Professional Documents
Culture Documents
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PDF "pdfFactory" www.fineprint.com.cn
CONTENTS
PREFACE.....................................................................................Q1-1 1-2
ENGINE REMOVE .................................Q2-1 2-4
ENGINE INSTALLATION......................................................Q 3-1 3-2
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Q11-1~11-2
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PDF "pdfFactory" www.fineprint.com.cn
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INSPECTION
Check the throttle valve and the jet
needle surface of dirt, scratches or wear.
CARBURETOR REMOVAL
Remove the seat.
Remove the luggage box.
Remove the side cover.
Remove the starter plunger wire.
Remove the throttle cable.
Remove the fuel tube from the
carburetor.
Loose the screw of the air cleaner band.
Loose the bolts between the intake pipe
& the carburetor.
Remove the carburetor.
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CARBURETOR INSTALLATION
The installation sequence is essentially
the reverse of remove.
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STANDARD : 1
1
round
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CYLINDER REMOVAL
Remove the cylinder head.
Remove the cylinder.
Remove the cylinder gasket.
NOTE:
Clean all the material of cylinder
gasket with a scraper.
PISTON REMOVAL
Remove the piston pin clip.
NOTE:
Do not let the clip fall into the
crankcase.
Remove the piston pin.
Remove the piston.
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CYLINDER INSPECTION
Inspect the cylinder bore for wear or
damage.
Measure the cylinder I. D. at three
places; top, middle and bottom of piston
travel and in two directions at right angle
to each other.
SERVICE LIMITS: 40.2
52.2
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NOTE:
i Avoid piston and piston ring
damage during installation.
i All ring should be installed
with the mark facing up.
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PISTON INSTALLATION
Install the piston, piston pin and new
piston pin clips.
NOTE:
i Piston the EX mark on the
exhaust side.
i Do not let the piston pin clip
fall into the crankcase.
CYLINDER INSTALLATION
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CRANKCASE REMOVAL
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CRANKSHAFT INSPECTION
Measure the connecting rod big end side
clearance with a feeler gauge.
SERVICE LIMIT: 0.55
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CRANKCASE INSTALLATION
Install the crankshaft bearing into the left
crankcase.
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BATTERY CHARGING
Connect charge position (+) cable to the
battery positive termini.
Connect the charge negative (-) cable to
the battery negative (-) terminal.
CHARGING CURRENT : STANDARD :
0.4A
SWIFTNESS : 4A
CHARGING TIME :
STANDARD :5
hrs
SWIFTNESS : 30
min
A.C.G. COIL INSPECTION
Check the continuity between the white
and the green wire.
STANDARD :
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BATTERY INSPECTION
Check the voltage of the battery.
FULL CHARGE : 13.013.2 v
UNDER CHARGE : 12.3 v
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C.D. I. INSPECTION
AC110V
GOOD
1. OFF NO SPARK
2. P
3. EXT
4. ON.1
SPARK
5. ON.2
NG
SPARK
NO SPARK
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A. C. G. INSPECTION
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START MOROTR
START MORTOR INSPECTION
Connect a battery (12 V) to the motor.
Check the performance of the motor.
NOTE :
Use a fully charged battery.
FLOAT DOWN
GREENYELLOW / WHITE
3045
500850
GREENBLUE / WHITE
400700
100700
450750
450750
BLUE / WHITE
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FLOAT UP
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GOOD
UP
DOWN
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POSITION
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OIL FLOAT
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DIMMER SWITCH
HI
LO
WHITE
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BULE /
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POSITION
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COLOR
START SWITCH
Color
POSITION
YELLOW /
RED
GREEN
OFF
ON
(N)
(N)
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ASH
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rT
position
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COLOR
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LIGHT / GREEN
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GREEN
OFF
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COLOR
POSITIO
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ON
SWITCH INSPECTION
MAIN SWITCH
COLOR
RED
POSITION
WHITE
OFF
ON
BLACK /
GREEN
BLACK
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M14:11.5-12.5kg-m
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DISASSENBLY
Remove the cir-clip.
INSPECTION
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BRAKE CALIPER
REMOVAL
Remove the caliper from the front fork.
Disconnect the brake oil tube.
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DISASSEMBLY
Remove the brake pad.
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