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VMOTO
Owner's Manual
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Monaco VMOTO Owner's Manual

VMOTO MONACO
OWNER
HANDBOOK
1 VMOTO MONACO V1 ............................................................................................. 4
2 GENERAL INFORMATION..................................................................................... 5
2.2 Specifications...................................................................................................... 6
2.3 Inspection Tips.................................................................................................... 7
2.4 Safety Precautions............................................................................................... 7
2.5 Torque Settings ................................................................................................... 8
2.6 Lubrication Points............................................................................................. 10
2.7 Trouble Shooting .............................................................................................. 12
2.7.1 Engine Fails to Start:................................................................................. 12
2.7.2 Poor spark ................................................................................................. 12
2.7.3 Poor idle .................................................................................................... 13
2.7.4 Poor acceleration and loss of power ......................................................... 13
3 INSPECTION AND ADJUSTMENT ...................................................................... 14
3.1 Regular Maintenance Schedule......................................................................... 14
3.2 Checking and Changing Engine Oil ................................................................. 14
3.3 Final Drive Gear Oil ......................................................................................... 16
3.4 Brake System .................................................................................................... 17
3.4.1 Front Brake Lever Free Play..................................................................... 17
3.4.2 Brake Fluid................................................................................................ 17
3.4.3 Refill Brake Fluid ..................................................................................... 17
3.4.4 Bleed Brake Line ...................................................................................... 18
3.4.5 Front Brake Disk....................................................................................... 18
3.4.6 Rear Brake Adjustment............................................................................. 18
3.4.7 Inspection of Brake Lining and Wheel ..................................................... 19
3.5 Tyre and Tyre Pressure ..................................................................................... 20
3.6 Air Filter............................................................................................................ 21
3.7 Battery............................................................................................................... 22
3.8 Spark Plug......................................................................................................... 22
3.9 Fuel Filter.......................................................................................................... 23
3.10 Carburettor Idle Speed ...................................................................................... 23
3.11 Throttle Valve ................................................................................................... 24
3.11.1 Throttle Lever Play Adjustment................................................................ 24
3.11.2 Carburettor Throttle Cable Play................................................................ 25
3.12 V Belt ................................................................................................................ 25
3.13 Lubrication........................................................................................................ 27
3.13.1 Engine oil level ......................................................................................... 27
3.13.2 Oil renewal................................................................................................ 27
4 CHASSIS .................................................................................................................. 29
4.1 Removal of Cover ............................................................................................. 29
5 TROUBLESHOOTING CHASSIS PROBLEMS .................................................... 30
5.1 Steering/ Suspension/ Front Wheels/ Front Brakes .......................................... 30
5.1.1 Troubleshooting ........................................................................................ 31
5.2 Front Wheel ...................................................................................................... 32
5.2.1 Inspection of Wheel Rim .......................................................................... 33
5.3 Rear Wheel........................................................................................................ 34
5.3.1 Brake lining assembly (brake shoe, brake shoe spring)............................ 35
5.4 Rear Shock Absorber ........................................................................................ 35
6 ELECTRICAL SYSTEM ......................................................................................... 36
6.1 Maintenance & troubleshooting........................................................................ 36
6.1.1 Starter System ........................................................................................... 38
6.2 Battery............................................................................................................... 38
6.2.1 Charging the battery.................................................................................. 39
6.2.2 Rectifier..................................................................................................... 39
6.2.3 Starter Relay.............................................................................................. 40
6.2.4 Operation of starter relay. ......................................................................... 40
1 VMOTO MONACO V1
This Owner Handbook was compiled by Gledhill & Associates and remains the property of Gledhill & Associates. This document may not be copied or distributed without the expressed permission of Gledhill & Associates. While all care has been taken in the compilation of this document, variation in manufacturer’s specification and production values may lead to some differences from your model of the scooter. Therefore care should be taken when undertaking maintenance or adjustments to check for compliance between the details in this manual and your scooter.
2 GENERAL INFORMATION
2.1 Description
2.2 Specifications
Total Length 1920 mm Total Width 705 mm Total Height 1165 mm Wheel Base 1265 mm Ground Clearance 120 mm Weight (dry) 100 Kg Engine Style Single cylinder, 4 stroke, air cooled. Engine Type 153QMI-3 Bore & Stroke 52.4 mm x 57.8 mm Intake Valve Gap (mm) 0.08 – 0.10 Exhaust Valve Gap (mm) 0.08 – 0.10 Lubrication Pump and splash Fuel Type 92/95 unleaded Fuel Capacity 6.8 litre Displacement 124.6 cc Nominal Engine Capacity 125 cc Maximum Power 6,2 KW @ 8000 rpm Standard Power 5.5 KW @ 7500 rpm Idle Speed 1800 +/- 100 Ignition Type CDI Starting Method Electric starter or kickstart Clutch Dry Shoe, Acentric Drive V-belt CVT Front Brake Hydraulic disc Rear Brake Cable drum Front Tyre Specification 120/70 – 12/4PR 25 psi Rear Tyre Specification 130/70 – 12/4PR 30 psi Max Load Weight 150 Kg Fuel Consumption (economy running) 2.8 litre/100 Km Max Speed 83 Km/Hr Engine Oil Type SAE 20W-40 Engine Oil Quantity 900 cc Gear Oil Type SAE 90# Gear Oil Quantity 120 cc Air Cleaner Type Paper filter Carburettor Type CVK Throttle Valve Diameter 24 mm Venturi Diameter 22.1 mm Throttle Valve Type Butterfly Ignition Type CDI Spark Advance BTDC 13deg/2950 rpm Spark Plug NGK CR7HSA Spark Plug Gap 0.6 - 0.7 mm
Battery 12V 7AH Head Lamp (H/L) 12V 35W/35W x1 Rear Lamp 12V 5W x1 Brake Lamp 12V 21W x1 Turn Lamp 12V 10W x4 Suspension Front Telescopic Suspension Rear Rocker Arm Frame Steel Tube
2.3 Inspection Tips
1. Bolts and bolt heads use the International Standard (Metric) measurement system. Use of tools other than those complying with the Metric system may cause damage to the parts.
2. Clean parts of any outside dirt or deposits before maintenance to prevent the chance of contaminants dropping into the engine and causing damage.
3. Use kerosene to clean-up disassembled parts. Check and measure parts after clean-up. Apply engine oil for lubrication to any contact and sliding surfaces of parts.
4. The packing, metal gasket, O-ring, seal, clamp, and clipper should be replaced with new ones after disassembly.
5. Pay attention to the orientation and relative positions of the major components. Arrange the parts in order during disassembly. Make marks if necessary to avoid mistakes in re-assembly.
6. Removing parts should start from small to big, from outside to inside. Assembly is in reverse order of disassembly.
7. The oil seals should be replaced with new ones after disassembly. The contact surface should be cleaned-up. Check shafts for scratches or burrs. Use special tools for assembly to avoid damaging the seal lip area. The manufacturer logo should face outward on seals and bearings. Apply grease at seal lip area.
8. Disconnect the battery negative (-) terminal before maintenance. Connect the positive (+) terminal first in assembly. Apply a thin layer of grease on terminals, and cover with terminal caps.
2.4 Safety Precautions
Warning: Engine Exhaust
Keep the area well ventilated during engine operation. Do not operate engine in an enclosed area. Carbon monoxide (CO) in exhaust fumes may lead to loss of consciousness and even death.
Warning: Petrol
Petrol is highly flammable. Avoid any naked flame during inspection of the petrol tank or of a petrol leak.
Warning: Battery Gasses and Battery Liquid
1. The battery liquid is highly corrosive. Avoid contact of the liquid with skin or eye. If any contact occurs, wash with large quantities of clean water and in the case of eye contact, consult a doctor.
2. The hydrogen released from battery during charging is explosive. Keep the area well ventilated during battery charging and avoid naked flame.
Warning: Brake Fluid
Brake fluid can damage the paint and some plastics. Cover the parts that can be damaged with cloth during maintenance of hydraulic brakes. If the brake fluid is spilt on plastic or a painted component, remove the fluid and wash the surface with water immediately.
Warning: High Temperature of Engine
The engine cover, cylinder, and exhaust pipe can be at a high temperature after the engine has been running. Wait for the engine to cool before working on it or use protective gloves.
2.5 Torque Settings
(Monaco representative figure)
Standard Torque Values of Bolts and Nuts
Specification
5 mm Bolt and Nut 40 8 mm Bolt and Nut 220 5 mm Flange Bolt and Nut 50 8 mm Flange Bolt and Nut 270 6 mm Bolt and Nut 100 10 mm Bolt and Nut 350 6 mm Flange Bolt and Nut 120 10 mm Flange Bolt and Nut 400 6 mm SH Bolt and Nut 90 12 mm Bolt and Nut 550
Torque Values of Chassis Components
No. Tightening Location Specification Torque (kg-cm)
Torque (kg-cm) Specification Torque (kg-cm)
1 Front Wheel Axle Self-lock Nut M12 500~600 2 Brake Disk Hex Bolt M5 180~280 3 Brake Clipper Tightening Bolt M8x35 210~250 4 Speed Meter Cable Nut X 60 5 Front Fork Bearing Tightening Nut M25x1.0 600~650 6 Rear Wheel Axle Self-lock Nut M16x10 600~900 7 Rear Brake Connecting Rod Bolt M16x32 50~80 8 Rear Brake Pin Self-lock Nut M8 250~270 9 Rear Upper Cushion Tightening Bolt M10×46 200~300 10 Rear Lower Cushion Tightening Bolt M8×35 200~300
Torque Values of Engine Components
Tightening Location Specification Torque (kg-cm) Quantities
Cylinder Head Bolt M6 80~100 4 Cylinder Stud Bolt M8x182.5 500~800 2 M8x195.5 2 Cylinder Intake Pipe Stud Bolt M6x50 500~800 2 Muffler and Exhaust Pipe Tightening Screw M6 100~120 2 Muffler & Right Crankcase Upper Tightening Screw Muffler & Right Crankcase Lower Tightening Screw Spark Plug M10 100~120 1 Valve Gap Adjust Lock Bolt M5 50~90 2 Fuel Filter Nut Cap M30 150~200 1 Cooler Fan Lock CR M6x18 500~800 4 Wire Assembly Lock Screw M6x20 800~1000 2 Start Clutch Gear Tightening Nut M22 (R.T.) 800~1000 1 Driven Belt Pulley Assembly M12 400~600 1 Gearbox Cover Tightening Bolt M6x28 100~1200 3 M6x35 3 Gearbox Oil Fill Cover Screw M8 90~150 1 Gearbox Oil Drain Cover Screw M8x12 90~150 1 Clutch Side Cover Screw M6x40 50~80 6 M6x65 2 Starter Arm Tightening Screw M6x22 100~120 1
M8x42 300~400 1
M8x38 300~400 1
2.6 Lubrication Points
(Monaco representative figure)
Chassis
Lubrication Area Lubrication Type
Inner Side of Acceleration Lever Grease Steering Bearing Grease Speed Meter Gear Grease Front Wheel Axle Bearing Grease Front Wheel Axle Grease Main and Side Stand Axles Grease Rear Wheel Bearing Grease Seat Cover Lock Grease Speed Meter Cable Grease Throttle Wire Grease Rear Brake Cable Grease Brake Assembly Brake Fluid
Engine
Lubrication Area Lubrication Type
Piston and Piston Rings SAE 10W-40 and API SE,SG Engine Oil Piston Pin Big End of Connecting Rod Rocker Arm Frictional Contact Area Cam Shaft and Chain Cylinder Frictional Area Oil Pump Chain Gears Contact Surface Bearing Operation Area O Rings Seal Lip Area
Starter Frictional Surface High Temperature Durable Grease Starting Cam Gear Spring Operation Frictional Area
Generator Connector Adhesives Gearbox Ventilation Tube
2.7 Trouble Shooting
2.7.1 Engine Fails to Start:
Check the following possible causes -
No fuel Dirty fuel filter Obstructed fuel pipe Obstructed ventilation tube on the fuel tank Damaged carburettor float needle valve Carburettor float chamber dirty Faulty carburettor float No spark from spark plugs Poor spark from spark plugs Dirty spark plugs Incorrect spark plug gap Wet spark plugs Loose adjustment screws in the carburettor Carburettor choke not operating Blocked carburettor idle nozzle Dirty air filter Engine flooded with fuel Loose spark plug Dead battery Poor contact of battery terminals Ignition or starter switch faulty Starter relay faulty Loose contacts or wiring Starter gear and clutch gear seriously worn Starter gear and clutch gear not engaging Faulty starter motor
2.7.2 Poor spark
Loose spark plugs Worn spark plugs Damaged high-voltage wiring Faulty distributor coils Ignition switch high resistance Relays faulty Loose spark plug connector Faulty C.D.I. Faulty distributor high-voltage wiring
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