Genuine PGO PM50 PM110 Service Manual

PREFACE

This manual offers all service specialist with professional technigues

techniguess of maintenance and repairing for PM50 &PM110. It provides a
Detailed guide for those whom may concern with how to maintain, repair,
Reassemble, and exchange parts of their scooters.

At every section, we illstrate 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 POG scooters.

FACTORY：
Motive Power Industry Co.,Ltd.

CONTENTS：

1.The specifications

2.Service information
(1)The operation notice
(2)Torque value
(3)Lubrication instruction
(4)Wiring diagram
(5)Troubleshooting

3.Checking and Adjustment
(1)Regular checking table
(2)Battery
(3)Cleaning air cleaner
(4)Final reduction mechanism oil
(5)Spark plug
(6)Compression pressure meas urement
(7)Ignition timing
(8)Throttle cables adjustment
(9)Idle adjustment
(10)Front brake adjustment
(11)Rear brake adjustment
(12)Tire

4.Dismantling, maintaining, repairing and assembling operation
(1)Lubrication system
(2)Plastic parts of chassis
(3)Engine dismantling
(4)Drive pulley, starter, clutch, driven pulley
(5)Cylinder head, cylinder, piston
(6)AC generator, flywheel magneto
(7)Final transmission mechanism
(8)Crankcase, crankshaft
(9)Carburetor
(10)Steering column, front wheel, brake comp, front fork
(11)Rear wheel, rear brake, rear damper

(12)Fuel tank, oil tank

5.Electric equipment
(1)Troubleshooting
(2)Battery
(3)Recharge system
(4)Ignition system
(5)Starting system

SCOOTER SPECIFICATION (1)

Name

PMX SPORT50

ERAME STEEL

TYPE PM-50D SUSPENSION SYSTEM

DIMENSION FRONT TELESCOPIC
TOTAL LENGTH 1820 REAR UNIT-ABSORBER
TOTAL WIDTH 660 TRANSMISSION
TOTAL HEIGHT 1090 RPIMARY RATIO 1
WHEELBASE 1220

SECONDARY RATIO

52/13*44/13
DRY WEIGHT 94KG CLUTCH C.V.T.
FRONT 37KG TIRE
REAR 57KG FRONT 120/70-12
TOTAL 94KG REAR 130/70-12
LOAD 2 PERSONS(110KG) BRAKE SYSTEM

LOADED WEIGHT FRONT DISC BRAKE
FRONT 69KG REAR DRUM BRAKE
REAR 135KG LIGHT
TOTAL 204KG HEAD LIGHT(H/L) 12V-18W/18W*2
TAIL LIGHT 12V-5W
CYCLE 2 BRAKING LIGHT 12V-21W
FUEL UNLEAD ED TURN LIGHT 12V-10W
CYLINDER NUMBER 1
ARRANGEMENT HORIZONTAL
DISPLACEMENT 49C.C.
BORE Í40.0mm
STROKE 39.2mm
COMPRESSION RATIO 6.8:1
MAX. POWER/RPM 3.0KW/7000RPM
AMX. TORQUE/RPM 5.2N.m/6500RPM
IDLE RPM

1900±100

IGNITION CDI
SPARK PLUG NGK BP7HS
COOLING FORCE AIR
STARTER

ELECTRIC、KICK

FUEL MIXING OIL PUMP
LUBRICATION SEPARATED

VEHICLT PERFORMANCE
TOP SPEED 65KM/H
FUEL CONSUMPTION 43KM/L
CLIMBING ABILITY

20°

SCOOTER SPECIFICATION (2)

Name

PMX SPORT110

ERAME STEEL

TYPE PM-110 D SUSPENSION SYSTEM

DIMENSION FRONT TELESCOPIC
TOTAL LENGTH 1820 REAR UNIT-ABSORBER
TOTAL WIDTH 660 TRANSMISSION
TOTAL HEIGHT 1090 RPIMARY RATIO 1
WHEELBASE 1220

SECONDARY RATIO

49*16*43/13
DRY WEIGHT 94KG CLUTCH C.V.T.
FRONT 37KG TIRE
REAR 57KG FRONT 120/70-12
TOTAL 94KG REAR 130/70-12
LOAD 2 PERSONS(110KG) BRAKE SYSTEM

LOADED WEIGHT FRONT DISC BRAKE
FRONT 69KG REAR DRUM BRAKE
REAR 135KG LIGHT
TOTAL 204KG HEAD LIGHT(H/L) 12V-18W/18W*2
TAIL LIGHT 12V-5W
CYCLE 2 BRAKING LIGHT 12V-21W
FUEL UNLEAD ED TURN LIGHT 12V-10W
CYLINDER NUMBER 1
ARRANGEMENT HORIZONTAL
DISPLACEMENT 106.2C.C.
BORE Í52.0mm
STROKE 50.0mm
COMPRESSION RATIO 6.6:1
MAX. POWER/RPM 5.7KW/7000RPM
AMX. TORQUE/RPM 8.4N.m/6500RPM
IDLE RPM

1900±100

IGNITION CDI
SPARK PLUG NGK BP 7HS
COOLING FORCE AIR
STARTER

ELECTRIC、KICK

FUEL MIXING OIL PUMP
LUBRICATION SEPARATED

VEHICLT PERFORMANCE
TOP SPEED 82KM/H
FUEL CONSUMPTION 38KM/L
CLIMBING ABILITY

20°

2.Service information ：

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

a.For engine
b. For chassis
c. Others

(3) Lubrication instruction

a.For engine
b. For chassis

c. Wheel bearing
(4)Wiring diagram
(5)Troubleshooting

1.Difficult starting or can’t

2.Weak acceleration

3.Engine running unsmoothly (low speed)

4.Engine running unsmoothly(high speed)

5.Clutch, drive, driven pulley

6.Handlebar steering astrayed when running

7.Front, rear damper not balanced

8.Bad braking

9.Oil indicator malfunction

10. Fuel indicafor malfunction

11.The 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 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 P.G.O.

6.When removing battery, please disconnect the negative cable(-) first.
However, please connect the positive cable(+) 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 befor selling out.

(2) Locking Torque Value:

1.Engine

No Locking location Thread dia

1 Cylinder head 7 1.0~1.4 When the engine is cold
2 Flywheel plate 10 3.2~4.0
3 Rear brake lever 6 1.0~1.2
4 Driving pulley 10 3.2~4.0
5 Clutch outer 10 3.5~4.0
6 Right crankcase 6 1.0~1.2
7 Drive gear box cover 6 1.0~1.2
8 Left crankcase 6 1.0~1.2
9 Draining and filler bolt 8 1.8 When the engine is cold
10 Inlet pipe 6 1.0~1.2
11 Flywheel magneto 6 1.0~1.2
12 Cooling fan 6 1.0~1.2
13 Muffler nut on cylinder head 6 1.0~1.2 When the engine is cold
14 Starting motor 6 1.0~1.4 When the engine is cold
15 Spark plug 14 2.5~3.0
16 Fan cover 6 1.0~1.2
17 Fixed plate, drive clutch 6 1.0~1.4
18 Nut of rear wheel axle 16 8.0~10.0 U TYPE NUT
19 Kick starter 6 1.0~1.2
20 Muffler bolt on crankcase 8

(mm)

Locking

torque kg-m

Remarks

2.chassis

1 Steering stem nut 10mm 3.0~4.0
2 Front axle nut 12mm 5.0~6.0
3 Fixed nut fasten eng. and

chassis

4 Fixed bolt fasten hanger and

chassis

5 Rear shock absorber(upper)

Rear shock absorber(lower)

6 Lock nut faster frt. brake disk

and frt. wheel rim

7 Lock bolt between frt. brake

caliper and frt. absorber

8 Lock bolt of frt braking hose 10mm 3.0~3.5

12mm 5.0~6.0

10mm 3.5~4.5

10mm

8mm
8mm 2.0~3.0

8mm 2.0~3.0

3.0~4.5

2.4~3.0

3.Other parts: Please refer the following table:
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 3.4-4.0
5 12mm bolt and nut 5.0-6.0
6 5mm screw 0.35-0.5
7 6mm screw 0.7-1.1
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

B. Chassis parts

C. Wheel bearing part

(5)Trouble shooting:

Loose carburetor draining
The fuel supply in carburetors

Is enough or smooth

No fuel supply in
carburetor

Remove spark plug, insert
Spark plug cover, and touch

Measurement of

Pressure is
normal

Insufficient or
No Pressure

Start engine: follow the
Engine has no

knocking

Engine knocking
dry

wet

1.difficult starting or can’t start:

Check and adjust Trouble condition The reason

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

•check there is fuel or not

‚pipe between ful tank and
carburetor is blocked
ƒFloat is blocked
„Fuel gauge is blocked
…auto cock is malfunction

•spark plug out of order

‚dirty

With engine check there is

ƒCDI 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
ˆdefective magneto coil

No sparking or
Weak sparking

Compression pressure

•starting clutch out of order
‚piston ring stuck
ƒreed 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
ƒwrong 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
ƒthrottle valve open too largely

2.Weak ac celeration:

Check and Adjust

Trouble condition

The reason

Start engine and open throttle
Gradually, check and inspect

Engine can’t rotate
Check ignition timing, (check

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
ƒfuel tank cover blocked
„muffler blocked
…auto chock is malfunctioned
†auto chock is malfunctioned

•CDI unit is out of order
‚alternator flywhe el 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
ƒcylinder body has sand hole
„Reed valve malfunction

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

Abnormal

Check engine overheat
Or not

Not overheat

overheat

Running accelerately or

knocking

Check the oil level in gear box
Is too much or dirty

•oil level is too high
‚oil level is too low

ƒoil does not interchange

Oil level is normal

Not normal

Check the combustion
color of cylinder head

•oil route is blocked

‚insufficient oil pumping from

oil pump

•piston and cylinder worn out
‚mixture is too lean
ƒbad 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
ƒclutch slip

No knocking

„mixture is too lean

…ignition timing is too early

3.Engine running unsmoothly (low speed and idling)

Check and adjust

Trouble condition

The reason

Correct

Not correct

Good

Faulty

Check if there is air

Good sparking

Or no sparking

Check A.C. Generator

good

fault

Check ignition timing

•CDI faulty
‚AC generator faulty

Adjust carburetor air screw

•mixture too rich
(to loose the screw)
‚mixture too lean
(to tight the screw)

adjustment

adjustment

Leakage on carburetor
gasket

•gasket broken

‚carburetor locking nut
loosen
ƒhose ruptured
„lntake manifold gasket
broken
…Carburetor O ring distorted

No leakage leakage

•spark plug dirty
‚CDI out of order
ƒAC magnet abnormal

Sparking abnormal

„ignition coil faulty

…H.V. coil disconnect or
short circuit

†main switch abnormal

•A.C. generator malfanction

‚hose is damaged
ƒair pipe is blocked or
damaged

△

4.Engine running unsmoothly (high speed)

Check and adjust

Trouble condition

The reason

timing

correct

Not correct

Check auto cock,
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
ƒautocock faulty

Is blocked or not

•clean and wash it

5.Clutch, drive and driven pulley

Trouble condition

The reason

Move the vehicle

And seems to rush out

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

ƒdriven plate spring distorted

„clutch lining worn-out

…driving pulley shaft gear teeth
cracked
†final gear damage

•clutch lining spring cracked or

worn out

‚weight rollers melt and stick to

driving face

ƒshaft worn out
(rear wheel rotates while idling)

•driving belt worn-out, distorted,
slipping
‚weight roller worn-out
ƒdriving plate worn-out
„driving plate spring distorted
…driving pulley shaft worn-out

•driving belt worn-out or slipping
‚weight roller worn-out
ƒdriving pulley shaft worn-out

•additional grease on driving belt,
pulley
‚driving belt worn-out
ƒdriven plate spring distorted
„driving pulley shaft worn-out

Engine runs, but it stops

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 heavy

Damper has abnormal noise

The reason

Trouble condition

The reason

points

(front and rear wheel pressure are normal)

•steering column lock nut locked too
tightly
‚steel ball cracked

•rear, front wheel bearing swings
‚front, rear wheel rim distorted
ƒfront axle nut is loose

•front and rear wheel center not well­ aligned
‚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
ƒdamper 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
ƒbrake cam worn -out
„brake hub worn-out

•brake lining worn-out
‚Alien material attached on brake lining
ƒ
rough

•
unsmoothly
‚brake lining contacting surface not
evenly
ƒwater or sand drop into brake system
„some grease on brake lining surface

Brake plate”△”mark

Noise when brake

Faulty performance

(adjustment according to standard procedure)

Contact surface of the wheel hub becomes

brake cable over stretching or moving

9.Oil indicator malfunction

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 electric
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
ƒmain switch abnormal
„circuit plug dropped off
…main wiring disconnected

And connect with

•bulb burn out

•electric plug is loose
or disconnected
‚main wiring disconnected
ƒwrong wiring connection

Check the lamp light
Up or not by moving

Float upward: lamp •float faulty
Extinguishes ‚oil gauge switch dis ­Float 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 disconnecte d
ƒwrong 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

Needle moves

Needle no motion

Do the short and opening

Needle

Needle on
motion

Check electric plug

good

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

Turn the signal lamp
On; check wiring of

•fuse burn-out
‚battery has no power
ƒmain switch abnormal
„circuit plug dropped off
…main wiring disconnected

Moving float up and
Down to check
The needle movement

Float abnormal

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

Fuel gauge abnormal

•electric plug is loose or
disconnected
‚wrong connection
ƒwire broken or short
circuit

moves

Not flash, not light

abnormal

Check and adjust

Trouble condition

The reason

Turn signal lamp on,

normal

No motion

Needel moves
good

No
movement

Move needle up and

Check electric plug
Connecting condition

good

abnormal

Remove the float

movement

Needle
moves

Needle 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

ƒbattery has no power
ƒmain 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(1 move/
Second), check the
Needle’s movement

lnsufficient or no damping
Oil inside the fuel gauge

•electric plug drop-off or
loose
‚wire broken or short
circuit

The starting motor abnormal

Check and adjust

Trouble condition

The reason

Check brake switch

Turn signal lamp
Of battery

Brake lamp

Brake lamp
normal

Lamp dims, no
Flashing no light

Push starting switch
normal

No function

Connect starting motor
To battery directly

Starting
Motor runs up

Starting motor
Has no motion

(a)Starting motor can not rotate

•fuse burn-out
‚battery has no power
ƒmain switch abnormal
„circuit plug dropped off
…main wiring disconnected

•battery has no power

•start switch bad
connetion
‚relay wire broken or
short circuit
ƒcircuit plug is loose

•carbon brush worn out
‚coil broken or short
circuit
ƒstarting motor wir e
broken
„circuit plug is loose,
drop-off
main wiring broken

No to check wiring

And check the function
Of start relay

Lights up

no light

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

Check and adjust

Trouble condition

The reason

Turn signal lamp
normal

Lamp dims, no
Flashing, no light

Connect starting
Battery directly

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 wi­ring of battery

Motor to

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
Loose or not

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

Spark plug cap is loose

Plug is poor
connection

•main switch faulty
‚defective magneto
coil
ƒpulse generator faulty
„defective ignition
coil

•main cable broke
‚poor connection of
joints or sockets

defective CDI

Defective ignition
coil

And H.V. cable is

Is loose or not

Between CDI plug and
Each terminals, check
The resistivity of

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

Check and adjust

Trouble condition

The reason

Measure batter’s
Voltage remain

The same

Voltage goes up

Goes down again

Check voltage rectifier
Plug is loose or not

good

loosen

Check the voltage

Voltage rectifier

good

No voltage

Check the resistivity
Of A.C. generator coil

normal

abnormal

Start engine, , then

Voltage higher
specification

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
malfunction
‚whi te cable disconnect

•defective coil
‚poor connection
ƒA.C. generator’s
charging abnormal (over charging) white cable
disconnected

measure the voltage
between chassisΘand

red cable⊕of
voltage of
rectifier

Of the cable of

•cable poor connection
‚poor connection of
black cable

Of the body of

Voltage rectifier
faulty

Than

To norma l value,
But after engine
Stop, the voltage

Voltage normal

3.Checking and Adjustment:

(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)Frt brake adjustment
(11)Rr brake adjustment
(12)Tire

(1)Regular checking table:

Front wheel

1.【O】mark indicates periodical checking

2.【※】indicates changing the parts

gen-era

l

che-cki

ng

○ ○ ○ ○ ○ ○
○ ○ ○ ○ ○ ○

○ ○
○ ○ ○ ○ ○

○ ○ ○ ○ ○ ○ ○

○
○

○

Item

Handlebar

steering

Suspension

column

front fork

Lever

Brake cable

Brake

Brake cam worn out ○

Wheel hub

and brake

shoe

axle

Rear wheel

axle

tire

Wheel

Axle Tighten the bolt and nut

Rim

Loose or swing

Operation

Turning angle

Damaged

Shaft fixed condition ○ ○ ○ ○ ○

Shaft:loose

a. clearance ○

b. movement of brake ○ ○ ○ ○ ○ ○ ○

loose or damage ○ ○ ○ ○ ○ ○

Change brake cable

a. clearance between hub

and lining

b. brake shoe and brake

lining worn-out

c. wheel hub worn and

damaged

damaged or distorsion
damaged or distorsion

Pressure

Cracked or damaged

tire thread worn out
tire surface or other

intruders

swingness and damage

condit-ion

first

month

or

Initial

500km

Checking period

home office

every6

months

5000km

or

every12

months

or

10000km

○ ○

every1

months

or

1000km

every3

months

or

2500km

○ ○ ○ ○ ○

every12

months

or

10000km

○

Judgement

standard

Clearance:

Front:5-7mm
Rear :5-7mm

※every 2 ears

○ ○ ○ ○ ○

○

○

○ ○

dia:rear:110.0mm

○

use:rear:111.0mm

○
○

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

2.0 2.0

standard

limit of

○ ○ ○ ○ ○
○ ○ ○ ○ ○

○ ○ ○ ○ ○

○ ○ ○ ○ ○

○ ○ ○ ○ ○

Change tire
according to △mark

Front axle nut torque

5.6-6.0kg-m
rear axle nut torque

11.0-13.0kg-m
Swingness limit
Vertical: below

2.0mm
Horizpmtal:be;pn

2.0mm

Remark

Check from

Stering column

Check from

Stering column

gen-era

Item

wheel

Bearing

Spring

Ass ’y part

Cnnecting

part

Rear Damper

Brake cam

Suspension

Transmission

arm

Absorber

Clutch and

Shift mec-

hanism

Clearance on

Front axle

Clearance on

rear axle

Damage

Condition

loose ○ ○ ○ ○ ○

loose or damage

condition

loose or damage

condition

Looseness on

Connecting

Part

Oil leakage

Damaged

Condition

Loose on ass ’y

part

Function

Gear oil

leakage

chec-ki

first

month

l

or

Initial

ng

500km

○ ○ ○ ○ ○ ○

○

○ ○
○ ○

Checking period

home office

every6

months

5000km

or

○

every12

months

10000km

or

every1

months

or

1000km

every3

months

or

2500km

○ ○ ○ ○ ○

○
○

○

○ ○

○ ○

○ ○ ○ ○ ○

every12

months

or

10000km

Judgement

standard

○

○

Remark

LH crank
case

Gear oil Change gear oil

○ ○ ○ ○ ○ ※every 2 ears

Clearance:

90C.C.

0.6~0.7mm

Ignition Spark plug

○ ○ ○ ○ ○

NCK:BP7HS
OR SAME
SPEC

Start

Mechanism

Electric

Wiring

Battery

Starting motor

gear

Recharge

Function

Electrolyte

level

Electrolyte

gravity

○

○ ○

○ ○ ○ ○ ○
○ ○ ○ ○ ○

○

○ ○

Level between
“UPPER” and
“LOWER”

When 20℃
Specific gravity:

1.270-1.290

Wire

circuit

Looseness or

Damage on plug

○ ○ ○ ○ ○

500rpm

Engine mechanism

Engine parts

Lubrication

system

Checking period

l

ng

first

month

or

Initial

500km

home office

every6

months

5000km

or

every12

months

or

10000km

every1

months

or

1000km

○ ○ ○ ○ ○

○ ○ ○ ○ ○

○ ○ ○ ○ ○ ○

○ ○ ○ ○ ○

○ ○ ○ ○ ○

○

gen-era

Item

Performance,

Noise

Low speed,

Acceleration

Exhaustion
Air cleaner ○ ○ ○ ○ ○

Cylinder, cy1-

Inder head, inlet

Pipe, locking

Condition

Compression

pressure

Oil leakage

Oil quantity,

Dirty

Oil quantity,

Oil filter

blocked

che-cki

every3

months

or

2500km

every12

months

or

10000km

○

○

Judgement

standard

Idling:1900±

100rpm

Locking torque
Cylinder head:
(cold)

1.0-1.2KG-m
inlet pipe: cold)

1.0-1.2kg-m
Using starting
motor.
7kg/c ㎡­6kg/c ㎡-600rpm

Remark

Check the
color of
exhausting-air

for 110cc
for 50cc

Fuel quantity

Fuel system

Fuel leakage

Clean

Carburetor

Carburetor’s

Throttle and

Choke function

Carburetor

Float height

Carburetor

Adjustment

Change fuel pipe

○

○

○

○ ○

○ ○ ○ ○ ○
○ ○ ○ ○ ○

○ ○ ○ ○ ○

※every 4 years

gen-era

Item

Lamp system

Horn, signal

Lamp, reflector

lock

Rear view

mirror

License plate Dirty or damaged

Function

Dirty or broken

Function

Function

Dirty or broken ○

che-cki

first

month

l

or

Initial

ng

500km

○
○ ○ ○ ○ ○ ○

○ ○ ○ ○ ○ ○

○ ○ ○ ○ ○

○

Checking period

home office

every6

months

5000km

or

every12

months

or

10000km

every1

months

or

1000km

every3

months

or

2500km

○ ○ ○ ○ ○

○ ○ ○ ○ ○

every12

months

or

10000km

Judgement

standard

Remark

Dashboard Function

Muffler
silencer

chassis

The previous

Abnormal case

others

Losseness or

Confirm it does

Decarbonate on

Combusion room

Damage on

Ass ’y part

Function

Loose or

Damaged

Not happen

Again

Chassis

Lubrication

And muffler

○

○

○ ○ ○ ○ ○

○ ○ ○ ○ ○

○

○

○ ○

○ ○

○ ○ ○ ○ ○

○

○

(2)Battery: Recharge when power is out

1.Open the cover and remove the battery cover.
àTake out the battery,

2.Remove the negative cable and then the positive
Cable,àtake out the battery to recharge.

3.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 current
Standard recharging:0.5A×5-10 hr or rapid recharging:5A×30min.(110c.c.)
Standard: 0.4A * 4-10Hr or Rapid:4A * 30min(50cc)

(3)Cleaning air cleaner

1.Remove air cleaner cover

2.Take out the air cleaner filter

3.Clean the filter by the compressor air

4.Assemble the air cleaner by reversing above procedure

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 90c.c. 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

(5)Spark plug

1.Remove spark plug

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

3.Clean the electrode, if it is dirty

4.Spark plug specification
NGK:BY7HS or same spec.

l Gap of spark plug:0.6~0.7mm

l Electrode

Burn out
Carbon piled up

l Washer is

Distorted or not

l Procelain is

Cracked or not

(6)Compression pressure measurement:

1.Measure it when the engine is warm.

2.Open the seat, remove the luggage.

3.Remove the cover.

4.Remove spark plug then place comp ­Ression pressure gauge.

5.Fully open the throttle, kick on kickstarter 5
Times continuously, measure the compression
Pressure.

6.Compression pressure:
110cc: 7kg/c ㎡-500rpm
50cc: 6kg/c ㎡-600rpm

7.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.

8.If the comperssion pressure is too high it is due
To carbon piled up on comb ustion chamber and
Piston tip.

(7) lgnition timing:

This scooter is using CDI set, it is no need to adjust ignition timing.
If ignition timing is not correct, check the CDI sets AC magneto, change it if it is abnormal.

checking ignition timing:

1.Open the seat, remove the luggage compartment

2.Remove the body cover

3.Remove fan case.

4.Check with ignition timing lamp.

keep the engin running at 1,900 ±100 r.p.m
If the checking mark should lay in ±3 apart
From “F”, mark.

5.ignition timing: B.T.D.C.
17° ±3° / @ 1900rpm

(8)Throttle cables adjustment:

1.check the clearance of throttle
twist grip.

2.Normal clearance:1.5-3.5mm

3.Adjust it by :

①ｔａｋｅ　ａｗａｙ　ｔｈｅ　ｒｕｂｂｅｒ　
②ｌｏｏｓｅｎ　ｔｈｅ　ｎｕｔ　
③rotating the adjuster nut to adjust the

clearance , change it if the throttle cables can’t be adjusted.

(9) ldle adjustment:

Note:

Function.

1.remove left body cover

2.start the engine and connect
the tachometer

3.adjust the throttle valve screw
to the specified revolution 1900±100rpm

4.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:
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:

1.check the clearance of front brake lever.
Clearance:2-5mm

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

Trybrake 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 brake fluid level:
a. Refill the brake fluid when the fluid eel is under the LOWER line.
b. Brake fluid specification:SAEJ-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)Rear brake adjustment

Note:

1.Check the clearance
Of rear brake lever.
Clearance: 10-20mm

2.If the clearance is
Beyond the above standard,
Adjust it by rotating the
Adjuster nut.
a. Lefthanded rotation enlarge
the clearance.
b. Righthanded rotation
reduce the clearance.

When the arrow of rear brake indicator lay in
The arrow of left crankcase, change the brake
Lining.

(12)Tire:

Check the tire before

1.Check the tire air pressure
Notice:

running

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

3.Tire dimension:
Front tire: 120/70-12
Rear tire: 130/70-12

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 tyre
“▲”to change a new tyre

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.Dismantling, maintaining, repairing and assembling operation:

(1)Lubrication system
(2)Plastic parts
(3)Engine dismantling
(4)Drive pulley, starter, clutch, driven pulley
(5)Cylinder head, cylinder, piston
(6)AC Generator flywheel magneto
(7)Final transmission mechanism
(8)Crankcase, crankshaft.
(9)Carburetor, reed valve, auto cock
(10)Steering column, front wheel, front damper, front fork
(11)Rear wheel, rear brake, rear damper
(12)Fuel tank, oil tank

(1)Lubrication system:

1.Lubrication system diagram.

2.Troubleshooting.
A. If there is too much white fume from exhaust system, which means too much
Carbon piled up on the spark plug or the oil quality is not good.
B. Engine over heating:

a. The adjustment of oil pump is not properly.(1ack of oil)
b. The quality of oil is not good.

C. Piston over burning.

a. There is air in the oil pump system.
b. Oil pump is out of order.

D. The route from oil tank to oil pump is blocked.

a. Ventilation hole on the tank cover is blocked.

Note:1.When removing oil pump, do not drop any unexpected objects into the oil pipe.

2.Please release the air if there is air trapped in the oil pipe.

3.Locking torque of oil pump:0.8-1.2kg-m

3.Removing oil pump.

Clean the oil pump and

Crank case before operation

a. Remove the luggage and rear bracket.
b. Remove the input/output o il pipe.
c. Take out the oil pump by removing

The locking screw on oil pump and
Oil gauge cable.

4.check oil pump.
Remove oil pump and check:
a. O-ring is distorted or not.
b. contactpart of crankcase is
injured or not.

d. Oil pump body is damaged or not
e. The gears are damaged or not.
f. Check seal and see if there

Is oil leakage or not.

g. Never dismantle oil pump it

Can not function well after
Dismantling.

5.Assemble the oil pump.

After assmebling, check the following:

c. oil leakage at any location.

a. Assemble the oil pump by reversing

Above procedure.
O-ring of oil pump should be lubricated by
Grease or oil, then place on cankcase.
The contact surface of oil pump and crank
Case should be assembled firmly.
The gears of oil pump should be lubri­Cated by grease.

b. Be sure oil pump screw is tightened nitely

Locking torque:0.8~1.2kg-m

a. the adjustment of control cables
b. Is there air in oil pipe.

6.Releasing air in the oil pump.

a. If there is air in the oil pipe, it will cause engine lubrication trouble
b. Releasing air operation means the release of air trapped in the air
pipe oil pipe and oil pump. Please firstly release air from the oil pipe

(a)Fill up specific amount of oil to oil tank.
(b)Place dry cloth under the oil pump.
©Remove oil pipe.
(d)Use injector to fill up the oil in the
oil pump body and oil pipe. Be sure the oil
pipe and oil pump are full of oil before
assembling.
(e)After assembling, check if there is still air
trapped in the oil pipe.

(2)Dismantling & assembling of plastic parts

1.screwing out the screws of front windshield

2.Screwing out the screws of windshield & front inner cover.
àtake off the windshield.

3.Screwing out the screws of the rear carrier
àtake off the rear carrier

4.Open the seat, screwing out the 9 screws of luggage compartment
àtake off the luggage compartment.

5.Screwing out the screws of front body
cover

àtake off the front body cover.

6.Screwing out the screws of left side cover

àtake off the left side cover.

7.Screwing out the screws of right side cover
àtake off the right side cover.

8.Screwing out the screws of rear cover
àtake off the rear cover.

9.Take off the upper & lower handle cover firstly, then screwing off the screws of front fender.

10.screwing out the screws of front inner cover.

11.screwing out the screws of front mudguard.

12.Before taking off the step floor, screwing out the screws of battery cover firstly
àtake off the battery cover.

13.Disconnect the negative cable firstly, then positive cable

Note: Pay attention not to clamp or scraping the cables by

àtake out the battery.

14.Screwing out the four screws of the step plate
àtake off the step plate.

15.Screwing out the screws of step floor & lo wer mudguard
àtake off the step floor & lower mudguard.

Locking torque:
M6:0.7-1.1kg-m
M5:0.35-0.5kg-m

the plastic parts when assembling.

(3)Dismantling Engine

A.Dismantling engine.

1.Take off the luggage compartment.

2.Remove vacuum pipe, fuel pipe, oil pipe. Cable of auto choke and carburetor.

4.Remove the cap of spark plug.

5.Remove engine hanger shelf’s nut, rear damper blot and rear brake cable.

6.Remove the engine.

B. installing engine.

1.Install engine please reserse above procedure.

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

3.After installing, inspect and adjust the following:
a. the wire connecting.
b. throttle cable, oil control cable.
c. fuel and oil route.
d. rear brake adjustment.

(4)Drive pulley, starter, clutch, driven pulley

A. Troubleshooting:

a. Engine starts, but vehicle does not move.

1.driving belt worn out

2.driven plate worn out

3.clutch lining worn out

b. The vehicle stops or trembles 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 abnormal.
Note:
No grease and oil allowed stain on the driving belt and driven plate.

B. Measurement data

Item

The bush inner dia of
Slide driving plate
Driving plate’s boss
Outer dia
Weight roller outer
Dia
Clutch cover 120.0-120.2 120.500
Driven plate spring
Free length
Driving plate sets
Outer dia
Slide driven plate
Inner dia

Standard value(mm) Limit of use(mm)

110cc 110cc

23.98-24.052 24.240

23.974-23.960 23.934

15.992-16.008 15.500

154.600 149.300

33.965-33.985 33.940

34.000-34.025 34.050

C. Driving pulley.

1.Remove the 10 screws of left cover.

2.Take off the left cover.

3.Remove the fixing nut of clutch.

4. Take off the ramp plate, belt & rear clutch, and the driving plate.

7. Loosen 2 hexagon screws, and take off the driving gear starter fixing plate set.

8.Remove the start idle gear set.

9.Assenbke driving pulley, please reverse above procedure.

Locking torque:
Change it when above 20.068 mm

10.Checking the driving belt

(1)check whether it is cracked or its rubber and fiber are loose or not
also check if they are extraordinarily worn out.
(2)driving belt width:
limit of use : change it when below 16.5mm.

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

1.M10 nut of driving pulley:3.5~4.0kg-m

2.M10 nut of clutch outer:3.5~4.0kg-m

(3)Remove ramp plate.
(4)Remove weight rollers.

12.Checking list:
(1)Check the wearing condition of weight roller.
limit of use:change it when below 15.5mm.

(2)Check inner dia of slide driving plate’s gasket.

(3)Check the wearing condition for driving pulley surface.

(4)Check the outer diameter of the driving plate’s boss.

Limit of use:

Limit of use: change it when
Below 23.934mm

13.Assemble the slide driving plate.
(1)Clean the inner surface of slide driving plate, then assemble the roller.
(2)Assemble the ramp plate.
(3)Please reverse the procedures of disassembling to finish assembling.

D. Starter dismantling

1.Dismantle the left crankcase cover

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

3.Remove five screws of partition plate.

4.Remove the stater spring from the start returning positioner.

5.Remove the driven gear comp of kick starter.

6.Remove the retaining c-type clip

7.Remove the spindle comp.

Of kick starter.

8.Checking the starter

a. Check the wearing condition of the outer diameter of the spindle comp
and the inner diamter of bush and gear.
b. Check the wearing condition of the shaft of driven gear comp, gear
sets and ratchet.

9.Assembling the starter

To ssemble the starter, follow the opposite procedures of dismantling.
Locking torque:M6:1.0~1.2kg-m

Note:

•Make sure that on end of the torsion spring is hooked on the groove of
driven gear, and another end of the torsion spring is hooked on the poled
inside the left crank case.
‚Put some grease on shaft and gear sets before assembling.

E. Clutch driven pulley

Locking torque:

1.Dismantle the clutch

a. Remove left crankcase cover.
b. Remove driving plate.
c. Remove driving belt.
d. Remove M10 locking nut, then the clutch.

2.Assembling the clutch:please follow the opposite procedure of dismantling.

M10:3.5~4.0kg-m

3.Checking the clutch:

Dismantling the clutch needs the special
Tool, please contact your dealers.

a. Check the clutch driven face.
Check the clutch cover about its wearing
Condition and inner diameter measurement.

Limit of use:
Change it when above 120.5mm

b. Check the clutch lining wearing condition
and measure the lining thickness
limit of use:change it below 2.5mm.

c. Check driven spring free
length:standard:154.6mm
Limit of use:change it as it
Is below 149.3mm

d. Check wearing condition of
driving plate set.
Outer diameter measurement:
Limit of use:change it as it
Is above 33.940mm

e. Check wearing condition of
slide driven plate.
Inner diameter measurement:
Limit of use:change it as it
Is above 34.060mm

f. Check is there any wearing
occur to the ditch area.

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

(5)Cylinder head, cylinder, piston:

A. Troubleshooting.

a. compression pressure is too low, difficult to start engine, low RPM running
unsmoothly.

1. Cylinder washer cracked.

2. Spark plug not being locking well.

3. Piston ring worn out or cracked.

4. Cylinder, piston worn out or injured.

5. Reed valve is out of order.

b. compression pressure is too high, engine overheating or knocking.
cylinder head or piston tip too much carbon accumulated.
c. piston noise

1. cylinder, piston worn out.

2. Piston pin hole, piston pin worn out.

3. Connecting rod small end or bearing worn out.

d.piston, cylinder noise

1.piston ring worn out or cracked.

2.Cylinder worn out or injured.

B.The operation notice:

1.clean before operation to avoid other object drop in engine.

2.The connecting washer must be washed cleanly.

3.Dismantle cylinder and cylinder head, don’t injure the contact surface.

4.Cylinder inner surface and piston outer face can’t be injured.

5.The dismantling part should be washed cleanly when checking, the contact surface
Shoulld lubricate by specified oil.

C-1. The operation data information for 110cc:

Item

Cylinder head flatness - 0.100
Piston outer diameter(measu-re
At the skirt area where is 12mm
From the skirt lower end)
Clearance between cylinder and
Piston
Piston pin hole inner dia 14.004-14.010 14.032
Piston pin outer diameter 13.998-14.000 13.074
Clearance between piston pin
And pin hole
Piston ring gap
(lst ring/2nd ring)
Connecting rod small end inner
Dia
Cylinder bore 52.000-52.020 52.05

Standard Value(mm) Limit of use(mm)

110cc 110cc

51.960-51.980 51.905

0.035-0.045 0.100

0.006-0.012 0.030

0.15-0.35 0.450

18.002-18.010 18.02

C-2. PISTON & CYLINDER DATAS for 50cc:

Part name/description

Cylinder head Flatness 0.100
cylinder Bore 39.995~40.015 40.050
Piston/
Piston ring

Piston outer diameter 39.950~39.970 39.895
Measuring location of piston outer dia.

Clearance b/w piston and cylinder 0.045~0.065 0.10
Piston pin hole inner dia 13.022~13.013 13.045
Piston pin hole inner diameter 10.002~10.008 10.025
Piston pin outer diameter 9.994~10.000 9.970
Clearance between piston and piston pin 0.004~0.018 0.030
Connecting rod small end inner dia 13.996~14.007 14.025

Clearance b/w Piston
ring piston and

(12mm from the lower end of skirt)

Lst ring

2nd ring 0.05~0.06 0.10

Standard Value

(mm)

0.05~0.06 0.10

Limit of use

(mm)

D. dismantle cylinder head, cylinder, piston

1.Remove the engine.

2.Screwing out the two M6-bolt of cooling cowl.

3.Screwing out the two M6-blot of fan cove r.

4.Remove the cooling cowl and fan cover.

5.Remove the spark plug.

6.Screwing out the two M6-nut of muffler and cylinder, and the two M8-bolt of crankcase.

7.Remove muffler.

8.Remove the four M7-nut of cylinder head, then remove cylinder head and cylinder head gasket.

9.Remove the C-type clip on the piston and piston pin by the nipper.
Take off piston.

10.Dismantling of the piston ring Remove the lst ring, then 2nd ring.

11.When assembling, please reverse the procedures of dismantling

Locking torque:
M7:1.0-1.4kg-m
M6:1.0-1.2kg-m

Opening end of piston ring

E. Check for the flatness of cylinder head.

Check the flatness of contact surface of cylinder head.

Limit of use:If it exceeds 0.1mm
Change a new one.

l cylinder
l piston
l piston pin snap
l piston pin
l needle bearing

F. Combustion chamber cleaning

lClean out the carbon piled up in combustion chamber.

Head gasket head

lDo not scratch the combustion chamber and contact surface of cylinder during
cleaning operation

G. Check cylinder and piston:

1.Check the wearing and damage condition on the contact surface of cylinder and piston.

2.Clean out the carbon on the cylinder exhausting port.

Be careful not to scratch the inner
Surface of cylinder.

3.Cylinder bore measurement:
(1)Measure each point : upper,middle,lower orderly, and in X.Y. axis to find the smallest value.
(2)Limit of use: it when over 52.050mm(110cc)

4.Piston outer diameter measurement:
(1)Measure at the skirt area where is 12 mm from the
skirt lower end.
(2)Limit of use: change if when below

51.905mm(110cc)

(3)Calculate the clearance between cylinder and piston.

Limit of use:change it when over 0.100mm

5.Inner diameter measurement of the piston pin hole
Limit of use: change it when over 14.032mm(110cc)

6.Outer diameter measurement of the piston pin

limit of use: change it when under 13.074mm(110cc)

7.Check piston ring:
Measure piston ring gap inside cylinder :
Limit of use: change new ones when the first ring and second ring are over 0.4mm

Push the piston ring into the cylinder
By piston, then measure the gap

8.Check connecting rod small end
(1)lnstall piston pin, bearing onto the connecting

rod small end, then check the looseness
of the piston pin.

(2)Measure the inner diameter o f the connecting

rod small end.

Limit of use: replace a new one when over 18.020mm. (110cc)

H. Installing cylinder and piston

1.Place the piston ring into the second ring ditch first, then install the
piston ring into the first ditch.

2

a. Piston ring should be installed into piston ring ditch by even force
b. After assembling, be sure that the piston ring sliding surface is at the same height as
the piston outer surface.
c. If the piston ring can not fit into the ditch, please clean up the carbon in the piston ring

ditch or piston ring itself.

3.

a. Piston ring must be installed in the correct location.
b. After installing the piston ring, it should be able to rotate freely.
c. If it is necessary to change the new piston ring, it must change the whole set.

4.

a. The location of the piston ring gap and the lock pin must be in opposite side.
b. The mark”à” on the piston tip must be pointing to the exhausing port.
c. Lubricate the piston pin before installation.

5.Please follow the opposite procedure of dismantling to install cylinder and cylinder head.

(6)A.C. Generator, Flyweel Magneto

A.Dismantling AC alternator flywheel magneto.

1.Remove fan cowl.

2.Screwing out the four M6-bolt of fan.

3.Screwing out the nut on flywheel.

4.Remove the AC flywheel magneto by special tool.

5.Remove the flywheel.

Locking torgue:

6.Remove the electric plug of AC Flywheel magneto.
Take out the magneto.

B. Install AC generator

To install, please reverse the dismantling procedures.

M6:1.0~1.2kg-m
M10:3.2~4.0kg-m

(7)Final Transmission Mechanism

A. Trouble shooting
lEngine can be started, but vehicle does n’t move.

1.Gear worn-out or cracked.

2.Gear burnt out.

lNoise occurs when running.

1.Gear worn out, burnt or gear surface damaged.

2.Bearing worn out or loosen.

lOil leakage

1.Too much oil.

2.Seal worn out or damaged.

B. Disassemble the final transmission mechanism.

1.Remove the rear wheel.

2.Drain off the oil in the gear box.

3.Remove the bolt in gear box cover, take off the gear box.

4.Remove final reduction gear and idle gear shaft.

5.Clean up the gear box

C. Check the final transmission mechanism

1.Check the wearing condition of the driving shaft and
gears.

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

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 procedures
Of disassembling. After locking the drain bolt, refill 110c.c of gear oil, SAE 140.

Locking torque: M6: 1.0~1.2 kg-m
M10: 3.5~4.0 kg-m
Drain bolt: M8: 1.8 kg-m

(8)Crankcase, Crankshaft:

A. Disassembling diagram

B. Troubleshooting.
Engine noise:

1.The bearing of final transmission mechanism is loose.

2.Crank pin bearing is loose.

3.The bearing of gear box is loose.

C. Data

Item Stardard value Limit of use.(mm)
Clearance of connecting rod big end
(Parallel direction to rod)
Clearance of connecting rod big end
(Perpendicular direction to rod)
Swingness of the crank shaft journal 0.03 0.10

0.20-0.50 0.76

- 0.04

D. Dismantle the crankcase and crankshaft.

1.Remove the engine from the chassis.

2.Remove left E/G case, driving pulley (driving plate) clutch and belt.

3.Remove air cleaner.

4.Remove carburetor.

5.Remove intake manifold and reed valve.

6.Remove oil pump, fan cowl and fan cover.

7.Remove cylinder, AC flywheel magneto.

8.Remove the left and right crankcase with special puller.

9.Remove center stand, separate RH/LH crankcase, take out crankshaft.

E. Check crankshaft:

1.measure the clearance between crank
shaft and co-rod big end.(Parallel
direction to rod)

2.check the looseness on X.Y. axis of the connecting rod big end(Perpendicular directions to rod)

Limit of use: change it when above 0.76mm

Limit of use: change it when above 0.04mm

3.measure the swingness of crank shaft neck.

Limit of use

A B

Change it when

Above 0.1mm

Change it when

Above 0.1mm

4.check the slackness of crankshaft bearing, if it is
slack, change a new one.

A B

60mm

F. Assemble the crankcase.

1.To assemble the crankcase, p lease reverse the procedures of disaseembling.

2.The locking torque value for bolts and nuts are all described in the previous chapters
Please refer.

(9)Carburetor, Reed Valve and Auto cock

A. Fuel system diagram

Fuel tank fuel gauge autocock

Fuel supplied to Carburetor

B: Carburetor dismantling diagram

01 CARBURETOR ASSY.
02 TOP SET
03 SPG., COMP.
04 PLATE SET
05 TUBE SET
06 JET NEEDLE
07 THROTTLE VALVE
08 SCREW SET
09 SCREW SET（A.S）
10 O RING
11 NEEDLE JET
12 SLOW JET
13 HOLDER, NEEDLE JET
14 MAIN JET
15 FLOAT VALVE SET
16 PIN, ARM
17 FLOAT SET
18 FLOAT CHAMBER SET

19 TUBE SET
20 "SCREW, WASHER"
21 CAP HOLDER

C. Troubleshooting:

a. Engine can not be started.

1.No fuel in the fuel tank.

2.Fuel pipe is blocked.

3.There is too much fuel in the cylinder.

4.Air cleaner is blocked.

b. Engine idling(RPM)unsteady, running not smoothly

1.Improper adjustment of the carburetor idling.

2.Ignition disorder.

3.Compression pressure is too low.

4.Air mixture is too thick.

5.Air mixture is too lean.

6.Air cleaner is blocked/

7.Air injection is not in good function.

8.Fuel is dirty.

c. Air mixture is too lean.

1.Carburetor main jet is blocked

2.The ventilation hole of the fuel tank cover is blocked.

3.Fuel filter is blocked.

4.Fuel pipe bended, squeezed or blocked.

5.Float valve is abnormal.

6.Fuel level is too low.

7.Air pipe is blocked.

d. Air mixture is too thick

1.Float valve is abnormal.

2.Fuel level is too high.

3.Air jet is blocked.

D. Dismantling carburetor

Note:

1.Remove the luggage box.

2.Loose the hose clamp between the carburetor
and the air c leaner.
Then remove the air cleaner.

3.Unscrew the fuel draining screw of the
carburetor. Drain off the fuel inside the
carburetor.

4.Remove the fuel pipe and the vacuum pipe on
the carburetor.

5.Remove the oil pile on the carburetor.

6.Remove the bolts on the intake manifold and
carburetor.

E. Dismantling float, nozzle

The auto choke has been properly adjusted already. Please do not adjust it further.
When there is blockage in the carburetor, please clean it by air compressor.

F. Reed valve

1.Dismantling reed valve.
(1)Take off the luggage box
(2)Remove the air cleaner
(3)Remove the carburetor.
(4)Unscrew the locking screw of the manifold
intake.

(5)Remove the manifold intake.

(6)Remove the reed valve.

2.checking for the reed valve.

§chang a new one when the reed valve is worn out or distorted.

§change a new one too when the base of the reed valve is cracked, injured or distorted.

G. Check the auto cock

1.When the engine stop, remove the fuel pipe from carburetor and check if there is fuel flow
Out or not.
It means auto cock functions well if the residue fuel(for the amount of 5-10cc)flows out
From the auto cock and fuel pipe. However, if it continues to flow out, it means that the
Vacuum pipe is blocked. please clean it.

2.Remove the vacuum pipe from the carburetor and suck it to produce a vacuum to have the
Fuel flow out from the fuel pipe. The fuel will stop flowing out if the vacuun disappear.
If the fuel does not flow out by the above operation, please check the followings:
(a) Clean out blockage in the vacuum pipe.
(b)Blow air into the inlet pipe of the auto cock.

3.Note:
Please remember to use a bowl to catch the flow-out at the end of the fuel pipe.
Keep away from fire or even spark during operation.

Autocock fuel outlet pipe

Vacuum pipe

(10)Steering column, front wheel, frt disc brake comp, 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 injured.

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 Standard value Limit of use.(mm)
Lining of frt brake pad 4.0 2.0
Disk of frt brake 3.6 3.1
Swingness of frt/rr wheel - 2
The lining of frt/rr Brake 4.0 2.0

C. Change 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 front handle cover.

3.Remove the rear handle cover, the speedometer and plugs of switch.

4.Remove the terminal of rear brake and the switch plug of the rear brake lamp.

5.Loose the thrott le cable pulley’s cover.

6.Remove the throttle cable and RH grip assembly.

7.Remove the locking blot of the front brake’s master cylinder on the steering, handlebar,
Then remove front brake’s master cylinder.

8.Remvoe the bolts and nuts fixed the handlebar o n the front damper.

9.Romove the steering handlebar.

10.To assemble the handlebar, please follow the opposite dismantling procedures.
Locking torque:
M6:1.0-2kg-m
M10:3.0-4.0kg-m

11.Before assembling, please put the grease onto the cables.

F. Front wheel:

1.Remove the locking nut of front wheel on the right side.

2.Pull out he axle of front wheel Remove the spacer ring and take off the
gear sets of the speedometer.

3.Remove the front wheel assembly.

4.To assemble, please reverse the procedures of
dismantling.
Locking torque:M10:3.0~4.0kg-m

Note:1.Put the movement -stop block of the speedometer gear assy above extruded block
Of the front fork.

2.Please put the grease onto the gear sets of the speedometer before assembling.

5.Checking front axle
a. Check the bending degree of the front axle.
b. Limit of use:chang it when above 0.22mm

6.Check the front wheel bearing. Rotate the wheel. If any noise or slackness is found,
Please change a new one.

7.Front wheel rim checking.
(a)check the swingness of the front wheel rim.
(b)Limit of use:

§Horizontal direction: change a new one when
above 2.0mm.

§Vertical direction: chenge a new one when
above 2.0mm.

F. Front Brake

Locking torque:

1.Disassembling and assembling the front brake comp.
a. Remove the two bolts fixed on the frt brake comp from
the front fork.
b. To assemble the frt. brake comp, please reverse the
dismatling procedures.

M8:2.0~3.0kg-m

2.The releasing of air from the frt brake comp.
The procedures:
a. Fill in the appropriate brake fluid to the storage tank.
b. When assembling the master cylinder cover, do not let
the brake fluid overflow from the
master cylinder of storage tank.
c. Put the spanner upon the drain screw of the caliper.
d. Lock and unlock the screw repeatedly to drain off the bubble.
e. Operate slowly the brake lever several times.
g. Loose the drain screw, then release the lever fully opened.
h. Lock the drain screw when the lever is fully opened.
i. Repeat the above procedures until all air within the brake system is released completely.
Locking torque of leaking screw:0.6kg-m

4.Disassembling and assembling the front brake disk.

Limit of use:

a. Remove the front wheel.
b. Remove the three nuts on the disk.
c. Remove the disk.
d. To assemble the disk, please reverse the disassembling procedure.
Locking torque M8:2.0~3.0kg-m

5.Checking for the front brake-disk. Standard thickness:3.6mm

Replace a new one when below 3.1mm

6.Check the front brake lining.
a. Standard thickness:4.0mm.
Limit of use:Replace a new one when the thickness is below 2.0mm.

Note: No grease allowed on the lining.

G. Front fork

1.Front fork system diagram.

Spring fixing bolt

Tube fixing screw

2.checking front fork:
Please change a new one if it is distorted.

3.Checking front damper:
Check the guiding rod of damper if it is bended. Also check if there is abnormal worn out or
damage.

Change a new guiding rod if it is bended

(11)Rear wheel, rear brake, rear damper:

A. Troubleshooting.

1.Rear wheel swings.
a. Wheel rim is distorted.
b. Tire worn out.
c. The wheel axle is improperly assembled.

2.rear damper is too soft.
a. Spring fatigue.

3.Bad braking
a. The adjustment of brake is not proper.
b. The brake lining is dirty.
c. The brake lining worn out.
d. The cam of brake lining is worn out.
e. The brake cam lever worn out.
f. The wheel hub worn out or damage.
g. The operation on the brake arm tooth is not good.

B. Data

Item

The swingness of rear wheel

Wheel hub inner diameter

Thickness of brake lining

Standard value(mm) Limit of use(mm)

- 2.0

110 111.0

4.0 2.0