XG-499 Gas Scooter Product Handbook

X-Treme TM Electric Scooters
XG-499
Gas Scooter
Product Handbook
PLEASE BE SAFE WHEN RIDING
ALWAYS WEAR A HELMET AND OBEY ALL LAWS!
Page1
IMPORTANT
THIS IS A 2-CYCLE ENGINE
IT REQUIRES A MIXTURE OF GAS AND 2-STROKE
ENGINE OIL
1. You must always use a gas/oil mixture. FAILURE TO DO SO
WILL VOID YOUR WARRANTY!
2. Use 32:1 Gas/Oil Mixture. 4 oz. of oil for every gallon of HighOctane gasoline.
3. Tanaka Perfect Mix, or similar quality 2-Cycle Engine Oil is
recommended. Oil can be purchased from your local X-Treme
Dealer, Outdoor Power Equipment Dealer, or a Power Sports
Dealer
4. High-Octane Fuel recommended. (90 octane or higher)
Failure to follow these INSTRUCTIONS will
VOID YOUR WARRANTY!
This PRODUCT IS NOT INTENDED FOR EXTREME or
OFF-ROAD Use! Please take care of your XG-499!
DO NOT JUMP or ABUSE THIS PRODUCT!
DO NOT RIDE IN WET/ICY CONDITIONS!
Failure to follow these instructions will
VOID YOUR WARRANTY!
If you have any questions, please contact X-Treme customer
service on the web at www.x-tremescooters.com
Page2
IMPORTANT
PLEASE READ THIS BEFORE USING THIS PRODUCT
READ THIS FIRST!
WARNING
This product does not conform to Federal Motor Vehicle Standards and is not
intended for operation on public streets, roads or highways. Serious injury can
result from the unsafe operations of this product. Operator can minimize these
risks by using certain safety equipment such as: safety helmet, goggles, gloves,
elbow and kneepads and appropriate footwear.
DO NOT operate this product in traffic, on wet, frozen, oily or unpaved surfaces or
under the influence of drugs and/or alcohol. Avoid uneven surfaces, potholes,
surface cracks and obstacles.
DO NOT use a water hose to clean this product. See Product Handbook for more
information.
This product is recommended for riders 16 YEARS OF AGE and older.
SAFETY

This product should not be used by persons without excellent vision, balance,
coordination, reflex, muscle and bone strength and good decision-making
capabilities.

This product should not be used by minors without adult supervision.

This product should not be used by persons unwilling or unable to take
responsibility for their own actions.

The user of this product assumes ALL risks associated with its use. To
minimize these RISKS, the user must wear safety helmet, goggles, gloves,
elbow and kneepads and appropriate footwear.

Never start the engine inside a closed room or building. Breathing exhaust
fumes can be fatal.
Page3
QUICK REFERENCE
SAFETY GUIDE
Fuel Safety



Mix and pour fuel outdoors away from sparks or flames.
Only use a container approved for fuel
Do not smoke or allow smoking near the X-Treme XG-499 while working on the
engine, or while the engine is running.
 Wipe up and clean all fuel spills before starting the engine.
 Move at least 10 feet away from where you fueled before starting engine.
 Stop engine before removing the fuel cap.
 It is recommended that you empty the fuel tank prior to shipping or storage to
prevent fuel leaks.
 Do not store your X-Treme XG-499 near open flames, furnaces, electric motors or
switches.
Maintenance




Maintain your X-Treme XG-499 as recommended in this Product Handbook.
Disconnect the spark plug cap before performing any engine maintenance, except
for carburetor adjustments.
Keep others away while making carburetor adjustments.
Use only quality replacement parts as recommended by the manufacturer.
Transportation and Storage



Allow the engine to cool, empty the fuel tank and fold the X-Treme XG-499
before carrying or storage.
It is recommended that you empty the fuel tank prior to shipping or storage to
prevent fuel leaks.
Clean the X-Treme XG-499 carefully and store in a cool, dry place.
Product Safety




Keep hands and feet away from moving parts.
Inspect the entire product prior to each use. Replace damaged parts. Check for
fuel leaks and make sure all fasteners are in place and securely fastened.
Replace all parts that are cracked, chipped or damaged before use.
Use only parts and accessories that are recommended by the manufacturer.
If a situation arises that is not covered in the manual,
proceed with caution and use good judgment.
Contact your dealer or X-Treme (www.x-tremescooters.com/support/)
if you need further assistance
Page4
TABLE OF CONTENTS
Important Information…………………………………….…………………………….. 2-3
Quick Reference…………………………………………………………………………. 4
Table Of Contents……………………………….……………...................................... 5-6
Getting To Know Your X-Treme XG-499………………………………………………. 7
Package Contents……………………………………………………………………….. 8
Getting Started………………..……………………………..…………………………… 8-11
Assembly……………………………………………………………………………. 8
Gas Tank Installation……………………………………………………………….. 8-9
Fueling……………………………………………………………………………….. 9-10
Starting……………………………………………………………………………….. 10
Riding/Braking.……………………………………………………………………… 11
Transporting and Storage………………………..……………………………………… 11
Operating Procedures…………………………………….……………………………... 12
Maintenance……………………………………………………………………………… 13-17
Recommended Tools……………………………………...................................... 13
Carburetor …………………………….…………………………………………….. 13-14
Brake System……………………………………………………………………….. 14-15
Tires and Wheels…………………………………………………………………… 15
Adjusting The Head Unit…………….…………………………………………….. 16
Adjusting The Chain…..………..……………….…………………………………. 16-17
Maintenance Schedule………………………………………………………………...... 17
Other Questions………………………..….…………………………………………….. 17
How To Guide…………………………………………………………………………….. 18-24
How To Adjust Chain Tension……………………………………………………… 18
How To Adjust Handle Bars……………………………………………………….. 18
How To Install Front Brake………………………………………………………….18
How To Mount Wheel………………………………………………………………. 18-19
How to Adjust Front Hub Brakes………………………………………………….. 19
Page5
How To Adjust Rear Hub Brakes………………………………………………….. 19
How To Adjust Throttle Cable……………………………………………………… 19-20
How To Install Fuel Lines………………………………………………………….. 20
How To Install Ignition Coil………………………………………………………….20
How To Install Engager…………………………………………………………….. 20-21
How To Install Pull Starter………………………………………………………….. 21
How To Remove and Install Transmission………………………………………. 21
How To Remove Engine…………………………………………………………… 21
How To Check Restricted Fuel Lines…………………………………………….. 22
How To Remove and Replace Transmission Bell Housing……………………. 22
How To Install Bearings……………………………………………………………. 22
How To Check For Spark………………………………………………………….. 22-23
How To Adjust Air/Fuel Mixture……………………………………………………. 23
How To Change Charger Socket…………………………………………………. 23-24
How To Change Fuse Holder……………………………………………………… 24
Troubleshooting………………………………………………………………………….. 24-25
Getting Broken Bolts Out………………………………………………………….. 24
Scooter Won’t Move…………………………………………………………………25
Diagrams………………………………………………………………………………….. 26-27
Rear Wheel Assembly……………………………………………………………… 26
Engine Diagram…………………………………………………………………….. 27
General Information/Tech Support……………………………….…………………….. 28
Page6
GETTING TO KNOW YOUR X-TREME XG-499
DO NOT RETURN TO STORE!
Do not use this vehicle for the first time until you have inflated the tires to the correct PSI.
Failure to follow these instructions may damage your vehicle and void your warranty.
CALL CUSTOMER SUPPORT OR GO ONLINE
1-253-777-0690
WWW.X-TREMESCOOTERS.COM/SUPPORT
For General Information or Parts Visit WWW.X-TREMESCOOTERS.COM
Page7
PACKAGE CONTENTS
Your X-Treme XG-499 comes with the following items in the box. Please locate
all of the following:
1.
2.
3.
4.
5.
6.
The X-Treme XG-499 Gas Scooter
Allen Wrench
Spark Plug Wrench
Product Handbook
Fuel Tank and lines
Tool Kit
GETTING STARTED
Please read and understand these instructions and the OPERATING
PROCEDURES section, prior to starting or riding your XG-499
Assembly
1. Carefully remove the XG-499 from the box.
2. Insert the handlebar down tube over the
front fork completely until the gold pin
snaps into place. Slide the clamp down to
the base of the tube and tighten the two
bolts securely. (Fig.1)
3. Attach the handlebars by first attaching the
large handlebar clamp to the top of the
handlebar down tube. Then attach the
handlebars to the clamp. Tighten all bolts
after adjusting the handlebars to the
desired tilted position. (Fig. 2)
4. The BRAKE LEVER is in the down position
for shipping. Using the provided Allen
Wrench, loosen the tension bolt, and adjust
the levers to a comfortable position.
*BE CAREFUL NOT TO PULL ON THE
CABLES!
Installing the fuel tank
The fuel tank on the XG-499 does not come fully installed from the factory, so it is
necessary to install it before initial use.
The fuel system consists of the carburetor; fuel tank, fuel supply line and the fuel return
line.
To install the tank:
Page8
1. Using an adjustable wrench, turn the screw counter-clockwise to loosen. (Fig1.).
2. Install the fuel tank and tank shield onto the mounting bracket.
clockwise to firmly attach the tank. (Fig.2).
3. Run the fuel lines directly behind the tube with the slot. (Fig.3).
Turn screws
4. Make sure the two fuel lines connect to the engine correctly.
Fueling
This is a two-stroke engine.
Only run the engine using a mixture of gasoline and 2-cycle engine oil.
PLEASE READ OPERATING PROCEDURES BEFORE FUELING!
1.
2.
Mix fuel (minimum 90 octane) and 2-cycle engine oil in separate container. Use
Tanaka Perfect Mix or a quality 32:1 2-cycle oil. Make sure the fuel is well mixed by
shaking the container
Make sure that the engine is off!
Page9
3. Slowly open the GAS CAP, so that
possible over-pressure disappears.
4. Clean the tank cap area to make sure
that it is free from excess dirt and
debris.
5. *Make sure that no dirt falls into the gas
tank.
6. Pour pre-mixed Gas/Oil mixture into the
GAS TANK. *Do not overfill.
7. After fueling, replace the GAS CAP and
tighten.
Starting
Move at least 10 feet away from where
you filled up the gas.
1. Set the CHOKE LEVER to the
CHOKED (UP) position. (Fig.5)
2. Pull the RECOIL STARTER briskly,
making sure to hold the handle in your
grasp.(Fig.6) *Note: Do not allow it to
snap back, let it back slowly. You may
want to give it a little throttle by gently
squeezing the GAS LEVER.
It may be necessary to repeat step 2
several times until the motor starts.
When starting the XG-499 for the first
time, it may be necessary to pull the
starter handle multiple times until it
starts.
*This is because the gas needs to be drawn
into the carburetor.
3. Once the engine has started, quickly
move the CHOKE LEVER into the RUN
(DOWN) position. (Fig.5)
4. After engine is started, let it warm up for
2-3 minutes before riding.
IF THE MOTOR KEEPS STALLING AT
IDLE SPEED, IT MAY BE NECESSARY
TO ADJUST THE IDLE SPEED ON THE
CARBURETOR.
Please refer to Carburetor Adjustment in
the maintenance section on page 13 for
instructions on how to adjust idle speed.
Page10
Riding
1. Make sure that all of the exposed bolts
and screws are tightened.
2. Raise the kickstand to its upright
position.
3. Make sure the engine is running.
4. Put one foot on the deck of the XG-499
while pushing off with the other foot,
gently rotate the THROTTLE GRIP, on
the right side of the handlebars. The
XG-499 will begin to move on its own
power.
5. Control your speed by rotating the
accelerator grip. The more you rotate,
the faster you will go.
Braking
1. To brake, release the THROTTLE GRIP
and depress the BRAKE LEVERS (on
the left/right side of the handlebars)
(Fig.7)
2. Gradually decrease the engine speed
to idle and press the kill switch button
located just to the left of the throttle
grip. (Fig.8) This will turn the engine
OFF.
TRANSPORTING/STORAGE
Your XG-499 is easily disassembled for compact storage or transporting by removing the
handlebar from the scooter. These two items are removed by simply loosening the
clamps. For the handlebar, locate the large clamp at the base of the handlebar and
loosen the bolts. Pull up to remove the handlebars from the front fork being careful not to
disconnect any wires and gently set the handlebars on the footplate. Be careful not to
lose your clamps by leaving them on the handlebar or post and tighten them in place.
Page11
OPERATING PROCEDURES
Fuel
WARNING!
This is a two-stroke engine. Only run the engine on fuel, which is properly
mixed with 2-cycle engine oil.
Provide good ventilation when fueling or handling fuel.




Always use gas with a minimum octane number of 90.
Use 2-stroke engine oil only. Mix 32:1 (or 5%), gas/oil mixture.
Never use multi-grade (10W/30) or waste oil.
Always mix fuel and oil in a separate clean, gas safe container.
Always start by adding half the amount of fuel, which is to be used.
Then add the whole amount of 2-cycle oil. Mix (shake) the fuel
container. Add the remaining amount of fuel. Mix (shake) the fuel/oil
thoroughly before filling the fuel tank.
Fueling
WARNING!





Always shut the engine off before refueling.
Slowly open the fuel tank, so that possible over-pressure disappears.
Before fueling, clean the tank cap area carefully, to insure that no dirt
falls into the tank. Make sure that the fuel is well mixed by shaking the
container.
Tighten the fuel cap carefully, after fueling.
Always move the unit at least 10 feet from the fueling area before
starting.
Starting
 Set the CHOKE LEVER to the CLOSED (UP) position.
 Pull the recoil starter handle briskly, making sure to keep the handle
in your grasp, and not allowing it to snap back.
 Once the engine is running, move the CHOKE LEVER to the RUN
(DOWN) position.
Note!
At this stage, if the engine does not start, repeat the starting procedure.
 After starting the engine, allow the engine 2-3 minutes to warm up
prior to riding.
Stopping
 Gradually decrease the engine speed to an idle speed and press
the stop switch on the handlebar tube.
Page12
MAINTENANCE
RECOMMENDED TOOLS
To adjust and service the X-Treme XG-499 you will need the following tools:






Allen Wrenches: 3/4/5/6 mm
Wrenches: 10/13/13 mm Open end wrench
Large Adjustable Crescent Wrench
Spark Plug Sockets
Philips Head Screwdrivers
Oil, Grease or Lubricant
CARBURETOR ADJUSTMENT
WARNING!
Never start the engine without the complete clutch cover assembled!
Otherwise the clutch can come loose and cause personal injuries.
In the Carburetor, fuel is mixed with air. When the engine is tested at
the factory, the Carburetor is basically adjusted. Further adjustment
may be required from time to time, depending on climate and altitude.
The Carburetor has two possible adjustments:
1. Idle speed adjustment (US Models – only option available, EPA
approved) Due to EPA air quality regulations, on US models the Air/Fuel Mixture
adjustment is pre-set on these carburetors by the factory and can’t be adjusted by
the consumer.
2.
Air/Fuel Mixture adjustments
Idle Speed Adjustment
1. Start the engine.
2. Using a long, Philips head screwdriver
gently turn the top screw clockwise until the
XG-550 starts to move forward.
3.Then back out by turning the screw
counterclockwise until the XG-550 stops.
*Correct idle speed is obtained when the
engine runs smoothly just below the RPM
when the XG-550 starts to move.
Air/Fuel Mixture Adjustment
1. Start the engine.
2. Using a long, standard screwdriver and
while holding the throttle wide open, turn
the bottom screw (with spring) clockwise as
far as possible, then back out 1 & ¼ to 1 &
½ turns until the engine rums smoothly.
Note: Standard idle RPM is about
2500-3000 RPM.
Page13
WARNING!
When the engine is idling, under no circumstances should your
XG-499 be moving.
If the XG-499 continues to move after idle speed adjustment, contact
X-Treme or your local X-Treme service center.
Cleaning the Air Filter
It is a good idea to occasionally clean the air filter to insure optimum
performance.
To clean the air filter:
1. Using a Philips head screwdriver, remove
the carburetor cover by turning the cover
screw counter-clockwise. (Fig.10).
2. Remove and clean the air filter (the
spongy material on top of the air intake),
with a damp rag. (Fig.11).
3. Put the air filter back into its original
position and replace the cover.
BRAKING SYSTEM
The XG-499 uses both front wheel and rear wheel disc/caliper system
activated by hand levers (on either side of the handlebar). Squeezing the
BRAKE LEVER with your left hand activates the front brake, and squeezing
the BRAKE LEVER with your right hand activates the rear brake. Make sure
to release the THROTTLE GRIP when engaging the brakes.
Practice braking on a smooth, dry surface to get used to the feel of the braking
system. Braking distance is affected by wet conditions and loose and uneven
Page14
riding surfaces.
Adjusting the Brakes.
The Brakes on the XG-499 should come fully adjusted from the factory.
However, it may be necessary to adjust the brake from time to time.
To adjust the brakes:
1. With one hand, depress the
brake caliper using your thumb
and forefinger (Fig.12).
2. With the other hand, adjust the
tension screw on the brake line.
a. Turn the tension screw
clockwise to loosen the
brake.
b. Turn the tension screw
counterclockwise to tighten
brake.
Squeaky Brakes
The brakes may squeak until they are broken in. This is normal
and will not affect the function or performance of the brakes. With
continued use the squeak should go away.
TIRE AND WHEELS
The X-Treme XG-499 uses an identical rim and tire assembly on the front and
rear wheels, which means that the tires can be rotated. The wheels are
actually two wheel halves (split rim) bolted together to make it easier to remove
and replace the tire and tube.
The rear wheel is fitted with a special spacer to accommodate the chain
sprocket, while the front wheel has a bracket for the disc brake.
Tire wear will differ based on rider weight, riding conditions and care.
Replacement tires can be obtained at your local X-Treme dealer, through
motorcycle shops, or from the X-Treme website at www.x-tremescooters.com
Tire Pressure
The tire must be inflated to a maximum of 50 P.S.I.. It is also
recommended to use a tube additive like Slime purchasable from any
motorcycle shop, to avoid inconvenient punctures.
Empty all air from the tire, prior to loosening the bolt to split the rim.
Page15
ADJUSTING THE HEAD UNIT
The head unit should come adjusted from the factory. However, riding on
rough terrain and general use may cause the head unit to become loose over
time. It may be necessary to adjust the head unit from time to time.
To adjust the head unit:
1. Rotate the handle bar as far right as it will
go to expose the HEAD UNIT (Fig.13).
2. Using a large adjustable wrench, gently
turn the BEARING LOCK clockwise to
tighten. *DO NOT OVER TIGHTEN OR
IT WILL DAMAGE THE BEARINGS.
ADJUSTING THE CHAIN
The chain will come adjusted from the factory. However, it may be necessary
to adjust the sprockets from time to time. The chain must be well aligned onto
the sprockets in order to avoid uneven wear. This will result in shortened
chain life.
How tight should the chain be?
 If the chain is skipping or jumping on the sprockets, this is too
loose and may be harmful.
 If the chain is making a humming sound when the wheel it
turning, this is too tight and may cause the chain to snap.
 The correct tension is achieved by adjusting the chain from its
loose position to when it becomes lightly tense.
To tighten the chains:
Slightly loosen the two axle bolts on both
sides of the rear wheel. (Fig.14). Then slowly
adjust the two adjusting screws on each side
of the rear tire (Fig.15) until belt reaches the
proper tension.
Page16
Occasionally rotate the rear wheel
to make sure belt is aligned.
Finally, lock and tighten the rear
axle bolts prior to riding.
MAINTENANCE SCHEDULE
Proper care of your X-Treme XG-499 will insure optimal performance and
longer life span. The following are a few maintenance suggestions that will
keep your X-Treme XG-499 running in top condition:
Daily Maintenance
Perform each time you ride your XG-499
 Clean the exterior of the unit with a soft, damp rag.
 Check that all nuts and bolts are securely tightened.
Weekly/Monthly Maintenance
 Check the pull starter, especially the cord and return spring.
 Remove the spark plug and check the electrode gap. Adjust it to
0.6mm, or change the spark plug.
 Clean the cooling fins on the cylinder head and check that the air
intake at the starter is not clogged.
 Clean the air filter.
OTHER QUESTIONS
For additional questions, service instructions, further information and important
phone numbers, please go to the X-Treme website at www.x-tremescooters.com
Thank you for purchasing an X-Treme XG-499 and please tell your friends how much fun
you’re having on the X-Treme XG-499
Page17
How To Adjust Chain Tension
1.) To set the chain tension, loosen the axle nuts.
2.) Then locate the chain tension bolts. These bolts go from the rear axle to the frame.
When you tighten the nuts on these bolts, they pull the whole axle and wheel back,
tightening the chain.
3.) Adjust the chain until when pushing down in middle you achieve 1/8 to 1/4 inch
movement. These bolts also controls wheel alignment, be sure to center the wheel in
the center of frame.
4.) After you have adjusted your chain and aligned your wheel tighten the axle nuts.
How To Install Handlebars
1.)
2.)
3.)
4.)
Place handlebars on lower half of bar clamp.
Locate top half of bar clamp and the four allen bolts.
Install top half of clamp with the four supplied allen bolts.
Adjust bars and tighten bolts.
How To Install Front Brake
1.) The assembly is held in place on the front side of the bracket on the fork and with the
single 10mm bolt from the front. Tighten this bolt until it is "snug" but not so tight that
the brakes will not move in and out.
2.) Once the brake assembly is mounted the pads are held in place magnetically with the
Wide Side up, the pad with One Slot to the outside and the pad with Two Slots on the
wheel side.
3.) The brake cable should be adjusted loose until the wheel is installed and then
adjusted first where it goes through the bolt, then at the brake handle and at the brake
assembly until smooth braking is achieved. Adjustment of brakes takes time to
achieve proper stopping.
4.) With brake assembly mounted proceed to the directions for mounting the wheel.
How To Mount Front Wheel
1.) Set the scooter on a box that holds the front far enough off of the ground for the wheel
to clear while installing. It may be helpful to have an extra set of hands to hold and
align the brakes, wheel, axle & spacers.
2.) Start by putting the axle through the Left Side Fork (as determined by standing on the
scooter and facing forward).
3.) Place the Smaller Spacer into the Wheel Hub and then place the Wheel between the
Forks with the Disk sandwiched between the Brake Pads.
Page18
4.)
5.)
6.)
7.)
8.)
Verify brake pads are position correctly.
Push the axle through until it just sticks out the other side of the wheel.
Add the Larger Spacer and push axle through the fork on the Right Side.
Start Nut on end of Axle.
Using two 17mm wrenches tighten the outside Axle Nuts snugly and evenly. To have
both Nylock nuts screwed on fully you may need to use the spare nut on one side.
The double nuts will allow the opposite side nut to screw on until the threads are fully
through the nylon locking portion.
9.) Spin front wheel to check that it spins freely. Some rubbing on the brakes is expected.
10.) Adjust brakes for proper stopping.
How To Adjust Front Hub Brakes
1.) Adjust cable tensioner on the front brake handle almost all the way tight or in.
2.) Block front wheel off the ground.
3.) Loosen the 10mm pinch nut on the gold brake lever just enough so it will slide on the
brake cable.
4.) Grab the end of the cable with a pair of pliers or vice grips and pull tight.
5.) Move the gold brake arm up the cable until the brake just begins to drag on the brake
drum.
6.) Tighten the 10mm nut on the gold brake arm.
7.) Further adjustment can be done with the adjusters at the brake lever. This will need to
be adjusted over time as the brakes are used.
How To Adjust Rear Hub Brakes
1.) Block rear wheel off the ground.
2.) Loosen the 10mm pinch nut on the gold brake lever just enough so it will slide on
brake cable.
3.) Grab the cable with a pair of pliers or vice grips and pull the cable tight.
4.) Move the gold brake arm up the cable until the brake just begins to drag on the brake
drum. Tighten the 10mm nut on the gold brake lever.
5.) Further adjustment can be done with the adjusters at the brake lever.
_______________________________________________________________________
How To Install Throttle Cable
1.) Unhook the throttle cable from the carburetor. Unscrew the screw from the center of
the air filter cover. Push throttle on carb to the open position and unhook cable
using a pair of needle nose pliers.
2.) Unthread the cable through the scooter. You may need to remove the deck plate to
Page19
get down to the cable within the scooter. Pull it through the body and then through
the handle bar down tube.
3.) Unscrew the two screws on the electric start section of the throttle. This piece
should split to allow you to remove the throttle cable from the handle. Release the
throttle cable from the handle.
4.) Unscrew the metal "L" piece that goes into the electric start.
5.) Screw the new throttle's "L" joint into the old electric start.
6.) Attach the cable to the old throttle handle.
7.) Replace the top portion of the split electric start plastic piece and tighten down onto
handle bar.
8.) Thread cable through the handlebar down tube and through the scooter.
9.) Reconnect it to the throttle on the carburetor. Make sure the throttle cable end
settles down into the groove on the throttle on the carb.
10.) Replace air filter cover and deck plate.
How To Install Fuel Lines
1.) Attach the larger diameter hose on the nipple that is straight.
2.) Attach the smaller diameter hose on the nipple that is bent at a 90 degree angle. It
also has the fuel filter attached.
3.) Squeeze the arms together on the retaining clip to increase the diameter and slide it
over the hose.
How To Install Ignition Coil
1.)
2.)
3.)
4.)
Unplug spark plug from wire.
Remove air breather assembly.
Remove plastic covering motor and exhaust.
At this point you can see the ignition coil. Remove the two bolts holding coil in
place.
5.) Reinstall new coil using a business card between the fly wheel and the coil as a
spacer. Tighten bolts with card in place, when bolts are tight then you can remove
the business card. Your coil should be gapped correctly.
6.) Reinstall the plastic motor covers and your scoot should have spark.
How To Install Engager
1.) Stick a screwdriver in the fin's on the right side of pull starter to hold the motor from
turning over.
2.) Take off net in center of engager.
3.) Unscrew and remove.
Page20
4.) Install new engager and tighten nut.
5.) Install pull starter.
How To Install Pull Starter
1.) Locate the four (4) screws on the Pull Starter.
2.) Unscrew them and the pull starter will come off.
3.) To re-install put Pull Starter on the Motor give it a little pull while holding it. This will
line it so that it sits flat on motor.
4.) Install screws and tighten.
How To Remove And Install Transmission
1.)
2.)
3.)
4.)
5.)
Remove rear fender screws.
Remove fuel tank.
Loosen axle nuts but do not remove axle.
Loosen the chain tensioners so wheel can move forward to remove chain.
On the transmission side remove the two 8 mm motor mount bolts, will have to go
through the holes in the metal plate on the right side of scooter.
6.) On the other side remove the allen head bolts that hold the motor in place.
7.) Remove the motor & transmission.
8.) Remove the bolts on the outside corners of the transmission.
9.) Remove the transmission.
10.) Reassemble is reverse order and add 1 ounce of 30 weight oil to the transmission.
How To Remove Engine
1.) On the rear of your scooter there is a chrome fender; remove the 7- 5mm allen head
bolts.
2.) Remove the plate on the side of the scoot that has two 10mm nuts and three 5mm
allen head bolts.
3.) Remove the air breather assembly, that way you can get to the throttle cable.
4.) Twist throttle handle while placing finger on the black throttle body on the carburetor.
Then release throttle handle to allow cable to dislodge from the throttle body. You
may have to try more than once, it can be tricky.
5.) Next you remove the transmission by removing the four gold 8mm bolts in a square
pattern.
6.) Remove the ground wire by loosening 4mm allen head bolt.
7.) Release white quick connection to free motor, this is your kill switch.
8.) Remove gas tank by loosening the two bolts at the top of tank; this needs to be done
for shipping purposes.
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How To Check Restricted Fuel Lines
1.)
2.)
3.)
4.)
Check the lines from your fuel tank.
Look at the lines where they enter the tank, through the rubber grommet.
Make sure these are not pinched or restricted in any way.
If they appear to be pinched by the rubber grommet simply pull the lines out and bore
the hole out slightly with something like a screw driver.
How To Remove And Replace Transmission Bell Housing
1.) You will need to remove the transmission. There will be 4 silver bolts on the outside.
Do not remove the black bolts.
2.) Take a photo of the transmission, so you will remember how it looked and went on the
scooter. That will help you in putting that back on.
3.) On the inside of that transmission, is the transmission bell housing. You will see a nut
that you will need to remove. Remove that, and you should be able to place the new
bell on.
4.) Tighten that down and put the transmission back on.
How To Install Bearings
1.) Remove the rear wheel.
2.) Remove the old bearing. To do this, you will need to insert something, like a screw
driver, from the opposite side and simply push it out.
3.) Put the new bearings in. You will want to use something like a rubber mallet so you do
not crack the bearings. Set the wheel on a flat, absorbent surface, like a work bench.
Tap the bearing into the wheel evenly.
4.) Re-install the tire and test ride.
How To Check For Spark
***Use Caution when testing in proximity of gasoline or gas vapors.
1.)
2.)
3.)
4.)
Remove the spark plug wire from the spark plug.
Remove the spark plug.
Install the spark plug wire back on the spark plug.
Place the spark plugs metal end against the side of the motor or frame.
** ATTENTION** THE NEXT STEP WILL CAUSE A SPARK!!
5.) Pull the rope or use the electric start and watch for a spark between the spark plugs
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6.)
7.)
8.)
9.)
electrodes.
If there was not a spark try to disconnect this kill switch wires. This will be the wire
that comes out of the top of the motor, and runs down under the deck plate.
Disconnect it at the white plastic connection.
Repeat step 5 to see if there is a spark.
If you still do not see a spark the problem is likely the ignition coil.
If you have spark after disconnecting the kill switch wire it is possible that your kill
switch is bad or the wire is shorted to ground.
How To Adjust Carburetor Air/Fuel Mixture
(If your engine has an air/fuel mixture screw – NON US Models Only)
1.) Block the rear wheel off the ground and make sure that it will not come down.
2.) Adjust the screw on the carburetor (the one with the spring) in all the way (do not over
tighten as this will ruin the mixture screw) and then out a turn and a half.
3.) Start the scooter and let it warm up.
4.) Snap the throttle wide open. If the motor hesitates adjust the mixture screw open till it
no longer hesitates.
5.) Test ride the scooter.
6.) If the scooter does not seem to develop full power adjust the mixture screw in or out
1/8 of a turn at a time until motor has full power and does not hesitate when the
throttle snapped open.
Alternative Method:
1.) Run the motor full throttle and adjust slowly until you achieve max rpm.
2.) Give a 1/4 turn counterclockwise to provide just a little rich and ride scooter.
How To Change Charger Socket
1.)
2.)
3.)
4.)
Locate the rear of the charging socket.
Follow wires and disconnect white plastic connector from controller.
Remove nut on back of charger socket.
Look down inside the connector; you will see the two metal pins. They are held in
place by a small tab that bends outward. Reach inside the front of the connector with
a dental pick or jeweler’s screwdriver and bend the tab in then pull the metal pin out
the back of the connector.
5.) Install the new charging socket and secure the nut.
6.) Reinsert the wires into the white connector making sure to match red-to-red and
black-to-black in the connection.
7.) Test new charger socket with charger.
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8.) Re-assemble.
How To Change Fuse Holder
1.) Remove the six Allen head bolts securing the deck plate.
2.) Unplug the two white connectors at the end of the fuse holder wires.
3.) Remove the large nut on the back side of the fuse holder.
4.) Slide the nut over the wire connectors one at a time and remove fuse holder from
frame.
5.) Assemble in reverse order.
Troubleshooting: Getting Broken Bolts Out
Okay, let's look at some of the more routine steps in removing a broken bolt. In all cases
the best rule of thumb is to start with the simplest procedures and work your way up from
there, as each approach fails to get results.
First, let's assume part of its shaft is protruding from the metal surface. In such cases it's
always best to try to remove it by clamping the Vise Grips (very tight!) onto the shaft and
attempting to turn it out. In our years of experience we've found that in about half the
attempts the bolt or screw comes out, so it's well worth trying.
Didn't work or the bolt broke off again? Now it's time to get out the drill, but first you need
to grind or file the bolt's shaft perfectly flat. Once you do you can use a drill bit or center
punch to locate the center of the shaft, then to create a starter-hole for the drill bit. Choose
a bit that's smaller than the diameter of the bolt shaft and start drilling.
In this case it's going to work better if you have a left-hand drill set, because once you've
drilled far enough into the bolt the drill will bind up and probably unscrew the remaining
shaft. If the drill goes all the way through the bolt shaft you can drill again, using a slightly
larger bit. Eventually you will be left with thin remnants of the bolt's threads which you can
remove with a dental pick or run a threading tap into the hole to clean it out. If you do need
a tap to clean up the threads, the size tap for the fuel tank bolt holes on the XG series
scooter is 5mm x .08mm.
If you don't have left-hand drill bits you should have an Easy-Out set. These are little
hardened bits with twisted flutes arranged in a left-hand pattern. The top of each bit is
squared to allow turning with a wrench. The bits are tapered, so the several sizes in the kit
will fit a large range of bolt sizes. The procedure is to drill into the broken shaft a short way,
hammer the appropriate Easy-Out bit into the hole until it wedges and then turn it out with
an adjustable wrench.
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Troubleshooting: Scooter Won’t Move
Remove the transmission. This is the part on the engine that has the sprocket attached.
Inside you will find the clutch bolted to the engine and you will find a circular piece that is
gold or brass in color. It will be bolted to the transmission. This is called the bell housing.
Either thee spring on the clutch may be gone or the bell has come off the transmission.
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Rear Wheel Assembly
Left Side consists of these parts from outside nut to inner wheel.
1. Nut
2. Washer
3. Chain tension bolts
4. FRAME-Scooter
5. ½” Spacer
6. Left inner wheel spindle - The brake disk is mounted on the left wheel spindle, and
the caliper is mounted to frame. Use the knurled screw to center caliper to disk.
Right Side consists of these parts from outside nut to inner wheel.
1. Nut
2. Washer
3. Chain tension bolts
4. ¾” Spacer
5. Right inner wheel spindle
6. Freewheel clutch is screwed into right inner hub
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ENGINE DIAGRAM
Page27
DO NOT RETURN TO STORE!
IF YOU NEED HELP
CALL CUSTOMER SUPPORT OR GO
ONLINE
Call 1-253-777-0690
WWW.X-TREMESCOOTERS.COM/SUPPORT
For General Information or Parts Visit
WWW.X-TREMESCOOTERS.COM
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REVISED 10/26/111