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HER CHEE GTC-50 Service Manual Download Page 5

ADLY

 

MOTO

 

 

1-2 

*** Attention of Operation *** 

 

Must lubricate to the appointed part with grease oil, and the canned lubrication. 

 

 

To confirm the locking parts and check the operation of each part after assembling. 

 

 

 

 

Must coordinate with each other and pay attention to the safety when working over 2 people. 

 

 

Meaning of Pattern and Notes 

The patterns and notes below are the direction and attentions of this service manual. 

 

 

  Lubrication 

 

 

 

Use the appointed lubricant in the appointed part. 

 

 

 

 

Use the lubricant to lubricate 

 

 

 

 

The part of using special tools. 

 

 

 

 

Use the general tools. 

 

 

 

 

Use new one after disassembling. 

 

 

  Attention! 

 

 

 

 

Danger and important operation! 

 

 

 

Summary of Contents for GTC-50

Page 1: ...SERVICE MANUAL GTC 50 January 2011 High power Engine HER CHEE INDUSTRLAL CO LTD ...

Page 2: ... edited is given in diagrams with Operation Sequence Key Points and Adjustment of Check for reference of the service staffs This Service Manual is finished in accordance with the model of GTC 50 Taking new model as standard if there are differences between the model described in this manual and the actual scooter HER CHEE INDUSTRIAL CO LTD ...

Page 3: ... system 4 Engine assembling disassembling 5 Cylinder head Cylinder and Piston 6 Starter Driving Wheel 7 Clutch Driven Wheel Assembly 7 Final Transmission Mechanism 8 Crank Shaft Case Transmission Box 9 Chassis Front Wheel Front Suspension Front Brake 10 Rear Wheel Rear Suspension Rear Brake 11 Electrical Device 12 Wiring Diagram 13 ...

Page 4: ...uts etc first tighten them according to the tightening tension stipulated with the opposite angle s way from big diameter s screw to small diameter s screw and from inside to outside Must use the pure and original oil grease and parts Must use the professional tools and the general tools to repair Must clean the parts checked after disassembling the parts and put the grease to lubricate the operat...

Page 5: ...nate with each other and pay attention to the safety when working over 2 people Meaning of Pattern and Notes The patterns and notes below are the direction and attentions of this service manual Lubrication Use the appointed lubricant in the appointed part Use the lubricant to lubricate The part of using special tools Use the general tools Use new one after disassembling Attention Danger and import...

Page 6: ...T WEIGHT 75Kg DISPLACEMENT 49 3 c c BORE X STROKE 40 x 39 2mm ENGINE TYPE 2 Stroke Single cylinder AIR COOLED COMPRESSION RATIO 7 1 IGNITION C D I IGNITION STARTER ELECTRIC KICK SUSPENSION Oil Damped shock absorber FRONT REAR TRANSMISSION AUTOMATIC CVT type TIRE 120 70 12 FRONT BRAKE DISC REAR BRAKE DRUM ...

Page 7: ...Support Screw of Muffler 2 6 1 2 Spark Plug 1 14 1 4 Bolt of Crank Shaft Case 6 6 10 Bolt of Engine Installation 1 8 5 0 Chassis Place of Locking Q ty Screw Diameter mm Locking Torque Kg m Spanner Nut of Handle Steering Steam 1 25 7 0 Front Wheel Axle Nut 1 10 4 5 Rear Axle Nut 1 14 11 Rear Brake Arm Screw 1 5 0 6 Upper Screw of Rear Shock Absorber 1 10 4 0 Lower Screw of Rear Shock Absorber 1 8 2...

Page 8: ...ADLY MOTO 1 5 The following drawing that shows the disassembling situation of the cover parts for Fox Plus scooters ...

Page 9: ...ADLY MOTO 1 6 ...

Page 10: ...ADLY MOTO 1 7 ...

Page 11: ...ADLY MOTO 1 8 ...

Page 12: ...ition Spark weak or no spark Spark plug defect or dirty CDI defect ACG defect spark strong Short circuit of H T coil Ignition wire broken or short Main switch defect Check compression pressure Weak or no Piston ring too weak Reed valve defect pressure is good Cylinder and piston ring wear out Leaking of cylinder gasket L R crankcase leaking Start up engine base on the instruction Igniting but no s...

Page 13: ...defect spark fair ACG defect Short circuit of H T coil Ignition wire broken or short Main switch defect Check compression pressure Cylinder and piston ring wear out compressing no compression Leaking of cylinder gasket Reed valve leaking L R crankcase leaking Check carburetor is blocked or not Vent tube blocked not blocked Blocked Check ignition timing Check CDI correct Incorrect ACG defect Adjust...

Page 14: ...t Timing incorrect ACG defect Check compression pressure Cylinder and piston ring wear out compressing no compression Leaking of cylinder gasket Reed valve leaking Check carburetor is blocked or not Air or Fuel path blocked not blocked Blocked Check engine is over heat or not A F mixture too thin not Over heating Fuel quality is bad Carbon deposit in combustion chamber Ignition timing too early Co...

Page 15: ...ing Intake manifold leaking Remove spark plug put into the cap and connect the spark plug to ground negative check the spark condition Spark weak or no spark Spark plug dirty or defect CDI defect ACG defect spark strong Short circuit of H T coil Ignition wire broken or short Main switch defect Remove starter plunger wire and check Connection wire is bad with resistance No resistance Plunger defect...

Page 16: ...el well Poor Tube and fuel filter blocked Fuel tank cap is blocked Check carburetor nozzle blocked or not Cleaning not blocked Blocked Remove starter plunger wire and check Connection wire is bad with resistance No resistance Plunger defect Connect starter plunger with 12V battery for 5 Min tubing pipe with fuel adding return yhen blow it Blowing Plunger defect not blown ...

Page 17: ...il Loosing Spark plug cap defect High tension coil defect No loose Remove CDI unit over the plug cap connect ground and check spark Abnormal Check concerned parts Bad Main switch Normal Normal Bad high tension coil Bad pulse coil Wire broken Bad connection Check Cdi with CDI tester or replace new CDI unit to test Abnormal CDI unit defect Normal Check ignition timing Abnormal Ignition coil defect ...

Page 18: ...G charging coil resistance Bad starter Normal range Out of range Yellow wiring broken Connection poor Check voltage of red and green wiring on rectifier connector No voltage Wire broken Battery with voltage Remove rectifier connector and check each device Normal Bad rectifier Abnormal Plunger defect Check ACG coil resistance value Normal Wire broken Abnormal AC Generator defect ...

Page 19: ...ice Time month Service Items Before riding 1st each 6 each 12 Judgement Standard Remarks Operating Device Handle Play loose tight Operation Wheels Right left turn round angle Front Fork Damage Installation of shaft Shaft Gap Direction Post Direction Post Brake Device Brake Play Try to run Correct brake Play of brake lever 10 20 mm Wires Loose tight and damage Gap of casing brake Wore of brake oper...

Page 20: ... horizontal under 3 mm vertical under 3 mm Rear wheel horizontal under 3 mm vertical under 3 mm Tightness of front bearing Tightness of rear bearing Suspension device Spring damage Spring of shock absorber Suspension arm damage of joint gap arm Tightness of installation Power transmission device Clutch action Crankcase oil leakage or damage Transmission gear oil Electric device Ignition device con...

Page 21: ...ty Leakage of fuel Throttle gate choke Fuel filter is clogged Oil level Alteration of pipes each 2 years Lights direction lights Action On off normal dirty damage Rear view mirror Instrument action Exhaust pipe muffler Installation loosed or damage Function of muffler Frame body loose or damage Abnormal from previous day confirm normal Others greasing of each part Cleaning combustion chamber exhau...

Page 22: ...he screws be sure of correct matching of all units Cowling Remove 4 tapping screws and 2 round head bolts Separate the joint of inner parts and remove the cowling Install with reverse sequence Front Cover Remove 4 tapping screws and 3 hex nuts Separate the joint of inner parts and remove the cowling Install with reverse sequence ATTENTION Be sure of not damaging the front pane land the front inner...

Page 23: ...ON After joining the pedal and the front interior covering mount it onto the chassis Luggage case Open the luggage case cover Remove 4 tapping screws and 1nut separate the join with the chassis the concave and the convex and remove the front cover Remove the main switch cap Follow the sequence in reverse order for assembly ATTENTION Be sure the joint of front cover and cowling jointing correctly b...

Page 24: ...right body covers Remove 2 hex bolts and the tail light assembly Follow the mounting sequence in reverse order ATTENTION Match the rear guard holes and the convex of the chassis Adjustment of the head light Adjustment of the beam of the head light is by loosening the screw underneath the head light ...

Page 25: ...The drawing shows the main serviceable parts Front felly damage slack Spark plug dirty damage Front tire wore damage air pressure Rear felly damage slack Front shock absorber damage slack Throttle vale action play Pull rod of rear brake play ...

Page 26: ...ayout The drawing shows the main serviceable parts Pull rod of front brake play Head light Front brake Motor oil pump Rear brake Transmission case oil leaking oil level Air filter dirty clogged changed Front shock absorber damage slack ...

Page 27: ...ADLY MOTO 2 9 Serviceable parts layout The drawing shows the main serviceable parts ...

Page 28: ...haft case after removing the rear break of engine Use professional tool to change driving shaft and pull out the shaft after fixing inner ring of bearing Diagnosis of Trouble Engine starts but vehicle does not move Transmission gears broken Transmission gears burns out Operate of noise Abrasion wore and teeth hurted of gear Bearing wore and loosened Gear oil leaking Too much gear oil filled Oil se...

Page 29: ...h drive face 7 6 4WARNNING First drain the oil of transmission Operation Parts name Q ty Remark 1 2 3 4 5 6 7 8 Disassembly Bolt Mission cover Washer Dowel pin Drive axle Main axle comp Plain washer Primary drive gear 5 1 1 2 1 1 1 1 Check the wear damage of shaft and gear Change new one 8 3 Assembly 8 1 Operation with sequence in reverse of disassembly ...

Page 30: ...ving Shaft Remove the driving shaft from mission cover WARNNING Don t damage joint face of mission cover Remove the oil seal of primary drive gear Remove the bearing Install the new bearing in the mission cover WARNNING Install the bearing with facing outside ...

Page 31: ...r transmission will be lowered by skid Don t rotation the starter when remove the front cap of left crankshaft case Diagnosis of Trouble Vehicle does not move after engine start up Drive belt wear out Drive face comp damage Clutch lining wear out Driven ass y spring defect Power insufficient Drive belt wear out Driven ass y spring defect Drive face dirty or oily Weight roller wear out ...

Page 32: ...of air cleaner ass y Operation Parts name Q ty Remark 1 2 3 4 5 6 Disassembly Hex socket bolt Carburetor tube bracket Left crank case cover Crankcase cover gasket Dowel pin Grommet 12 1 1 1 2 1 4WARNNING Check the air cleaner whether worsen or harm Assembly 6 1 Operation with sequence in reverse of disassembly ...

Page 33: ...nk case cover Operation Parts name Q ty Remark 1 2 3 4 5 6 7 8 9 Disassembly Kick pinion spring clip Kick pinion Hex washer face bolt Kick crank External ring clamp Plain washer Starting shaft ass y Starting shaft reset spring Bushing 1 1 1 1 1 1 1 1 1 4WARNNING Rotating pedal kick crank and remove the assembly ...

Page 34: ...on when inside and outside reset spring overlap use flat driver will inside outside spring part then press main shaft Installation of Kick Pinion Kick Pinion Spring Clip Set kick starter shaft first Turning starter hang kick pinion spring clip on crank shaft case convex and assembly of kick pinion to the location of removing Turning starter let starting shaft and kick pinion conjoin Check of Start...

Page 35: ... MOTO 7 5 Starter Driving Disc Clutch Transmission Disc Check the wear damage of kick pinion Check the wear damage of kick pinion spring clip Check the wear damage of starting shaft bearing and driving gear ...

Page 36: ...ly Hex washer face bolt Cone spring washer One way clutch Clamp washer Primary fixed sheave Bushing V Belt Primary sliding slot wheel Oil ring Hex nut Covering of clutch Drive face ass y 1 1 1 1 1 1 1 1 1 1 1 1 4WARNNING Don t hurt transmission belt Separation assembling 7 7 Separation assembling 7 8 Assembly 12 1 Operation with sequence in reverse of disassembly ...

Page 37: ...ransmission Disc Disassembly of Sliding Driving Disc Operation Parts name Q ty Remark 1 2 3 4 Disassembly Cam plate Cam plate sliding Weight roller Primary sliding slot wheel 1 3 6 1 Assembly 4 1 Operation with sequence in reverse of separating ...

Page 38: ...Rubber buffer Driving plate of clutch 1 3 3 3 3 3 1 4WARNNING Must replacing when the buffer have damage hardening and distortion 8 9 10 11 12 13 14 15 16 17 18 Drive face ass y Axle ring of spring Compression spring Secondary spring seat Guide pin Secondary sliding slot wheel Oil ring Oil seal Needle bearing Internal circle clip Radial ball bearing Secondary fix slot wheel Assembly 18 1 Operation...

Page 39: ... appointed in sliding face before the installation Diagnosis of Troubles Low compression pressure poor start idle speed not stable Air leakage of cylinder head gasket Wear damage the piston ring Wrong installation of spark plug Wear damage the cylinder and piston Inlet valve poor Compression pressure too high overheating locking Piling up carbon of cylinder head or piston head Piston Knocking Nois...

Page 40: ...ADLY MOTO 6 2 Disassembly of Cylinder Head Cylinder Piston Disassembly of L R side cover Disassembly of generator Disassembly of spark plug cap Disassembly of cylinder air throud ...

Page 41: ... crank case 6 7 8 9 10 Piston Piston ring clip Piston pin Piston Piston ring needle bearing of small side 2 1 1 2 1 Assembly 10 1 Operation with sequence in reverse procedure Installation of Piston Ring Remove carbon muck inside ring ditch and piston ring during disassembly Do not scratch piston and do not bend piston rings Install top piston ring 2nd piston ring into piston Press the ring on few ...

Page 42: ...ine Crank shaft case Crank shaft Exchange bearing of final transmission mechanisms Disassembly of Engine Disassembly of external cap of body Disassembly of luggage case Disassembly of throttle valve Adjustment the throttle cable Adjustment the rear break cable Adjustment the oil pump control cable ...

Page 43: ...able Cable of rear brake Throttle cable Hex washer face bolt of engine Bolt Engine Nut Engine bracket bolt Engine bracket 2 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 4WARNNING The oil over flow when remove the oil tube so use clip or plug stop the seal 4WARNNING Don t damage rear fender when remove the engine Actually for brace the frame avoid body turn inside out Assembly 16 1 4WARNNING Carry out following a...

Page 44: ...ooth h Poor idle speed adjustment of carburetor h Low compression pressure h Poor ignition system h Bad adjustment of air adjusting screw on carburetor h Air filter is clogged h Poor auto side plunger on carburetor h Idle speed nozzle is clogged Mixed air too thin h Nozzle of carburetor is clogged h Gasoline filter is clogged h Vent of gasoline tank is clogged h Gasoline pipe cranked broke clogged...

Page 45: ...e speed Operation Parts Name Q ty Remarks 1 2 3 4 5 6 7 8 9 10 11 Disassembly Pan phillips bolt Throttle valve Throttle cable Throttle valve spring Carburetor washer Throttle cover Including the reducer Sealing set Washer Needle nozzle Clamp Adjusted screw 2 1 1 1 1 1 1 1 1 1 1 WARNNING Loosing top cap of carburetor and removing WARNNING Remove from guide wire of throttle valve ...

Page 46: ...re Throttle cover Including the reducer Washer Throttle valve spring Throttle cable Throttle valve Pan phillips bolt 1 1 1 1 1 1 1 1 1 1 1 WARNNING Assembly of needle nozzle WARNNING Assembly of throttle valve WARNNING Assembly of throttle cable WARNNING Aim the ditch of throttle valve to chamber then install throttle valve into carburetor Lock the throttle cover ...

Page 47: ...r Operation Parts Name Q ty Remarks 1 2 3 4 5 6 7 8 Disassembly Throttle valve set Gasoline pipe Motor oil joint Starter wire of carburetor Vacuum pressure tube Clip Intake manifold hose clamp Carburetor 1 1 1 1 1 1 1 1 3 Assembly 8 1 Motor oil joint WARNNING Don t let dust enter into carburetor WARNNING Release air ...

Page 48: ...sassembly Assembly Carburetor h Disassembling of carburetor h Adjust the idle speed h Adjust the air adjust screw WARNNING No fire Before disassembling loose oil draining screw draining out the gasoline from carburetor FUEL INSTALLATION ...

Page 49: ...11 12 13 Carburetor Ass y Throttle screw set Air adjust screw set Float chamber seal 1 1 WARNNING Must confirm rerotation location before disassembling not locking too much avoid to hurt seat face 12 Assembly 13 1 Air adjust screw set Operating with sequence in reverse of Disassembling WARNNING use high pressure air clean each way of carburetor WARNNING must adjust air screw when changing air scre...

Page 50: ...Hex washer face bolt Intake manifold Reed valve ass y Reed valve gasket 1 4 1 1 1 4 5 Assembly 5 1 Reed valve ass y Reed valve gasket Assembling with sequence in reverse of disassembly WARNNING Using new washer the washer must aim at hole of reed valve WARNNING confirm no secondary air entering after installing FUEL INSTALLATION Disassembly of Fuel Tank ...

Page 51: ...ket Inner carrier Oil tube Tube 4 1 1 1 1 6 7 8 9 Petrol gauge ass y Joint of petrol gauge wire Round phillips bolt Oil lever gauge gasket Hex flat head phillips bolt 1 4 1 4 WARNNING Clip the tube avoid fuel over flow 8 Assembly 9 1 Oil lever gauge gasket 1 Operating with sequence in reverse of disassembly Change new one FUEL INSTALLATION Disassembly of Petrol Gauge Disassembling wire joint of pe...

Page 52: ...OTO 4 9 Don t damage petrol gauge wires Remove the petrol gauge WARNNING Don t curving float arm of petrol gauge Operation with sequence in reverse of disassembly FUEL INSTALLATION Disassembly of Air Cleaner ...

Page 53: ...4 5 6 7 8 9 Disassembly Hex socket bolt Plain washer Self tapping screw Air cleaner case cap Air cleaner element Air cleaner case Air cleaner joint Cleaner guide pipe Grommet 2 1 3 1 4 1 1 2 1 Assembly 9 1 Operating with sequence in reverse of disassembly ...

Page 54: ...s Too much smoke means too much carbon muck piping up the spark plug Poor synchronizing adjust of motor oil pump too much exhaust Bad quality of engine motor oil Over heating Poor synchronizing adjustment of motor oil pump too much exhaust Bad quality of engine motor oil Piston burnt Short of engine oil or engine oil pipe is clogged Poor adjustment of motor oil pump lesser the exhaust There have a...

Page 55: ...crankcase Operation Parts Name Q ty Remarks 1 2 3 4 Fuel pipe Oil connection pipe Pan phillips bolt Motor oil pump 1 1 2 1 WARNNING Clogging the pipe with clamp or plug for avoiding fuel flow out Remove from both side of motor oil pump Assembly 4 1 Assembly with sequence in reverse of disassembly WARNNING Smear motor oil to new O ring then assembly motor oil pump The oil pump must installed correc...

Page 56: ...ssembly Fuel pipe Fuel connection pipe Pan phillips bolt Control cable Motor oil pump 1 1 2 1 1 1 WARNNING Fill motor oil with clean container Assembly 5 1 Operation with sequence in reverse of disassembly WARNNING Connect correct oil pipe after assembly release the air in motor oil pump ...

Page 57: ...Chap 4 Dis mounting of engine Chap 5 Disassembly of cylinder head and cylinder Chap 6 Disassembly of ACG Chap 12 Disassembly drive face ass y Chap 7 Must disassembly of final reduction mechanism when change the left crank case Must use special tool into the inner ring of crank shaft bearing and pull in crank shaft to assembly when assembly crank case crank shaft put new bearing into crank case and...

Page 58: ...6 7 8 9 10 11 12 13 Disassembly Hex socket bolt Right crank shaft case Dowel pin Fix shaft of crank shaft case External circle clip Crank shaft Radial ball bearing Right Radial ball bearing Left Hex socket bolt Oil seal bracket Right oil seal Left oil seal Radial ball bearing 6 1 2 1 2 1 2 1 1 1 1 1 2 Assembly 13 1 ...

Page 59: ...ft when disassembling Use the bearing puller to remove the crankshaft bearing from crank shaft then remove the R L crank case Bearing puller TLJT 00 WARNNING Must remove the oil seal when separate the crank case and never use the old oil seal Assembly of Crank Case Clean the crank case with gasoline and check the each part whether damaged or crack WARNNING Smear of oil on sliding surface of each s...

Page 60: ...aft into right crank case Put crank shaft assembly into left crank case WARNNING Smear the 2 stroke oil to main bearing and big end of connecting rod Note the position of connecting rod Put left oil seal into L crank shaft case surface depth under 1 0 mm ...

Page 61: ...nk Case Crank Shaft Assembly of Crank Case Install the dowel pins in the joint face of left crank case Install the right crank case Bearing puller TLJT 00 Install the new R oil seal to crank case Bearing puller TLJT 00 ...

Page 62: ... steering ball race Steel ball inside ball race broken Tire pressure insufficient Brake efficiency abnormal Brake lining wear out Brake pads adjust not correct Brake disc attrition Tire wear out Poor Brake Bad adjustment of brake Wear the brake pad Steering handle not straight L R suspension not balanced Front fork banded Front tire axle banded tire wear out Front wheel shaking Front rim defected ...

Page 63: ...arks 1 2 3 4 5 6 Disassembly of Front Wheel Nut nylon Speedometer gear Hex washer face bolt Front collar Front fender Front brake disc 1 1 1 1 1 1 Assembly 6 1 Operation with sequence in reverse procedure WARNNING Assembly of right fork shall be aimed at convex of speedometer gear ...

Page 64: ...isassembly of front wheel Operation Parts name Q ty Remarks 1 2 3 4 Disassembly Front collar Oil seal Radial ball bearing Front wheel spacer tube 1 1 2 1 Assembly 4 1 Operation with sequence in reverse procedure WARNNING Must change the R L bearing set ...

Page 65: ... Disassembly of Front Disk Operation Parts name Q ty Remarks 1 2 3 4 Disassembly Front collar Brake disc hex socket bolt Nylon insert lock nut Front brake disc 1 3 1 1 Assembly 4 1 Operation with sequence in reverse procedure ...

Page 66: ...er Hex socket bolt Fixed belt of steering handle Bracket of rear brake lever 1 1 1 8 9 10 11 Steering Handle Hex flange nut with serration Hex washer face bolt Steering handle Handle grip 1 1 1 1 1 10 7 4 Assembly 11 1 Steering handle Bracket of rear brake lever Rear brake cable 1 1 1 Operation with sequence in reverse procedure WARNNING Install steering handle with handle convex at ditch of steer...

Page 67: ...anner nut Steering stem dust cover Lathe cone on steering top 2 2 1 1 WARNNING Not to damage steering stem 4 5 6 Race ball 5 Steel ball race Lathe on steering inner 3 1 2 2 7 8 Bolt Front inner fender 2 1 9 10 11 Hex bolt Washer Front fork 2 2 1 WARNNING Remove L R tube by loose these two hex bolts Assembly 11 1 Operation with sequence in reverse procedure ...

Page 68: ... smoothly Slightly tie up the bottom spanner nut and backward about 1 8 turn Confirm the steering rotation smooth and gap of steering stem Special Tool fixed nut spanner Keep the bottom spanner nut fixed to avoid the nut rotate with the upper spanner nut Locking Torque 7 0 kg m Special Tool Fixed nut spanner ...

Page 69: ...es Rear wheel shaking The shape of rear rim damaged Tire defected Rear suspension too soft Spring too soft Brake efficiency abnormal Brake pad adjust not correct Brake pad attrition Brake pad cam part wear Brake cam wear The tooth groove setting poor of break arm ...

Page 70: ...n Parts name Q ty Remarks 1 2 3 4 5 Disassembly Muffler Hex washer face bolt Hex head phillips bolt Assembly of exhaust pipe Collar Gasket of exhaust pipe 2 2 1 1 1 6 7 8 Rear wheel Nut Plain washer Rear wheel 1 1 1 Assembly 8 1 Assembling with sequence in reverse of disassembly ...

Page 71: ...peration Parts name Q ty Remarks 1 2 3 4 5 6 7 8 Disassembly Adjusted nut of rear brake Rear brake fixture Rear brake cable shoe shoe strain spring of rear brake Hex washer face bolt Rear brake arm Reset spring Brake cam shaft 1 1 1 2 2 1 1 1 1 Assembly 8 1 Assembly with sequence in reverse of disassembly ...

Page 72: ...N BRAKE Disassembly of Rear Cushion Operation Parts name Q ty Remarks 1 2 3 4 5 Disassembly Hex washer face bolt Nut nylon insert Plain washer Hex bolt Rear cushion 1 2 2 1 1 Assembly 5 1 Assembly with sequence in reverse of disassembly ...

Page 73: ...llening connection wire of battery Fuse broke Poor main switch Low voltage Poor charging of battery Poor contact Poor charging system Bad rectifier Current off and on Poor contact of battery wires Poor contact of discharging system Poor contact or short circuit of ignition system Light weak Battery discharging Resistance of wiring switch too big Poor changing system Fuse broke Poor contact broke a...

Page 74: ...h but no lighting Bad bulb Bad switch Guide wire broke Fuse broke Battery discharging Bad wiring Pointer of fuel gage unstable Loose socket head of guide wires Poor fuel gage Bad gage RPM unsmooth Ignition primary circuitry Bad ignition coil Wire or poor contact Poor contact main switch Ignition secondary circuitry Bad ignition coil Bad spark plug Bad high voltage wires Power leakage of spark plug...

Page 75: ...ADLY MOTO 12 3 ELECTRICAL DEVICE Solid Wiring Diagram ...

Page 76: ... 2 3 4 5 6 Disassembly Helmet box mat Battery end Battery end Self tapping screw Battery cover Battery 1 1 1 2 1 1 WARRNING Disassembly battery from end to end 2 Assembly 6 1 Battery terminal Assembling with sequence in reverse of disassembly WARRNING Connect end first next end cover with cap ...

Page 77: ...ry voltage with digital voltmeter Check Charging System Power leakage test Disassembly ground guide wire from battery after turning OFF main switch next connect voltmeter to the end between terminal ground guide wires Check voltage when main switch is OFF WARNNING Check voltage according to sequence from big to small Voltmeter s fuse will be broke when check voltage over the under limitation choos...

Page 78: ... consume the power in battery Assembly voltmeter to terminal of main fuse start engine open light rise running amount and check charging voltage current Charging current 1 2 Amp 5000rpm Voltage of charging control 14 15V 5000rpm Check Voltage of Front Lighting Control Disassembly front covering of handle WARNNING Check head light which wires connecting Start engine turn ON light switch open high b...

Page 79: ...f AC Check voltage adjuster when voltage Is not in the range controlling Control voltage 12 14V 5000rpm Check Voltage Adjuster Check voltage adjuster Disassembly connection head of voltage adjuster Check return of wiring edge connection head Disassembly of ACG ...

Page 80: ...ain washer Fly wheel of generator Semi cycle of electric disc Whole body bolt Hexagon socket bolt 2 2 1 1 4 1 1 1 2 1 2 1 1 1 WARRNING Take the good care no hurt coil Assembly 14 1 Assembling with sequence in reverse of disassembly ACG Charging Coil Check WARNNING Checking in the engine connected With start motor Disassembly ACG connection Check resistance of charging wire lighting wire Standard v...

Page 81: ...d in the right place Conduction Test Check once coil resistance of ignition terminal Standard valve 20 0 3 0 5Ω WARNNING Check ignition status with performance tester due to this test has its own stanard Check twice coil resistance between spark plug cap terminal Standard valve 9 5 11 kΩ spark plug cap in team Remove spark plug cap from high Voltage coil Check twice coil resistance between high vo...

Page 82: ...tarting Motor Disassembly of starting motor Operation Parts name Q ty Remarks 1 2 3 4 5 6 7 Separation Bolt set Casing Armature rotor Carbon brash Oil ring Oil ring Front fixed seat 2 1 1 2 1 1 1 Assembly 7 1 Assembling with sequence in reverse of disassembly ...

Page 83: ...ack 0 20Ω 90 110Ω Check Main Switch Remove connection of main switch guide wire check conductivity between each terminal Color tea black red black red LOCK OFF ON Exchange Remove front covering Remove 2 bolts disassembly main switch Installing with the sequence in reverse of disassembly Check switch of handle Remove front covering Disassembly connection of handle switch check conductivity between ...

Page 84: ...OFF ON Power Switch Color blue white Black Up Down Exchange of Bulbs Head light bulb Remove front covering of handle press down the connection and turn it to change head light bulb Dash light Remove rear covering of handle pull out the connection of bulb and replace the bulb ...

Page 85: ...E Rear light Brake light Rear direction light bulb Remove 2 screws pull out the light Covering to front disassembly hook on light brake light covering and disassembly light covering of direction light and bulb finally change bulb MENO ...

Page 86: ......

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