Genuine Scooter Company Buddy 170 Service Manual

PREFACE

This manual offers all service specialists with the technological procedures of

maintenance, repairing for Buddy170

detailedly show those whom may concern

how to maintain, repair, change parts,troubleshoot and reassemble, etc.

At every important section we illustrate by assembly, explosiondiagrams and
photographs, if necessary, please check the diagrams already shown.

Though we have tried our best, please kindly instruct us any faults found in this
manual.

MOTIVE POWER INDUSTRY CO., LTD.

CONTENTS

1. The specification 1

2. Service information 2

(1)The operation notice 3
(2)Looking torque value 4
(3)Lubrication instruction

(4)Periodical maintenance table 9
(5)Wiring diagram 11
(6)Troubleshooting 12

3. Checking and adjustment 25

(1)Checking table 26
(2)Battery 30
(3)Clean the air cleaner 31
(4)Oil screen 32
(5)The final reduction mechanism oil 32
(6)Spark plug 33
(7)Compression pressure measurement 33
(8)Valve clearance 34
(9)Ignition timing 34

(10)Front brake adjustment 35

(11)Rear brake adjustment 36
(12)Tire 36
(13)Throttle cables adjustment 37

4. Dismantling, maintaining, repairing and assembling operation 38

(1)Lubrication system 39
(2)Plastic parts of chassis 43
(3)Engine dismantling 48

(4)Drive pulley, starter, clutch,driven pulley 50
(5)Cylinder head and valve 59
(6)Cylinder and piston 64
(7)AC generator flywheel 69
(8)Final transmission mechanism 72
(9)Crankcase, crank shaft 76

(10)Steering stem, front wheel, front brake comp., front fork 82

(11)Rear wheel, rear brake, rear damper 91

5. Engine Management System(PGO 2nd-stage EMS) 96

(1)PGO 2nd-stage EMS structure 97

(2)EMS units 98

(3)EMS diagnostic 99

6. Electric equipment 122

(1)Troubleshooting 123

(2)Battery 124
(3)Recharge system 126
(4)Starting system 128
(5)Starting clutch 130
(6)Handle bar switch 132

1. Specification yChassis steel pipe

ySuspension

yName PA-170DAAE front: telescopic
yModel PA-170 rear: 4-bar linkage,
yDimension uni-absorber

Overall length: 1710mm yTransmission
Overall width: 645mm primary reduction :direct drive
Overall height: 1090mm second reduction:40/16*43/13
Overall base: 1210mm clutch type: centrifugal dry type

yWeight selector : V belt ,C.V.T.

Total net weight: 107kg yWheel
front: 40kg front: 100/90-10
rear: 67kg rear: 100/90-10

Carrying capacity: yTire
2 passengers:150kg
Total weight:257kg front 1.50 kg/cm2
Front: 81kg rear 1.75 kg/cm2

Rear: 176kg yBrake

y

Performance front: 190mm hydraulic

Fuel consumption: 40km/L disk brake

rear: drum brake

yGradient ability:26∘ ySpeedometer 90mile
yEngine yLamp

Model: C9 front: 12V-35W/35W*1
Fuel: unleaded or leaded

Cooling system: forced air cooling
by fan license plate: 12V-5W * 1
brake lamp: 12V-21W/5W * 1
Cylinder signal lamp : 12V-10W * 4
bore: 61.0mm yHorn AC 12V
stroke: 57.8mm ySilencer: diffusible absorption
number 1 closed type
Arrangement: horizontal
Displacement: 168.9cc Trail: 71mm
Compression ration 10.5:1 Front wheel travel: 55.5 mm
Ignition: ECU Rear wheel travel: 61 mm
Start: electric start
Lubrication: pressuring and spraying

1

2. Service information:

(1) The notice for operation3
(2) Locking torque value

a. For engine
b. For chassis
c. Others

(3) Lubrication instruction6

a. For engine
b. For chassis
c. Wheel bearing

(4) Periodical maintenance table

(5) Wiring diagram

(6) Troubleshooting

1. Engine not running or slowly running during start-up

2. Engine running but start-up failing during start-up

3. Trouble of hot start

4. Trouble of cold start

5. Trouble of start-up anytime despite RPM normal

6. Start-up normal but idle speed unstable anytime

7. Start-up normal but idle speed unstable during warm-up

8. Start-up normal but idle speed unstable with warm-up finished

9. Start-up normal but idle speed unstable or stall with load such as front lamp applied

10. Start-up normal but idle speed too high

11. RPM low or stall during acceleration

12. Acceleration slow

13. Acceleration powerless; performance bad

2

(1) The operation notice:

1. Always replace gasket, O ring, cotter, pins and clip whenever reassembled.

2. When tighten screws or nuts, lock tightly as per specified locking torque, and in the sequence of
cross direction.

3. Use PGO, or PGO Recommended parts.

4. After dismantling please wash all parts necessary for checking and grease all
contact surface when reassembling.

5. Use grease recommended by P.G.O.

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

6. Before installing a new fuse, confirm the specification is correct or not.

7.After reassembling, please re-check that all connecting point, locking parts,
circuits, polar characteristics are good, before selling out.

3

(2) Torque value:

a. Engine:

NO Locking location Q’TY

Thread dia.

(mm)

Locking torque (kg-m) Remark

1 Cylinder head bolt A (intake) 2 6 0.9~1.1
2 Cylinder head bolt B (Exhaust) 2 8 2.2
3 Cap, oil filter graze 1 30 1.5~2.0
4 Flange nut, cam shaft base 4 8 2.2
5 Fixing nut, air valve adjustment 2 5 0.7 Greasing on thread
6 Guiding pin bolt, inner chain adjustment 1 6 0.9~1.1
7 Oil bolt 1 8 1.7~2.0
8 Fixing nut, clutch outer 1 12 5.0~6.0

9 Nut, driven plate 1 12 5.0~6.0
10 Nut, driving plate 1 12 5.0~6.0
11 Spark plug 1 10 1.2~1.3
12 Nut, drive clutch 1 22 9.0~10.0 Left thread
13 Screw, inner chain adjuster 1 6 0.4~0.6

b. Chassis:

NO Locking location Q’TY

Thread dia.

(mm)

Locking torque (kg-m) Remark

1 Locking nut, steering stem 1 10 4.5

2 Front axle nut 1 12 4.5 ~ 5.5 U type nut

3 Rear axle nut 1 16 11~ 13 U type nut

4 Rear shock absorber bolt(upper) 1 10 4.0

5 Rear shock absorber bolt(lower) 1 8 2.4 ~ 3.0

6 Front brake caliper bolt 2 8 2.0 ~ 3.0

7 Chassis bolt, engine hanger bracket 2 10 3.5 ~ 4.5

8 Engine bolt, engine hanger bracket 1 10 3.0 ~ 4.0

9 Brake hose bolt 2 10 3.0 ~ 3.5
10 Air release valve 1 6 0.6
11 Front drum brake arm bolt 1 6 1.0
12 Rear drum brake arm bolt 1 6 1.0

4

c. Other parts please refer the following table:

Standard torque values:

NO Item Torque (kgf-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

5

(3)Lubrication instruction:

A.

Engine

NO Lubrication location Oil type Remarks

1 crankcase:rotating part,

sliding part

premium 4 stroke

Auto-separated

Lubrication

2 cylinder:rotating part,

sliding part.

motorcycle oil

or SAE15W40

Total: 1000 c.c.

Replacement 800c.c

3 drive gear box SAE85-140 Total 110 c.c.

Replacement 90c.c

4 gasket of starter shaft clean grease (#3)

5 start idle gear sliding

parts

clean grease (#3)

6

B. Chassis

Steel ball, steering item

Front brake fluid

Front brake cam

7

C. Wheel bearing

Final transmission mechanism

gear oil

Motor oil

Speedometer gear-clean grease

Front wheel bearing-clean grease

8

(4) PERIODICAL MAINTENANCE TABLE

MONTHS/DISTANCE(IN MILE)FOR CHECKING

Item

Model
4T

Checking Content

1 or

200 mile

3 or

1800

mile

6 or

3600

mile

9 or

5400

mile

12 or

7200

mile

15 or

9000

mile

18 or

10800

mile

Engine oil* 4T

Replace 800cc total 1000cc

R Replace it initially 200 mile,

and then replace it per 1800mile
Oil Filter Replace R replace it per 3600mile
Coarse oil filter*
(on oil draining
bolt)

4T

Clean or replace it if necessary C

clean it initially 200mile

and then replace it per 3600mile if necessary

Air cleaner 4T Crack and blockage check. I
Air filter 4T Clean or replace it if required I I I I I I

Gear oil* 4T 90cc, total 110 cc

R R I I R I I

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

I I I I

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*

4T Check looseness. Adjust it if

required

I I I

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

required

I I I I

N

uts, bolts,

fasteners

4T Tighten it if required I L I L I L

Battery 4T Recharge the battery it required.

Clear the poles.

I

I I I I I

Valve gap* 4T 0.08mm/ IN&EX

Adjust it

when

necessary

C I C I C

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

necessary.

R I R I R

Fuel feeding
system*

EXCEPT

EMS

Crack and blockage check.

Replace it if necessary.
Fuel feeding
system *

EMS

ONLY

(Injection)

Inspect hose, clamp

I R

I

Engine idle
speed*

4T 4T engine: 1700±100 rpm

A A

I I R

Carburetor idle
A/F
Adjustment*

4T

Check and adjust referring to

CO/HC Percentage.

A A A A A A A

EMS function
check*

EMS

ONLY

(Injection)

Inspect EMS function, and clear

the defect memory if necessary

I

A A A A A

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.

9

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 every two years.

4. Change the brake fluid hose every four years.

10

(5) Wiring diagram.

11

(6) Trouble shooting:

Procedure to maintain the Electronic Management System (EMS)

 Systematic procedure to diagnose any troubles for reparation

Items to be checked first prior to any diagnoses for engine troubles:

1. Make sure of the engine trouble indicator normally running;

2. Check with a trouble diagnosis meter to ensure no trouble information recorded;

3. Check any trouble phenomenon hinted by the vehicle owner and trouble-related conditions.
External check:

(1) Check any leakage from a fuel hose.
(2) Check any leakage from a vacuum pipe.
(3) Check any jam, leakage, flattening, or damage at an air inlet.
(4) Check the ignition system for break or aging of any high-voltage cable and ignition status.
(5) Check grounding of any wire harness clean and securely fixed.
(6) Check any sensor or actuator’s connector loosened or poorly contacted.

Note: Repair any trouble specified herein first which may affect the subsequent diagnoses or reparation.

 Diagnosis assist:

1. Make sure of no engine-related trouble records;

2. Make sure of any offered troubles;

3. Follow the said procedure to complete inspections and find no any unconformable situation;

4. Do not ignore any effect from maintenance, cylinder pressure, mechanical timing, or fuel on the
system;

5. Replace ECU for tests.

In the event of any trouble eliminated, ECU should be the source of trouble; if not, install the original
ECU and repeat the procedure to recheck.

 Trouble:

 Engine not running or slowly running during start-up
 Engine running but start-up failing during start-up
 Trouble of hot start
 Trouble of cold start
 Trouble of start-up anytime despite RPM normal
 Start-up normal but idle speed unstable anytime
 Start-up normal but idle speed unstable during warm-up
 Start-up normal but idle speed unstable with warm-up finished
 Start-up normal but idle speed unstable or stall with load such as front lamp applied
 Start-up normal but idle speed too high
 RPM low or stall during acceleration
 Acceleration slow
 Acceleration powerless; performance bad

12

1. Engine not running or slowly running during start-up

General trouble location: 1. Battery; 2. Start motor; 3. Main wiring or power switch; 4. Engine mechanism.
Procedure for general diagnoses:

No. Operating Procedure

Detection

Results

Subsequent Steps

Yes Next step

1

Check the voltage between two battery terminals with a
multi-meter to ensure the voltage between 11 and 12V
during start-up of the engine.

No Replace the battery.

Yes Next step

2

Keep the power switch “ON” and check the voltage at the
positive terminal on the start motor over 8V.

No

Fix or replace wiring
harness.

Yes

Fix or replace the start
motor.

3

Remove the start motor and check its status for open
circuits or jam attributed to lubrication insufficient.

No Next step

Yes

Change applicable
lubricant.

4

For any trouble in winter only, check lubricant in the engine
wrong for big resistance of the start motor.

No Next step

Yes

Correct resistance inside
the engine.

5

Check mechanical resistance inside the engine causing the
motor not running or slowly running.

No Repeat the said step.

2. Engine running but start-up failing during start-up

General trouble location: 1. Oil tank empty; 2. Fuel pump; 3. RPM sensor; 4. Ignition coils; 5. Engine
mechanism.
Procedure for general diagnoses:

No. Operating Procedure

Detection

Results

Subsequent Steps

Yes Next step

1

Connect a fuel pressure gauge before the fuel inlet of the
nozzle; press the power switch repeatedly if necessary or start
the engine to check the fuel pressure at 300kPa or so.

No

Repair the fuel supply
system.

Yes Next step

2

Connect the EMS diagnosis tester and check “Engine RPM”;
start the engine to check any

RPM signal output.

No

Correct circuits of the
RMP sensor.

Yes Next step

3

Disconnect the ignition cable and connect a spark tester; start
the engine and check any high-voltage flash (blue/white).

No

Repair the ignition
system.

Yes

Eliminate any
mechanical trouble of
the engine.

4

Check pressure of the engine cylinder and find any possibility
of pressure insufficient.

No Next step

Yes Diagnosis assist

5

Connect an EMS adapter and p ress the power switch to check
voltages at Pins 5#, 10#, and 23#; check grounding at Pins 2#
and 21#.

No

Repair the relevant
circuits.

13

3. Trouble of hot start

General trouble location: 1. Water in fuel; 2. Fuel pump; 3. Engine temperature sensor; 4. Ignition coils
Procedure for general diagnoses:

No. Operating Procedure

Detection

Results

Subsequent Steps

Yes Next step

1

Connect a fuel pressure gauge before the fuel inlet of the nozzle;
start the engine to check the fuel pressure at 300kPa or so.

No

Repair the fuel
supply system.

Yes Next step

2

Disconnect the ignition cable and connect a spark tester; start the
engine and check any high-voltage flash (blue/white).

No

Repair the
ignition system.

Yes

Correct circuits
or replace the
sensor.

No Next step

3

Press the engine temperature sensor connector and start the
engine; check if the engine successfully started. (Or

install a
series-connected resistor (300Ω) in lieu of the engine
temperature sensor at the engine temperature sensor

connector. Check if the engine is successfully started.)

No Next step

Yes Replace fuel.

4 Check fuel and observe any trouble attributed to fuel just added.

No Next step

Yes Diagnosis assist

5

Connect an EMS adapter and p ress the power switch to check
voltages at Pins 1#, 19#, and 29#; check grounding at Pins 8# ﹐
35#and 36#.

No

Repair the
relevant circuits.

14

4. Trouble of cold start

General trouble location: 1. Water in fuel; 2. Fuel pump; 3. Engine temperature sensor; 4. Nozzle; 5. Ignition
coils; 6. Air throttle and & idle air bypass; 7. Engine mechanism.
Procedure for general diagnoses:

No. Operating Procedure

Detection

Results

Subsequent Steps

Yes Next step

1

Connect a fuel pressure gauge before the fuel inlet of the
nozzle; start the engine to check the fuel pressure at 300kPa
or so.

No Repair the fuel system.

Yes Next step

2

Disconnect the ignition cable and connect a spark tester;
start the engine and check any high-voltage flash
(blue/white).

No Repair the ignition system.

Yes

Correct circuits or replace
any sensor.

3

Press the engine temperature sensor connector and start the
engine; check if the engine successfully started. (Or

install
a series-connected resistor (2500Ω) in lieu of the engine
temperature sensor at the engine temperature sensor

connector. Observe if the engine is successfully started.)

No Next step

Yes

Clean the air throttle and
the idle air bypass.

4

Slightly pull the throttle to check if the engine is easily
started.

No Next step

Yes

Replace the defective
nozzle.

5

Disassemble the nozzle and check any leakage or jam in
the nozzle with a nozzle cleaner & analyzer.

No Next step

Yes Change fuel.

6

Check fuel and observe any trouble attributed to fuel just
added.

No Next step

Yes

Eliminate any mechanical
trouble of the engine.

7

Check pressure of the engine cylinder and find any
possibility of pressure insufficient.

No Next step

Yes Diagnosis assist

8

Connect an EMS adapter and press the power switch to
check voltages at Pins 1#, 19#, and 29#; check grounding
at Pins 8# ﹐35#and 36#.

No Repair the relevant circuits.

15

5. Trouble of start-up anytime despite RPM normal
General trouble location: 1. Water in fuel; 2. Fuel pump; 3. Engine temperature sensor; 4. Nozzle; 5. Ignition
coils; 6. Air throttle and & idle air bypass; 7. Air intake; 8. Ignition timing; 9. Spark plug; 10. Engine
mechanism.
Procedure for general diagnoses:

No. Operating Procedure

Detection

Results

Subsequent Steps

Yes

Repair the air intake
system.

1 Check any jam of the air filter and leakage of the air intake.

No Next step

Yes Next step

2

Connect a fuel pressure gauge before the fuel inlet of the
nozzle; start the engine to check the fuel pressure at 300kPa or
so.

No

Repair the fuel supply
system.

Yes Next step

3

Disconnect the ignition cable and connect a spark tester; start
the engine and check any high-voltage flash (blue/white).

No

Repair the ignition
system.

Yes Next step

4

Check the spark plug in the cylinder and its model and gap
conformable to specifications.

No

Adjust or change the
spark plug.

Yes

Correct circuits or
replace the sensor.

5

Press the engine temperature sensor connector and start the
engine; check if the engine is successfully started.

No Next step

Yes

Clean the air throttle
and the air intake for
idle speed.

6 Slightly pull the throttle to check if the engine is easily started.

No Next step

Yes

Change the defective
nozzle.

7

Disassemble the nozzle and check any leakage or jam in the
nozzle with a nozzle cleaner & analyzer.

No Next step

Yes Change fuel.

8

Check fuel and observe any trouble attributed to fuel just
added.

No Next step

Yes

Eliminate any
mechanical trouble of
the engine.

9

Check pressure of the engine cylinder and find any possibility
of pressure insufficient.

No Next step

Yes Next step

10

Check if mechanical ignition timing of the engine is
conformable to specifications.

No

Correct ignition
timing.

Yes Diagnosis assist

11

Connect an EMS adapter and p ress the power switch to check
voltages at Pins 1#, 19#, and 29#; check grounding at Pins
8# ﹐35#and 36#.

No

Repair the relevant
circuits.

16

6. Start-up normal but idle speed unstable anytime

General trouble location: 1. Water in fuel; 2. Nozzle; 3. Spark plug; 4. Air throttle and idle air bypass; 5.Air
intake; 6. ISC; 7. Ignition timing; 8. Spark plug; 9. Engine mechanism.
Procedure for general diagnoses:

No. Operating Procedure

Detection

Results

Subsequent Steps

Yes

Repair the air intake
system.

1 Check any jam of the air filter and leakage of the air intake.

No Next step

Yes Change

2 Check the Idle governor for the control valve jammed.

No Next step

Yes Next step

3

Check the spark plug and its model and gap conformable to
specifications.

No Adjustment or change

Yes Cleaning

4

Check the air throttle and the idle air bypass for any carbon
deposition.

No Next step

Yes

Replace the defective
nozzle.

5

Disassemble the nozzle and check any leakage or jam in the
nozzle with a nozzle cleaner & analyzer.

No Next step

Yes Change fuel.

6 Check fuel and observe any trouble attributed to fuel just added.

No Next step

Yes

Eliminate any
mechanical trouble of the
engine.

7

Check pressure of the engine cylinder and find any big difference
in pressure.

No Next step

Yes Next step

8

Check if mechanical ignition timing of the engine is conformable
to specifications.

No Correct ignition timing.

Yes Diagnosis assist

9

Connect an EMS adapter and p ress the power switch to check
voltages at Pins 1#, 19#, and 29#; check grounding at Pins 8# ﹐
35#and 36#.

No

Repair the relevant
circuits.

17

7. Start-up normal but idle speed unstable during warm-up

General trouble location: 1. Water in fuel; 2. Engine temperature sensor; 3. Spark plug; 4. Air throttle and
idle air bypass; 5. Air intake; 6. Idle governor; 7. Engine mechanism.
Procedure for general diagnoses:

No. Operating Procedure

Detection

Results

Subsequent Steps

Yes

Repair the air intake
system.

1 Check any jam of the air filter and leakage of the air intake.

No Next step

Yes Next step

2

Check the spark plug and its model and gap conformable to
specifications.

No

Adjustment or
change

Yes Clean relevant parts.

3

Remove the Idle governor and check the air throttle, the isc,
and the idle air bypass for any carbon deposition.

No Next step

Yes

Correct circuits or
replace any sensor.

4

Press the engine temperature sensor connector and start the
engine to check any instability of the idle speed during
warm-up of the engine.

No Next step

Yes

Change the defective
nozzle.

5

Disassemble the nozzle and check the nozzle leaking or
blocked, or the flow out of tolerance with a nozzle cleaner &
analyzer.

No Next step

Yes Change fuel.

6

Check fuel and observe any trouble attributed to fuel just
added.

No Next step

Yes

Eliminate any
mechanical trouble of
the engine.

7

Check pressure of the engine cylinder and find any big
difference in pressure.

No Next step

Yes Diagnosis assist

8

Connect an EMS adapter and p ress the power switch to check
voltages at Pins 1#, 19#, and 29#; check grounding at Pins
8# ﹐35#and 36#.

No

Repair the relevant
circuits.

18

8. Start-up normal but idle speed unstable with warm-up finished

General trouble location: 1. Water in fuel; 2. Engine temperature sensor; 3. Spark plug; 4. Air throttle and
idle air bypass; 5. Air intake; 6. ISC; 7. Engine mechanism.
Procedure for general diagnoses:

No. Operating Procedure

Detection

Results

Subsequent Steps

Yes

Repair the air intake
system.

1 Check an y jam of the air filter and leakage of the air intake.

No Next step

Yes Next step

2

Check the spark plug and its model and gap conformable to
specifications.

No

Adjustment or
change

Yes Clean relevant parts.

3

Remove the ISC and check the air throttle, the ISCand the idle air
bypass for any carbon deposition.

No Next step

Yes

Correct circuits or
replace any sensor.

4

Press the engine temperature sensor connector and start the engine
to check any instability of the idle speed during warm-up of the
engine.

No Next step

Yes

Change the defective
nozzle.

5

Disassemble the nozzle and check the nozzle leaking or blocked, or
the flow out of tolerance with a nozzle cleaner & analyzer.

No Next step

Yes Change fuel.

6 Check fuel and observe any trouble attributed to fuel just added.

No Next step

Yes

Eliminate any
mechanical trouble
of the engine.

7

Check pressure of the engine cylinder and find any big difference
in pressure.

No Next step

Yes Diagnosis assist

8

Connect an EMS adapter and p ress the power switch to check
voltages at Pins 1#, 19#, and 29#; check grounding at Pins 8# ﹐
35#and 36#.

No

Repair the relevant
circuits.

19

9. Start-up normal but idle speed unstable or stall with load such as front lamp applied

General trouble location: 1. ISC 2. Nozzle.
Procedure for general diagnoses:

No. Operating Procedure

Detection

Results

Subsequent Steps

Yes Clean relevant parts.

1

Remove the ISC and check the air throttle, the ISCand the idle
air bypass for any carbon deposition.

No Next step

Yes Go to Step 4.

No Next step

2

Check if the engine’s output power is increased with the load
applied; use the EMS diagnosis tester to check any change in
the ignition advance angle, duration of fuel injection, and air
input.

No Repair the air

regulating system.

Yes

Change the defective
nozzle.

3

Disassemble the nozzle and check the nozzle leaking or
blocked, or the flow out of tolerance with a nozzle cleaner &
analyzer.

No Next step

Yes Diagnosis assist

4

Connect an EMS adapter and p ress the power switch to check
voltages at Pins 1#, 19#, and 29#; check grounding at Pins
8# ﹐35#and 36#.

No

Repair the relevant
circuits.

20

10. Start-up normal but idle speed too high

General trouble location: 1. Air throttle and idle air bypass; 2. Vacuum tube; 3, ISC ; 4. Engine temperature
sensor; 5. Ignition timing.
Procedure for general diagnoses:

No. Operating Procedure

Detection

Results

Subsequent Steps

Yes Adjustment

1 Check the throttle cable for jammed or too tight.

No Next step

Yes

Repair the air intake
system.

2

Check the air intake system and the connected vacuum tube
for any leakage.

No Next step

Yes Clean relevant parts.

3

Remove the ISC and check the air throttle, the ISCand the idle
air bypass for any carbon deposition.

No Next step

Yes

Correct circuits or
replace any sensor.

4

Press the engine temperature sensor connector and start the
engine; check if the engine’s the idle speed is too high.

No Next step

Yes Next step

5

Check if mechanical ignition timing of the engine is
conformable to specifications.

No

Correct ignition
timing.

Yes Diagnosis assist

6

Connect an EMS adapter and p ress the power switch to check
voltages at Pins 1#, 19#, and 29#; check grounding at Pins
8# ﹐35#and 36#.

No

Repair the relevant
circuits.

21

11. RPM low or stall during acceleration

General trouble location: 1. Water in fuel; 2. Inlet pressure sensor & air throttle sensor; 3, Spark plug; 4. Air
throttle & idle air bypass; 5. Air intake; 6.ISC ; 7. Nozzle; 8. Ignition timing;

9. Exhauster.
Procedure for general diagnoses:

No. Operating Procedure

Detection

Results

Subsequent Steps

Yes

Check the air intake
system.

1 Check the air filter for any jam.

No Next step

Yes Next step

2

Connect a fuel pressure gauge before the fuel inlet of the nozzle;
start the engine to check the fuel pressure at 300kPa or so during
the idle status.

No

Repair the fuel supply
system.

Yes Next step

3

Check the spark plug in the cylinder and its model and gap
conformable to specifications.

No

Adjustment or
replacement

Yes Clean relevant parts.

4

Remove the ISC and check the air throttle, the ISCand the idle
air bypass for any carbon deposition.

No Next step

Yes Next step

5 Check the inlet pressu re sensor, the air throttle and circuits.

No

Correct circuits or
replace any sensor.

Yes

Replace the defective
nozzle.

6

Disassemble the nozzle and check any leakage or jam in the
nozzle with a nozzle cleaner & analyzer.

No Next step

Yes Change fuel.

7 Check fuel and observe any trouble attributed to fuel just add ed.

No Next step

Yes Next step

8

Check if ignition timing of the engine is conformable to
specifications.

No Correct ignition timing.

Yes Next step

9 Check the exhauster for exhaust normally discharged.

No

Repair or replace the
exhauster.

Yes Diagnosis assist

10

Connect an EMS adapter and p ress the power switch to check
voltages at Pins 1#, 19#, and 29#; check grounding at Pins 8# ﹐
35#and 36#.

No

Repair the relevant
circuits.

22

12. Acceleration slow

General trouble location: 1. Water in fuel; 2. Inlet pressure sensor and air throttle sensor; 3. Spark plug; 4.
Air throttle and idle air bypass; 5. Air intake; 6. ISC ; 7. Nozzle; 8. Ignition timing; 9. Exhauster.
Procedure for general diagnoses:

No. Operating Procedure

Detection

Results

Subsequent

Steps

Yes

Check the air
intake system.

1 Check the air filter for any jam.

No Next step

Yes Next step

2

Connect a fuel pressure gauge before the fuel inlet of the
nozzle; start the engine to check the fuel pressure at 300kPa
or so during the idle status.

No

Repair the fuel
supply system.

Yes Next step

3

Check the spark plug in the cylinder and its model and gap
conformable to specifications.

No

Adjustment or
replacement

Yes

Clean relevant
parts.

4

Remove the ISC and check the air throttle, the ISCand the
idle air bypass for any carbon deposition.

No Next step

Yes Next step

5

Check the inlet pressure sensor, the air throttle sensor and
circuits.

No

Correct circuits or
replace any
sensor.

Yes

Replace the
defective nozzle.

6

Disassemble the nozzle and check any leakage or jam in the
nozzle with a nozzle cleaner & analyzer.

No Next step

Yes Change fuel.

7

Check fuel and observe any trouble attributed to fuel just
added.

No Next step

Yes Next step

8

Check if the engine’s ignition timing is conformable to
specifications.

No

Correct ignition
timing.

Yes Next step

9 Check the exhauster for exhaust normally discharged.

No

Repair or replace
the exhauster.

Yes Diagnosis assist

10

Connect an EMS adapter and press the power switch to
check voltages at Pins 1#, 19#, and 29#; check grounding
at Pins 8# ﹐35#and 36#.

No

Repair the
relevant circuits.

23

13. Acceleration powerless; performance bad

General trouble location: 1. Water in fuel; 2. Inlet pressure sensor and air throttle sensor; 3. Spark plug; 4.
Ignition coils; 5. Air th rottle and idle air bypass; 6. Air intake; 7. ISC ; 8. Nozzle; 9. Ignition timing; 10.
Exhauster.

Procedure for general diagnoses:

No. Operating Procedure

Detection

Results

Subsequent

Steps

Yes Reparation

1

Check any troubles such as clutch slip, low tire pressure, brake drag,
wrong tire size.

No Next step

Yes

Repair the air
intake system.

2 Check the air filter for any jam.

No Next step

Yes Next step

3

Connect a fuel pressure gauge before the fuel inlet of the nozzle; start the
engine to check the fuel pressure at 300kPa or so during the idle status.

No

Repair the fuel
supply system.

Yes Next step

4

Disconnect the ignition cable and connect a spark tester; start the engine
and check any high-voltage flash (blue/white).

No

Repair the ignition
system.

Yes Next step

5

Check the spark plug in the cylinder and its model and gap conformable
to specifications.

No

Adjustment or
replacement

Yes

Clean relevant
parts.

6

Remove the ISC and check the air throttle, the ISCand the idle air bypass
for any carbon deposition.

No Next step

Yes Next step

7 Check the inlet pressure sensor, the air throttle sensor and circuits.

No

Correct circuits or
replace any sensor.

Yes

Replace the
defective nozzle.

8

Disassemble the nozzle and check any leakage or jam in the nozzle with
a nozzle cleaner & analyzer.

No Next step

Yes Change fuel.

9 Check fuel and observe any trouble attributed to fuel just added.

No Next step

Yes Next step

10 Check if the engine’s ignition timing is conformable to specifications.

No

Correct ignition
timing.

Yes Next step

11 Check the exhauster for exhaust normally discharged.

No

Repair or replace
the exhauster.

Yes Diagnosis assist

12

Connect an EMS adapter and press the power switch to check voltages at
Pins 1#, 19#, and 29#; check grounding at Pins 8# ﹐35#and 36#.

No

Repair the
relevant circuits.

24

3.Checking and Adjustment:

(1)Periodical checking table

(2)Battery

(3)Clean air cleaner

(4)Oil screen

(5)The final reduction mechanism oil

(6)Spark plug

(7)Cylinder pressure

(8)Valve clearance

(9)Ignition timing

(10)Front brake adjustment

(11)Rear brake adjustment

(12)Tire

(13)Throttle cable adjustment

25

(1) Periodical checking table:

1.[○] mark indicates periodical checking

2.[＊] indicates changing the parts

Checking period

Check item

Gen­eral
che­cking

First

Month

Or

Initial

200mile

Home

Per6 per12

Months months

Or or

3000mile 6000mile

Office

Per1 per3 per12

Months months months

Or or or

600mile 1500mile 6000mile

Judgement

standard

Remark

Loose,swing

○

○ ○ ○ ○ ○

A Suspension
Steering
Handlebar

performance

○

○ ○ ○ ○ ○

Suspension: turning angle

○

○

a.cracked

○ ○ ○ ○ ○

b.shaft fixed
condition

○ ○ ○ ○ ○

From steering
column

Front fork

c.shaft:loose

○ ○

○

B: Brake

a.clearance

○

○ ○ ○ ○ ○

Clearance:

Front:10-20mm

Rear :10-20mm

Check
from
Steering
column

Brake lever

b.movement
ofbrake

○ ○ ○ ○ ○ ○ ○

Loose or damage

○ ○ ○ ○ ○ ○

brake

Brake cables
change

※per 2 years

Brake cam Worn out

○

a.

drum and plate

clearance between

○ ○ ○ ○ ○

b.brake shoe and br
ake plate worn out

○

○ ○

Brake drum

And brake

shoe

c.brake drum
worn and
damage

○

○

Standard dia:

Rear:130.0mm

Limit of use:

Rear:131mm

mark type

front axle:dam­age or cracked

○

rear axle:worn
or damage

○

Check rear

Axle

Wheel pressure

○ ○ ○ ○ ○ ○ ○

Unit:kg/c ㎡:

Front:1.5

Rear :1.75

Wheel cracked
Or damage

○

○ ○ ○ ○ ○

Wheel gap and
worn

○

○ ○ ○ ○ ○

Gaplimit:

Front

wheel:0.8mm

rea wheel:0.8mm

Wheel surface
Or other metals

○

○ ○ ○ ○ ○

Axle nut screw
Pin tightness

○ ○ ○ ○ ○

Front axle screw

torque

5.0~6.0kg-m

rear axle torque

11..0~13.0kg-m

Nut
location

wheel

Wheel rim swi­Ngness and da­Mage condition

○ ○ ○ ○ ○

Swingness ofr front

Rear wheel rim.

Vertical

swing:2mmbelow

Horizpmta;”:2mm

below

26

Checking period

Check item

Gen­eral
che­cking

First

Month

Or

Initial

200mile

Home

Per6 per12

Months months

Or or

3000mile 6000mile

Office

Per1 per3 per12

Months months months

Or or or

600mile 1500mile 6000mile

Judgement

standard

Remark

Wheel Front

Bearing of axle,
Looseness

○ ○ ○ ○ ○ ○

Rear

○

○

Rear damper spring
cracked

○

○ ○ ○ ○ ○

ass’ part loose
or damage

○ ○ ○ ○ ○

Connecting part
Loose

○

○

Bracket loose or
Damage

○

○

Suspen­sion

Connecting
Part loose

○

○

Oil leakage

○

○ ○

Cracked

○

○ ○

Damper

damper

assy's part,
Loose

○

○ ○

○ ○ ○ ○ ○

Clutch and
Change
Speed
mechanism

○ ○ ○ ○ ○

Power

Transmi-

ssion

Supply
grease

○ ○ ○ ○ ○

※per 2 year

Ignition

○ ○ ○ ○ ○

Clearance:

0.6~0.7mm

NGK:C7RHSA

OR SAME

SPEC

Start
mechanis
m

Starting
Motorpinion
Meshing

○

○ ○

wiring Recharge

Effect

○ ○ ○ ○ ○

Electroly­Te quantit

○ ○ ○ ○ ○

Level between

“UPPER” AND

“LOWER”

battery

Electroly­Te s. g r a­vity

○

○ ○

WHEN 20℃

SPECIFIC

GRAVITY:

1.270~1.290

Electric

Install-

Ment

wire
circuit

Wire conn­ecting
Loose or
cracked

○ ○ ○ ○ ○

27

Checking period

Check item

Gen­eral
che­cking

First

Month

Or

Initial

200mile

Home

Per6 per12

Months months

Or or

3000mile 6000mile

Office

Per1 per3 per12

Months months months

Or or or

600mile 1500mile 6000mile

Judgement

standard

Remark

Performance,
noise

○ ○ ○ ○ ○

Low speed,
Accleration

○ ○ ○ ○ ○

Idling:1700±
100rpm

Exhaustion

○

○ ○ ○ ○ ○

Check the clolr
Or usting exha

-air

Air cleaner

○ ○ ○ ○ ○

Cylinder, cyl­inder head inlet
Pipe, locking
Condition

○

Locking torque
Cylinder head:
(cold)

1.0~1.2kg/m
inlet pipe/c ;d) p

1.0-1.2kg/m

Engine
parts

Compression
pressure

○

○

Using stating
Motor.
11kg/c ㎡(650rpm)

Oil leakage

○ ○ ○ ○ ○

Oil quantity,
Dirty

○ ○ ○ ○ ○

Change every
1800mile

Oil quantity,

○ ○

Lubr­icat­Ion
Syst­em

Oil filter

○ ○

○ ○

Change every

3000mile

Fuel quantity

○

Fuel leakage

○ ○ ○ ○ ○

Fuel pipe
Changing

※per 4 years

Engine

fuel
syst­em

Fuel pump

○

○ ○ ○

28

Checking period

Check item

Gen­eral
che­cking

First

Month

Or

Initial

200mile

Home

Per6 per12

Months months

Or or

3000mile 6000mile

Office

Per1 per3 per12

Months months months

Or or or

600mile 1500mile 6000mile

Judgement

standard

Remark

Performance ○

○ ○ ○ ○ ○

Lamp system

Dirty, cracked

○ ○ ○ ○ ○ ○

Horn turn
Signal
Reflector

Performance ○ ○ ○ ○ ○ ○

Horn
Turn signal

lock

Performance

○ ○ ○ ○ ○

Rear view

mirror

Check the

illumination

○ ○ ○ ○ ○ ○

Blinker linc-

Nese plate nu-

Mber&mark

Dirty

cracked

○

Instrument

board

performance

○

○ ○ ○ ○ ○

Ass’y part

Loose

cracked

○ ○ ○ ○ ○

Muffler

silencer

performance

○

○ ○

chassis

loose or

cracked

○

○ ○

The earlier

Abnormal

condition

Confirm it does

Not happen

again

○

Chassis

Lubrication

○ ○ ○ ○ ○

others

Decoking mixer

,muffler,

silencer

○

○

29

(2) Battery: Recharge when run out of it

1.Remove the floor mat.

2.Screwing out the two screws on the battery cover; remove the battery cover.

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

4.Re-assembling the battery as the opposite procedure of disassembling after recharging.

Note:

A. Do not take out the sealed bolt when recharging.

B. Without refilling water for the battery.

Please recharging (12V) as the following current.

Time standard: 0.7A*5~10Hr or Rapid: 3A*1Hr

30

(3) Clean air cleaner

1.Remove air cleaner cover.

2.Take out the air cleaner filter.

3.Clean the filter by compressed air.

4.Assemble the air cleaner by the opposite procedure.

MOTOR OIL

Attn: Do not start engine when air cleaner is not installed.

Oil volume

N

ote:

A. The vehicle must park on the flat ground

Before checking.
B.Start engine for 2~3 min., and stop engine
For 2~3 min., then check the oil volume.

1.Take out the oil meter to check the oil

Vo l u m e .

2.Refill oil to upper limit when oil volume

Is below the lower limit.

Exchange Oil

1.Turn off the engine and remove the oil meter. Oil meter

2.Screw out the oil draining bolt on the bottom

Torque:1.5kg-m

Lower limit

Upper limit

N

ote: The oil will flow out easier when the

engine is warm.

Engine oil volume : Disassembling : 1.0 liter
Exchanging : 0.80~0.85liter

When checking the leakage of oil, start the engine

At idling for a few minutes, then check the oil volume.

31

(4)

Oil screen

Cleaning for the oil screen

z Drain the Oil in the engine, remove the

Oil draining bolt the spring and the

Screen.

z If any adherent material is found,

please use detergent to clean the screen.

z Check the 0-ring. If it is damaged, change

a new one.

z Re-install the screen, the spring, 0 ring

and the Oil draining bolt.

Locking torgue:1.5kg-m

O-ring

Oil
Draining
Bolt

2.Second oil filter

z Replace it per 5,000km
z Torque: 8 ±0.2 N-M

Oil filter

Oil
Screen

spring

(5) The final reducing 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 filling bolt

to drain the gear oil off.

d. Lock the draining bolt before refill 1

gear o

10c.c.

il and then lock the filling bolt.

Draining bolt

Filling Bolt

e. Locking torque: 1.8kg.m

32

(6)Spark plug

1.Remove spark plug.

2.Check the spark plug electrode and see whether it is burnt out/ carbonized or not.

3.Clean the electrode, if it is dirty.

zSpark plug specification

NGK: CR6HSA

Gap of spark plug:0.6~0.7mm spark plug

Electrode burnt out

Carbon piled up or not

Washer is distorted or not

Porcelain is cracked or not

(7) Cylinder Pressure

1.Measure it when the engine is warm.

2.Remove the cover at the right hand of the

step floor.

3.Remove the spark plug then place cylinder

pressure gauge. Then fully open the throttle and act

on the starter motor to measure the compression

pressure.

Compression pressure: 11kg/cm

2

at 650 rpm

*When the compression pressure is too low, check the

following:

a. Valve leakage or not

b. Valve clearance

c. Gasket of the cylinder head is damaged.

d. Piston ring worn-out

e. Piston or cylinder worn-out

*The cylinder compression pressure is usually too high when there is too much carbonization in

the combustion chamber and the piston tip.

33

(8)Valve Clearance

Note: Checking and adjustment of valve clearance

only can be done under 35

o

C of engine

temperature.

1.Remove cylinder head cover.

2.Remove intake pipe from the cover of cylinder head.

3.Screw out the cap nut.

4.Remove cylinder head.

5.Rotate cooling fan, the mark on cam shaft gear must reach

The upper dead position, the “T” mark on generator fly must align with the crankcase mark.

Note: There is depressure reverse rotation device on cam

shaft. So never rotate cam shaft reversal when
ad

j

usting, otherwise valve can not be adjusted.

zValve clearance:IN-0.08mm

Ex-0.08mm

zLoosen locking nut, then rotate adjusting nut to adjust the

valve clearance.

N

ote: Re-check valve clearance after lock the nut.

(9) Ignition Timing

N

ote: It is no need to adjust ignition timing and CDI set.

When ignition timing is not correct, just check the

ignition system.

1.Remove the checking hole cover of ignition timing.

2.Using the ignition timing light to assure the ignition timing is

correct.

3.Under idling, it means in good function when crankcase’s

mark matches to the “F” on the flywheel.

4.Raise the engine revolution to 5000 rpm slowly, it means in

good function, if the crankcase's mark matches with Entering

point of the flywheel.

34

(10) Front Brake Adjustment

1.Check the clearance of front brake lever

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.

N

ote: Try brake lever to see if it’s loose. Check the

brake oil.once air mixed in the oil pipe, which
will reduce or damage the brake efficiency or
even its function.

3.Check the oil level:

a. Refill the brake oil when the level is under the LOWER line.

b. Oil specification: DOT3

Note:

a. To prevent the oil 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 oil that is not complied with spec.

d. In case the oil stains on the eyes, wash with water at once and then ask for medical care

immediately.

35

(11) Rear Brake Adjustment

1.Check the clearance of rear brake lever.

Clearance: 10~20mm

2.If the clearance is beyond the above

Standard, adjust it by rotation the screw.

a. Left-handed rotation-Enlarge the clearance.

b. Right-handed rotation-Reduce the clearance.

N

ote: When the arrow of rear brake indicator align with the arrow of left crankcase, change

the brake lining.

(12) Tire:

1.Check Tire air pressure.

2.Tire pressure:

Front tire: 1.50kg/cm

2

Rear tire: 1.75kg/cm

2

3.Tire specification:

Front tire: 100/90-10

Rear tire: 100/90-10

Note:

1.Check and adjust the tire pressure when it is too low.

The pressure is according to the carrier, driver, passenger, accessories and cruise speed

2.Proper loading is very important for steering, riding, braking, performance and safety. Never

carry any parcel unfastened.

Load the heaviest parcel on the center of vehicle, balancing the weight on both sides.

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

36

3.Check if there is any sharp object piece the tire.

4.Check the depth of wheel stripe.

zDepth (front and rear): According to the mark of

tire”▲” indicating the necessity to change a new

tire.

(13) Throttle cables Adjustment

1.Check the clearance of throttle

2.Normal clearance: 1.5~3.5mm

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

37

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 and valve
(6) Cylinder and piston
(7) AC generator
(8) Final transmission mechanism
(9) Crankcase, crank shaft
(10) Carburetor
(11) Steering stem, front wheel, frt brake comp., frt fork
(12) Rear wheel, rear brake, rear damper
(13) Fuel tank

38

(1) Lubrication System

Lubrication System Diagram (PA150)

39

Oil Pump

Dismantling

1.Remove the 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.

40

8.Remove oil pump separate plate by
taking 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.

Assembly

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

2.Install the oil pump shaft.

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 carnkcase.

8.Tighten the oil pump after installation.

N

ote:
The notch of the oil pump shaft should comply
With the notch of the inner

g

ear.

N

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

41

Measurement data

item

Standard Value

( mm )

Limit of use

( mm )
Clearance between the inner gear
And outer gear

_ 0.12

Clearance between the outer gear
And oil pump body

0.045-0.10 0.12

Oil

pump

Clearance between gear end and
Oil pump body

0.045-0.10 0.12

Troubleshooting

Reduction in fuel oil volume Engine burning-out
a.Natural consumption a.Zero or too low oil pressure
b Leakage of fuel b.Blockage in oil route
c.Piston loop seizes, or improperly install- c.Did not use the fuel oil recommended
ation
d.Worn out of valve’s oil seal

42

(2)Plastic parts of Chassis

A.Dismantling the plastic parts

1.Removal of luggage compartment

z Open the seat, take off the screws of the luggage compartment.

2.Removal of fuel tank

z Open the lock cover of the fuel tank.

zTake off the fuel tank cover.

zTake off both the right and left
handles by removing the screws off.

43

3.Removal of left and right hand
Side covers.

zTake off the screws of left and right

side covers.

zRemove the left and right hand side

cover.

4.

Removal of front mudguard

zRemove the screws of front fender.
zTake off the front mudguard.

44

B.Dismantling the Fender

1.Take off the screws of front inner cover
And fender.

2.Take off the screws between the front
Fender and chassis.

3.Separate the head light and signal lamp
Cable.

4.Take off the fender.

45

C.Dismantling the upper handle
cover.

1.Remove the left and right
Back mirror.

2.Remove the screws of upper
And lower handle cover.

3.Unplug the speedometer cable.

4.Unplug each switch cables.

5.Remove the upper handle cover.

46

D.Dismantling the step plates and lower
D.Dismantling the step plates and lower
Mudguard:

1.Take off the screws of the four
step plates and take off the four
step plates.

2.Screwing out the screws of lower
mudguard.

E.Dismantling the step floor and front
inner cover:

1.screwing out the screws of battery
cover.

2.Disconnect the negative, then
positive cable.

3.Screwing out the screws between the
step floor and front inner cover
Take off the front inner cover.

4.Pull out both the negative and
Positive battery cables, Take off
The step floor.

5.When assembling, the procedures
Will be reversed.
M6:0.7-1.1kgf-m
M5:0.35-0.5kgf-m

N

ote:Avoid clamping and scraping the

Cables or pipes by the plastic parts.

47

(3)Engine dismantling:

A.Dismantling engine
B.lnstalling engine

48

A.Dismantling engine

1.Take off the luggage compartment.

2.Take off the left and right body
covers.

3.Take off the lower mudguard fender.

4.Remove vacuum pipe, fuel pipe ,auto
choke, cap of spark plug, rear
brake cable carburetor pipe, engine
suspension nut, starter motor cable,
flywheel plate and rear damper bolt.

5.Remove the engine.

B.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 adjustment
d.fuel and oil route

49

(4)Drive pulley, starter clutch. driven pulley

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

50

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.

B2..Measurement data for buddy170

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

The inner dia. Of slide driving
plate

24.011~24.052

24.10

The outer dia. Of boss, movable
Driving plate

23.96.~23.974 23.94

Belt width

20.0~21.0

19.0

Clutch lining thickness

3

1.5

Clutch lining thickness 125.0~125.2

125.5

Driven plate spring, free length 151

127

The outer diameter of driven
Plate sets

33.965~34.025 33.95

The inner diameter of slide
Driven plate

34.000~34.025 34.06

The outer diameter of weight
Roller set

17.920~18.080 17.40

51

(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.

52

4.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 : 3800 ± 300 rpm

5.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 : 5100 ± 400 rpm

53

5.To assemble the driving pulley, reverse the whole procdeure.

Locking torque:

1.Nut of driving pulley M10:4.0-5.5kg/m.

2.Locking nut of clutch M10:4.0-5.5kg/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:
change it below using limit

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.

change it below when below using limit

54

(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.

55

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 positioner.

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.

N

ote:
cMake 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.
dPut some grease in every shaft and gear sets
before assembly.

56

E. Clutch driven pulley

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:
M10:4.0~5.5kg.

m

3.Checking clutch:
dismantling tool

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

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

57

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.
zlimit of use: change it above 33.95mm.

e.Check wearing condition of slide driven plate.
And measure its Inner diameter.
zlimit 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.

58

(5)Cylinder head and valve

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

59

A.Troubleshooting.

If the cylinder head is malfunctioned, usually it can tell from the measurement of the

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

1.Unsmooth idle speed

-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

IN/EX

Standard Value

(mm)

Limit of use

(mm)

IN 0.08

－

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

EX 0.08

－

Compression pressure(throttle open full)

8.2kw/7000rpm

IN 26.625(150CC) 26.23(150CC)

Height of the cam’s convex part

EX 26.53(150CC) 26.13(150CC)

IN 10.00~10.015 10.10

Inner diameter of rocker arm shaft

EX 10.00~10.015 10.10

IN 9.972~9.987 9.91

Outer diameter of rocker arm shaft

EX 9.972~9.987 9.91

Valve base angle

IN&EX 1.0 1.8

IN 4.975~4.900 4.90

Outer diameter of valve stem

EX 4.955~4.970 4.90

IN 5.000~5.012 5.30

Inner diameter of valve guide

EX 5.000~5.012 5.30

IN 0.010~0.037 0.08

Clearance between valve stem and
Valve guide

EX 0.030~0.057 0.10

60

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.

61

Check cam shaft
Check the convex surface and the height and see whether it has
Been damaged.

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

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

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.

NOTICE

:
Do check if there is any damage on the cam rocker arm
Sliding surface.

2.Cam shaft holder and cam rocker arm outer dia
measurement:

3.Cam rocker arm inner dia measurement:

Limit of use : replace it above 10.10mm.

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

Limit of use : replace it above 10.10mm.

Limit of use : replace it below 9.91mm.

5.Clearance between the Cam rocker arm and rocker arm shaft.
Limit of use : replace it above 0.10mm.

WHEN INSTALLING:

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

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

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

NOTICE

:
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.

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

NOTIC

E:
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.

62

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

N

otice:

Not to injure the contact

Surface of the cylinder.

Avoid any object dropping info the engine.

Further dismantling

Use the valve contracting tool to remove valve pin,

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

N

otice:

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

63

(6)Cylinder and piston

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

C.Data ()

Part name /description

Standard value

( mm )

Limit of use

( mm )

Bore

61.000~61.010 61.10

Curve

- 0.05

Cylindrility

- 0.05

Cylinder

Roundness

- 0.05

lst ring 0.02~0.06 0.10

Clearance b/w Piston and
Piston ring

2nd ring 0.01~0.05 0.10
lst ring 0.15~0.35 0.50
2nd ring 0.15~0.35 0.50

Clearance of cutting

section

side ring 0.2~0.7 0.9

Piston outer diameter

60.980~60.960 60.90

Measuring location of piston outer dia.

Down to7.5mm from the
piston skirt

---

Clearance b/w piston and cylinder

0.025~0.035 0.10

Piston/

Piston ring

Piston pin hole inner dia

15.000~15.006 15.045

Piston pin outer diameter

15.000~14.994 14.960

Clearance between piston and piston pin

0.020~0.017 0.025

Connecting rod small end inner dia

15.010~15.028 15.060

64

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.

2.The contact surface of gasket must be clean.

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.

65

D.Dismantling

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

Dot’ drop the clip into the crankcase.

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

Don’t make piston ring worn out or damage

d

piston ring.

c.

PISTON OUTER DIA MEASUREMENT:

1.Measuring location:
Perpendicular to the piston pin hole, down to
5mm(BUDDY170) form the piston skirt.

2.The clearance between the piston and piston pin:

Limit of use : change it when less than 61.0mm.

Limit of use : change it when above 0.005m.

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.

4.The maximum clearance between the cylinder and

piston pin.

Limit of use : Change it when above 0.1mm.

Limit of use : Change it when above 61.10mm.

66

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.

d.Checking the flatness of cylinder contact

Limit of use : Roundness:change it when above

0.05mm.
Cylindrility:change it when above

0.05mm.

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 15.060mm.( 170ENGINE)

67

E.Installing Cylinder and piston

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.

3.Assembly the piston, piston pin and piston pin

N

OTICE:

Do not drop other objects into the crankcase.

clip.

N

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

g

the crankcase with rags.

b.Installing piston

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

2.Lubricate the Cylinder inner surface, piston and piston rings by Motor Oil.

3.Install the piston ring into the cylinder carefully.

N

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

68

(7)A.C. Generator

A.Dismantling AC generator
B.Installing AC generator

69

Dismantling AC generator

1.Rimove fan cowl.

2.Remove the M6 screws

3.Remove screws of flywheel magneto.

4.Remove the AC flywheel magneto by special tool.

5.Remove the flywheel.

6.Remove the electric plug of AC flywheel magneto.

70

B.Installing AC generator

To install, please reverse the dismantling procedure.

Locking torque:
M6: 1.0~1.2kg/m
M10: 3.2~4.0kg/m

71

(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

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

1.Gear worn-out or cracked.

2.Gear burnt out.

zNoise occur when running.

1.Gear worn out, burnt or gear surface.

2.Bearing worn out of loosen.

zOil leakage

1.Too much oil

2.Seal worn out or damaged.

72

3.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.

73

4.Remove the final reduction gear
And 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: 16 T (buddy170)

74

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

Gear teeth number

40/13T (buddy170)

3.Check the wearing condition of the final
reduction gear.
43T

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 110cc of gear oil SAE90.

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

75

(9)Crankcase, Crankshaft:

A. Disassembling diagram.
B. Troubleshooting.
C. Data
D. Remove crankcase and crankshaft.
E. Check crankshaft.
F. Assemble the crankcase.

76

A. Disassembling diagram

Torque: 1.0~1.2kg-m

B. T r oubleshooting

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.

77

C.Data

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

Clearance of connecting rod big end

axle direction

0.15~0.35 0.55

Clearance of connecting rod big end

vertical direction.

0.006~0.014 0.05

Swingness of the crank shaft journal. 0~0.015 0.05

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.

78

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 0.05mm.

2.Measure the swing ness of the crankshaft
journal.

Limit of use

A B

Change it when above

0..05mm

Change it when above

0.05mm

B

A

3.Check the looseness of crankshaft bearing.

If it is loosen, replace to a new one.

F.Assemble crankcase:

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.

79

(A)Troubleshooting

zDifficult 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

zMixed 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

80

zToo much fuel in the engine

1.Air cleaner blocked

2.Mixed air is too dilute in the idle system

zSparking unsteady while increasing speed

1.Ignition system malfunction.

2.Air mixture is too dilute

zDifficult 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 auto chock system blocked

9.Bad adjustment of fuel level

zMixture 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

81

(10)Steering stem, front wheel, frt brake comp and front fork.

A. Troubleshooting
B. Data
C. Steering handlebar
E. Front wheel
F. Front brake
G. Front fork

82

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 is not even.
b.Front fork is crooked.
c.The axle of front fork is crooked, wheel is aslant.

3.front wheel swings.

a.wheel rim is distorted.
b.bearing of front axle too free.
c.wheel rib is distorted.

a. Wheel is not good.
b.Front wheel axle locked improperly.

4.front damper is too soft, spring fatigue.

5.noise in front damper.

a.noise comes from damper box.
b.locking screw of damper is slackness.

B.Data

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

Lining of frt brake 4.0 2.0

Disk of frt brake 3.6 3.1

Swingness of frt/rr wheel - 2.0

83

C.Changing the speedometer cable

1.Remove the fixed screws of the front cover.

2.Remove the nut of speedometer cable.

3.Remove the front handle cover.

`

4.Remove the fixed screws of

speedometer cable on the
right of front wheel.

5.Draw out the damage

speedometer cable.

6.Assemble the new cable

follows the opposite
procedure of dismantling.

NOTE:Put the grease onto the

Inner cable before
Assembling.

84

(B)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.

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

Locking T orque:
M6 :1.0-1.2kg-m
M10 :3.0-4.0kg-m

85

(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 0.2mm.

86

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:
zHorizontal direction:
Change a new one when above 2.0mm.
zVertical direction:
Change a new one when above2.0mm.

87

(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.

a. Lock and unlock the screw several times to

Release the bubbles.

b. Operate slowly the brake lever several

times.
c. Clamp the brake lever to the end.
d. Loose the drain screw, then open the lever completely.
e. Locking the drain screw and then loose it when the lever is opened completely.
f. Repeat above procedure until all the air in the brake system has been released

Completely.

Locking torque of leaking screw: 0.6 kg-m

88

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.

Front fork oil type: SAE 10W20
Capacity (each side): 80 CC

N

OTE:

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

89

5.Disassembling and assembling the front brake-disk.
a.Remove the front wheel.
b.Remove three nuts on the disk.
c.Remove the disk.
d.Assemble the disk follows the disassembling procedure.

Locking torque M8: 2.0~3.0kgm

6.Checking the front brake-disk.
Standard thickness of disk: 3.6mm
Limit of usage: change it when below 3.1mm

7.Checking the front brake-lining.
a.standard thickness: 4.0mm.
limit of use:As the thickness is below 2.0mm, change it.

N

ote:No grease on the lining.

90

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

A.Troubleshooting.
B.Data.
C.Dismantling the rear wheel.
D.Checking the rear wheel.
E.Rear brake.
F.Rear damper.

91

A.Troubleshooting.

1.Rear wheel swings.

a.wheel rim is distorted.
b.wheel is abnormal.
c.improperly assemble the wheel axle.

2.Rear damper is too soft

a.rear damper spring fatigue.

3.Bad braking
a.the adjustment of brake is not good.
b.the brake lining is dirty.
c.the brake lining is worn out.

d.the cam of brake lining is worn out

e.the brake cam lever is worn out.

f.the brake hub is worn out.

g.the assembling of brake lever gear trough is not good.

B.Data

Item Standard value(mm) Limit of use(mm)
The swings of rear wheel - 2.0
Brake hub inner diameter 130 131.0
Thickness of brake lining 4.0 2.0

92

C.Dismantling and assembling

The rear wheel.

1.Remove the fixed screws and
bolts of the exhaust pipe.

2.Remove the fixed screws of
the rear wheel drum.

3.Remove the bolts.

4.Remove the rear wheel.

5.To assemble the rear wheel,
please reverse the
dismantling procedures.

Locking torque: M6: 0.7-1.1kg.m
M14: 8.0-10.0kg.m

D.Checking the rear wheel.

zcheck the swings of rear wheel.
zradial direction:

change it as it is above 2.0mm

zhorizontal direction:

change it as it is above 2.0mm.

93

E.Rear brake:

1.Rear brake disassembling diagram.
(1)Checking rear brake hub:
a.measure the inner diameter of rear brake
hub.
b.limit of use:change it as the diameter is
above 131.0mm

(2)Checking brake lining:

a.measure the thickness of rear brake lining.
b.Limit of use:As the thickness is less than

2mm, change it.

94

F.Rear damper

1. Rear damper

disassembling diagram

95

5. Engine Management System(PGO 2nd-stage EMS)

(1)PGO 2nd-stage EMS structure
(2)EMS units
(3)EMS diagnostic

96