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Vento zipr3i, Service Manual

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                                                                             Rev 01/ page133 of 143  

TIGHTENTING TORQUE O F SCREW THREAD PARTS   

 ENGINEITEM 

 

N

M 

Cylinder guide cover tapping screw 

 

          1-4 

Fan guide cover lock bolt 

 

10-12 

Cylinder cover locknut 

 

15-18 

Spark plug 

 

15-18  

Inlet pipe lock bolt 

10-12    

Cooling fan impeller lock screw 

 

10-12 

Flywheel lock bolt 

 

45-50        

Magneto stator coil lock screw 

 

10-12 

Magneto exciting lock screw 

 

3-5        

Oil pump 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 cover lock bolt 

 

10-12 

Main drive wheel face locknut 

 

35-38 

Driven wheel face locknut 

 

35-38 

Driven wheel face clutch locknut 

 

55-60 

Exceeding clutch outside lock screw 

 

10-12 

Electrical start idle press board screw 

 

10-12 

Gear case lock bolt 

 

10-12 

Left crankcase discharging oil hole lock    
bolt 

 

22-25 

Left crankcase positioning pin shaft  
locknut 

 

18-22 

                   

Summary of Contents for zipr3i

Page 1: ......

Page 2: ...ance and servicing of VENTO Zip r3i Scooter This manual contains an introductory description on VENTO Zip r3i and procedures for Inspection Service and overhaul of its main components This Manual is intended those who have enough knowledge and skills for servicing of VENTO vehicles Without such knowledge and skills you should not attempt servicing by relying on this manual only Instead please cont...

Page 3: ...e sure that the Engine oil Gear oil what you are using should come under API classification BREAK IN PROCEDURES During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to BREK IN before subjecting the engine to maximum stresses The future performance and reliability of the engine de...

Page 4: ... ensure that it is completely seated in its groove and securely fitted Do not use self locking nuts a few times over If parts replacement is necessary replace the parts with VENTO Genuine parts or their equivalent When removing parts that are to be reused keep them arranged in an orderly manner so that they may be reinstall in proper order and orientation Always use special tools when required Alw...

Page 5: ...t Air cleaner Dual polyurethane foam Starting System Electric start Kick pedal for Manual Start Lubricating System Auto lubrication by Oil Pump ELECTRICAL Ignition System Electronic CDI Ignition Timing 150 at 5000 RPM Spark Plug NGK R BR8HSA Storage Battery YUASA YB4L 4 Battery Capacity 12V 4Ah Magneto AC Fuse 10Amp Headlight 12V 35 35 Watt Turn Indicators X4 12V 3 Watt Tail light stop light 12V 5...

Page 6: ...attery 7 Service and adjustment procedures 9 Cylinder head nut and exhaust pipe bolt 9 Cylinder head and cylinder 9 Spark plug 10 Air cleaner 11 Fuel level line 12 Throttle cable 12 Engine idle speed 12 Oil pump 13 Gear oil 14 Braking 15 Tire 17 Steering 17 Front shock absorber 18 Rear shock absorber 18 Vehicle bolts and nuts 18 ...

Page 7: ...Interval Months 2 12 24 36 48 Storage battery I I I I I Cylinder head nut and exhaust pipe bolt T T T T T Cylinder head and cylinder C C C C Spark plug C R C R Air cleaner Inspect Clean every 3000 Kms 1890 miles Replace every 12000 Kms 1750 Miles Idle speed rpm I I I I I Throttle cable play I I I I I Oil pump I I I I I Gear oil I R R I I I I I Fuel line Replace every 4 years Brake I I I I I I I I ...

Page 8: ...0Kms 630 miles 2 months and every 6000 Kms 3780 miles 12 months Open seat and then remove the battery box cap in theMiddle of helmet box Disconnect Negative terminal Cable first then Positive terminal Cable of Battery Measure the voltage between the ve and ve terminal of Battery charge the Battery if the voltage is below the specified limit ...

Page 9: ...ELAK MODEL BCT7 CAUTION During Inspection if the battery on the vehicle is found defective before replacing with a new battery it is important to check the battery charging circuit BATTERY CHARGING CIRCUIT TEST The MAGNETO generated AC current which is rectified into DC current by Voltage Regulator It is automatically charging the battery depending upon condition of the battery load and engine rpm...

Page 10: ...new battery 8 12 hrs For old battery 12 14 hrs WARNING Always open all the caps of battery before charging Keep flames sparks away from the battery Turn ON or OFF Switch at charger not at battery terminal Don t charge the battery if electrolyte temperature is more than 45ºC Do not quick charge the battery INSTALLATION Connect positive terminal first then negative terminal BATTERY CAPACITY 12Volt 6...

Page 11: ...move the cylinder head cover bolt 3 Remove spark plug Suppressor cap 4 Tighten the nuts evenly one by one to the specified torque Tighten the nuts in the Specified order Tightening Torque Cylinder head nut 15 18N m Exhaust pipe bolt 15 18N m Cylinder and cylinder head Remove carbon every 6000 km 3780 miles or 12 months Carbon deposits in the combustion chamber and the cylinder head will raise the ...

Page 12: ...BON DEPOSIT Check to see the carbon deposit on the Spark Plug If the carbon is deposited remove it with a spark plug cleaner machine or carefully using a tool with a pointed end Check to see the worn out or burnt condition of the electrodes If it is extremely worn or burnt replace the plug and also replace the plug if it has a broken insulator damaged thread etc Thickness gauge Spark plug gap 0 6 ...

Page 13: ... cleaning solvent out of the washed element By pressing it between the palms of both hands do not twist Or wring the air cleaner element or it will develop tears Immerse cleaned filter element in CCI or CCI Super oil and Squeeze the oil out of the element leaving it slightly wet With oil Fit the element to the Air cleaner case properly Install Air cleaner in the reverse order of removal CAUTION Be...

Page 14: ...onths and Every 6000 kms 3780 miles or after 12 months thereafter Adjust the throttle cable play warm up the engine at normal running condition NOTE A warm engine means an engine that has been run for 10 minutes Connect an Digital Tachometer to the connecting portion of the magneto lead wire as shown In the illustration Use the selector key C position Adjust the Idling Screw to obtain the Idling R...

Page 15: ...d 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 mark on the oil pump control lever Is aligned with the index mark when the throttle valve is positioned as above If the marks are not aligned loosen lock nuts and turn the adjuster in or out to align the mark...

Page 16: ...e hose after every 4 years Front brake fluid level Keep the scooter upright and place the handlebar straight Check brake fluid level by observing the lower limit line On the brake fluid reservoir When the level is below the lower limit line replenish with Brake fluid that meets the following specification Specification and classification DOT 3 or DOT4 WARNING The brake system of this scooter is fi...

Page 17: ...rvoir to the upper end of the inspection Window Replace the reservoir cap to prevent entry of dirt Attach a pipe to the caliper bleeder valve and insert the free end of the pipe into a receptacle Bleed air from the bleeder valve Squeeze and release the brake lever several times in rapid succession And squeeze the lever fully without releasing it Loosen the bleeder valve by turning it a quarter of ...

Page 18: ...AKE SHOE WEAR This vehicle is equipped with the brake lining limit Indicator on the rear brake Inspect brake lining limit as follows First check if the brake system is properly Adjusted When operating the brake check to see that the tip of indicator is within the range 3 If the tip of indicator is beyond the range 4 the brake shoe assembly should be replaced with a new set of shoes ...

Page 19: ...h 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 reaches the following specification Tire Tread depth limit 1 6 mm 0 064 Inch Use Tire depth gauge STEERING Inspect at initially 1000 kms 630 miles 2 months and every 6000 kms 3780 miles thereafter Steering should...

Page 20: ...kms 630 miles 2 months and every 6000 km 3780 miles 12 months thereafter These bolts and nuts listed below are important safety components They must be tightened to the specified torque No Item N m Kg m 1 Front axle nut 37 44 3 7 4 4 2 Steering stem locknut 37 44 3 7 4 4 3 Handlebar tightening nut 37 44 3 7 4 4 4 Handlebar positioning bolt 37 44 3 7 4 4 5 Brake hose tightening bolt 22 29 2 2 2 9 6...

Page 21: ...Rev no 01 page 21of 128 ...

Page 22: ...rated under wet or rainy condition Before 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 If grease gets on the linings brake slippage will result Steering stem bearing Front wheel bearing Engine bracket Rear brake camshaft Side stand A Rear brake shaft and rear brake cable Speedome...

Page 23: ... grooves Ruptured or otherwise defective cylinder head gasket COMPRESSION PRESSURE TESTING PROCEDURE NOTE Before testing the engine for compression pressure make sure that the cylinder head nuts are tightened to the specified torque values Have the engine warmed up Idling before testing Be sure that the battery used is in fully charged condition Remove the parts concerned and test the compression ...

Page 24: ...TIAL ENGAGEMENT INSPECTION Warm up the engine to its normal running temperature Connect the digital tachometer Seated on the motorcycle on the level ground increase the engine RPM slowly and note the RPM at which the motorcycle begins to move forward ENGAGEMENT RPM 2700 3100 RPM 2 CLUTCH LOCK UP INSPECTION Perform this inspection to determine if the clutch is engagement and not slipping Apply the ...

Page 25: ...the engine in place 24 Engine removal and reinstallation 25 Engine components inspection and servicing 33 Crankshaft 33 Clutch shoe inspection 34 Drive belt inspection 35 Movable driven face inspection 35 Roller and sliding surface inspection 35 Driven face pin and oil seal inspection 36 ...

Page 26: ...ever Clutch cover Kick starter shaft Kick driven gear Fixed drive fan Fixed drive gear V belt Movable drive face Starter driven gear Starter drive gear Clutch housing Gear case cover Transmission gear Clutch shoe Engine center Intake pipe Reed valve Oil pump Oil pump gear Cylinder head Cylinder Piston Engine right side Cooling fan Magneto Starter motor ...

Page 27: ...nd reinstallation Engine removal Remove ignition coil Remove muffler Remove cylinder cover Remove cooling fan cover Remove cooling fan Remove magneto rotor nut Remove the magneto rotor Remove magneto rotor and key Remove oil pump and retainer ...

Page 28: ...move cylinder head and cylinder Place a cloth stopper below the piston and Remove the circlip with pliers Remove the piston pin and piston Remove the kick starter lever Remove clutch cover Remove the kick starter shaft spring and Kick starter shaft ...

Page 29: ...r gear Remove the kick starter nut with the special a tool Caution The nut has counter clockwise thread Remove fan and v belt Disassemble the movable drive face Remove the kick starter shaft Remove starter idle gear cap and starter pinion Remove starter motor Remove the clutch housing with the special tool ...

Page 30: ...clip and final driven gear Remove the idle gear shaft assay Remove the rear axle nut Remove the rear wheel Remove brake shoes and rear axle shaft Remove the rear brake cam lever indicator plate and camshaft Remove spring Remove cotter pin and shaft Remove main stand Remove crankcase securing screws ...

Page 31: ...Rev no 01 page 31of 128 Disassemble crankcase with a special tool Remove crankcase Loosen the clutch shoe nut Remove the nut while holding down clutch Shoe assembly with both hands as shown ...

Page 32: ...ngs Caution Do not attempt to disassemble the clutch shoe assy Otherwise the clutch shoe may be damaged Remove the movable driven face seat with a thin bared screwdriver Remove the pins movable driven face and fixed driven face Remove circlip Remove bearing with special tool Caution Replace the removed bearing with a new one Remove bearing with special tool Remove the spacer Remove the oil seal fr...

Page 33: ...ng the bearings with special tools Remove the bearing retainer Remove oil seal with the special tools Caution Replace the removed oil seal with a new one Remove the bearing with special tooling Caution Replace removed bearing with a new one Remove the drive shaft bearing and idle shaft bearing Caution The removed bearings should be replaced with new ones ...

Page 34: ...ed bearing should be replace with a new one Remove the left crankshaft bearing Caution the removed bearing should be replaced Bushing inspection Inspect the bushing for wear or damage If any defects are found replace the bushing Crankcase bushing disassembly Use two steel tubes of appropriate size to press the engine mounting bushings on a vise as shown in the illustrations Engine components inspe...

Page 35: ...leakage of the fuel air mixture or oil Inspect for damage and be sure to replace seal is found Crankshaft Crankshafts run out Support the crankshaft with v blocks as shown with the two end journals resting on the blocks Position the dial gauge as shown and rotate the crankshaft to read the run out as shown Correct or replace the crankshaft if the run out is greater than the specified limit Service...

Page 36: ...the big end of the conrod to one side and measure the side clearance with the thickness gauge Standard 0 10 0 45 mm 0 004 0 018 in Service limit 1 00mm 0 039 in Connecting rod small end i d Measure the connecting rod small end diameter with a caliper gauge Service limit 14 040mm Clutch shoe inspection If the engine rpm doesn t coincide with the specified rpm range then disassemble and inspect the ...

Page 37: ...r cracks abnormal wear and separation or contamination with oil Measure the drive belt width with vernier calipers Replace it if the belt width is less than the service limit or and defect has been found Service limit 16 0mm 0 630in Caution Always keep the drive belt away from any greasy material Movable driven face inspection Inspect the belt contact surface of the drive face for wear scratches o...

Page 38: ... face pin and oil seal inspection Turn the driven face and check to see that the driven faces 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 inspection Inspect the belt contacting surface of both Driven faces for any scratches wear and Damage Replace driven face with a new one if ...

Page 39: ...Rev 01 page92 of 143 CHAPTER 4 Section 1 01 Section 1 02 FUEL AND LUBRICATION SYSTEM Contents FUEL SWITCH 38 CARBURETOR 39 OIL PUMP 41 ...

Page 40: ...ap diaphragm until it is higher than this valves spring pressure The fuel valve in the fuel is then forced to open due to this diaphragm operation and allows fuel to flow into the carburetor float chamber CARBURETOR Carburetor Type Identification code Throat tube diameter Main jet size Idle needle jet size Fuel needle clamp position Idle air adjusting screw Float height Throttle cable play Side Dr...

Page 41: ...f fuel on engine and jet settings are made so as to satisfy and balance all of these conditions Therefore the jet should not be replaced with a size other than the original And the 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 following ...

Page 42: ...Rev 01 page95 of 143 ...

Page 43: ...h clean air in right proportion in the carburetor and then air fuel mixture is supplied to the combustion chamber of the engine In engine this air fuel mixture is controlled by the intake valve and camshaft rocker arm mechanism 1 AIR FUEL FLOW CHART AIR FUEL Atmosphere Fuel tank Air cleaner assy Strainer fuel cock Filters Sedimentation bowl Fuel Tap Filter Venturi Inlet Floater Chamber Diffuser of...

Page 44: ...speed 10 12 1 3 Slow speed 12 14 1 4 Medium speed 15 17 1 5 High speed 13 15 1 CARBURETTOR CIRCUITS ZIP r3i CARBURETOR HAS FOLLOWING 6 MAIN CIRCUITS 1 Fuel Intake circuit 2 Choke circuit 3 Idling speed circuit 4 Slow speed circuit 5 Medium speed circuit 6 Highspeedcircuit ...

Page 45: ... starting since it requires rich mixture Hence choke knob is being operated from the carburetor Due to this an air stopper Butterfly valve comes on the way to the venturi Air filter side of the carburetor thus reducing the amount of air being mixed with fuel Excessive fuel is being sucked from the slow jet and less quantity of air enters from the choke valve and from the small opening below the th...

Page 46: ...n Air fuel mixture is being supplied by slow jet and also from main jet This is due to partial opening of throttle valve lifts needle jet upwards Hence some quantity of air fuel mixture coming out from main jet diffuser also mixes along with slow jet mixture to increase the mixture quantity as required by engine 5 MEDIUM SPEED CIRCUIT Economy speed range Further acceleration the air fuel mixture s...

Page 47: ... MOTORCYCLE REMOVAL 1 Turn fuel switch OFF position 2 Disconnect fuel pipe from carburetor by pressing clip 3 Loosen the clamp over air cleaner connecting tube Air duct 4 Drain the fuel from carburetor float chamber in a separate pan loosening drains screw 5 Remove insulator clamp screw 6 Pull out the carburetor assy Along with insulator from air duct 7 Open the carburetor top cap pull out the thr...

Page 48: ...BURETTOR Screw the slow jet Ensure that all holes are clearly visible on the slow jet body Fix needle jet from main jet hole Ensure that the smaller dial faces towards carburetor body hole Tighten the needle jet holder Ensure that all holes clearly visible on the needle jet holder body Screw the main jet along with jet holder Insert the float arm pin through the pivot and the float Check float hei...

Page 49: ...lowly till engine RPM increases to the peak highest speed position while setting Now stop adjusting air screw Maximum recommended air screw opening position 1 turns out Readjust Idling speed to 1800 100 RPM by the throttle stop screw ensure that exhaust emission Carbon Monoxide CO 1 5 to 2 0 After adjusting Idling speed check for its stability flat spot missing if any by accelerating few times Rep...

Page 50: ...143 Article II CHAPTER 5 Article III ELECTRICAL SYSTEM CONTETNS IGNITION SYSTEM 49 CHARGING AND LIGHTING SYSTEM 51 STARTER SYSTEM 54 FUEL GAUGE 57 OIL LEVEL CHECK LIGHT AND TURN SIGNAL INDICATOR 57 SWITCHS 59 BATTERY 60 ...

Page 51: ... to the gate of SCR 3 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 CHECKING WITH ELECTRO TESTER Connect the CDI test lead to the coil s primary connector Connect the high tension leads red lead to the spark plug cord and the black lead to the black lead of ...

Page 52: ...at least five minutes continuously To insure proper operation under the temperature of actual riding MAGNETO EXCITING COIL Remove the right frame side cover Disconnect the exciting coil lead wire black with red tracer Using a Multimeter measure the resistance between the B R lead wire and ground If the resistance checked is incorrect replace the coil Exciting coil restance 140 220 ...

Page 53: ...and generate AC as the flywheel rotor turns AC generated in the charging coil flows to the regulator rectifier which changes AC to DC The DC Then charges the battery On the other hand lighting coil supplies AC current to the headlight taillight and meter light under the regulated condition R e g u lato r rec tifie r F u se B a tte r M a g n et o H e a d lig h t Ta illig h t L ig h t ...

Page 54: ...e and keep it running at 5000 RPM with light switch turned on condition NOTE When making the test be sure that the battery is fully charged condition Digital Tachometer For measuring engine RPM Specified charging output Voltage 12 14 Volt at 5000 RPM Fuse Battery ...

Page 55: ...PM STATOR COILS RESISTANCE VALUE Coil Description Resistance Value Charging Coil 285 to 375 Pick up Coil 120 20 at 20o C Light Coil Less than 2 Battery Charging Coil Less than 2 Use Multimeter tester to measure the resistance between the lead wire and ground If the checked resistance is incorrect replace the coil Regulator rectifier Disconnect the lead wire coupler Using the Multimeter 1 Range mea...

Page 56: ...ton 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 Starter motor removal and disassembly Remove the starter motor disassemble the starter motor as shown in the illustration Starter relay Starter motor Fuse Battery Starter button Front brake switch Ignition switch Rear brake switch ...

Page 57: ...be difficult to turn over To prevent the periodically inspect the length of the brushes and replace them when they are too short or chipping Service Limit 3 5mm 0 14in Commutator If the commutator surface is dirty starting performance will decrease Polish the commutator with 400 or similar fine emery paper when it is dirty Service Limit 0 2mm 0 008in Segment Mica ...

Page 58: ... STARTER RELAY INSPECTION Disconnect lead wire R W of the starter motor Turn on the ignition switch and squeeze the front or rear brake lever and then inspect the continuity between the Red and Red White lead wires at the starter relay when pushing the starter button If the starter relay is in sound condition Continuity is found Disconnect the starter relay lead wire coupler Check the coil for ope...

Page 59: ... and B W lead wires The fuel meter is normal if it s pointer indicates the E empty position when the specified voltage is applied to the circuit and if it s pointer indicates the F full position when the resistor is changed to 10 ohms If either one or both indications are abnormal replace the fuel gauge with a new one FUEL GAUGE SENDING UNIT INSPECTION Disconnect the lead wires coming out of the f...

Page 60: ... to a certain level the remaining amount of oil has become approximately 160 ml the oil level check light turns on and 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 alternatively as one being lit white the other unit pl refer electric diagram below ...

Page 61: ...d SPECIFICATIONS Type designation YUASA YB4L B Capacity 12V 4Ah Specific gravity Fully charged Needs Charging 1 24 1 28 at 27 0 C Below 1 220 INITIAL CHARGING FILLNG ELECTROLYTE Remove the aluminum tape sealing the battery electrolyte filler holes ...

Page 62: ...Insert the nozzles of the electrolyte container into the Battery s electrolyte filler holes holding the container firmly so that it does not fall Take precaution not to allow any of the fluid to spill Make sure air bubbles are coming up each electrolyte container and leave in the position for about more than 20 minutes NOTE If no air bubbles are coming up from a filter port tap the bottom of the t...

Page 63: ...nd to be coated with rust or an acidic white powdery substance then this can be cleaned away with sandpaper RECHARGING OPERATION Apply multimeter to measure the voltage of battery If the reading is below 12 0V it should be recharge with a battery charger NOTE When recharging remove the battery form the vehicle NOTE When recharging don t remove the sealing caps from the battery Recharging Current T...

Page 64: ... page117 of 143 CHAPTER 6 SERVICING INFORAMTION Contents Troubleshooting 63 Wiring diagram 65 Battery 67 Wire cable and brake hose routing 69 Special tools 75 Thread parts tightening torque 77 Service data 78 ...

Page 65: ...or replace Repair or replace Replace Tighten Replace Replace Clean and dry Replace Replace Replace Clean Clean or replace Replace Clean or replace Engine stalls easily 1 Carbon deposited on the spark plug 2 Defective CDI ignition coil unit 3 Clogged fuel hose 4 Clogged jets in carburetor 5 Clogged exhaust pipe Clean Replace Clean Clean Clean Noisy engine Noise appears to come from piston 1 Piston ...

Page 66: ...place Adjust or replace Clean Clean and prime Clean Dirty or heavy exhaust smoke 1 Too much engine oil into the engine 2 Use of incorrect engine oil Check oil pump Change Engine lacks power 1 Excessively worn cylinder or piston rings 2 Stiff piston rings in place 3 Gas leaks from crankshaft oil seal 4 Spark plug gaps incorrect 5 Clogged air cleaner element 6 Float chamber fuel level out of adjustm...

Page 67: ...edle jet is clogged 3 Fuel level is improperly set 4 Throttle valve is not operating properly 5 Fuel filter is clogged Check and clean Check and clean Check and replace Check throttle valve for operation Check and clean Overflow and fuel level fluctuations 1 Needle valve is worn or damaged 2 Spring in needle valve is broken 3 Float is not working properly 4 Foreign matter has adhered to needle val...

Page 68: ...n the battery Repair or retighten Replace Replace Replace the battery Magneto overcharges 1 Internal short circuit in the battery 2 Resistor element in the regulator rectifier damaged or defective 3 Regulator rectifier unit poorly grounded Replace the battery Replace Clean and tighten ground connection Complaint 7 Symptom and possible causes ii Remedy Unstable charging 1 Defective regulator rectif...

Page 69: ...k the magneto and regulator rectifier circuit connections and make necessary adjustments to obtain specified charging operation Replace the battery and correct the charging system Replace the battery Replace the battery Reversed battery polarity 1 The battery has been connected the wrong way round in the system so that it is being charged in the reverse direction Replace the battery and be sure to...

Page 70: ...le or crooked tire Replace Replace Wobbly front wheel 1 Distorted wheel rim 2 Worn front wheel bearings 3 Defective or incorrect tire 4 Loose nut on axle 5 Loose nuts on the rear shock 6 Worn engine mounting bushing 7 Loose nuts or bolts for engine mounting Replace Replace Replace Retighten Retighten Replace Tighten Front suspension too soft 1 Weakened springs 2 Oil leakage of shock absorber Repla...

Page 71: ...isc 5 Air entered into hydraulic system 6 Worn shoe 7 Friction surfaces of shoes are dirty with oil 8 Excessively worn drum 9 Too much brake lever play Repair or replace Replace Clean disc and pads Replace Bleed air Replace Replace Replace Adjust Brake squeaking 1 Carbon adhesion on pad surface 2 Tilted pad 3 Damaged wheel bearing 4 Worn pad 5 Foreign substance entered into brake fluid 6 Clogged r...

Page 72: ...Rev 01 page125 of 143 Leakage of brake fluid 1 Insufficient tightening of connection joints 2 Cracked hose 3 Worn piston seal Replace or repair Replace Replace Brake drags 1 Rusty moving parts Replace ...

Page 73: ...Rev 01 page126 of 143 WIRE CABLE AND BRAKE HOSE ROUTING ...

Page 74: ...Rev 01 page127 of 143 Carburetor ...

Page 75: ...Rev 01 page128 of 143 e ...

Page 76: ...Rev 01 page129 of 143 Ignition coil Starting relay CDI HORN ...

Page 77: ...Rev 01 page130 of 143 ...

Page 78: ...L NUMBER DESCRIPTION 1 2 3 4 5 6 7 8 9 10 T01 T02 T03 T04 T05 T06 T07 T08 T10 T 11 T shape of sleeve Sleeve tools 7mm 8mm 10mm 12mm 13mm Flywheel remover Sleeve 18mm 24mm Screw remover Cylinder pressure gauge Piston pin remover Spark plug remover Flywheel lock bolt remover Clutch clamp 3 ...

Page 79: ...Rev 01 page132 of 143 10 ...

Page 80: ... 5 Oil pump 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 cover lock bolt 10 12 Main drive wheel face locknut 35 38 Driven wheel face locknut 35 38 Driven wheel face clutch locknut 55 60 Exceeding clutch outside lock screw 10 12 Electrical start idle...

Page 81: ...istortion 0 04 0 0016 1st ring 0 02 0 06mm Piston ring free cotter end clearance 2en ring 0 02 0 06mm Piston ring close end clearance 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 Piston pin outside diameter 9 994 10 000 0 3935 0 3937 9 98 0 3929 CONNECTI...

Page 82: ...8 0 071 1 2 0 005 Clutch engagement 3000 300r min Clutch closedown 6000 300r min TRANSMISSION SYSTEM Gear Ratio DESCRIPTION STANDARD TOLERANCE Final reduction ratio Gear reduction ratio Drive belt width 16 8 17 2 0 6614 0 6772 16 4 0 6457 Driven face spring free distance 69 2 72 64 5 2 54 CARBURETOR Manufacturer and type Side draft Identification code PZ19JB Venturi 19mm Main jet size 80 Pilot jet...

Page 83: ...N SPECIFICATION Headlight high beam 12V 35W 35W Dipped headlight 12V 35W Taillight 12V 21W 5W Front turn light 12V 10W Rear turn light 12V 10W Turning signal indicator light 12V 3W High beam indicator light 12V 1 7 W Meter indicator light 12V 1 7 W Alarm indicator light Light diode Brake and rim Description Specification Tolerance Brake lever play Rear 15 20mm Hub diameter Rear 110 mm 110 7 mm Bra...

Page 84: ...Engine oil Description Specification Remark Fuel type Unleaded gasoline 90 or high octane number is recommended Fuel tank capacity 5 2L Gear oil SAE85 90 Gear oil capacity 0 10 0 01L Gear oil change period 2000 Kms Engine Oil tank capacity 0 9 0 1L Engine oil grade 2 T Oil Brake fluid grade DOT3 or DOT4 ...

Page 85: ...This document was created with Win2PDF available at http www daneprairie com The unregistered version of Win2PDF is for evaluation or non commercial use only ...

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