SERVICE MANUAL 150cc Engine

Transcription

SERVICE MANUAL
150cc Engine
TABLE OF CONTENTS
CHASSIS NUTS AND BOLTS
1
ENGINE
3
LUBRICATION SYSTEM
18
FUEL SUPPLY SYSTEM
22
TRANSMISSION COMPONENTS
27
ELECTRICAL STARTING SYSTEM
30
BELT DRIVE CVT MECHANISM
36
CLUTCH
40
REAR TRANSMISSION SYSTEM
45
ELECTRICAL SYSTEM
50
IGNITION SYSTEM
56
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Always pay attention to the unit
s nuts and bolts. Some loosening after use is normal. Check to
ensure that all nuts and bolts are tight.
Torque Tightening Chart
Bolt
Diameter
4
5
6
8
10
12
14
16
18
Conventional Marked Bolt
N.m
Kg.m
Ib-ft
1~2
0.1 ~ 0.2
0.7 ~ 1.5
1~4
0.2 ~ 0.4
1.5 ~ 3.0
4~7
0.4 ~ 0.7
3.0 ~ 5.0
10 ~ 16
1.0 ~ 1.6
7.0 ~ 11.5
22 ~ 35
2.2 ~ 3.5
16.0 ~ 25.5
35 ~ 50
3.5 ~ 5.5
25.5 ~ 40
50 ~ 80
5.0 ~ 8.0
36.5 ~ 58
80 ~ 130
8.0 ~ 13.0
58 ~ 94
130 ~ 190
13.0 ~19.0
94 ~ 137.5
N.m
1.5 ~ 3
3~6
8 ~ 12
18 ~ 28
40 ~ 60
70 ~ 100
110 ~ 160
170 ~ 250
200 ~ 280
8.8 Marked Bolt
Kg.m
Ib-ft
0.15 ~ 0.3
1.0 ~ 2.0
0.3 ~ 0.6
2.0 ~ 4.5
0.8 ~ 1.2
6.0 ~ 8.5
1.8 ~ 2.8
13.0 ~ 20.0
4.0 ~ 6.0
29.0 ~ 43.5
7.0 ~ 10.0
50.5 ~ 72.5
11.0 ~ 16.0
79.5 ~ 115.5
17.0 ~ 25.
123.0 ~ 181.0
20 ~ 28.0
144.5 ~ 202.5
FUEL SWITCH (PETCOCK)
• Periodically clean the petcock externally with grease remover and water.
• Check for any leaks or seeping fuel.
• Replace the petcock if there are any leaks found.
This vehicle has a manually operated fuel valve. There are three positions.
“ON” position
The normal operating position for the fuel valve lever is the “ON” position. In this position, fuel will
ÀRZWRWKHFDUEXUHWRr.
“RES” position
If the fuel level in the fuel tank becomes too low for the engine to operate with the fuel valve lever
in the “ON” position, turn the lever to the “RES” position to use the reserve fuel supply, and refuel
as soon as possible.
“OFF” position
The closing position for the fuel valve is the “OFF” position.
When the vehicle is not in use, always make sure the petcock is in the “OFF” position.
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2
ENGINE
ENGINE COMPONENTS INSPECTION AND SERVICING
ENGINE COMPONENTS AND CRANK CONNECTING ROD
MECHANISM INSPECTION AND SERVICING
ENGINE COMPONENTS: CYLINDER
CYLINDER REMOVAL
The removal can be done on the vehicle body.
• Remove cylinder head.
• Remove cylinder.
• Remove cylinder gasket, bolts
• Clean cylinder gasket and remove any debris.
Caution!
Do not damage the cylinder area. Make sure not to drop anything,
including cylinder gasket material, into the crankcase.
CYLINDER INNER WALL WEAR INSPECTION
Use a bore diameter dial gauge to measure the degree of wear.
The measure point is divided into three sectional planes in the axial direction: upper, middle and
lower; measure every plane each time on the mutually perpendicular directions (X, Y), the measured least dimension is the cylinder bore; at the most upper position measured is the largest
diameter, and the lowest position measured is the smallest diameter, their difference is the cylindricity of the cylinder. At the same cross section, measure the difference of diameter between two
points mutually perpendicular; which is the circularity of the cylinder.
In order to make the measuring point perpendicular with the bore axis of the cylinder, and to ensure the precision of the measurement, the bar of the gauge can
be slightly swung in the direction of the gauge bar, and take the smallest reading
number as the result.
In the situation without a dial gauge, a feeler gauge can be used to make relativity measurement.
put a new piston into the cylinder, and use the feeler gauge to measure the gap between the
piston skirt and the cylinder wall. T hen ¿gure out the abrasion loss of the cylinder. If the circularity of the cylinder exceeds the limit, then a cylinder reboring machine should be used to rebore
the cylinder, and enlarge its diameter by 0.5mm or 1.00mm, then ¿t the piston and piston ring
which size are also enlarged. If the wear is too severe and cannot be reworked, then a new cylinder should be installed.
Cylinder bore
Cylindricity
Circularity
57.4mm
0.05mm
0.05mm
3
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CRANKSHAFT AND CRANKCASE INSPECTION
• Replace the whole set of the crankshaft if serious wear is found while inspecting. Measure the
axial trend clearance of the big end of the connecting rod.
• When measuring, put the large end of the connecting rod close to the crank, and insert the feeler
gauge between the other side and the crank, for the correct end play.
Service Limit
0.55mm
• Measure the radial trend (X,Y) clearance of the big end of the connecting rod.
Service Limit
0.05mm
• Measure the main shaft journal jump of the crankshaft.
If this measurement is too great, it will cause the engine to shake abnormally, shortening the
life of the engine It must be examined carefully when inspecting.
Service Limit
0.10mm(A=90)
0.10mm(B=105)
• Examine if there is any loose, or unusual sound when the crank journal bearing turns. If there is,
the whole set should be changed.
• After cleaning the crankcase, inspect if there is any damage.
• Inspect whether the joint face of the crankcase is smooth and clean. While reassembling, notice if it
will affect the sealing performance between the left and right crankcase.
$IWHUWKHDERYHLQVSHFWLRQLIWKHFUDQNFDVHKDVVRPHVXUIDFHGDPDJHXVHRLOVWRQHWRrefinish it.
If damage is too severe, replace the cover.
Because the right and left crankcase axle hole must be concentric, they
should be replaced at the same time.
CRANKSHAFT AND CRANKCASE INSTALLATION
• Mount the crankcase oil seal.
• Put the cam chain into the left crankcase.
• Put the crankshaft into the left crankcase.
Pay attention to avoid damaging the oil seal with the cam chain.
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CAMSHAFT INSTALLATION
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ROCKER ARM AND ROCKSHAFT
ROCKER ARM AND ROCKSHAFT REMOVAL
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ROCKER ARM AND ROCKSHAFT INSPECTION
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11
• Measure the inner diameter of the rocker arm.
Service Limit
10.04mm
• Measure the outer diameter of the rockshaft.
Service Limit
9.96mm
ROCKER ARM AND ROCKSHAFT INSTALLATION
噝 R
ead the “ EX” mark on the camshaft holder, then mount the exhaust port rocker arm to the rockshaft.
• M ount the inlet port rocker arm to the rockshaft. Apply some oil to the rockshaft before mounting.
CAM CHAIN TENSIONER
The chain tensioner must be in good working condition for proper chain tension.
1. Cam chain
2. Cam chain tensioner
3. Cam chain tensioner lifter.
4. Gasket
5. Cam chain tensioner pivot
6. Cam chain guide
7. Bolt
8. Nut
9. O-ring
10. O-ring
The operational principle of the tensioner is as shown in the picture.
As for the adjustment of the cam chain tensioner, clockwise
tightens, and counterclockwise loosens.
12
VALVE AND VALVE SPRING
VALVE AND VALVE SPRING REMOVAL
• Remove cylinder head.
• Remove valve cotter pin and compressor.
• Remove upper spring race.
• Remove valve spring.
• Remove lower spring race.
• Remove valve stem oil seal.
• Remove valve.
The removed parts should be placed in order to
avoid confusion. It’s better to place the intake valve
parts and exhaust valve parts separately.
VALVE AND VALVE SPRING INSPECTION
• Inspect the valve for bending or burning.
• Inspect for smooth action between the valve and the valve guide.
• Measure the outer diameter of the valve stem.
Service Limit
4.94mm
• Measure the free length of the inner and outer valve spring.
Valve
Inner spring
Outer spring
Inlet valve
31.2mm
34.1mm
Exhaust valve
31.2mm
34.1mm
VALVE AND VALVE SPRING INSTALLATION
• Mount the spring retainer, valve guide oil seal.
It is recommended to replace the valve guide oil seal with a new one.
• After applying oil on the valve stem, mount it into the valve guide.
• Mount the inner and outer valve springs.
• Mount the valve locker with a spring compressor.
When mounting, the twisting direction of the inner and outer springs must be opposite.
• Tap on the valve gently two or three times with a rubber hammer to make the valve and the valve
lock connect well.
Do not damage the valve.
13
VALVE GUIDE
Carbon accumulation on the valve guide will make the
valve move roughly, causing the valve to not
open or close properly.
Valve guide abrasion is one of the causes of white smoke from the exhaust pipe.
TO CLEAN CARBON ACCUMULATION OFF THE VALVE GUIDE
• Remove the valve and springs etc.
• Clean the carbon accumulation with a valve guide reamer.
Generally, only turn right when using the reamer, and do not
push in or out directly with the reamer.
VALVE GUIDE INNER DIAMETER MEASUREMENT
Service Limit
5.03mm
Calculate the clearance between the valve stem and the valve guide
(the inner diameter of the guide subtracted by the outer diameter of the valve stem).
Valve
Service Limit
Inlet valve
0.08mm
Exhaust valve
0.10mm
When the abrasion of the valve guide exceeds the service limit, it should be replaced; after replacing a new valve guide, the valve retainer must be adjusted.
VALVE GUIDE REPLACEMENT
• Heat the cylinder head to 212 ~ 302°F (100 ~ 150°C)
The cylinder head must be wholly and quickly heated
WRWKHVSHFL¿FGHJUHHDQGFDQQRWEHKHDWHGSDUWOy, or
it will cause the cylinder head to distort. The temperature is very high, two technicians are recommended.
• Tap the valve guide out with a valve guide remover or similar tool.
Do not damage the cylinder joint face
14
• After tapping the valve guide, you need to trim it with a reamer.
When using the reamer, cutting oil must be used. The reamer
can only be turned right; do not push in or out directly.
• Clean the cylinder head, and remove the scraps generated while ramming.
VALVE SEAT
The relative position between the valve seat and the working surface of the valve is very important for
the valve to seal properly.
VALVE SEAT WIDTH MEASUREMENT
• Clean the carbon accumulation in the combustion chamber.
• Measure the width of the valve seat with a vernier caliper.
Standard
Service Limit
0.6-1.2mm
1.8mm
When abrasion causes the valve seat width to be uneven, too wide or
too narrow, it will result in poor contact between the valve and the valve
seat, and not seal tight. At this time it must be reamed with a customized valve seat milling cutter.
The valve seat milling cutter is the customized trimming tool for the
valve seat, and it has three cutting angles: 32, 45, and 60.
While trimming, press the valve seat milling cutter to make rotary motion with 40 ~ 50 N force.
Some oil must be applied on the valve seat milling cutter, to eliminate scraping when trimming.
VALVE SEAT FINISHING
• Ream out the defects on the working surface with a 45° coarse
tooth milling cutter.
Do not ream too much.
15
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17
LUBRICATION SYSTEM INSPECTION AND SERVICING
GENERAL INTRODUCTION
The picture shows the functional diagram of the lubrication system. After the lubrication oil crosses
WKH¿OWHUVFUHHQ, it is pumped by the rotator oil pump. Some of the oil goes into the big end of the
connecting rod and splashes on the cylinder wall and the small end of the connecting rod; the rest
goes through some oil passages, such as the shaft neck of the camshaft, and splashes on the
cam rockshaft and cam chain. The lubrication oil that falls back into the oil groove can be recirculated.
18
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1
• Mount the right crankcase cover positioning bolt.
• Mount the trigger winding and the stator coil.
• Tighten the right crankcase cover positioning bolt.
The bolt should be gradually diagonally tightened in
two to three steps. $IWHU¿QLVKLQJWKHLQVWDOODWLRQLQspect for any oil leaks.
FUEL SUPPLY SYSTEM INSPECTION AND SERVICING
CV CARBURETOR
The CV carburetor is a constant vacuum carburetor. The picture shows the structure of the CV
carburetor.
1. Gasket set
2. Float valve set
3. Needle jet set
4. Float set
5. Float chamber set
6. Screw set A
7. Screw set B
8. Valve plate set
9. Starter valve set
10. Air cut valve set
11. Compression coil spring
12. Screw
13. Carburetor assy.
14. Top comp.
15. Vacuum piston comp.
16. Needle jet holder
17. Plate clip
18. Holder cap
19. Tube A
20. Tube B
21. Screw
22. Screw
23. Washer screw
24. Washer screw
25. Washer screw
26. Clip
27. Clip
28. Tube
29. Main jet
30. Slow jet
4
1
6
22
CARBURETOR IDLING ADJUSTMENT
AIR ADJUSTING SCREW ADJUSTMENT
Step one: T urn on the air adjusting screw in the turn out by the prescribed number of turns.
Turn out number of turns
2 3/4 – 2 1/4
Step two: Adjust the throttle by adjusting the screw to the prescribed idle rpm.
Step three: Left and right, adjust the air adjusting screw slightly to ¿nd the highest position
of the rpm.
Increase throttle quickly and gently (the rpm is from low to high), and return throttle immediately,
then observe 10 to 15 minutes, to observe if the idle remains the same.
VACUUM CHAMBER
The picture shows the structure of the vacuum chamber of the
CV carburetor.
VACUUM CHAMBER REMOVAL
• Remove the body cover. Remove the automatic choke
lead wire.
• Loosen the fuel drain bolt, and drain the fuel in the Àoat
chamber. Remove the fuel line and the vacuum pipe.
• Loosen the throttle cable adjusting nut and positioning nut;
remove the throttle cable.
• Loosen the carburetor air inlet vent clip and the inlet manifold clip;
remove the carburetor.
• Remove the vacuum cover bolt, and remove the vacuum cover.
Notice: move slowly to prevent the spring from ejecting.
• Take out the spring, the vacuum membrane and the plunger.
• Press down the holding clamp of the needle valve top, and turn left
to take out the clamp.
• Take out the spring and needle valve.
Do not damage the vacuum membrane.
• Inspect the needle valve for wear.
• Inspect the vacuum membrane for damage.
• Inspect the plunger for damage.
23
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24
Before removing ¿rst tighten the two screws gently, counting the number of turns
Remove screws. Do not use excessive force to avoid damaging the air adjusting screw
head surface.
• Remove the main fuel injection nozzle and fuel injection needle seat.
FLOAT CHAMBER INSTALLATION
,QVSHFWWKHÀRDWIRUDQ\GDPDJHDQGIRUIXHOLQWKHÀRDW,QVSHFWWKHÀRDWYDOYHDQGÀoat valve
seat for wear. If there is wear, it should be replaced.
Clear every fuel line and air line on the carburetor body with compressed air.
• Install the main fuel injection nozzle and fuel injection needle seat.
• Install the air adjusting screw and choke adjusting screw, and turn them to the proper position according to the noted number of turns while removing.
0RXQWWKHÀRDWYDOYHWKHÀRDWDQGWKHÀRDWSLQ
• TLJKWHQWKHÀRDWSLQSRVLWLRQLQJVFUHw.
FUEL LEVEL INSPECTION
• Measure the fuel level height.
Fuel level height
18.5mm
,QVSHFWWKHÀRDWIRUDQ\GDPDJHDQGLQVSHFWWKHÀoat valve for excess wear.
&RQ¿UPWKDWWKHXSDQGGRZQPRYHPHQWRIWKHÀoat is normal.
CARBURETOR INSTALLATION
,QVSHFWWKHÀRDWIRUDQ\GDPDJHDQGLQVSHFWWKHÀoat valve for excess wear.
&RQ¿UPWKDWWKHXSDQGGRZQPRYHPHQWRIWKHÀoat is normal.
• Reverse the removal procedure for installation.
• After installing, confirm that all carburetor linkage and cables are in correct position. Verify that
carburetor is in idle position.
25
AIR CUT VALVE (ACV)
The air cut valve can avoid some abnormalities when the throttle closes too quickly.
The structure of the air cut valve is shown in the picture.
AIR CUT VALVE REMOVAL
• Remove the air inlet manifold of the cut valve.
• Remove the bolt. R emove the vacuum membrane cover,
the spring, and the vacuum membrane.
AIR CUT VALVE INSTALLATION
• Mount the vacuum membrane on the carburetor.
• Mount the spring, the vacuum membrane cover, and the lock
bolt.
The bottom side of the vacuum membrane should
be aligned with the carburetor. The top side should
be aligned with the vacuum membrane.
AIR CHECK VALVE
The air check valve starts working under 31mph (50 km/h), and opens the second air inlet to
reduce CO2 displacement.
AIR CHECK VALVE INSTALLATION
Reverse the procedure for removal
When installing, make sure all the connecting pipes are connected properly,
and that they are not squeezed, bent, or clogged up.
26
TRANSMISSION COMPONENTS
STARTING MECHANISM INSPECTION AND SERVICING
The starting mechanism can be divided into two types: kick starting and electric starting.
KICK RETURN STARTING MECHANISM
SPIRAL SPLINE TRANSFERRING STYLE STARTING MECHANISM
The picture shows the structure of the spiral spline transferring style starting mechanism.
14
20
10
17
8
9
7
23
1
22
6
11
12
25
7
7
5
3
13
16
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1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Kick starter spring stopping plate
Drive face
Drive face boss
Movable drive face comp.
Weight roller set
Ramp plate
Slide piece
Starting driver pulley
Starter gear friction spring
Starter idle gear comp.
Starter idle shaft
Starter idle spring
Kick starter spindle comp.
14. Bush
15. Spindle bush
16. Kick starter spring
17. Special pin
18. Washer
19. Washer
20. Washer
21. Nut
22. Bolt
23. Roller
24. Face drive collar
25. Clip
SPIRAL SPLINE TRANSFERRING STYLE STARTING MECHANISM REMOVAL
• Remove the left crankcase cover.
• Remove the crankcase gasket and dowel pins.
• Remove the movable driving plate (the whole set).
• Remove the starting spindle washer.
27
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,QVSHFWWKHVWDUWLQJ idle shaft for abrasion or other damage.
,QVSHFWWKHVWDUWLQJspindle bushing and the starting idle
shaft hole for abrasion or other damage
28
SPIRAL SPLINE
TRANSFERRING STYLE STARTING MECHANISM INSTALLATION
Install according to the pictures .
• Assemble the starting idle shaft set. Before assembling, apply a
little grease on the bore of the idle shaft.
• Assemble the starting spindle, the return spring and the spring
holding pin. A little grease should be applied on the starting
spindle where it is under stress .
• Align the idle shaft holding pin with the groove of the crankcase
then insert.
Before installing, apply a little grease on the groove
of the rotary retaining spring on the idle shaft.
The rotary retaining spring should be aligned with
WKHVSHFL¿FJURRYHRIWKHFUDQNFDVHWRLQVWDOO
• Align the scribing mark of the starting spindle with the punching
mark of the idle shaft then mount the starting spindle.
• Hook on the two ends of the return spring.
• Install the return spring stopping plate.
• Install the crankcase dowel pin and gasket.
• Install the driven belt and the driving plate.
• Install the left crankcase cover and lock tightly.
• Install the starting pedal.
29
ELECTRICAL STARTING SYSTEM
STARTER MOTOR
The starter motor is actually a direct current (DC) motor, and its structure is shown in the picture.
1.
2.
3.
4.
5.
6.
Outer Cover, Motor
Rotor, Motor
Base, Carbon Brush
Plate, Positive Electrode
Carbon Brush, Positive Electrode
Carbon Brush, Negative Electrode
7. O-ring
8. O-ring
9. Bolt
10. Spring Washer
11. Washer
12. O-ring
13. Screw
STARTER MOTOR REMOVAL
%HIRUHUHPRYDO¿UVWVKXWRff the main switch, and
disconnect the battery connecting wire. Then press
the starting button; at this time the starter motor
should not run. Do this to insure safety.
• Remove the starter motor lead wire clamp.
• Remove the starter motor holding bolt, and remove the starter
motor.
• Roll up the rubber wate-resistance cover, and remove the
starter motor joint.
• Remove the motor case bolt, the carbon brush seat, and the
motor case, etc.
30
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1
STARTER MOTOR INSTALLATION
• Apply some oil on the dust seal.
• Install the carbon brush on the carbon brush base.
• Apply a little oil on the moving part of the armature ends.
• Put the carbon brush into the bracket, and then install the
carbon brush base.
Do not damage the contact area of the carbon brush
and the armature. When installing, do not damage
the lip of the dust seal.
• Mount the new O-ring on the carbon brush base.
• Install armature into starter motor case, making sure
not to damage the carbon brushes.
• Tighten motor case bolts.
Make sure the starter motor case is free of metal
particles because it is magnetic.
%HIRUHLQVWDOOLQJWKHVWDUWHUPRWRURQWKHYHKLFOHDIWHUDVVHPEOLQJLW¿rst
connect the lead wires and check that the motor is running normally.
• Apply oil on the O-ring, and install the starter motor.
• Tighten holding bolts.
32
REDUCTION MECHANISM
The picture shows the structure of the reduction mechanism.
1. Starter reduction gear
2. Starter reduction gear shaft
3. Starting clutch gear comp.
4. Starting clutch outer comp.
5. Flange starting clutch
6. Starting clutch roller spring
7. Spring holder
8. Starter motor
9. Starter motor lead wire
10. Clamp
11. Clamp
12. Bolt
13. Nut
14. Washer
15. Dowel pin
16. Key woodruff
17. Roller
18. Needle bearing
19. O-ring
20. Screw
21. Bolt
REDUCTION GEAR INSPECTION
• Remove the starting clutch.
• Remove the reduction gear to inspect its wearing degree.
• Measure the inner diameter of the reduction gear shaft. It
should be replaced when the diameter is more than 10.05mm.
• Measure the outer diameter of the reduction gear shaft. It
should be replaced when the diameter is less than 9.94mm.
33
ENGAGING MECHANISM
STARTING CLUTCH REMOVAL
• Remove the right crankcase cover.
• Remove the left crankcase cover.
• Hold the drive face with the universal set wrench.
• Remove the starting clutch ¿xing nut.
1RWLFHWKDWWKHWKUHDGRIWKH¿[LQJQXWVKRXOGEHOHIW
handed rotation.
• Remove the starting clutch (the whole set).
STARTING CLUTCH INSPECTION
,QVSHFWWKHPRYHPHQWEHWZHHQWKHFOXWFKDQGWKHGULYLQJJHDU.
The driving gear should smoothly turn clockwise, and
should not move counterclockwise.
,QVSHFWWKHFRQWDFWVXUIDFHEHWZHHQWKHGULYLQJJHDUDQGWKH
QHHGOHEHDULQJ for abrasion or other damage,WVKRXOGEH
replaced if the surface is damaged.
• Measure the inner diameter of the driving gear,WVKRXOGEHUH
placed when the diameter is more than 32.06mm.
,QVSHFWWKHFRQGLWLRQRIWKHQHHGOHEHDULQJ,WVKRXOGEHUHSODFHGLI
there is any damage.
,QVSHFWWKHFRQWDFWVXUIDFH between the outer clutch component DQGWKHUROOHr for abrasion or other damage.
• Inspect the roller for injury.
• Inspect the spring for distortion.
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• Measure the inner diameter of the ÀDQJHFOXWFK,WVKRXOGEH
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• Remove the clutch friction plate.
• Remove the whole clutch/driven plate set.
• While compressing the driven pulley spring with the
clutch spring compressor, remove the nut on the
shaft.
• Disassemble the clutch with the driven pulley.
• Remove the circlip, and remove the connecting piece.
• Remove the clutch centrifugal weight set and the spring.
CLUTCH INSTALLATION
• Mount the clutch damper rubber onto the drive plate pin.
• Mount the new clutch weight set and spring on the drive plate.
• Install the connecting piece, the circlip, and the bottom plate.
• Finally reverse the removal procedure for installation.
To avoid damaging the spring when assembling the clutch and the driven plate,
you must use a clutch spring compressor. The driven pulley must be free of grease.
41
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• Supply the oil with the prescribed speci¿cation and oil level.
• Mount the level bolt.
• After replacing the oil, inspect for any oil leaks.
TRANSMISSION CASE
TRANSMISSION CASE REMOVAL
• Remove the driven belt pulley.
• Drain out the oil in the transmission case.
• Remove the drive sprocket.
• Remove the bolt, and remove the transmission case cover.
• Remove the gasket and the dowel pin.
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sub shaft/sub shaft gear.
TRANSMISSION CASE GEAR INSPECTION
• Check the sub shaft/sub shaft gear for wear and other damage.
&KHFNLIWKH¿QDOJHDU and the ¿nal gear shaft for wear and
other damage.
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Electrical System
CHARGING SYSTEM INSPECTION AND SERVICING
ELECTRIC LEAKAGE TESTING
• Turn the main switch to the “OFF” position.
• Disconnect the negative ground wire from the battery.
• Connect the positive end of the ammeter with the negative end of the battery.
• Connect the negative end of the ammeter with the ground wire.
• Test the electric leakage. In general, the number should be less than 1 m A; if it is
unusual, check for is a short circuit of the main switch and the main wiring.
CHARGING STATUS INSPECTION
• Install the fully charged battery.
• Connect the voltmeter between the binding posts of the battery.
• Remove the fuse, and connect the ammeter with two ends of the fuse.
• Connect the tachometer to the engine (it’s not needed when there is rpm
indicator on the vehicle).
• Start the engine, and accelerate slowly0 easure the charging voltage and current.
Charging voltage (V)
Charging current (A)
13.5 ~ 15.5
0.5
*Measuring condition: 5000 r/min
If the voltage is not in the range of the above-speci¿ed value, please inspect the voltage regulator.
50
BATTERY
The battery is an important component of the electric system. The battery used on the vehicle is
a maintenance-free battery. For long periods of storage, the battery will discharge. It should be
charged every 3 months. After 2 ~3 years of regular usage, the capacity of the battery will lessen
and will need changing. Replace with the same type of battery.
BATTERY REMOVAL
Shut down the main switch to make sure no electric current goes through the vehicle.
• Disconnect the negative battery lead wire ¿rst.
• Disconnect the positive battery.
The disconnecting order cannot be reversed. When disconnecting the
positive cable, do not touch the body of the vehicle with the removal
tool, or it will short circuit and ignite gas that will damage the battery.
BATTERY INSTALLATION
Connect the positive cable ¿rst, then connect the negative cable.
BATTERY OPEN-CIRCUIT VOLTAGE INSPECTION
Disconnect the cable on the battery terminals.
Disconnect the negative pole ¿rst, then the positive pole.
Measure the voltage between the two poles of the battery.
Full charging
Under charging
51
13.1V
12.3V
BATTERY CHARGING
• Lift the battery out of the vehicle.
• Connect the positive pole of the charger with the positive pole of the battery.
• Connect the negative pole of the charger with the negative pole of the battery.
• Charge the battery for the charging time marked on the battery.
Unless it is urgent, do not use fast charging. There should be no smoking or open ¿re
near the battery when charging. At the beginning or the end of charging, turn off the
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Measure the voltage 30 minutes after charging is ¿nished. It should reach the speci¿ed value,
or recharging is needed.
Charging Current
Charging Time
Normal
Fast
Normal
Fast
0.7 A
3.0 A
5-10 hours
30 minutes
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Charging Result
PRIMARY COIL
The picture shows the structure of a common generator.
1.
3.
4.
5.
Cooling Fan
Generator assembly
Flywheel comp.
Stator comp.
Washer
6. Bolt
7. Nut
8. Bolt
9. Bolt
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57
TRIGGER WINDING
• Remove the connector of the trigger winding wire.
• Measure the resistance value between the trigger winding (green/red wire) and the body ground
wire.
a&
Standard Value
When the actual value is more than the standard value, it should be replaced.
CDI COMPONENT
7KH&',FRPSRQHQWLQVSHFWLRQLVVLPLODUWRWKHUHJXODULQVSHFWLRQ7KH&',
component inspection is also divided into two steps: First inspect every wiring,
winding or FRLOFRQQHFWHGZLWK&',WKHQLQVSHFWWKH&',FRPSRQHQW
REMOVE THE CDI COMPONENT.
&KHFNWKHFRQQHFWRUIRUORRVHQHVVRUHURVLRQ
,QVSHFWWKHFRQGXFWLRQDQGWKHUHVLVWDQFHYDOXHRIWKHPDLQVZLWFKWKHLJQLWLRQFKDUJLQJFRLO
the trigger winding, and the ignition coil. When the main switch is in “OFF” position, it should be
conducted. The resistance value of every coil should be the standard value.
,QVSHFWWKHUHVLVWDQFHYDOXHEHWZHHQHYHU\&',FRPSRQHQWWHUPLQDO,IWKHDFWXDOYDOXHLVQRWLQ
WKHUDQJHRIWKHYDOXHLQWKHFKDUWWKHQWKH&',FRPSRQHQWLVIDXOW\.
CDI COMPONENT
SW (B/W)
SW (B/W)
EXT (B/R)
3&*5
(*RU*:C
,*1%<
0.5 ~ 50
10 ~ 1000
0.5 ~ 50

EXT (B/R)
a
10 ~ 1000
0.5 ~ 50

3&*5
a
a
1 ~ 10

(*RU*:
a

1 ~ 100
,*1%<

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Please carefully read the instrument speci¿FDWLRQWRNQRZKRZWRSURSHUO\RSHUDWH
&RQQHFW&',FRPSRQHQWZLWKWKHVSHFLDOZLUHRIWKHWHVWLQJLQVWUXPHQW
2EVHUYHWKHVSDUNFRQGLWLRQRQWKHLQVWUXPHQWZKHQWKHVZLWFKLVWXUQHGRQGLIferent positions
(OFF, P, EXT2121
58
IGNITION COIL
IGNITION COIL REMOVAL
• Remove the spark plug cap.
• Remove the primary ignition coil wire.
• Remove the ignition coil-positioning bolt, and remove the ignition coil.
IGNITION COIL INSTALLATION
• Reverse the removal procedure for installation.
When installing, connect the black/yellow wire of the primary ignition coil with the
black/yellow connector of CDI, and the green wire with the green connector of the
CDI.
PRIMARY IGNITION COIL INSPECTION
Standard Value
a.&
,IWKHUHVLVWDQFHYDOXHLVLWLQGLFDWHVWKHFRLOLVEDGDQGVKRXOGEHUHSODFHG
SECONDARY IGNITION COIL INSPECTION
Install the spark plug cap, and measure the resistance value of the secondary ignition coil.
Standard Value
a.&
If the resistance value is in the standard range, it is good; howeverLQGLFDWHVWKHFRLOLVEDG
Remove the spark plug cap, and measure the resistance value of the secondary ignition coil.
Standard Value
a.&
If the resistance value is in the standard range, indicates it is good; howeverLQGLFDWHVWKHFRLOLV
bad.
The ignition coil also can be inspected and measured with the ignition testing instrument.
Please operate properly according to the instructions.
6HWWKHPHDVXULQJVZLWFKRIWKHLJQLWLRQFRLORQWKH9SRVLWLRQDQGFRQQHFWWKHLJQLWLRQFRLO
Turn the switch of the testing instrument to the “ON” position. Observe the spark and
inspect the spark situation of the ignition coil. If it is a normal consistent spark, it is good; if
WKHVSDUNGRHVQRWÀDVKFRQVLVWHQWOy, it is not good.
SPARK PLUG
• Clean the carbon around the spark plug to prevent it from dropping into the cylinder. Remove the
spark plug.
59
When installing, connect the black/yellow wire of the primary ignition coil with the
black/yellow connector of CDI, and the green wire with the green connector of CDI.
&OHDQWKH¿Oth and carbon accumulation on the spark plug with a steel brush or a blade.
• Inspect the spark plug gap in general it should be about 0.6 ~ 0.7mm.
• When the carbon accumulation and wear of the spark plug are too severe, replace the spark
plug. Replace with the spark plug of the same speci¿cation.
60
INDEX
AIR ADJUSTING SCREW ADJUSTMENT
AIR CHECK VALVE
AIR CHECK VALVE INSTALLATION
AIR CUT VALVE (ACV)
AIR CUT VALVE INSTALLATION
AIR CUT VALVE REMOVAL
ARMATURE INSPECTION
AUTOMATIC SIDE STARTER INSPECTION
BATTERY
BATTERY CHARGING
BATTERY INSTALLATION
BATTERY OPEN-CIRCUIT VOLTAGE INSPECTION
BATTERY REMOVAL
BEARING ON THE LEFT CRANKCASE BODY REPLACEMENT
BEARING ON THE TRANSMISSION CASE COVER REPLACEMENT
BELT DRIVEN CVT MECHANISM INSPECTION AND SERVICING
23
26
26
26
26
26
31
24
51
52
51
51
51
48
47
36
CAM CHAIN TENSIONER
CAMSHAFT
CAMSHAFT INSPECTION
CAMSHAFT INSTALLATIION
CAMSHAFT REMOVAL
CAPACITIES
CARBURETOR
CARBURETOR IDLING ADJUSTMENT
CDI COMPONENT
CDI COMPONENT
CHAIN ADJUSTRMENT
CHARGING STATUS INSPECTION
CHARGING SYSTEM INSPECTION
CHARGING SYSTEM INSPECTION AND SERVICING
12
10
10
11
10
31
2
23
25
58
58
65
50
50
50
CHASSIS
CLUTCH
2
1
46
61
CLUTCH DISASSEMBLING
CLUTCH INSPECTION
CLUTCH INSTALLATION
CLUTCH REMOVAL
CONNECTING ROD END INSPECTION
CONTROLING MECHANISM
CRANK CONNECTING ROD MECHANISM
CRANK CONNECTING ROD SET
CRANKCASE AND CRANKSHAFT REMOVAL
CRANKSHAFT AND CRANKCASE INSPECTION
CRANKSHAFT AND CRANKCASE INSTALLATIION
CV CARBURETOR
CYLINDER
CYLINDER INNER WAL WEAR INSPECTION
CYLINDER REMOVAL
DRIVE BELT PULLEY
DRIVE BELT PULLEY INSPECTION
DRIVE BELT PULLEY INSTALLATION
DRIVE BELT PULLEY REMOVAL
DRIVEN BELT PULLEY
DRIVEN BELT PULLEY INSPECTION
DRIVEN BELT PULLEY INSTALLATION
DRIVEN BELT PULLEY REMOVAL
DRIVEN PLATE BEARING REPLACEMENT
ELECTRIC LEAKGAE TESTING
ELECTRIC SYSTEM
ELECTRICAL STARTING MECHANISM
ENGAGING MECHANISM
40
40
41
40
4
36
4
5
6
7
7
22
3
3
3
38
38
39
38
42
42
44
42
43
50
50
30
33
ENGINE
ENGINE COMPONENTS
ENGINE COMPONENTS AND CRANK CONNECTING ROD
ENGINE COMPONENTS INSPECTION AND SERVICING
6
6
6
6
ENGINE OIL
FINAL GEAR OIL
FLOAT CHAMBER
FLOAT CHAMBER INSPECTION
FLOAT CHAMBER REMOVAL
FOAM FILTER MAINTENANCE
2
2
24
25
25
24
1
62
FUEL LEVEL INSPECTION
FUEL SUPPLY SYSTEM INSPECTION AND SERVICING
FUEL SWITCH (PETCOCK)
GENERATOR INSTALLATION
GENERATOR REMOVAL
GENERATOR REMOVAL AND INSPECTION
25
22
1
18
36
54
53
53
IGNITION CHARGING COIL
IGNITION COIL
IGNITION COIL INSTALLATION
IGNITION COIL REMOVAL
IGNITION SYSTEM INSPECTION
IGNITION SYSTEM INSPECTION AND SERVICING
IGNITION TIME INSPECTION
KICK RETURN STARTING MECHANISM
LUBRICATION SYSTEM INSPECTION AND SERVICING
MAIN WIRING – SUB ELECTRIC CIRCUIT CONDITION INSPECTION
57
59
59
59
56
56
56
27
18
54
MECHANISM INSPECTION
MECHANISM INSPECTION AND SERVICING
OIL PUMP ASSEMBLING
OIL PUMP INSPECTION
OIL PUMP INSTALLATION
OIL PUMP REMOVAL
OIL REPLACEMENT
OIL SYSTEM INSPECTION AND REPLACEMENT
OIL SYSTEM INSPECTION AND SERVICEING
28
3
21
20
21
19
19
19
50
PISTON PIN INSPECTION AND SERVICING
PISTON RINGS INSPECTION AND SERVICING
PISTON RINGS SET UP
4
4
5
63
PISTON SET
PISTON SET INSTALLATION
PRIMARY COIL
PRIMARY COIL INSPECTION
PRIMARY IGNITION COIL INSPECTION
REAR TRANSMISSION MECHANISM INSPECTION AND SERVICING
REDUCTION GEAR INSPECTION
REDUCTION MECHANISM
REGULATE RECTIFIER
REGULATE RECTIFIER INSPECTION
REMOVE THE CDI COMPONENT.
RESISTOR
RESISTOR RESISTANCE VALUE MEASUREMENT
ROCKER ARM AND ROCKSHAFT
ROCKER ARM AND ROCKSHAFT INSPECTION
ROCKER ARM AND ROCKSHAFT INSTALLATION
ROCKER ARM AND ROCKSHAFT REMOVAL
ROTARY OIL PUMP
4
5
52
53
59
45
33
33
54
55
58
55
55
11
11
11
11
19
SECONDARY IGNITION COIL INSPECTION
SPARK PLUG
SPIRAL SPINE TRANSFERRING STYLE STARING MEACHANISM REMOVAL
SPIRAL SPLINE TRANSFERRING STYLE STARTING MECHANISM
SPRIAL SPLINE TRANSFERRING STYLE STARTING
STARING CLUTCH INSTALLATION
STARTER MOTOR
STARTER MOTOR INSTALLATION
STARTER MOTOR REMOVAL
STARTER REPLAY INSPECTION
STARTING CLUTCH INSPECTION
STARTING CLUTCH REMOVAL
STARTING MECHANISM INSPECTION AND SERVIVING
59
59
28
28
28
35
30
32
30
35
34
34
27
64
TIGHTENING TORQUE CHART
TRANSFERRING STYLE STARTING MECHANISM INSTALLATION
TRANSMISSION BELT
TRANSMISSION BELT INSPECTION
TRANSMISSION CASE
TRANSMISSION CASE GEAR INSPECTION
TRANSMISSION CASE OIL INSPECTION
TRANSMISSION CASE OIL REPLACEMENT
TRANSMISSION CASE OIL REPLACEMENT
TRANSMISSION CASE REMOVAL
TRANSMISSION COMPONENTS INSPECTION AND SERVICING
TRIGGER WINDING
VACUUM CHAMBER INSTALLATION
VACUUM CHAMBER REMOVAL
VALVE AND VALVE SEAT AIR IMPERMEABILITY INSPECTION
VALVE AND VALVE SEAT LAPPING
VALVE AND VALVE SPRING
VALVE AND VALVE SPRING INSPECTION
VALVE AND VALVE SPRING REMOVAL
VALVE CLEARANCE
VALVE CLEARANCE ADJUSTMENT
VALVE GUIDE
VALVE GUIDE INNER DIAMETER MEASUREMENT
VALVE GUIDE REPLACEMENT
VALVE MECHANISM INSPECTION AND SERVICING
VALVE SEAT
VALVE SEAT FINISHING
VALVE SEAT TOUCHING POSITION INSPECTION
VALVE SEAT WIDTH MEASUREMENT
65
1
28
44
44
26
26
45
45
55
57
27
58
24
23
17
17
13
13
13
2
9
14
14
14
8
15
15
16
15