SERVICE MANUAL

RT-50

January 2008
High power Engine
HER CHEE INDUSTRLAL CO., LTD.
 INTRODUCTION
This Service Manual is provided as the technical information
for the check & preparation of ADLY RT-50 scooter, and the
direction edited is given in diagrams with "Operation Sequence",
"Key Points", and "Adjustment of Check" for reference of the
service staffs.

This Service Manual is finished in accordance with the model

of RT-50. Taking new model as standard if there are differences
between the models described in this manual and the actual
scooter.

HER CHEE INDUSTRIAL CO., LTD.

 CONTENTS

Chapter 01 Chapter 1 INFORMATION FOR PREPARATION………… 1

Chapter 02 CHECK AND ADJUST………………………………………….

Chapter 03 ENGINE REMOVAL…………………………………………….

Chapter 04 CYLINDER HEAD / CYLINDER / PISTON…………………..

Chapter 05 CRANK CASE & CRANK SHAFT…………………………….

Chapter 06 Transmission……………………………………………………

Chapter 07 Final Transmission Mechanism……………………………..

Chapter 08 Fuel System……………………………………………….........

Chapter 09 Front Wheel / Front Suspension / Front Brake……………

Chapter 10 Rear Wheel / Suspension / Brake……………………………

Chapter 11 Electrical Device………………………………………………..

Chapter 1 Information for Preparation
Attention on Operation
z All washers, oil rings, clamp rings, opening pins shall be duly replaced by a new
item when dismounted.

z 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.

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 lubricated.

Chapter 1 Information for Preparation

Attention on Operation

z Certified lubricants in cans shall be used on all the elements to be lubricated.

z After assembly, performance of all elements shall be duly checked and the
locking shall be duly verified.

z In case of an operation is 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: Replace by new items after dismounting

Attention

Dangerous and important operations

Chapter 1 Information for Preparation
 SPECIFICATION

TYPE RT 50
LENGTH 1585mm
WIDTH 700 mm
HEIGHT 960 mm
WHEEL BASE 1070 mm
NET WEIGHT
ENGINE TYPE 2-STROKE, Single Cylinder
COOLING AIR COOLED
DISPLACEMENT 49.26 C.C.
BORE×STROKE 40.0×39.2
COMPRESSION RATIO 7.2:1
IGNITION C.D.I
STARTER ELECTRIC / KICK
SUSPENSION Hydraulic Shock Absorber
TRANSMISSION AUTOMATIC
TIRE Front 120/90-10 (Option
FRONT/REAR Rear 120/90-10 (Option
FRONT BRAKE Disc
REAR BRAKE Drum

Chapter 1 Information for Preparation

LOCKING TORQUE

Adopt the standard torque locking for the item unlisted.

STANDARD TORQUE：
Type Locking Torque (kg-m)
5 mm Screw 0.4
6 mm Screw 1.0
6 mm Hex Washer Face Bolt / Nut 1.2
8 mm Hex Washer Face Bolt / Nut 2.7
10 mm Hex Washer Face Bolt / Nut 4.0

CHASSIS：
Locking Place Quantity Dia. (mm) Locking Torque (kg-m)
Spanner Nut of Handle Steering 1 25 7.0
Steam
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-check Screw 1 8 1.3
Joint Screw of Exhaust Manifold 2 6 1.2
Exhaust Pipe Support Screw of 2 6 1.2
Muffler
Spark Plug 1 14 1.4
Bolt of Crank Shaft Case 6 6 10
Bolt of Engine Installation 1 8 5.0

Chapter 1 Information for Preparation

 The following drawing that shows the disassembling situation of the cover parts for
RT50 scooter.

Chapter 1 Information for Preparation

INFORMATION FOR PREPARATION
REVOLUTION NOT STABLE (LOW R.P.M.)

Diagnose Check and Adjust Reason of Trouble

ignition timing adjusting

normal C.D.I damage

abnormal
pulser coil damage

adjust the carburetor fuel

adjuste screw

mixture gases too lean

adjusting isn't (loosing screw)
adjusting is correct
correct mixture gases too rich
(locking screw)

carburetor sucking air

gasket damage
the screw of carburetor is
no sucking air sucking air loosen
(-) pressure tube broken
loosen spark plug,
connecct with spark cap
and contract with frame,
check the spark plug spark damage or stain
sparking ? C.D.I damage
A.C.G damage
sparking normal sparking abnormal coil damage
spark plug cable damage odr short
main switch damage
check A.C.G

A.C.G damage
normal abnormal air hole damage or blocking
(-) pressure tube damage

end
Chapter 1 Information for Preparation
INFORMATION FOR PREPARATION
REVOLUTION NOT SMOOTH(HIGH SPEED)

Diagnose Check and Adjust Reason of Trouble

adjusting ignite timeing

C.D.I damage
normal abnormal
ACG pulse coil damage

adjusting valve gap

adjusting isn't correct

normal abnormal valve set damage

check fuel cup supply

normal ? fule filter blocking
air hole of fuel tank blocking
fuel cup damage
fuel of tank is too less
normal abnormal

carburetor blocking

cleaning

no blocking blocking

check and adjust valve

timing

valve timing is valve timing isn't camshaft gear mark position is not
correct correct correct

check the spring of valve

spring broken or
normal spring damage
elastic deformation

end
Chapter 1 Information for Preparation

INFORMATION FOR PREPARATION

CHARGE ABNORMAL

Diagnose Check and Adjust Reason of Trouble

start engine and measure
voltage of the two
terminal for battery

voltage of battery voltage of battery

can't go up is normal
battery damage

measure the resistance of

ACG coil

coil damage
measure value
normal
too high
terminal damage
YL wire damage

check the regulator

battery have not

battery have voltage R wire damage
voltage

check socket of regulator

loosen ?

regulator damage
normal abnormal
socket damage

ACG damage
(over charge)
check the voltage between
regulator and frame
main switch at ON main switch at ON
the battery have the battery have no GR wire broken
voltage voltage

check the socket of

regulator

normal socket loosen socket damage

regulator damage
Chapter 1 Information for Preparation
INFORMATION FOR PREPARATION
SPARK PLUG NO SPARKING

Diagnose Check and Adjust Reason of Trouble

change spark plug and

check again

no sparking or
sparking strong the previous spark plug damage
weak

check spark plug, cap,

ignition coil loosen?

loosen no loosen spark plug cap loosen

check C.D.I unit socket

loosen ?

normal abnormal socket damage

check the terminal of

C.D.I unit unimpeded?
measure resistance

normal abnormal

check relate spare parts

main switch damage
pulser coil damage
normal abnormal coil damage
lighten coil damage

main switch damage

socket, joint connect abnormal

change CDI unit

normal abnormal the previous C.D.I unit damage

change ignition coil

abnormal the previous coil damage

Chapter 2 Check and Adjust
Way of Check & Adjustment
1. Mark “○” is checking time.
2. Mark “☆” is the regular exchange of service items.
This exchange time is just for general riding of the majority not for the special use,
please arrange with this principle according to the difference of the riding condition.

Service Time (month)

Service Items Judgment Remarks
Before
1st each 6 each 12 Standard
riding
Operating Device
Handle- Play, loose/tight ○
Operation ○
Wheels- Right/left turn ○
round angle
Front Fork-Damage ○ ○ Direction Post
Installation of shaft ○ ○ Direction Post
Shaft Gap ○
Brake Device
Brake- Play ○ ○
Try to run ○ ○ ○ Play of brake
Correct brake ○ ○ ○ ○ lever 10-20 mm
Wires- Loose / tight and ○ ○ ○
damage
Gap of casing & brake ○ ○
Wore of brake & operating ○ Direction
parts
Wore & Damage of casing Standard diameter 110 mm
○ Limitation 110.5mm
Riding Device front rear

Tires-Air pressure of tires ○ ○ ○ Air 1.50 kg/cm2 1.75 kg/cm2

pressur
e
tire 120/90-10 130/90-10

Chapter 2 Check and Adjust

2-1
 Service Time (month)
Service Items Before
Judgement Standard Remarks
1st each 6 each 12
riding
Riding Device
Tires Ditch-front and rear
Check & damage of tires ○ ○ ○ wheel till 0.8 mm
Abnormal & ditch in tires ○ ○ ○
Bolt & nut of tires locking ○ ○ Flocking torsion
Front wheel – 4.0~5.0
kg-m
Rear wheel –10~12
kg-m
Damage of wheels ,disc ○ ○ ○ Vibration of wheel
Front wheel – horizontal
under 3 mm, vertical
under 3 mm,
Rear wheel – horizontal
under 3 mm, vertical
under 3 mm
Tightness of front bearing ○
Tightness of rear bearing ○
Suspension device
Spring -damage ○ Spring of
shock
absorber
Suspension arm – damage ○
of joint gap
& arm
Tightness of installation ○
Power transmission device
Clutch -action ○ ○ ○
Crankcase oil leakage or ○
damage
Transmission gear oil ○ ○
Electric device
Ignition device -condition ○ ○ Gap of spark plug
of ignition 0.6~0.7 mm
spark plug
Battery -connection of ○
terminal
Wiring of electrical ○
appliance – damage or
loose in connection place

Chapter 2 Check and Adjust

2-2
 Service Time (month)
Service Items Before
Judgement Standard Remarks
1st each 6 each 12
riding
Engine
Body – starting & abnormal ○ ○
noise Idle : 1800±100 rpm
low speed & accelerating ○ ○ ○
exhaust ○ ○
air filter ○ ○
Lubrication device
Oil and oil filter ○ ○ Warning light lighting
Oil leakage ○ ○
Fuel installation
Gasoline filter is dirty ○
Leakage of fuel ○ ○
Throttle gate & choke ○
Fuel filter is clogged ○
Oil level ○
Alteration of pipes each 2 years
Lights & direction lights
Action ○ ○
On/off normal , dirty , ○
damage
Rear view mirror ○ ○
Instrument –action ○
Exhaust pipe & muffler
Installation loosed or ○
damage
Function of muffler ○
Frame & body –loose or ○
damage
Abnormal from previous ○
day –confirm
normal
Others- greasing of each ○ ○
part
Cleaning combustion ○
chamber , exhaustpipe ,
and carbon muck in muffler

Chapter 2 Check and Adjust

2-3
Disassembly of External Parts
Remove the external parts for checking and adjustment
Read cover separate the join with the chassis (the
* Open the seat. concave and the convex) and remove
* Remove the 2 hex-nuts, 1 bolt to the front cover.
remove the luggage rack. * Remove the main switch cap.
* Remove 10 self-tapping screws and 2 * Follow the sequence in reverse order
round-headed bolts.. for assembly.
* Remove the central and body cover ATTENTION：
* Install with reverse sequence. - Be sure the joint of front cover and
ATTENTION： cowling jointing correctly before
- Please do keep away the unit of the tie-up the screws and nuts.
body and the pedal from damages.
- Before tightening the screws, be Tail light assembly
sure of correct matching of all units. * Remove 2 hex bolts and rear fender
assembly.
Cowling * Remove the left and right body
* Remove 4 tapping screws and 2 covers.
round-head bolts. * Remove 2 hex bolts and the tail light
* Separate the joint of inner parts and assembly.
remove the cowling. * Follow the mounting sequence in
* Install with reverse sequence. reverse order.
ATTENTION：
Front Cover - Match the rear guard holes and the
* Remove 4 tapping screws and 3 hex- convex of the chassis.
nuts.
* Separate the joint of inner parts and
remove the cowling. Handle covering
* Install with reverse sequence. * Remove the rear mirror
ATTENTION： * Remove 3 tapping screws, separate
- Be sure of not damaging the front the joint from the handle rear cover
pane land the front inner union (the and remove the cover.
convex and concave portions). * Dismantle the speedometer cable
- While tightening the screws, be sure adapter.
of the matching with the luggage * Remove the speedometer and head
case. light assembly.
Floor panel * Dismantle the handle switch wiring.
* Remove the L/R side cover and body * Follow the reverse sequence for ass’y
cover. ATTENTION：
* Remove 4 hex bolts. - Matching the joint of handle cover
* Separate the front interior covering with the head light case.
joint (the claw and the groove) and - Load the cables and wires
remove the pedal. accordingly.
* Follow the sequence in reverse order - After the assembly, check the
for assembly. function of all switches.
ATTENTION：
- After joining the pedal and the front
interior covering, mount it onto the Adjustment of the head light
chassis. * Adjustment of the beam of the head
Luggage case light is by loosening the screw
* Open the luggage case cover. underneath the head light
* Remove 4 tapping screws and 1nut,

Chapter 2 Check and Adjust

2-4
 Serviceable parts layout
The drawing shows the main serviceable parts.

Front brake lever Rear brake lever

Head light

Rear shock absorber

Front shock
Rear tire

Front tire
Transmission
Air filter

Front brake Rear brake

Chapter 2 Check and Adjust
Serviceable parts layout
The drawing shows the main serviceable parts.

Oil level sensor

Main switch Starter relay
CDI

Battery

Main fuse

Flash relay
Regulator

Horn

Coil & Spark plug cap

Chapter 3 Engine Removal

Attention of Operation
• Following operation needs remove the engine from frame body.
–Disassembly crank shaft case
–Remove 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.

4-1
Chapter 4 Engine Removal

Operation / Parts Name Q’ty Remarks

Disassembly
1 ACG wire /wire of start motor 2 WARNNING:
2 Starter wire of carburetor 1 • The oil over-flow when remove the oil
3 Oil tube 1 tube, so use clip or plug stop the seal.
4 Fuel tube 1
5 Vacuum pressure tube 1
6 Cap of spark plug 1
7 Hex washer face bolt of rear 1
8 cushion 1
9 Oil pump control cable 1
10 Cable of rear brake 1
11 Throttle cable 1
12 Hex washer face bolt of engine 1
13 Bolt 1 WARNNING:
14 Engine 1 • Don’t damage rear fender when remove
15 Nut 2 the engine.
16 Engine bracket bolt 1 • Actually for brace the frame, avoid body
Engine bracket
turn inside out.
Assembly WARNNING:
16→1 Carry out following adjusting after
installation.
–Cable of throttle valve
–Oil pump control cable
–Rear break cable

4-2
Chapter 4 Engine Removal

Engine Removal
Remove L/R step bar.
Remove air filter and muffler.
Disconnect fuel/oil/vacuum tube on the
carburetor.
Disconnect throttle cable.
Disconnect all electrical connectors and
spark plug cap from engine to main wire
harness. Step Bar
Disconnect rear wheel brake cable.

Notice:
Plug all tubes to avoid fuel/oil leak.

Auto choke cable

With the main stand raise, loosen the
rear shock absorber fix bolt and engine
to bracket mounting nut.

With assistant to hold vehicle frame then

remove engine to bracket mounting nut. Air filter

Raise the vehicle frame to apart the

engine with rear wheel and main stand.

Notice:
Store the vehicle frame firmly to avoid
falling damage.
Engine to bracket Rear shock
mounting nut absorber fix bolt

Engine Installation
Install the engine and related
components in the reverse order of
removal.

4-3
Chapter 4 Cylinder Head / Cylinder / Piston
Attention of Operation
• Can be operating when engine on the vehicle.
• Must cleaning before operating, avoiding dust enter to engine.
• Remove the gasket dust stay on joint face.
• When remove the cylinder, avoid to using screw driver to damage the joint face.
• Avoid to damaging the cylinder inner surface and piston face.
• Cleaning before check parts, and smear motor oil appointed in sliding face before
installation.

Diagnosis of Troubles
Low compression pressure, poor start, idle speed not stable
• Air leakage of the cylinder head gasket
• Wear out or damage of the piston ring
• Wrong installation of spark plug
• Wear out or damage of the cylinder and piston
• Reed valve is poor.

Compression pressure too high, overheating, locking

• Carbon accumulated on the cylinder head or piston top.

Piston knocking noise

• Wear out of the cylinder and piston
• Wear out of the piston pin hole and piston pin
• Wear out of the needle bearing of crank connecting rod (small end)

Piston ring noise

• Wear out or damage of the piston ring
• Wear out or damage of the cylinder
Chapter 4 Cylinder Head / Cylinder / Piston
Chapter 4 Cylinder Head / Cylinder / Piston

Operation / Parts Name Q’ty Remarks

Disassembly
Cylinder head
WARNNING:
1 Nut of cylinder head 4 –Cross loosing the nuts 2-3 times.
2 Cylinder head 1
3 Cylinder head gasket 1
Cylinder
WARNNING:
4 Cylinder 1 –Don’t knock cooling fin.
5 Cylinder gasket 1 –During cleaning the gasket beware not
to damage joint face of cylinder and
crank case.
Piston

6 Piston ring clip 2

7 Piston pin 1
8 Piston 1
9 Piston ring 2
10 needle bearing of small side 1
Assembly –Operation with sequence in reverse
10→1 procedure.

Removal
Disassembly of right side generator
cover.
Remove air filter and spark plug cap
Disassembly of muffler.

Separate the oil tube on air shroud.

Pull out air-shroud of the cylinder.
Generator Cover Muffler
Chapter 4 Cylinder Head / Cylinder / Piston

Remove cylinder head, cylinder and

piston
Loosen then remove four cylinder head
fixed nuts.
Remove the cylinder head and gasket
Remove the cylinder head.
Pull the cylinder out of engine.
Remove piston pin clip by using a long
nose pliers.
Pull the piston pin out of piston and
remove the piston from connecting rod

Inspection cylinder head

Clean the carbon and oil accumulation
on the combustion chamber.
Use a metal ruler and thickness gauges
to check the cylinder head gasket
surface.
Replace the cylinder head for any
corrosion and/or irregularity.

Inspection cylinder & piston

Use a thickness gauges to check the
space between piston rings and piston.
Standard: 0.03mm~0.05mm
Wear Limited: 0.10mm
Replace the piston and rings in set.

.
Use a thickness gauges to check the
piston rings gap.
Standard: 0.15mm~0.35mm
Wear Limited: 0.60mm
Chapter 4 Cylinder Head / Cylinder / Piston
Notice:
Installation Always replace a new cylinder head
Remove carbon muck inside ring ditch gasket.
and piston ring during disassembly.
Do not scratch piston and do not bend Tighten the cylinder head fix nuts
piston rings. crossed.
Install top-piston ring & 2nd piston ring Torque valve: 140 kgf.cm ( 10 lb.ft)
into piston.
Press the ring on few points after
installed into piston to ensure the ring
goes deep enough into the ditch
WARNNING:
Change whole set of piston ring
with genuine parts.

Install the piston to connecting rod.

Notice:
Arrow mark on the top of piston toward
to exhaust port.

Compress the piston rings the insert to

the cylinder.
Notice:
Make sure the ring gap at the dowel
point on the ring groove.

Install cylinder head gasket and cylinder

head.
 Arrow mark

Chapter 4 Cylinder Head / Cylinder / Piston

Install the air shroud and cover in the

reverse order of removal.
Notice:
Do not bend the oil tube.
Chapter 4 Cylinder Head / Cylinder / Piston
Lubrication System
Attention of Operation

‧Pay attention to avoid dust enter to the interior of engine and motor oil pipe when
disassembly the motor oil pump.
‧Never disassembly motor oil pump.
‧Must draw out the air on the pump if there have air in the pump when disassembly
pipe of carburetor.
‧After disassembling the motor oil connection tube, must fulfill the motor oil in the
connection pipe, then, connect the tube.

Diagnosis of Troubles

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.
Over heating
‧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 air in the motor oil pipes system.
‧Bad motor oil pump.
Clogging oil from oil tank
‧Vent of motor oil case’s cap is clogged.
‧Filter of motor oil is clogged.
Preparation standard
‧Use separating motor oil appointed (use for 2-stroke).
‧Content of motor oil tank : 1.1 liter

Chapter 4 Cylinder Head / Cylinder / Piston

Dismounting of Oil Pump

* Remove the R side body cover and helmet box.

* Remove the cooling fan cover and cylinder head cover.

＊WARNNING:
Operating after cleaning motor oil pump around and no dirt enter into the crankcase.

Operation / Parts Name Q’ty Remarks

1 Oil tube from oil tank 1 WARNNING:
Clogging the pipe with clamp or plug
for avoiding fuel flow out.
2 Oil tube to carburetor 1 Remove from both side of motor oil
3 Pan phillips bolt 2 pump.
4 Control cable 1
Assembly • Assembly with sequence in reverse
of disassembly.
＊WARNNING:
−Smear motor oil to new O ring ,then
assembly motor oil pump.
−The oil pump must installed correctly
into crank case.

Chapter 4 Cylinder Head / Cylinder / Piston

Dismounting of Oil Tank

Operation / Parts Name Q’ty Remarks

Disassembly WARNNING:
2 Oil cap 1 Fill motor oil with clean
3 Oil level sensor 1 container.
15 Pan phillips bolt 2
5 Oil tube to oil pump 1
6 Motor oil pump 1
Assembly WARNNING:
Connect correct oil pipe after
Operation with sequence in assembly, release the air in
reverse of disassembly. motor oil pump.
Chapter 5 CRANK CASE & CRANK SHAFT
Attention of Operation

This chapter explaining the necessary procedure of disassembling crank case due to
repair & maintain the crank shaft.
Before disassembling of crank case, please refer related articles of following
procedures.
–Disassembly of oil pump
–Disassembly of carburetor
–Disassembly of reed valve
–Removal of engine
–Disassembly of cylinder head and cylinder
–Disassembly of ACG
–Disassembly drive face ass’y

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 put into new oil seal after assembling crank case.

Diagnosis of Troubles

Noise of Engine
Damaged of the crankshaft bearing.
Damaged of needle bearing of connecting rod.

6-1
Chapter 6 CRANK CASE & CRANK SHAFT
Disassembly of ACG
Remove fan cover air shroud. Fan cover
Remove cooling fan

Flywheel
ACG coil
& bracket

Cooling fan

Loosen the flywheel fix nut

Use special puller to remove the
flywheel. Flywheel
puller

Disassembly oil pump

Remove oil drive gear cover gasket.
Loosen two pump fixing bolts
Pull out the oil pump.

Installation
Install the in the reverse order of
removal.

Notice: Grease the gear

Fixing bolts
Grease oil pump and drive gears before
covering the gasket.

6-2
Chapter 6 CRANK CASE & CRANK SHAFT

Operation / Parts name Q’ty Remark

Disassembly
1 Hex socket bolt 6
2 Right crank shaft case 1
3 Dowel pin 2
4 Fix shaft of crank shaft case 1
5 External circle clip 2
6 Crank shaft 1
7 Radial ball bearing (Right) 2
8 Radial ball bearing (Left) 1
9 Hex socket bolt 1
10 seal bracket 1
11 Right oil seal 1
12 Left oil seal 1
13 Radial ball bearing 2
Assembly
13→1
Chapter 6 CRANK CASE & CRANK SHAFT

Disassembly of Crank Case

Loosen all fixed bolts on crank case.
Install the puller on right crank case,
separate the R. crank case and L. crank
case.
: Crank case puller (TLJT-03)

Install the puller on left crank case,

remove the crank shaft from the crank
case.
: Crank case puller (TLJT-03)

Notice:
Don’t knock the crank shaft 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)

Notice:
Must remove the oil seal when
separate the crank case, and never use
the old oil seal.
Chapter 6 CRANK CASE & CRANK SHAFT

Assembly of Crank Case

Clean the crank case with gasoline, and
Liquid seal
check the each part whether damaged
or crack.
Notice: Dowel pins
Smear of oil on sliding surface of each
shaft in crank case after checking.
Cleaning the washer dust of joint face,
and amend the part damage with oil
stone.

Put new crank shaft into right crank

case.
Install the dowel pins in the joint face of
left crank case.
Apply liquid seal in joint surface of left
crank case.
Oil seal
Put crank shaft assembly into left
crank case.

Notice:
Smear the 2-stroke oil to main bearing
and big end of connecting rod.
Note the position of connecting rod.

Install the right crank case.

Fix bolts
Tighten all fix bolts in specify torque.

Oil seal
bracket
Put left oil seal into L. crank shaft case,
surface depth under 1.0 mm.

Install the new R. oil seal to crank case.

Install oil seal bracket and tighten the
bracket fixing bolt.
Chapter 6 CRANK CASE & CRANK SHAFT

Assembly of ACG
Install oil pump drive gear.
Install oil pump
Install new cover gasket.
Connect oil tubes and pump cable.
Oil tube
Notice:
Grease oil pump and drive gears before Gasket

covering the gasket.

Install generator bracket and coil.
Insert the ACG wire to R crank case. Pump cable

Install flywheel and cooling fan.

Notice:
After install piston, cylinder and cylinder
head then install cylinder air shroud and
fan cover.

Air shroud
Fan cover
Chapter 6 Transmission
Attention of Operation

Don’t make greases stick to surface of transmission belt or belt plate.

Otherwise, the efficiency of power transmission will be lowered by skid.
Don’t switching 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

10-1
Chapter 6 Transmission
Disassembly of Left Crankcase Cover
Remove air cleaner first before start to disassembly CVT cover.

Operation / Parts name Q’ty Remark

Disassembly

1 Hex socket bolt 12

2 Carburetor tube bracket 1
3 Left crank case cover 1
4 Crankcase cover gasket 1 WARNNING:
5 Dowel pin 2 Check the air cleaner whether worsen
6 Grommet 1 or harm.

Assembly Operation with sequence in reverse of

6→1 disassembly.

10-2
Chapter 6 Transmission
Disassembly of Kick Starter

Operation / Parts name Q’ty Remark

Disassembly
1 Kick pinion spring clip 1
2 Kick pinion 1 WARNNING:
3 Hex washer face bolt 1 Rotating pedal kick crank and remove
4 Kick crank 1 the assembly.
5 External ring clamp 1
6 Plain washer 1
7 Starting shaft ass’y 1
8 Starting shaft reset spring 1
9 Bushing 1
Operation / Parts name Q’ty Remark
Assembly
9 Washer 1
8 Starting shaft reset spring 1 WARNNING:
7 Starting shaft ass’y 1 Unable into main shaft fix position when
6 Plain washer 1 inside and outside reset spring overlap,
5 External ring clamp 1 use flat-driver will inside、outside spring
4 Kick crank 1 part, then press main shaft.
3 Hex washer face bolt 1
2 Kick pinion 1
1 Kick pinion spring clip 1

10-3
Chapter 6 Transmission
Check of Starting Shaft & Kick Pinion
Check the wear and/or damaging of
starting shaft and gear.
Check the tightness and/or damage of
starting shaft reset spring.
Check the wear and/or damage of bush.

Check the wear and/or damage of kick

pinion.
Check the wear & damage of kick pinion
spring clip.

Check the wear & damage of starting

shaft, bearing and driving gear.

Installation of Starting Shaft &

Kick Pinion
Setting kick starting shaft first.
Turn starting shaft spring clip on crank
case convex and assembly of kick
pinion to it’s position.
Rotated the starting shaft, let starting
shaft gear and kick pinion conjoin.
Chapter 6 Transmission
Disassembly of Left Crank Case (→7-2)

Operation / Parts name Q’ty Remark

Disassembly
1 Hex washer face bolt 1 WARNNING:
2 Cone spring washer 1 Don’t hurt transmission belt.
3 One-way clutch 1
4 Clamp washer 1
5 Primary fixed sheave 1
6 Bushing 1
7 V-Belt 1
8 Primary sliding slot wheel 1 Separation / assembling (→ 7-7)
9 Oil ring 1
10 Hex nut 1
11 Covering of clutch 1 Separation / assembling (→ 7-8)
12 Drive face ass’y 1
Assembly ‧Operation with sequence in reverse
12→1 of disassembly.
Chapter 6 Transmission
Disassembly Driver and Driven
Pulley
Driven pulley
Remove driver and driven pulley fixed
Driver pulley
nuts.
Remove driver pulley fix sheave.
Remove driven pulley ass’y with V belt.

Pull up driven pulley sliding slot from

driven pulley ass’y to remove the V belt. V belt

Inspection
Measure the width of V belt.
Standard: 17.7 mm
Wear Limited: 16.6 mm

Measure the inside width of clutch cover.

Standard: 112.0 mm
Wear Limited: 112.5 mm
Chapter 6 Transmission
Disassembly of Sliding Driving Disc

Operation / Parts name Q’ty Remark

Disassembly

1 Cam plate 1
2 Cam plate sliding 3
3 Weight roller 6
4 Primary sliding slot wheel 1

Assembly ‧Operation with sequence in reverse

4→1 of separating.
Chapter 6 Transmission
Disassembly Driver Pulley Sliding
Ass’y
Remove driver pulley sliding ass’y from
driver shaft.
Detach the bushing, cam plate and
weight roller from driver pulley sliding
ass’y.

Inspection
Check the bushing sliding smoothly or
not.

Measure the width of weight roller.

Standard: 15.0 mm
Wear Limited: 14.5 mm
Replace all six roller at same time.
Chapter 6 Transmission
Disassembly of Clutch / Transmission Belt Disc

Operation / Parts name Q’ty Remark

Disassembly
Clutch

1 Nut 1
2 C retaining ring 3
3 Washer 3
4 Clutch weight set 3
5 Clutch weight spring 3 WARNNING:
6 Rubber buffer 3 Must replacing when the buffer have
7 Driving plate of clutch 1 damage, hardening and distortion.
Drive face ass’y
8 Axle ring of spring
9 Compression spring
10 Secondary spring seat
11 Guide pin
12 Secondary sliding slot wheel
13 Oil ring
14 Oil seal
15 Needle bearing
16 Internal circle clip
17 Radial ball bearing
18 Secondary fix slot wheel
Assembly ‧Operation with sequence in reverse
18→1 of separating.
Chapter 6 Transmission
Disassembly Driven Pulley Sliding
Ass’y
Notice:
Use a bench pliers to fix the sliding
ass’y before loosen nut.

Inspection
Measure the thickness of clutch pads.
Standard: 4.0 mm
Wear Limited: 2.5 mm

Measure the length of clutch reducer

spring.
Standard: 114 mm
Wear Limited: 100 mm

Check the sliding of slot wheel.

Chapter 7 Final Transmission Mechanism
Attention of Operation

This chapter explaining the final reduction mechanism maintenance.

The operating can be done that engine in the vehicle.
For no hurting case cap, changing the bearing of left crank shaft 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 damage of gear
Bearing wore and loosened.
Gear oil leaking
Too much gear oil filled.
Oil seal wear out or damage.
Chapter 7 Final Transmission Mechanism
Disassembly of primary drive gear / final reduction mechanism
Disassembly of rear tire(→11-2).
Disassembly of clutch / drive face(→7-6).
Notice:
First drain the oil of transmission.

Operation / Parts name Q’ty Remark

Disassembly
1 Bolt 5
2 Mission cover 1
3 Washer 1
4 Dowel pin 2
5 Drive axle 1
6 Main axle comp. 1 ‧Check the wear & damage of shaft
7 Plain washer 1 and gear. Change new one. (→8-3)
8 Primary drive gear 1
Assembly ‧Operation with sequence in reverse
8→1 of disassembly.
Chapter 7 Final Transmission Mechanism
Change the Driving Shaft

Remove the driving shaft from mission

cover.

Notice:
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.

Notice:
Install the bearing with facing outside.
Chapter 8 Fuel System
Attention in Operation
Fuel is flammable and explosive under certain conditions. Ensure work area is well
ventilated. Do not smoke or allow open flames or sparks in the vicinity.
When draining a fuel tank or whenever a fuel line is disconnected, obstruct line with
a hose pincher or equivalent device.
Pay attention to the parts which using gasoline.
Pipes & cable must be in accordance with the location directed of wiring diagram.
Release air in motor oil pump when remove motor oil pipe.

Diagnosis of Trouble

No starting Mixed air too rare

No gasoline in tank h Nozzle of carburetor is clogged
Gasoline blocked h Gasoline filter is clogged
Too much fuel in cylinder h Vent of gasoline tank is clogged
Air filter is clogged h Gasoline pipe cranked, broke,
clogged
Idle speed unstable or carburetor h Poor action of valve of float chamber
rotation not smooth h Gasoline level too low
Poor idle speeds adjust of carburetor. h Air pipe is clogged
Low compression pressure
Poor ignition system Mixed air too rich
Bad adjustment of air adjusting screw h Poor action of valve of float chamber
on carburetor h Gasoline level too high
Air filter is clogged h Air nozzle is clogged
Poor auto side-plunger on carburetor h Auto side-plunger poor
Idle speed nozzle is clogged
Chapter 8 Fuel System
Disassembly / Assembly Valve of Throttle
Disassemble of left body covering
Adjust the free play of throttle
Adjust of reverse rotation of idle speed

Operation / Parts Name Q’ty Remarks

Disassembly
1 Pan phillips bolt 2 WARNNING:
2 Throttle valve 1 Loosing top cap of carburetor, and
3 Throttle cable 1 removing.
4 Throttle valve spring 1
5 Carburetor washer 1 WARNNING:
6 Throttle cover 1 Remove from guide wire of throttle
7 Sealing set 1 valve.
8 Retainer 1
9 Needle 1
10 Clamp 1
Assembly
10 Clamp 1 WARNNING:
9 Needle 1 Assembly of needle nozzle.
8 Retainer 1 WARNNING:
7 Sealing set of guide wire 1 Assembly of throttle valve.
6 Throttle cover 1 WARNNING: Assembly of throttle cable.
5 Washer 1 WARNNING:
4 Throttle valve spring 1 Aim the ditch of throttle valve to chamber
3 Throttle cable 1 then install throttle valve into carburetor.
2 Throttle valve 1 Lock the throttle cover.
1 Pan phillips bolt 1
Chapter 8 Fuel System
Disassembly of Carburetor
Remove the air cleaner ass’y .
Remove the left body cover

Operation / Parts Name Q’ty Remarks

Disassembly
1 Throttle valve set 1
2 Gasoline pipe 1
3 Motor oil joint 1
4 Starter wire of carburetor 1
5 Vacuum pressure tube 1
6 Clip 1
7 Intake manifold hose clamp 1
8 Carburetor 1
Assembly
8→1 WARNNING:
Don’t let dust enter into carburetor.
3 Motor oil joint WARNNING: Release air.
Chapter 8 Fuel System
Disassembly / Assembly Carburetor
Disassemble of carburetor.
Adjust the idle speed.
Adjust the air adjust screw.

WARNNING:
Fuel is flammable and explosive under certain conditions. Ensure work area is well
ventilated. Do not smoke or allow open flames or sparks in the vicinity.
Before disassembling, loose oil-draining screw, draining out the gasoline from
carburetor.

Operation / Parts Name Q’ty Remarks

Disassembly
Plunger starter
1 Pan phillips bolt 1
2 Start plug screw 1
Float Chamber
3 Pan phillips bolt 4
4 Float chamber 1
5 Float chamber gasket 1
6 Float pin 1
7 Float 1
8 Needle valve 1
9 Drain plug 1
10 Over flow tube 1
 Carburetor Ass’y
11 Air adjust screw set 1
12 Throttle screw set 1 WARNNING:
13 Pilot jet 1 Must confirm rotation location before
14 Needle nozzle 1 disassembling, not locking too much
avoid to hurt seat face.
15 Main nozzle 1
Assembly
15→1 WARNNING:
Install carburetor in reverse order Use high pressure air clean each way of
of disassembly. carburetor.
11 WARNNING:
Air adjust screw set Must adjust air screw when changing air
screw and carburetor ass’y.
Chapter 8 Fuel System
Disassembly of Inlet Valve
Disassemble of body cover.
Disassemble of carburetor.

Operation / Parts Name Q’ty Remarks

Disassembly
1 Intake manifold hose clamp 1
2 Hex washer face bolt 4
3 Intake manifold 1
4 Reed valve ass’y 1
5 Reed valve gasket 1
Assembly Assembling with sequence in reverse
5→1 of disassembly.
WARNNING:
4 Reed valve ass’y Using new washer , the washer must
5 Reed valve gasket aim at hole of reed valve.
WARNNING:
confirm no secondary air entering
after installing.
Chapter 8 Fuel System
Disassembly of Fuel Tank
WARNNING:
When draining a fuel tank or whenever Body cover
a fuel line is disconnected, obstruct line fix bolts
with a hose pincher or equivalent de-
vice.
Shall be wiped off when fuel overflowed.

Disassemble of body cover.

Disassemble of fuel tank fix bolts
Disconnecting fuel tube on fuel cup and
remove fuel tank

Fuel tank
fix bolts
Installation
Install fuel tank in reverse order of
disassembly.
Chapter 8 Fuel System
Disassembly of Air Cleaner

Operation / Parts Name Q’ty Remarks

Disassembly
1 Hex socket bolt 2
2 Plain washer 1
3 Self-tapping screw 3
4 Air cleaner case cap 1
5 Air cleaner element 4
6 Air cleaner case 1
7 Air cleaner joint 1
8 Cleaner guide pipe 2
9 Grommet 1

Assembly Install air cleaner in reverse order of

disassembly.
9→1
Chapter 9 Front Wheel / Front Suspension / Front Brake

Attention of Operation
Support the frame body steady before remove the front wheel.
Don’t invert the front wheel when installing.

Diagnosis of Trouble
Heavy steering movement Steering handle not straight
Over tied of the steering ball race L/R suspension not balanced
Steel ball inside ball race broken Front fork banded
Tire pressure insufficient Front tire axle banded, tire wear-out

Brake efficiency abnormal Front wheel shaking

Brake lining wear-out Front rim defected
Brake pads adjust not correct Loose of front rim bearings
Brake disc attrition Tire defect
Tire wear-out Bad adjustment of the front axle

Poor Brake
Bad adjustment of brake
Wear the brake pad
Chapter 9 Front Wheel / Front Suspension / Front Brake
Disassembly / Assembly of Front Wheel

Operation / Parts name Q’ty Remarks

Disassembly of Front Wheel
1 Nut nylon 1
2 Speedometer gear 1
3 Hex washer face bolt 1
4 Front collar 1
5 Front fender 1
6 Front brake disc 1
Assembly Operation with sequence in reverse
6→1 procedure.
WARNNING:
When assembling of right fork, shall be
aimed at convex of speedometer gear.
Chapter 9 Front Wheel / Front Suspension / Front Brake
Assembly / Disassembly of Front Rim
Disassembly of front wheel.

Operation / Parts name Q’ty Remarks

Disassembly

1 Front collar 1
2 Oil seal 1
3 Radial ball bearing 2
4 Front wheel spacer tube 1

Assembly Operation with sequence in reverse

4→1 procedure.

WARNNING:
Must change the R/L bearing set.
Chapter 9 Front Wheel / Front Suspension / Front Brake
Assembly / Disassembly of Front Disk

Operation / Parts name Q’ty Remarks

Disassembly

1 Front collar 1
2 Brake disc hex socket bolt 3
3 Hex flange nut with serration 3
4 Nylon insert lock nut 1
5 Plain washer 1
6 Front brake disc 1

Assembly Operation with sequence in reverse

6→1 procedure.
Chapter 9 Front Wheel / Front Suspension / Front Brake
Disassembly of Steering Handle
Disassembly of throttle handle
Dismount rear brake cable

Operation / Parts name Q’ty Remarks

Disassembly
Rear brake lever
1 Nut 1
2 Left lever set bolt 1
3 Rear brake lever 1
4 Rear brake cable 1
Bracket of rear brake lever
5 Hex socket bolt 1
6 Fixed belt of steering handle 1
7 Bracket of rear brake lever 1
Steering Handle
8 Hex flange nut with serration 1
9 Washer 1
10 Hex washer face bolt 1
11 Steering handle 1
12 Handle grip 1
Assembly Operation with sequence in reverse
12→1 procedure.
11 Steering handle 1 WARNNING:
7 Bracket of rear brake lever 1 Install steering handle with handle
4 Rear brake cable 1 convex at ditch of steering stem.
The convex of brake lever bracket
should be fit into handle bar.
Chapter 9 Front Wheel / Front Suspension / Front Brake
Disassembly of Steering Stem
Disassembly of front wheel.
Disassembly of steering handle

2
3
5
11

6 3
9

5
10 6

Operation / Parts name Q’ty Remarks

Disassembly
1 Spanner nut 2 WARNNING:
2 Steering stem dust cover 1 Not to damage steering stem.
3 Lathe cone on steering top #2 1
5 Steel ball race
6 Lathe on steering inner #3 2
2
WARNNING:
9 Hex bolt 2 Remove L/R tube by loose these two
10 Washer 2 hex bolts.
11 L/R Front fork 2
Assembly Operation with sequence in reverse
11→1 procedure.
Chapter 9 Front Wheel / Front Suspension / Front Brake

Turning Front Fork to Left / Right

Turn the front fork several times to make
the ball race rotate smoothly.
Slightly tie-up the bottom spanner nut
then backward the nut about 1/8 turn.
Confirm the steering rotation smooth
and gap of steering stem.

Special Tool: Fixed nut spanner

Keep the bottom spanner nut fixed to

avoid the nut rotate when tighten the
upper spanner nut.

Torque: 7.0 kg-m

Special Tool: Fixed nut spanner

Chapter 10 Rear Wheel / Suspension / Brake
Attention of Operation
WARNNING:
The dusts inside brake hub are containing harmful material. Do not use air to blow
the dusts. Use specified detersive or clean cloth to wipe off those dusts.

Diagnosis of Troubles
Rear wheel shaking Brake efficiency abnormal
The shape of rear rim damaged Brake pad adjustment not correct
Tire defected Brake pad attrition
Brake lining base wear out
Rear suspension too soft Brake cam wear out
Tire defected Poor setting of the break arm tooth

Explode View of Rear Wheel

Chapter 10 Rear Wheel / Suspension / Brake
Disassembly of Rear Wheel

Operation / Parts name Q’ty Remarks

Disassembly
Muffler
1 Hex washer face bolt 2
2 Hex socket bolt 2
3 Muffler 1
Rear wheel
4 Nut 1
5 Rear wheel 1
Assembly –Operation with sequence in reverse
5→1 procedure.
Chapter 10 Rear Wheel / Suspension / Brake
Disassembly / Assembly of Rear Brake
Disassemble rear wheel first before this operation.

Operation / Parts name Q’ty Remarks

Disassembly
1 Adjusted nut of rear brake 1
2 Rear brake fixture 1
3 Rear brake cable 1
4 shoe/shoe strain spring of rear 2/2
5 brake 1
6 Hex washer face bolt 1
7 Rear brake arm 1
8 Reset spring 1
9 Brake cam shaft 1
Assembly Operation with sequence in reverse
8→1 procedure.
Chapter 11 Electrical Device

Attention of Operation

Remove battery for charging.

Do not charge battery in fast speed if it’s not urgent necessary.
Check voltage with multi-meter.
Replace the battery with same specification.
Due to CDI ignition device is not adjustable. Check CDI set & ACG if ignition is poor.
Replacing it if it’s poor, confirm ignition time with original service meter.
Starter motor can be disassembly without remove the engine.

Diagnosis of Trouble Poor charging system

No power Fuse broke
Battery discharging Poor contact, broke and short circuit
Shaky connection of battery wires of connection head or socket head.
Fuse broke Fail regulator
Poor main switch Fail ACG

Low voltage Spark plug no works

Poor charging of battery Poor contact spark plug.
Poor contact Poor contact, broke and short circuit
Poor charging system of main wire.
Bad regulator –Between ACG & C.D.I.
–Between CDI & ignition coil
Current off and on –Between CDI & main switch.
Shaky connection of battery wires Bad ignition coil
Poor contact of charging system Fail CDI set
Poor contact or short circuit of ignition Fail ACG
system
High/low beams can’t be changed
Light weak Burn down bulb
Battery discharging Poor lighting switch
Resistance of wiring switch too big
Chapter 11 Electrical Device

Starter motor no working RPM unsmooth

Fuse burn down Ignition — primary circuitry
Battery charging insufficient –Bad ignition coil.
Bad main switch –Wire or poor contact.
Poor start switch –Poor contact main switch.
Poor front / rear brake switch. Ignition — secondary circuitry
Poor start breaker –Bad ignition coil.
Poor contact or broke of winding –Bad spark plug.
Poor starter motor –Bad high voltage wires.
–Power leakage of spark plug.
Powerless starter motor Ignition time
Battery charging insufficient –Bad ACG.
Bad contact of brush –Poor installation of statue inductor.
Un-knew blocked in motor or gear. –Fail CDI.

Starter motor running but engine not Oil indicator light not working (when
running without oil)
Small gear had wear out of starter Insufficient battery power
motor. Fuse burn
Counter rotation of starter motor Bad main switch
Battery insufficient Bad gauge
Bad switch of fuel height.
Turn on main switch, but no lighting
Bulb burn down Flashing oil indicator light
Bad switch Guide wires broke.
Guide wire broke. Poor action of floating
Fuse burn down Poor fuel gauge
Battery insufficient
Bad wiring

Fuel gauge unstable

Loose socket head of guide wires.
Wear out of contact point
Bad gauge
Chapter 11 Electrical Device

Solid Wiring Diagram

Chapter 11 Electrical Device

Disassembly of Battery
Remove seat
Battery
Remove rear fender
Disconnect battery wires from negative (-)
terminal first.

Check Voltage of Battery

Remove seat and remove battery
connection wires.
Rear fender
Check voltage between battery terminals.
Charging sufficiently : over 12.8 V
Charging insufficiently : 11.5-12.8V
WARNNING:
Check battery voltage with digital
voltmeter.

Check Charging System

Power leakage test
Turn “OFF ” the main switch.
Disconnect ground guide wire from
battery.
Connecting voltmeter to the end between
terminal (–) & ground guide wires.
WARNNING:
Check voltage according to sequence
from big to small.
Voltmeter’s fuse will be broken if the
voltage over the limitation that choosing.
Do not turn “ON” the main switch when
check current.

Current Leakage : under 1 mA

Chapter 11 Electrical Device

Check Charging Status

WARNNING:
Voltage will have big change by following
the charging status of battery.
Therefore the check must process after
battery completely charging and the
voltage over 12.8 V.
There will produce big current in battery
when using electrical starter.
Check Voltage Regulator
Disconnect the voltage regulator.
Assembly voltmeter to terminal of Check return of wiring edge connection
main fuse then start the engine. head.
Turn on the light and increasing engine WARNNING: Check in range of AC.
RPM then check charging voltage & Check voltage regulator when voltage
current. is not in the control range.
Charging current : 1~2 Amp/5000rpm
Voltage of charging control: Control voltage: 12~14V/5000rpm
14~15V/5000rpm

Check Voltage of Front Lighting

Control
Disassemble front cover of handle bar.

WARNNING:
Check head light which wires connecting.

Start engine, turn “ON“ light switch,

change to high beam.
Check voltage between green (+) &
black (-) guide wires.
Chapter 11 Electrical Device

Disassembly of ACG

Operation / Parts name Q’ty Remarks

Disassembly

1 Hexagon socket bolt 2

2 Plain washer 2
3 Self-tapping screw 1
4 Cap of electric disc 1
5 Hexagon socket bolt 4
6 Plain washer 1
7 Fan 1
8 Hexagon nut 1
9 Spring washer 2
10 Plain washer 1
11 Fly wheel of generator 2
12 Semi-cycle of electric disc 1 WARRNING:
13 Whole body bolt 1 Take the good care, no hurt coil.
14 Hexagon socket bolt 1

Assembly Assembling with sequence in reverse of

14→1 disassembly.
Chapter 11 Electrical Device

ACG ( Charging Coil ) Check

WARNNING:
Checking the engine connected
with starter motor.

Disconnect ACG connector.

Check resistance of charging wire &
lighting wire.

Standard valve (20℃)

Charging wire : 0.2~1.0
Lighting wire: 0.1~0.8

Ignition Coil

Disassembly
Disconnect the spark plug cap.
Disconnect coil wire and loosen the fix
bolts, then remove ignition coil.

Assembly
Install in reverse order of disassembly.
WARNNING:
Guide wire must be installed in the right
place.

Conduction Test
Check once coil resistance of ignition
terminal.
Standard valve (20℃): 0.3~0.5Ω
Chapter 11 Electrical Device

WARNNING:
Check ignition status with performance
tester due to this test has its own
standard.

Check twice of 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 of coil resistance between.
high voltage & (-) terminal.
Standard valve : 5~7 kΩ
(without spark plug cap)
Chapter 11 Electrical Device

Starting motor

Operation / Parts name Q’ty Remarks

Separation

1 Bolt set 2
2 Casing 1
3 Armature rotor 1
4 Carbon brash 2
5 Oil ring 1
6 Oil ring 1
7 Front fixed seat 1
Assembly
7→1 Install in reverse order of disassembly.
Chapter 11 Electrical Device

Fuel Gage Switch of Lights

Remove fuel gage. Color Yellow/red Blue
Put the float to up end down end to
OFF
check the resistance between each ON ○ ○
terminal.
Power Switch
Terminal of Up end of Down end
Guide wire float of float Color blue/white Black
Green & Up
0~20Ω 90~110Ω
black Down ○ ○

Main Switch Exchange of Bulbs

Disconnect the connector of main switch
Check the conductivity between each Head light bulb
terminal. Remove front covering of handle press
down the connection and turn it to
black/ black change head light bulb.
Color tea red
red
LOCK ○ ○
OFF ○ ○ Dash light
ON ○ ○ Remove rear covering of handle pull
out the connection of bulb, and replace
Exchange the bulb.
Remove front covering.
Remove 2 bolts, disconnect main switch Rear light / Brake light / Rear
connector. direction light bulb
Install in reverse order of disassembly. Remove 2 screws, pull out the light
Covering to front, disassembly hook on
Handle Switch Assemble light / brake light covering, and
Remove front covering. disassembly light covering of direction
Disconnect handle switch connector, light and bulb, finally change bulb.
check conductivity between each
terminal.