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ADLY MOTO

1-1

INFORMATION FOR PREPARATION

Attention on Operation

All washers, oil rings, clamp rings, opening pins

shall be duly replaced by a new item

when dismounted.

Locking of all screws, nuts, cross screws shall be performed in the order of first the large
screws and then the small ones and from inside to outside in opposite angles by tightening
the torque locks.

All items must use original parts, pure oil and greases.

All service shall use special tools and general tools to repair.

All dismounted items requiring for checks shall be duly cleaned and for assembly, all
items shall be duly lubricated.

Содержание SS-100

Страница 1: ...SERVICE MANUAL SS 50 100 March 2008 High Power Engine HER CHEE INDUSTRIAL CO LTD ...

Страница 2: ...e edit description is given in diagrams with Operation Sequence Highlights and Checking Arrangement for reference of the service staffs The information illustrations or contents included in this manual may be different with the actual scooter in case specifications are changed Your understanding will be appreciated HER CHEE INDUSTRIAL CO LTD ...

Страница 3: ...ation 4 Engine dismounting disassembling 5 Cylinder head Cylinder and Piston 6 Starter Driving Disc Clutch Transmission 7 Final Transmission Mechanism 8 Crankcase Crankshaft and Transmission box 9 Chassis Front wheel Brake Suspension 10 Rear heel Brake Suspension 11 Electrical devices 12 Wiring diagram 13 ...

Страница 4: ...crews shall be performed in the order of first the large screws and then the small ones and from inside to outside in opposite angles by tightening the torque locks z All items must use original parts pure oil and greases z All service shall use special tools and general tools to repair z All dismounted items requiring for checks shall be duly cleaned and for assembly all items shall be duly lubri...

Страница 5: ... performed by over 2 people the assignment shall be conducted in coordination and safety shall be the first priority z Definition of signs The sign given in the Service Manual shall refer to the operation methods and observation OIL Lubrication by designated lubricant GREASE Lubrication by grease Special Tool Parts on which special tools shall be used General Tool General tools shall be used New R...

Страница 6: ...DISPLACEMENT 49 26 C C 95 57 C C BORE STROKE 40 0 39 2 52 45 COMPRESSION RATIO 7 2 1 5 8 1 IGNITION C D I C D I STARTER ELECTRIC KICK ELECTRIC KICK SUSPENSION Hydraulic Shock Absorber Hydraulic Shock Absorber TRANSMISSION AUTOMATIC AUTOMATIC SS Ⅰ 120 70 12 Front Rear 120 70 12 Front Rear TIRE FRONT REAR SS Ⅱ 120 70 12 120 70 12 SS Ⅰ Disc Disc FRONT BRAKE SS Ⅱ Double Disc Double Disc REAR BRAKE Dru...

Страница 7: ...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 7 Engine Mounting Bracket 1 8 6 0 ENGINE Locking Place Quantity Dia mm Locking Torque kg m Screw of Cylinder Cap 4 6 1 0 Flywheel Nut 1 10 3 8 Clutch Jacket Nut 1 11 3 8 Driving Disc Nut 1 28 5 5 Nut of Transmission Disc 1 10 3 8 Oil ...

Страница 8: ...ADLY MOTO 1 5 INFORMATION FOR PREPARATION The following drawing that shows the disassembling situation of the cover parts for SS50 100 scuuter ...

Страница 9: ...djuster Reason of Trouble fuel tank without gasoline tubing to carburetor blocking float chamber tubing of carburetor blocking fuel filter blocking fuel cup blocking air hole of fuel tank blocking spark plug grimy or damage C D I damage main switch damage ACG fulser coil damage high tension coil damage or no gap ACG lighting coil damage valve set damage cylinder piston piston ring damage cylinder ...

Страница 10: ... engine over heat increase engine speed or continue turning at high speed Check and Adjust air cleaner blocking fuel supply isn t smooth air hole of air tank blocking exhaust pipe blocking auto plunger starter damage film of carburetor damage fuel cup damage C D I damage pulser coil damage valve gap adjusting isn t correct valve set over abrade valve set damage cylinder piston abrade cylinder gask...

Страница 11: ...w carburetor sucking air loosen spark plug connecct with spark cap and contract with frame check the spark plug sparking check A C G end Reason of Trouble C D I damage pulser coil damage mixture gases too lean loosing screw mixture gases too rich locking screw spark damage or stain C D I damage A C G damage coil damage spark plug cable damage odr short main switch damage A C G damage air hole dama...

Страница 12: ...ite timeing adjusting valve gap check fuel cup supply normal carburetor blocking check and adjust valve timing Reason of Trouble C D I damage ACG pulse coil damage fule filter blocking air hole of fuel tank blocking fuel cup damage fuel of tank is too less camshaft gear mark position is not correct normal spring broken or elastic deformation end check the spring of valve adjusting isn t correct va...

Страница 13: ...erminal for battery measure the resistance of ACG coil check the regulator check socket of regulator loosen Reason of Trouble battery damage coil damage terminal damage YL wire damage R wire damage regulator damage socket damage ACG damage over charge main switch at ON the battery have voltage main switch at ON the battery have no voltage normal socket loosen GR wire broken regulator damage socket...

Страница 14: ...ion coil loosen check C D I unit socket loosen check the terminal of C D I unit unimpeded measure resistance check relate spare parts Reason of Trouble the previous spark plug damage spark plug cap loosen main switch damage pulser coil damage coil damage lighten coil damage the previous C D I unit damage socket damage normal abnormal main switch damage socket joint connect abnormal change CDI unit...

Страница 15: ...ch 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 Handle handle front 10 20 mm Wires Loose tight and damage Gap of casing brake Wore of brake operating parts Direction Wore Damage of casing ...

Страница 16: ...ntal under 2 0 mm vertical under 2 0 mm Tightness of front bearing Tightness of rear bearing Buffer device Spring damage Spring of shock absorber Suspension arm damage of joint gap arm Buffer oil leakage or damage Tightness of installation Power transmission device Clutch action Transmission Level way of direction hole oil fill to the mark of the hole It s rear Gear case Electril device Ignition d...

Страница 17: ...e filter is dirty Leakage of fuel Throttle gate choke Fuel filter is clogged Oil level Alteration of pipes 9 each 2 years Lights direction lights Action On off normal dirty damage Rear mirror view Reflector license tag dirty damage Instrument action Exhaust pipe muffler Installation loosed or damage Function of muffler Frame body loose or damage Abnormal from previous day confirm normal Others gre...

Страница 18: ... decoration strip and cowling Install with the reverse sequence WARNNING 6 Do not break the union of body and pedal 6 Before locking screws please confirm the matching correct of all parts Front cover Remove 3 pan flat bolts 1 hex bolt Remove 12 self tapping screws Disconnect the light connectors Install with the reverse sequence WARNNING 6 Do not damage break the joint of inner body and front dam...

Страница 19: ...he reverse sequence WARNNING 6 Installing to the luggage box after composing confirming the pedal with the joint of luggage case correctly Disassembly of Luggage Case Remove front fender Disconnect the light connectors Remove power switch cap Remove edge nut on luggage case Install with the reverse sequence WARNNING 6 Going on the installation operation after jointing correctly the luggage case an...

Страница 20: ...ly with the sequence in reverse of disassembly WARNNING 6 Ensuring the joint of tail light hole correct with the bulge of truck Handle Covering Remove 4 self tapping screws separate the joint with speedometer Remove the handle covering Assembly with the sequence in reverse of disassembly WARNNING 6 Aim handle covering correctly the handle covering back s joint ...

Страница 21: ...ADLY MOTO 2 7 CHECK AND ADJUST Layout of Parts Maintenance The location of main parts of maintenance are showed as follows ...

Страница 22: ...rting the engine turn slightly the throttle to feed motor oil idle speed At same time of rising the rotation of engine confirm the working of control rod The condition will be appeared with bad synchronizing as follows 6 Starting difficult and having smoke when opening degree of motor oil pump s connection rod is too big 6 Piston will be burnt when the opening degree of motor oil pump s connection...

Страница 23: ...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 Overheating 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 ai...

Страница 24: ...4 INSTALLATION OF LUBRICATION Disassembly of Motor Oil Pump Remove right side cover Remove stator cover Remove A C G 4WARNNING Operating after cleaning motor oil pump around and no entering to the crank shaft case ...

Страница 25: ... pipe with clamp or plug for avoiding fuel flow out Remove from both side of motor oil pump Remove from oil pump Assembly 5 1 Assembly with sequence in reverse of disassembly 4WARNNING Smear motor oil to new O ring then assembly motor oil pump The oil pump must installed correctly into crank case 4WARNNING Don t loosen adjusted screw on control cable but must adjust oil pump after assembling if ne...

Страница 26: ...rks 1 2 3 4 5 Disassembly Joint of oil disassembly oil pipe Joint of wires Bolt Oil tank Grommet 1 1 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 ...

Страница 27: ...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...

Страница 28: ...tion of idle 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 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 ...

Страница 29: ...of guide wire Throttle cover 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 ...

Страница 30: ...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 ...

Страница 31: ...LATION Disassembly 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 ...

Страница 32: ...loat Needle valve 4 1 1 1 1 1 1 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 ...

Страница 33: ...4 5 Disassembly Intake manifold hose clamp 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 4WARNNING Using new washer the washer must aim at hole of reed valve 4WARNNING confirm no secondary air entering after installing ...

Страница 34: ... Operation Parts Name Q ty Remarks 1 2 3 4 5 Disassembly Hex bolt Tail light fix bracket 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...

Страница 35: ...Petrol Gauge Disassembling wire joint of petrol gauge and remove 4 hex phillips bolt WARNNING 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 ...

Страница 36: ...ame Q ty Remarks 1 2 3 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 ...

Страница 37: ...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 ...

Страница 38: ... cable 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 WARNNING The oil over flow when remove the oil tube so use clip or plug stop the seal WARNNING Don t damage rear fender when remove the engine Actually for brace the frame avoid body turn inside out Assembly 16 1 WARNNING Carry out following ad...

Страница 39: ...oil appointed in sliding face before installing Diagnosis of Troubles Low compression pressure poor start idle speed not stable Air leakage of cylinder head washer 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 Noise Wear the c...

Страница 40: ...MOTO 6 2 CYLINDER HEAD CYLINDER PISTON Disassembly of Cylinder Head Cylinder Piston Disassembly of cover 4 7 Disassembly of cenerator cover 12 7 Disassembly of muffler 11 2 Disassembly of spark plug cap 5 2 ...

Страница 41: ...nder washer of crank shaft 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 of disassembly Installation of Piston Ring Install top piston ring 2nd piston ring in piston Do not scratch piston and do not bend piston rings Remove carbon muck inside ring ditch and piston ring when not installed...

Страница 42: ...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 ...

Страница 43: ...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 WARNNING Check the air cleaner whether worsen or harm Assembly 6 1 Operation with sequence in reverse of disassembly ...

Страница 44: ...ank 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 WARNNING Rotating pedal kick crank and remove the assembly ...

Страница 45: ...n 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 Starte...

Страница 46: ...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 Kick pinion Kick pinion spring clip ...

Страница 47: ...bly 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 WARNNING Don t hurt transmission belt Separation assembling 7 7 Separation assembling 7 8 Assembly 12 1 Operation with sequence in reverse of disassembly ...

Страница 48: ...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 ...

Страница 49: ...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...

Страница 50: ...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...

Страница 51: ...h drive face 7 6 WARNNING 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 ...

Страница 52: ...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 ...

Страница 53: ...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...

Страница 54: ...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 ...

Страница 55: ...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...

Страница 56: ...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 ...

Страница 57: ...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 ...

Страница 58: ... the steering ball race Steel ball inside ball race broken Air too less inside of front tire 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 ri...

Страница 59: ...Single Disc Iron Rim Operation Parts name Q ty Remarks 1 2 3 4 5 6 Disassembly of Front Wheel Nut nylon Brake hose Hex washer face bolt Front collar Front fender Front brake disc 1 1 1 1 1 1 Assembly 6 1 Assembling with sequence in reverse of disassembly WARNNING Assembly of front fork shall be aimed at convex of front fork ...

Страница 60: ...emarks 1 2 3 4 5 6 7 Disassembly of Front Wheel Nut nylon Brake hose Hex washer face bolt Front collar Front fender Front brake disc right Front brake disc left 1 1 1 1 1 1 1 Assembly 7 1 Assembling with sequence in reverse of disassembly ARNNING Assembly of front fork shall be aimed at convex of front fork and brake arm ...

Страница 61: ...ngle Disc Aluminum Rim Operation Parts name Q ty Remarks 1 2 3 4 5 6 Disassembly of Front Wheel Nut nylon Brake hose Hex washer face bolt Front collar Front fender Front brake disc 1 1 1 1 1 1 Assembly 6 1 Assembling with sequence in reverse of disassembly WARNNING Assembly of front fork shall be aimed at convex of front fork ...

Страница 62: ...sassembly of front wheel Front Wheel IRON RIM Operation Parts name Q ty Remarks 1 2 3 4 Disassembly Oil seal Radial ball bearing left Front wheel spacer tube Radial ball bearing right 1 1 1 1 Assembly 4 1 Assembling with sequence in reverse of disassembly WARNNING Must change the R L bearing set ...

Страница 63: ...el Aluminum Rim Operation Parts name Q ty Remarks 1 2 3 4 Disassembly Oil seal Radial ball bearing left Front wheel spacer tube Radial ball bearing right 1 1 1 1 Assembly 4 1 Assembling with sequence in reverse of disassembly WARNNING Must change the R L bearing set ...

Страница 64: ... Disassembly of Front Brake Disassembly of front disc Operation Parts name Q ty Remarks 1 2 3 4 Disassembly Front collar Brake disc hex socket bolt Hex flange nut with serration Front brake disc 1 3 3 1 Assembly 4 1 Assembling with sequence in reverse of disassembly ...

Страница 65: ...tion Right lever set bolt Lever of front brake 1 1 1 1 4 5 6 7 8 Lever of front brake Hex socket bolt Master cylinder bracket Master cylinder sub Throttle cable Handle 1 1 1 1 1 7 6 Assembly 8 1 Throttle cable Master cylinder sub 1 1 Assembling with sequence in reverse of disassembly WARNNING Adjusting gap of throttle WARNNING Install make the convex of master cylinder bracket and hole of handle a...

Страница 66: ...ADLY MOTO 10 9 Front Wheel Front Suspension Front Brake Disassembly of Steering Stem Disassembly of front wheel Disassembly of steering handle ...

Страница 67: ...top 2 2 1 1 WARNNING No damage main rod front brake 4 5 6 Race ball 5 Steel ball Lathe on steering inner 3 1 2 2 7 8 Bolt washer Front inner fender 2 2 1 9 10 11 Hex bolt Hex bolt Front fork 2 2 1 WARNNING Remove L R tube by loose these two hex bolts 5 2 1 Assembly 10 1 Steel ball Steering stem dust cover Spaner nut 2 1 2 WARNNING Note the direction of installing bearing Assembly 10 11 ...

Страница 68: ... 1 1 1 5 6 7 Bracket of rear brake lever 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 10 7 4 Assembly 11 1 Steering handle Bracket of rear brake lever Rear brake cable 1 1 1 Assembling with sequence in reverse of disassembly WARNNING Install steering h...

Страница 69: ...Left Turn the front fork several times make the bearing smoothly Confirm the rotation smooth and gap of steering main rod fixed nut spanner B For no back turning together with up cone seal ring locking fixed screw to fix it Locking Torque 7 0 kg m Fixed nut spanner B Fixed nut spanner A ...

Страница 70: ...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 ...

Страница 71: ...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 ...

Страница 72: ...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 ...

Страница 73: ...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 ...

Страница 74: ...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...

Страница 75: ...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...

Страница 76: ...on Parts name Q ty Remarks 1 2 3 4 Disassembly Helmet box mat Battery end Battery end Battery 1 1 1 1 WARRNING Disassembly battery from end to end 2 Assembly 4 1 Battery terminal Assembling with sequence in reverse of disassembly WARRNING Connect end first next end ...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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 4WARNNING Checking in the engine connected With start motor Disassembly ACG connection Check resistance of charging wire lighting wire Standard ...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 85: ...ADLY MOTO 12 3 ELECTRICAL DEVICE Solid Wiring Diagram ...

Страница 86: ...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 ...

Страница 87: ......

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