SERVICE MANUAL

150cc Engine
 TABLE OF CONTENTS
CHASSIS NUTS AND BOLTS 1
ENGINE 3
LUBRICATION SYSTEM 18
FUEL SUPPLY SYSTEM 22
TRANSMISSION COMPONENTS 27
ELECTRICAL STARTING SYSTEM 30
BELT DRIVE CVT MECHANISM 36
CLUTCH 40
REAR TRANSMISSION SYSTEM 45
ELECTRICAL SYSTEM 50
IGNITION SYSTEM 56
 CHASSIS NUTS AND BOLTS

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Always pay attention to the unit s nuts and bolts. Some loosening after use is normal. Check to
ensure that all nuts and bolts are tight.

Torque Tightening Chart

Bolt Conventional Marked Bolt 8.8 Marked Bolt
Diameter N.m Kg.m Ib-ft N.m Kg.m Ib-ft
4 1~2 0.1 ~ 0.2 0.7 ~ 1.5 1.5 ~ 3 0.15 ~ 0.3 1.0 ~ 2.0
5 1~4 0.2 ~ 0.4 1.5 ~ 3.0 3~6 0.3 ~ 0.6 2.0 ~ 4.5
6 4~7 0.4 ~ 0.7 3.0 ~ 5.0 8 ~ 12 0.8 ~ 1.2 6.0 ~ 8.5
8 10 ~ 16 1.0 ~ 1.6 7.0 ~ 11.5 18 ~ 28 1.8 ~ 2.8 13.0 ~ 20.0
10 22 ~ 35 2.2 ~ 3.5 16.0 ~ 25.5 40 ~ 60 4.0 ~ 6.0 29.0 ~ 43.5
12 35 ~ 50 3.5 ~ 5.5 25.5 ~ 40 70 ~ 100 7.0 ~ 10.0 50.5 ~ 72.5
14 50 ~ 80 5.0 ~ 8.0 36.5 ~ 58 110 ~ 160 11.0 ~ 16.0 79.5 ~ 115.5
16 80 ~ 130 8.0 ~ 13.0 58 ~ 94 170 ~ 250 17.0 ~ 25. 123.0 ~ 181.0
18 130 ~ 190 13.0 ~19.0 94 ~ 137.5 200 ~ 280 20 ~ 28.0 144.5 ~ 202.5
FUEL SWITCH (PETCOCK)
• Periodically clean the petcock externally with grease remover and water.
• Check for any leaks or seeping fuel.
• Replace the petcock if there are any leaks found.

This vehicle has a manually operated fuel valve. There are three positions.

“ON” position
The normal operating position for the fuel valve lever is the “ON” position. In this position, fuel will
ÀRZWRWKHFDUEXUHWRr.

“RES” position
If the fuel level in the fuel tank becomes too low for the engine to operate with the fuel valve lever in
the “ON” position, turn the lever to the “RES” position to use the reserve fuel supply, and refuel as
soon as possible.

“OFF” position
The closing position for the fuel valve is the “OFF” position.
When the vehicle is not in use, always make sure the petcock is in the “OFF” position.
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 ENGINE
ENGINE COMPONENTS INSPECTION AND SERVICING
ENGINE COMPONENTS AND CRANK CONNECTING ROD MECHANISM
INSPECTION AND SERVICING

ENGINE COMPONENTS: CYLINDER

CYLINDER REMOVAL
The removal can be done on the vehicle body.
• Remove cylinder head.
• Remove cylinder.
• Remove cylinder gasket, bolts
• Clean cylinder gasket and remove any debris.

Caution!
Do not damage the cylinder area. Make sure not to drop anything, including
cylinder gasket material, into the crankcase.

CYLINDER INNER WALL WEAR INSPECTION

Use a bore diameter dial gauge to measure the degree of wear.

The measure point is divided into three sectional planes in the axial direction: upper, middle and
lower; measure every plane each time on the mutually perpendicular directions (X, Y), the
measured least dimension is the cylinder bore; at the most upper position measured is the largest
diameter, and the lowest position measured is the smallest diameter, their difference is the
cylindricity of the cylinder. At the same cross section, measure the difference of diameter between
two points mutually perpendicular; which is the circularity of the cylinder.

In order to make the measuring point perpendicular with the bore axis of the
cylinder, and to ensure the precision of the measurement, the bar of the gauge
can be slightly swung in the direction of the gauge bar, and take the smallest
reading number as the result.

In the situation without a dial gauge, a feeler gauge can be used to make relativity measurement.
put a new piston into the cylinder, and use the feeler gauge to measure the gap between the piston
skirt and the cylinder wall. T hen ¿gure out the abrasion loss of the cylinder. If the circularity of the
cylinder exceeds the limit, then a cylinder reboring machine should be used to rebore the cylinder,
and enlarge its diameter by 0.5mm or 1.00mm, then ¿t the piston and piston ring which size are
also enlarged. If the wear is too severe and cannot be reworked, then a new cylinder should be
installed.
Cylinder bore 57.4mm
Cylindricity 0.05mm
Circularity 0.05mm

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CRANKSHAFT AND CRANKCASE INSPECTION
• Replace the whole set of the crankshaft if serious wear is found while inspecting. Measure the
axial trend clearance of the big end of the connecting rod.

• When measuring, put the large end of the connecting rod close to the crank, and insert the feeler
gauge between the other side and the crank, for the correct end play.
Service Limit 0.55mm
• Measure the radial trend (X,Y) clearance of the big end of the connecting rod.
Service Limit 0.05mm
• Measure the main shaft journal jump of the crankshaft.
If this measurement is too great, it will cause the engine to shake abnormally, shortening the life
of the engine It must be examined carefully when inspecting.
Service Limit 0.10mm(A=90)
0.10mm(B=105)
• Examine if there is any loose, or unusual sound when the crank journal bearing turns. If there is,
the whole set should be changed.

• After cleaning the crankcase, inspect if there is any damage.

• Inspect whether the joint face of the crankcase is smooth and clean. While reassembling, notice if
it will affect the sealing performance between the left and right crankcase.

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RQHWRrefinish it. If damage is too severe, replace the cover.

Because the right and left crankcase axle hole must be concentric, they
should be replaced at the same time.

CRANKSHAFT AND CRANKCASE INSTALLATION

• Mount the crankcase oil seal.
• Put the cam chain into the left crankcase.
• Put the crankshaft into the left crankcase.

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Pay attention to avoid damaging the oil seal with the cam chain.

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CAMSHAFT INSTALLATION
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 ROCKER ARM AND ROCKSHAFT

ROCKER ARM AND ROCKSHAFT REMOVAL

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ROCKER ARM AND ROCKSHAFT INSPECTION

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• Measure the inner diameter of the rocker arm.

Service Limit 10.04mm
• Measure the outer diameter of the rockshaft.
Service Limit 9.96mm
ROCKER ARM AND ROCKSHAFT INSTALLATION
噝 Read the “ EX” mark on the camshaft holder, then mount the exhaust port rocker arm to the
rockshaft.

• Mount the inlet port rocker arm to the rockshaft. Apply some oil to the rockshaft before mounting.

CAM CHAIN TENSIONER

The chain tensioner must be in good working condition for proper chain tension.
1. Cam chain
2. Cam chain tensioner
3. Cam chain tensioner lifter.4. Gasket
5. Cam chain tensioner pivot
6. Cam chain guide
7. Bolt
8. Nut
9. O-ring
10. O-ring

The operational principle of the tensioner is as shown in the picture.

14
 As for the adjustment of the cam chain tensioner, clockwise
tightens, and counterclockwise loosens.
VALVE AND VALVE SPRING
VALVE AND VALVE SPRING REMOVAL
• Remove cylinder head.
• Remove valve cotter pin and compressor.
• Remove upper spring race.
• Remove valve spring.
• Remove lower spring race.
• Remove valve stem oil seal.
• Remove valve.

The removed parts should be placed in order to avoid confusion. It’s better to place the
intake valve parts and exhaust valve parts separately.

VALVE AND VALVE SPRING INSPECTION

• Inspect the valve for bending or burning.
• Inspect for smooth action between the valve and the valve guide.
• Measure the outer diameter of the valve stem.

• Measure the free length Service Limit 4.94mm

of the inner and outer valve spring.

Valve Inlet valve Exhaust valve

Inner spring 31.2mm 31.2mm
Outer spring 34.1mm 34.1mm

VALVE AND VALVE SPRING INSTALLATION

• Mount the spring retainer, valve guide oil seal.

It is recommended to replace the valve guide oil seal with a new one.

• After applying oil on the valve stem, mount it into the valve guide.
• Mount the inner and outer valve springs.
• Mount the valve locker with a spring compressor.

When mounting, the twisting direction of the inner and outer springs must be opposite.

• Tap on the valve gently two or three times with a rubber hammer to make the valve and the valve
lock connect well.

Do not damage the valve.

15
VALVE GUIDE
Carbon accumulation on the valve guide will make the
valve move roughly, causing the valve to not open or
close properly.

Valve guide abrasion is one of the causes of white smoke from the exhaust pipe.

TO CLEAN CARBON ACCUMULATION OFF THE VALVE

GUIDE
• Remove the valve and springs etc.

Generally, only turn right when using the reamer, and do not
push in or out directly with the reamer.

• Clean the carbon accumulation with a valve guide reamer.

VALVE GUIDE INNER DIAMETER MEASUREMENT

Service Limit 5.03mm

Calculate the clearance between the valve stem and the valve guide
(the inner diameter of the guide subtracted by the outer diameter of the valve stem).

Valve Inlet valve Exhaust valve

Service Limit 0.08mm 0.10mm

When the abrasion of the valve guide exceeds the service limit, it should be
replaced; after replacing a new valve guide, the valve retainer must be adjusted.

VALVE GUIDE REPLACEMENT

• Heat the cylinder head to 212 ~ 302°F (100 ~ 150°C)

The cylinder head must be wholly and quickly heated

• Tap
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The temperature is very high, two technicians are
recommended.
valve guide out with a valve guide remover or similar tool.

Do not damage the cylinder joint face

16
 When using the reamer, cutting oil must be used. The reamer
can only be turned right; do not push in or out directly.

• After tapping the valve guide, you

need to trim it with a reamer.

• Clean the cylinder head, and remove the scraps generated while ramming.

VALVE SEAT
The relative position between the valve seat and the working surface of the valve is very important for
the valve to seal properly.

VALVE SEAT WIDTH MEASUREMENT

• Clean the carbon accumulation in the combustion chamber.
• Measure the width of the valve seat with a vernier caliper.

When Standard 0.6-1.2mm abrasion causes

the valve Service Limit 1.8mm seat width to be
uneven, too wide or too
narrow, it will result in poor contact between the valve and the valve
seat, and not seal tight. At this time it must be reamed with a
customized valve seat milling cutter.

The valve seat milling cutter is the customized trimming tool

for the valve seat, and it has three cutting angles: 32, 45,
and 60.

While trimming, press the valve seat milling cutter to make

rotary motion with 40 ~ 50 N force.

Some oil must be applied on the valve seat

milling cutter, to eliminate scraping when
trimming.

VALVE SEAT FINISHING

• Ream out the defects on the
working surface Do not ream too much. with a 45°
coarse tooth milling cutter.

17
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LUBRICATION SYSTEM INSPECTION AND SERVICING

GENERAL INTRODUCTION
The picture shows the functional diagram of the lubrication system. After the lubrication oil crosses
WKH¿OWHUVFUHHQ, it is pumped by the rotator oil pump. Some of the oil goes into the big end
of the connecting rod and splashes on the cylinder wall and the small end of the connecting rod; the
rest goes through some oil passages, such as the shaft neck of the camshaft, and splashes on the
cam rockshaft and cam chain. The lubrication oil that falls back into the oil groove can be
recirculated.

20
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1
• Mount the right crankcase cover positioning bolt.
• Mount the trigger winding and the stator coil.
• Tighten the right crankcase cover positioning bolt.

The bolt should be gradually diagonally tightened in two to

three steps.
$IWHU¿QLVKLQJWKHLQVWDOODWLRQLQspect for any oil leaks.

FUEL SUPPLY SYSTEM INSPECTION AND SERVICING

CV CARBURETOR
The CV carburetor is a constant vacuum carburetor. The picture shows the structure of the CV
carburetor. 7. Screw set B
1. Gasket set 8. Valve plate set
2. Float valve set 9. Starter valve set
3. Needle jet set 10. Air cut valve set
4. Float set 11. Compression coil spring
5. Float chamber set 12. Screw
6. Screw set A 13. Carburetor assy.

24
14. Top comp.
15. Vacuum piston comp.
16. Needle jet holder
17. Plate clip
18. Holder cap
19. Tube A
20. Tube B
21. Screw
22. Screw
23. Washer screw
24. Washer screw
25. Washer screw
26. Clip
27. Clip
28. Tube
29. Main jet
30. Slow jet

6
 CARBURETOR IDLING ADJUSTMENT

AIR ADJUSTING SCREW ADJUSTMENT

Step one: Turn on the air adjusting screw in the turn out by the prescribed number of turns.
Turn out number of turns 2 3/4 – 2 1/4
Step two: Adjust the throttle by adjusting the screw to the prescribed idle rpm.
Step three: Left and right, adjust the air adjusting screw slightly to ¿nd the highest position of
the rpm.

Increase throttle quickly and gently (the rpm is from low to high), and return throttle immediately,
then observe 10 to 15 minutes, to observe if the idle remains the same.

VACUUM CHAMBER
The picture shows the structure of the vacuum chamber of the
CV carburetor.

VACUUM CHAMBER REMOVAL

• Remove the body cover. Remove the automatic choke
lead wire.
• Loosen the fuel drain bolt, and drain the fuel in the Àoat
chamber. Remove the fuel line and the vacuum pipe.
• Loosen the throttle cable adjusting nut and positioning nut; remove the throttle cable.
• Loosen the carburetor air inlet vent clip and the inlet manifold clip;
remove the carburetor.

• Remove the vacuum cover bolt, and remove the vacuum

cover.Notice: move slowly to prevent the spring from ejecting.

• Take out the spring, the vacuum membrane and the plunger.

• Press down the holding clamp of the needle valve top, and turn
left to take out the clamp.
• Take out the spring and needle valve.

• Inspect Do not damage the vacuum membrane. the needle

valve for wear.
• Inspect the vacuum membrane for damage.
• Inspect the plunger for damage.

26
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Before removing ¿rst tighten the two screws gently, counting the number of turns Remove
screws. Do not use excessive force to avoid damaging the air adjusting screw head
surface.

• Remove the main fuel injection nozzle and fuel injection needle seat.

FLOAT CHAMBER INSTALLATION

,QVSHFWWKHÀRDWIRUDQ\
GDPDJHDQGIRUIXHOLQWKHÀRDW,QVSHFWWKHÀRDWYDOYHDQGÀoat valve seat for
wear. If there is wear, it should be replaced.

Clear every fuel line and air line on the carburetor body with compressed air.

FLOAT CHAMBER INSTALLATION

• Install the main fuel injection nozzle and fuel injection needle seat.
• Install the air adjusting screw and choke adjusting screw, and turn them to the proper position
ac-cording to the noted number of turns while removing.
‡0RXQWWKHÀRDWYDOYHWKHÀRDWDQGWKHÀRDWSLQ
• TLJKWHQWKHÀRDWSLQSRVLWLRQLQJVFUHw.

FUEL LEVEL INSPECTION

• Measure the fuel level height.
Fuel level height 18.5mm
‡,QVSHFWWKHÀRDWIRUDQ\GDPDJHDQGLQVSHFWWKHÀoat valve for excess wear.
‡&RQ¿UPWKDWWKHXSDQGGRZQPRYHPHQWRIWKHÀoat is normal.

CARBURETOR INSTALLATION
‡,QVSHFWWKHÀRDWIRUDQ\GDPDJHDQGLQVSHFWWKHÀoat valve for excess wear.
‡&RQ¿UPWKDWWKHXSDQGGRZQPRYHPHQWRIWKHÀoat is normal.

28
CARBURETOR INSTALLATION
• Reverse the removal procedure for installation.
• After installing, confirm that all carburetor linkage and cables are in correct position. Verify
thatcarburetor is in idle position.
AIR CUT VALVE (ACV)

AIR CUT VALVE REMOVAL

• Remove the air inlet manifold of the cut valve.
• Remove the bolt . Remove the vacuum membrane cover,
the spring, and the vacuum membrane.

AIR CUT VALVE INSTALLATION

The air cut valve can avoid some abnormalities when the throttle closes too quickly.
The structure of the air cut valve is shown in the picture.

• Mount the vacuum membrane on the carburetor.

• Mount the spring, the vacuum membrane cover, and the lock
bolt.

The bottom side of the vacuum membrane should be AIR

aligned with the carburetor. The top side should be
aligned with the vacuum membrane.
CHECK VALVE
The air check valve starts working under 31mph (50 km/h), and opens the second air inlet to
reduce CO displacement.2

AIR CHECK VALVE INSTALLATION

Reverse the procedure for removal

When installing, make sure all the connecting pipes are connected properly, and
that they are not squeezed, bent, or clogged up.

29
 TRANSMISSION COMPONENTS
STARTING MECHANISM INSPECTION AND SERVICING
The starting mechanism can be divided into two types: kick starting and electric starting.

KICK RETURN STARTING MECHANISM

SPIRAL SPLINE TRANSFERRING STYLE STARTING MECHANISM

The picture shows the structure of the spiral spline transferring style starting mechanism.
14
20 10

8 17
9
7 23 1

22
6
11
12
13

7 25 2 16 19
3
15
7 25
5

24
4 21

18

1. Kick starter spring stopping plate

2. Drive face 14. Bush
3. Drive face boss 15. Spindle bush
4. Movable drive face comp. 16. Kick starter spring
5. Weight roller set 17. Special pin
6. Ramp plate 18. Washer
7. Slide piece 19. Washer
8. Starting driver pulley 20. Washer
9. Starter gear friction spring 21. Nut
10. Starter idle gear comp. 22. Bolt
11. Starter idle shaft 23. Roller
12. Starter idle spring 24. Face drive collar
13. Kick starter spindle comp. 25. Clip
SPIRAL SPLINE TRANSFERRING STYLE STARTING MECHANISM REMOVAL
• Remove the left crankcase cover.
• Remove the crankcase gasket and dowel pins.
• Remove the movable driving plate (the whole set).

30
• Remove the starting spindle

washer.‡5HPRYHWKHUHWXUQVSULQJVWRSSLQJSODWHDQGUHPRYHWKH
UHWXUQVSULQJ
‡5HPRYHWKHZKROHVWDUWLQJOHYHU set
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‡,QVSHFWWKHstarting spindle for abrasion or other damage.
‡,QVSHFWWKHVWDUWLQJ idle shaft for abrasion or other
damage.

31
‡,QVSHFWWKHVWDUWLQJspindle bushing and the starting idle shaft hole for abrasion or
other damage

SPIRAL SPLINE TRANSFERRING STYLE

STARTING MECHANISM INSTALLATION
Install according to the pictures .

• Assemble the starting idle shaft set. Before assembling, apply a

little grease on the bore of the idle shaft.

• Assemble the starting spindle, the return spring and the spring
holding pin. A little grease should be applied on the starting
spindle where it is under stress .

• Align the idle shaft holding pin with the groove of the
crankcasethen insert.

• Before installing, apply a little grease on the groove Align

of the rotary retaining spring on the idle shaft. the
The rotary retaining spring should be aligned with
WKHVSHFL¿FJURRYHRIWKHFUDQNFDVHWRLQ
VWDOO
scribing mark of the starting spindle with the punching mark of the
idle shaft then mount the starting spindle.
• Hook on the two ends of the return spring.
• Install the return spring stopping plate.

• Install the crankcase dowel pin and gasket.

32
 • Install the driven belt and the driving plate.
• Install the left crankcase cover and lock tightly.
• Install the starting pedal.

ELECTRICAL STARTING SYSTEM

STARTER MOTOR
The starter motor is actually a direct current (DC) motor, and its structure is shown in the picture.
1. Outer Cover, Motor

7. O-ring
2. Rotor, Motor 8. O-ring
3. Base, Carbon Brush 9. Bolt
4. Plate, Positive Electrode 10. Spring Washer
5. Carbon Brush, Positive Electrode 11. Washer
6. Carbon Brush, Negative Electrode 12. O-ring
13. Screw
STARTER MOTOR REMOVAL

%HIRUHUHPRYDO¿UVWVKXWRff the main switch, and disconnect the battery

connecting wire. Then press the starting button; at this time the starter motor should
not run. Do this to insure safety.

• Remove the starter motor lead wire clamp.

• Remove the starter motor holding bolt, and remove the starter
motor.

33
• Roll up the rubber wate-resistance cover, and remove the starter motor joint.
• Remove the motor case bolt, the carbon brush seat, and the motor case, etc.

34
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1

36
STARTER MOTOR INSTALLATION
• Apply some oil on the dust seal.
• Install the carbon brush on the carbon brush base.
• Apply a little oil on the moving part of the armature ends.
• Put the carbon brush into the bracket, and then install the carbon
brush base.

Do not damage the contact area of the carbon brush

and the armature. When installing, do not damage the
lip of the dust seal.

• Mount the new O-ring on the carbon brush base.

• Install armature into starter motor case, making sure not to
damage the carbon brushes.
• Tighten motor case bolts.

Make sure the starter motor case is free of metal particles

because it is magnetic.

%HIRUHLQVWDOOLQJWKHVWDUWHUPRWRURQWKHYHKLFOHDIWHUD
VVHPEOLQJLW¿rst connect the lead wires and check that the motor is running
normally.

• Apply oil on the O-ring, and install the starter motor.

• Tighten holding bolts.

REDUCTION MECHANISM
The picture shows the structure of the reduction mechanism.

37
 1. Starter reduction gear 12. Bolt
2. Starter reduction gear shaft 13. Nut

3. Starting clutch gear comp. 14. Washer

4. Starting clutch outer comp. 15. Dowel pin
5. Flange starting clutch 16. Key woodruff
6. Starting clutch roller spring 17. Roller
7. Spring holder 18. Needle bearing
8. Starter motor 19. O-ring
9. Starter motor lead wire 20. Screw
10. Clamp 21. Bolt
11. Clamp

REDUCTION GEAR INSPECTION

• Remove the starting clutch.
• Remove the reduction gear to inspect its wearing degree.
• Measure the inner diameter of the reduction gear shaft. It
should be replaced when the diameter is more than
10.05mm.
• Measure the outer diameter of the reduction gear shaft. It
should be replaced when the diameter is less than 9.94mm.
ENGAGING MECHANISM

STARTING CLUTCH REMOVAL

• Remove the right crankcase cover.
• Remove the left crankcase cover.

38
• Hold the drive face with the universal set wrench.
• Remove the starting clutch ¿xing nut.

1RWLFHWKDWWKHWKUHDGRIWKH¿[LQJQXWVKRXO
GEHOHIW handed rotation.

• Remove the starting clutch (the whole set).

STARTING CLUTCH INSPECTION

‡,QVSHFWWKHPRYHPHQWEHWZHHQWKHFOXWFKDQGWKHGULYLQJJHDU.
The driving gear should smoothly turn clockwise, and should not move counterclockwise.

‡,QVSHFWWKHFRQWDFWVXUIDFHEHWZHHQWKHGULYLQJJHDUDQGWKH
QHHGOHEHDULQJ for abrasion or other damage,WVKRXOGEH replaced if the surface is
damaged.
• Measure the inner diameter of the driving gear,WVKRXOGEHUH placed when the diameter is
more than 32.06mm.
‡,QVSHFWWKHFRQGLWLRQRIWKHQHHGOHEHDULQJ,WVKRXOGEHUHSODFHGLI there
is any damage.
‡,QVSHFWWKHFRQWDFWVXUIDFH between the outer clutch
component DQGWKHUROOHr for abrasion or other damage.
• Inspect the roller for injury.
• Inspect the spring for distortion.
‡,IWKHGDPDJHLVVHULRXVLWVKRXOGEHUHSODFHG

• Measure the inner diameter of the

ÀDQJHFOXWFK,WVKRXOGEH replaced when the diameter is
more than 27.94mm.

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• Remove the clutch friction plate.

• Remove the whole clutch/driven plate set.
• While compressing the driven pulley spring with the clutch s
p r in g compressor, remove the nut on the shaft.
• Disassemble the clutch with the driven pulley.
• Remove the circlip, and remove the connecting piece.
• Remove the clutch centrifugal weight set and the spring.

CLUTCH INSTALLATION
• Mount the clutch damper rubber onto the drive plate pin.
• Mount the new clutch weight set and spring on the drive plate.
• Install the connecting piece, the circlip, and the bottom plate.
• Finally reverse the removal procedure for installation.

To avoid damaging the spring when assembling the clutch and the driven plate,
you must use a clutch spring compressor. The driven pulley must be free of
grease.
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• Supply the oil with the prescribed speci¿cation and oil level.
• Mount the level bolt.
• After replacing the oil, inspect for any oil leaks.

TRANSMISSION CASE

TRANSMISSION CASE REMOVAL

• Remove the driven belt pulley.
• Drain out the oil in the transmission case.
• Remove the drive sprocket.
• Remove the bolt, and remove the transmission case cover.
• Remove the gasket and the dowel pin.

54
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TRANSMISSION CASE GEAR INSPECTION

• Check the sub shaft/sub shaft gear for wear and other damage.

‡&KHFNLIWKH¿QDOJHDU and the ¿nal gear shaft for wear and other damage.

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Electrical System
CHARGING SYSTEM INSPECTION AND SERVICING

ELECTRIC LEAKAGE TESTING

• Turn the main switch to the “OFF” position.
• Disconnect the negative ground wire from the battery.
• Connect the positive end of the ammeter with the negative end of the battery.
• Connect the negative end of the ammeter with the ground wire.
• Test the electric leakage. In general, the number should be less than 1 m A; if it is unusual,
check for is a short circuit of the main switch and the main wiring.

CHARGING STATUS INSPECTION

• Install the fully charged battery.
• Connect the voltmeter between the binding posts of the battery.
• Remove the fuse, and connect the ammeter with two ends of the fuse.
• Connect the tachometer to the engine (it’s not needed when there is rpm indicator on the
vehicle).
• Start the engine, and accelerate slowly0 easure the charging voltage and current.
Charging voltage (V) 13.5 ~ 15.5
Charging current (A) 0.5
*Measuring condition: 5000 r/min

If the voltage is not in the range of the above-speci¿ed value, please inspect the voltage regulator.

59
BATTERY
The battery is an important component of the electric system. The battery used on the vehicle is a
maintenance-free battery. For long periods of storage, the battery will discharge. It should be
charged every 3 months. After 2 ~3 years of regular usage, the capacity of the battery will lessen
and will need changing. Replace with the same type of battery.

BATTERY REMOVAL

Shut down the main switch to make sure no electric current goes through the vehicle.

• Disconnect the negative battery lead wire ¿rst.

• Disconnect the positive battery.

The disconnecting order cannot be reversed. When disconnecting the

positive cable, do not touch the body of the vehicle with the removal tool,
or it will short circuit and ignite gas that will damage the battery.

BATTERY INSTALLATION
Connect the positive cable ¿rst, then connect the negative cable.

BATTERY OPEN-CIRCUIT VOLTAGE INSPECTION

Disconnect the cable on the battery terminals.

Disconnect the negative pole ¿rst, then the positive pole.

Measure the voltage between the two poles of the battery.

Full charging 13.1V
Under charging 12.3V
BATTERY CHARGING
• Lift the battery out of the vehicle.
• Connect the positive pole of the charger with the positive pole of the battery.
• Connect the negative pole of the charger with the negative pole of the battery.
• Charge the battery for the charging time marked on the battery.

Unless it is urgent, do not use fast charging. There should be no smoking or open ¿re near
the battery when charging. At the beginning or the end of charging, turn off the
FKDUJHU¿UVWLQRUGHUWRDYRLGWKHFRQQHFWLQJSDUWDUFLQJ

Measure the voltage 30 minutes after charging is ¿nished. It should reach the speci¿ed value, or
recharging is needed.

Charging Current Normal 0.7 A

Fast 3.0 A

60
 Charging Time Normal 5-10 hours
Fast 30 minutes
Charging Result 2SHQFLUFXLWYROWDJH•9

PRIMARY COIL
The picture shows the structure of a common generator.

1. Cooling Fan
Generator assembly 6. Bolt
3. Flywheel comp. 7. Nut
4. Stator comp. 8. Bolt
5. Washer 9. Bolt

61
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TRIGGER WINDING
• Remove the connector of the trigger winding wire.
• Measure the resistance value between the trigger winding (green/red wire) and the body ground
wire.
Standard Value aŸƒ&
When the actual value is more than the standard value, it should be replaced.

CDI COMPONENT

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FWLRQ7KH&', component inspection is also divided into two steps: First
inspect every wiring, winding or
FRLOFRQQHFWHGZLWK&',WKHQLQVSHFWWKH&',FRPSRQHQW

REMOVE THE CDI COMPONENT.

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QLWLRQFKDUJLQJFRLO the trigger winding, and the ignition coil. When the main switch is in
“OFF” position, it should be conducted. The resistance value of every coil should be the standard
value.

67
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CDI COMPONENT
SW (B/W) EXT (B/R) 3&*5 (*RU*: ,*1%<
SW (B/W) a’ a’ a’ ’
EXT (B/R) 0.5 ~ 50 a’ ’ ’
3&*5 10 ~ 1000 10 ~ 1000 1 ~ 100 ’
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WUXPHQW

Please carefully read the instrument speci¿FDWLRQWRNQRZKRZWRSURSHUO\

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RQGLIferent positions
(OFF, P, EXT2121
IGNITION COIL
IGNITION COIL REMOVAL
• Remove the spark plug cap.
• Remove the primary ignition coil wire.
• Remove the ignition coil-positioning bolt, and remove the ignition coil.

IGNITION COIL INSTALLATION

• Reverse the removal procedure for installation.

When installing, connect the black/yellow wire of the primary ignition coil with the
black/yellow connector of CDI, and the green wire with the green connector of the CDI.

PRIMARY IGNITION COIL INSPECTION

Standard Value a.Ÿƒ&
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SECONDARY IGNITION COIL INSPECTION

Install the spark plug cap, and measure the resistance value of the secondary ignition coil.

68
 Standard Value a.Ÿƒ&
If the resistance value is in the standard range, it is good; however ’LQGLFDWHVWKHFRLOLVEDG
Remove the spark plug cap, and measure the resistance value of the secondary ignition coil.
Standard Value a.Ÿƒ&
If the resistance value is in the standard range, indicates it is good;
however’LQGLFDWHVWKHFRLOLV bad.

The ignition coil also can be inspected and measured with the ignition testing instrument.

Please operate properly according to the instructions.

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Turn the switch of the testing instrument to the “ON” position. Observe the spark and inspect
the spark situation of the ignition coil. If it is a normal consistent spark, it is good; if
WKHVSDUNGRHVQRWÀDVKFRQVLVWHQWOy, it is not good.

SPARK PLUG
• Clean the carbon around the spark plug to prevent it from dropping into the cylinder. Remove the
spark plug.
When installing, connect the black/yellow wire of the primary ignition coil with the
black/yellow connector of CDI, and the green wire with the green connector of CDI.

‡&OHDQWKH¿Oth and carbon accumulation on the spark plug with a steel brush or a blade.
• Inspect the spark plug gap in general it should be about 0.6 ~ 0.7mm.
• When the carbon accumulation and wear of the spark plug are too severe, replace the spark plug.
Replace with the spark plug of the same speci¿cation.

69
 INDEX
AIR ADJUSTING SCREW ADJUSTMENT 23
AIR CHECK VALVE 26
AIR CHECK VALVE INSTALLATION 26
AIR CUT VALVE (ACV) 26
AIR CUT VALVE INSTALLATION 26
AIR CUT VALVE REMOVAL 26
ARMATURE INSPECTION 31
AUTOMATIC SIDE STARTER INSPECTION 24
BATTERY 51
BATTERY CHARGING 52
BATTERY INSTALLATION 51
BATTERY OPEN-CIRCUIT VOLTAGE INSPECTION 51
BATTERY REMOVAL 51
BEARING ON THE LEFT CRANKCASE BODY REPLACEMENT 48
BEARING ON THE TRANSMISSION CASE COVER REPLACEMENT 47
BELT DRIVEN CVT MECHANISM INSPECTION AND SERVICING 36
CAM CHAIN TENSIONER 12
CAMSHAFT 10
CAMSHAFT INSPECTION 10
CAMSHAFT INSTALLATIION 11
CAMSHAFT REMOVAL 10
CAPACITIES 31
CARBURETOR 2
CARBURETOR IDLING ADJUSTMENT 23
CARBURETOR INSTALLATION 25
CDI COMPONENT 58
CDI COMPONENT 58
CHAIN ADJUSTRMENT 65
CHARGING STATUS INSPECTION 50
CHARGING SYSTEM INSPECTION 50
CHARGING SYSTEM INSPECTION AND SERVICING 50
CHASSIS 2
CHASSIS NUTS AND BOLTS 1
CLUTCH 46

61
CLUTCH DISASSEMBLING 40
CLUTCH INSPECTION 40
CLUTCH INSTALLATION 41
CLUTCH REMOVAL 40
CONNECTING ROD END INSPECTION 4
CONTROLING MECHANISM 36
CRANK CONNECTING ROD MECHANISM 4
CRANK CONNECTING ROD SET 5
CRANKCASE AND CRANKSHAFT REMOVAL 6
CRANKSHAFT AND CRANKCASE INSPECTION 7
CRANKSHAFT AND CRANKCASE INSTALLATIION 7
CV CARBURETOR 22
CYLINDER 3
CYLINDER INNER WAL WEAR INSPECTION 3
CYLINDER REMOVAL 3
DRIVE BELT PULLEY 38
DRIVE BELT PULLEY INSPECTION 38
DRIVE BELT PULLEY INSTALLATION 39
DRIVE BELT PULLEY REMOVAL 38
DRIVEN BELT PULLEY 42
DRIVEN BELT PULLEY INSPECTION 42
DRIVEN BELT PULLEY INSTALLATION 44
DRIVEN BELT PULLEY REMOVAL 42
DRIVEN PLATE BEARING REPLACEMENT 43
ELECTRIC LEAKGAE TESTING 50
ELECTRIC SYSTEM 50
ELECTRICAL STARTING MECHANISM 30
ENGAGING MECHANISM 33
ENGINE 6
ENGINE COMPONENTS 6
ENGINE COMPONENTS AND CRANK CONNECTING ROD 6
ENGINE COMPONENTS INSPECTION AND SERVICING 6
ENGINE OIL 2
FINAL GEAR OIL 2
FLOAT CHAMBER 24
FLOAT CHAMBER INSPECTION 25
FLOAT CHAMBER INSTALLATION 25
FLOAT CHAMBER REMOVAL 24
FOAM FILTER MAINTENANCE 1
62

FUEL LEVEL INSPECTION 25

FUEL SUPPLY SYSTEM INSPECTION AND SERVICING 22
FUEL SWITCH (PETCOCK) 1
GENERAL INTRODUCTION 18
GENERAL INTRODUCTION 36
 GENERATOR INSTALLATION 54
GENERATOR REMOVAL 53
GENERATOR REMOVALAND INSPECTION 53
IGNITION CHARGING COIL 57
IGNITION COIL 59
IGNITION COIL INSTALLATION 59
IGNITION COIL REMOVAL 59
IGNITION SYSTEM INSPECTION 56
IGNITION SYSTEM INSPECTION AND SERVICING 56
IGNITION TIME INSPECTION 56
KICK RETURN STARTING MECHANISM 27
LUBRICATION SYSTEM INSPECTION AND SERVICING 18
MAIN WIRING – SUB ELECTRIC CIRCUIT CONDITION INSPECTION 54
MECHANISM INSPECTION 28
MECHANISM INSPECTION AND SERVICING 3
OIL PUMP ASSEMBLING 21
OIL PUMP INSPECTION 20
OIL PUMP INSTALLATION 21
OIL PUMP REMOVAL 19
OIL REPLACEMENT 19
OIL SYSTEM INSPECTION AND REPLACEMENT 19
OIL SYSTEM INSPECTION AND SERVICEING 50
PISTON PIN INSPECTION AND SERVICING 4
PISTON RINGS INSPECTION AND SERVICING 4
PISTON RINGS SET UP 5

63

PISTON SET 4
PISTON SET INSTALLATION 5
PRIMARY COIL 52
PRIMARY COIL INSPECTION 53
PRIMARY IGNITION COIL INSPECTION 59
REAR TRANSMISSION MECHANISM INSPECTION AND SERVICING 45
REDUCTION GEAR INSPECTION 33
REDUCTION MECHANISM 33
REGULATE RECTIFIER 54
REGULATE RECTIFIER INSPECTION 55
REMOVE THE CDI COMPONENT. 58
RESISTOR 55
RESISTOR RESISTANCE VALUE MEASUREMENT 55
ROCKER ARM AND ROCKSHAFT 11
ROCKER ARM AND ROCKSHAFT INSPECTION 11
ROCKER ARM AND ROCKSHAFT INSTALLATION 11
ROCKER ARM AND ROCKSHAFT REMOVAL 11
ROTARY OIL PUMP 19
SECONDARY IGNITION COIL INSPECTION 59
SPARK PLUG 59
SPIRAL SPINE TRANSFERRING STYLE STARING MEACHANISM REMOVAL 28
SPIRAL SPLINE TRANSFERRING STYLE STARTING MECHANISM 28
SPRIAL SPLINE TRANSFERRING STYLE STARTING 28
STARING CLUTCH INSTALLATION 35
STARTER MOTOR 30
STARTER MOTOR INSTALLATION 32
STARTER MOTOR REMOVAL 30
STARTER REPLAY INSPECTION 35
STARTING CLUTCH INSPECTION 34
STARTING CLUTCH REMOVAL 34
STARTING MECHANISM INSPECTION AND SERVIVING 27
64

TIGHTENING TORQUE CHART 1

TRANSFERRING STYLE STARTING MECHANISM INSTALLATION 28
TRANSMISSION BELT 44
TRANSMISSION BELT INSPECTION 44
TRANSMISSION CASE 26
TRANSMISSION CASE GEAR INSPECTION 26
TRANSMISSION CASE OIL INSPECTION 45
TRANSMISSION CASE OIL REPLACEMENT 45
TRANSMISSION CASE OIL REPLACEMENT 55
TRANSMISSION CASE REMOVAL 57
TRANSMISSION COMPONENTS INSPECTION AND SERVICING 27
TRIGGER WINDING 58
VACUUM CHAMBER INSTALLATION 24
VACUUM CHAMBER REMOVAL 23
VALVE AND VALVE SEAT AIR IMPERMEABILITY INSPECTION 17
VALVE AND VALVE SEAT LAPPING 17
VALVE AND VALVE SPRING 13
VALVE AND VALVE SPRING INSPECTION 13
VALVE AND VALVE SPRING REMOVAL 13
VALVE CLEARANCE 2
VALVE CLEARANCE ADJUSTMENT 9
VALVE GUIDE 14
VALVE GUIDE INNER DIAMETER MEASUREMENT 14
VALVE GUIDE REPLACEMENT 14
VALVE MECHANISM INSPECTION AND SERVICING 8
VALVE SEAT 15
VALVE SEAT FINISHING 15
VALVE SEAT TOUCHING POSITION INSPECTION 16
VALVE SEAT WIDTH MEASUREMENT 15
65