PREFACE This manual offers all service specialists with the technological procedures of maintenance, repairing for LIGERO-50 detailedly show those whom may concern how to maintain, repair, change parts, troubleshoot and reassemble, etc. At every important section we illustrate by assembly, explosion diagrams and photographs, if necessary, please check the diagrams already shown. Though we have tried our best, please kindly instruct us any faults found in this manual. MOTIVE POWER INDUSTRY CO., LTD.
CONTENTS 1. The specification 4 2. Service information 5 6 7 9 12 13 (1)The operation notice (2)Looking torque value (3)Lubrication instruction (4)Wiring diagram (5)Troubleshooting 3.
5.
SPECIFICATIONS Model Overall Length Overall width Overall height Seat height Wheelbase Dry weight Engine Model Piston displacement Bore Stroke Compression ratio Ignition Clutch Shifting Lubricant Steering angel Left Right LIGERO-50 1780mm 645mm 1060mm 770mm 1210mm 99kgs P2 49CC 40.0mm 39.2mm 6.
Vehicle model reorganization: 1. Movable model 2.
2. Service information: (1)The notice for operation-------------------------------------------------------------------- 6 (2)Locking torque value----------------------------------------------------------------------- 7 a. For engine b. For chassis c. Others (3)Lubrication instruction--------------------------------------------------------------------- 9 a. For engine b. For chassis c.
(1) The operation notice: 1. Always replace gasket, O ring, cotter, pins and clip whenever reassembled. 2. When tighten screws or nuts, lock tightly as per specified locking torque, and in the sequence of cross direction. 3. Use PGO, or PGO Recommended parts. 4. After dismantling please wash all parts necessary for checking and grease all contact surface when reassembling. 5. Use grease recommended by P.G.O. 6.
(2) TORQUE VALUE 1. Engine: No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Locking Thread Dia (mm) torque kg-m Cylinder head 7 1.0~1.4 Flywheel outer 10 3.2~4.0 Rear brake lever 6 1.0~1.2 Driving pulley 10 3.2~4.0 Clutch outer 10 3.5~4.0 Right crankcase 6 1.0~1.2 Drive gear box cover 6 1.0~1.2 Left crankcase 6 1.0~1.2 Draining and filler bolt 8 1.8 Inlet pipe 6 1.0~1.2 Flywheel magneto stator 6 1.0~1.2 Cooling fan 6 1.0~1.2 Muffler nut on cylinder head 6 1.0~1.2 Starting motor 6 1.0~1.
3.Other parts please refer the following table: Standard torque values: NO 1 2 3 4 5 6 7 8 9 10 11 Item 5mm bolt and nut 6mm bolt and nut 8mm bolt and nut 10mm bolt and nut 12mm bolt and nut 5mm screw 6mm screw 6mm flange bolt and screw 7mm flange bolt and screw 8mm flange bolt and screw 10mm flange bolt and screw Torque (kgf- m) 0.45-0.6 0.8-1.2 1.8-2.5 3.4-4.0 5.0-6.0 0.35-0.5 0.7-1.1 1.0-1.4 1.0-1.4 2.0-3.0 3.0-4.
(3)Lubrication instruction: A. Engine NO 1 Lubrication location Crankcase: rotating part, Sliding part Oil type Remarks Auto-separated Premium 2 stroke Lubrication Motorcycle oil Or SAE#30 2 Cylinder: rotating part, Sliding part. 3 Drive gear box SAE85-140 Total 110 c.c. Replacement 90c.
B.
C.
(5)Trouble shooting: 1.
2.Unsmooth rotation(Weak acceleration ; inefficient horsepower) Check and Adjust start engine and open throttle gradually. check and inspect engine can rotate up The reason Trouble condition engine can’t rotate up completely air cleaner blocked fuel supply system abnormal fuel tank cover blocked muffler blocked auto cock is malfunctioned auto chock is malfunctioned Check ignition timing, check with ignition timing lamp CDI unit is out of order Timing is correct Timing is not correct.
3. Engine running not smoothly(low speed and idling): Check and adjust Trouble condition The reason Check ignition timing correct Not correct CDI faulty pulse generator faulty Adjust carburetor oil screw good adjustment faulty adjustment Check if there is air Leakage on carburetor gasket No leakage leakage mixture too rich (loosen the screw) mixture too lean.
4.
5.
6.No sparking, spark plug Check and adjust Trouble condition The reason Replace new spark Plug, then check again Weak sparking Or no sparking Good sparking spark plug faulty Check spark plug, cap And H.V.
3.
(1) Periodical checking table: 1.[○] mark indicates periodical checking 2.[＊] indicates changing the parts Check item A Suspension Loose,swing Steering Handlebar performance Suspension: turning angle a.cracked b.shaft fixed Front fork condition c.shaft:loose B: Brake a.
Check item Wheel Front Bearing of axle, Looseness Rear Damper Rear damper spring cracked ass’ part loose or damage Connecting part Loose Bracket loose or Damage SuspenConnecting sion Part loose Oil leakage Cracked damper assy's part, Loose Clutch and Change Power Speed Transmi- mechanism Ssion General checking Supply grease Electric InstallMent Ignition Start mechanis m wiring battery wire circuit First Month Or Initial 500km ○ Checking period Home Office Per6 per12 Per1 per3 Months months Month
Check item General checking First Month Or Initial 500km Engine Engine Performance, parts noise Low speed, Accleration Exhaustion ○ Air cleaner Checking period Home Office Per6 per12 Per1 per3 Months months Months months Or or Or or 5000km 1000km 1000km 2500km Judgement per12 Remark standard months or 10000km ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ Cylinder, cylinder head inlet Pipe, locking Condition ○ Compression pressure ○ ○ Idling:1900± 100rpm Check the clolr Or exhausti
General checking Check item Lamp system Performance Dirty, cracked Horn turn Signal Reflector lock Rear view mirror Performance First Month Or Initial 500km Checking period Home Office Per6 per12 Per1 per3 Months months Months months Or or Or or 5000km 1000km 1000km 2500km Judgement per12 standard months or 10000km ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ Performance ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ Check the illumination Blinker lin
(2) Battery: Recharge when run out of it 1.Remove the floor mat. 2.Screwing out the two screws on the battery cover; remove the battery cover. 3.Remove the negative cable and then the positive cable, take out the battery to recharge. 4.Re-assembling the battery as the opposite procedure of disassembling after recharging. Note: A. Do not take out the sealed bolt when recharging. B. Without refilling water fo r the battery. Please recharging (12V) as the following current. Time standard: 0.
(3) Clean air cleaner 1. 2. 3. 4. Remove air cleaner cover. Take out the air cleaner filter. Clean the filter by compressed air. Assemble the air cleaner by the opposite procedure. Attn: Do not start engine when air cleaner is not installed. (4)MOTOR lubricant oil . take off the cap of oil tank check the level of oil.
(5) The final reducing mechanism oil 1.Change the oil in the gear box: a. Turn off the engine after warm up. b. Put a bowl under the engine. c. Remove the draining bolt and filling bolt to drain the gear oil off. d. Lock the draining bolt before refill 110c.c. gear oil and then lock the filling bolt. e. Locking torque:1.8kg.
(6)Spark plug 1.Remove spark plug. 2.Check the spark plug electrode and see whether it is burnt out/ carbonized or not. 3.Clean the electrode, if it is dirty. Spark plug specification NGK: BP7HS or BPR7HS equivalent Gap of spark plug:0.6~0.7mm spark plug Electrode burnt out Carbon piled up or not Washer is distorted or not Porcelain is cracked or not (7) Cylinder Pressure 1.Measure it when the engine is warm. 2.Remove the cover at the right hand of the step floor. 3.
(8) Ignition Timing Note: It is no need to adjust ignition timing and CDI set. When ignition timing is not correct, just check the ignition system. 1.Remove the checking hole cover of ignition timing. 2.Using the ignition timing light to assure the ignition timing is correct. 3.Under idling, it means in good function when crankcase’s mark matches to the “F” on the flywheel. 4.
(9) Idling Adjustment Note: Adjust idling only when the engine is warm. 1.Remove the checking hole cover of carburetor. 2.Start the engine and connect the tachometer. 3.Adjust the throttle valve screw to the specified revolution. 4.Specified idling revolution: 1900 ± 100rpm If rpm is still unsteady or fuel up is not smooth, please re-adjust the fuel intake screw. (10) Front Brake Adjustment 1.Check the clearance of front brake lever Clearance: 10-20mm. 2.
(11) Rear Brake Adjustment 1.Check the clearance of rear brake lever. Clearance: 10~20mm 2.If the clearance is beyond the above Standard, adjust it by rotation the screw. a. Left-handed rotation-Enlarge the clearance. b. Right-handed rotation-Reduce the clearance. Note: When the arrow of rear brake indicator align with the arrow of left crankcase, cha nge the brake lining. (12) Tire: 1.Check Tire air pressure. 2.Tire pressure: Front tire: 1.50kg/cm2 Rear tire:1.75kg/cm2 3.
3.Check if there is any sharp object piece the tire. 4.Check the depth of wheel stripe. Depth (front and rear): According to the mark of tire” ” indicating the necessity to change a new tire. (13) Throttle cables Adjustment 1.Check the clearance of throttle 2.Normal clearance: 1.5-3.5mm Adjust it by rotating the adjust nut. Change it if the throttle cables can’t be adjusted.
4. Dismantling, Maintaining, Repairing and assembling operation (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) Lubrication system Plastic parts of Chassis Engine dismantling Drive pulley, starter, clutch, driven pulley Cylinder head and valve Cylinder and piston AC generator Final transmission mechanism Crankcase, crank shaft Carburetor Steering stem, front wheel, frt brake comp.
(3)Engine Dismantling A. Dismantling engine. 1.Take off the luggage compartment. 2.Take off the left and right body covers. 3.Take off the lower mudguard fender. 4.Remove vacuum pipe, fuel pipe, auto choke, cap of spark plug, rear Brake cable carburetor pipe, engine flywheel shelf’s nut, starter Motor cable plate and rear damper bolt. 5.Remove the engine. B. Installing Engine. 1.To install engine, please reverse the above procedures. 2.Locking torque: M8: 2.0~3.0kg- m M10: 3.0~4.0kg- m M12: 5.0~6.0kg- m 3.
(4)Drive pulley, starter & clutch A. Troubleshooting: a. Engine starts, but vehicle does not move. 1.driving belt worn out 2.driven plate worn out 3.clutch lining worn out 4.driving plate’s spring broken b. The vehicle stops or trembles when running, 1.clutch lining spring cracked or broken. c. Can’t reach high speed, no pick-up 1.driving belt worn out. 2.Driving plate spring distortion. 3.Weight roller worn out. 4.Driving plate abnormal.
C. Driving pulley. 1.Take off the 8 screws of left Cover, remove the left cover. 2.Take off the left cover.
3.Remove the fixing nut of the clutch. 4.Take off the ramp plate. 5.Take off the belt and the rear clutch. 6.Take off the driving plate. • Take off the driving gear start set.
7.Remove the start idle gear fixing plate. 8.Take off the idle gear.
9.To assemble the driving pulley, please reverse above procedure. Locking torque: 1.Nut of driving pulley:M10: 3.2~4.0kg- m 2.Locking nut of clutch:M10: 3.5~4.0kg- m 10.Checking the driving belt (1)check whether it is cracked or not or its rubber and fiber are loose or not check also if they are extraordinarily worn out. (2)driving belt width: limit of use : change it below 17.0mm. 11.
13.Assemble the slide driving plate. (1)Clean the inner surface of slide driving plate, then assemble the roller. (2)Assemble the ramp plate. (3)Please reverse the procedures of disassembling to finish assembling.
D. Starter dismantling 1.Dismantle the left crankcase cover 2.Remove the hexagon nut, then remove the starter lever. 3.Remove five screws of isolating plate. 4.Remove the starter spring from the start returning positioner. 5.Remove the driven gear comp of kick starter. 6.Remove the retaining c-type clip 7.Remove the spindle comp. Of kick starter. 8.Checking the starter a. Check the wearing condition of the outer diameter of the spindle comp and the inner diameter of bush and gear. b.
E. Clutch driven pulley 1.Dismantle the clutch a. Remove left crankcase cover. b. Remove driving plate. c. Remove driving belt. d. Remove the M10 locking nut, then the clutch. 2.Assembling the clutch: please follow the opposite procedure of dismantling. Locking torque: M10: 3.5~4.0kg- m 3.Checking the clutch: Dismantling the clutch needs the special Tool. please contact your dealers. a. Check the clutch driven face. Check the clutch cover about its wearing Condition and inner diameter measurement.
c. Check driven spring free length: standard: 87.9mm Limit of use: change it as it Is below 82.5mm(50cc) d. Check wearing condition of driving plate set. Outer diameter measurement: Limit of use: change it as it Is above 33.950mm e. Check wearing condition of slide driven plate. Inner diameter measurement: Limit of use: change it as it Is above 34.070mm f. Check is there any wearing occur to the ditch. g. Check wearing condition of seal location, if necessary change a new one.
(5)Cylinder and piston: A. Troubleshooting. a. compression pressure is too low, difficult to start engine and running unsmoothly. 1. Cylinder head gasket cracked. 2. Spark plug is not well- locked. 3. Piston ring worn out or cracked. 4. Cylinder, piston worn out. 5. Reed valve is defective. b. compression pressure is too high, engine overheating or abnormal noise. 1.piston tip has too much carbon piled up. c. Abnormal piston noise 1. cylinder and piston worn out. 2. Piston pin hole or piston pin worn out.
D. cylinder head, cylinder, and piston dismantling. 1.Remove the engine. 2.Screwing out the two M6-bolt of cooling cowl. 3.Screwing out the two M6-blot of fan cover. 4.Remove the cooling cowl and fan cover.
5.Remove the spark plug. 6.Remove the two M6 nuts on the muffler and cylinder. Also remove the two M8-bolt of crankcase. 7.Remove muffler. 8.Remove the four M7-nut on the cylinder head, then remove the cylinder head and cylinder head gasket.
9.Remove the Cylinder and the gasket. 10.Remove the c type clip on the piston and piston pins by the nipper. •Take off piston. 11.Dismatling of the piston ring Take off the first piston ring then the second ring. 12.When assembling please reverse the procedures of dismantling. Locking torque: M7:1.0-1.4kg- m M6:1.0-1.
(6)A.C. Generator, Flyweel A.Dismantling AC generator 1.Remove fan cowl. 2.Remove the M6 screws(4) 3.Remove Screws of flywheel magneto 4.Remove the AC flywheel magneto by special tool.
5.Remove the flywheel. 6.Remove the electric plug of AC Flywheel magneto. Take out the magneto. B. Install AC generator To install, please reverse the dismantling procedures. Locking torgue : M6: 1.0~1.2kg- m M10: 3.2~4.
(7)Final Transmission Mechanism A. Trouble shooting Engine can be started, but vehicle doesn’t move. 1.Gear worn-out or cracked. 2.Gear burnt out. Noise occurs when running. 1.Gear worn out, burnt or gear surface damaged. 2.Bearing worn out or loosen. Oil leakage 1.Too much oil. 2.Seal worn out or damaged. B. Disassemble the final transmission mechanism. 1.Remove the rear wheel. 2.Drain off the oil in the gear box.
3.Remove the 6 bolt in gear box cover 4.Take off the gear box. 5.Take out the final reduction gear and idle gear shaft. 6.
C. Check the final transmission mechanism 1.Check the wearing condition of the driving shaft and gears. 2.Check the wearing condition of the idle gear shaft and idle gears. 3.Check the wearing condition of the final reduction gear. 4.Check the wearing condition of the oil seal and bearing. D. Assemble the final transmission mechanism:please follow the opposite procedures Of disassembling. After locking the drain bolt, refill 90c.c of gear oil, SAE 85W/140. Locking torque: M6: 1.0~1.2 kg- m M10: 3.5~4.
E. Check for the flatness of cylinder head & cylinder. Check the flatness of contact surface of cylinder head & cylinder. Limit of use: If it exceeds 0.1mm Change a new one. F. Combustion chamber cleaning Clean out the carbon piled up in combustion chamber.
G. Check cylinder and piston: 1.Check the wearing and damage condition on the contact surface of the cylinder and piston. 2.Clean out the carbon on the cylinder exhausting port. Be careful not to scratch the inner Surface of cylinder. 3.Cylinder bore measurement: (1)Measure each point (A)(B)(C) orderly, and in X.Y. axis to find the smallest value. (2)Limit of use: 50cc-change it when over 40.
4.Piston outer diameter measurement: (1)Measure at the skirt area where is 12 mm from the skirt lower end of skirt. (2)Limit of use: 50cc-change if when below 39.895mm (3)Calculate the clearance between the cylinder and piston. Limit of use: change it when over 0.100mm 5.Inner diameter measurement of the piston pin hole Limit of use: change it when over 14.
6.Outer diameter measurement of the piston pin limit of use: change it when under 9.970mm(50cc ENGINE) 7.Check piston ring: Measure piston ring gap: Limit of use: change new ones when the first ring and second ring are over 0.
8.Check connecting rod small end (1)lnstall piston pin, bearing onto the connecting rod small end, then check the looseness of the piston pin. (2)Measure the inner diameter of the connecting rod small end. Limit of use: replace a new one when over 14.025mm.(50cc ENGINE) H. Installing cylinder and piston 1.Place the piston ring into the second ring ditch first, then install the piston ring into the first ditch. 2 a. Piston ring should be installed into piston ring ditch by even force b.
(8)Crankcase, Crankshaft: A.
B. Troubleshooting. Engine noise: 1.The bearing of final transmission mechanism is loose. 2.Crank pin bearing is loose. 3.The bearing of gear box is loose. C. Data Measuring Item Clearance of connecting rod big end (Parallel direction to rod) Clearance of connecting rod big end (Perpendicular direction to rod) Swingness of the crank shaft neck Standard value Limit of use.(mm) 0.20-0.50 0.71(50cc) - 0.04 0.03 0.
D. Dismantle the crankcase and crankshaft please follow the following procedures: 1.Remove the engine. 2.Remove the left crank case, the driving pulley (driving plate) clutch and belt. 3.Remove the air cleaner.
4.Remove the carburetor. 5.Remove the intake manifold and reed valve. 6.Remove the oil pump, fan cowl and fan itself.
7.Remove the AC flywheel magneto. 8.Dismantle the right and left crankcase. There are all together 7 bolts. 9.Remove center stand, left and right crankcase and take out the crankshaft.
E. Check the crankshaft: 1.measure the clearance between crank shaft and co-rod big end.(Parallel direction to rod) Limit of use: Replace a new when above 0.71mm 2.check the looseness on X.Y. axis of the connecting rod big end(Perpendicular directions to rod) Limit of use: Replace a new one when above 0.
3.measure the swingness of crank shaft neck. Limit of use A B Change it when Change it when Above 0.1mm Above 0.1mm A B 60mm 4.check the slackness of crankshaft bearing, if it is slack, change a new one. F. Assemble the crankcase. 1.To assemble the crankcase, please reverse the procedures of disaseembling. 2.The locking torque value for bolts and nuts are all described in the previous chapters Please refer.
(9)Carburetor, Reed Valve and Auto cock A.
B: Carburetor dismantling diagram 01 02 03 04 05 06 07 08 09 10 11 12 CARBURETOR ASSY. TOP SET SPG., COMP. PLATE SET TUBE SET JET NEEDLE THROTTLE VALVE SCREW SET SCREW SET（A.
C. Troubleshooting: a. Engine can not be started. 1.No fuel in the fuel tank. 2.Fuel pipe is blocked. 3.There is too much fuel in the cylinder. 4.Air cleaner is blocked. b. Engine idling(RPM)unsteady, running not smoothly 1.Improper adjustment of the carburetor idling. 2.Ignition disorder. 3.Compression pressure is too low. 4.Air mixture is too thick. 5.Air mixture is too lean. 6.Air cleaner is blocked. 7.Air injection is not in good function. 8.Fuel is dirty. c. Air mixture is too lean. 1.
D. Dismantling carburetor 1.Remove the luggage box. 2.Loose the hose clamp between the carburetor and the air cleaner. Then remove the air cleaner. 3.Unscrew the fuel draining screw of the carburetor. Drain off the fuel inside the carburetor. 4.Remove the fuel pipe and the vacuum pipe on the carburetor. 5.Remove the oil pile on the carburetor. 6.Remove the bolts on the intake manifold and carburetor. E. Dismantling float, nozzle Note: The auto choke has been properly adjusted already.
F. Reed valve 1.Dismantling reed valve. (1)Take off the luggage box (2)Remove the air cleaner (3)Remove the carburetor. (4)Unscrew the locking screw of the intake manifold. (5)Remove the intake manifold. (6)Remove the reed valve. 2.checking for the reed valve. chang a new one when the reed valve is worn out or distorted. change a new one too when the base of the reed valve is cracked, injured or distorted.
G. Check the auto cock 1.When the engine stop, remove the fuel pipe from carburetor and check if there is fuel flow Out or not. It means auto lock functions well if the residue fuel(for the amount of 5-10cc)flows out From the auto cock and fuel pipe. However, if it continues to flow out, it means that the Vacuum pipe is blocked. please clean it. 2.Remove the vacuum pipe from the carburetor and suck it to produce a vacuum to have the Fuel flow out from the fuel pipe.
(11)Steering stem, front wheel, frt brake comp and front fork. A. Troubleshooting B. Data C. Steering handlebar E. Front wheel F. Front brake G.
A.Troubleshooting 1.steering handlebar is abnormal, too tight. a. steering mechanism; washer of conical bush locked too tightly. b. steering mechanism; steel ball is cracked. c. steering mechanism; steel ball base and washer of conical base is damaged. d. wheel pressure is too low. 2.steering handlebar is aslant. a. left and right damper is not even. b.Front fork is crooked. c. The axle of front fork is crooked, wheel is aslant. 3.front wheel swings. a.wheel rim is distorted. b.
C.Changing the speedometer cable 1.Remove the fixed screws of the front cover. 2.Remove the nut of speedometer cable. 3.Remove the front handle cover. 4.Remove the fixed screws of speedometer cable on the right of front wheel. 5.Draw out the damage speedometer cable. 6.Assemble the new cable follows the opposite procedure of dismantling. NOTE:Put the grease onto the Inner cable before Assembling.
(D)Steering handlebar 1.Remove the LH/RH back mirrors. 2.Remove the upper handle cover. 3.Remove the nuts on front fork and handlebar. 4.Take off the fixing bolt. 5.Remove the nut and bolt of the front fork fixed on The handlebar. 6.Take off the handle bar. 7.When assembling, please follow the opposite procedures. Locking Torque: M6 :1.0-1.2kg- m M10 :3.0-4.0kg- m 8.Before assembling, please add grease on each cable.
(E)Front wheel 1.Remove the locking nut of the front wheel on the right side. 2.Draw out the axle of front wheel, remove the ring and take off the gear sets of speedometer. 3.Remove the front wheel assy. 4.Assemble the front wheel follows the opposite procedure of dismantling. Locking Torque: M10: 3.0-4.0kg- m Note: 1.Put the lock block of speedometer gear assy upon the extrusion of the front fork. 2.Put the grease onto the grease sets of speedometer before assembling. 5.Checking the front wheel axle a.
6.Front wheel bearing checking Turn the tire. If the bearing is Loosen or any occurrence for noise, Please change a new one. 7.Front wheel rim checking (1)Check the swing of the front wheel rim. (2)Limit of use: Horizontal direction: Change a new one when above 2.0mm. Vertical direction: Change a new one when above2.0mm.
(F)Front brake 1. Disassembling and assembling of the front brake comp. a.Remove two bolts fixed on the front brake comp and the front fork. b.Remove the front brake comp. c.Assemble the front brake comp. Follows the opposite procedure of dismantling. Locking Torque: M8: 2.0~3.0kg- m 2.Air releasing of the front brake comp The procedure of air releasing a.Fill the enough brake oil to the container b.
3.Front fork checking: If it is bent or cracked, please replace with a new one. 4.Front shock absorber checking Check is there any unusual damage or worn-out condition, and whether the guide rod of the Front fork is crooked or not. Front fork oil type: SAE 10W20 Capacity (each side): 70 CC NOTE: If the guide rod is crooked, it should be replaced by a new one or repaired.
5.Disassembling and assembling the front brake-disk. a. Remove the front wheel. b. Remove three nuts on the disk. c. Remove the disk. d. Assemble the disk follows the disassembling procedure. Locking torque M8: 2.0~3.0kgm 6.Checking the front brake-disk. Standard thickness of disk: 3.6mm Limit of usage: change it when below 3.1mm 7.Checking the front brake-lining. a.standard thickness: 4.0mm. limit of use: As the thickness is below 2.0mm, change it. Note: No grease on the lining.
(12)Rear wheel, rear brake, rear damper: A.Troubleshooting. B.Data. C.Dismantling the rear wheel. D.Checking the rear wheel. E.Rear brake. F.Rear damper.
A.Troubleshooting. 1.Rear wheel swings. a.wheel rim is distorted. b.wheel is abnormal. c.improperly assemble the wheel axle. 2.Rear damper is too soft a.rear damper spring fatigue. 3.Bad braking a.the adjustment of brake is not good. b.the brake lining is dirty. c.the brake lining is worn out. d.the cam of brake lining is worn out e.the brake cam lever is worn out. f.the brake hub is worn out. g.the assembling of brake lever gear trough is not good. B.
C.Dismantling and assembling The rear wheel. 1.Remove the fixed screws and bolts of the exhaust pipe. 2.Remove the fixed screws of the rear wheel drum. 3.Remove the bolts. 4.Remove the rear wheel. 5.To assemble the rear wheel, please reverse the dismantling procedures. Locking torque : M6: 0.7-1.1kg.m M14: 8.0-10.0kg.m D.Checking the rear wheel. check the swings of rear wheel. radial direction: change it as it is above 2.0mm horizontal direction: change it as it is above 2.0mm.
E.Rear brake: 1.Rear brake disassembling diagram. (1)Checking rear brake hub: a.measure the inner diameter of rear brake hub. b.limit of use:change it as the diameter is above 111.0mm (2)Checking brake lining: a. measure the thickness of rear brake lining. b.Limit of use: As the thickness is less than 2mm, change it.
F.Rear damper 1.
(13)Fuel tank A. Troubleshooting: 1.Engine can’t start: a. No fuel in fuel tank. b. Fuel pipe is blocked. c.. Auto cock and fuel filter is blocked. d. The membrane of fuel cock over extended. 2.The mixture is too lean. a. Ventilation hole is blocked. b. Fuel pipe is crooked, squeezed, or blocked. c. Auto cock and fuel filter is dirty. B. Dismantling and assembling Fuel Tank 1.Remove the luggage box. 2.Open the rear cover of the fuel Tank and take it off. 3.Remove the left and right rear handle bars. 4.
5.Remove the fuel pipe. 6.Remove the connecting terminal of the fuel gauge. 7.Remove the fuel gauge. 8.Remove the fixing blot of the fuel tank. 9.Take off the fuel tank. 10.When re-assembling, please follow the opposite procedure of disassembling. Locking torque: M6: 1.0-1.
5.Electric equipment: (1)Troubleshooting (2)Battery 1.check specific gravity of eletrolyte 2.recharge (3)Recharge system 1.the wiring diagram of recharge system 2.check A.C. flywheel magneto 3.check regulator/ rectifier. (4)Ignition system 1.the wiring of ignition 2.check spark plug 3.check H.T. Cable and H.T. coil 4.check C.D.I. set (5)Starting system 1.the wiring of starting 2.checking the starter 3.dismantling the starting motor 4.
Currency is unstable. A.Recharge system: 1.The wiring of battery connects No power: improperly. 1.battery over charge 2.Ignition system connects abnormally. No electrolyte in battery. 3.Ignition system is short circuit. Battery becomes white. 4.Lamp system connects abnormally or Short circuit in battery. Short circuit. Regulator malfunction Abnormal recharge system: 2.the battery wires disconnected. 1.The plug part connects abnormally, 3.fuse is broken. Wire broken or short circuit. 4.
(2)Battery: Always, remove the battery negative Cable(-), then remove positive cable (+). But connect the positive cable (+)first, then connect the negative cable(-) when assembling. 1.Recharging Connection method: Connect the positive cable(+)of the recharger to the positive cable(+)of the battery; and The negative cable(-)of the recharger to the negative cable(-)of the battery. Recharging currency: Please recharge(12V) according to the following currency and time. Standard: 0.
2.Testing the recharging performance This test needs to be done under the Battery has been recharged completely a. This test needs to be done after engine is warm- up. And take off the luggage case Firstly. b. Disconnect the orange cable of regulator. c. Open the fuse box to remove the white cable d. Connect currency meter between red/ white cable fuse. While testing, the red wire cable must not touch the frame. d. Set the headlamp switch at “OFF” , engine rotation is at 2000 rpm while testing.
(3)Recharge system 1.
2.Check A.C. flywheel magneto. a. Remove the LH side strip and LH body cover. b. Measure the resistance value of terminals. Yellow black 0.1-1.0 White black 0.2-2.0 3.Check regulator measure the resistance value between each terminal, it should be in specified range, otherwise change a new one.
(4)Ignition system: 1.the wiring of ignition 2.
2.Check the spark plug. Spark Plug 3.Check the H.T. cable and H.T. coil by using the CDI tester. Please follow the instruction manual. 4.CDI sets checking. Check with the CDI tester and Please follow the instruction Manual. If the CDI is broken down, please Change a new one.
(5)Starting system 1.
2.Checking Other spare parts comp. Checking. Change a new one when there is any scratch, damage or burnt on the surface. Any adherent metal powder in-between the layers of the direction exchanger sho uld be cleaned. The conductivity check among each contact surfaces to other parts. The non-conductivity check between the armature pivot and each layer of the direction exchanger.
(7)Handle bar switch The colors for each switch cables: Head Light Switch Operation Dark green Yellow Yellow/black Blue Starting Button /Color ● OFF ● ON ● ● ● Operation /Color FREE Green/White PUSH HI/LO bean Operation /Color HI Blue LOW Purple/White ● ● Operation /Color PUSH FREE N Yellow/green ● Pink Blue/White L ● ● To L ● ● Brown Lock Off On ● ● ● ● ● R ● Main Switch PUSH To R Black ● Signal Light Switch Operation/Color ● Horn Switch Brown/White ● ● Blac
