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Generic Race 50, Service Manual

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13.1 Preparation data .......................................................................................................................................162 
13.2 Fault diagnosis .........................................................................................................................................163 
13.3 Cylinder body ..........................................................................................................................................163 
13.4 Piston .......................................................................................................................................................165 
13.5 Installation of piston ................................................................................................................................170 

XIV. Drive disk/Clutch/Driven Wheel / Foot start mechanism 

174 

14.1 Preparation data .......................................................................................................................................174 
14.2 Fault diagnosis .........................................................................................................................................174 
14.3 Left crankcase cover ................................................................................................................................175 
14.4 Drive disk.................................................................................................................................................175 
14.5 Clutch/driven wheel.................................................................................................................................178 
14.6 Disassemble the clutch and the driven wheel ..........................................................................................180 
14.7 Installation ...............................................................................................................................................186 
14.8 Foot start mechanism...............................................................................................................................186 

XV. Decelerator 

137 

15.1 Preparation data .......................................................................................................................................189 
15.2 Fault diagnosis .........................................................................................................................................189 
15.3 Gear Case.................................................................................................................................................189 
15.4 Installation ...............................................................................................................................................191 

XVI. Crankcase 

140 

16.1 Preparation data .......................................................................................................................................194 
16.2 Fault diagnosis .........................................................................................................................................195 
16.3 Crankcase.................................................................................................................................................195 
16.4 Installation ...............................................................................................................................................199 

Exhaust emission system inspection and maintenance  144 
XVII. Exhaust emission and control system        145 

17.1 Warranty of Exhaust emission and control system..................................................................................201 
17.2 Regular maintenance guideline................................................................................................................202 
17.3 Mechanical function of the exhaust control system.................................................................................203 
17.4 Catalyst converter system ........................................................................................................................205 

17.5Countermeasure of idle speed emission exceeding specified value

（

Two-stroke

）

................................206 

Summary of Contents for Race 50

Page 1: ...Service Manual Holtvej 8 10 H ruphav 6470 Sydals Telefon 45 73 15 11 00 Fax 45 73 15 11 01 E mail info scanmi dk www scanmi dk CVR 27 73 31 07 November 2010 Race 50...

Page 2: ...1 User s operation and maintenance manual for double wheel motorcycle RACE 50...

Page 3: ...system 72 1 5 Voltage and current regulator 73 1 6 Charge coil of the alternator 74 1 7 Disassembly of alternator 74 II Ignition system 61 2 1 Preparation data 61 2 2 Fault diagnosis 79 2 3 Ignition...

Page 4: ...ng bar 123 7 5 Front fork 124 VIII Rear wheel rear suspension 97 8 1 Preparation data 128 8 2 Fault diagnosis 128 8 3 Real wheel 129 8 4Rear shock absorber 130 IX Fuel tank seat mat 136 9 1 Preparatio...

Page 5: ...echanism 186 XV Decelerator 137 15 1 Preparation data 189 15 2 Fault diagnosis 189 15 3 Gear Case 189 15 4 Installation 191 XVI Crankcase 140 16 1 Preparation data 194 16 2 Fault diagnosis 195 16 3 Cr...

Page 6: ...nto force since regular inspection After Chapter I is the explanation of the gist of disassembly assembly and inspection of engine entire vehicle and electric fittings There are exploded view system d...

Page 7: ...forbidden in working space or the place stored gasoline Battery Battery could give off explosive gases so keep it away from incineration area or open flame or where smoking is permissible When chargi...

Page 8: ...vehicle to maintain the dirt of parts or external subassembly should be purged in order to prevent that falling into engine chasis or braking system After dismantling and before measuring attrition va...

Page 9: ...mblies that should be made from outside to inside and started from small one The complicated assembly transmission case for instance should be stored according to proper assembly sequence in order to...

Page 10: ...ind out whether they are suitable if they are mixed For the installation of oil seal the grease should be filled in oil seal groove as installing oil seal it should check the smoothness of oil seal wh...

Page 11: ...the tool to withstand one or two internal and external bearing runners If the strength is only applied onto a rolling ring no matter internal or external the bearing may be damaged as dismantling and...

Page 12: ...urce or any place where may bite it when it is moving When laying a cable along a handle avoid it being strained too tightly or loosely and it can not interfere with any adjacent part at any turning p...

Page 13: ...ows the code of the manufacture plant The anti refit name plate is stuck inside the helmet bucket the frame name plate is riveted to on the frame Figure 1 1 2 The engine series number is inscribed on...

Page 14: ...hen tighten all bolts or nuts diagonally to specified torques step by step unless described otherwise 5 Clean the removed parts with washing fluid Before assembly lubricate all sliding planes 6 After...

Page 15: ...o guarantee a smooth dismounting The list of specific tools for the assembly and dismantling of engine components and the figure of real objects can be seen in table 1 1 and table 1 2 Table 1 1 Name R...

Page 16: ...15 Figure 1 5 Figure 1 6 Figure 1 7 Figure 1 8 Figure 1 9 Figure 1 10 Handle Figure 1 11 Figure 1 12 Thickness gauge clearance gauge...

Page 17: ...7 Name Remarks rest wrench inner hexagon wrench circular wrench micrometer magnetic stand V shape block dial indicator square caliper spring clip ring clipper whack type screw drive front fork oil sea...

Page 18: ...17 Figure 1 19 Figure 1 20 Figure 1 21 Figure 1 22 Figure 1 23 Figure 1 24 Figure 1 25 Figure 1 26 Figure 1 27 Figure 1 28 1 Bush head 2 Shake handle 3 Ratchet type wrench 4 Connecting rod...

Page 19: ...e 1 30 3 Tools used for electric apparatus components The list of specific tools for the testing of electric apparatus components as well as the figure of real objects can be seen in table 1 31 and ta...

Page 20: ...19 Figure 1 34...

Page 21: ...tly Front rim 3 50 12 Outer cover of rear wheel 130 70 12 Air cleaner 3XG Tyre specification Rear rim 3 50 12 Petrol capacity 5 0 2L Clutch type Dry centrifugal type Engine Carburetor type IIF 45 Tran...

Page 22: ...21 RACE 50...

Page 23: ...22...

Page 24: ...eak or none at all Check spark plug and its cap for malfunction Check supply of ignition power Check ignition coil for short circuit or open circuit Check internal wiring of ignition system for short...

Page 25: ...clogging Engine shuts down in a very short time after start Engine can continue to work after start Inside of carburetor clogged or float height excessive Carburetor starting device i e starting riche...

Page 26: ...d during running Check cooling system Air cooling engine Check radiating fins for sticking mud and sand or excessive oil stains Clea n Check cooling fan and its cowl for damage forced air cooling engi...

Page 27: ...leration Combustible mixture too rich 1 Check air cleaner for clogging 2 Check carburetor starting device i e starting richer system for proper operation 3 Check carburetor float for insufficient heig...

Page 28: ...ient elastic force 3 Check piston ring and cylinder for wear Start engine increase throttle opening slowly and observe for speed change of engine Engine speed rises with increase of throttle opening E...

Page 29: ...eck if cable wire of throttle control cable can be pulled to move smartly in cable jacket and if throttle valve spring is too soft Chec k for under size clear ance betw een spark plug electr odes 1 Ch...

Page 30: ...eck tire pressure Air pressure too low Air pressure normal Inflate until full as required Check fuel tank fuel cock oil delivery pipe carburetor etc for oil leak Troubleshoot as appropriate Check mixt...

Page 31: ...then screw off oil dipstick with engine running under high speed to check if engine oil filler port smokes Transmission shift is difficult Start engine and check it for too high idle speed Readjust C...

Page 32: ...wheel broken or having insufficient elastic Repl ace Disassemble crankcase to check if approach depths of gears are satisfactory Approach depths of gears sufficient Approach depths of gears insufficie...

Page 33: ...caliper gasket for damage map cracking and aging 4 Check surface of brake caliper piston and that of oil cylinder wall for excessive wear or damage Drum brake fails Check if free stroke of brake grip...

Page 34: ...No voltage display Voltage display available Conductor from connector to battery opened Use an ohm meter to check and measure rectifier or rectification regulator for malfunction Disconnect bundle con...

Page 35: ...coil of magneto for short circuit Circuit between rectifier rectification regulator or battery and ignition switch shorted Replace charge coil 1 Check if electrolyte inside battery is insufficient 2...

Page 36: ...crewdriver or thick conductor After connection starting motor rotates normally After shorted starting motor can rotate normally After connection starting motor does not rotate yet and no engaging soun...

Page 37: ...ct Remove connecting conductors of starting motor and battery from start relay depress start button and then use an ohm meter to measure if resistor between battery terminal and starting motor termina...

Page 38: ...horn makes loud and clear sound and turn signal lamp comes on Electric horn does not make sound and turn signal lamp does not Power supply from battery is Score and touch positive and negative of batt...

Page 39: ...electrolyte inside battery is insufficient 3 Check if density of electrolyte in battery is too low 4 Check for sulphated or shorted pole plate in battery Disconnect rectification regulator from conne...

Page 40: ...connection illuminating lamp light is set right After disconnection illuminating lamp light is still comparatively dim Flat voltage of rectification regulator too low Check charge coil and internal wi...

Page 41: ...button to check operation of electric horn Electric horn can make loud and clear sound Electric horn does not make any sound or is hoarse Power supply from battery is normal Battery level runs low Re...

Page 42: ...uctor and ground instantly to check status of sparks Sparks are generated during scoring and touch No sparks are generated during scoring and touch Connect power supply conductor of electric horn and...

Page 43: ...r between brake lamp switch and brake lamp shorted or opened Power supply conductor between ignition switch and brake lamp switch opened or shorted Battery is undercharged Check if brake lamp keeps il...

Page 44: ...timing Bolt nut fixture Rim tyre Tyre specification Preparation requirement General Warning Before starting engine please confirm whether there is favorable ventilation and do not start engine in a c...

Page 45: ...44...

Page 46: ...wheel 120 70 12 Front rim 3 50 12 145 170kpa Outer cover of rear wheel 130 70 12 Tire pressure unit Kpa RACE 50 Rear rim 3 50 12 170 195kpa front wheel axle clamping nut 100 113 N m Torque force value...

Page 47: ...46 Rear turn signal lamp E3 001024 Rear view mirror Rear view mirror E3 001002 Horn Horn E4 000066 Side reflector E11 020614 Reflector Rear reflector E11 020613 Muffler Muffler EUR02 CAT...

Page 48: ...e tool Shock absorber inspection I I I General purpose tool Bolt inspection I I I I I I Torque spanner Oil leak inspection of gear case I I I I I I General purpose tool Spark plug inspection or replac...

Page 49: ...nsibility 2 If the motorcycle is driven on the sandstone road or under the environment of severe contamination the times of purging air filtrator should be increased to prolong the service life 3 For...

Page 50: ...49 Reinspect mobile oil level...

Page 51: ...er cover Remove pipe clip 4 Remove the air filter Dismantle the clamping screw of the cover of air filter Take down the upper cover of the filter Dismantle the filter element from the filter Check to...

Page 52: ...51 Attention Please confirm whether the air cleaner is installed as installing air cleaner cover...

Page 53: ...ing spark plug pleae install it with hands and tighten by spark plug socket Battery Dismantle battery Open the battery cell lid Dismantle the clamping bar components of battery cell Dismantle the nega...

Page 54: ...e positive pole wire Take out battery Measure the voltage between the battery terminals Fully charged 13 1V Undercharge 12 3V Attention The inspection of charging state should be made by voltage meter...

Page 55: ...n not be used generally except in emergency The voltage should be measured every 30 minutes after charging Charging current standard 0 4 A Quick 4 0A Charging period standard 10 15 hours Quick 30 minu...

Page 56: ...timing lamp before any operation Remove fender 1 Start engine and idle it Check ignition timing If symbol F aligns with the mark symbol on right crankcase cover it indicates that the ignition timing...

Page 57: ...56 high...

Page 58: ...Install the inspection bolt of gear oil Attention Confirm the airtightness of bolt and whether it is out of clutch and damage Changing gear oil Dismantle the inspection bolt of gear oil Dismantle the...

Page 59: ...ment of the front rear brake Free displacement of the front brake Measure the free displacement of the front brake handle at the tip of the brake handle Free displacement 10 20mm Free displacement of...

Page 60: ...the liquid level of the brake fluid is vertical to or is lower than the graphic arrow brake liquid should be injected in till the ceiling level Note During the examination the oil pump body should be...

Page 61: ...block if the motorcycle does not move or the engine misses Replace the new part if necessary Front rear suspension system Front Strain the front brake and compress the front shock absorber up and down...

Page 62: ...it to check whether the engine suspension bush is loosened Nut bolt fixture Check whether the bolt nut and fixture of the motorcycle is loosened If so please tighten to specified torque force value R...

Page 63: ...ce value Torque force value front wheel axle clamping nut 100 113 N m rear wheel fixed nut 100 113 N m Direction column bearing and handle fixing Swing the handle to check and confirm whether the lead...

Page 64: ...63...

Page 65: ...teners in Electrical System Fastening location and name of fastener Tightening torque N m Starting motor clutch cover bolt Fixing nut of starting motor clutch cover Rectifier bolt Fixing bolt of ignit...

Page 66: ...65...

Page 67: ...66 Charging system...

Page 68: ...67 1 Battery 12V 4AH 2 Cushion lock module 3 Horn 4 Rectifier 5 Power lock module 6 Igniter 7 Relay 8 Release resistor...

Page 69: ...regulator the battery will have too high voltage which may shorten its service life 3 Long rest of the battery will result in self discharge and the electric capacity will reduce therefore it must be...

Page 70: ...ltage limit Charge limit 14 8V 0 4V 5000rpm Torque value Tools Rectifier bolt 5 0 N m Multiple use fixing spanner Fixing bolt of high tension coil 9 0 N m Flywheel dissembler Flywheel fixed nut 5 0 N...

Page 71: ...70 Bad act of voltage and current regulator...

Page 72: ...f disassembly Attention In order to prevent short circuit connect positive pole first before the negative pole Please do not disconnect battery when you perform overall lineup otherwise internal damag...

Page 73: ...ard 0 A Fast 0A Charging time Standard 10 15h Fast 30m Charge completed open circuit voltage 12 8V or above 1 4 Charging system 1 4 1Short circuit test Remove the ground wire off the battery connect t...

Page 74: ...e main wire circuit Disassemble the 4P plug of the voltage and current regulator Inspect the conduction between main wire terminals with the following methods Item wire color Judging method between th...

Page 75: ...rmal the voltage regulator should be replaced 1 6 Charge coil of the alternator Attention Inspection of the charge coil of alternator may be conducted on the engine Inspection Disassemble the 6P joint...

Page 76: ...mbly Disassemble the body guard Remove right body fender Remove fixing bolts and screws and take off fan cover Remove 4 fixing bolts of cooling fan to take the latter off Fix the flywheel with a multi...

Page 77: ...heel in the key groove on the crankshaft and confirm Align the flywheel groove with the retaining key of the shaft Attention Confirm no bolts are on the inner face of the flywheel because of magnetism...

Page 78: ...77 Ignition system...

Page 79: ...78 1 Battery 12 4AH 2 Ignition coil assembly 3 Rectifier 4 Power lock module 5 Igniter 6 Relay 7 Cushion lock module 8 Horn Ignition system...

Page 80: ...r not 6 Inspect whether the spark plug is utilized at a proper thermal value Improper spark plug may lead to unsmooth operation of engine or burn out of the spark plug 7 Inspection in the chapter is b...

Page 81: ...80 Avometer...

Page 82: ...ct of CDI group when item is abnormal or when there is no spark in the sparkplug side voltage Normal high voltage no spark bad act of spark plug or power leak in secondary coil bad act of ignition coi...

Page 83: ...82...

Page 84: ...ure of the air cylinder is achieved in the test when the spark plug is installed on the cylinder head Connect the wire of ignition coil and connect the primary coil terminal black white with the diver...

Page 85: ...l area of the avometer prod mustn t be touched by fingers to prevent electroshock If the peak voltage of the CDI terminal has an abnormal value disassemble the right body guard and the alternator join...

Page 86: ...or eroded Inspection item Testing terminal Standard value 20 Main switch red red white Conducted when main switch at OFF Trigger Blue white white green 100 500 primary ignition coil black white black...

Page 87: ...ange the primary coil is good The resistance value stands for broken line in the coil so replace with a new product 2 5 3 Secondary coil Measure the resistance value between the wire of spark plug cov...

Page 88: ...87 Disassemble the body guard Disassemble the lead connector of the trigger...

Page 89: ...n the blue white terminal at the engine side and the body ground Standard value 100 500 20 If the measured value exceeds the standard value replace the alternator D J621 2 8 0 5 D J7031 2 8 21 Interfa...

Page 90: ...89 BATTER Y R ELAY BR AKE SW I TC H BR AKE SW I TC H STAR TER SW I TC H STAR TO R M O TO R Startup system Startup diagram...

Page 91: ...90 1 Battery 12V 4AH 2 Cushion lock module 3 Horn 4 Rectifier 5 Power lock module 6 Igniter 7 Relay 8 Release resistor...

Page 92: ...engine Please refer to disassembly operation in disassembly Preparation reference Item Standard value Allowable limit Brush length of startup motor 6 2mm 3mm Liner of startup idler shaft 8 3mm Outer d...

Page 93: ...92...

Page 94: ...e main switch must be switched to OFF before disassembly of the startup electrical machinery Dismantle the bonding strip of the battery and turn on the power supply to see whether the startup electric...

Page 95: ...Inspect whether the oil seal is worn out or damaged 3 3 4 Assembly Oil seal in the front cover and coating of grease Mount the electric brush on the brush holder Spread grease on the active parts of...

Page 96: ...dering cup is installed Check the O ring for damage If abnormal situation is found replace it with a new one Apply engine oil to the O ring and then fit it on the starting motor Install the wire clamp...

Page 97: ...is no voltage on the starting relay line inspect the wire and conduction of the brake switch 3 4 3 Inspect the earth line of the start relay Remove the connector of start relay Inspect conduction bet...

Page 98: ...97 reads 0...

Page 99: ...mber of head lamp E4 0012026 B Certification number of front turn signal lamp E3 001024 C Certification number of tail lamp E11 000054 D Certification number of rear turn signal lamp E3 001024 E Certi...

Page 100: ...measured after disassembled from the motorcycle 4 2 Fault diagnosis Main switch is pushed to ON but the light doesn t work Bad act of the bulb Bad act of the switch Poor contact of the connector or b...

Page 101: ...et screws of left and right rear fenders so that tail lamp shade can be taken off Disconnect wire connectors of tail lamp and left and right turn signal lamps Remove left and right rear fenders 1 tail...

Page 102: ...ove the instrument Install the speed indicator back to the original position in the reverse order of disassembly 4 7 Main switch 4 7 1 Inspection Remove front cover twin lamp panel Remove foot protect...

Page 103: ...the battery then it is the fine conditions 4 9 Handle switch Remove left and right rear view mirrors Remove set screws of left and right combination switches Loosen left and right combination switche...

Page 104: ...103...

Page 105: ...rocker arm Fixing nut of rear wheel Fixing bolt of welded module of steering handle Lock nut of front wheel spindle Front wheel spindle Fixing nut of rear wheel Top nut of rear shock absorber Bottom...

Page 106: ...m F Free stroke of brake lever 10 20mm 1 Hydraulic brake assembly 2 Gasket 3 Oil pump body 4 Plunger module 5 Oil cup pad 6 Oil cup cover 7 Screw M4 10 8 Fixing cover of handle seat 9 Screw M6 23 10...

Page 107: ...Washer 29 Mounting nut of front brake disc M10 1 25 Rear brake drum A Mounting torque value of the nut 11 shown in the figure 100 113N m B Bore of brake drum 110mm Wear limit 111mm C Thickness of bra...

Page 108: ...uction Matters needing attention in operation Attention Inspect the brake before riding the motorcycle 5 1 1 Specification Item Standard value mm Allowable limit mm thickness of front brake disc 4 0 3...

Page 109: ...friction lining module installed improperly 4 Brake shoe friction lining module and brake disc contaminated Strange sound in braking 1 Brake shoe and friction lining module worn 2 Brake shoe friction...

Page 110: ...ont wheel 5 3 2 Inspection Inspect whether the brake pad is worn out and replace it if necessary Measure the brake pad and brake disc and put down the maximal value Specification RACE 50 diameter of f...

Page 111: ...of oil pump body module 5 9 N m Mounting bolt of front brake cylinder module 22 29 N m Do not allow oil stains to stick to friction lining If oil stains stick to friction lining clean with brake wash...

Page 112: ...spection Check brake drum and brake shoe for wear When needed replace Measure thickness of brake shoe and bore of brake drum and take down the maximum values Attention Be sure to use a micrometer to m...

Page 113: ...If the brake pad and brake disc are polluted with oil rinse them with brake cleaning fluid Rear brake 1 Bolt 7 Brake shoe module 4 2 Rearbrakerockerarmmodule 7 8 Brakeshoetensionspring 5 3 Nut 9 Oute...

Page 114: ...8 Back mudguards 19 Back shelf 20 Frame board 21 Bolt M6 30 22 helmet hooks 23 screws M5 14 24 self tapping screw ST4 12 25 Front cover screws 26 Boss screw bolt M6 14 27 bolts M6 12 28 cards 29 bolts...

Page 115: ...tection components Back licence brackets back mudguards battery lid foot panel lower lid inside mudguards helmet hooks foot guard board component Attention Do not damage any body cover during installa...

Page 116: ...115 Front wheel...

Page 117: ...2 1 25 8 axle M12 1 25 224 9 Front wheel left axis cover 10 gear wheel bracket component nuts 11 valve cap A Tire specifications outer tire120 70 12 B Wheels specifications 3 50 12 C Rims facing poor...

Page 118: ...proof shade 6 siamesed steel bowl 7 steel ball 5 8 down bearings up steel bowls 9 down bearings down steel bowls 10 odometer line clamps 11 bolts M6 12 12 A Installed torque value in the map of bolt 1...

Page 119: ...rip 5 Accelerator handle 6 Accelerator wire components 7 Flat screw M5 25 8 Screw M5 10 9 liquid shake hand knob 10 A Installation torque values of bolts 2 direction knob fixes the bolts in the map 2...

Page 120: ...d the front wheel floating ground should not be attention to the ground can not be invertible During the operating the brake shoes block friction chip components brake disc can not be attached to oil...

Page 121: ...ls rotate with difficulties The wheel axle bearing or the gear seats are in failure 7 2 5 Strange noise in front shock absorber Friction noise in shock absorber guard Loosening of bolts in shock absor...

Page 122: ...121 Remove the braking disk Remove axle sheath oil seal axle 6201 2RS axle insulating sheath axle 6201 2RS Note see P87 for figure RACE 50 for dismantling and mounting front wheel...

Page 123: ...on if the value exceeds 2 0mm replace the rim Transverse direction if the value exceeds 2 0mm replace the rim 7 3 2 3 Inspect the front wheel bearing Remove front wheel axle braking disk Remove front...

Page 124: ...ricant is grease of calcium radicle first Mount front wheel axle 8 front wheel components of gear seat 10 Bolts M12 1 25 7 Make certain that the joint position is matched well when mounting components...

Page 125: ...move braking fluid tube wires of odometer Remove steering bar Remove in sequence the fastening bolts 4 anti sliding washer Remove the upside and downside steel bowl and steel balls 7 of the upside axl...

Page 126: ...balls 21pcs Lubricate the seat ring of top seat with grease Rotate the steering bar left and right to make steel balls contacted closely Tools Wrench for screw bolts Confirm smoothly sliding of front...

Page 127: ...of rear brake 8 rear indicator 9 position return spring of rear brake 10 mounting bolts of rear crank 11 bolts 12 dust proof lid 13 screw M8 31 14 components of rear shock absorber 15 locking pin A T...

Page 128: ...on spring of braking plate 6 cram shaft of rear brake 7 crank components of rear brake 8 rear indicator 9 position return A Specification of outer tire 130 70 12 B Speciation of rim 3 50 12 Wobbling l...

Page 129: ...ere cannot be any oil stain stuck to the surface of the brake disc or brake pad Preparation reference Item Standard value mm Allowable limit mm Vertical direction 2 0 Run out of rear wheel Transverse...

Page 130: ...ccentricity through the dial gauge Allowable limit Vertical direction Replace for that is above 2 0mm Transverse direction Replace for that is above 2 0mm When the swinging degree of the rear wheel ex...

Page 131: ...130 Rear wheel 8 4 Rear shock absorber...

Page 132: ...move the fixing bolts of rear shock absorber Unload the rear shock absorber 8 4 2 Installation Install the rear shock absorber Torque value Upper fixing bolt 37 44 N m Lower fixing bolt 22 29 N m The...

Page 133: ...132...

Page 134: ...ine 3 bolts M12 1 25 4 screw bolts for hanging rack M10 41 1 25 5 bolts M10 1 25 6 welded components for welded components of power A Caution must turn the fuel switch to the OFF position when dismant...

Page 135: ...eat mat lock 10 screw M6 20 11 prop for rear luggage rack 12 screw M6 12 13 tight wire of seat mat 14 rivet3 2 7 Fuel tank A Fuel capacity 5 0 2L B Torsion for screw 2 5 9 N m C Length of the vacuum t...

Page 136: ...nsulation spring 6 hoop 8 7 vacuum tube 360mm 8 hoop 7 9 fuel tube 2250mm 10 filter components 11 fuel position sensor 12 screw M5 16 13 gasket of fuel position sensor 14 seal rubber 15 gasket 5 16 fi...

Page 137: ...ention in operation The place for dismantling should be far away from fire must turn the fuel switch to the OFF position when dismantling the fuel tank Torsion for screwing bolts must meet the determi...

Page 138: ...ielding lid Remove oil pot Remove seat mat 7 and helmet bucket Remove rear luggage rack 8 Remove left right shielding plate Remove components of rear handrail and helmet bucket mounting seat Turn the...

Page 139: ...stallation Mounting should follow the reversed procedure of dismantling Torsion for mounting Screw bolts for rear luggage rack prop 5 9 N m Screw bolts for fuel tank 5 9 N m Screw bolts for helmet buc...

Page 140: ...139 Inspection and maintenance of engine Table of torque value of engine fastener Fastening area and fastener name Tightening torque N m...

Page 141: ...Crank box left lid cover screw bolt Crank box left cover screw bolt Driving hub screw bolt Idling hub screw bolt Idling hub clutch screw bolt Surpassing Clutch outer ring screw bolt idling wheel of E...

Page 142: ...141...

Page 143: ...te Worm and worm wheel should run flexibly without block and one side locking meanwhile the worm wheel has a little leap axially O ring in oil pump must not have edge cutting No oil leakage comes from...

Page 144: ...the engine trial operation after assembling retighten it firmly till to the oil flowing out to be seen Function of the lubrication system supplying lubricating oil to the wear surface to reduce part w...

Page 145: ...sure too low Machine oil leak Oil path blocked Wear and improper installation of the piston ring Machine oil not used 10 3 Oil pump 10 3 1 Disassembly Loosen the fixed bolt and take off the chain cove...

Page 146: ...145 Take off the magnetic motor stator rotator and bracket Take off worm wheel from the crankshaft take off oil pump component...

Page 147: ...the installation according to the reversed sequence of dismantle 10 3 3 Inspection Inspect worm wheel teeth surface whether there is damage Inspect key slot whether there is breakage Oil pump cover Oi...

Page 148: ...147 Measure element outside diameter Allowable limit 2 61mm Carburetor...

Page 149: ...ater 5 Floater pin 6 Main jet 7 Idle speed injection nozzle 8 Main foam pipe 9 Idle speed adjusting screw Note Gasoline is very dangerous no smoke at work place Use cloth to block the intake manifold...

Page 150: ...he gasoline inside the float chamber must be discharged Otherwise the gasoline inside the float chamber will deteriorate and block the idle speed nozzle resulting in insecurity of idle speed Function...

Page 151: ...Fuel system blocked Idle system or choke system blocked Bad act of piston Secondary air inlet of suction system Too dense gas mixture Intermittent flashover in acceleration Bad operation of enrichment...

Page 152: ...151...

Page 153: ...dle valve If the needle valve is seriously worn electric starting valve components should be replaced Loosen the bolt and dismantle the upper cover Take out the spring and the plunger components Exami...

Page 154: ...rn down then the carburetor body should be replaced If the float tongue piece is worn down it should be replaced Examine the oil needle of the carburetor to see if it is damaged or worn down If so the...

Page 155: ...154 Idle speed injection nozzle Idle adjusting screw...

Page 156: ...800rpm Screw the mixture adjustment bolt to the end with proper force At this point the engine will stall if not inspect whether air escapes at the interface of air filter whether the bolt is tightene...

Page 157: ...fixing bolt 3 Cylinder head 4 Cylinder gasket 5 Cylinder block Note In order to guarrante the sealing between cylinder head and cylinder block the cylinder head undertakes a very big bolt pretightenin...

Page 158: ...compressed air before inspecting and measuring The function of cylinder head The cylinder head which seals cylinder block consists of combustion chamber with piston bears high temperature high pressu...

Page 159: ...158...

Page 160: ...ct the cylinder head whether it is broken Inspect the planeness of the cylinder head bottom plane Allowable limit 0 04mm 12 5 Cylinder head installation Implement mounting in a reverse order with dism...

Page 161: ...160 Air cylinder piston...

Page 162: ...161 1 Piston 2 Piston pin 3 Cylinder block 4 Cylinder gasket 5 Cylinder head 6 Nut 7 Spark plug...

Page 163: ...piston motion It also transmits part of the heat in the air cylinder to the surrounding cooling media Function of piston Bearing the pressure caused by burning of combustible mixture gas and pass the...

Page 164: ...002 0 014 0 02 Small end inner diameter of the connecting rod 14 016 14 034 14 06 13 2 Fault diagnosis Low compression pressure White fume in vent pipe The piston is worn out burnt out or broken The...

Page 165: ...after dismantle the air cylinder cover 13 3 2 Inspectionof air cylinder body Inspect the wear and tear of the cylinder inner wall Severe wear and replace it Inspect the cylinder face planeness of the...

Page 166: ...piston Inspect the piston piston pin and piston ring Unload the piston ring Attention Do not break or damage the piston ring Clean away the carbon deposit in the piston ring groove Unload the piston...

Page 167: ...lowable limit 0 5mm Measure the bore diameter of the piston pin hole Allowable limit 12 04mm Measure the outer diameter of the piston pin Allowable limit 11 96mm Clearance of piston pin hole and pisto...

Page 168: ...on Allowable limit 39 9mm Inspect the abrasion and wear of the cylinder inner wall Attention Measure the bore diameter of the cylinder at the upper middle and lower part when keeping an angle of 90 de...

Page 169: ...168...

Page 170: ...ecting rod small end Allowable limit 14 06mm 13 4 2 Installation of piston Install the guide pin Paint the engine oil on each piston ring and piston Install the piston in the right place with the mark...

Page 171: ...ring and retaining ring Attention Install the notch face of the pistion skirt towards air intake duct 13 5 Installation of piston Install the guide pin Paint the engine oil on each piston ring and pi...

Page 172: ...e disk Clutch Driven Wheel Note The grease can not attach on the surface of the V belt during operation it must be removed if it is attached to reduce the slip between the V belt and belt wheel to the...

Page 173: ...Foot start mechanism Note The grease can not attach on the surface of the V belt during operation it must be removed if it is attached to reduce the slip between the V belt and belt wheel to the mini...

Page 174: ...173 1 Snap ring 2 Start claw 3 Idle gear 4 Idle gear shaft 5 Start shaft component 6 Foot start shaft spring...

Page 175: ...nd the driven wheel is transmitted through the triangle belt Preparation reference Unit mm Item Standard value Allowable limit the right half of the internal diameter of the drive wheel 25 989 26 052...

Page 176: ...is worn out The clutch spring is broke The surface of the driving pulley is stained 14 3 Left crankcase cover Disassembly Dismantle the fixing bolt of the case cover and take down the gasket and the...

Page 177: ...om the drive disk Check whether the triangle belt is chapped and whether the rubber and cotton yarn fall off or are abnormally worn out Measure the width of the triangle belt Allowable limit 16mm Atte...

Page 178: ...177 14 4 2 Decompose the right half components of the drive wheel Check the abrasion of the ball bearing Measure the external diameter of the ball bearing Allowable limit 14 4mm...

Page 179: ...Fix the outer part of clutch with the fixing tool and dismantle the fixing nut Take down the outer part of clutch clutch driven wheel 14 5 2 Decomposing the clutch Dismantle the check ring and decompo...

Page 180: ...179 Retainer ring Friction plate...

Page 181: ...ickness of the friction plate Allowable limit 1 5mm 14 6 Disassemble the clutch and the driven wheel When dismantling the clutch pressing spring use the clutch spring compressor in the operation Atten...

Page 182: ...181 Loosen the compressor and decompose the clutch and driven wheel...

Page 183: ...ment of the driven wheel Dismantle the oil seal from the left half part of the driven wheel Check the free length of the clutch spring Protective jacket of the spring The left half weldment of the dri...

Page 184: ...ng sleeve of the driven wheel Allowable limit 33 06mm 14 6 1 Replacement of the right half bearing of driven wheel Take down the needle bearing from the right half driven wheel Dismantle the elastic c...

Page 185: ...leeve Attention Compress the outer rolling bearing into the shaft sleeve with the marked side outward Then fill the 8 9g grease in the whole shaft cavity Assemble the elastic check ring Install the ne...

Page 186: ...ed ring and install it on the left half sliding sleeve of the driven wheel Combine the left half and right half parts of the drive wheel Paint grease on the guide pin install in the guide slot Install...

Page 187: ...wise the spring will be damaged 14 7 Installation The order of assembling the driven disk clutch and driven wheel is opposite to that of disassembly 14 8 Foot start mechanism Disassembly Check Dismoun...

Page 188: ...ion Inspect the wear condition of the idle wheel Measure the clamping force of the snip ring General standard value 8 12N Note 1 Snap ring 2 Start claw 3 Idle gear 4 Idle gear shaft 5 Start shaft comp...

Page 189: ...188 Decelerator Function Transfer torque and decide final output torque and revolution...

Page 190: ...of the final output 15 2 Fault diagnosis The motor can not move when the engine is started The drive gear is broken The drive gear is burnt out The gear oil is leaked The gear oil is too much The oil...

Page 191: ...190...

Page 192: ...the gearbox cover Attention The bearing which is pushed out can not be used and should be replaced The disassembly of bearings and oil seal should use special tools Dismantle the oil seal on the gear...

Page 193: ...192 Attention The assembly of bearings and oil seal should use special tools to prevent damage Crankcase...

Page 194: ...wall casting part avoid stamp during the work to prevent deformation and breakage All parts should clean and blow cleanlily by high compressed air before inspecting and measuring The oil in crankcase...

Page 195: ...engine Its primary function is supporting the crankshaft clutch gearbox cylinder body as well as the cylinder cover and bearing bursting impact of combustion and movement inertia force of crankshaft...

Page 196: ...n are loosened Clutch depressed 16 3 Crankcase 16 3 1 Disassembly of crankcase Loosen bolt take off the start drive gear Take off the gear on the satellite wheel seat Dismount crankcase fixing bolts D...

Page 197: ...ff the crankshaft from the crankcase Scrape off the gasket on the crankcase joint face Attention Don t damage the crankcase joint face Dismount oil sealing from the left crankcase Oil sealing Oil seal...

Page 198: ...197 Dismount oil sealing from the right crankcase 16 3 2 Inspection Clearance measurement of connecting rod big end in right and left direction Allowable limit 0 6mm...

Page 199: ...ng rod big end in X and Y direction Allowable limit 0 05mm Inspect whether there are strange noises or loosening in rotation of the crank shaft bearing If there is strange noises or loosening replace...

Page 200: ...e dismantling of the oil seal should use special tools 16 4 Installation The order of assembling crankcase is opposite to that of the disassembly Attention The installation of oil seal should use spec...

Page 201: ...ilencer body 3 Silencer decoration cover 4 Silencer front section 5 Bolt M6 16 6 Bolt M8 35 7 Bolt M8 20 8 Exhaust pipe gasket component 9 Nut M6 10 Silencer damping sleeve 11 A Torque value for bolt...

Page 202: ...rantee that within riding of 15 thousand km regular or irregular exhaust inspection standards implemented by the government will be satisfied 3 If the following conditions occur this warranty clause i...

Page 203: ...ct inspection before delivered out of the company and meets standards of air pollution emission But since customers differ in use of our products we ve established the following regular inspection tab...

Page 204: ...n 5 Matters needing attention The disorder of ignition charge and fuel system will have great impact on the catalyst device therefore if you feel disorder of the engine please go to designated dealers...

Page 205: ...evice Introduce the air into the vent pipe so that the CO and HC incomplete combustion could be turned into innocuous gas in the second reaction Difference Device Constituting part Objective and funct...

Page 206: ...st converter 1 For Keep the vehicles loaded with catalyst converter away from inflammable materials the engine is too hot to be touched shortly after it is started or stalled 2 Keep the vehicles loade...

Page 207: ...for delivery Qualified Qualified Qualified Qualified Qualified 7 Do not drive vehicle with bad ignition 8 Do not repair the engine ignition system by dismantling the spark plug and starting the engin...

Page 208: ...207 Remark 1 Measure with idle speed measuring procedure Remark 2 Adjust the engine speed within the stipulation with a set screw and measure idle speed CO HC...

Page 209: ...208...

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