GY6 Manual

QMB139 (GY6)

4-Stroke
OHV Engine & Transmission
!"#"$%
Service and Maintenance Manual
&
Contents

General Information

Technical
Tips 1

Torque Settings
8

Lubrication
Requirements
9

Trouble
Shooting 12

Scheduled Maintenance

Fuel
Filter
&
Throttle 17

Air
Filter
& Plug
Spark 18
!" #$
Valve Adjustment 19
%
Ignition
Timing &
20
'
Gear (
Oil
21

Lubricating
System
)
Engine
Requirements *
23
(
Oil +
Change ,
24
(
Oil Pump "
Removal -
25
(
Oil Pump .
Assembly
27

Fuel System
'
General %/
Information *&
30

Troubleshooting *
31
+
Carburettor *
32

Cylinder Head & Valves
(""0
Overview ,*
43
+.#
Cylinder 1#
Head 2 .
Disassembly ,3
46
!"
Valve " 4/ %
Removal
Inspection -&
50
Cylinder 1#
+.# Head
Assembly
. 55
--

Cylinder
& Piston
'
General %/
Information -
59
+.#
Cylinder "
Removal 3
61

Piston "
Removal & %
Inspection 3
62
.
Reassembly 3,
64

Drive
Pulley & Clutch
'
General %/
Information 3
67
2"
Drive 5
Belt + "
Cover "
Removal 3
69
2"
Drive 5
Belt
Replacement
72
2" .
Drive Pulley "
Removal *
73
6
Roller Weights ,
74
+
Clutch .
Assembly 3
76
!
Transmission
'
General %/
Information
81
2
Transmission .
Disassembly *
83
Bearing
5 Replacement
84
,

Transmission .
Assembly -
85
""
Crankcase & Crankshaft
'
General %/
Information
87
+
Crankcase 2 .
Disassembly
89
+ /
Crankshaft "
Removal & %
Inspection
91
+
Crankcase .
Assembly
92

Charging
System
Circuit 2
+ Diagram 94
,
(""0
Overview 95
-
Charging .
+ System
99

! /
Voltage Rectifier &&
100
7
Magneto &
101

Ignition
+
Circuit 2
Diagram &3
106
'
General %/
Information &
107
CDI 8+
+2% (Capacitor Discharge
2 Ignition)
% 9 109
&
%
Ignition +
Coil 110&
7 +
Magneto Pickup Coil 111

Starter
System
+
Circuit 2
Diagram 112

Starter 7
Motor "
Removal & %
Inspection 114,
1. General Information
Technical Tips
eReplace all gaskets, o-rings, circlips eSpecial service tools may be required
and cotter pins when performing to perform maintenance and repairs on
maintenance on the scooter. Nuts and this scooter. Always use the proper tools
bolts on all engine covers should be to prevent damage to the scooter.
tightened in a diagonal pattern to
uniformly distribute clamp
force.
eClean and lubricate all engine parts

during the disassembly and reassembly
process to prevent damage to the
engine.
eUse lubricants recommended in this

manual at all times to assure peak
performance from the scooter.
eUse only genuine replacement parts

when performing repairs to the scooter.
1
Technical Tips (continued)

eWhen performing maintenance on the eWhen disconnecting the battery, always
scooter, make sure that all moving parts disconnect the negative terminal first.
and controls move freely and return to
their proper position.
eMake sure that tools and service

eWhen connecting the battery, always equipment do not come in contact with
connect the positive terminal first. both battery terminals.
eCover both battery terminals with a

light coat of grease to prevent
corrosion.
2

eWhen replacing fuses, always use an eWhen assembling wire connectors,
exact replacement. Do not use fuses of press firmly to assure the lock tab fully
a higher amp rating! engages.
%
eReplace all rubber caps on wire
connectors after performing
maintenance.
eMake sure that all wire terminals are

eWhen disconnecting wire connectors, properly in place before attempting to
press firmly on the locking tab and pull assemble any wire connector.
the body of the connectors. Never pull
on the wires
3

eMake sure that all wiring connectors are fully eNever reuse damaged wire terminals or
seated and lock tubs engaged. connectors.
eCheck if almuce of connector is covered and eReplace all rubber covers on wire connectors
fixation is tight. to prevent water from getting into the
connector.
eStrip of main wire must be fixed on assigned

position.
eMake sure that all protective covers are

properly in place over the wiring connectors.
elnsulator of aluminum strip must be affixed to

wires.
eMake sure that all wiring harness retainers are

properly placed.
¢Do not over tighten wiring ties to prevent

pinching of wires.
eNever reuse damaged wire terminals or
connectors. Do not allow wiring harness to hang in loose
loops.
4

eMake sure that all wire clips are eMake sure that the wiring harness and
properly attached. all wires do not contact hot components
or surface parts of the scooter.
=~ NO a=
YES NO
GD) Coo)
eMake sure that the wiring harness and eMake sure that the wiring harness and
all wires do not contact moving or all wires do not contact sharp edges or
rotating parts of the scooter. parts of the scooter. Use tape to prevent
damage to wires on sharp edges.
5
eDo not pull wires too tightly.
eUse tape to protect against sharp edges.
eMake sure that all rubber grommets are in

place to protect the wiring harness.
eDo not reuse broken or frayed wires.
eRepair or replace wires as necessary.
6
Definitions of diagrams
The following icons are used to highlight important
operations in the service of the scooter.
Lubricating oil required.
m!
[crease| Grease required.
Engine oil required.
Special tools required.
Special attention required.
Dangerous and important,

special care required.
7
Torque Settings
Standard Torque Settings
General Torque Requirements for Standard Fasteners
Fastener Type Torque Fastener Type Torque
5mm Cap Screw 5 kg/cm 5mm Socket Head Screw .4 kg/cm
6mm Cap Screw 1 kg/cm 6mm Socket Head Screw .9 kg/cm
8mm Cap Screw 2.2 kg/em 8mm Flange Head Screw 1.2 kg/cm
10mm Cap Screw 3.5 kg/cm 10mm Flange Head Screw 2.7 kg/cm
12mm Cap Screw 5.5 kg/cm 12mm Flange Head Screw 4.0 kg/cm
Special Torque Settings

Torque Requirements for Engine Fasteners
Fastener Type eet ny lori. Ibs) Comments
Cylinder Bolt A 2 8 9
Cylinder Bolt B 2 8 9
Oil Filter Screen Cap 1 30 1.5
Exhaust Pipe Flange Bolt 2 6 9
Flange Screw Belt Pulley 4 8 2.0 Lubricate with Engine Oil
Valve Adjusters 2 5 .9 Lubricate with Engine Oil
Cam Chain Adjuster 1 6 1.0
Guide Plate Screw 1 8 1.3
/ Oil Fill Screw
Clutch Cover Screw 1 12 5.5
Clutch Driven Unit 1 12 5.5
Mounting Screw
Starter Motor Mounting Screw 2 6 1.0
Oil Pump Mounting Screw 3 6 1.2
Clutch Driver Mounting Screw 1 12 5.5
ACG coil Mounting Screw 3 6 1.0
Cam Chain Adjuster Screw 1 6 5
Spark Plug 1 10 1.2
Torque Requirements for Frame Fasteners
Fastener Type omer an leew Ibs) Comments
Cylinder Bolt A 1 25.4 8-12

Cylinder Bolt B 1 10 4-5
Oil Filter Screen Cap 1 14 8-10
Exhaust Pipe Flange Bolt 1 10 3-4
Flange Screw Belt Pulley 1 8 2-3 Use Soft Set Lock-Tite
Valve Adjusters 1 5 a5)
8
Lubrication Requirements: Engine
Item Location Recommended Lubricant
valve guide valve stem moving part SAE 5W 30 Engine Oil

cam shaft lug surface APISG Grade Engine Oil
valve rocking arm friction surface oll
camshaft drive chain grease
cylinder fixed screw bolts and nuts oil
around piston and piston ring groove oll
around piston pin oil
cylinder surface oil
connecting rod, piston pin bore oll
connecting rod big end oil
crankshaft R, L side oil seal oil
starter reduction rear engaging (mating) part
coundershaft gear engaging part oil
final gear engaging part oil
each bearing rotational part grease
o-ring surface oil
oil seal lip oll
starter idle gear oil

friction spring moving part, shaft moving part grease
shaft moving groove part oil
starter drive axle grease
AC-generator connector adhesive
9
TYPICAL INSTALLATION
TYPICAL INSTALLATION
FUEL LINE
IGNITION COIL
\ THROTTLE
—
L————_
=
=
IGNITION CABLE
CRANKCASE VENT
VACUUM LINE
ROCKER COVER VENT
10
10
LL
11
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Trouble Shooting Guide

Starter Failure or Hard Starting
Check Adjust Faulty Condition Cause of Trouble
Loosen carburetor overflow screw

and check if there is fuel in it r— No fuel in tank
'
'
'
'
'
'
'
t
Vv
t— Passage from tank
Po "
to carburetor blocked
t— Float passage clocked
Supply apply No fuel suppl .
enough fuel 0 fuel supplied to carburetor t— Air hole in fuel tank cap blocked
-— Fuel filter blocked
+— Fuel filter screen blocked
'— Vacuum switch faulty
Remove spark plug install it in its
' cap and connect it to engine to r— Spark plug bad
for spark po ” L— Spark plug dirty and broken
t— C.D.I. bad
fo t— Pickup coil bad
There is spark over in spark plug | | There is no spark or weak spark|—- Ignition coil broken circuit
or short circuit
-— Ignition coil broken wire
ro--- or short circuit
L_ Main switch bad
| No compression pressure
-— Starter clutch bad
or compression pressure Valve too tight
too low t— Valve set bad
+— Cylinder piston or piston ring bad
peo ee eee eee -— Cylinder gasket leaking
t— Valve burned
— Valve timing improper
[
| (Engine) having ignition -— Automatic choke performance
spark but not to start Air inlet improper manifold
-— Ignition time wrong
'— Carburetor oil quanitity
regulation screw bad
Carburetor oil level too high

Auto-enriching device start
Spark plug wet | | Spark plug dry enrichment faulty
——q
Throttle valve opening too wide
12
12

(under speed, no power)
Air filter blocked

Fuel choke
Fuel tank cap air bleeder
blocked
Exhaust pipe blocked
Auto choke bad
Carburetor diaphram broken
Automatic oil cup bad
C.D.I. bad
Ignition coil bad
- Valve gap adjustment improper

Valve gap correct Valve gap incorrect Valve seat excessively worn
(valve out shooting excessively)
Valve seat bad
Cylinder or piston worn
Cylinder gasket leaking
Compression pressure normal ssion pressure too low
.
Valve timing bad
No blockage Blocked Clean
- - Clean
D irty or discolored
| Spark plug heat value .improper
Engine oil too much

Engine oil too little
Engine oil unchanged
Oil passage blocked

Oil pump delivery
r— Piston or cylinder worn

t— Mixture excessively thin fuel improper
t— Combustion chamber carbon
deposit too much
'— Ignition time too early
r-— Combustion chamber
t— Carbon deposit too much
t— Fuel bad
No knocking Knocking t— Clutch slipping
|
:
t— Mixture weak
'— |gnition timing too early
13
13
Trouble Shooting Guide (under speed, no power)

‘Adjust ignition time = hw ,
C.D.I. bad
' Adjust carbureator adjusting screw) an

woe — l Mixture lean
(to loosen screw)
| Good | | Pad Kp Mixture
Too rich (to tighten screw)
' Check for carburetor gasket air leakage 1 ---»
r— Heat shield bad
+— Carburetor hold-down nut loose
| No air | | Air intaken
+— Heat shield broken
eee eee eee eee ee ( '— Negative pressure pipe broken
Remove spark plug and install it in its cap and '
connect it with engine to check for spark over !
r— Spark plug bad or dirty

-— CDI bad
t— lgnition coil bad

| Check A.C.V. Ly — Main switch bad spark plug
eee lead broken or short circuit
Bad +— Negative pressure pipe damaged

'— Air bleeder blocked or damaged
14
14

(high speed)
Adjustment improper
Camshaft worn
Valve seal bad
Too little fuel

Fuel filter blocked
Vacuum switch bad
No blocking Blocked Clean
Spring broken or fatigued Spring bad
15

(no spark)
' Replace
spark plug and check again. =} - - - - - ,
| Sark weakor aes

Spark weak or sparkless
|__| Sear stron
[ Spark svore}_ Former spark plug bad
Check spark plug cap and ignition coil for looseness t ---»
Check for conduction between connector

terminals and test CDI resistance
Normal Abnormal
Main switch bad

Normal [Ainormal 4}. | Pickup coil bad
Ignition coil bad
-— Main cable broken

L_ Connector plug poor contact
' Use CDI tester to check CDI Loy
[Abnormal
————______
| |}_ Ignition coil bad
16
16
2.
2. Scheduled Maintenance
Fuel Filter
1. Remove luggage box (2-2)
2. Check fuel line for ageing or damage.
3. Replace with a new one in case damaged

or leaking.
Throttle Lever Operation
1. Check throttle for proper operation.
2. Check throttle grip free play.

Free play: 2-6mm (.078 in.-.236 in.).
3. Adjust free play using the adjusting nut in

the throttle cable and the adjuster at the
carburetor.
eMajor adjustment should be made at

carburetor.
eAdjust it by loosening the jam nut and rotating

adjusting nut.
eFine adjustment should be made at the throttle

grip.
eRemove outer cover, loosen jam nut and

rotate adjusting nut to adjust it.
17
17
2.
Air Filter
Filter Replacement
1. Remove air filter cap, fix

screw and remove the air filter
cap.
2. Check filter for dirt or

damage. Replace as necessary.
Do not attempt to clean the

filter element.
Replacing Frequency 2 @
1. More frequent replacement

AIR FILTER
is required if vehicle is driven on
dusty roads or in the rain.
AIR FILTER CAP
2. Make sure the air filter
cover is securely in place.
Spark Plug
1. Remove spark plug.

GAP, DIRTY CARBON
2. Check spark plug for BUILD-UP CHECKING
burning, dirt or deposit.
3. Clean it with a spark-plug . SPARK (2) neo7

cleaner or steel brush in case PLUG 022-024 inch
of dirt or carbon deposits.
Specified spark plug: CYLINDER

NGK: C7HSA Champion HEAD COVER
Check spark plug gap
Gap: 0.6-.07mm (.022-.024 in.)
4. Check plug for dirt, carbon INSULATOR CRACK

CHECKING
build-up or cracking of insulator.
18
18
2.
Valve Adjustment
© Always check and adjust with

engine temperature lower than
35°C (95°F)
1. Remove cylinder head cover.

CYLINDER
HEAD COVER
2. Rotate cooling fan to camshaft. Locate
mark at center top, aligning magneto
fly wheel mark with that on crankcase.
Magneto “T” mark and box crankshaft
mark.
Valve gap checking and

adjustment valve gap:
IN: 0.05mm (.00197 in.)
EX: 0.05mm (.00197 in.)
3. To adjust the valve gap, loosen am nut

and rotate adjusting nut.
Valve Adjustment Wrench HOLE IN CAM GEAR

AWAY FROM ENGINE
Be sure to check valve gap again, CAMSHAFT
after locking jam nut. CHAIN GEAR
Carburetor Idle Speed
Idle adjustment should be made

with the engine warmed up.
1. Remove cover.
2. After the engine warms up, connect it

to an engine revolution counter.
3. Adjust idle screw until specified

revolution is obtained.
Minimum idling speed: 1900+190rpm
4. Readjust the screw if the idle speed

is not steady or fuel cannot be
properly applied.
19
19
2.
Ignition Time
Equipped with CDI, there is no need

for ignition setting.
Check ignition system if ignition time

© is incorrect.
Dismount right body cover.

wnr
Remove ignition timing inspection.

Check ignition timing using the timing light.
Crankcase mark must be aligned with mark
“F” on flywheel while engine is at idle
speed. The timing should advance as the
RPM is increased.
The timing mark should align with the

crankcase mark at 3000 RPM. IGNITION TIMING
INSPECTION
Cylinder Pressure
1. Measure cylinder pressure with the engine

warmed up.
2. Dismount middle luggage box and middle
cover (2-2).
Remove spark plug.
1. Install cylinder pressure gauge.

2. With throttle valve fully open, start starter
motor to measure cylinder pressure. (21 3psi)
3. Compression pressure: 15kg/cm2
-600rpm.
4. If the pressure is excessively low, check for
the following:
eValve leakage |
eValve gap too tight MARK "F" ———
Cylinder head gasket damaged PROPERLY ALIGNED
ePiston ring worn
Piston or cylinder worn
5. Check combustion chamber and piston top

for excessive deposit if compression pressure
is too high.
20
2.
GEAR OIL INLET
Final check of gear engine oil reduction HOLE/CHECK HOLE —+
Checking oil volume, build up main foot

rest so that build up body becomes
vertical on plain ground.
1. Dismount gear oil adjusting bolt after

stopping engine.
2. The oil level should be just under the

regulation screw bolt hole. Add gear oil when oil
level is too low.
eGear oil recommended: SAE 90W

L OIL DRAINAGE BOLT
AND WASHER
3. Build up gear oil regulator screw bolt.
4. Confirm whether or not the packing washer

is broken.
Changing Gear Oil
1. Remove gear oil adjusting bolt and drain oil.
2. Confirm whether or not packing washer is

broken.
3. Add recommended gear oil.
eGear oil capacity: 0.12I-40ES

eBolt torque: 0.9kg-m 780 lbs.
4. Check if there is any leakage after work is

performed.
Transmission Belt
1. Detach the left crankcase cover (9-2).
2. Check whether there is wear and tear of

transmission belt.
3. Change with new one when necessary or

during timely maintenance.
TRANSMISSION BELT —————
21
21
3.
3. Lubricating System
Lubricating System
ROCKER ARM
CRANKSHAFT
ZX ©
FILTER SCREEN
ENGINE OIL PUMP
22
3.
Topic Page Topic Page
Overall engine requirements 4-2 Engine Oil Pump Removal 4-4

Problem diagnosis 4-2 Oil Pump Disassembly 4-5
Engine oil/filter screen 4-3 Checking 4-5
Oil Volume 4-3 Assembling 4-6
Oil Changed 4-3 Installation 4-6
Overall Engine Requirements

Special Attention
Use proper motor oil SAE 10W 30.
Use only clean, fresh oil.
Do not rebuild oil pump. Replace with a new pump when needed.
Check for leakage after replacing pump.
Basic Material
Item Nunmul value; Replace at

Gap between inner rotator and external rotor — 0.12mm_ — .005in
Engine oil pump Gap between external rotor and pump body — 0.12mm_— .005in
Gap between and surface of rotor and pump body | 9.95-0.10mm| 09:-2mm — .008in
.001-.004in
Problem Diagnosis
Loss of engine oil

eEngine oil natural consumption. Engine burning excessive oil
Engine oil leakage. *Blocked oil passage.
ePiston ring wear, bad assembly. Use of wrong oil.
eValve guide oil seal is worn. Worn rings.
eValves worn or damaged.
No oil pressure
ePump worn.
eUse of wrong oll.
Oil level low.
23
3.
3.Lubricating System
Engine Oil/Filter Screen
Oil Volume
1. Check oil with scooter parked on level

ground on center stand.
Scooter must be on center stand

when oil volume is checked.
Run engine for two or three minutes

and then turn it off. After two to three
minutes, check the oil level.
2. Check the oil level when the oil dipstick is

unscrewed and out.
3. Add oil to upper limit level on the dipstick.
Oil Changed
© It is easier to drain oil when motor is

warm.
1. Remove drain bolt to completely drain oil.

2. Disassemble the oil filter screen cover
and take off the oil filter screen. Use
high-pressure air to clean the filter screen.
Wash with solvent and dry before reinstalling.
3. Check o-ring for damage. Replace if

necessary.
4. Assemble engine oil filter screen and filter
screen cover.
eTorsion value: 1.4kg-m

1300 ft Ibs
5. Add assigned oil to determined volume.
eEngine oil capacity: 0.8L

©320ES
6. Check for oil leaks.

7. Runengine for 1-2 minutes at idle speed. OIL FILTER SCREEN
8. Turn engine off and check oil level. Add Sy h O-RING
oil if needed. \ 7 J 3)
24
24
3.
Oil Pump Removal
1. Remove engine right outer

cover fan magnetor.
2. Remove alternator rotor.

WASHER
3. Remove stator pules coil.
4. Remove eight bolts of

right crankshaft case cover
and take off crankshaft case
cover. r & @ ; (5)
5. Remove washer and fixed Ww ON

pin.
6. Remove the fixed nut of

the gear in the oil pump.
7. Take off the gear of the oil

pump.
8. Remove fixed bolts of oil

pump module body.
9. Take off oil pump.
10. Take off two o-rings.
11. Check o-rings for

damage.
12. Replace if necessary.
OIL PUMP
O-RINGS
25
3.
Oil Pump Disassembly
OIL PUMP BODY
1, Remove three fixed screws in oil pump FIXED SCREWS -

body.
2. Disassemble oil pump.
OIL PUMP BODY
EXTERNAL ROTOR
Checking
1. Check the gap between the oil pump module

body and the external rotator.
eUsed limit: 0.12mm (.005 in.).
Check the gap between the surface of the EXTERNAL ROTOR

rotator and the body. INTERNAL ROTOR
eUsed limit: 0.2mm (.008 in.).
26
3.
Assembling
1. Assemble inner and outer 1)

rotators and oil pump
shaft. EXTERNAL ROTOR
INTERNAL ROTOR PUMP SHAFT
Be careful of
© alignment between
pump bearing unfilled
corner and inner
rotator unfilled corner.
2. Assemble pump cover

and tighten screws.
Installation
1. First put two o-rings at

the oil pump seat.
2. Put oil pump in the

crankshaft case.
First add oil to pump

and then assemble.
3. Tighten the three fixed

Screws.
OIL PUMP
O-RINGS
27
3.
4. Install gear of oil pump and
then fix nut.
eTorsion value: 0.8-1.2kg-m

¢7-8ft lbs WASHER
5. Assemble right crankshaft

case cover, 8 screws and tighten.
6. Assemble pulse coil, stator

and rotor.
7. Install fan and cover.
FIXED NUT
MAGNETOR COIL
ROTOR
FAN COVER
28
4.
4. Fuel System
REGULATOR
RESISTOR
ENRICHMENT
@) WHITE @) YELLOW @@ GREEN/BLACK
29
29
4.
4.Fuel System
General information 5-2 Disassembly of Accelerator Pump 5-10

Troubleshooting 5-3 Checking Accelerator Pump 5-10
Disassembly of Carburetor 5-4 Assembly of carburetor 5-11
Checking Auto-choke 5-4 Disassembling Fuel tank 5-12
Air cutoff valve 5-6 Assembly of Fuel Tank 5-12
Assembling 5-6 Carburetor Adjustment 5-13
Vacuum Chamber-Break Down 5-7 Automatic Fuel Valve 5-14
Assembly of Vacuum Chamber 5-7 Fuel Meter Sending Unit 5-14
Float bowl and Disassembly 5-8 Air Filter Inspection 5-15
Checking Float Valve 5-9
General Information
A
Warning! eCheck all o-rings for damage. Replace as
Work on the fuel system in a necessary.
well-ventilated area that is free of
sparks or open flames. Do not breathe eRemove carburetor from the scooter before
the vapors from the gasoline. Wear attempting to service the fuel bowl or vacuum
protective gloves to prevent skin canister.
irritation.
eWhen cleaning the carburetor, remove the
eOpen the bowl drain and allow all gasoline in vacuum diaphragm before using air or solvents
the carburetor to drain into an appropriate for cleaning. This will prevent damage to the
container prior to removing or servicing It. diaphragm.
Remove control cables and wires carefully to eWhen storing the scooter for a period of time
prevent damage. exceeding one month, use a quality fuel
stabilizer to prevent deterioration of the fuel
and damage to the carburetor.
Repairing material
Specification Standard valve

Carburetor type Constant velocity-CVK
Venturi Bore 17mm (.67 in.)
Fuel Level mm
Main jet
Idle jet .27 mm (.12 in.)
Idle speed 1600 RPM
Throttle free play 5mm (.125 in.)
Mixture screw setting 3 turns out
30
4.
4. Fuel System
Troubleshooting
Engine is hard to start Misfire under acceleration
eNo spark ePoor spark
eLow compression eAir mixture screw too lean
eNo fuel in carburetor eBad accelerator pump
-Blocked fuel line
-Blocked fuel filter Poor drivability
-Blocked vacuum line eWeak spark/bad ignition system
-Leaky vacuum line eBlocked fuel line
-Dirty float needle eBlocked fuel filter
Float set too high Bad fuel
eWater in fuel
Too much fuel to engine eAir leak at carburetor or manifold
-Blocked air filter elmproper float level
-Manifold air leak eBad auto choke
-Bad auto choke eObstructed jet in carburetor
-Blocked air passage in carburetor eVacuum slide stuck
eDamaged vacuum diaphragm
Air/fuel mixture too rich or too lean eDirt in carburetor
eBad auto choke
ePlugged idle jet
eFloat needle stuck or dirty
Float height too high or too low
eBlocked air passage in carburetor
eDirty air filter
eAir leak at carburetor or manifold
31
31
4.
4. Fuel System
Disassembly of carburetor
1. Remove seat and helmet

storage tub.
2. Remove right side body panel.
3. Disconnect cable connector for

auto choke.
4. Loosen carburetor drain screw

and drain fuel from float bowl.
CARBURETOR DRAIN
5. Loosen clumps in intake tube SCREW LOCATED
and main fold. UNDERNEATH FLOAT BOWL
6. Loosen throttle cable and

remove from support and from
throttle control plate.
7. Remove fuel line from

carburetor. AUTO CHOKE
8. Remove air inlet tube from

carburetor and pull carburetor
straight back out of intake manifold.
9. Remove auto choke from

carburetor.
Checking Auto Choke
1. Check resistance volume. AIR INLET TUBE
2. Standard value below 5 when

cold.
3. Connect auto choke to 12V

battery.
4, Plunger should extend 3/8 inch

in 5 minutes. \ AIR SCREW
)
THROTTLE CABLE
32
32
4.
4. Fuel System
5. Check pin and seat for

wear.
6. Replace if necessary.
7. Place auto choke in

mounting location and press
down firmly.
8. Put lock ring in position and

fasten screw
AUTO CHOKE y
MOUNTING LOCATION
FIX PLATE
Lerlex,
a
om |
RS! AG Uf S
33
4.
4. Fuel System
Air Cut Off Valve
1. Disassemble two screws in fuel

guide fixed plate and remove fixed
plate.
2. Disassemble two screws in air

cut off valve.
3. Take off spring and vacuum

plate.
4. Check for wear on plate, replace

if necessary.
5. Clean the passage way to

remove dirt or varnish.
FUEL GUIDE
FIXED PLATE
Assembling
1. Install plate to carburetor. O-RING
2. Install spring and cover of air

cut-off valve. AIR CUTOFF
; ae VALVE COVER
3. Build up fuel guide line fixed plate ;:
and tighten two screws. 5 (2)
Be sure that furrow of vacuum ™, %

plate is aligned with the . Gan =
carburetor glove. SS “ey
:
Make sure that cover tightens SPRING = ~
into place. VACUUM PLATE (3)
34
4.
4. Fuel System
Vacuum Chamber-Break down
1. Remove two screws and take off

cover.
2. Remove spring, diaphragm piston.
3. Remove fuel pin and slide.
Take special care not to

damage diaphragm. Replace
if damaged. SPRING
Checking
1. Check pin for wear and replace if
necessary.
DIAPHRAGM
PISTON (2)
Assembling
1. Install piston or plate to body of

carburetor.
2. Push the button of the piston to

vacuum chamber side and keep open
completely. Install spring and cover.
3. Install screw.
Be sure to hold slide and

piston in up position when
installing cover and tighten
screw.
35
4.
4. Fuel System
Float Bowl
Disassembling
1. Disassemble three screws and

take off float bowl.
2. Remove float pin spring.
3. Remove high-speed jet, low-speed

jet and fuel volume control screw.
Be careful not to break the

fuel jets and control screw. FLOAT AREA
Count the turns when removing

the fuel volume control screw.
FLOAT BOWL
When reinstalling jets and
screws, do not over tighten.
4. Clean jets with solvent and

compressed air.
5. Clean body of carburetor by

blowing air through all passages.
MAIN FUEL JET

FUEL PIN LOW SPEED
JET
FUEL PIN
SPRAY NOZZLE
FUEL VOLUME
REGULATION
36
4.
4. Fuel System
Checking
1. Check float valve and valve seat

for damage.
MAIN FUEL JET
FUEL PIN LOW SPEED
2. Check float valve and valve seat
JET
wear, pitting or buildup of dirt.
FUEL PIN
SPRAY NOZZLE
3. Any leakage of the valve or a
buildup of dirt will affect the fuel level FUEL VOLUME
in the float bowl and cause drivability REGULATION
problems.
4. Assemble the low speed jet, fuel

pin spray nozzle, fuel pin spray seat
and main jet into the bottom of the
carburetor housing.
5. Set the fuel level in the bowl by

adjusting the fuel regulation screw. The
standard setting is 2 turns, plus or
minus a 1/4 turn.
6. Assemble the float valve, float and

float pin to the bottom of the
carburetor using the retainer pin.
7. Check the operation of the float

and valve. All parts should move freely FLOAT
and not bind. VALV
8. After assembling the float, check

for proper fuel level using a small ruler
or a float gage. The proper fuel level
is 20.5mm (.807 in.).
FLOAT PIN
37
4.
4. Fuel System
Accelerator Pump
1. Remove two screws on pump

and take off cover.
2. Take off spring and acceleration

pump plate.
Checking
1. Check acceleration pump plate

for cracks or hardening of the rubber.
Replace as necessary.
2. Check for blocked fuel passages.
3. Clean by high pressure air.
4. Reverse steps to reassemble.

SPRING
© Me
5. Take special care with the ACCELERATION
accelerator pump plate to avoid PUMP PLATE
damage.
38
4.
4. Fuel System
Assembly of Carburetor
1. Slide carburetor carefully

into the manifold, making sure to
align the tab on the manifold with
the notch on the carburetor.
Securely tighten the clamp screw
to fix the carburetor in place. Do
not over tighten the screws as
this can cause damage to the
manifold.
2. Attach the inlet pipe to the

rear of the carburetor and
tighten the clamp screw.
3. Attach the throttle cable to

the throttle by installing the cable
lug into the notch on the throttle
plage. Insert the outer casing of
the throttle cable into the cable
support bracket. Make sure to
align the “D” shape of the
adjusting sleeve with the ‘D”
shape hole of the bracket.
4. Use the adjusting nut and

stop nut to set the cable tension.
Correct adjustment should allow
1/4 inch of free play in the
cable. AIR SCREW
5, Attach the fuel line from the iy

tank to the inlet on the
carburetor and clamp securely. THROTTLE CABLE
6. Connect the wiring harness

from the auto choke to the
proper connection on the main
wiring harness.
7. After starting the engine, set

the idle speed using the idle
adjusting screw.
39
4.
4. Fuel System
Carburetor Adjustment
NOTE: SOME COMPONENTS
It is generally not necessary REMOVED FOR CLARITY.
to adjust the mixture screw
on the side of the
carburetor. This screw is FUEL VOLUME
preset at the factory and REGULATION
will have little effect on the
performance of the
carburetor.
1. If this screw has been removed

for cleaning of the carburetor, it
should be reset carefully. The
standard setting is two turns out,
plus or minus 1/4 turn.
2. To set this position, run the

engine until warm and allow it to
idle. Turn the screw in or out a little
at a time and measure the idle
RPM. The correct setting is
achieved when the idle speed is
maximized.
3. Adjust the idle speed of the

engine once the engine has been
warmed up.
4. Set the warm idle speed to

1900RPM, plus or minus 1OORPM.
5. Check for engine return to idle

speed after running at part throttle.
IDLING SPEED An
She
Ae
6. Make sure that the throttle ADJUSTMENT SCRE
cable allows the throttle control
plate to return to the StoM screw.
7. lf needed, readjust the mixture

screw to help stabilize idle
performance.
40
40
4.
4. Fuel System
Automatic Fuel Valve
1. Disconnect the fuel line and the vacuum line

from the control valve and from the carburetor VACUUM LINE — CONTROL VALVE
and intake manifold. Carefully inspect these
lines. Any blockage, deterioration, damage, or
cracking of these lines can cause improper
functioning of the fuel valve. Replace these
lines as necessary.
2. Always make sure that the clamps work

properly when replacing these lines in order to
assure a tight seal of the lines at the fittings on
the valve, carburetor and manifold.
FUEL LINE
3. To check the operation of the valve, apply a
vacuum to the input fitting of the valve. Fuel
should flow freely when the vacuum is applied
and stop when it is removed.
4. Never attempt to clean the valve with high-

pressure air. This will damage the valve and
require replacement.
Fuel Meter Sending Unit
1. Disconnect the sending unit wiring harness.
2. Disconnect four mounting screws.
3. Lift and turn the sending arm to allow the

float arm and float to be removed from the fuel
tank. Take care not to bend or damage the float
arm as this can cause improper readings.
4. Check the movement of the arm. It should

move freely without binding or hesitation. Check
the continuity of the coil. If itis open, the unit
needs replacement. When reassembling the
sending units, make sure that the gasket Is not
damaged to avoid leakage.
A
41
4.
4. Fuel System
Air Filter Inspection
1. Remove air filter cover

Screws.
2. Remove cover.
3. Remove air filter element.
4. Remove clamp on air inlet

tube.
AIR PIPE G@ @
AIR FILTER
5. Disconnect air tube from
carburetor.
AIR FILTER COVER
6. Remove air box. Make sure
that the element is clean and free
of dirt and oil. Excessive dirt and
oil on the element can reduce
engine performance.
7. During reassembly, make sure

that the cover and tube
connections are tight and do not
leak. Air filter box leakage can
reduce engine performance.
42
42
5.
5. Cylinder Head Valve
43
5.
en information rs Valve Seat Chamfer Cutting Tools 7-12

rouble diagnosis - ; /
Camshaft Disassembly 7-4 Valve Seat Cutting ile
Bearing Rocker Arm Installing Cylinder Head 7-14
Cylinder Head Break Down 7-9 , ;

Checking Cylinder Head 7.9 Camshaft Chain Regulator Assembling 7-16
Valve and Valve Guide 7-10
Important Information
eWhen working on the cylinder head and valve eWhen measuring parts to determine wear,
train, always use engine oil to lubricate sliding wash the parts with solvent and dry them in
parts when assembling. Never assemble dry order to get accurate measurements.
parts into the valve train.
eWhen disassembling the valve components,
eThe camshaft is lubricated by engine oil keep them in order and reinstall them in the
supplied via an oil passage in the cylinder reverse order.
head. Make sure that this passage is clean and
open when you reassemble the head.
Item Standard valve |_ Used Limit

Valve gap (cold) IN (0.04) 0.05 —_
EX (0.04) 0.05 —_
Cylinder head compressed pressure 15kg/cm2-600rpm —
Cylinder head surface twisting 0.05
Camshaft cover angle height IN 25,761 25.681
EX 25,604 25.24
Valve rocker arm inner diameter IN 10,000-10.015 10.10
EX 10,000-10.015 10.10
Valve rocker arm bearing outer diameter IN 9,972-9,987 9.91
EX 9,972-9,987 9.91
Valve seat angle IN 1.0 1.8
EX 1.0 1.8
Valve bar outer diameter IN 4,975-4,900 4.9
EX 4.955-4,970 49
Valve guide pipe inner diameter IN 5,000-5,012 5.3
EX 5,000-5,012 5.3
Gap between valve bar and guide pipe IN 0.010-0.037 0.08
EX 0.030-0.057 0.10
Valve spring Inner spring 29.1 26.1
Outer spring 33.5 30.5
44
44
5.
Torque Value Slow Speed Hitch
eCamshaft bolt 16 ft Ibs Compression pressure too low
eLubricate threads with oil Bad valve gap
eValve gap adjusting screw cap 7 ft lbs Burning or curving of valve
Bad valve timing
°
GENERAL TOOLS
Broken valve spring
Bad valve seat
Leakage of cylinder head gasket
General tools Warped cylinder head surface or cracking
eValve spring compressor Bad spark plug
e45 degrees IN/EX
eValve seat reamer 24.5mm Compression Pressure Too High
ePlane reamer 30 degrees IN eToo much carbon buildup in combustion
eValve seat reamer25mm chamber
ePlane reamer 32 degrees EX
eValve seat reamer 22mm White Smoke from Exhaust Pipe
ePlane reamer 60 degrees IN/EX eWearing of valve guide
eValve seat reamer 26mm eBroken oil seal
eReamer damping fixture 5mm
Abnormal Noise
°
SPECIAL TOOLS
eBad valve gap
eBroken or burning of valve or valve spring
eWearing and breaking of camshaft
Special tools eWearing of inner chain adjusting plate
eValve spring compressor accessories eWearing of cam shaft and valve rocker arm
eValve gap regulatory spanner
eValve guide screwdriver
eValve guide reamer
Trouble Diagnosis
eConfirm poor operation of cylinder head by
measuring pressure or by noise produced
by engine upper end.
45
5.
Disassembling of Camshaft t
1. Disassemble middle cover. (2-2)
2. Remove four bolts and two nuts, take off

valve cover.
3. Disassemble cam chair adjusting bolt and

spring.
4. Use the kick-start lever to slowly turn engine

CYLINDER
until “T” mark on flywheel lines up with indicator
HEAD COVER
on crankcase. Check position of camshaft to
find if both valves are closed. The hole in the
cam gear should be away from the engine. If
this is not correct, rotate the crank one
revolution to achieve this alignment.
5. Remove four bolts and remove camshaft

Caps.
CAMSHAFT HOLE IN CAM GEAR

CHAIN GEAR AWAY FROM ENGINE
OQ
2D
(BW
‘ Z)
@
&
46
46
5.
6. Remove rocker arms and pivots.
7. Remove camshaft gear from camshaft

chain.
8. Remove camshaft.
9. Check Camshaft
10. Check cam lift.

Use limit: IN: 25.681mm below change
eEX: 25.524mm below change
KS ROCKER ARMS
11. Check surface of cam lobes for weary OS
surface breakdown, scuffing or cracking.
12. Check camshaft and bearing for loose fit or

damage.
13. If any excessive wear or damage is found,

replace the camshaft.
CAMSHAFT
CAMSHAFT
BEARING
47
47
5.
Checking of Camshaft Bearing Rocker Arm
1. Check if camshaft bearing fixed seat and

camshaft rocker arm and camshaft rocker
bearing is worn or broken.
CAMSHAFT
2. Measure outer diameter of camshaft FIXED SEAT
bearing fixed seat and camshaft rocker arm. CAMSHAFT ROCKER
Used limit: 9.91mm (.390 in.). Change if worn ARM BEARING
larger.
elnner diameter of camshaft rocker arm.

Used limit: 10.10mm (.398 in.). Change if
worn larger.
eOuter diameter of camshaft rocker arm

bearing and camshaft rocker arm.
Used limit: 9.91mm (.390 in.).Change if
worn larger.
eThe gap between camshaft rocker arm

and camshaft rocker arm bearing.
Used limit: 0.10mm (.004 in.). Change if

worn larger.
Disassembly of Cylinder Head
1. Remove camshaft bearing. (7-4)
2. Remove carburetor (5-4)
3. Remove exhaust pipe. (2-4)
3. Remove inlet manifold.
48
5.
4. Remove fan cover.
5. Remove bolt and screw

of engine cover.
6. Disassemble and
remove engine cover.
7. Pull up on cylinder head Rt

to break gasket and slide off
cylinder stands. LOCATING PIN —_—§
CYLINDER HEAD
8. Take off location pin and
cylinder head gasket.
9. Take off camshaft chain

guide bar.
CYLINDER HEAD
49
5.
Breaking Down of Cylinder Head
1. Use valve spring compressor to take off

lock clip and supporter and valve spring, spring
seat valve.
Place parts in sequence after

SPRING
disassembling and assemble in reverse
VALVE
order during reassembly. COMPRESSOR
2. Clean carbon deposits from combustion
chamber.
3. Remove gasket material on cylinder head

surface.
COMBUSTION
Don't damage cylinder head sealing CHAMBER
surface.
Checking Cylinder Head
1. Check spark plug hole for damage.

2. Check valve spring seats for alignment.
Used limit: 0.05mm (.002 in.) above align

eMeasure length of inner and outer springs.
Used limit:
eChange if inner spring below 26.1mm
(1.03 in.).
eChange if outer spring is below 30.5mm
(1.2 in.).
50
5.
Valve and Valve Guide
1. Check if valve is beat, burnt or broken. (3)

VALVE PIPE REAMER
2. Check if valve and valve guide are blocked.
3. Measure every valve stem’s outer diameter.

eUsed limit: Change if below 4.9mm.
Remove carbon deposits from valve

guide using a reamer.
O°
SPECIAL TOOLS
Rotate reamer in proper direction and

do not stop rotation to push in or pull
out.
4. Measure inner diameter of every valve

guide.
Used limit:
IN: Change if above 5.3mm.
EX: Change if above 5.3mm.
Valve guide replacement
1. Operate cylinder at the temperature of

about 100°C-15°C 212F.
Heat cylinder head quickly and evenly

to prevent warping.
2. Press, cut or pry out the valve guide.
Be careful to not damage cylinder head VALVE GUIDE

surface. SCREW DRIVER
TO PRY OUT
51
51
5.
3. Press in the new valve guide. Spread engine

oil on new o-ring and build up new valve guide
pipe. Make sure cylinder head is still warm (3)
when pressing in new guides. VALVE GUIDE
SCREW DRIVER
4, Size valve guide with reamer after installing. TO PRY OUT
GUIDE
Use cutting oil on reamer. Rotate
reamer in proper direction and do not
stop rotation to punch in or pull out.
5. Clean cylinder head and get rid of cut bits of

metal and dust.
(1)
SPECIAL TOOLS
Special tools
eValve guide pipe reamer
eValve Seat Checking and Correcting (4)
eValve Seat Checking
. VALVE PIPE REAMER
6. Remove carbon deposit from combustion
chamber valves.
7. Spread emery on seat surface between

valve and valve seat. Use polishing bar to wear
in valve.
8. Take out valve and check valve seat surface.

Change if valve surface is course or facial
polished.
Valve seat surface width checking

Used limit: above 1.8mm (.07 in.) correct.
9. Correct valve seat with chamfered tool if (9)

surface width is not even, too wide or too
narrow. | 1.8mm
(.07 in.) max
| Qe
|| VALVE SEAT
| SURFACE WIDTH
52
5.
Valve Seat Chamfer Cutting Tools
Refer to valve chamfered tool handbook for IN, EX: (30mm) A 60°
details.
1. Press and rotate with 4-5kg 10-12 lb force

to polish and cut when correcting. IN, EX: (32mm) « 306
Use chamfered tool after spreading
engine oil on it.
IN: (24.5mm) ‘ 45°

EX: (27.5mm)
Valve Seat Cutting

CORSE SURFACE
1. Do not polish or cut excessively.
2. Cut primary surface with 450 cutting head.
3. Chamfer inner edge with 320 cutting head.
4. Correct inner surface by sixty-degree

cha mfered tool.
AK VALVE SEAT SURFACE WIDTH
AK VALVE SEAT SURFACE WIDTH
»
60°
53
5.
5. Trim valve seat to assigned

seat width and valve seat width 1.2mm
with 45 degree chamfered cutting (5) “A ( .047 in.)
tool. »
Standard valve: 1.0 mm (.393 in.)

Check contact place of valve 45°
seat.
6. Polish with 30-degree

chamfered cutting tool if he CONTACT PLACE
contact place is too high. Trim to Ga) TOO HIGH
assigned width with 45-degree
chamfered cutting tool. Polish VALVE SEAT
valve contact surface with emery A SURFACE WIDTH
and polishing bar after correcting [—
bar.
7. Wash and clean cylinder and

valve after polishing and grinding.
Rotate and press softly

when polishing. Don’t put
emery into valve and valve CONTACT PLACE
guide pipe when polishing. TOO LOW
VALVE SEAT
8. Spread red ink on 45-degree SURFACE WIDTH
seat surface and confirm if the
center of the contact surface of
the valve is even after correction.
Building Up of Cylinder Head
1. Build Up Spring Seat
Use new oil seals when

reassembling.
2. Spread engine oil on valve

stem and put into valve guide.
3. Build up inner and outer valve SPRING

spring and put in valve collar VALVE
using spring compressor. COMPRESSOR
54
5.
4. Use valve spring compressor

accessory to make valve contact with
valve collar. Tap with plastic mallet two or
three times, softly, on the ends of the
valve to seat collars.
SPRING
When using mallet, be careful to VALVE
COMPRESSOR
not damage valves.
Installing Cylinder Head
1. Install locating pin and gasket.
2. Install cam chain adjuster plate.
3. Slide cylinder head over studs and

into place.
CYLINDER HEAD
GASKET
CAMSHAFT ——?
CHAIN GUIDE BAR
55
5.
Camshaft Assembly
1. Assemble rocker arm

and rocker shaft.
Make alignment
between shaft end
and fixed screw
bolt hole of
camshaft seat
when valve rocker
shaft is assembled.
2. Install the camshaft into

the cylinder head. Seat the
camshaft into the fixed
seat and check alignment.
3. Install camshaft fixed

seat.
4. Rotate flywheel and

align “T” mark on flywheel
with crankshaft mark.
5. Align the camshaft

chain gear round hole away
from engine.
6. Install camshaft chain

on camshaft gear.
7. Assemble fixed studs.

CAMSHAFT
CHAIN GEAR gy
8. Assemble camshaft (4)
seat, space and nut into
cylinder head. Tighten
cylinder head nut and bolt
securely.
Torque vaive:
Camshaft fixed nut:
2.0kg-m 15 ft Ibs
HOLE IN CAM GEAR

AWAY FROM ENGINE "T" MARK
56
5.
Camshaft Chain Regulator
Assembling
1. First, build up camshaft

chain regulator and spacer.
Second, lock two fixed bolts.
Third, put spring into camshaft
chain regulator. Last, assemble
the o-ring and fixed bolt.
Press down regulator

master jaw and drive
down driving bar
when camshaft chain
regulator is
assembled.
Torsion valve: 0.3-0.5 kg-m

Regulate valve gap: (3-5)
2. Change the ring of he

cylinder head cover and
assemble the cylinder head
cover.
© Put o-ring into furrow.
'— UNDERSIDE OF
CYLINDER HEAD COVER
57
5.
3. Lock fixed screw bolt of cylinder

head cover.
Torsion valve: 0.8-1.2 kg-m
4. Spread grease on threading

position of camshaft fixed seat
screw bolt.
5. Lock two or three times at

diagonal of camshaft fixed seat
screw Cap.
58
6.
6. Cylinder and Piston
5.
59
6.
Material 8-2 Removing the piston 8-3

Troubleshooting 8-2 Assembling the piston 8-7
Removing the cylinder 8-3 Assembling the cylinder 8-8
Checking the Cylinder 8-5
Important Points
eThe work on the cylinder and piston can be done on the engine without complete disassembly.
eAfter taking them apart, clean and dry the cylinder and piston with the compressed air before measuring and testing.
unit: mm
Item Normal size Max. Service
Allowance
Cylinder ID (0.04) 0.05 39.10
Distortion — 0.05
Cylindricity — 0.05
Out-of-roundness — 0.05
Piston Clearance between 0.015-0.055 0.09

the ring and the ring groove 0.015-0.055 0.09
0.08-0.20 0.45
Compressed gap 0.05-0.20 0.45
0.20-0.70 __
Piston ring | OD of piston 38.980-38.780 | 38.7
Check point of OD 9mm away from skirt |_| ——
Clearance between piston and cylinder 0.010-0.040 0.1
ID of the piston pin hole 13.002-13.008 13.04
OD of the piston pin 12.994-13.000 12.96
Clearance between the piston pin and the hole 0.002-0.014. 0.02
ID of the small end of the connecting rod 13.016-13.034 13.06
Troubleshooting
eln case of difficulty starting or unsteady running at Compression Pressure is Too High
low speeds, check if there is white smoke coming eCarbon deposits on the piston and the combustion
out of the air hole pipe of the crankcase. If that is chamber.
the case, the piston ring is worn, burnt or broken.
White Smoke Coming Out of the Exhaust Pipe
Low Compression Pressure eThe piston ring is worn or damaged.
eThe piston ring is worn, burnt or broken. eThe piston/cylinder is worn or damaged.
eThe piston/cylinder is worn or damaged.
Knocking Noise by the Piston
eThe cylinder, the piston or the piston ring is worn.
eThe piston pin and its hole are worn.
60
6.
Removing the Cylinder
1. Detach the cylinder head (refer to 7-6).
2. Remove the chain guide of the cam

chain. CYLINDER HEAD
3. Remove the cylinder. |

NOTE: CHAIN REMOVED FROM
4. Remove the cylinder gasket and the F} ILLUSTRATION FOR CLARITY.
locating pin from the top of the cylinder
and the base of the cylinder.
Removing the Piston
1. Remove the piston pin snap ring.
Attention:
Don’t drop the snap ring
into the crankcase.
2. Take out the piston pin and then the

piston.
©
LOCATING PIN
3. Push the piston pin from the side
opposite the removed snap ring.
4. Use asmall punch or drift pin if

necessary and top gently with a softfaced
bummer.
Use caution to keep from

scratching the piston surfaces.
PISTON
PISTON
PISTON PIN
61
61
6.
Checking the piston, the piston pin and the
piston ring.
Attention:
Don’t damage or break the ring.
eo PIN
1. Remove all of the carbon deposits
from the ring groove.
2. Mount the ring and measure the

clearance of the ring groove.
PISTON
SNAP
Maximum service allowance: RING
The top ring: Replace when it goes
beyond 0.09mm (.035 in.).
The second ring: Replace when it

goes beyond 0.09mm (.035 in.).
3. Remove the piston rings.

Install the piston rings into the bottom of
the cylinder.
Attention:
Use the piston head to press the
rings into place in the cylinder.
4. Measure the piston ring gap in bore.
Maximum service allowance:

Replace when it goes beyond
0.45mm (.018 in.).
Measure the ID of the piston pin hole.

PISTON
RING GAP
13.04mm (.51 in.).
62
6.
6. Measure the OD of the piston pin.

Replace when it is below 12.96 mm, (.51 in.).
7. Measure the OD of the piston. oe

| PISTON PIN
Attention:
Measure it in a position which forms 90 degree with
the center of the piston pin and which is 9mm away
from the skirt.

Replace when it is below 38.7 mm (1.52 in.).
8. Measure the clearance between the piston pin and the pin
hole.

Replace when it goes beyond 0.02 mm (.0008 in.).
Checking the Cylinder
1. Check whether it’s scratched, worn or damaged in its inner

surface.
2. Measure its ID in three positions (upper, middle and lower)

which form 90 degrees (x-y direction) with the piston hole.

Repair or replace when it goes beyond 0.1mm (.004 in.).
The difference between X and Y directions is
out-of-roundness.
The cylindricity is the ID difference (between X and Y

directions), measuring at three positions (upper, middle and
lower). The largest measured value will be considered the
result. This indicates a taper of the cylinder.

Out-of-roundness:
Cylindricity:
63
6.
3. Check the distortion of the
cylinder.

Repair or replace when it goes
beyond 0.05mm (.002 in.).
4. Measure the ID of the small end

of the connecting rod.

13.06mm (.51 in.).
Attention:
CONNECTING
Don't scratch the piston or ROD
break the piston ring.
When replacing the ring,

keep the surface with the “T”
mark up.
After assembling, make sure

that the ring can be turned
freely in the ring groove.
5. Lightly coat the rings with engine

oil before installing them on the
piston.
6. Make sure to keep ring end gaps

rotated at 120° increments.
<*— EXPANDING RING
7. Cover piston and rings with a
<— SIDE RING
light coat of engine oil.
20mm
(.79 in.)
TOP RING
SECOND RING
OIL RING
64
64
6.
8. Install the chain guide lever of the cam.
Attention:
Make sure that the lug of the guide
lever enters the notch of the cylinder.
Assembling the Piston
1. Scrape away the gasket adhering on the

surface of the crankcase.
Attention:
Be sure not to let any matter drop
into the crankcase.
2. Assemble the piston and the piston pin.
Attention:
When assembling, keep the mark “in”
(on the top of the piston) toward the
inlet valve.
Be sure not to let the piston pin snap

ring fall into the crankcase. Use a
cloth to keep debris out of the
crankcase.
PISTON
PISTON PIN
65
6.
Assembling the Cylinder
3. Install the locating pin and the

gasket to the crankcase.
4. Coat the inner surface of the

cylinder, the piston and the piston ring
with oil.
5. When assembling the piston rings,

they must be compressed into the
cylinder.
Attention:
Don't damage or break the
piston ring.
Be sure not to make the

position of the ring gap point
to the inlet and outlet valves
and parallel with the
piston ring.
66
7.
7. Driving Belt Device & The Starting Lever
Important Points 9-2 The Clutch/Transmission Pulley 9-10

Troubleshooting 9-2 Removing the Clutch/
Detaching the Left Crankcase Cover 9-3 Transmission Pulley
Removing the Starting Pivot 9-3 Disassembling the Clutch/ 9-10
Checking the Starting Pivot 9-4 Transmission Pulley
Installing the Starting Assembly 9-4 Checking the Clutch 9-11
Assembling the Left Crankcase Cover 9-5 Transmission Pulley
Checking the Driving Belt 9-6 Replacing the transmission pulley 9-12
Replacing the Driving Belt 9-6 and the bearing
Assembling the Driving Belt 9-7 The Clutch/Transmission 9-13
The Driving Pulley-Dismounting 9-7 Pulley Assembly
Taking the Driving Pulley Apart 9-7 Assembling the Clutch Housing 9-14
Checking the Driving Pulley 9-8
Assembling the Driving Pulley 9-9
The Overrunning Clutch Removal 9-9
Checking and Assembling 9-9
the Overrunning Clutch
67
7.
Important Points
eThis chapter is about the driving unit, the eThe surface of the driving belt and the drive units
clutch/driven unit and the starting lever. are not allowed to have oil adhering to them. If
there is any, remove it to minimize the slip
eThe work on them can be done on the engine, between the belt and the drive units.
without the disassembly.
Tech Criterion
Item Normal Size Max. Serice Allowable

ID of the sleeve of the sliding driving plate 23.989-24.05- 24.24
OD of the hub of the sliding driving plate 20.010-22.025 19.97
Width of the driving belt 18 17
Thickness of the clutch brake lining 2.0
ID of the clutch housing 107.0-107.22 107.5
Free length of the driven belt spring 98.1 107.5
OD of the driving plate 33.965-33.985 92.8
ID of the sliding driving plate 34.0-34.25 34.06
OD of the roller 13.0 12.4
Torque Troubleshooting
The nut of the driving plate
3.8kg/m 28ft Ibs The motorcycle doesn’t run after the engine is
The nut of the clutch housing started
5.5kg/m 4Oft Ibs eThe driving belt is worn
The bolt of the driving plate eThe driving plate is broken
0.3kg/m 40in Ibs eThe brake lining is worn or broken
The nut of the clutch/driving plate eThe spring of the driven plate is fractured
0.45kg/m 40in Ibs
Sudden breakdown during running
°
eThe spring of the brake lining is fractured
°
GENERAL TOOLS SPECIAL TOOLS
Power can’t develop fully

eUniversal stand — Compressing device for eThe driving belt is worn
clutch spring Distortion of the driven belt spring
Socket (39mm) for eThe roller is worn
Socket (39mm) for the fix nut eThe driving plate surface is dirty
eBearing driver
68
7.
Detaching the Left [_ CLIP OF THE AIR TUBE

Crankcase Cover
1. Unlock the clip for the air

tube for the driving belt. LJ1i39QMB
2349671049
2. Remove eight bolts and then

take off the left crankcase cover
and the locating pin.
3. Check whether the gasket is

damaged or fractured.
Removing the Starting Pivot
1. Remove the starting lever

from the pivot.
2. Remove the retainer and the

washer from the starting pivot.
3. Turn the starting pivot gently

and remove the driving gear and
the friction spring together.
4. Remove the starting pivot

and the return spring.
5. Detach the starting pivot

sleeve.
STARTING
PIVOT GEAR
FRICTION
SPRING STARTING
PIVOT
69
7.
Checking the Starting Pivot
1. Check if the pivot and the -»

gear are worn. Check if there is ~N
any softness of the starting

PIVOT SLEEVE
return spring. Check if there is
any excessive wear on the pivot ™N
sleeve.
RUBBER SLEEVE
2. Check if the driven gear is

worn or has failed. Check if the
friction spring is worn or
fractured.
@)
3. Check if there is any STARTING
PIVOT
excessive wear on the bearing
part of the starting pivot and of
the shaft of the driven gear.
Replace any parts showing
excessive or unusual wear. FRICTION SPRING
DRIVEN GEAR
Installing the Starting

Assembly
1. Install the starting pivot

sleeve and the return spring to BEARING PART OF THE
the crankcase cover. SHAFT OF THE DRIVEN GEAR
BEARING PART
OF STARTING
PIVOT
70
7.
2. As shown in the
picture on the right,
assemble the driven
gear and the friction
spring. Maintain the
orientation as shown.
3. Install the starter

pivot (3a). Install the
washer, then the
retainer (3b).
Assembling the
Left Crankcase
Cover
WASHER
1. First, install the
locating pin, then the
gasket.
2. Assemble the left

crankcase cover, and
then tighten the eight
fix bolts diagonally. STARTING LEVER
Install the air tube
together, and then
install the retainer.
LEFT CRANK COVER
71
71
7.
Checking the Driving Belt
1. Detach the left crankcase

cover.
2. Check if the driving belt is

cracked, frayed, or if there is
abnormal wear. Measure the width
of the belt. Maximum service
allowance: 17mm (.7 in.).
Replacing the Driving Belt
1. Remove the eight fix bolts, Za
then remove he crankcase cover. RETAINING DEVICE —

OR SPANNER
WRENCH )
2. Remove driving pulley. Use a
retaining device to hold the driving
pulley and screw out of the 10mm
(.39 in.) bolt.
3. Remove the driving pulley.

DRIVING BELT
4. Remove the driving belt from
the clutch driving pulley. CLUTCH DRIVEN PULLEY
72
7.
Assembling the Driving Belt
1. Turn the driving pulley clockwise to keep DRIVING —-o5

the notches of the belt in expanded condition. BELT
Then install the new driving belt.
2. Install the driving belt on the driving

pulley. Install the driving pulley, the starting
ratchet and 10mm (.39 in.) washer. Then YY
install and tighten the nut. Torque: 3,8kg/m
28ft Ibs
Attention:
During assembly, be sure to align the
splints of the driving unit with those
on the crank shaft with the ratchet.
. . . DRIVIN
The Driving Pulley-Dismounting LES |
in
3. Use a retaining device or spanner wrench STARTING
PATCHER —
to hold the driving pulley.
4. Screw out the 10mm (.39 in.) nut, and

then remove the ratchet, the 10mm (.39 in.)
nut and the driving pulley.
Taking the Driving Pulley Apart
5. Remove the driving pulley and the sleeve DRIVING ——

from the crankshaft. PULLEY
DRIVING PULLEY SLEEVE ———
73
7.
6. Remove the retainer.
7. Remove the rollers.
ROLLER
RETAINER
Checking the driving pulley (2)
1. Check the wear of the rollers.

Measure the OD of the roller.
Maximum service allowance.

Replace when it is below 12.4mm OR EVE PULLEY
(.47 in.).
2. Check the wear of the driving pulley

sleeve. Measure the OD of the moving
section of the sleeve.

Replace when it is below 33.94mm
(1.37 in.).
74
74
7.
Driving Pulley
Install the driving pulley sleeve and the

driving pulley on the crankshaft (1a). Install the
driving belt on the crankshaft (1b). Install the
driving pulley and the washer (1c). DRIVING PULLEY ——J
SLEEVE
Tighten 10mm (.39 in.) nut.
Torque: 3.8kg/m 28tt Ibs
Attention:
There mustn't be any grease on the
surface of the driven belt and the driving
pulley.
The Overrunning Clutch (Starter Pinion)

Removal
Remove the left crankcase cover .

arwn
Remove the driving pulley.

Remove the seat of the overrunning clutch. DRIVING ——\
Remove the overrunning clutch. BELT
Checking and Assembling
6. Check if the bearing part of the overrunning

clutch shaft is worn.
7. Check if the clutch runs smoothly.
8. Check the wear of the gear and the bearing
part of the shaft.
9. Coat the bearing part of the clutch shaft
with a bit of grease.
10. Assemble it in the opposite sequence of
removal.
DRIVING
(6) PULLEY
OVERRUNNING
CLUTCH
BEARING SECTION
OF SHAFT
75
7.
CLUTCH HOUSING ——
The Clutch/Transmission Pulley
Removing the Clutch/Transmission
Pulley
1. Remove the driving pulley. Then

use a Spanner wrench to hold the SPANNER
clutch housing to screw out the 10mm = =WRENCH”
(.39 in.) nut. 10mm —4
FIX NUT
2. Remove the clutch housing.
Remove the clutch/transmission pulley.
Remove the driving belt from the
clutch/transmission pulley.
DRIVING BELT
CLUTCH
HOUSING
CLUTCH TRANSMISSION PULLEY
Disassembling the
Clutch/Transmission Pulley
5. Use a spring compressor for the

clutch spring to press down the
SEAL COVERING
transmission pulley spring to remove
OF SHAFT COLLAR
the special nut (28mm, 1.102 in.).
6. Remove the clutch spring.
7. Remove the sealing cover of the

shaft collar.
76
7.
2
8. Remove the guide rolling pin from the
transmission pulley assembly, and then
take out the o-ring and the oil seal. OIL SEAL
Checking the Clutch O-RING Z| !
Sz
Transmission Pulley TRANSMISSION
PULLEY
1. Check the wear of the clutch housing. GUIDING PIN
Measure the ID of the clutch housing.

107.5mm (4.23 in.).
2. Check the wear of the clutch lining.

Measure the thickness of the lining.

Replace, when it is below 2.0mm
(.078 in.).
3. Measure the free length of the

transmission pulley spring.

Replace when it below 92.8mm
(3.65).
77
7.
4. Check the wear of the transmission pulley. (4)

Measure the OD of the pulley. LS
Maximum service allowance: —> <— \<——
J
Replace when it is below 19.97mm (S77) &
(79 in). (| C4
“a | |
5. Check the wear of the transmission pulley.
Measure the ID of the pulley.

Replace when it goes beyond 24.24mm
(.95 in.). INNER BEARING
6. Check if the guide rolling pin is excessively @)

worn or unevenly worn.
Replacing the transmission pulley and the

bearing
1. Check the needle bearing for wear or

excessive free play, gritty feel or noise.
2. Check the housing bearing for wear.

Remove the retainer and take out the housing
bearing.
3. Drive in the new housing bearing, keeping

the lid side up.
Attention:
Grease new bearings when
installing. Grease able to resist
> 230.
BEARING PULLER
78
7.
4. Drive in the new needle bearing,

keeping the “mark” side up.
®
The Clutch/Transmission Pulley
Assembly
1. Assemble the transmission pulley

guide pin and oil seal.
GUIDE LEVER OF
THE PULLER CS)
2. Install the sealing cover of the
collar.
3. Assemble the transmission pulley

—4
disk and the spring to the clutch
assembly, pressing down with the
@
spring compressor for the clutch
spring.
4. Install the 28mm fix nut and GUIDE ROLLING PIN

tighten it. O-RING
Torque: 5.0-6.0kg/m 35-40ft Ibs
@
&
SEALING COVER OF
THE SHAFT COLLAR
79
7.
CLUTCH HOUSING ——
4. Assembling the clutch/transmission
pulley, put the driving belt onto the
clutch/transmission pulley, then onto the
driving shaft.
Assembling the Clutch Housing

SPANNER
WRENCH ——_}
5. Use a spanner wrench to hold the
10mm —4
housing, then install the 10mm (.39 in.)
FIX NUT
nut and tighten it.
Torque: 5.5kg/m 38ft Ibs

Assemble the left crankcase cover.
DRIVING BEE
CLUTCH
HOUSING
CLUTCH TRANSMISSION PULLEY
80
8.
8. The Final Transmission Assembly
81
81
8.
General Information 10-2 Replacing the Bearing 10-5

Dismantling the Final 10-3 (on the side of the crankcase)
Transmission Assembly Assembling the Final Gear Set 10-5
Replacing Bearing 10-4
(on the side of the
transmission gearbox cover)
General Information
eDesignated oil: SAE 90# Gear Oil
eFilling 0.12L 4 ounces
eChanging 0.10L 3.5 ounces
()
SPECIAL TOOLS
eBearing pulling set 12mm

eBearing pulling set 15mm
eSleeve shaft for assembling the crankshaft
eSleeve lever for assembling the crankshaft
°
GENERAL TOOLS
—
eBearing outer race driver 3740mm

eBearing outer race driver 3235mm
eGuide lever for the bearing driver 17mm
eBearing driver
Troubleshooting
The scooter doesn’t run after the engine is

started
eThe transmission gear failed
eThe driving belt is worn or broken
eThe clutch failed
Developing abnormal noise when it runs

eThe gear is worn, burnt or has damaged teeth
eThe bearing is worn and getting loose
Oil leakage
Too much oil
eThe oil seal is broken
82
8.
Dismantling the final

transmission assembly
1. Remove the rear brake cable.

FIX BOLT
2. Remove the rear wheel
(refer to 13-3).
3. Remove the left crankcase

cover (refer to 9-2).
4. Remove the driven pulley of the

clutch (refer to 9-5).
5. Drain the oil out of the final

transmission.
6. Remove the bolts of the final

transmission gearbox.
7. Remove the transmission FINAL ——+

gearbox cover. TRANSMISSION
SHAFT
8. Remove the gasket and the
locating pin. SUB SHAFT ——4
Detach the final transmission — priviING SHAFT

gearbox cover
1. Check the final transmission

assembly.
2. Check if the sub shaft gear is

worn or damaged. SUB SHAFT
3. Check if the final transmission

gear is burnt or damaged.
FINAL
TRANSMISSION
SHAFT
83
8.
4. Check if the bearing in the left FINAL SHAFT

TRANSMISSION
BEARING
—
crankcase and the oil seal are worn
or damaged. SUB SHAFT BEARING
5. Check if the driving shaft (the

main clutch shaft) and the gear are
worn or damaged.
6. Check if the oil seal in the

bearing of the transmission gearbox
cover and that of the bearing of the
final gear shaft are worn or have
failed.
Attention:
Don’t dismantle the final
transmission gearbox, except
that some parts have to be
OIL SEAL
replaced. While replacing
the driving shaft, the oil seal
DRIVING SHAFT BEARING
must be replaced by new
ones.
Replacing Bearing (on the side

of the transmission gearbox
cover)
1. Use a bearing puller to remove

the bearing in the final transmission
gearbox.
2. Remove the oil seal on the final

transmission shaft.
3. Drive in the new bearing to the

final transmission cover.
84
8.
Replacing the Bearing (on the

side of the crankcase)
1. Remove the driving shaft (the

clutch main shaft).
DRIVING SHAFT
Then remove the oil seal of the
shaft.
2. Use a bearing puller to remove

the bearing in the final transmission
gearbox.
O-RING
3. Drive the new bearing into the
final transmission gearbox. Install
the new oil seal fro the drive shaft.
BEARING
Assembling the Final Gear Set
1. First, install the drive shaft into

the final gearbox. Then install the
final transmission gear shaft
(output shaft) to the final gearbox.
85
8.
3. Attach the sub shaft and the

washer to the final transmission
gearbox. Install the resin washer to
the sub shaft; install the locating pin
and the new gasket.
4. Put on the final gearbox cover.
5. Tighten the bolts of the final

gearbox cover.
6. Assemble the clutch/driving

pulley disk (refer to 9-8).
7. After assembling, fill the gear box LOCATING PIN

with 90w gear oil (refer to 3-7).
Designated gear oil: SAE 90#

Volume of the gearbox:
Filling: 0.12L 4 ounces
Changing: 0.10L 3.5 ounces
8. Screw up the oil screw and

tighten it.
Torque: 1.0-1.4kg/m 8-1 0ft Ibs
9. Start the engine to check if there

is oil leakage.
FIX SCREW a
10. Check the oil level. Replenish it
with the designated gear oil when the GEAR OIL INLET
oil is not sufficient (through the oil HOLE/CHECK HOLE
checking hole). a
L OIL DRAINAGE SCREW
86
9.
9. The Crankcase and the Crankshaft
87
9.
Topic Page
Important points 11-1

Diagnosis 11-1
Dismantling the crankcase 11-3
The crankshaft 11-4
Assembling the crankcase 11-5
Important Points
eThe chapter gives instructions related to the eAC generator (refer to Chapter 14)
crankshaft and dismantling the crankcase.
Before striking, it’s necessary to take the eThe carburetor and the air filter (refer to Chapter
engine apart. 14)
Complete the following work before taking the eThe rear wheel and the rear buffer (refer to
crankcase apart. Remove the following: Chapter 13)
eThe cylinder head (refer to Chapter 7) eThe starting motor (refer to Chapter 16)
eThe cylinder and the piston (refer to Chapter 8) eThe oil pump (refer to Chapter 4)
eThe driving plate and the driven plate (refer to

Chapter 9)
Tech Criteria
Item Normal size Max. Service Allowance
The clearance of the both sides of the

big end of the connecting rod 0.10-0.35 0.55
Crankshaft The clearance of X-Y directions of the 0-0.008 0.05

journal of the big end of the connecting ~ ,
rod
Run out 0.10
Torque:
Crankcase bolt 0.9kg/m 7ft Ibs
Bolt for the chain adjusting guide lever cam _1.0kg/m 8ft Ibs
Troubleshooting
Abnormal noise from the engine

eThe crankshaft bearing is getting slack
eThe crankshaft pin bearing is becoming loose
88
9.
Dismantling the
Crankcase @
1. Detach the bolt of the RETAINING SCREW

; on . OF THE CHAIN
chain adjusting guide lever GUIDE LEVER
of the cam and remove the
lever.
2. Remove assembly
bolts of the crankcase.
3. Dismantle the right and

left crankcases.
CRANKSHAFT
Attention:
Don’t damage the
gasket surface.
When separating
the crankcases,
don’t use a
screwdriver to
pry them apart.
4. Remove the gasket and

the locating pin.
5. Remove the crankshaft

from the crankcase.
89
9.
7. Scrape the gasket away from

the joint surfaces.
Attention: be sure not to

scratch the joint surfaces.
8. Remove the oil seal from the

left crankcase.
9. Remove the oil seal from the

right crankcase.
The Crankshaft
1. Measure the left and right

clearance between both sides of
the big end of the connecting rod.

Replace when it goes beyond @
0.55mm (.02 in.).
CRANKSHAFT
90
9.
2. Check the clearance of the journal of the

big end of the connecting rod in X-Y directions.

(.002 in.).
3. Measure the run-out of the crankshaft.
Maximum service allowance;

(.004 in.).
4. Check if there is any abnormal noise and

looseness when the crankshaft bearing
revolves. Replace totally if any abnormal
noise/looseness is detected.
Assembling the Crankcase

1. Use the following tools to install the oil seal
of the crankcase:
eBearing outer race driver

eBearing outer race 32x35mm
(1.26 in. x 1.38 in.)
CRANKSHAFT
BEARING
91
91
9.
2. Install the cam chain into the left

crankcase.
3. Assemble the crankshaft into the left

crankcase.
| LOCATING PIN
LOCATING PIN _ ls
CRANKSHAFT
Be sure not to let the chain

damage the oil seal.
4. Put the new locating pin and the

gasket onto the left crankcase.
Attention:
Keep the left crankcase downward
to assemble with the right
crankcase.
5. Tighten the bolts of the crankcase.
92
9.
6. Install the cam chain

adjusting lever.
7. Install the o-ring onto the

bolt of the chain adjusting
lever.
8. Coat the o-ring with oil,

and then lock it.
Attention:
Be sure to put the o-
ring into the groove.
oes RETAINING SCREW

OF THE CHAIN
HF GUIDE LEVER
93
10.
10. The Battery and the Charging System
Q &
aS
MCAOS
Sy m RECTIFYING VOLTAGE
Wt STABILIZER
RESISTOR
|__ A.C. MAGNETO
™
7
| 3-—___| ™m |-—~__|
nN
AUTO 4 RECTIFYING
A.C. MAGNETO | eto “Bam | OE
HEAD LAMP
SWITCH
‘SW a BATTERY
STABILIZER 1OVAAH
@ GREEN/YELLOW @) GREEN (@) YELLOW @) WHITE ©) RED
94
10.
Topic Page __ Topic Page
Instructions 14-1 The Charging System

Diagnosis 14-2 Testing short circuit 14-7
The battery 14-3 Assembling the magnetor 14-8
The charging system 14-4 The Magneto Charging Coil 14-9
The rectifying voltage stabilizer 14-5 Checking The magneto lighting coil 14-9
The magneto charging coil 14-6 Checking the Resistor 14-9
Checking the resistor 14-6 Dismounting the Magneto 14-9
Dismantling the magneto 14-6 Assembling the Magneto 14-11
Important Points
The electrolyte (diluted sulfuric acid) is very toxic. DO NOT allow acid to splash onto clothes, the skin
or eyes to protect them from burning. Eye contact with acid may cause blindness. In case of contact
with the acid, use a large amount of clean water to flush and rinse the areas in which the acid came
into contact. See a Physician immediately. If the electrolyte acid gets into clothes, it will permeate to
the skin. Remove tainted clothes immediately and then put them in water to rinse.
eThe battery can withstand numerous cycles of charging and discharging as long as it is not left in a
discharged condition for a long period of time.
elf the battery is overcharged, it can be detected by close inspection of the battery itself. If the
battery is exposed to an extreme overcharged condition, it can break down and short circuit
internally. In this condition, the battery will produce zero voltage under all load and charge conditions.
An overcharged battery can “boil off” the electrolyte solution. This problem can be due to excessive
time on a battery charger or a failed voltage regulator.
elf the scooter is left to sit for a long time or is stored, the battery will slowly discharge. It is
advisable to recharge the battery before attempting to start the scooter after a period of storage.
eWhen filling a new battery with acid, allow it to sit and “breath” for fifteen minutes before installing it
into the scooter or charging it. It is advisable to charge a new battery after filling with acid even
though it may appear to have sufficient charge.
eWhen working on the scooter’s electrical system, make sure that the main switch is turned off
and/or the battery is disconnected. Disconnecting and reconnecting of live circuits can cause high
instantaneous currents that can damage the battery and cause injury.
eAny short-circuiting of the wiring can cause damage to the battery.
95
10.
Tech Criteria
Item Data
Capacity/Type 12 V-4AH or 12V-5AH
VOLT (20°C) Fully charging 3
13.1V
Battery Low ow limilimit 3

12.3V
Charging CUR Standard: 0.4A; Fast: 2A

Charging hours Standard: 5-10 hrs; Fast lhr
Capacity 0.144KW/5000rpm
Vy , Resistance of lighting coil (20°C) | Between yellow-clean| 0.1-1.0 OHM
agneto
° Resistance of charging coil (20°C) | Between white-clean | 0.2-1.2 OHM
Type Single phase, half-wave SCR charging;

SCR half-wave short circuit mode
Rectifing Volt Light 12-14/5000 rpm (multimeter, RPM meter)

+ ightin
Stabilizer Limited volt emg 13.5 +/-0.5V
Charging 14.5 +/ 0.5V/3000-8000rpm
Resistance (20°C) 5W/4. OHM
Resistor Resistance (20°C) 30W/7.5 OHM
Torque Tool
The bolt of the triggering coil O.5kg-m 40in lbs _ Universal fixing wrench
The fix bolt of the coil 0.9kg-m 4ft Ibs Fly wheel puller
The fix bolt of the flywheel 3.8kg-m 25ft lbs Multi-meter
The bolt of the cooling fan 0.9kg-m 7ft Ibs
Diagnosis
Low voltage
No power supply elmproper battery charging
eBattery over-discharging ¢Bad contact
eBattery wiring improper ePoor charging system
eBurnt fuse Damaged rectifying volt stabilizer
Broken electro switch lock
Poor charging system
Unstable current eBad contact, breaking or short circuit
eBad battery wiring contact of the wiring connector
eBad contact of discharging system ePoor rectifying stabilizer
ePoor contact/short circuit of the lighting eDamaged magneto
system.
96
10.
Detaching the Battery
1. Remove the screws of the battery cover under

the floor mat.
2. Open the cover and remove the battery cable

attachment screws.
Attention:
First detach the negative (-) terminal wire,
then the (+) terminal wire. When detaching
the positive (+) terminal wire, make sure
that the tool does not contact the frame.
3. When assembling, operate in the opposite

sequence of dismounting.
© Attention:
In order to prevent short circuiting, first
connect the (+) terminal wire, then the
negative (-) terminal wire
Checking the charging

condition (open circuit volt)
1. Open the battery cover and disconnect the
battery.
2. Measure the voltage across the terminals of

the battery.
Fully charged: 13.1V

Inadequately charged: 12.3V
© Attention:
Use a volt meter to check the charging
condition.
Charging
1. Connect the (+) terminal pole of the charger
to the (+) terminal pole of the battery and the
negative (-) terminal pole of the charger to the
negative (-) terminal pole of the battery.
97
10.
Attention:
eNo sparks should be allowed around the
battery.
eTurn off the charger first, either at the

beginning or the end of the charging, to
prevent sparks, which can cause an
explosion.
eWhen charging, operate at the current

and time marked on the battery.
eUnless in an emergency situation, do not

use fast charging.
eMeasure the voltage only 30 minutes

after charging.
Charging current:
Standard 0.4A
Fast: 2A
Charging Hours:
Standard: 5-10hrs
Fast: Lhrs.
When charging ends:

Open-circuit voltage: above 12.8V
Note: During charging, the temperature of the

battery is not allowed to go beyond 45°C (110°F).
98
10.
The Charging System
Testing short circuit
1. Detach the earth wire from the battery.
2. Connect the ammeter between the "-" terminal

of the battery and the earth wire, the main switch
being in the “off” position to check whether it’s
short-circuited.
Attention:
The (+) terminal terminal of the multi-meter
is connected to the "-" pole of the battery,
while negative (-) terminal wire of the
multimeter is connected to the earth wire.
3. When an abnormal sign appears, check if

there is a short circuit in the main switch and the
main cable.
Checking the Charging Condition

1. When the battery is in full charging condition,
use a multimeter to test.
2. After the engine is warmed up, install the

fully-charged battery. Connect the voltmeter
across the terminals of the battery.
3. Remove the main fuse and connect the

ammeter between the terminals.
4. Connect the RPM meter to the engine.
5. Start the engine, when the speed of the

engine slowly rises, measure the charging voltage
and current.
Limiting Voltage/Current:
Below 14-15V0.5A (Below 5000rpm)
When the limiting voltage goes beyond the above

scope, check the rectifying voltage stabilizer
(refer to 14-5). witch Position
RPM OFF P H
2500 >1.0A |} >1.0A) >1.0A
5000 >1.5A} >1.5A) >1.5A
99
10.
The rectifying voltage stabilizer
1. Checking the main cable circuit.
2. Detach the 4P plug from the

rectifying voltage stabilizer.
3. Check the conductivity between

terminals of the main cable in the
following way:
Item (matching color wire)
Checking the Rectifying RECTIFYING

Voltage Regulator VOLTAGE
STABILIZER
1. After the main cable has been

tested and found normal, check the plug
of the rectifying voltage stabilizer
contact well and measure the resistance
among the terminals of the regulator.
© Attention:
Make sure that your finger
doesn't touch the metal part
of the test bar of the multi-meter
because the human body has
RED ——+
resistance.
YELLOW
— yf
© Use a multimeter to test.
© Test positions per chart.
2. When the resistance among the

\_ GREEN
terminals is abnormal, replace the
rectifying voltage stabilizer. '_ WHITE
Multimeter
Multi. () | White | Yellow | Red | Green
meter ©)
White CO} 3K-50K | CO

Yellow CO CO | 5K-100K
Red CoO CoO CoO
100
100
10.
The Magneto Charging Coil
Attention:
This operation of the magneto charging
coil can be accessed within the engine.
Checking
1. Detach the connecting plug of the magneto.
2. Use a multimeter to measure the resistance

between the white wire of the magneto and the CONNECTING PLUG
ground. OF MAGNETO
Criterion: 0.2-1.2 OHM (20°C)

When the value goes beyond the criterion,
replace the magneto coil.
Checking The magneto lighting coil
Attention:
This operation of the lighting coil can be
accessed within the engine.
1. Detach the connecting plug of the magneto.
2. Use a multimeter to measure the resistance

between the yellow wire and the ground.
Criterion: 0.1-1.00HM (20°C)

When the value goes beyond the criterion,
replace the magneto coil.
Checking the Resistor
1. Measure the resistance between the resistor

wire and the ground.
Criterion: 30W7.5 OHM: 6.0-9.0 OHM

5W14 OHM: 13-15 OHM
Dismounting the Magneto
1. Detach the right side guide strip (refer to 2-3)

Remove the four bolts, four screws and remove
the fan cover.
101
101
10.
3. Remove the four bolts and remove

the cooling fan.
4. Use a universal solid wrench to

secure the flywheel. Detach the fix nuts
of the flywheel.
5. Use a spanner wrench hold flywheel

while removing the retaining nut. SPANNER WRENCH
FLY WHEEL
6. Use a flywheel puller to remove the
flywheel.
7. Remove and save the key.
8. Detach the connecting wire of the

magneto.
UNIVERSAL
WRENCH
102
102
10.
3. Detach the stator of the magneto.
4. Remove the bolts of the triggering

coil.
5, Remove the rubber sleeve of the

magnetor wire from the right
crankcase.
6. Remove the triggering coil.
TRIGGERING
Assembling the Magneto
1. Attach the triggering coil to the

right crankcase.
2. Lock the fix bolts of the triggering

coil.
Torque:
The triggering coil: 0.5kgem
4Oin Ibs
The stator: 0.9kgem 7ft Ibs
3. Setup the rubber sleeve of the

magneto wire.
103
10.
4. Connect the connecting

wire of the magnetor.
5. Clean the cone part of the

crankshaft and of the flywheel
Be sure to lay the locating key MAGNETO
of the flywheel into the keyway
on the crankshaft precisely.
Point the groove of the flywheel
to the locating key on the
crankshaft and then assemble
it.
Attention:
Make sure that there
is no bolt/nut inside
the flywheel, and then
assemble it.
6. Use a universal solid wrench

to hold the flywheel, and then
lock the nut.
Torque: 3.8¢m
7. Setup the cooling fan

CONNECTING PLUG
Torque: 0.9kgem LOCATING KEY —— OFMAGNETO
COOLING SPANNER WRENCH

FLY WHEEL
UNIVERSAL
WRENCH
104
104
10.
8. Install the fan cover and securely

tighten fasteners.
FAN COVER
105
105
11.
11. Ignition System
OQ &
ALT o>
SPARK PLUG 22
SV — MAIN SWITCH
s
|__ A.C. MAGNETO

PICKUP COIL ——
MAIN
ian) )
t ° IGNITION
COIL SPARK
PLUG
| CDI
UNIT
[-]
FUSE BATTERY ed
———_ 12V4AH — —_—
BLUE 6 BLUE/YELLOW BLACK/YELLOW (G) GREEN
106
106
11.
11. Ignition System
Topic Page
General Information 15-2

Troubleshooting 15-3
CDI unit inspection 15-4
Ignition Coil Removal Steps 15-5
Magneto Pickup Coil Inspection 15-6
Spark Advance Angle Inspection 15-6
General Information
eCheck ignition system in accordance with the eMake sure spark plug heat range is correct.
troubleshooting procedure in Section 15-2. Using an incorrect spark plug will result in
improper engine operation or spark plug
eAs the ignition system has an electric damage.
automatic spark control in the CDI unit, there is
no need for spark advance angle adjustment. Peak voltage is used as reference point in
tests. Record coil resistance tests.
eCDI should not be disconnected or subjected
to input. Damage or failure can occur. eWhen inspecting spark plug, refer to related
instructions in Chapter 3.
ePoor contact may be the cause of many faulty
ignition system cases. Check all terminal eWhen removing AC generator and pickup coil,
connections to be sure they are clean and tight refer to instructions in Chapter 14.
whenever troubleshooting an electrical problem.
Reference Standard
Item Standard valve

Standard (NGK)C7HSA Champion Z9Y
Specific spark plug Hot (NGK)C6HSA
Cold (NGK)C8HSA
Spark plug gap 0.6-0.7mm
Spark advance angle Maximum advance in "F" position | 13° +/- 1° (2000r/min)
Primary coil 0.1-1.0 OHM
Ignition coil resistance Secondary coil With cap 7-9K OHM
Without cap] 34K OHM

Pickup coil resistance 1-10 OHM
Primary ignition coil peak voltage Over 120V

Pickup coil peak voltage Over 2.1V
107
107
11.
11. Ignition System
Troubleshooting
High Tension Voltage Too Low

eCrankshaft revolution too slow or battery
voltage too low
elgnition system wiring loose
Faulty ignition coil
eFaulty CDI unit
eFaulty pickup coil
High Tension Voltage Intermittent

eFaulty main switch
ePoor CDI terminal connection
ePoor CDI ground
eFaulty pickup coil
ePoor high-tension lead terminal connection
eFaulty CDI unit
High Tension Voltage Normal but No Spark

eFaulty spark plug
eFaulty spark plug cap
No High Tension Voltage

eFaulty main switch
eBattery discharged or faulty rectification
system
eFaulty charge system
eFaulty CDI United Equine Foundation No
Intermittent High Tension Voltage

eBattery voltage too low
eFaulty charge system
108
108
11.
11. Ignition System
CDI Inspection
1. Remove the three screws from the

battery case cover.
2. Disconnect the CDI module from the wire

harness.
3. Test resistance of the terminals with a

multi-meter.
Attention:
Since there is a semiconductor in
return circuit, testing results may be
significantly different if different multi-
meters are used.
If the pointer on the dial flickers and

© finally stops during testing, it should
be regarded as normal. Because the
capacitor in the CDI module is
charged while being tested, it cannot
discharge.
BLACK/YELLOW
BLUE/YELLOW
GREEN
Ny
Q
Zhe
BLACK/RED + Za fi
BLACK/WHITE i f
109
109
11.
11. Ignition System
Ignition Coil Removal Steps
1. Remove the middle box.
2. Remove the spark plug cap.
3. Disconnect the wires, remove the ignition

coil jam nuts and remove the ignition coil.
Inspection
4. Check the ignition coil circuit. The spark

advance angle does not need to be adjusted.
If the spark advance is abnormal, check the

CDI, pickup coil or magneto. Replace the
ignition coil if necessary.
5. Test the primary coil resistance, the

standard value of which should be 0.1-1.0Q.
6. Test the secondary coil resistance from

spark plug cap negative terminals. The
standard value should be 7-9kQ (with cap)
and 3-4kQ (without cap).
7. Test coil using after-market spark tester.
8. Perform the following inspection in

accordance with the operating instructions in
the manual.
a. Set the ignition coil tester switch

to 12V and connect the tester to
the ignition coll.
b. Turn the switch to the ON position

to check spark frequency from the
inspection door.
In good condition: Sparking continuously

In faulty condition: Sparking abnormally.
110
110
11.
11. Ignition System
Magneto Pickup Coil Inspection
This test is to be conducted with

the stator mounted in the engine.
1. Remove the fan cover.
2. Disconnect the magneto.
3. Test the pickup coil resistance between i oe nN

the blue/yellow and green lead terminals
whose standard value is 80-160.
4, Dismounting the magneto (refer to

14-6).
Charging Coil Inspection
1. Test the charging coil resistance

between the black/red and the green lead
terminals whose standard value is 500-600 . MAGNETO
Spark Advance Angle Inspection
© Since a CDI is used, there is no need

to adjust the timing advance.
If the spark advance is abnormal,

© inspect CDI, pickup coil or magneto.
Replace if necessary.
3. Remove timing lid.
4. After the engine is warmed up, check

the spark advance angle by the spark timing
lamp. It is proper for “F” to align with + 2°
with the engine revolving at a speed of
1700rpm.
The spark advance angle should be 13° +

1° (2000r/min).
111
111
12.
1 2. Starter System
O O)
Sy ZZ (
BRAKE SWITCH ( AS Bes BRAKE SWITCH
STARTER — x.
START SWITCH
MAIN SWITCH
FUSE (10A)
FRONT REAR 3)
— BATTERY
—T BRAKE
_- LAMP
BRAKE =
SWITCH
RED A) YELLOW/RED © GREEN/YELLOW

G) GREEN
112
112
12.
12. Starter System
General Information 16-2 Starter Motor Inspection 16-6

Troubleshooting 16-2 Starter Motor Installation 16-6
Starter Motor Removal 16-3 Starter Pinion Removal 16-7
Starter Disassembly 16-3 Starter Pinion Inspection 16-7
Starter Inspection 16-3 Starter Pinion Installation 16-7
Inspecting the Starter Relay 16-5
General Information
eThe starter motor can be removed without
disassembly of the engine.
Installation Reference Standard
Item Standard valve Wear Limit

Starter motor brush length 8.5 mm (.335 in.) 5 mm (.2 in.)
Fastener Torque Specification

Starter motor clutch cover bolt
1.2kg-m 8-9 ft Ibs
Starter motor clutch jam nut
9.5kg-m 65-68ft Ibs
°
SPECIAL TOOLS
Hex key
(=)
GENERAL TOOLS
Open end wrenches
Troubleshooting
Starter Motor Does Not Turn Starter Motor Turns Over Slowly
eFuse broken eBattery discharged
eBattery discharged ePoor or faulty cable connections
eFaulty main switch eStarter motor gear seized by a foreign object
eFaulty starter clutch
eFaulty brake switch Starter Motor Turns — Engine Does Not Rotate
eFaulty starter clutch
eStarter motor reversal
eBattery discharged
113
113
12.
12. Starter System
Starter Motor Removal
Never work on the starter (2)

motor until main switch is
turned off and the battery
ground wire is
disconnected to ensure A
that the motor cannot
turn.
1. Remove the starter motor

lead clamp.
2. Remove the two bolts and STARTER MOTOR

remove the starter motor. HOUSING
3. Roll up the water-proof rubber

cover to disconnect the starter
motor.
Starter Disassembly
1. Remove the two case bolts

and remove the motor housing
from the internal parts.
Starter Inspection
2. Inspect brushes and

commutator for wear, damage or
discoloration. Replace if
necessary.
3. Clean attached metal particles

from the commutator surfaces.
4. Measure the resistance

between each contact surface of
the components.
5. Make sure there is no

conduction current between each
commutator segment and the
armature shaft.
114
114
12.
12. Starter System
6. Check the starter motor

housing conductivity. Be sure
there is no conduction current
between the cable terminal and
the starter motor housing.
7. Check conductivity between

the lead terminal and the brush.
Replace them if necessary.
8. Measure the brush length. Its

service limit is 5mm (.2 in.).
Replace it if necessary. Check
brush holder for conduction
current. Replace if necessary.
9. Inspect bearing in front
Gf
ty
bracket for smooth rotation and
\
for looseness when installed.
Replace it if necessary. Inspect
dust cover for wear or damage.
OIL SEAL
BEARING =
115
115
12.
12. Starter System
10. Apply grease to the dust cover.
11. Install spring brush in tts holder. DUST COVER
12. Apply a light film of grease to both ends of

the sliding surfaces of the armature shaft.
13. Install armature in front bracket.
Make sure the surfaces between the

brush and the armature are not
damaged.
Be sure the dust cover lip is not

damaged by the armature mount shaft.
14. Install a new o-ring in front bracket.

ARMATURE
15. Engage motor housing with that of front SHAFT
bracket. Install two housing bolts.
When engaging the housing with the

front bracket, install the armature first,
hold the armature shaft and then install
the housing in case the armature is
drawn out by the magnet.
Starter Relay Inspection @3)

1. Remove right side body panel. ARMATURE
SHAFT
2. With main switch in the “on”
position, depress the starter button
to check for a click, which indicates
proper operation of relay. If starter
button is depressed without a click,
perform the following steps.
eTest starter relay voltage.

elnspect starter relay ground
return circuit.
elnspect starter relay. FRONT
BRACKET
116
116
12.
12. Starter System
3. To inspect starter relay voltage: Stand the

scooter on is center stand, measure the voltage
between the starter relay negative terminal
(green/yellow cable) and the ground.
Turn the main switch to “on”, pull the brake

levers and make sure the battery voltage is
available at the relay (12 volts). If there is no
battery voltage, inspect the brake switch
electrical conductivity and wiring.
To inspect starter relay:
1. Remove the right side body panel.
2. Disconnect the starter relay unit coupler

from the wire harness and remove it. Use ohm
meter or continuity tester to check coll.
3. Connect the meter to terminals card D.

This circuit should read closed. Use ohm meter
or continuity tester C.
4. Check contactor.
5. Connect the meter to terminals A and B.

This circuit should read open with terminals C
and D disconnected and read closed with
terminals C and D applied to 12 volt supply.
Starter Motor Installation
1. Apply grease to the starter motor o-ring

and install the starter motor.
2. Install the two bolts.
3. Connect the starter motor terminals to the

harness.
117
117
12.
12. Starter System
3. Remove the four bolts and remove

the cooling fan.
4. Use a universal solid wrench to

secure the flywheel. Detach the fix nuts
of the flywheel.
5. Use a spanner wrench hold flywheel

while removing the retaining nut. SPANNER WRENCH
FLY WHEEL
6. Use a flywheel puller to remove the
flywheel.
7. Remove and save the key.
8. Detach the connecting wire of the

magneto.
UNIVERSAL
WRENCH
118
118

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eClean and lubricate all engine parts

eUse lubricants recommended in this

eUse only genuine replacement parts

Technical Tips (continued)

eMake sure that tools and service

eCover both battery terminals with a

Technical Tips (continued)

eMake sure that all wire terminals are

Technical Tips (continued)

eStrip of main wire must be fixed on assigned

eMake sure that all protective covers are

elnsulator of aluminum strip must be affixed to

eMake sure that all wiring harness retainers are

¢Do not over tighten wiring ties to prevent

Technical Tips (continued)

Technical Tips (continued)

eDo not pull wires too tightly.

eUse tape to protect against sharp edges.

eMake sure that all rubber grommets are in

eDo not reuse broken or frayed wires.

eRepair or replace wires as necessary.

Technical Tips (continued)

Lubricating oil required.

[crease| Grease required.

Engine oil required.

Special tools required.

Special attention required.

Dangerous and important,

Special Torque Settings

Fastener Type eet ny lori. Ibs) Comments

Torque Requirements for Frame Fasteners

Fastener Type omer an leew Ibs) Comments

Cylinder Bolt A 1 25.4 8-12

valve guide valve stem moving part SAE 5W 30 Engine Oil

starter idle gear oil

AC-generator connector adhesive

ROCKER COVER VENT

Trouble Shooting Guide

Check Adjust Faulty Condition Cause of Trouble

Loosen carburetor overflow screw

Carburetor oil level too high

Trouble Shooting Guide

Air filter blocked

- Valve gap adjustment improper

No blockage Blocked Clean

Engine oil too much

Oil passage blocked

r— Piston or cylinder worn

Trouble Shooting Guide (under speed, no power)

Check Adjust Faulty Condition Cause of Trouble

' Adjust carbureator adjusting screw) an

r— Spark plug bad or dirty

t— lgnition coil bad

Bad +— Negative pressure pipe damaged

Trouble Shooting Guide

Too little fuel

No blocking Blocked Clean

Spring broken or fatigued Spring bad