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Generic XOR 50 ccm, Service Manual, Page: 81 / 110

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Generic XOR 50 ccm Service Manual Download Page 81

 

81

BRAKE CALIPER REASSEMBLY 

Reassemble and remount the calliper in the reverse 

order of removal and disassembly, and also carry out 
the following steps. 
CAUTION: 

Wash the calliper components  with fresh brake fluid 
before reassembly. Never use cleaning solvent or 

gasoline to wash them.Apply brake fluid to the calliper 
bore and piston to be inserted into the bore. 
 

Reassemble and remount the calliper. (refer to preceding bove pages)

 

WARNING: 

Bleed air after remounting the calliper. (refer to above pages) 
 

 
 
 

 

MASTER CYLINDER REMOVAL AND DISASSEMBLY 

Remove the handlebar cover. (Refer to above page) 
Disconnect the front brake light switch lead wires. 

 

 
 
 
 
 
 
 

Place a cloth underneath the union bolt on the master 
cylinder to catch spilled drops of brake fluid. Unscrew 

the union bolt and disconnect the brake hose master 
cylinder joint. 

 
 
CAUTION:

 

Completely wipe off any brake fluid adhering to any part of motorcycle. The fluid reacts 

chemically with paint, plastics, rubber materials, etc. 

 

 
 
 

 
Remove the master cylinder. 
 

Summary of Contents for XOR 50 ccm

Page 1: ......

Page 2: ...icing the scooter should carefully review the manual before performing any repair or services Major modifications and changes incorporated later will be advised to GENERIC product distributor in each...

Page 3: ...3 GENERAL INFORMATION TYPE IDENTIFICATION FUEL AND ENGINE OIL BREAK IN PROCEDURE PRECAUTIONS AND GENERAL INSTRUCTIONS SPECIFICATIONS CONTENT...

Page 4: ...number is 95 or more ENGINE OIL For GENERIC CCI SYSTEM we recommend special engine oil you can choose high quality two stroke engine oil without being diluted if without special oil GEAR OIL Use high...

Page 5: ...her s safety when several persons do Inspect looseness and operating state of components after reassembling them Take high care of gasoline which is explosive and never use gasoline as lotion The word...

Page 6: ...e stopper style Air cleaner dry Starting system electric and kicking start Lubricating system pressure lubricating ELECTRIC Ignition mode CDI Ignition timing 15 0 at 1500RPM Spark plug BP8HS Storage b...

Page 7: ...nd service procedures Storage battery Spark plug Cylinder head nut and exhaust pipe bolt Cylinder head and cylinder Fuel level line Air cleaner Throttle cable Engine idle speed Oil pump Gear oil Braki...

Page 8: ...d exhaust pipe bolt T T T T T Cylinder head and cylinder change all 12000 km C R C R Spark plug R R R R Air cleaner Clean every 3000KM 2000 miles Idle speed rpm I I I I I Throttle cable play I I I I I...

Page 9: ...y Inspect at initially 1000KM 600 miles 2 months and every 6000KM 4000 miles 12 months thereafter Uncover seat and then remove the battery box cap in the Middle of helmet barrel Disconnect negative po...

Page 10: ...ark plug cap 4 Tighten the nuts evenly one by one to the their specified torque Tighten the nuts in the order indicated Tightening torque Cylinder head nut 15 18N m Exhaust pipe bolt 15 18N m Cylinder...

Page 11: ...cified gap using a thickness gauge Thickness gauge Spark plug gap 0 6 0 7 mm 0 024 0 028 inch Check the spark plug for burnt condition If abnormal replace the spark plug as indicated in the chart NGK...

Page 12: ...lter core in the reverse order of removal CAUTION Before and during the cleaning operation inspect the core for tears A tore core must be replaced Be sure to position the filter core so that no incomi...

Page 13: ...controlled by amount of throttle opening Check the oil pump in the following manner to confirm correct operation for throttle valve full opening position Turn the throttle grip full open Check whether...

Page 14: ...brake hose every 4 years Front brake fluid level Keep the scooter upright and place the handlebar staight Check brake fluid level by observing the lower limit line on the brake fluid reservoir When th...

Page 15: ...rapped air exposes the machine and rider it is essential that after remounting the brake and restoring the brake system to the normal condition the brake fluid circuit be purged of air in the followin...

Page 16: ...th care the fluid reacts chemically with paint plastics rubber materials etc Rear brake Turn adjusting nut so that the the play of the brake lever is 15 25MM as shown in the illustration Brake shoe we...

Page 17: ...cooter with the excessively worn tires will decrease riding stability and consequently invite dangerous situation It is highly recommended to replace the tire when the remaining depth of tire tread re...

Page 18: ...6 2 Handle tightenging nut 37 44 3 7 4 4 3 Steering sterm locknut 37 44 3 7 4 4 4 Disc brake caliper fixing bolt 22 29 2 2 2 9 5 Disc brake master cylinder hose fixing bolt 22 29 2 2 2 9 6 Disc brake...

Page 19: ...19 14...

Page 20: ...efore lubricating each part clean off any rusty spots and wipe off any grease oil dirt of grime WARNING Be careful not to apply too much grease to the rear brake camshaft otherwise brake slippage will...

Page 21: ...inspection and servicing Bearings Oil seals crankshaft automatic clutch inspection cylinder head cylinder piston reed valve engine remounting oil seals bearings bushings crankshaft crankcase rear axle...

Page 22: ...he engine from the frame Engine left side Kicking starter lever Clutch brake pad kit Driver left face V belt Driver belt right face Electric starter gear Super clutch Driven face Engine center Carbure...

Page 23: ...r z Remove cooling fan cover z Remove cylinder cover z Remove cooling fan z Remove magneto nut with special tools z remove magneto rotor and half circle key with special tools z remove magneto stator...

Page 24: ...d z remove cylinder head and cylinder z Place a cloth stopper beneath the piston and remove the circlip with a plier z remove the piston pin and piston z Remove the kick starter lever z Remove side co...

Page 25: ...emove starting driven ratchet wheel by removing the nuts z Remove fan and V belt z Disassemble the movable drive face z Remove electric gear press board electric gear and super clutch z Remove starter...

Page 26: ...ve the clutch housing with the special tool Peg key z drain gear oil z remove rear axle nut z remove rear wheel z remove brake shoe and rear axle z Remove the rear brake cam lever indicator plate and...

Page 27: ...in and shaft z remove main stand z remove gearcase cover z Remove paper gasket and middle gear assy z Remove output gear assy z remove carburetor z remove intake pipe z remove reed valve and paper gas...

Page 28: ...the nut while holding down clutch shoe assy by both hands as shown in the illustration WARNING Gradually back off the clutch shoe assy pressed down by hands to counter the clutch sparing load Releasi...

Page 29: ...place the removed bearing with a new one z Remove inner bearing with special tool CAUTION Replace the removed bearing with a new one z Remove the spacer Remove the oil seal from the gearcase cover wit...

Page 30: ...e a new one z remove left crankcase shock absorber bushing with special tool warning use a new bushing wrap the oil seal with two appropriate size of sheet irons and clamp it shown as fig z Remove rig...

Page 31: ...ck with the dial gauge rigged to read the runout as shown Service limit 0 05mm 0 002in Excessive crankshaft runout is often responsible for abnormal engine vibration Such vibration shortens engine lif...

Page 32: ...32 Connecting rod small end inside diameter Measure the connecting rod small end diameter with a caliper gauge Service limit 14 040mm...

Page 33: ...electric tachmeter to the connecting portion of the magneto lead wire black with red tracer Seated on the scooter with the scooter on level ground increase the engine RPMs slowly and note the RPM at...

Page 34: ...e condition of the inner clutch wheel surface for scrolling cracks or uneven wear Measure inside diameter of the clutch wheel with inside calipers Measure the diameter at several points to check for a...

Page 35: ...turn smoothly If any stickiness or hitches are found visually inspect the lip of oil seal driven face sliding surface and sliding pins for wear or damage Driven face inspect the belt contacting surfac...

Page 36: ...bore to an oversize be sure to chamfer the edges of ports and smooth the chamfered edges with emery paper To chamfer use a scraper taking care not to nick the wall surface NOTE Minor surface flaws on...

Page 37: ...ring is to be measued with the ring fitted squarely into the cylidner bore and held at the least worn part near the cylidner bottom as shown in the illustration Service limit 0 75mm 0 030in As the pi...

Page 38: ...ut there are a number of reassembling steps that demand or deserve detailed explanation or emphasis These steps will be taken up for respective parts and components Oil seals fit the oil seals to the...

Page 39: ...39 shock absorber bushing positon install bearing in the cover Don t install the bearings on the crankshaft Install shock absorber bushing Install crankshaft without bearings...

Page 40: ...GENERIC NO 1215 evenly to the mating surface of the right half of the crankcase z Tighten the crankcase screws securely z Check if crankshaft rotates smoothly Install gearcase bearing Install new bea...

Page 41: ...nstall middle gear position pin by installing middle gear axle gasket and thrust gasket z install gearcase cover into crankcase and lock bolt z tighten each screw z screw oil drain nut 11 tightening t...

Page 42: ...42 z install the bearing in the fixed driven face with the special tool z install sliding bearing...

Page 43: ...pply grease to the lip of oil seals and groove of inside of movable driven face GENERIC special super grease NOTE When reinstalling the movable face to the fixed face make sure that the oil seal is po...

Page 44: ...iven face all the way outside to provide the maximum ble clearance CAUTION the belt should be positioned so that the arrows on the belt periphery point the normal turning direction The V belt contact...

Page 45: ...should be used GENERIC super grease z Mount the three dampers on the movable drive plate and install it on the movable drive face z Position the O RING on the movable drive face z Install the movable...

Page 46: ...ided inside sliding surface of the kick driven gear and install on the end of the crankshaft Wipe off excess grease QIANJIANG super grease Install washer and spring NOTE When Installing washer face th...

Page 47: ...47 Starter assy z Inject lubrication into start bearing and lubrication in the end of starter shaft GENERIC SPECIAL LUBRICATION z Tighten starter shaft gasket Install starter ratchet wheel and circlip...

Page 48: ...s shown in the illustration Tightening toque 8 12Nm 0 8 1 2kg m 6 0 8 5Ib ft PISTON z install the piston rings on the piston The first and the second ring keystone ring NOTE Position the ring so that...

Page 49: ...t coincide with the grovve portion of the piston z apply oil on the position and cyoinder wall surfaces and install the cylinder over the piston carefully z tighten the cylinder head nut to the specif...

Page 50: ...z Install oil hose Intake pipe z install intake pipe Magneto z clear crankshaft and magneto rotor z install half circle key z install paper gasket and stator coil and fix them z tighten to specified t...

Page 51: ...uiding cover z install fan guiding cover z install pipe screw and screw for tightening muffler to their specified torque 8 12Nm 0 8 1 2kg m 6 0 8 5Ib ft 18 28Nm 1 8 2 8kg m 13 0 20 0Ib ft z lubricate...

Page 52: ...52 CHAPTER 4 FUEL AND LUBRICATION SYSTEM CONTENTS FUEL SWITCH CARBURETOR OIL PUMP...

Page 53: ...pressure acts upon the diaphragm of the fuel switch and it pressed down the spring which supports the diaphragm so that the fuel passageway is opened and fuel is fed to the carburetor When the engine...

Page 54: ...manufacturer type Identification code Throat tube diameter Main jet size Idle needle jet size Oil needle clamp position Idle air adjusting screw Float height equal vacuum PZ19JB 19mm 80 57 5 3 rd groo...

Page 55: ...positions of adjustable parts should not be changed except when compensation for the mixture ratio due to altitude differences or other climatic conditions When adjustment is necessary refer to the f...

Page 56: ...56 CHAPTER 5 ELECTRICAL SYSTEM CONTENS IGNITION SYSTEM CHARGING AND LIGHTING SYSTEM STARTER SYSTEM FUEL GAUGE OIL LEVEL CHECK LIGHT AND TURN SIGNAL INDICATOR SWITCHS BARTERY...

Page 57: ...te of SCR As the SCR conducts the energy which has been charged in the capacitor is instantaneously discharged through the primary winding of the ignition coil CDI UNIT AND IGNITION COIL INSPECTION CH...

Page 58: ...ronic tester Ignition coil testing lead Use portable tester to check it Test the resistance between igntion ground wire and spark plug cap Ignition coil second resistance 12 18 KQ MAGNETO EXCITING COI...

Page 59: ...ywheel rotor turns AC generated in the charging coil flows to the regulator recifier which changes AC to DC The DC Then charges the battery Charging output check start the engine and keep it running a...

Page 60: ...ocket tester to measure the resistance between the lead wire and ground If the resistance checked is not correct replace the coil Rregulator rectifier Disconnect the lead wire couple Using the pocket...

Page 61: ...witch and battery depressing the starter button while squeezing the front or rear brake lever energizes the relay causing the contact points to close which connects the starter motor to the battery St...

Page 62: ...ground by plcing probe pins on each commutator segment and rotor core and on any two segments at various places With the brushes lifted off the commutator surface If the coil is found to be open circu...

Page 63: ...l and empty positions Connect a 90 ohm resistor between the Y B and B W lead wires The fuel meter is normal if its pointer indicates the E empty position when the specified voltage is applied to the c...

Page 64: ...nd remains lit When the turn signal switch is turned on and the turn signal light flashes the turn signal indicator light oil level check light also flashes both being not concurrently but alternative...

Page 65: ...WITCH RED ON RED WHITE MAIN SWITCH BROWN TURN RIGHT TURN LEFT DIRECTION SWITCH ORANGE GREEN BLACK GREEN WHITE PASSING LIGHT YELLOW RED PURPLE DIPPED HEADLIGHT HIGH BEAM OFF BULE AZURY EXCHANGE LIGHT S...

Page 66: ...filler holes Do not remove or pierce the sealed areas of the electrolyte container Insert the nozzles of the electrolyte container into the battery s electrolyte filler holes holding the container fi...

Page 67: ...urrent should be not more than 4A at any time After recharging wait for more than 30 minutes and apply multimeter to measure the battery voltage If the battery voltage is less than12 5V please rechare...

Page 68: ...EASSEMBLY AND REMOUNTING FRONT BRAKE BRAKE PAD REPLACEMENT CALIPER REMOVAL AND DISASSEMBLY CALIPER AND DISC INSPECTION CALIPER REASSEMBLY MASTER CYLINDER REMOVAL AND DISASSEMBLY MASTER CYLINDER INSPEC...

Page 69: ...xad screw and remove decorating cap rear carrier and oil tank lock remove side cover by loosing side cover screw 3 unlock oil pump cap and remove it two tapping screw are exposed remove them remove ta...

Page 70: ...2 removing under cover by loosing the left and right tapping screws under cover installation 3 The sequence if installation is ther reverse of removal front cover removal 1 Unscrew tapping screw and r...

Page 71: ...PEDAL REMOVAL 1 Remove power lock housing by unscrewing bolt 3 remove legshield and pedal by unscrewing the four bolts Legshield and pedal installation 4 the sequence of legshield and pedal is the re...

Page 72: ...72 HANDLE COVER REMOVAL 1 Remove front handle cover by unscrewing the six tapping screws 2 Remove master cylinder by removing the bolt...

Page 73: ...73 3 Disconnect throttle cable and oil pump cable 4 Remove rear brake cable adjusting nut...

Page 74: ...74 Handle cover removal 5 remove all cables 6 Remove handle cover by unscrewing bolt Handle cover unstallation 7 The sequence of removal is the reverse of reomval...

Page 75: ...ng 10 gearcase 11 valve mouth cap remove Remove the front brake caliper by removing the mounting bolts NOTE Do not operate the front brake lever while dismounting caliper remove mounting bolt remove t...

Page 76: ...dust seal and bearing should be replaced with new ones AXLE SHAFT Check the axle shaft runout with a micrometer and replace it if the runout exceeds the limit Service limit 0 25mm 0 010in WHEEL RIM M...

Page 77: ...llowing steps install this wheel bearing with the special tools as shown in this illustration CAUTION Install this wheel bearing for left side Install the brake disc as shown in photo When installing...

Page 78: ...he calliper 1 disc brake assy 2 disc brake handle lever 3 tightening bolt 4 nut M6 5 master cylinder 6 tightening seat 7 bolt M6X23 8 brake hose assy 9 brake caliper 10 connecting board tightening bol...

Page 79: ...and catch the brake fluid in a suitable receptacle CAUTION Nevere re use the brake fluid left over from the last servicing and stored for long periods Remove the calliper Remove the brake pads Remove...

Page 80: ...nd wear Check the disc for wear with a micrometer Its thickness can be checked with disc and wheel in place Ralpace the dise if the thickness exceeds the service limit Service Limit 3 5 mm 0 14 in Wit...

Page 81: ...per refer to preceding bove pages WARNING Bleed air after remounting the calliper refer to above pages MASTER CYLINDER REMOVAL AND DISASSEMBLY Remove the handlebar cover Refer to above page Disconnect...

Page 82: ...e dust boot Remove the circlip with the special tool Remove the piston primary cup with return spring Remove the reservoir cap and diaphragn Drain brake fluid MASTER CYLINDER INSPECTION Inspect the ma...

Page 83: ...also carry out the following steps CAUTION Wash the master cylinder components with fresh brake fluis before reassembly Never use cleaning solvent or gasoline to wash them Apply brake fluid to the cy...

Page 84: ...r brake light switch lead wires Remove the rear brake cable Remove throttle grip case Remove throttle cable 1 handle jointing assy 2 bolt GB5789 M10X1 25X45 3 nut GB6187 M10X1 25 4 left handlebar 5 th...

Page 85: ...w locknut with special tool remove fornt fork assy by removing upper outer steel bowl NOTE Not drop the steering stem balls remove front fork remove bearing lower race by chisel Remove steel balls Num...

Page 86: ...86...

Page 87: ...NSPECTION inspect the removed parts for the following abnormalities bearing race wear and brinelling Worn and damaged steel balls Distortion of steering stem or handlebar Inspect the suspension for da...

Page 88: ...ball Apply grease when installing the upper and lower steel balls QTY upper 21 lower 21 Tighten the steering outer race with special tool then extrude it 1 8 1 4round NOTE adjustment will vary from sc...

Page 89: ...ed torque 37 44N M NOTE After performing the adjustment and installing the handlebar rock the front wheel forward and backward to ensure that there Is not play and that the procuder is accomplished co...

Page 90: ...1 Tire 130 70 12 2 rear rim assy 3 brake pad kit assy 4 brake pad kit spring 5 rear brake tension 6 rear indicator 7 anti dust cover 8 rear brake camshaft 9 bolt M6 30 10 valve 11 nut M16 1 5 12 rear...

Page 91: ...eel Remove brake shoes INSPECTION REAR RIM Measure inner diameter of rear rim hub with micrometer if measured diameter exceeds 110 7 replace it with a new one Brake shoes Check the brake shoe and deci...

Page 92: ...rear axle shaft side Install the protrusion of indicator plate to the groove of Camshaft When installing the brake cam shaft aligh the groove of camshaft with the slit of on cam shaft When installing...

Page 93: ...93 SERVICING INFORAMTION Troubleshooting Battery Vehicle Wiring diagram Wire cable and brake hose routing Special tools Thread parts tightening torque Service data CONTENTS...

Page 94: ...ective CDI ignition coil unit Clogged fuel hose Clogged jets in carburetor Clogged exhaust pipe Clean Replace Clean Clean Clean Noisy engine Noise appears to come from piston Piston or cylinder worn d...

Page 95: ...r piston rings Stiff piston rings in place Gas leaks from crankshaft oil seal Spark plug gaps incorrect Clogged air cleaner element Float chamber fuel level out of adjustment Clogged air cleaner eleme...

Page 96: ...e joint or starter Pilot outlet is clogged Starter plunger is not fully close Check and clean Check and replace Check and clean Check and replace Medium or high spee d trouble Main jet or main air jet...

Page 97: ...Replace Replace Magneto charge but charging rate is below the specificatio ns Lead wires tend to get shorted or open circuited or loosely connected at terminal Grounded or open circuited stator coils...

Page 98: ...is too old Check the magneto and regulator rectifier circuit connections and make necessary adjustments to obtain specified charging operation Replace the battery and correct the charging system Repla...

Page 99: ...or engine mounting Replace Replace Replace Retighten Retighten Replace Tighten Front suspension too soft Weakened springs Oil leakage of shock absorber Replace Replace Front suspension too stiff Not e...

Page 100: ...e entered into brake fluid Clogged return port of master cylinder Brake shoe surface glazed Loose front wheel axle or rear wheel axle nut Worn shoe Repair surface with sandpaper Modify and fitting Rep...

Page 101: ...101 WIRE CABLE AND BRAKE HOSE ROUTING...

Page 102: ...102 carburetor...

Page 103: ...103...

Page 104: ...104 Ignition coil Starting relay CDI HORN POWER SWITCHH...

Page 105: ...ER DESCRIPTION 1 2 3 4 5 6 7 8 9 10 T01 T02 T03 T04 T05 T07 T08 T09 T10 T shape of sleeve sleeve tools 7mm 8mm 10mm 12mm 13mm flywheel remover sleeve 18mm 24mm screw remover cylinder pressure gauge pi...

Page 106: ...106...

Page 107: ...mp lock screw 5 9 Right crankcase lock bolt 10 12 Bearing press board lock bolt 10 12 Cylinder double head bolt 15 18 Motor tightening bolt 10 12 Left crankcase cover lock screw 10 12 Left crankcase c...

Page 108: ...rance 0 15 0 35 0 0059 0 0138 0 8 0 0315 1st ring 0 02 0 06 0 0008 0 0024 Piston ring to groove clearance 2en ring 0 02 0 06 0 0008 0 0024 Piston pin bore 10 002 10 008 0 3938 0 3940 10 030 0 3949 Pis...

Page 109: ...GUO flat inhale stopper type Identification code PZ19JB Throat tube diameter 19mm Main jet size 80 Pilot jet size 57 5 Oil needle clamp position 3nd groove Idle air adjusting screw Extrude 1 2 1 2 1 t...

Page 110: ...Rear 15 20mm Hub diamter Rear 110 mm 110 7 mm Brake shoe thickness Rear 4mm 2 5 mm Brake disc thickness front 4 0 0 2 3 mm Tire size Front rear 120 70 12 130 70 12 Tire surface thickness front rear 12...

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