TGB Hornet 50 Service Manual Download

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CONTENT

1. REGULAR INSPECTION -----------------------------------------

1-1 Delivery Introduction ---------------------------------------------------2

1-2 Inspection Before Running -------------------------------------------4

1-3 Regular Inspection ------------------------------------------------------5

1-4 General Inspection ------------------------------------------------------6

2. MAINTENANCE INFORMATION------------------- ------------

2-1 Specification Sheet -----------------------------------------------------7

2-2 Maintenance Data ---------------------------- ---------------------------8

2-3 Special Tools --------------------------------------------------------------9

2-4 List of Grease & Oil Adopted ----------------------------------------12

2-5 Circuit Drawings ---------------------------------------------------------13

2-6 Tighting Torque of Screws---------------------------------------------14

2-7 Simplified Troubleshooting -------------------------------------------16

2-8 Troubleshooting ----------------------------------------------------------17

3. DESCRIPTION OF COMPONENTS AND ASSEMBLY ---

3-1 Cover and Seat -----------------------------------------------------------26

3-2 Engine ----------------------------------------------------------------------27

3-3 Transmission Mechanism --------------------------------------------30

3-4 Electric System -----------------------------------------------------------35

3-5 Body --------------------------------------------------------------------------37

4. DISASSEMBLY REPAIRMENT

------------ ------------------------39

4-1 Notice for Disassembly Repairment ------------------------------40

4-2 Removal and lnstallation of Engine -------------------------------41

4-3 Disassembly and Assembly of Engine ---------------------------43

4-4 Removal and Assembly of Carburetor ---------------------------73

4-5 Removal and Inspection and Assembly of Electric Parts --75

4-6 Removal and Inspection and Assembly of Body Parts -----80

Summary of Contents for Hornet 50

Page 1: ...crews 14 2 7 Simplified Troubleshooting 16 2 8 Troubleshooting 17 3 DESCRIPTION OF COMPONENTS AND ASSEMBLY 25 3 1 Cover and Seat 26 3 2 Engine 27 3 3 Transmission Mechanism 30 3 4 Electric System 35 3 5 Body 37 4 DISASSEMBLY REPAIRMENT 39 4 1 Notice for Disassembly Repairment 40 4 2 Removal and lnstallation of Engine 41 4 3 Disassembly and Assembly of Engine 43 4 4 Removal and Assembly of Carburet...

Page 2: ...d press the START button C If ATV is not started release the START button and try again after a few minutes Each start should be less than five seconds to avoid battery consumption Note This is Manual CHOKE ATV and the choke lever is in the left handle bar The fuel is controlled only by throttle grip The accelerator has to return to its original place when ATV is not in use D If ATV can not be sta...

Page 3: ...pection and Maintenance Inform customers of the importance of inspection before running and regular inspection A Inspection Before Running Riders should perform inspection by themselves before running B Regular Inspection Regular inspection should be performed after the first month and the three month and every three months afterwards 5 Description of Warranty System Clearly identify the content o...

Page 4: ...g to see the brake effect of front and rear brakes 1 Is the air pressure proper 1 Check if the air pressure of tire is sufficient with a gauge or by sight The recommended pressure of tire is 4 p s i 2 Groove should be deep enough 1 Check if the groove of tires is enough 3 Unusual wear is not desired 1 Check landing flat of tire to see if any unusual wear appears 4 Breaking and damage are not desir...

Page 5: ... km 6000 km 12000 km 18000 km MONTHS ITEM 0 months 2 months 12 months 24 months 36 months Battery I I I I I Tire I I I I I Brake I I I I I Brake fluid I I I R I Bolts and nuts I T T T T Spark plug R R R Air cleaner Clean every 3000 km Final gear oil Replace every 5000 km Cylinder head nut exhaust pipe bolts T T T T Steering system I I I I I Suspension system I I I I I Engine idle rpm I I I I I Muf...

Page 6: ...ile assembling 3 Only designated TGB oils should be used on spare parts 4 Clean the vehicle before maintenance to avoid dirt or mud on disconnected parts 5 The locking sequence of Bolt and Nut should be from inside to outside or in diagonal step Reverse the sequence to loose 6 Special tools should be used when necessary 7 Attention should be paid to avoid damage or loss of disconnected parts Clean...

Page 7: ...ed Gasoline Lubrication Method Oil Supplied Separately by Oil Pump Cooling Type for Engine Air Cooled by Cooling Fan Ignition Method C D I Ignition device w o point Rim comp Size Front 7 x 5 2 Rear 7 x 5 2 Front 8 x 5 5 Rear 8 x 7 0 Spark Plug BPR7HS NGK Clearance 0 6 0 7mm BPR7HS 10 NGK Clearance 0 9 1 0mm Battery 12V 7Ah 12V 7Ah flywheel magneto Alternating Output 12V 50W Alternating Output 12V ...

Page 8: ...f Big End at Con Rod 0 1 0 55 1 0 0 1 0 55 1 0 Runout of Crank Shaft 0 0 05 0 1 0 0 05 0 1 CVT Free Length of Clutch Spring 23 8 25 0 23 8 25 0 Thickness of Clutch Lining 3 0 2 0 3 0 2 0 Bore of Clutch Housing 110 110 15 110 40 110 110 15 110 40 BRAKE Bore of Brake Drum 85 85 6 85 85 6 Brake Lining O D 84 3 82 3 84 3 82 3 Thickness of Disc Brake Lining 4 7 3 7 4 7 3 7 Engine Oil Capacity 0 9L 0 9L...

Page 9: ...9 2 3 Special Tools ...

Page 10: ...10 2 3 Special Tools ...

Page 11: ...11 2 3 Special Tools ...

Page 12: ...GB Gear Oil 85w 90 Transmission Gear Oil for Scooters GA50400002 TGB Supper Oil JASO FC Apply in oil tank GA55100002 Three Bond 1322 Under M10 Screw For medium fixing for Flywheel Magneto GA50400005 TGB Supper Grease No I Apply in Oil Seal GA55100003 DOT 3 Brake Oil For Brake GA5040006 TGB Supper Grease No 2 Apply in Kick Starter GA50400008 TGB Supper Grease No 4 For Movable Drive Face Comp GA5040...

Page 13: ...13 2 5 Circuit Drawing ...

Page 14: ...10 4 450 550 10 Rear Shock Absorber Bolt 10 2 450 550 11 Steering shaft Assy Nut 10 2 400 450 12 Steering Linkage Nut 10 4 250 13 Steering Joint Nut 10 4 250 350 14 Steering Shaft Housing Nut 8 2 140 160 15 Steering Stem Lock Nut 14 1 700 750 16 Chain Adjustment Bolt 12 4 500 600 17 Rear Axle Nut 27 1 800 18 Raer Axle Nut 27 1 950 19 Master Cylinder Bolt 6 2 80 120 20 Brake Disc Bolt 10 3 200 250 ...

Page 15: ...lt of Kick Starter 6 80 120 Nut of Driven Pulley Assy 28 400 600 Nut of Clutch Housing 10 400 600 Bolt of Fuel Inlet 8 90 150 Screw of Fuel Outlet 6 40 70 Bolt of Left engine case 10 550 600 Bolt of Lower left engine case 12 550 600 General Torque Thread General Bolt kg cm Heavy Duty Bolt kg cm 4 10 20 15 30 5 20 40 30 60 8 100 160 80 120 10 220 350 300 400 12 350 550 500 600 ...

Page 16: ...fuel reaching the carburetor I No gasoline in fuel tank 2 Clogged hole in the fuel tank cap 3 Clogged or defective fuel cock 4 Clogged fuel hose or defective vacuum hose Compression too low I Excessively worn cylinder or piston rings 2 Spark plug too loose 3 Broken cracked or otherwise failed piston Replace Clean dry Replace Replace Replace Replace Clean Clean or replace Clean or replace Replace T...

Page 17: ...17 ...

Page 18: ...18 ...

Page 19: ...ose adjustment screws in the carburetor Carburetor choke Obstructed carburetor slow nozzle Ailing carburetor threshold Obstructed air filter grill Leakage in cylinder washer Seriously damaged cylinder piston Dead battery Poor contact of battery pin and conductors Starting switch with poor or failure Starting relay with broken wire or short circuit Loose contact and wiring Starting gear and speedin...

Page 20: ...20 2 8 2 Troubleshooting for poor skip of spark plugs ...

Page 21: ... voltage wiring z Poor main switch z Main wiring broken or in short circuit z Ignition coil broken or in short circuit z Poor adapter contact Load properly the C D I adapter Check C D I terminals passage and testing of resistance Weak sparks Replacement of poor spark plugs Check for loose C D I contacts Loose Normal a Poor PICK UP b Poor main switch c Poor contact of adapter d Broken main wiring o...

Page 22: ...r engagement of cylinder head washer z Severe wear of cylinder piston piston ring Replacement of the filter grill Is the carburetor buoyant level normal Fair adjustment Is the air filter grill obstructed Poor Fair Adjustment or replacement of the buoyant needle valve Fair Poor Check if the choke valve fails valve does not open Check of for air between the carburetor and the air inlet Fair Poor Cor...

Page 23: ...23 2 8 5 Poor acceleration and horse power ...

Page 24: ...piston piston ring for wear Correct adjustment or replacement when Check for normal fluid level in the buoyant Cleaning or Fair Poor Check the i Check of needle Fair Poor low l l Check fuel pipe and carburetor for obstruction Adjustment Fair Poor Cleaning or ...

Page 25: ...haust System 3 2 2 Carburetor 3 2 3 Lubrication Cooling System 3 3 TRANSMISSION MECHANISM 3 3 1 Power Transmission 3 3 2 Continuous Variable Transmission 3 3 3 Reducing Gear 3 3 4 Kick Starter 3 4 ELECTRIC SYSTEM 3 4 1 Ignition Battery Device 3 5 BODY 3 5 1 Frame Fuel and Oil System 3 5 2 Front Rear Suspension System 3 5 3 Brake System ...

Page 26: ... please do not wash with volatile fluid such as gasoline B If thecovers were damaged please replace the new covers Otherwise the covers will cause the injury 3 1 2 SEAT A The seat has to be locked If theseat is not locked during riding it will be affect tehsafety and even cause injury B The seat is controlled by the seat lock on the rear ...

Page 27: ...econd rings and the expander ring installed in the inner side of 2nd ring FOR 50C C Two Piston Rings FOR 90C C F Con Rod with needle bearing on both big end and small end G Bearing with a ball bearing on each left and right rand side 2 Air In Take Exhaust System A Air Filter with pre filter and filter to eliminate dust and dirt B Carburetor VM16 Auto Choke type C Reed Valve with steel single reed ...

Page 28: ... needle jet are elevated to let gasoline pass through the main jet and mix with air and go into the crank case 2 Manual Choke System In cold condition the path should in be close condition and the fuel will flow into engine directly After starting ATV ATV should remain in idle condition for 3 5 minutes Then Activate the Manual Choke and the path should return in open condition ...

Page 29: ... Combustion Chamber B Oil Pump Double outlets type The Injection Volume Incresed by the revolutions of crankshaft and the opening of throttle C Forced Air Cooled Engine In order to achieve the stable cooling both when the vehicle is moving and parked it is covered with air guide from the Cooling Fan to the Cylinder Head The outside air is imported into the Cylinder Head and Cylinder by the Cooling...

Page 30: ...ontinuous variable transmission which makes the Pulley of both Drive Ends and Driven Ends move toward the shaft center to alter V Belt contact pitch circle to change the transmission ratio automatically Due to the increasing revolution speed of Engine the pitch circle on the Drive Pulley is enlarged by centrifugal force and pushed out of the Belt to lengthen the radius of pitch circle The Belt at ...

Page 31: ...Face to moderate the rise of temperature in the Clutch Cover 3 Driven Pulley A Because the revolving radius of V Belt at the Drive End is enlarged the Face Comp Movable Drive is squeezed out by the V Belt at the Driven End to shorten the revolving radius B There is a Torque Cam on the Movable Drive Face C Torque Cam is loaded from outside When the outside load is higher than the engine s output th...

Page 32: ... variable transmission is achieved smoothly along with its speed B During quick speeding because the torque cam begins to act the quick transformation can be achieved in high speed C After the transmission ATV speed can also rise according to the ratio with the rise of revolving speed of Engine ...

Page 33: ... I Electric Self Starter A Starting Motor of BENDIX type With Safety Starting Mechanism B The Starting Motor can act only when the Front Brake or Rear Brake is applied C Starting Motor is installed at the bottom of Flywheel Magneto D Starter Switch is installed on the Left Hand Handle Starter Motor revolves to activate Pinion Gear Assy to fly out of the Pinion Gear and connect with the Starter Gea...

Page 34: ... gear of Starter Shaft will drive the right hand kick starter to revolve the crank shaft to start the engine C After the Engine is started the Ratchet of the Left kick Starter will stop the power transmission to the Kick Starter Driven Gear D When the Kick Starter Lever is released the Kick Starter Gear will remove from Kick Starter Driven Gear and go back to its original place ...

Page 35: ...wer is given by flywheel magneto The voltage is controlled by voltage regulator Power is charged to battery A Flywheel Magneto Flywheel rotor includes four poles crossed N poles and S poles The stator consists of one high tension ignition coil and three low tension coils for charging and lighting to create change of magnetic field by rotating the flywheel to generate electricity ...

Page 36: ...e the Aluminum Seal on the filling hole of battery 2 Remove the cover bar and battery sealing bolt 3 Insert the filling hole of electrolyte container into the filling hole of battery Try not to spillage it 4 There are three pipes on each side Tap the bottom of container lightly when the electrolyte bubbles Pulling it out will be unnecessary 5 Remove the container from the battery after all electro...

Page 37: ...y after the removal of the steering shaft assy 3 Manual fuel shutoff control On means the fuel valve can supply fuel flowing into carburetor Off means the fuel valve stop the fuel flow into carburetor Res means the fuel valve supply the fuel from the reserve supply to the engine 4 Oil Tank Oil Tank is made of plastic with the capacity of 0 9L When the red indicating lamp of Oil Level is lit there ...

Page 38: ...telescopic absorber between the crank case and ATV body B Rear Axle Movable by telescopic shock absorber 3 5 3 Brake System I Front Brake Drum Brake Front brake include two brake cables Upper cable is to control the front right side brake and lower cable is to control the front left brake Drum brake includes the drum lining pad and shoe It is operated manually by pulling the front brake on the rig...

Page 39: ...ARBURETOR 4 4 1 Removal of Carburetor 4 4 2 Inspection of Carburetor 4 4 3 Assembly of Carburetor 4 5 REMOVAL AND INSPECTION OF ELECTRIC ITEMS 4 5 1 Removal and Inspection of Ignition and Charging System 4 5 2 Removal and Inspection of Starter Mechanism 4 5 3 Removal and Inspection of Fuel Tank 4 5 4 Removal and Inspection of Oil Indicator lamp 4 6 REMOVAL AND INSPECTION OF BODY PARTS 4 6 1 Remova...

Page 40: ... should be avoided while reassembling 7 When important revolving and reciprocating parts such as Cylinder Head Cylinder Piston Piston Ring and Crank have been replaced the vehicle can not go for full speed running immediately Preliminary running should be applied below 4000 rpm within 20hour 8 While assembling the main lip of oil seal should face inwards oil chamber and the antidust sub lip should...

Page 41: ... I Flywheel Magneto Lead 2 Engine Earth Ground Lead 3 Auto Choke cable 4 B Remove the Throttle Cable on Carburetor Piston 5 C Remove Oil Hose 6 D Remove Negative Pressure Hose 7 and Remove Fuel Hose 8 E Remove Front Rear Engine Mounting Shaft 9 F Lift Body ...

Page 42: ... case Install Engine Mounting Shaft and lock B Install Ignition Coil Flywheel Magneto Engine Earth and Auto Choke Cable C Install Oil Hose Release the bubble by releasing Bolt on the Oil Pump to let the oil flow Relock the Bolt until no bubble appears D Install Carburetor negative pressure hose I fuel hose 2 Make sure to lock the circlip ...

Page 43: ... Remove the Clutch Housing Remove the Driven Belt Pulley Detailed Disassembly Remove Nut of Driven Pulley Assy Remove Clutch Assy Remove the Spring Remove the Spring Sheet Remove the Roller Pin Remove the Fixed Shaft Assy Remove the Needle Roller Bearing Remove the C Type Circlip Remove the Ball Bearing Remove the O Ring Remove the Oil Seal 5 Remove the Fan Cover Remove the Cooling Fan Remove the ...

Page 44: ...e Gear Remove the Idling Shaft Remove the Washer Remove the Snap Ring Remove the RH and LH Bearings and Oil Seal of Main Shaft 12 Remove the Nut of Rear Wheel Remove the Rear Wheel Remove the Lining of Rear Brake Remove the Rear Wheel Shaft Remove the Cam Con Rod of Rear Brake Remove the Cam of Rear Brake Remove the oil seal Bearing of Rear Shaft 13 Remove the Right Hand Crank Case Remove the Cran...

Page 45: ... spring 3 D Remove washer 4 E Remove the left hand starter assy 5 F Remove the RH starter 6 WARNING Because it is LH thread inside the RH starter it is necessary to use deep bush while removing to avoid contact with the crank shaft and remove the RH starter by using pneumatic wrench turns to right hand If it turns to left hand the wrong direction it will damage the crank shaft easily Special Tool ...

Page 46: ...se the nut quickly because the components will fly out and cause injury Release lightly will be enough special Tool GA5000051F04 E Press tightly the both sides of Clutch unscrew and remove the Nut Warning Press tightly the Clutch Assy while unscrewing the Nut so that the spring will not jump out Release slowly after the nut is removed F Remove the Clutch Assy G Remove the Spring H Remove the Sprin...

Page 47: ... prevent the rotation of Flywheel Magneto Remove Flange Nut of Flywheel Housing Special Tools GA5000051F04 E Apply tools to lock on the thread hole of Flywheel Housing hook the end of Crank Shaft and remove the Flywheel Housing Special Tool GA5000051F22 F Remove Key G Disassemble Screw of Coil and remove the coil 6 Removal of Starter Motor A Remove the Screw 1 of Starter Motor and remove the Start...

Page 48: ...ark Plug C Remove Cylinder Cowling D Unscrew the Cylinder Screw by diagonal step E Remove Cylinder Head Cylinder Gasket and Cylinder 10 Piston A Remove Piston Pin Cir clip 6 The used Circlip must be discarded and never to use again otherwise it will be barred between piston and cylinder for looseness and the engine is broken B Remove Piston Pin 7 C Remove Piston 8 D Remove Piston Ring 9 Overexpand...

Page 49: ...e the Drive Shaft 1 from the Gear Box Cover E Remove the Cir clip 2 of Rear Shaft F Remove the Left Hand Washer 3 of Idling Shaft G Remove the Gear 4 of Rear Shaft H Remove the Gear 5 of Idling Shaft I Remove the Right Hand Washer 6 of Idling Shaft J Hook the Right Hand Bearing 7 of Drive Shaft with special tool and remove the Bearing special Tool GA5000051F12 K Remove the Oil Seal 8 of Drive Shaf...

Page 50: ...ock Crank Case 2 and Crank Shaft 3 to remove RH Crank Case Special Tool GA5000051F05 C Use a special tool to lock LH Crank Case 4 and Crank Shaft 3 to push out the Crank Shaft Special Tool GA5000051F05 D Dig out the Oil Seal of RH Crank Shaft with a screw driver E Remove the bearing of RH Crank Shaft with a special tool Special Tool GA5000051F19 ...

Page 51: ...ve the oil seal by tapping G Remove the bearing 2 of LH crank shaft by tighting the nut of the special tool Special Tool GA5000051F21 H Put the crank case on the spacer shown Push the outer ring of the bush with another spacer And press the bush out with a vice Reassembly Assemble with the reverse sequence of disassembly ...

Page 52: ...C Fully open the throttle lever and start the starter motor Read the indicator value on the pressure gauge Compression Pressure Standard 6 8kg cm2 500rpm Limit 5 0gk cm2 2 Turn the throttle stopping screw 1 and adjust to the revolution of 1800 100rpm 3 Turn the adjusting screw 2 of throttle cable and keep the clearance of steel cable in the throttle cable in 2 4mm counted by outside diameter of th...

Page 53: ... of inlet on the LH crankcase Make sure if the gear oil reaches the bottom of refilling bolt B Remove the bolt and drain bolt of outlet to drain the gear oil C Relock the outlet screw Screw Torque 40 70kg cm D Refill 90cc of TGB gear oil from the oil inlet E Tighten the oil inlet bolt Screw Torque 90 150kg cm ...

Page 54: ...for unusual damage crack or abrasion B Measure the exterior diameter at 15m m 50C C 20m m 90C C height above the piston bottom and the perpendicular to the pin hole Replaced if it is less than 40 89mm 50 C C 49 89 90 C C C Replaced when the piston pin hole exceeds 10 04mm 50 C C 12 04 mm 90 C C 9 Inspection of Piston Ring A Check for unusual abrasion damage or carbon deposit B Put the piston ring ...

Page 55: ...0nm 14 Inspection of Clutch Spring A Inspect crack and damage from the appearance B Replaced when the free length at curved hook is above 25 5mm 15 Inspection of CVT Spring Replaced if the free length of spring is less than 100mm 16 Inspection of Clutch Lining A Check for oil stain crack and unusual damage from the appearance B Replaced if the thickness of lining is less than 2 0mm 17 Inspection a...

Page 56: ... Cir clip of Rear Axle Assemble the Washer Assemble the Idling Shaft Assemble the Rear Axle Gear Assemble the Cir clip of Rear Axle Gear Assemble the Oil Seal of Drive Shaft Assemble the LH Bearings of Drive Shaft Assemble the Drive Shaft Assemble the Cover of Gear Box Refill the Gear Oil 4 Assemble the Needle Roller Bearing of Con Rod Assemble the Piston Ring Assemble the Piston Assemble the Pist...

Page 57: ... Roller Bearing Assemble the Fixed Driven Face Comp Assemble the Roller Pin Assemble the Spring Sheet Assemble the Spring Assemble Clutch Assy Tighten Nut of Driven Pulley Assy Assemble the Driven Pulley Assy Assemble the Clutch Housing Assemble the Nut of Clutch Housing Comp 12 Assemble the O Ring of Movable Drive Face Comp Assemble the Guide Block Assemble the Roller Set Assemble the Movable Dri...

Page 58: ...rear lug of crank case The size of Spacer pressed into the Bush should be a little less the exterior diameter of outer ring of Bush The Spacer must be pressed onto the outer ring not the inner ring C Apply a thin layer of grease GA50400005 onto the lip of oil seal of the right hand crank case and install the oil seal 3 with special tool Special Tool GA5000051F30 Slanting of oil seal and damage to ...

Page 59: ...l Tool GA5000051F08 Avoid damage to the Lip of Oil Seal while drawing in Knocking on the crank shaft is not allowed and dust and dirt into the crank chamber should be avoided H Apply seal agent GA50400001 evenly to the contact surface of RH and LH crank cases Do not apply too thick Avoid entering of seal agent into joints and the crank chamber I Install knock pin J Assemble RH crank case 3 and LH ...

Page 60: ...lip of oil seal 8 of drive shaft and then press into the gear box cover with special tool Avoid damage to the lip of oil seal lnstall horizontally and slanting is not allowed Special Tool GA5000051F30 J Press in the LH bearing 9 of drive shaft with special tool Special Tool GA5000051F17 K Press the drive shaft 10 evenly into the gear box cover L lnstall the gear box cover and lock the bolt in sequ...

Page 61: ... b There is a cone surface on the 1st ring 7 place the engraved surface with R mark upwards while installing The opening of piston ring should point to the knock pin 9 of piston while installing Do not put too much force while open to let the piston through so that the piston ring will not be damaged For 90C C engine there are two cone piston Rings without expansion ring C Install the cir clip 5 o...

Page 62: ...ation C Apply more than 3cc of TGB oil GA50400002 evenly on the inside of the cylinder and the outside of the piston D Install cylinder gasket 2 E Install piston 1 into cylinder The arrow mark on the piston has to be install toward the exhaust port F Install cylinder head gasket G Install cylinder head 6 H Screw the flanged nut 7 of cylinder head by diagonal step Screw Torque 120 130 kg cm I Insta...

Page 63: ...ump 2 6 Assembly of Reed Valve A Install the reed valve 5 on the in take pipe B Install the gasket 6 and the in take pipe 4 into the crank case C Screw the fender bracket 7 on the in take pipe 7 Assembly of Starter Motor A Apply a thin layer of grease GA50400004 on the shaft of pinion gear assy and then install into the crank case B Install two knock pins 9 C Install starter idle gear cap 10 and s...

Page 64: ...64 4 3 3 Assembly of Engine D Install the starter gear I into the left hand crank shaft 2 E Install the starter motor and tight the bolt with cable clamp ...

Page 65: ...Crank Case C Clean the taper of crank shaft and install the key Tap lightly to its position D Install the flywheel magneto Avoid the drop of key and make sure to the position of the flywheel magneto E Use tool to avoid the turning of flywheel magneto Special Tool GA5000051F04 Screw Torque 350 450 kg cm F Install pick up 1 ...

Page 66: ... Install fan case 1 The lead has to go through the groove of right hand crank case and damage should be avoided B Install cooling fan 2 C Install fan cowling 3 The starter motor and flywheel magneto lead 4 have to be installed into the lead groove as shown ...

Page 67: ...6 one for top and bottom each E Install the fixed driven face comp 2 into the movable driven face comp 6 Avoid damage to the lip of oil seal F Install three roller guide pins 7 G Install two O rings 8 H Apply about 5g of grease GA50400005 to the groove of the Cam I Apply a little grease GA50400005 to the inside of spring sheet and manually push the spring sheet in lightly J Install the spring K Pr...

Page 68: ...y hand Install V belt and then install to the drive shaft Wipe cleanly the grease on belt surface and the pulley surface N Install the clutch housing 3 Remove all grease inside the clutch housing and lining surface O Screw the nut 4 of clutch housing with tool to stop turning or use pneumatic wrench screw Torque 400 600 kg cm special Tool GA5000051F04 ...

Page 69: ... 1 into the movable drive plate 2 and then install the movable drive plate 2 into the movable drive face comp 7 C Install the O ring 3 and the cover 4 D Tighten the screw 5 Press the movable drive plate all the time while installing or the roller will turn to stand up and requiring re adjustment E Apply a thin layer of grease GA50400008 to the hole of movable drive face comp and then inserted by t...

Page 70: ... Special deep socket sleeve should be adopted while screwing WARNING This component is left hand threaded thus turning counterclockwise to screw will be necessary when assemble Use general sleeve or trying too hard to tighten will cause damage to the thread of left hand crank shaft which will cause to the replacement of crank shaft assy special Tool GA5000051F36 I Install the left hand starter 3 J...

Page 71: ...spring to the hook 4 of clutch cover D Install two knock pins E Install gasket and washer of clutch cover The gasket and washer are made into two sizes 0 5mm and 1 5mm thick Choose according to the original thickness F Install the clutch cover and screw the mounting screw by diagonal step G Install the kick starter lever 5 and screw the bolt screw Torque 80 120 kg cm The kick starter lever and the...

Page 72: ... Engine 13 Assembly of Muffler A Install the muffler Put on the bolt and nut first B Screw the bracket bolt of Exhaust pipe screw Torque 80 120 kg cm C Tighten the bolt with the bracket of frame screw Torque 300 400 kg cm ...

Page 73: ...retor I Removal of Carburetor A Remove the right hand side cover B Remove the air cleaner C Remove the fuel hose I D Remove the negative pressure hose 2 E Remove the carburetor cap 3 and piston valve 4 F Remove the auto choke terminal 5 H Remove the carburetor ...

Page 74: ...slightly higher idling speed than normal then adjust the air adjusting screw 1 to obtain the most even running Then unscrew the idle speed screw again until you obtain the normal idling speed Finally to obtain the best engine running it is worth rechecking by very carefully readjusting the air adjusting screw 3 Assembly of Carburetor A Install o ring washer and spring B Install the idle speed scre...

Page 75: ...em 1 Ignition and Charging Circuit A Figure 1 Circuit Description With regard to the generation of the flywheel magneto a CDI and HTcoil ignition coil are adopted to control the ignition and angle for high voltage parts b Regulating rectifier is adopted to supply and control lamp and charging voltage for low voltage parts B Inspection of Ignition Coil and C D I a C D I CAPACITOR DISCHARGE IGNITION...

Page 76: ...lectric Resistance of Rectifier Red Black White Red Yellow White Red Black White White Red Yellow White 5 100K Red Black White 5 100K D Inspection of Coil Assy a Test the electric resistance value between each wire b Testing Range X I KΩ Electric Resistance of Coil Assy Tester Connect to Wire Electric Resistance Red Black Yellow White Ground Lamp 0 76Ω 20 White Red Ground Charge 0 97Ω 20 Black Red...

Page 77: ...ge of electrode with eyes d Clean with special tool or wire brush if it is dirty e Replace spark plug if complete recovery is impossible f The gap between electrode and ground electrode should be correctly adjusted and kept between 0 6 0 7mm for 50C C 0 9 1 0mm for 90C C F Assembly of the Spark Plug a assemble the spark plug Torque 250 300kg cm b assembl the cap of spark plug ...

Page 78: ...e C Connect the coil end with 12V Power supply as Figure 2 a beep sound means they are connected D Inspection of Starter Motor a Inspect wearness and roughness of contact surface on carbon brush 1 b Inspect the surface wearness and burning of the commutator 2 c Measure the outside diameter of the Commutator 2 d The commutator and the armature core 3 or shaft 4 should not be passed through between ...

Page 79: ...k Otherwise it can not take off the fuel tank 4 5 4 Removal and Inspection of Oil Warning Indicator A Inspection of Oil Warning indicator a When the ignition switch is at the position of between on and off the oil warning indicator must be lit b When the start button is pressed the oil warning indicator must be lit also c The indicator must be lit when the gray and brown wires are connected Diseng...

Page 80: ...per and lower brake cable and throttle cable in the right handle bar C Remove the rear brake cable in the left handle bar D Remove the handle bar E Release the the housing nut 1 F Remove the shock absorber 2 G Remove the front wheel H Remove the brake drum I Remove the turning linkage bar 3 J Remove the turning joint 4 J Remove the A Arm control Linkage Assy 5 K Remove the steering stem lock nut 6...

Page 81: ...spring is decayed or leaking oil and check for any unusual wear of between the upper and lower connecting seats I Check for any unusual wear of the steering race 4 6 1 3 Assembly of Steering shaft Assy A Assemble the steering shaft with the frame Nut torque 800 900kg cm B Assemble the A Arm control linkage assy Nut torque 450 550kg cme in the welding part C Assemble the turning joint Nut torque 25...

Page 82: ...the rear brake cable in the left handle bar C Remove the left handle bar D Remove the chain from the engine case 1 E Release the chain gear 2 F Remove the rear axle bracket 3 G Remove the shock absorber 4 H Remove the brake disc 5 I Release the axle nut 6 J Remove the rear swing assy 7 K Remove the Housing of Rear Axle ...

Page 83: ...e Swing arm I Check if the shock absorber spring is decayed or leaking oil and check for any unusual wear of between the upper and lower connecting seats 4 6 2 3 Assembly of Rear Axle A Assemble the housing of rear axle Nut torque 600 800kg cm B Assemble the rear swing assy Nut torque 250kg cm C Assemble the rear axle Nut torque 800 950kg cm D Assemble the brake disc Nut torgue 250kg cm E Assemble...

Page 84: ...nusual wear mark on the drum Inner Diameter of Brake Drum Standard 85mm Replaced over Limit 85 6mm B Inspection of Brake and Disc Lining a Measure the outside diameter perpendicular to the brake cam and anchor pin on the brake lining Confirm if the assembly of the brake lining is correct and if the brake cam completely returns to the original place b Check for any crack or damage on each part c Ch...

Page 85: ... the Brake drum and disc B Assemble the wheel C Assemble the Slf lock nut Nut torque 400 450kg cm D Assemble the Fixed nut Nut torque 500 550kg cm E Install the new Pin in each assembly F Check the pressure of tire if it is in the normal 4 0 PSI If not please inflat the tire until the pressure is in the normal ...

Page 86: ...sure that the handle bar is in the center position b Check the rotating angle of handle bar There is a small circle mark on the handle bar for reference The circle should be parallel with the hole of fixed board c Lock 4 screws and torque is 150 200 kg cm shown in Fig 1 Step 4 Assemble the caliper a Unlock the screws of caliper and connect the caliper with handle bar b Check the angle of brake lev...

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