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3.7  Battery 

Disassembly: 

Foot mat. (If present) 
Battery box cover.  
Disconnect the battery negative “

－

” 

cable, and then the positive “

＋

” cable. 

Warning: 

Do not touch tools with any metal parts of the frame while disconnecting 

positive “+” cable.  A resulting short circuit could cause sparking and damage to the 
battery. 

 

Inspection: 

This motorcycle uses a lead/acid wet cell battery. Top up as required with 

distilled water or battery electrolysis fluid 

Assembly: 

Assembly is in reverse order of disassembly procedures. 

Warning: 

First connect the positive “

＋

” cable and then the negative“

－

” cable.

 

 

3.8  Spark Plug 

Disassemble: 

 

Remove spark plug HT lead.  

Note: 

Blow away deposits around the spark plug with blower before removing spark plug. 

Otherwise, the dust may drop into cylinder resulting in damage to the engine. 

Inspection: 

Check if spark plug has carbon deposits, is burned, or cracked. Use a steel 

brush to remove carbon deposits and adjust the spark plug gap. Replace a burned or 
cracked spark plug with new one. 

Содержание VMOTO

Страница 1: ...VMOTO MONACO OWNER HANDBOOK ...

Страница 2: ... Brake Fluid 17 3 4 3 Refill Brake Fluid 17 3 4 4 Bleed Brake Line 18 3 4 5 Front Brake Disk 18 3 4 6 Rear Brake Adjustment 18 3 4 7 Inspection of Brake Lining and Wheel 19 3 5 Tyre and Tyre Pressure 20 3 6 Air Filter 21 3 7 Battery 22 3 8 Spark Plug 22 3 9 Fuel Filter 23 3 10 Carburettor Idle Speed 23 3 11 Throttle Valve 24 3 11 1 Throttle Lever Play Adjustment 24 3 11 2 Carburettor Throttle Cabl...

Страница 3: ...shoe spring 35 5 4 Rear Shock Absorber 35 6 ELECTRICAL SYSTEM 36 6 1 Maintenance troubleshooting 36 6 1 1 Starter System 38 6 2 Battery 38 6 2 1 Charging the battery 39 6 2 2 Rectifier 39 6 2 3 Starter Relay 40 6 2 4 Operation of starter relay 40 ...

Страница 4: ...xpressed permission of Gledhill Associates While all care has been taken in the compilation of this document variation in manufacturer s specification and production values may lead to some differences from your model of the scooter Therefore care should be taken when undertaking maintenance or adjustments to check for compliance between the details in this manual and your scooter ...

Страница 5: ...2 GENERAL INFORMATION 2 1 Description ...

Страница 6: ... Idle Speed 1800 100 Ignition Type CDI Starting Method Electric starter or kickstart Clutch Dry Shoe Acentric Drive V belt CVT Front Brake Hydraulic disc Rear Brake Cable drum Front Tyre Specification 120 70 12 4PR 25 psi Rear Tyre Specification 130 70 12 4PR 30 psi Max Load Weight 150 Kg Fuel Consumption economy running 2 8 litre 100 Km Max Speed 83 Km Hr Engine Oil Type SAE 20W 40 Engine Oil Qua...

Страница 7: ...he parts in order during disassembly Make marks if necessary to avoid mistakes in re assembly 6 Removing parts should start from small to big from outside to inside Assembly is in reverse order of disassembly 7 The oil seals should be replaced with new ones after disassembly The contact surface should be cleaned up Check shafts for scratches or burrs Use special tools for assembly to avoid damagin...

Страница 8: ...t remove the fluid and wash the surface with water immediately Warning High Temperature of Engine The engine cover cylinder and exhaust pipe can be at a high temperature after the engine has been running Wait for the engine to cool before working on it or use protective gloves 2 5 Torque Settings Monaco representative figure Standard Torque Values of Bolts and Nuts Specification Torque kg cm Speci...

Страница 9: ...inder Stud Bolt M8x182 5 500 800 2 M8x195 5 2 Cylinder Intake Pipe Stud Bolt M6x50 500 800 2 Muffler and Exhaust Pipe Tightening Screw M6 100 120 2 Muffler Right Crankcase Upper Tightening Screw M8x42 300 400 1 Muffler Right Crankcase Lower Tightening Screw M8x38 300 400 1 Spark Plug M10 100 120 1 Valve Gap Adjust Lock Bolt M5 50 90 2 Fuel Filter Nut Cap M30 150 200 1 Cooler Fan Lock CR M6x18 500 ...

Страница 10: ... Acceleration Lever Grease Steering Bearing Grease Speed Meter Gear Grease Front Wheel Axle Bearing Grease Front Wheel Axle Grease Main and Side Stand Axles Grease Rear Wheel Bearing Grease Seat Cover Lock Grease Speed Meter Cable Grease Throttle Wire Grease Rear Brake Cable Grease Brake Assembly Brake Fluid ...

Страница 11: ...ng Rod Rocker Arm Frictional Contact Area Cam Shaft and Chain Cylinder Frictional Area Oil Pump Chain Gears Contact Surface Bearing Operation Area O Rings Seal Lip Area Starter Frictional Surface High Temperature Durable Grease Starting Cam Gear Spring Operation Frictional Area Generator Connector Adhesives Gearbox Ventilation Tube ...

Страница 12: ...ws in the carburettor Carburettor choke not operating Blocked carburettor idle nozzle Dirty air filter Engine flooded with fuel Loose spark plug Dead battery Poor contact of battery terminals Ignition or starter switch faulty Starter relay faulty Loose contacts or wiring Starter gear and clutch gear seriously worn Starter gear and clutch gear not engaging Faulty starter motor 2 7 2 Poor spark Loos...

Страница 13: ... tube Obstructed carburettor idle jet Leaking head gasket Severely worn cylinder piston piston rings 2 7 4 Poor acceleration and loss of power Brakes binding Air filter grill dirty Dirty spark plugs Incorrect spark plug gap Incorrect ignition timing Incorrect adjustment of carburettor Faulty choke valve in carburettor Dirty or obstructed carburettor jets Faulty carburettor float needle valve Dirty...

Страница 14: ...I I Spark Plug C C C C Fuel Filter R R Carburettor I I C Valve A A A A V Belt I Bolts and Nuts T T T T T T Note 1 If ridden on dusty roads or in wet conditions shorten the inspection and replacement schedule for air filter 2 If ridden under heavy load frequent long distance travel shorten the replacement schedule for engine oil 3 Clean the spark plug regularly and replace the spark plug if necessa...

Страница 15: ...ng Engine Oil Note Change engine oil according to regular maintenance schedule If ridden with heavy loads or long distances shorten the maintenance schedule for oil changes Put oil tray under the left crankcase and remove the oil drain plug Re install the drain plug when the engine oil is drained Note that on some engines the drain plug and the oil strainer plug are the same Clean up the oil filte...

Страница 16: ...Warm the engine and check the engine oil level again 3 3 Final Drive Gear Oil Place the motorcycle on the main stand for inspection Clean grease around the drain plug Disassembly Oil refill plug Oil drain plug Note Put an oil tray under the gearbox before removing the drain bolt plug Inspection Check if the oil drain plug washer is damaged Replace with new one if it is damaged Drain gear oil Assem...

Страница 17: ...age in the brake system Warning If there is low or no load when the brake lever is activated check if there is air in the brake system or if there is fluid leakage 3 4 3 Refill Brake Fluid Place the motorcycle on the main stand for inspection Disassembly 2 tightening bolts on reservoir cover Diaphragm Refill brake fluid to correct level Assembly Assembly is in reverse order of disassembly procedur...

Страница 18: ... 1 to 5 until all air has been expelled Note Torque of bleeder valve 60 kg cm 3 4 5 Front Brake Disk Inspection If there are scratches or if there is damage or wear replace with new one Note The minimum disk thickness 3 0 mm Brake disk eccentricity Note A The max eccentricity 0 5 mm B If eccentricity is not within the limit check tyre roundness If wheel rim roundness is not within the limit change...

Страница 19: ...tightening bolts on exhaust pipe connector 2 tightening bolts between exhaust pipe and right crankcase Tightening nut on rear wheel axle Washer Rear wheel Inspection check rear wheel rim inner diameter If it is badly worn replace with a new one Note 1 Use vacuum to clean wheel rim and lining 2 Use the Vernier callipers to measure the diameter of wheel rim If the diameter is larger than 111 mm then...

Страница 20: ...disassembly procedures Note 1 Torque of rear wheel bearing bolt 600 900 kg cm 2 Torque of 2 bolts on exhaust pipe connector 100 120 kg cm 3 Torque of 2 bolts on exhaust pipe and right crankcase 300 400 kg cm 3 5 Tyre and Tyre Pressure Inspection Check if tyre has been cracked damage worn inclusions stone nail glass etc If tyre is in poor condition replace with new one Note Tyre specifications in s...

Страница 21: ... Check if filter is dirty or broken If dirty or broken replace with a new one Note 1 If ridden on dusty roads or in wet conditions shorten the replacement schedule for the air filter 2 Don t start engine when air filter is not installed Dirt or foreign objects introduced as a result may result in engine damage Assembly Assembly is in reverse order of disassembly procedures Note Please install air ...

Страница 22: ...tilled water or battery electrolysis fluid Assembly Assembly is in reverse order of disassembly procedures Warning First connect the positive cable and then the negative cable 3 8 Spark Plug Disassemble Remove spark plug HT lead Note Blow away deposits around the spark plug with blower before removing spark plug Otherwise the dust may drop into cylinder resulting in damage to the engine Inspection...

Страница 23: ...nch Do not over tighten the spark plug Note Torque of spark plug 100 120 kg cm 3 9 Fuel Filter Inspection Check if it is hardened damaged or leaking If any of these conditions exist replace with new one 3 10Carburettor Idle Speed Note Place the motorcycle on the main stand for inspection Start engine and adjust idle speed at when the engine has warmed up ...

Страница 24: ...y rotating the screw counter clockwise 3 Engine idle speed range 1800 100 rpm 3 11Throttle Valve Inspection Check if the throttle valve operation is smooth Note 1 Throttle lever free play 2 6 mm 2 Micro adjustment is performed at throttle lever Macro adjustment is performed at carburettor throttle valve cable 3 11 1 Throttle Lever Play Adjustment Procedures Open dust boot Loose lock bolt Adjust by...

Страница 25: ...le Play Adjustment Procedure Note First adjust the throttle lever play If it does not satisfy the specification then adjust the carburettor throttle play Loosen the locking nut Rotate the adjusting nut Note 1 Increase play by rotating the screw clockwise 2 Reduce play by rotating the screw counter clockwise Tighten the nut after adjustment 3 12V Belt Note Place motorcycle on the main stand for ins...

Страница 26: ... Loose the air duct tightening ring Kick start arm tightening bolt Kick start arm 8 clutch side cover tightening bolts Clutch side plate Gasket Secure the drive plate and remove the lock nut and gasket Drive plate ...

Страница 27: ... any grease on pulley or V belt Note 1 Drive plate screw is left threaded 2 Torque of drive plate nut 800 1000 kg cm 3 Torque of clutch side nut 50 60 kg cm 4 Torque of kick starter arm screw 100 120 kg cm 3 13Lubrication 3 13 1 Engine oil level The engine must be in cold and the scooter positioned on its stand on level ground Inspect the oil level with the dip stick on the filler cap Top up to th...

Страница 28: ...After draining the oil clean the oil level gauge check the O ring seal and fit the drain plug strainer again Tightening torque 150 kg cm Add oil to the required level through the oil level gauge Lubrication Type SAE 10W 40 Engine oil capacity Engine disassembled 900c c Oil change 750c c Replace the oil level gauge Note Run the engine after a few minutes then recheck the oil level ...

Страница 29: ...4 CHASSIS 4 1 Removal of Cover ...

Страница 30: ...eering Suspension Front Wheels Front Brakes Note 1 Lower leg shield must be removed before the front wheel is removed Raise the wheel above ground and support the scooter body firmly 2 The brake cylinder and lining should be kept free from grease during work on the front suspension Helmet Case Carrier Bottom Plate Leg Shield Lower Leg Shield Rear Lower Handlebar Cover Front Mudguard Mudguard Fixed...

Страница 31: ...e shock absorber and the outer tube joint 2 Noise coming from friction between the shock absorber spring and the outer tube 3 Noise coming from shock absorber movement due to loose mounting 4 Bent moving parts of the absorber Front wheel swing 1 Bent wheel rim 2 Insufficiently tightened bolts of front wheel axle 3 Badly fitted or damaged front wheel bearing 4 Worn tyres Inefficient braking 1 Uncle...

Страница 32: ...of the seal of the brake calliper piston 7 Deteriorated brake fluid 8 Air in the brake system 5 2 Front Wheel Place the scooter on the main stand for maintenance Disassembly Speed meter cable nut 2 tightening bolts on calliper Calliper Note Do not apply brake when removing calliper from brake disk Front wheel Inspection Check for eccentricity and wear ...

Страница 33: ... stand Rotate the wheel slowly and use dial gauge to measure eccentricity Note 1 The transverse eccentricity should be within 3 0 mm 2 The lateral eccentricity should be within 3 0mm Caution 1 Speedometer gear assembly fillister and wheel hub flange should be aligned 2 The wheel hub flange fillister and front fork flange should be fully matched ...

Страница 34: ...e of speed meter cable nut 60kg cm 5 3 Rear Wheel Place the scooter on the main stand for maintenance Disassembly 1 Exhaust pipe 2 Lock screw nut and washer 3 Rear wheel Note 1 Use vacuum to clean wheel rim and lining 2 The transverse eccentricity should be within 3 0mm 3 The lateral eccentricity should be within 3 0 mm ...

Страница 35: ...ake adjusting nut and remove brake cable Brake arm cover Brake spring Rear brake connecting rod Rear brake cam axle Assembly Assembly is in reverse order of disassembly Note Apply a thin layer of grease to the contact areas Torque of rear brake connecting rod bolt 50 80 kg cm Torque of lock pin nut 250 270 kg cm Torque of rear wheel self locking nut 600 900 kg cm 5 4 Rear Shock Absorber Place the ...

Страница 36: ...d level reach the upper limit line 3 If a battery is unused for a long time its charge will decrease A recharging is necessary around every 3 months for unused batteries 4 To charge the battery remove it from the scooter and loosen the filler plugs Do not connect or disconnect the charger terminals while power is on as sparking may ignite hydrogen gas from the battery 5 During battery charging hyd...

Страница 37: ...rectifier Excessive specific weight of electrolyte 1 Insufficient recharging 2 Leaking of electrolyte 3 Reaction between sulphuric acid and pole plates Too low capacity 1 Insufficient recharging 2 Pole plates reacting with sulphuric acid 3 Insufficient electrolyte 4 Pole plates damaged due to excessive recharging Inefficient recharging system 1 Bad contact at connectors short circuit or broken cir...

Страница 38: ...ug d Too high electric resistance of spark plug 6 1 1 Starter System Starter motor not operating 1 Damaged battery 2 Battery circuit broken bad contact or too large resistance at connections 3 Fuse blown 4 Defective ignition switch 5 Defective front and or rear brake switches 6 Defective starter motor switch 7 Defective starter motor relay 8 Defective starter motor 9 Electric cables defective or b...

Страница 39: ...dequate ventilation Note 1 Standard charging current 0 6 A for 5 10 hours 2 Quick charging current 6 0 A for 30 minutes 3 Do not use quick charge except for emergency as battery life can be shortened 4 Measure the battery voltage 30 minutes after battery is charged The battery voltage should be higher than 12 8 V 6 2 2 Rectifier Note 1 Check if wire harness is undamaged before checking rectifier a...

Страница 40: ...n stand for inspection Inspection Turn the main switch to ON position and press the starter button Note 1 If there is a snap sound then the function is normal 2 If there is no snap sound then the function is abnormal Please check 1 Starter relay ground circuit 2 Starter relay voltage ...

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