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KEEWAY Focus Maintenance Manual

Manual is about: Keeway Focus/Matrix Motorcycles Maintenance Manual

Summary of Focus

  • Page 1

    1 matenance manual model: focus/matrix copy right: keeway international development co.,ltd. Feb.2006.

  • Page 2

    2 if you have any problems can not fnd the solution in this manual, please fell free to contact with: keeway international development co.,ltd 2000 szentendre u.8 kozuzo. Hungary tel:0036-26-500005 fax:0036-26-312034 emai: info@keewaymotor.Com our engineer are very glad to give you the necessary ass...

  • Page 3: Index

    3 index the service manual has been specially prepared to provide all the necessary information for the proper maintenance and servicing of focus/matrix. The focus/matrix is a new type of scooter that has many techinal features such as: v-belt drive automatic transmission forced air-cooling system c...

  • Page 4

    4 index termly maintenance and repair 2 engine 3 fuell and lubricate system 4 electrical system 5 frame 6 maintenance information 7 general principles 1.

  • Page 5

    5.

  • Page 6

    6 general principles type identification 1-1 fuel and engine oil 1-1 break-in procedure 1-1 precautions and general instructions 1-2 maintenance tools 1-3 specifications 1-4 contents.

  • Page 7: 1-1 General Principles

    7 1-1 general principles type identification ① ① ① ① engine number engine number① is carved on rear crankcase as shown in figure. Both frame nuber and engine number are designed specially for registering your scooter and ordering spare parts. Fuel and engine oil be sure to use specified fuel and eng...

  • Page 8: 1-2 General Principles

    8 1-2 general principles precautions and general instructions correctly abide by the following items when disassembling and assembling scooter: □ don’t run engine indoors with little or no ventilation; □ be sure to replace new bushings, circlips, o-rings and cotter pins with new ones； caution it is ...

  • Page 9: 1-3 General Principles

    9 1-3 general principles specifications dimension and net weight overall length…… 1830mm overall length……… 695mm overall height……… 1160 mm wheelbase……………… 1295mm net weight……………… 92kg chassis front shock absorber……spring, without damp rear shock absorber……spring, oil damp turning angle … … … … … 48 ...

  • Page 10

    10 termly maintenance and repair content periodic maintenance and service schedule……………………… 2-1 maintenance and service procedures…………………………… 2-2 storage battery………………………………………………… 2-2 spark plug………………………………………………………… 2-3 cylinder head nut and exhaust pipe bolt……………………… 2-3 cylinder head and cylinde...

  • Page 11

    11 periodic maintenance and service schedule the following table lists all required intervals for maintenance and service，following which, you are assred to have your scooter perform in the best way. Note do more frequent maintenance when often riding on bad road periodic maintenance table mile 600 ...

  • Page 12

    12 maintenance and adjustment procedures the section describes the servicing procedures for each item of the periodic maintenance requirements. Storage battery inspect at initially 1000km（600 miles，2 months） ， andevery 6000km（4000 miles，12 months）thereafter □ uncover seat, and then remove the batter...

  • Page 13

    13 cylinder head nuts and exhaust pipe bolts tighten at initially 1000 km（600 miles，2 moths） ，and every 6000 km（4000 miles，12 months） if cylinder head nuts are not tightened to the specified torque, may result in leakage of compressed fuel-air mixture and reduce output, tighten the cylinder head nut...

  • Page 14

    14 spark plug neglecting the spark plug maintenance eventually leads to difficult starting and poor performance. If the spark plug is used for a long time, the electrode gradually burns away and carbon builds up along the inside part. In accordance with the periodic table, the plug should be removed...

  • Page 15

    15 air cleaner clean every 3000km（2000 miles） ① ① ① ① if the air cleaner is clogged with dust, intake resistance will， be increased with a resultant decrease in power output and an increase in fuel consumption. Check and clean the element in the following manner. ③ ③ ③ ③ remove clamp ① and screw ②，t...

  • Page 16

    16 connect an electric tachometer to the connecting protiion of the magneto lead wire as shown i nthe illustration. Use the selector key “c’ position. Tachometer adjust the throttle stop screw to obtain the idle r/min as follows: idle speed：1400±100r/min finally adjust the throttle cable play. Oil p...

  • Page 17

    17 gear oil inspect at initially 1000 km（ （ （ （600 miles， ， ， ，2 months） ） ） ）and every 6000 km（ （ （ （4000 miles， ， ， ，12 months） ） ） ）thereafter. Inspect gear oil periodically as follows: remove the cover and hose remove the kicking starter lever remove clutch cover remove oil level bolt and inspec...

  • Page 18

    18 warning： ： ： ： brake fluid, if it leaks, will interfere with safe running and immediately discolor painted surfaces. Check the brake hoses for cracks and hose joints for leakage before riding. Brake pads wearing condition of brake pads can be checked by observing the limit line ① marked on the pa...

  • Page 19

    19 note： ： ： ：when bleeding the brakign system, replenish the brake fluid reservoir if necessary. Make sure that there is always some fluid visible in the reservoir. Close the bleeder vavle, disconnect the pipe. Fill the reservoir with brake fluid to the upper end of the inspection window. Bleeder v...

  • Page 20

    20 tire inspect at initially 1000km（600 miles，2 months） and every 6000km（4000 miles，12 months）thereafter tire pressure： if the pressure is too high, the scooter will tend to rede stiffly and have poor traction. Conversely, if tire pressure is too low, stability will be adversely affected. Thereafter...

  • Page 21

    21 front shock absorber adjust at initially 1000km（600 miles，2 months）and every 6000 km（4000 miles，12 months）thereafter. Inspect the front shock absorber for oil leakage or other damage, and replace the defective parts, if necessary. Rear shock absorber adjust at initially 1000km（600 miles，2 months）...

  • Page 22

    22 ③ ③ ③ ③ ① ① ① ① ② ② ② ② ④ ④ ④ ④ ⑤ ⑤ ⑤ ⑤ ⑥ ⑥ ⑥ ⑥ ⑦ ⑦ ⑦ ⑦ ⑧ ⑧ ⑧ ⑧ ⑨ ⑨ ⑨ ⑨ ⑩ ⑩ ⑩ ⑩ 14.

  • Page 23

    23 lubrication proper lubrication is important for smooth operation and long life of each working part of the scooter. The major lubrication points are indicated below： note： 1. Lubricate exposed parts which aare subject to ruse with engine oil. 2. Before lubricating each part, clean off any rusty s...

  • Page 24: Engine

    24 engine contens engine components removal with the engine in place engine removal and remounting engine removal engine remounting engine disassembly engine components inspection and servicing bearings oil seals crankshaft automatic clutch inspection cylinder head cylinder piston reed valve engine ...

  • Page 25: Engine Left Side

    25 engine components removable with the engine in place the parts listed below can be removed and reinstalled without removing the engine from the frame. Engine left side kicking starter lever clutch brake pad kit driver left face v-belt driver belt right face electric starter gear super clutch driv...

  • Page 26

    26 engine assy. Remove the muffler remove cooling fan cover remove cylinder cover remove cooling fan remove magneto nut with special tools. Remove magneto rotor and half circle key with special tools. Remove magneto stator and paper gasket remove oil pump.

  • Page 27

    27 remove worm wheel and oil seal press board remove cylinder head and cylinder place a cloth stopper beneath the piston and remove the circlip with a plier. Remove the piston pin and piston. Remove the kick starter lever. Remove side cover remove movable ratchet wheel and clip.

  • Page 28

    28 remove starting driven ratchet wheel by removing the nuts. Rmove fan⑤ and v-belt⑥. Disassemble the movable drive face⑦. Remove electric gear press board, electric gear and super clutch remove starter motor.

  • Page 29

    29 remove the clutch housing with the special tool. Drain gear oil remove rear axle nut remove rear wheel remove brake shoe⑤ and rear axle⑥。 remove the rear brake cam lever①，indicator plate② and camshaft③..

  • Page 30

    30 remove spring④ remove cotter pin⑤ and shaft⑥ remove main stand⑦ remove gearcase cover remove paper gasket① and middle gear assy.②, remove output gear assy.③ remove carburetor remove intake pipe remove reed valve and paper gasket..

  • Page 31: Sliding Shaft

    31 remove crankcase fixing shaft disassemble crankcase with special tools remove crankcase with special tools remove crankshaft bearing with special tools sliding shaft warning： ： ： ：use a new sliding shaft..

  • Page 32

    32 unscrew clutch shoe nut with special tools. Remove the nut while holding down clutch shoe assy. By both hands as shown in the illustration. Warning：gradually back off the clutch shoe assy. Pressed down by hands to counter the clutch sparing load. Releasing the hand suddenly may cause the followin...

  • Page 33: Remove Circlip

    33 remove circlip remove bearing with special tool. Caution：replace the removed bearing with a new one. Remove bearing with special tool. Caution： ： ： ：replace the removed bearing with a new one. Remove the spacer remove the oil seal from the gearcase cover with the speical tool. Caution： ： ： ：repla...

  • Page 34: Warning：

    34 remove gearcase cover bearing with special tool remove left crankcase oil seal do it with special tool warning： ： ： ：use a new oil seal remove left crankcase bearing with special tool warning： ： ： ：use a new one remove left crankcase shock absorber bushing with special tool warning： ： ： ：use a ne...

  • Page 35: Warning：

    35 remove right crankcase oil seal with special tool warning： ： ： ：use a new oil seal remove right crankcase bearing sliding bearing warning： ： ： ：use a new bearing.

  • Page 36

    36 engine components inspection and servicing bearings clear bears with solvent and lubricate with engine oil before inspecting. Turn the inner ring and check to see that the inner rieng turns smoothly. If it does not turn lightly, quietly and smoothly, or if noise is heard, the bearing is defective...

  • Page 37

    37 oil seal damage to the lip of the oil seal may result in leakage of the fuel-air mixture or oil. Inspect for damage and be sure to replace the damaged seal if found. Crankshaft crankshaft runout support crankshaft by“v” block, with the dial gauge rigged to read the runout as shown. Service limit：...

  • Page 38

    38 and centrifugal mechanism located in the clutch. To insure proper performance and long lifespan of the clutch, it is essentiall that the clutch engages smoothly and gradually. Two inspection checks must be performed to thoroughly check the operation of the drivetrain. Follow the procedures listed...

  • Page 39

    39 if the engine r/min doesn’t coincide with the specified r/min range, then disassemble the clutch. Clutch shoe---inspect the shoes visually for chips, cracking, uneven wear and burning, and check the thickness of the shoes with vernier calipers. If the thickness is less than the following service ...

  • Page 40

    40 roller and sliding surface inspect each roller and sliding surface for wear or damage. Driving face spring measure the free distance of the driven face spring. If the length is shoter than the service limit, replace the spring with a new one. Service limit: 104.5mm(4.11in) driven face pin and oil...

  • Page 41

    41 if the largest reading at any portion of the staightedge excees the limit, rework the surface by rubbing it against emery paper laid flat on the surface plate in a lapping manner. The surface must ge smooth and perfectly falt in order to secure a tight join: a leaky joint can be the cause of redu...

  • Page 42

    42 be taken in the intake-to-exhaust port direction and at 20mm from the cylinder top surface. Unit：mm standard service limit cylinder 40.005-40.020 40.075 piston 39.94-39.955 39.885 cylinder to piston 0.06-0.07 0.120 decarboning decarbon the piston and piston ring grooves, as illustration. After cl...

  • Page 43

    43 with a new one. The end gap of each ring is to be measued with the ring fitted squarely into the cylidner bore and held at the least worn part near the cylidner bottom, as shown in the illustration. Service limit：0.75mm(0.030in) as the piston ring wears, its end gap increases reducing reducing en...

  • Page 44

    44 engine reassembly reassembly is generally performed in the reverse order of disassembly, but there are a number of reassembling steps that demand or deserve detailed explanation or emphasis. These steps will be taken up for respective parts and components. Oil seals fit the oil seals to the crank...

  • Page 45

    45 shock absorber bushing positon install shock absorber bushing install crankshaft bearing press bearing into cankshaft install crankshaft.

  • Page 46

    46 decide th length between the webs referring to the figure at righ when rebuilding the crankshaft. Standard width between webs:： ： ： ：38±0.1mm(1.496±0.004in) when mounting the crankshaft into crankcase, it is necessaryto pull its left end into the crankcase with the special tool. Caution: never fi...

  • Page 47

    47 crankcase wipe the crankcase mating surfaces with clraning solvent. Apply qianjiang no.1215 evenly to the mating surface of the right half of the crankcase tighten the crankcase screws securely. Check if crankshaft rotates smoothly. Install gearcase bearing install new bearing and oil seal into g...

  • Page 48

    48 install output axle gearshift install middle gear, position pin by installing middle gear axle①, gasket② and thrust gasket③ install gearcase cover into crankcase and lock bolt. Tighten each screw screw oil drain nut○ 11 tightening torque： ： ： ：4-7 n.M (0.4-0.7kg-m,3.0-5.0 ib-ft).

  • Page 49

    49 install the bearing② in the fixed driven face① with the special tool. Install sliding bearing ③。.

  • Page 50

    50 install the bearing ① with special tool install the spacer ② and circlip③. Install the new oil seals④ and ⑤ to the movable driven face with the special tool. Apply grease to the lip of oil seals and groove of inside of movable driven face. Qianjiang special super grease note: when reinstalling th...

  • Page 51

    51 install the movable driven face seat①. Install the clutch shoe assembly② and nut ③. Tighten the nut③ to the specified torque with the special tool. Tightening torque： ： ： ：40-60 n.M (4.0-6.0kg.M 29.0-43.5ib-ft) insert the v-belt between the driven faces as deep inside possible while pulling the m...

  • Page 52

    52 apply grease to all the sliding and rolling surfaces for six roller weights. For each weight, approximately 1.5g of grease should be used. Qianjiang supre grease mount the three dampers ① on the movable drive plate② and install it on the movable drive face. Position the o-ring on the movable driv...

  • Page 53

    53 insert the spacer④ position the movable drive face subassembly on the crankshaft as shown in illustration. Note ： ： ： ： thoroughly clean the belt contact to be free from oil. Install the fixed drive fan①. Tighten the nut to the specified torque with special tool. Connecting rod fixer tightening t...

  • Page 54: Starter Assy.

    54 fill the final gear box with engine oil up to the level hole. Oil capacity： 90ml tighten the oil level bolt to the specified torque. Tightening torque：9-15m.M starter assy. Inject lubrication into start bearing and lubrication in the end of starter shaft qianjiang special lubrication tighten star...

  • Page 55

    55 install the dowel pins① install the new gaskets(② and ③) apply qianjiang bond no. 1215 to the clutch cover as shown in the illustration. Qianjiang bond no. 1215 note: install the kick starter lever as shown in the illustration. Tightening toque： ： ： ：8-12n.M (0.8-1.2kg-m, 6.0-8.5ib-ft) piston ins...

  • Page 56: Oil Pump

    56 apply oil for the piston and install the piston to the connecting rod. Note ： ： ： ： the arrow mark ① on the piston head should point the exhaust side. The circlip should be mounted in such a position that the mating ends of the circlip do not coincide with the grovve portion of the piston. Apply ...

  • Page 57: Reed Valve

    57 reed valve install reed valve paper gasket. Install reed valve install oil hose instake pipe install intake pipe magneto clear crankshaft and magneto rotor install half circle key install paper gasket and stator coil, and then fix them tighten to specified torque with special tool specified torqu...

  • Page 58

    58 install cooling fan install guiding cover install fan guiding cover install pipe screw ① and screw for tightening muffler to their specified torque. ①：8-12n.M(0.8-1.2kg.M,6.0-8.5ib-ft) ②：18-28n.M(1.8-2.8kg.M,13.0-20.0ib-ft) lubricate brake cam shaft with qijiang special grease..

  • Page 59

    59 chapter 4 fuel and lubrication system contents fuel switch carburetor oil pump.

  • Page 60: Fuel Switch

    60 fuel switch when the engine has started, a negative pressure(vacuum) is generated at the intake port. The negative pressure acts upon the diaphragm of the fuel switch and ti pressed down the spring which supports the diaphragm so that the fuel passageway is opened and fuel is fed to the carbureto...

  • Page 61

    61 carburetor carburetor carburetor manufacturer/type identification code throat tube diameter main jet size idle needle jet size oil needle clamp position idle air adjusting screw float height qianjiang-wenling-china，equal vacuum pz19jb 19mm #80 #57.5 3 rd groove extrude 1 2 1 ± 2 1 turnout 13±1mm.

  • Page 62

    62 carburetion proper carburetion is determined according to the results of various tests, mainly concerning engine poer, fuel consumption and cooling effect of feul on engine, and jet settings ard made so as to satisfy and balance all of these conditions. Therefore, the jet should not be replaced w...

  • Page 63

    63 chapter 5 electrical system contens ignition system charging and lighting system starter system fuel gauge oil level check light and turn signal indicator switchs bartery.

  • Page 64

    64 ignition system the ignition system consists of a flywheel magneto, a cdi&ignition coil unit and a spark plug. ①as the rotor tatates, an ac current is induced in the coil. Then current induced in the ○ a direction charges up the capacitor. ②as the rotor rotates further, the current is induced in ...

  • Page 65

    65 ● ● ● ●note the spark in the spark gap window. It should be strong and continuous, not intermittent, acrossa preset 8mm(0.32in) gap. Allow the spark to jump the test gap for at least five minutes continuously. To insure proper operation under the temperature of actual riding. Electronic tester ig...

  • Page 66

    66 charging and lighting system the charging system uses the flywheel magnetoas shown in the figure. The charging and lighting coils are mounted on the magneto stator and generate ac as the flywheel rotor turns. Ac generated in the charging coil flows to the regulator/recifier which changes ac to dc...

  • Page 67

    67 no-load performance disconnect the magneto lead wire coupler. Start the engine and keep it running at 5000r/min. Using a pocket tester, measure the ac voltage between the white and red tracer lead wire and ground. If the tester reading is as follows, magneto is in good condition. Standard no-load...

  • Page 68

    68 starter system description the starter system is shown in the diagram below: namely, the starter motor, relay, starter switch and battery. Depressing the starter button while squeezing the front or rear brake lever energizes the relay, causing the contact points to close which connects the starte...

  • Page 69: Starter Relay Inspection

    69 starter motor inspecition carbon brushes when the brushes are worn, the motor will be unable to produce sufficient torque, and the engine will 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 l...

  • Page 70

    70 fuel level meter/gauge fuel meter inspection to test the fuel meter two different checks may be used. The first,and simplest test will tell if the mete is operating but will not indicate the meters accuracy throughout the range.To perform the test,lift the seat and remove the right frame cover,th...

  • Page 71

    71 signal system signal system signal system signal system the same bulb is used tor both oil level check light and turn signal indicator light.The circuitry is shown below.When the oil level has fallen to a certain level (the remaining amount of oil has become approximately 160 ml,the oil level che...

  • Page 72

    72 switch switch switch switch 转向开关 绿/白 关 机油开关 红/白 开 棕/白 左转 右转 橙 绿/黑 黄 近光 远光 变光开关 黄/红 蓝 浅蓝 灯控开关 黄/红 大灯 会车灯 关 绿/红 黄 粉红 墨绿 喇叭开关 关 开 绿/黄 启动开关 开 关 红/白 关 开 刹车开关 红/白 红 开 锁定 关 电源锁 红/白 紫 棕 紫 黑.

  • Page 73

    73 b bb battery attery attery attery specifications specifications specifications specifications type designation yb4l-b capacity 12v 4ah standard electrolyte 1.28(20℃) initial charging initial charging initial charging initial charging fillng electrolyte ·remove the aluminum tape ① sealing the batt...

  • Page 74

    74 rechargeing operation rechargeing operation rechargeing operation rechargeing operation ·apply multimeter to measure the voltage of battery. If the reading is below 12.0v，it should be recharged. Note: when recharging, remove the battery form the vehicle. Note: when recharging, don’t remove the se...

  • Page 75: Chapter 6    Chassis

    75 chapter 6 chassis contents leg shield and frame side covers· · ·· ·· ·· ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · leg shield removal· ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ·· ·· · ·· ·· ·· ·· leg shield remounting· ··· ·· ·· ·· ·· ·...

  • Page 76

    76 side cover removal 1. Remove seat and helmet barrel by opening seat and loosing tightening screw①. 2. Loose hexad screw③ and remove decorating cap②,rear carrier and oil tank lock④，remove side cover ⑥ by loosing side cover screw⑤⑦； 3. Unlock oil pump cap and remove it, two tapping screw are expose...

  • Page 77: Under Cover Removal

    77 under cover removal 1. Unscrew screw② and bolt① 2. Removing under cover by loosing the left and right tapping screws④； . Under cover installation 3．the sequence if installation is ther reverse of removal. . Front cover removal 1．unscrew tapping screw①, and remove front cover③ by removing front co...

  • Page 78

    78 legshield and pedal removal 1. Remove power lock housing ② by unscrewing bolt①. 3. Remove legshield and pedal by unscrewing the four bolts③ legshield and pedal installation 4. The sequence of legshield and pedal is the reverse of reomval； ② ③ ①.

  • Page 79

    79 handle cover removal 1． remove front handle cover ② by unscrewing the six tapping screws① 2. Remove master cylinder by removing the bolt③; ① ③ ① ① ① ① ① ① ① ②.

  • Page 80

    80 3．disconnect throttle cable③ and oil pump cable④ 4．remove rear brake cable adjusting nut⑤ ① ③ ① ④ ① ⑤.

  • Page 81

    81 handle cover removal 5. Remove all cables； 6．remove handle cover by unscrewing bolt⑥ handle cover unstallation 7. The sequence of removal is the reverse of reomval ⑥.

  • Page 82: Front Wheel

    82 front wheel 1. Front rim 2. Middle bushing 3. Oil seal 4. Roller bearing gb6201-2rs 5. Tire 6. Valve mouth 7. Nut gb6817 8. Front shaft 9. Front wheel left bushing 10. Gearcase 11. Valve mouth cap remove ·remove the front brake caliper① by removing the mounting bolts. Note：do not operate the fron...

  • Page 83

    83 inspection and disassembly wheel bearing inspect the play of bearing inner ring by hand while mounted in the wheel. Rotate the inner ring by hand to inspect if any abnormal noise occurs or rotating smoothly, replace the bearing if there is anything ucusual. ·remove the dust seal. Caution: the rem...

  • Page 84

    84 reassembly and remounting reassemble and remount this front wheel in the reverse order of removal, and also carry out the following steps: ．install this wheel bearing with the special tools as shown in this illustration. Caution: install this wheel bearing for left side.. Install the brake disc a...

  • Page 85: Front Brake System

    85 front brake system brake pad replacement remove the calliper by removing the mounting bolts ① . Note: do not operate the front brake lever while dismounting the calliper. 1. Disc brake assy. 2. Disc brake handle lever 3. Tightening bolt 4. Nut m6 5. Master cylinder 6. Tightening seat 7. Bolt m6x2...

  • Page 86

    86 ·remove the brake pads. Caution: replace the brake pads as a set,otherwise braking performance will be adversely affected. Reassemble and remount the calliper. Caliper removal and disassembly remove the brake hose and catch the brake fluid in a suitable receptacle. Caution: nevere re-use the brak...

  • Page 87

    87 caliper and disc inspection inspect the calipe cylinder bore wall or micks,scratches or other damage. Inspect piston for damage and wear. Inspect each rubber part for damage and wear. Check the disc for wear with a micrometer.Its thickness can be checked with disc and wheel in place. Ralpace the ...

  • Page 88

    88 brake caliper reassembly reassemble and remount the calliper in the reverse order of removal and disassembly, and also carry out the following steps. Caution: wash the calliper components with fresh brake fluid before reasse- mbly. Never use cleaning solvent or gasoline to wash them.Apply b- rake...

  • Page 89

    89 remove the brake lever and brake switch. Remove the dust boot. Remove the circlip with the special tool. Remove the piston/primary cup with return spring. Remove the reservoir cap and diaphragn. Drain brake fluid. Master cylinder inspection inspect the master cylinder bore for any scratches or ot...

  • Page 90

    90 inspect the piston surface for scratches or other damage. Inspect the primary cup and dust boot for wear or damage. Master cylinder reassembly and ermounting reassemble and remount the master cylinder in the reverse order of removal and disassembly,and also carry out the following steps. Caution:...

  • Page 91

    91 steering stem and front suspension removal and disassembly （refer to preceding page） □ remove the handle cover（refer to preceding page） □ remove under decorating cover（refer to the preceding page） □ remove legshield（refer to preceding page） □ remove front wheel（refer to preceding page） □ disconne...

  • Page 92

    92 □ remove disc brake system by unscrewing tightening bolt. □ remove handle by removing tightening bolt □ unscrew locknut with special tool □ remove fornt fork assy. By removing upper outer steel bowl note: not drop the steering stem balls. □ remove front fork □ remove bearing lower race by chisel....

  • Page 93

    93 inspection □ inspect the removed parts for the following abnormalities. Bearing race wear and brinelling. Worn and damaged steel balls distortion of steering stem or handlebar. □ inspect the suspension for damage.

  • Page 94: Reassembly And Remounting

    94 reassembly and remounting reassemble and remount the steering stem, handlebar and front fork in the reverse order of disassembly andremoval, and also carry out the following steps. Install the right left suspension arms. Steel ball apply grease when installing the upper and lower steel balls. Qty...

  • Page 95: ①  And Bolt

    95 install handlebar and tighten the screw① ① ① ① and bolt to the specified torque：37-44n.M ① note: after performing the adjustment and installing the handlebar, rock the front wheel forward and backward to ensure that there is not play and that the procuder is accomplished correctly. If play is not...

  • Page 96

    96 rear wheel and brake 1. Tire 130/70-12 2.Rear rim assy. 3. Brake pad kit assy. 4.Brake pad kit spring 5. Rear brake tension 6. Rear indicator 7. Anti-dust cover 8. Rear brake camshaft 9. Bolt m6Χ30 10.Valve 11.Nut m16Χ1.5 12. Rear brake arm 13. Valve cap.

  • Page 97

    97 remove □ place the scooter on level ground. □ remove muffler. □ remove rear small fender. □ remove locknut and rear wheel. □ remove brake shoes. Inspection rear rim measure inner diameter of rear rim hub with micrometer, if measured diameter exceeds 110.7, replace it with a new one. Brake shoes c...

  • Page 98

    98 reassembly and remounting reassemble and remount the rear wheel and brake in the reverse of removal, and also carry out the following steps: □ turn the punched mark① on the camshaft to the rear axle shaft side. □ install the protrusion ② of indicator plate to the groove ③ of camshaft. □ when inst...

  • Page 99

    99 servicing inforamtion troubleshooting batteru vehicle wiringd diagram wire, cable and brake hose routing special tools thread parts tightening torque service data contents.

  • Page 100

    100 troubleshooting engine complaint symptom and possible causes remedy engine does not start, or is hard to start. Compression too low 1. Excessively worn cylinder or piston rings. 2. Stiff piston ring in place. 3. Gas leaks from the joint in crankcase, cylinder or cylinder head. 4. Damaged reed va...

  • Page 101

    101 complaint symptom and possible causes remedy engine runs poorly in high-speed range. 1. Excessively worn cylinder or piston rings. 2. Stiff piston ring in place. 3. Spark plug gaps to narrow. 4. Ignition not advanced sufficiently due to poorly working cdi & ignition coil unit. 5. Defective magne...

  • Page 102

    102 complaint symptom and possible causes remedy medium- or high-speed trouble. 1. Main jet or main air jet is clogged. 2. Needle 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 repla...

  • Page 103

    103 starter button is not effective. 1. Battery run down. 2. Defective switch contacts. 3. Brushes not seating properly on commutator in starter motor. 4. Defective starter relay. 5. Defective starter pinion gears 6. Defective front or rear brake light switch circuit. Recharge and replace. Replace. ...

  • Page 104

    104 noisy front suspension. 1. Not enough grease. 2. Loose nuts on suspension. Refill. Retighten. Wobbly rear wheel. 1. Distorted wheel rim. 2. Defective or incorrect tire. 3. Loose nuts on the rear shock absorber. 4. Worn engine mounting bushing. 5. Loose nuts or bolts for engine mounting. Replace....

  • Page 105

    105 wiring diagram 电 子 钟 转 向 指 示 灯 远 光 指 示 灯 机 油 报 警 指 示 灯 电 源 锁 冷 光 源 刹 车 开 关 闪 光 蜂 鸣 器 蓄 电 池 启 动 继 电 器 整 流 /稳 压 器 电 子 点 火 器 点 火 线 圈 火 花 塞 dg 熄 火 开 关 防 盗 器 防 盗 器 喇 叭 m 油 量 表 前 右 转 向 灯 前 照 灯 夜 小 灯 前 左 转 向 灯 后 刹 车 开 关 灯 控 开 关 变 光 开 关 喇 叭 开 关 启 动 电 机 启 动 开 关 喇 叭 磁 电 机 转 向 开 关 机 油 开 关 油 位 传 感 器 后 右 转 向...

  • Page 106

    106 wire, cable and brake hose routing.

  • Page 107

    107 carburetor.

  • Page 108

    108.

  • Page 109

    109 ignition coil starting relay cdi horn power switchh.

  • Page 110

    110 special tools listed below for removal and reinstallation no. Tool number description 1 2 3 4 5 6 7 8 9 10 t01 t02 t03 t04 t05 t07 t08 t09 t10 “t”shape of sleeve sleeve tools（7mm,8mm,10mm,12mm,13mm） flywheel remover sleeve (18mm,24mm) screw remover cylinder pressure gauge piston pin remover spar...

  • Page 111

    111 ④ ⑤ ⑥ ⑦ ⑧ ⑨ ⑩.

  • Page 112

    112 tightenting torque o f screw thread parts engine item 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 ...

  • Page 113

    113 service data cylinder+piston+piston ring unit：mm(in) item standard tolerance piston to cylinder clearance 0.06-0.07 (0.0024-0.0028) 0.120 (0.0047) cylinder bore 40.005-40.020 (1.5750-1.5756) 40.075 (1.5778) cylinder diameter 39.94-39.955 (1.5724-1.5746) 39.885 (1.5703) cylinder distortion 0.04 (...

  • Page 114: Unit: Mm(In)

    114 clutch unit: mm(in) item standard limit clutch wheel inner diameter 112.00-112.15(4.410-4.415) 112.5(4.429) clutch shoe thickness 1.8(0.071) 1.2(0.005) clutch engagement 3000±300r/min clutch closedown 6000±300r/min transmission system+driving chain unit：mm(in) except ratio item standard toleranc...

  • Page 115

    115 wattage item 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 b...