

- 0.005

- 0.005
lst ring 0.03~0.07 0.10
2nd ring 0.02~0.06 0.10

lst ring 0.10~0.25 0.50
2nd ring 0.10~0.25 0.50
side ring 0.2~0.7 ---

57.470~57.490

Down to 5 mm from the
piston skirt

57.400

---

0.025~0.035 0.10

15.006~15.012

14.990~14.992

15.030

14.96

0.020~0.017 0.025

15.010~15.028

15.060

A.Troubleshooting.

a.Compression pressure is too low, difficult to start engine

and engine running

unsmoothly.

1.Cylinder head gasket cracked

2.Spark plug is not well locked

3.Piston ring worn out or cracked

4.Cylinder, piston worn out.

5.Reed valve is out of order.
b.Compression pressure is too high; Engine overheating; abnormal noise.

1.piston tip has too much carbon accumulated.
c.Abnormal piston noise

1.Cylinder and piston worn out.

2.Piston pin hole or Piston pin worn out.

3.Connecting rod small end or bearing worn out.
d.Abnormal piston or cylinder noise

1.Piston ring worn out or cracked

2.Cylinder worn out or cracked

B.The operation notice

1.Clean before operation to avoid particles dropping into the engine.
The contact surface of gasket must be clean.

2.

3.Dismantle cylinder and cylinder head by screw driver. Do not injure the contact surface.

4.Cylinder inner surface and piston outer face can’t be injured. Contact
Surface should lubricate by specified oil.

D.Dismantling

Dot’ drop the clip into the crankcase.

Don’t make piston ring worn out or damaged

a.Dismantling Cylinder

1.Remove the cylinder head.

2.Remove 2 bolts, then the camshaft chain adjuster

3.Remove CAM chain guide.

4.Remove cylinder.

5.Remove the cylinder gasket, lock pin and
clean the gasket on the cylinder.

b.Dismantling piston

1.Remove the piston pin clip.
NOTICE:

2.Remove the piston pin and take off
the piston.

3.Check piston, piston pin, piston ring.

4.Remove the piston ring

NOTICE: NOTICE:

5.Clean the carbon in the groove of the
piston ring.

c.PISTON OUTER DIA MEASUREMENT:

1.Measuring location:

Perpendicular to the piston pin hole, down to

5mm(150CC) form the piston skirt.

Limit of use : change it when less than 57.4mm.( 150CC)

2.The clearance between the piston and piston pin:

3.Checking any wearing, damage inside the cylinder.
Vertical to piston pin, and in X-Y direction to
measure cylinder bore from the upper, middle and
lower location.

Limit of use : Change it when above 57.6mm(150CC)

4.The maximum clearance between the cylinder and
piston pin.

5.The difference between the X and y is the

roundness.

6.The cylindrility is the max value of the

difference between the upper, Middlle and
lower position of the inner dia in X or Y
direction.

Limit of use : Roundness:change it when above

0.005mm.
Cylindrility:change it when above

0.005mm.

d.Checking the flatness of cylinder contact

surface.

Limit of use : change it when above 0.05mm.

e.Connecting rod small end inner diameter
measurement.

Limit of use : change a new one when above 15.06mm.( 150CC)

E.Installing Cylinder and piston

NOTICE:

NOTICE:

crankcase and to clog the crankcase with rags.

a.Installing piston and piston rings

1.Lubricate the piston rings by motor oil.

NOTICE:

a. Be careful not to scratch the piston

and not to break the piston ring.

b.The mark (on the ring) should be

upward when installing.

c.after installing, the ring should be

smoothly rotated.

2.Clean up the residual gasket on the

crankcase.

Do not drop other objects into the crankcase.

3.Assembly the piston, piston pin and piston pin

clip.

a.The mark “IN” on the piston tip should face
to the INLET side.
b.Do not drop the piston pin clip into the

b.Installing piston

1.Fix the lock pin and gasket on the crankcase.

2.Lubricate the Cylinder inner surface, piston and piston rings

3.Install the piston ring into the cylinder carefully.

by Motor Oil.

NOTICE:
a.The piston ring cannot be damaged or cracked.
b.The cutting section of three rings must be arranged at intervals of 120°

(7)A.C. Generator

A.Dismantling AC generator

B.Installing AC generator

Dismantling AC generator

1. Dismantle the rear section of muffler.

2. Remove fan cowl.

3. Remove the M6 screws

4. Remove screws of flywheel magneto.

5. Remove the AC flywheel magneto by special tool.

6. Remove the flywheel.

7. Remove the electric plug of AC flywheel

magneto.

B.Installing AC generator

To install, please reverse the dismantling procedure.

Locking torque:
M6: 1.0~1.2kg/m
M12: 3.2~4.0kg/m

(8)Final transmission mechanism

A. Troubleshooting.

B. Dismantle the final transmission mechanism.

C. Check the final transmission mechanism.

D. Assemble the final transmission mechanism.

A. Troubleshooting

Engine can be started, but the vehicle doesn’t move.

1.Gear worn-out or cracked.

2.Gear burnt out.

Noise occur when running.

1.Gear worn out, burnt or gear surface.

2.Bearing worn out of loosen.

Oil leakage

1.Too much oil

2.Seal worn out or damaged.

B. Disassemble the final transmission mechanism:

1.Remove the rear wheel.

2.

Drain the oil in the gear box.

3.Remove the bolt in the gear box

cover.
Take off the gear box.

3.Remove the final reduction gear
A

nd idle gear.

5.Clean up the gear box.

C. Check the final transmission mechanism

1.Check the wearing condition of driving shaft and gears.
Gear teeth number: 14 T (125CC) ; 15 T (150CC)

2.Check the wearing condition of idle gear shaft
and idle gears.

Gear teeth number 42 T (150CC)

3.Check the wearing condition of the final
reduction gear.

4.Check the wearing condition of the oil seal and bearing.

D. Assemble the final transmission mechanism, please follow the opposite procedure
Of disassembling. After locking the drain bolt, refill 90cc of gear oil SAE90.

Locking torque:M6: 1.0~1.2kg/M
M10: 3.5~4.0kg/M
Drain bolt: M8: 1.8kg/M

(9)Crankcase, Crankshaft:

A

. Disassembling diagram.

B. Troubleshooting.

C. Data

D. Remove crankcase and crankshaft.

E. Check crankshaft.

F. Assemble the crankcase.

A. Disassembling diagram

Torque: 1.0~1.2kg-m

B. Troubleshooting
Engine noise:

1.The bearing of final transmission mechanism is loosen.

2.Crank pin of bearing is slack.

3.The bearing of gear box is loosen.

C.Data

Item Standard value(mm) Limit of use.(mm)

Clearance of connecting rod big end

0.10~0.35 0.55

axle direction

Clearance of connecting rod big end

- 0.04

vertical direction.

Swingness of the crank shaft journal. 0.03 0.10

D. Remove the crankcase and crankshaft by the following procedures:

1.Remove the engine.

2.Remove the muffler.

3.The carburetor.

4.Engine corer.

5.Cylinder head.

6.Cylinder.

7.The driving plate.

8.AC flywheel magneto.

9.The starter clutch.

10.Oil pump.

11.Bolts of left/right crankcase.

E.Check crankshaft

1.Measure the difference of the connecting

rod big end between the X and Y

Limit of use : replace it when above 0.04mm.

2.Measure the swing ness of the crankshaft

journal.

imit of use

L

A B

Change it when above

Change it when above

0.1mm

3.Check the looseness of crankshaft bearing.
If it is loosen, replace to a new one.

0.1mm

A

.Assemble crankcase:

F

1.assemble crankcase according to the opposite procedure of disassembling.

2.The locking torque of bolts and nuts are described in previous chapter please refer.

B

(10)Carburetor:

A.General theory
B.Troubleshooting.
C.Dismantling the carburetor.
D.Dismantling the float and nozzle.

CARBURETOR SPECIFICATIONS:

ITEM SPECIFICATION
Model M2-150
Carburetor type KEIHIN CVK24
Bore size 24 mm
I.D. NO 046
Idle r/min
Float height

1700 ±±±± 100

18.0 ±±±± 0.5 mm
Main jet #102
Jet needle 4HLGL
Needle jet P-O
Pilot jet #35
Pilot screw

1 1/ 2 turns out

(PRE-OPENING)

(A) General theory

DIAPHRAGM AND PISTON OPERATION

The carburetor is a variable-venturi type, whose venturi cross sectional area is increased or
decreased automatically by the piston valve. The piston valve moves according to the negative
pressure present on the downstream side of the venturi A. Negative pressure is admitted into the
diaphragm chamber  through an orifice  provided in the piston valve.

Rising negative pressure overcomes the spring  force, causing the piston valve  to rise into the
diaphragm chamber and prevent the air velocity from increasing. Thus, air velocity in the venturi
passage is kept relatively constant for improved fuel atomization and precise air/fuel mixture.

SLOW SYSTEM

This system supplies fuel during engine operation when the throttle valve  is closed or slightly
opened. The fuel from the float chamber  is metered by the pilot jet  where it mixes with air
coming in through the pilot air jet . This mixture, rich with fuel, then goes up through the pilot
passage to the pilot screw . Part of the mixture is discharged into the main bore through bypass
ports . The mixture is metered by the pilot screw  and sprayed into the main bore through the
pilot outlet port .

COASTING ENRICHMENT SYSTEM

The coasting enrichment system is included in the slow system
Joining of the air from upper part of then carburetor inlet side to pilot air passage  which obtains
proper fuel/air mixture ratio. But if the throttle valve is closed suddenly, a large negative pressure
generated in the cylinder which is applied to the diaphragm . The valve  which interlocks with the
diaphragm  closes an air passage , thus, the fuel/air mixture ratio by controlling air flow in the
pilot circuit.

. At the normal running operation,

MAIN SYSTEM

As the throttle valve  is opened, engine speed rises and negative pressure in the venturi A

increases. This causes the piston valve  to move upward.

The fuel in the float chamber  is metered by the main jet . The metered fuel enters the needle

jet , mixes with the air admitted through the main air jet  and forms an emulsion.

The emulsified fuel then passes through the clearance between the needle jet  and jet needle 

and is discharged into the venturi A, where it meets the main air stream being drawn by the engine.

Mixture proportioning is accomplished in the needle jet . The clearance through which the

emulsified fuel must flow ultimately depends on throttle position.

AUTO-ENRICHENER (AUTO-CHOKE) SYSTEM

The automatic enrichener (automatic choke) device consists of the PTC heater A, the
thermo-wax B and the plunger/needle . When the thermo-wax B is cold, the plunger/needle 
moves upward, Fuel is drawn into the enrichener circuit from the float chamber .

Enrichener jet  meters this fuel, which then flows into fuel pipe  and mixes with the air
coming From the upper part of the float chamber . The mixture, rich in fuel content, reaches upper
part of The fuel pipe and mixes again with the air coming through a passage extending from main
bore .

The two succesive mixings of fuel with air are such that proper fuel/air mixture for starting is
produced when the mixture is sprayed out through outlet port  into the main bore.

NOTE:

n enrichener is operated almost the same way as a choke.

A

When the engine is cold:
The automatic enrichener passage is always open as the thermo-wax remains atomospheric temperature.

When the engine is started:
According to the PTC heater temperature, the thermo-wax gradually expands and closes enrichener
passage by the needle of the plunger.

FLOAT SYSTEM

The float  and needle valve  work in conjunction with one another. As the float chamber ,
the float  rises and the needle valve  pushes up against the valve seat. When this occurs, no fuel
enters the float chamber.

As the fuel level falls, the float lowers and the needle valve  unseats itself; admitting fuel
into the float chamber .

In this manner, the needle valve  admits and shuts off fuel to maintain the appropriate fuel
level inside the float chamber .

ACCELERATOR PUMP SYSTEM

This system works only when the rider opens throttle grip quickly as pump send the necessary
amount of fuel to the carburetor bore for correcting fuel/air mixture ratio. When the rider open the
throttle grip quickly, the intaken air volume becomes large and air velocity at the bottom of the
throttle valve (piston valve)is slow and sucking volume of fuel is less.

The throttle valve lever  pulls lever  with the cable, and lever  turns and pushes rod . The
rod  pushes plunger . This plunger pushes out the fuel through outlet pipe , spraying fuel into
the main bore.

INSPECTION

Check the following parts for damage and clogging.
* Pilot jet * Piston valve
* Main jet * Starter jet
* Main air jet * Gaskets and O-rings
* Pilot air jet No.1 & No.2 * Pilot outlet and bypass
* Needle jet holder * Coasting enrichement valve
* Float * Needle valve
* Jet needle * Valve seat

if any abnormal condition is found, wash the part clean. If
damage or clogging is found, replace the part with a new
one.

CARBURETOR CLEANING

!WARNING

Some carburetor cleaning chemicals, especially
diptype soaking solutions, are very corrosive and
must be handled carefully. Always follow the chemi­cal manufacturer’s instructions on proper use, han­dling and storage.

 Clean all jets with a spray-type carburetor cleaner and
dry them using compressed air.
 Clean all circuits of the carburetor thoroughly-not just the
perceived problem area. Clean the circuits in the
carburetor body with a spray-type cleaner and allow each
circuit to soak, if necessary, to loosen dirt and varnish.
Blow the body dry using compressed air.

!CAUTION

Do not use a wire to clean the jets or passageways.
A wire can damage the jets and passageways, if
the components cannot be cleaned with a spray
cleaner it may be necessary to use a dip-type clean­ing solution and allow them to soak. Always follow
The chemical manufacturer’s instructions for proper
use and cleaning of the carburetor components.

 after cleaning, reassemble the carburetor with new seals
and gaskets.

AUTO-ENRICHENER INSPECTION

for the purpose of checking temperature.



Disconnect the lead wire coupler.

 Remove the cover.
 Connect the positive ⊕ terminal of a 12V battery to

Yellow/white lead and the negative Θ terminal to Black/
White.
 Check that the auto-enrichener section  (PTC heater
built-in area)is heated in 5 minutes after the battery has
been connected.

NOTE:

o inspect the function, check for change of temperature

T
from the cold condition.

!CAUTION

Do not attempt to disassemble the auto-enrichener

FLOAT HEIGHT ADJUSTMENT

To check the float height, turn the carburetor upside down.
Measure the float height A while the float arm is just con­tacting the needle valve using vernier calipers.
Bend the tongue as necessary to bring the float height A
To the specified level.

Float height A: 20.8 ± 1.0mm

78

(B) Troubleshooting

D

ifficult to start

1.No sparking in spark plug.

2.Compression pressure too low.

3.No fuel in the carburetor

-air cleaner blocked

-oil pipe blocked

-bad adjustment of the fuel level
float valve is jell
Mixed air too dilute

1.Main jet blocked

2.Float valve blocked

3.Fuel level too low

4.Fuel system blocked

5.Second air sucked into intake system

6.Bat vacuums during piston movement

7.Throttle valve malfunction
Too much fuel in the engine

1.Air cleaner blocked

2.Mixed air is too dilute in the idle system

Sparking unsteady while increasing speed

1.Ignition system malfunction.

2.Air mixture is too dilute

Difficult to start, Ignition off, Unstable idling

1.Fuel system blocked

2.Ignition system malfunction

3.Air mixture is too dilute or too thick

4.Fuel deterioration

5.Second air sucked into intake system.

6.Bad idle adjustment

7.Bad fuel volume adjustment

8.Idle system or fueling system blocked

9.Bad adjustment of fuel level

Mixture air too thick

1.Auto chock system malfunction

2.Float valve malfunction

3.Fuel level is too high

4.Air route blocked

5.Dirty air cleaner

6.Fuel overwhelming in carburetor

78

(C)Dismantling the carburetor

Note :Fuel volume adjusting screws have been set up properly before sale thus there is no

1.Remove the auto starter
connector.

2.Remove the throttle cable,
then the fuel pipe from the
carburetor.

3.Remove the screws on the intake manifold.

4.Unscrew the fixing belt on the connecting pipe.

5.Remove the carburetor.

Assembling the carburetor
To assemble the carburetor, please follow the reversed procedures of the dismantling and do
the following adjustment after installation is finished:

-Adjust the throttle cable

-Idle adjustment

Adjustment of fuel volume adjusting screws

need for self-adjustment. However, when dismantling, a record of the turning loop
has to be dept for future assembling purpose. Put up the center stand while adjustment.

1.After the engine is warm up, adjust the stopping screw throttle of throttle valve to the
standard rpm.
Idle rpm 1,700±100rpm

2.Adjust the fuel volume adjusting screws to the highest stable rotation.
This rotation value is the optimum setting of throttle

3.Fuel up for several times, make sure that the idle rpm is within the standard rpm.
Repeat the above procedure if the idle rpm is unstable.

(D)The float nozzle

Note:

△

Note:

damages.

Note:

Notice

△

Notice

1.Dismantling
Remove the screws to take off the float chamber.
Remove the float, the float pin, and float valve.

2.Checking
Check the float valve, valve base to see
whether it is blocked or damaged.
Check the float valve, valve base surface
if sectional worn out or dirty.

△

When the valve is too dirty or severely worn-not, the
Valve base will not close completely thus will result
In increasing of fuel level and fuel leakage problem.
A new replacement is needed.

emove the main jet, needle jet base, needle jet,

R
slow jet and fuel adjusting screws.

Avoid any damage on the jets and the fuel adjusting
screws.
Before dismantling, record the number of turning
loops.
No screwing-in movement by force to avoid any

se the detergent solution to clean the jets. Fuel

U

adjusting

After cleaning off the blockage and the

dirt, screw

blow dry by compressed air.

Remove the vacuum and air-interrupt valve for
Cleaning.

3.Assembling
Assemble the slow jet, needle jet, main jet and

fuel adjusting screws.



Record the number of turning loops before
dismantling

ssemble the float valve, float and float pin.

A

4.Checking fuel level

Check after the checking on the float valve
and the float is done.
Put the float gauge on the float chamber
perpendicularly to the main jet for
measurement.

(D)Handle bar, front wheel, front brake and front fork:

A. Troubleshooting

1.steering handlebar is abnormal, too tight.
a.steering mechanism; washer of conical bush locked too tightly.
b.steering mechanism; steel ball is cracked.
c.steering mechanism; steel ball base and washer of conical base is damaged.
d. wheel pressure is too low.

2.steering handlebar is aslant.
a. left and right damper are not even.
b.Front fork is crooked.
c. The axle of front fork is crooked or the wheel is aslant.

3.front wheel swings.
a.wheel rim is distorted.
b.bearing of front axle is loose.
c.wheel spoke is distorted.
d.Tire worn out.
e. The wheel axle is improperly assembled.

4.front damper is too soft, or spring fatigue.

5.Noise in front damper.
a.noise comes form the shock absorber tube.
b.locking screw of damper is loose.

B. Data

Item Model

Standard value(mm)

Limit of use.(mm)

thickness of frt pad BLUR-150/220
Disk of frt brake BLUR-150/220
thickness of REAR pad
Swingness of frt/rr

BLUR-150/220
BLUR-150/220

wheel

8.3 5.3

4.0 3.5

10.0 7.0

- 2.0

C. Change the speedometer cable:

Note:

Put

some

grease onto the inner cable before assembling.

1.Remove the front handle cover.

2.Remove the nut of the speedometer cable.

3.Remove the fixed screw of the speedometer cable on the front wheel.

4.Pull out the damaged speedometer cable.

5.To assemble the new cable, please follow the opposite of dismantling procedures.

(D)Steering handlebar

1.Remove the LH/RH back mirrors.

2.Remove the upper handle cover.

3.Remove the nuts on front fork and handlebar.

4.Take off the fixing bolt.

5.Remove the nut and bolt of the front fork fixed on
The handlebar.

6.Take off the handle bar.

7.When assembling, please follow the opposite procedures.

Locking Torque:
M6 : 1.0-1.2kg-m
M10 : 3.0-4.0kg-m

8.Before assembling, please add grease on each cable.

(E)Front wheel

1.Remove the locking nut of the front

wheel on the right side.

2.Draw out the axle of front wheel,

remove the ring and take off the
gear sets of speedometer.

3.Remove the front wheel assy.

4.Assemble the front wheel follows

the opposite procedure of
dismantling.
Locking Torque:
M10: 3.0-4.0kg-m

Note:

1.Put the lock block of speedometer gear assy upon the extrusion of the front fork.

2.Put the grease onto the grease sets of speedometer before assembling.

5.Checking the front wheel axle

a. Check the bending degree of the front axle.
b. Take note of the bending degree on the middle of axle.
c. Limit of use: Change it when above 0.2 mm.

6.Front wheel bearing checking

Turn the tire. If the bearing is
Loosen or any occurrence for noise,
Please change a new one.

7.Front wheel rim checking

(1)Check the swing of the front wheel rim.
(2)Limit of use:
Horizontal direction:
Change a new one when above 2.0mm.
Vertical direction:
Change a new one when above 2.0mm.

(F)Front brake

1. Disassembling and assembling of the front
brake comp.

a. Remove two bolts fixed on the front brake
comp and the front fork.
b. Remove the front brake comp.
c. Assemble the front brake comp.

Follows the opposite procedure of
dismantling.

Locking Torque:

M8: 2.0~3.0kg-m

2.Air releasing of the front brake comp

The procedure of air releasing
a .Fill the enough brake oil to the container
b. Do not let the brake oil overflow from the
master cylinder or container when assemble
the master cylinder cover.

c. Put the spanner upon the drain screw.
d. Lock and unlock the screw several times to

release the bubbles.
e. Operate slowly the brake lever several times.
f. Clamp the brake lever to the end.
g. Loose the drain screw, then open the lever completely.
h. Locking the drain screw and then loose it when the lever is opened completely.
i. Repeat above procedure until all the air in the brake system has been released

Completely.

Locking torque of leaking screw: 0.6 kg-m

3.Front fork checking:
If it is bent or cracked, please replace with a new one.

4.Front shock absorber checking

Check is there any unusual damage or worn-out condition, and whether the guide rod of the
Front fork is crooked or not.

Fork oil type: SAE 10W20
Capacity (each side): 95 CC (BLUR-150/220)

NOTE:
If the guide rod is crooked, it should be replaced by a new one or repaired.

Tube fixing screw

Spring fixing bolt