4 STROKE ENGINE

SERVICE AND REPAIR MANUAL
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Tab|e cf Ccntents
Chapter Tcp|c Fage
CH/l1Lb ì: lntroduct|on Z
CH/l1Lb Z: Bodv Cover and LxHaust 3vstem Zß
CH/l1Lb 3: 3cHedu|ed la|ntenance 33
CH/l1Lb 4: lubr|cat|n¿ 3vstem 4b
CH/l1Lb b: lue| 3vstem bZ
CH/l1Lb b: Ln¿|ne bemova| and lnsta||at|on b/
CH/l1Lb /: Cv||nder Head Va|ve /ì
CH/l1Lb ß: Cv||nder and l|ston ßß
CH/l1Lb 9: 0r|v|n¿ Be|t 0ev|ce & 1He 3tart|n¿ lever 9b
CH/l1Lb ìC: 1He l|na| 1ransm|ss|on /ssemb|v ììC
CH/l1Lb ìì: 1He Crankcase and tHe CranksHalt ììb
CH/l1Lb ìZ: 1He lront wHee|, lront Brake, ìZ4
lront Buller and tHe lront lork
CH/l1Lb ì3: 1He bear wHee|, tHe bear Brake & bear 3Hock ì4C
CH/l1Lb ì4: 1He Batterv and tHe CHar¿|n¿ 3vstem ì4b
CH/l1Lb ìb: l¿n|t|on 3vstem ìbC
CH/l1Lb ìb: 3tarter 3vstem ìbb
CH/l1Lb ì/: leters, 3w|tcHes and l|¿Ht|n¿ 3vstem ì/3
lN0L/ ìßC
I. Genera| Infcrmat|cn
lb/lL N0lBLb C01 l03l1l0N
LN0lNL N0lBLb C01 l03l1l0N
Tcp|c Fage
Ln¿|ne and lrame Number los|t|ons ì·ì
lroduct 3pec|hcat|ons ì·Z
and 1ecHn|ca| 0ata
1ecHn|ca| 1|ps ì·3
1oruue 3ett|n¿s ì·ìì
Tcp|c Fage
1oo|s ì·ìZ
0|| and 0rease 3upp|v CHart ì·ì3
Contro| Cab|es and w|r|n¿ 0|a¿ram ì·ì4
la||ure 0|a¿nost|cs ì·Zì
Lccat|cn fcr: Eng|ne Number/Frame Number
I. Genera| Infcrmat|cn
Frcduct Spec|hcat|cns and Techn|ca| Data
Scccter Mcde| JL50QT-18
JL50QT-X1/8
JL50QT-14
Length ìbßbmm |bb.b |ncHesì
W|dth bbCmm |Zb |ncHesì
He|ght ìC/Cmm |4Z |ncHesì
Whee| base ìì9bmm |4/ |ncHesì
Eng|ne type 4·stroke 0HC
D|sp|acement 49.bcc
Fue| requ|rements lead·lree ¿aso||ne
Dry we|ght
lront 3bk¿s |// |bsì
bear bbk¿s |ìZ3 |bsì
1ota| 9ìk¿s |ZCC |bsì
Curb we|ght
lront 3/k¿s |ßì.b |bsì
bear bCk¿s |ì3Z |bsì
1ota| 9/k¿s |Zì3.b |bsì
T|re s|ze
lront 3.CC x ìC
bear 3.CC x ìC
Grcund c|earance ßCmm |3.Zb |ncHesì
3topp|n¿ d|stance 4m lrom 3Ckm/Hr
ìb lt lrom ìß mpH.
1urn|n¿ rad|us ì.bbm |b.b ltì
Eng|ne Specs
1vpe 4·stroke 3l
3tart|n¿ L|ectr|c/k|ck start
Cv||nders 3|n¿|e
Combust|on cHamber Hem|spHer|ca|
Va|ve tra|n 3|n¿|e 0HC
Bore 39mm |ì3.34 |ncHesì
3troke 4ì.4mm |ì.b3 |ncHesì
0|sp|acement 49.bcc
Compress|on rat|o ìC.b:ì
Compress|on pressure ìbk¿/cm
Zìbps|

lower Z.Z Hl @ ßCCC bll
1oruue 4.b lt |bs @ bCCC bll
lntake t|m|n¿ b` B10C·Zß` /10C
LxHaust t|m|n¿ 3ß` BB0C·b` B10C
Va|ve |asH .Cbmm
ld|e speed ìßbC·ì9CCbll
0|| svstem lressure/sp|asH
0|| pump lnterna| ¿ear
0|| h|ter lu||·Now h|ter and screen
0|| capac|tv .ßl |3Z ozì
Coo||n¿ 0ucted lorced a|r
A|r c|eaner loam and paper
Carburetcr type CVb bC
Ventur| ìßmm
Thrctt|e mechan|sm ButterNv tvpe
Ign|t|cn system C0l tvpe
ì3`B10C @ ZCCC bll
3park p|u¿ N0b C/H3/ CHamp|on
/9Y
0ap .b·.bmm |.CZZ·.CZ4 |ncHì
Batterv ìZV 4/H
Dr|ve system
C|utcH 0rv mu|t| p|ate
1ransm|ss|on CV1
3H|lt|n¿ /utomat|c
l|na| 0r|ve 0oub|e reduct|on
ìst step 3.Z:ì
Znd step 3.4:ì
Steer tube ang|e b4`
Steer|ng ang|e 4b`
T|re pressure frcnt ì./bk¿/cm |Zbps|ì
T|re pressure rear Z.Zbk¿/cm |3bps|ì
Frcnt brake Hvdrau||c d|sc
Rear brake lecHan|ca| drum
Suspens|cn frcnt 1e|escop|c
Suspens|cn rear 1ra|||n¿ arm
Shcck abscrber frcnt Co|| spr|n¿/Hvdrau||c
Shcck abscrber rear Co|| over Hvdrau||c sHock
Frame type 1ubu|ar space lrame
I. Genera| Infcrmat|cn
ºbep|ace a|| ¿askets, o·r|n¿s, c|rc||ps
and cotter p|ns wHen perlorm|n¿
ma|ntenance on tHe scooter. Nuts and
bo|ts on a|| en¿|ne covers sHou|d be
t|¿Htened |n a d|a¿ona| pattern to
un|lorm|v d|str|bute c|amp
lorce.
º0se |ubr|cants recommended |n tH|s
manua| at a|| t|mes to assure peak
perlormance lrom tHe scooter.
º0se on|v ¿enu|ne rep|acement parts
wHen perlorm|n¿ repa|rs to tHe scooter.
º3pec|a| serv|ce too|s mav be reuu|red
to perlorm ma|ntenance and repa|rs on
tH|s scooter. /|wavs use tHe proper too|s
to prevent dama¿e to tHe scooter.
ºC|ean and |ubr|cate a|| en¿|ne parts
dur|n¿ tHe d|sassemb|v and reassemb|v
process to prevent dama¿e to tHe
en¿|ne.
Techn|ca| T|ps
I. Genera| Infcrmat|cn
ºwHen perlorm|n¿ ma|ntenance on tHe
scooter, make sure tHat a|| mov|n¿ parts
and contro|s move lree|v and return to
tHe|r proper pos|t|on.
ºwHen connect|n¿ tHe batterv, a|wavs
connect tHe pos|t|ve term|na| hrst.
ºwHen d|sconnect|n¿ tHe batterv, a|wavs
d|sconnect tHe ne¿at|ve term|na| hrst.
ºlake sure tHat too|s and serv|ce
euu|pment do not come |n contact w|tH
botH batterv term|na|s.
ºCover botH batterv term|na|s w|tH a
||¿Ht coat ol ¿rease to prevent
corros|on.
Techn|ca| T|ps (ccnt|nued)
I. Genera| Infcrmat|cn
Techn|ca| T|ps (ccnt|nued)
ºwHen rep|ac|n¿ luses, a|wavs use an
exact rep|acement. 0o not use luses ol
a H|¿Her amp rat|n¿|
ºbep|ace a|| rubber caps on w|re
connectors alter perlorm|n¿
ma|ntenance.
ºwHen d|sconnect|n¿ w|re connectors,
press hrm|v on tHe |ock|n¿ tab and pu||
tHe bodv ol tHe connectors. Never pu||
on tHe w|res
ºwHen assemb||n¿ w|re connectors,
press hrm|v to assure tHe |ock tab lu||v
en¿a¿es.
ºlake sure tHat a|| w|re term|na|s are
proper|v |n p|ace belore attempt|n¿ to
assemb|e anv w|re connector.
YL3
N0
I. Genera| Infcrmat|cn
Techn|ca| T|ps (ccnt|nued)
ºlake sure tHat a|| w|r|n¿ connectors are lu||v
seated and |ock tubs en¿a¿ed.
ºCHeck |l a|muce ol connector |s covered and
hxat|on |s t|¿Ht.
ºlake sure tHat a|| protect|ve covers are
proper|v |n p|ace over tHe w|r|n¿ connectors.
ºNever reuse dama¿ed w|re term|na|s or
connectors.
ºNever reuse dama¿ed w|re term|na|s or
connectors.
ºbep|ace a|| rubber covers on w|re connectors
to prevent water lrom ¿ett|n¿ |nto tHe
connector.
º3tr|p ol ma|n w|re must be hxed on ass|¿ned
pos|t|on.
ºlnsu|ator ol a|um|num str|p must be alhxed to
w|res.
ºlake sure tHat a|| w|r|n¿ Harness reta|ners are
proper|v p|aced.
º0o not over t|¿Hten w|r|n¿ t|es to prevent
p|ncH|n¿ ol w|res.
º0o not a||ow w|r|n¿ Harness to Han¿ |n |oose
|oops.
I. Genera| Infcrmat|cn
Techn|ca| T|ps (ccnt|nued)
ºlake sure tHat a|| w|re c||ps are
proper|v attacHed.
ºlake sure tHat tHe w|r|n¿ Harness and
a|| w|res do not contact mov|n¿ or
rotat|n¿ parts ol tHe scooter.
ºlake sure tHat tHe w|r|n¿ Harness and
a|| w|res do not contact Hot components
or surlace parts ol tHe scooter.
ºlake sure tHat tHe w|r|n¿ Harness and
a|| w|res do not contact sHarp ed¿es or
parts ol tHe scooter. 0se tape to prevent
dama¿e to w|res on sHarp ed¿es.
YL3
YL3 YL3
N0
N0
N0
N0
I. Genera| Infcrmat|cn
Techn|ca| T|ps (ccnt|nued)
º0o not pu|| w|res too t|¿Ht|v.
º0se tape to protect a¿a|nst sHarp ed¿es.
ºlake sure tHat a|| rubber ¿rommets are |n
p|ace to protect tHe w|r|n¿ Harness.
º0o not reuse broken or lraved w|res.
ºbepa|r or rep|ace w|res as necessarv.
I. Genera| Infcrmat|cn
Techn|ca| T|ps (ccnt|nued)
º0o not tw|st or knot w|res wHen
perlorm|n¿ ma|ntenance on tHe scooter.
ºlake sure tHe w|r|n¿ Harnesses to tHe
Hand|ebars are not too t|¿Ht or too |oose
bv turn|n¿ tHe Hand|ebars botH r|¿Ht and
|elt wH||e mak|n¿ sure tHere |s no p|ncH|n¿
or pu|||n¿ ol tHe w|res.
ºlake sure tHat vou understand tHe proper
use ol test euu|pment to perlorm
ma|ntenance on tHe scooter. 1H|s w|||
prevent acc|denta| dama¿e to tHe
e|ectr|ca| svstem ol tHe scooter.
º0se e|ectr|ca| contact c|eaner and
abras|ve paper to c|ean corros|on lrom anv
w|re term|na|s.
º1ake care to prevent |nadvertent dama¿e
to w|r|n¿ and cab|es.
YL3
N0
N0
I. Genera| Infcrmat|cn
Techn|ca| T|ps (ccnt|nued)
Dehn|t|cns cf d|agrams
1He lo||ow|n¿ |cons are used to H|¿H||¿Ht |mportant
operat|ons |n tHe serv|ce ol tHe scooter.
lubr|cat|n¿ o|| reuu|red.


0rease reuu|red.

Ln¿|ne o|| reuu|red.



3pec|a| too|s reuu|red.

3pec|a| attent|on reuu|red.


0an¿erous and |mportant,
spec|a| care reuu|red.
I. Genera| Infcrmat|cn
Tcrque Sett|ngs
1oruue
Standard Tcrque Sett|ngs
bmm Cap 3crew
bmm Cap 3crew
ßmm Cap 3crew
ìCmm Cap 3crew
ìZmm Cap 3crew
.b k¿/cm
ì k¿/cm
Z.Z k¿/cm
3.b k¿/cm
b.b k¿/cm
1oruue lastener 1vpe lastener 1vpe
bmm 3ocket Head 3crew
bmm 3ocket Head 3crew
ßmm l|an¿e Head 3crew
ìCmm l|an¿e Head 3crew
ìZmm l|an¿e Head 3crew
.4 k¿/cm
.9 k¿/cm
ì.Z k¿/cm
Z./ k¿/cm
4.C k¿/cm
0enera| 1oruue beuu|rements lor 3tandard lasteners
Number
0sed
Spec|a| Tcrque Sett|ngs
Cv||nder Bo|t /
Cv||nder Bo|t B
0|| l||ter 3creen Cap
LxHaust l|pe l|an¿e Bo|t
l|an¿e 3crew Be|t lu||ev
Va|ve /djusters
Cam CHa|n /djuster
0u|de l|ate 3crew
/ 0|| l||| 3crew
C|utcH Cover 3crew
C|utcH 0r|ven 0n|t
lount|n¿ 3crew
3tarter lotor lount|n¿ 3crew
0|| lump lount|n¿ 3crew
C|utcH 0r|ver lount|n¿ 3crew
/C0 co|| lount|n¿ 3crew
Cam CHa|n /djuster 3crew
3park l|u¿
Z
Z
ì
Z
4
Z
ì
ì
ì
ì
Z
3
ì
3
ì
ì
1oruue
k¿ m ||n. |bsì
Comments
0|a.
|mmì
lastener 1vpe
ß
ß
3C
b
ß
b
b
ß
ìZ
ìZ
b
b
ìZ
b
b
ìC
.9
.9
ì.b
.9
Z.C
.9
ì.C
ì.3
b.b
b.b
ì.C
ì.Z
b.b
ì.C
.b
ì.Z
lubr|cate w|tH Ln¿|ne 0||
lubr|cate w|tH Ln¿|ne 0||
1oruue beuu|rements lor Ln¿|ne lasteners
Number
0sed
Cv||nder Bo|t /
Cv||nder Bo|t B
0|| l||ter 3creen Cap
LxHaust l|pe l|an¿e Bo|t
l|an¿e 3crew Be|t lu||ev
Va|ve /djusters
ì
ì
ì
ì
ì
ì
1oruue
k¿ m ||n. |bsì
Comments
0|a.
|mmì
lastener 1vpe
Zb.4
ìC
ì4
ìC
ß
b
ß·ìZ
4·b
ß·ìC
3·4
Z·3
.b
0se 3olt 3et lock·1|te
1oruue beuu|rements lor lrame lasteners
I. Genera| Infcrmat|cn
epa|r ol tHe
scooter, a comp|ete bas|c set ol metr|c s|zed
too|s |s reuu|red. 1H|s sHou|d |nc|ude; 0pen·end
wrencHes, sockets and ratcHet, Hex kevs, stra|¿Ht
and lH|||ps screw dr|vers, standard p||ers,
need|e·nosed p||ers, w|re cutters, w|re str|ppers,
scraper, p|n puncH, Hammer and solt laced ma||et.
lor a more extens|ve tear down and rebu||d ol tHe
scooter, tHere are a var|etv ol spec|a| too|s tHat
w||| be reuu|red. 1Hese |nc|ude tHe lo||ow|n¿:
ºVa|ve spr|n¿ compressor
ºVa|ve ¿u|de reamer
ºlee|er ¿a¿e set
º3||de Hammer bear|n¿ and sea| remover
ºBear|n¿ press
º1oruue wrencH
ºb|n¿ compressor
ºC|utcH spr|n¿ compressor
ºl|v wHee| pu||er
ºL|ectron|c mu|t| meter
Tcc| Requ|rements
I. Genera| Infcrmat|cn
Lubr|cat|cn Requ|rements: Eng|ne
va|ve ¿u|de va|ve stem mov|n¿ part
cam sHalt |u¿ surlace
va|ve rock|n¿ arm lr|ct|on surlace
camsHalt dr|ve cHa|n
cv||nder hxed screw bo|ts and nuts
around p|ston and p|ston r|n¿ ¿roove
around p|ston p|n
cv||nder surlace
connect|n¿ rod, p|ston p|n bore
connect|n¿ rod b|¿ end
cranksHalt b, l s|de o|| sea|
starter reduct|on rear en¿a¿|n¿ |mat|n¿ì part
coundersHalt ¿ear en¿a¿|n¿ part
hna| ¿ear en¿a¿|n¿ part
eacH bear|n¿ rotat|ona| part
o·r|n¿ surlace
o|| sea| ||p
starter |d|e ¿ear
lr|ct|on spr|n¿ mov|n¿ part, sHalt mov|n¿ part
sHalt mov|n¿ ¿roove part
starter dr|ve ax|e
/C·¿enerator connector
Item Lccat|cn Reccmmended Lubr|cant
3/L bw 3C Ln¿|ne 0||
/ll·30 0rade Ln¿|ne 0||
o||
¿rease
o||
o||
o||
o||
o||
o||
o||
o||
o||
¿rease
o||
o||
o||
¿rease
o||
¿rease
adHes|ve
I. Genera| Infcrmat|cn
LN0lNL 0ll:
º3lLL00lL1Lb
0blVL
0bL/3L:
º3lLL0 lL1Lb llL/lBlL 3H/l1
ºlb0N1 wHLLl BL/blN0
ºBb/bL C/l
ºll/L0 llN
ºlb0N1 3H0Cb /B30bBLb B/3L
0bL/3L:
ºCLN1Lb 31/N0 llV01
0bL/3L:
ºbL/b wHLLl BL/blN0
0bL/3L:
ºbL/b Bb/bL lLVLb llV01
0bL/3L:
º3L/1 l/1CH
0bL/3L:
ºbL/b Bb/bL
00l0L llNL
0bL/3L:
ºBb/bL C/l
/N0 llN
º/pp|v o|| to tHe lo||ow|n¿ parts.
º0se ¿rease |n tHe parts otHer tHan spec|hed
ones.
º/pp|v en¿|ne o|| or ¿rease to tHe mov|n¿ parts to
prevent abnorma| no|se and to ra|se durab|||tv.
Chass|s
I. Genera| Infcrmat|cn
Cab|e Rcut|ng D|agram
/010l/1lC BY·l/33
31/b1Lb bL3l31/NCL
ll/3HLb
H0bN
l/lN 3wl1CH
1Hb011lL C/BlL
lb0N1 Bb/bL
3wl1CH lL/0
lb0N1 Bb/bL C/BlL
bL/b Bb/bL 3wl1CH lL/0
3lLL00lL1Lb C/BlL
bL/b Bb/bL C/BlL
HL/0ll0H1 lL/0 C0NNLC10b
HL/0ll0H1 bL3l31/NCL
V0l1/0L bL00l/1l0N/bLC1lllLb
I. Genera| Infcrmat|cn
3lLL00lL1Lb C/BlL
lb0N1 0l3C Bb/bL H03L
bL/b Bb/bL C/BlL
1Hb011lL C/BlL
/010l/1lC
LNblCHlLN1
bL3l31/NCL
HL/0ll0H1
bL3l31/NCL
V0l1/0L bL00l/1l0N bLC1lllLb
l/lN H/bNL33
1Hb011lL C/BlL
bL0 B/11LbY C/BlL l03l1lVL
l03L
0bLLN B/11LbY C/BlL NL0/1lVL
I. Genera| Infcrmat|cn
I. Genera| Infcrmat|cn
l0Nl1l0N C0ll
l0Nl1l0N C/BlL
V/C00l llNL
b0CbLb C0VLb VLN1
Cb/NbC/3L VLN1
1Hb011lL
l0Ll llNL
I. Genera| Infcrmat|cn
l0Ll 3LN30b
1Hb011lL C/BlL
31/b1Lb LNblCHlLN1
V/C00l llNL
V/C00l llNL
l0Nl1l0N C0ll
Cb/NbC/3L
BbL/1HLb
Cb/NbC/3L BbL/1HLb
l0Ll l/33/0L
l0Ll V/l0b bL10bN lllL
31/b1Lb LNblCHlLN1
C/BlL
31/b1Lb l010b C/BlL
l/lN wlblN0 H/bNL33
l/lN wlblN0
H/bNL33
lVC |l0Ll
C0N1b0l V/lVLì
3l/bb ll00
I. Genera| Infcrmat|cn
B
/
w
w
B
|
l
/
3
3
0
ll
l
L
b

3
w
l1
C
H
H
L
/
0

l
l0
H
1
l
0
L
l

l
L
1
L
b
l
b
0
N
1
1
0
b
N
l
L
l
1
l
l0
H
1
l
B
|
0
b
1
0
b
N

3
w
l1
C
H
B
l
0
H
0
b
N

B
0
1
1
0
N
b
L
/
b

B
b
/
b
L

3
w
l1
C
H
l
0
L
l

3
L
N
0
L
b
0
N
0
l
l
B
0
/
Y
0
N
0
l
l
B
b
B
/
w
0
l
/
lN

3
w
l1
C
H
B
l
Y
B
/
w
l
l0
H
1

3
w
l1
C
H
B
r
b
L
/
b

1
0
b
N
l
l0
H
1

|b
l0
H
1
ì
1
/
ll
/
B
b
/
b
L
l
l0
H
1
b
L
/
b

1
0
b
N
l
l0
H
1

|l
L
l
1
ì
H
l0
H

B
L
/
l

lN
0
lC
/
1
0
b

l
l0
H
1
l
L
1
L
b

l
l0
H
1
1
0
b
N

lN
0
lC
/
1
0
b

l
l0
H
1
l
b
0
N
1

1
0
b
N

b
l0
H
1

l
l0
H
1
H
0
b
N
0
N
0
l
l
0
l
b
0
N
1
3
1
/
b
1
lN
0

B
b
/
b
L

B
/
1
1
L
b
Y
l
l
/
3
H
L
b
b
L
l
/
Y
b
w
ì
4
/
0
1
0
L
N
b
lC
H
L
b
B
0
1
1
0
N
b
/
Y
0
N
0
l
l
0
3
w
l1
C
H
0
/
Y
0
N
0
l
l
L
l
L
b
0
L
N
C
Y
3
1
0
l

3
w
l1
C
H
0
B
/
w
Y
0
/
B
B
0
0
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r
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l
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r
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Z
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b
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l
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3
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b
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L
b
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l
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b
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l1
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l
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e
I. Genera| Infcrmat|cn
Trcub|e Shcct|ng Gu|de
Starter Fa||ure cr Hard Start|ng
Check Adjust Fau|ty Ccnd|t|cn Cause cf Trcub|e
3upp|v app|v
enou¿H lue|
1Here |s spark over |n spark p|u¿
1est compress|on pressure
1Here |s no spark or weak spark
No compress|on pressure
or compress|on pressure
too |ow
Norma| compress|on pressure
No lue| supp||ed to carburetor
loosen carburetor overNow screw
and cHeck |l tHere |s lue| |n |t
bemove spark p|u¿ |nsta|| |t |n |ts
cap and connect |t to en¿|ne to
lor spark
3tart accord|n¿ to operat|n¿ metHod
No |¿n|t|on spark
3park p|u¿ wet 3park p|u¿ drv
|Ln¿|neì Hav|n¿ |¿n|t|on
spark but not to start
bemove spark p|u¿ a¿a|n and cHeck
No lue| |n tank
l|oat passa¿e c|ocked
lassa¿e lrom tank
to carburetor b|ocked
/|r Ho|e |n lue| tank cap b|ocked
lue| h|ter screen b|ocked
Vacuum sw|tcH lau|tv
lue| h|ter b|ocked
3park p|u¿ bad
l|ckup co|| bad
3park p|u¿ d|rtv and broken
C.0.l. bad
l¿n|t|on co|| broken c|rcu|t
l¿n|t|on co|| broken w|re
or sHort c|rcu|t
la|n sw|tcH bad
or sHort c|rcu|t
3tarter c|utcH bad
Cv||nder p|ston or p|ston r|n¿ bad
Va|ve too t|¿Ht
Va|ve set bad
Cv||nder ¿asket |eak|n¿
Va|ve t|m|n¿ |mproper
Va|ve burned
/utomat|c cHoke perlormance
Carburetor o|| uuan|t|tv
/|r |n|et |mproper man|lo|d
l¿n|t|on t|me wron¿
re¿u|at|on screw bad
Carburetor o|| |eve| too H|¿H
1Hrott|e va|ve open|n¿ too w|de
/uto·enr|cH|n¿ dev|ce start
enr|cHment lau|tv
I. Genera| Infcrmat|cn
Check Adjust Fau|ty Ccnd|t|cn Cause cf Trcub|e
Ln¿|ne bll 0b low Ln¿|ne bll
l¿n|t|on t|m|n¿ correct l¿n|t|on t|m|n¿ |ncorrect
3upp|v en¿|ne w|tH lue| and watcH
be¿u|ate |¿n|t|on t|me us|n¿ t|m|n¿ |amp
Va|ve re¿u|at|on la||ure
1est compress|on pressure determ|n|n¿
Va|ve ¿ap correct Va|ve ¿ap |ncorrect
/|r h|ter b|ocked
lue| tank cap a|r b|eeder
b|ocked
lue| cHoke
LxHaust p|pe b|ocked
Carburetor d|apHram broken
/utomat|c o|| cup bad
/uto cHoke bad
C.0.l. bad
l¿n|t|on co|| bad
C|ean
3park p|u¿ Heat va|ue |mproper
Va|ve seat bad
C|ean
Va|ve t|m|n¿ bad
Cv||nder or p|ston worn
0|| passa¿e b|ocked
0|| pump de||verv
Ln¿|ne o|| too mucH
Ln¿|ne o|| uncHan¿ed
Ln¿|ne o|| too ||tt|e
Cv||nder ¿asket |eak|n¿
Va|ve ¿ap adjustment |mproper
Va|ve seat excess|ve|v worn
|va|ve out sHoot|n¿ excess|ve|vì
Compress|on pressure norma| Compress|on pressure too |ow
No b|ocka¿e B|ocked
Not d|rtv or d|sco|ored 0|rtv or d|sco|ored
CHeck lor carburetor b|ocka¿e
bemove spark p|u¿ to cHeck
Norma| |eve| too mucH
CHeck en¿|ne o|| |eve| or uua||tv |n crank case
Norma| /bnorma|
CHeck cv||nder Head |ubr|cat|on
Not too Hot too Hot
CHeck en¿|ne Heat|n¿
No knock|n¿ bnock|n¿
/cce|erat|on or run at a H|¿H speed cont|nuous
l|ston or cv||nder worn
depos|t too mucH
l|xture excess|ve|v tH|n lue| |mproper
Combust|on cHamber carbon
l¿n|t|on t|me too ear|v
Combust|on cHamber
C|utcH s||pp|n¿
Carbon depos|t too mucH
lue| bad
l|xture weak
l¿n|t|on t|m|n¿ too ear|v
Trcub|e Shcct|ng Gu|de
(under speed, nc pcwer)
I. Genera| Infcrmat|cn
Trcub|e Shcct|ng Gu|de (under speed, nc pcwer)
Check Adjust Fau|ty Ccnd|t|cn Cause cf Trcub|e
Norma| /bnorma|
0ood Bad
/djust |¿n|t|on t|me
/djust carbureator adjust|n¿ screw
CHeck lor carburetor ¿asket a|r |eaka¿e
bemove spark p|u¿ and |nsta|| |t |n |ts cap and
connect |t w|tH en¿|ne to cHeck lor spark over
No a|r /|r |ntaken
C.0.l. bad
1r|¿¿er co|| bad
l|xture |ean
1oo r|cH |to t|¿Hten screwì
|to |oosen screwì
l|xture
0ood Bad
0ood Bad
CHeck /.C.V.
Heat sH|e|d bad
Ne¿at|ve pressure p|pe broken
Carburetor Ho|d·down nut |oose
Heat sH|e|d broken
3park p|u¿ bad or d|rtv
l¿n|t|on co|| bad
C0l bad
Batterv d|scHar¿ed
|ead broken or sHort c|rcu|t
la|n sw|tcH bad spark p|u¿
/.C.V. bad
Ne¿at|ve pressure p|pe dama¿ed
/|r b|eeder b|ocked or dama¿ed
I. Genera| Infcrmat|cn
Trcub|e Shcct|ng Gu|de
(h|gh speed)
Check Adjust Fau|ty Ccnd|t|cn Cause cf Trcub|e
Norma| /bnorma|
Norma| /bnorma|
/djust |¿n|t|on t|m|n¿
/djust va|ve ¿ap
CHeck lue| |n automat|c o|| cup
CHeck carburetor lor b|ocka¿e
Norma| /bnorma|
C.0.l. bad
1r|¿¿er co|| bad
/djustment |mproper
CamsHalt worn
Va|ve sea| bad
No b|ock|n¿ B|ocked
Correct wron¿
CHeck va|ve t|m|n¿ adjustment
0ood 3pr|n¿ broken or lat|¿ued
CHeck va|ve spr|n¿
1oo ||tt|e lue|
lue| h|ter b|ocked
Vacuum sw|tcH bad
C|ean
1|me ¿ear marks not a||¿ned
3pr|n¿ bad
I. Genera| Infcrmat|cn
Trcub|e Shcct|ng Gu|de-Imprcper ßattery Charg|ng
(ßattery cverd|scharge cr cvercharge)
Check Adjust Fau|ty Ccnd|t|cn Cause cf Trcub|e
Batterv vo|ta¿e uncHar¿ed Norma| |ìZ.b·ì4Vì
Norma| 1est va|ve too H|¿H
3tart en¿|ne and measure batterv term|na|s lor ||m|ted vo|ta¿e
1est /C ma¿netor co|| res|stance va|ue
CHeck re¿u|ated rect|her. 1est vo|ta¿e bv connect|n¿ red w|re
to pos|t|ve term|na| wH||e ne¿at|ve term|na| bodv
CHeck rect|her connector lor |oosen
Vo|ta¿e No vo|ta¿e
Batterv serv|ce ||le over
Batterv bad
lau|tv re¿u|ated rect|her
lau|tv connector
Co|| bad
Ye||ow w|re broken c|rcu|t
lau|tv connector
Norma| /bnorma|
Batterv w|tH ma|n sw|tcH on Hav|n¿ no vo|ta¿e w|tH ma|n sw|tcH |n `on`
1est vo|ta¿e bv connect|n¿ ¿reen w|re to and to bodv.
Norma| 3pr|n¿ broken or lat|¿ued
CHeck re¿u|ated rect|her connector lor poor contact
bed w|re broken
/C0 bad
0reen w|re broken
Connector contact poor
be¿u|ated rect|her bad
lmproper|v cHar¿ed |overcHar¿edì
I. Genera| Infcrmat|cn
Trcub|e Shcct|ng Gu|de
(nc spark)
Check Adjust Fau|ty Ccnd|t|cn Cause cf Trcub|e
3park weak or spark|ess 3park stron¿
lroper loose
bep|ace spark p|u¿ and cHeck a¿a|n
CHeck spark p|u¿ cap and |¿n|t|on co|| lor |ooseness
CHeck C0l connector lor |ooseness
CHeck lor conduct|on between connector
term|na|s and test C0l res|stance
Norma| /bnorma|
lormer spark p|u¿ bad
la|n sw|tcH bad
l¿n|t|on co|| bad
l|ckup co|| bad
C0l bad
la|n cab|e broken
Connector p|u¿ poor contact
3park p|u¿ cap |oose
loor Contact
Norma| /bnorma|
Norma|
Norma|
Norma|
/bnorma|
/bnorma|
/bnorma|
/bnorma|
CHeck re|ated parts
0se C0l tester to cHeck C0l
CHeck |¿n|t|on co|| us|n¿ C0l tester
l¿n|t|on co|| bad
I. Genera| Infcrmat|cn
ßcdy Exp|cded V|ew
Z. ßcdy Ccver and Exhaust System
º0o not use excess|ve lorce wHen remov|n¿ bodv
pane|s. 0se a hrm, cons|stent lorce to d|sen¿a¿e
tHe tabs and remove tHe pane|s.
º0o not prv or pound on tHe bodv pane|s. 1He
mount|n¿ tabs are not des|¿ned to w|tHstand
prv|n¿, pound|n¿ or tw|st|n¿.
larts to be removed and seuuence ol remova|.
ºlront Head||¿Ht and meter cover.
ºBack Head||¿Ht and meter cover.
ºlront lender.
ºlront bodv cover.
ºlront bodv pane|.
º3eat and He|met box.
ºbear HandHo|d and ta||||¿Ht assemb|v.
ºlootboard cover and batterv cover.
ºlootboard and rear cover.
ºlront lrame cover.
ºCovers and bodv s|de pane|s.
ºBottom cover.
1oruue reuu|rements
ºBodv mount|n¿ nuts and screws ì.Zk¿·m
ºLxHaust p|pe bo|ts 3bk¿·m
Tcp|c Fage
0enera| lnlormat|on Z·ì
Bodv Cover bemova| Z·Z
LxHaust 3vstem bemova| Z·4
Genera| Infcrmat|cn
ßcdy Ccver Remcva|
Frcnt Fane| Remcva|
ì. bemove one lront cover
screw lrom lront ol pane|.
Z. bemove two screws on botH
|elt and r|¿Ht s|des. bemove
lront pane|. lnsta|| lront pane| |n
tHe reverse order.
Frcnt Ccver Remcva|
3. bemover rear cover, |elt and
r|¿Ht s|de covers and lront wHee|.
4. bemove two screws |n lront
cover |4aì.
and remove two screws on eacH
s|de ||elt and r|¿Htì |4bì. bemove
lront cover.
b. lnsta|| lront cover |n tHe
reverse remova| order.
b. lake sure to support tHe
scooter wH||e remov|n¿ tHe lront
wHee| to prevent |t lrom
la|||n¿.
Frcnt and Rear Hand|ebar
Ccver Remcva|
/. bemove two screws on lront
ol Hand|ebar cover and remove
one screw |n botH r|¿Ht and |elt
s|des ol rear Hand|ebar cover.
ß. 0|sconnect Head||¿Ht |ead
and remove lront Hand|ebar
cover.
9. 0|sconnect speedometer
|ead, |elt and r|¿Ht sw|tcHes and
brake sw|tcH connector. bemove
one hx screw |n rear Hand|ebar
cover.
ìC. bemove tHe hx screw |n eacH
s|de ol rear Hand|ebar cover.
bemove rear Hand|ebar cover.
ìì. bemove tHe remova| order
lor |nsta||at|on.
lb0N1 C0VLb
3CbLw3
4a
4b
/
lb0N1
H/N0lLB/b
C0VLb
9
3lLL00lL1Lb C/BlL
lb0N1 Bb/bL
3wl1CH lL/0
lb0N1 Bb/bL
C/BlL
bL/b Bb/bL
3wl1CH lL/0
bL/b Bb/bL C/BlL
Z. ßcdy Ccver and Exhaust System
Z. ßcdy Ccver and Exhaust System
ßcdy Ccver Remcva|
ì. bemove m|dd|e |u¿¿a¿e
box alter open|n¿ tHe seat
and remov|n¿ tHe lour |ock
nuts.
Z. bemove two center cover
screws.
3. bemove center cover.
4. bemove |elt and r|¿Ht
cover. |Z·3ì
b. bemove tHree rear·rack
screws.
b. bemove rear rack.
/. bemove screws |n rear ol
bodv pane|.
ß. bemove tHe two screws |n
tHe lront ol tHe bodv
pane|.
9. 0|sconnect seat |ock |ead.
ìC. bemove tHe remova|
order lor |nsta||at|on.
lake sure to connect
seat |ock |ead wHen
|nsta|||n¿ bodv cover.
ì
3
/
3L/1
ll00lL l000/0L B0/
CLN1Lb
C0VLb
b
b
l000/0L b/Cb
Z. ßcdy Ccver and Exhaust System
R|ght and Left S|de Mc|d
Remcva|
ì. bemove two rear bodv screws.
Z. bemove tHree screws |n e|tHer
s|de ol mo|d.
3. bemove |elt and r|¿Ht s|de
pane|s.
ßcdy under Ccver Remcva|
b. bemove rear bodv pane|.
b. bemove |elt and r|¿Ht s|de
pane|s.
/. bemove two nuts |n e|tHer s|de
ol bodv under cover.
ß. bemove bodv cover.
F|ccr Fane| Remcva|
ì. bemove batterv cover,
d|sconnect batterv |ead and
d|smount batterv.
Z. 0|sconnect C.0.l. w|re and take
|t out ol batterv box.
3. bemove bodv cover.
4. bemove tHe speed·||m|t|n¿
¿overnor.
b. bemove lour cHeck bo|ts |n tHe
Noor pane|.
b. bemove Noor pane|.
ì Z
7 /
ll00b C0VLb
b
B00Y 0N0Lb C0VLb
N013
Z. ßcdy Ccver and Exhaust System
Frcnt ßcx Remcva|
ì. bemove lront cover and lront pane|.
Z. bemove two catcH bo|ts |n tHe lront ol
tHe Noor pane|.
3. bemove tHe lront box catcH bo|t.
4. bemove ma|n sw|tcH outer r|n¿ and tHen
remove lront box outward|v and upward|v.
Frcnt and Rear Fenders Remcva|
ì. bemove tHe two hx screws |n tHe lront
lender.
Z. 0|smount tHe lront lender.
3. bemove tHe two catcH bo|ts |n tHe
rear lender stav.
4. bemove tHe rear lender stav.
Exhaust F|pe Remcva|
ì. bemove tHe two nuts |n tHe p|pe jo|nt.
Z. bemove tHe two p|pe catcH bo|ts.
3. bemove tHe exHaust p|pe.
4. bemove tHe jo|nt r|n¿.
ºlns!all exhaus! pipe join! rinç beíore
ins!allinç exhaus! pipe.
ºlns!all exhaus! pipe join! nu!s and ías!en
!hem and !hen ins!all exhaus! pipe ca!ch
bol!s and ías!en !hem.
]oroue.
ºLxhaus! pipe ca!ch bol! 3.bkç´m
ºLxhaus! pipe join! jam nu! 1.2kç´m
ºUse a new exhaus! pipe carrier rinç when
reassemblinç !he exhaus! sys!em.
Z
Z
4
lb0N1 B0/
lb0N1 lLN0Lb
Z
Z
3. Schedu|ed Ma|ntenance
Tcp|c Fage
lrame and 1|re 1vpe 3·Z
la|ntenance CHart 3·3
lue| l||ter 3·4
1Hrott|e 0perat|on lever 3·4
/|r h|ter 3·b
bep|ac|n¿ lreuuencv 3·b
3park l|u¿ 3·b
Va|ve /djustment 3·b
Carburetor ld|e 3peed 3·b
l¿n|t|on 1|m|n¿ 3·/
Cv||nder lressure 3·/
bemov|n¿ tHe 3park l|u¿ 3·/
l|na| beduct|on 0ear Ln¿|ne 0|| 3·ß
Tcp|c Fage
0r|ve Be|t 3·ß
bear Brake /rm 3·9
Brake 3vstem lront Brake 3·9
bear Brake 3·9
lront lamp /djustment 3·ìC
C|utcH Ln¿a¿ement 3·ìC
lront 3uspens|on 3·ìC
bear 3uspens|on 3·ìC
Nut and Bo|t 1|¿Htness 3·ìì
Co||ar b|m 1|re 3·ìì
/|r lressure 3·ìì
1|re 3tandards 3·ìì
3teer|n¿ 3vstem 3·ìZ
Genera| Infcrmat|cn
Warn|ng
/|wavs make sure vou are |n a we||·
vent||ated area belore tHe en¿|ne
starts. Never start tHe en¿|ne |n an
enc|osed area. 0aso||ne powered
en¿|ne exHaust lumes are po|sonous
and can cause |oss ol consc|ousness
and deatH. 0o not smoke or a||ow
open Names or sparks |n or near tHe
area wHere relue||n¿ |s perlormed or
wHere ¿aso||ne |s stored.
3. Schedu|ed Ma|ntenance
Frame
ºlront brake |ever lree p|av: ìC·ZCmm
ºbear brake |ever lree p|av: ìC·ZCmm
T|re type
ºlront: 3.CC xìC
ºbear: 3.CC xìC
1oruue:
ºlront wHee| ax|e nut 4.C·b.Ck¿/m
ºbear wHee| ax|e nut ß.C·ìC.Ck¿/m
1|re un|t: k¿/cm
Z
ì lerson
lront
bear
ì.b, ì/ ps|
Z.C, Z3 ps|
ì./b, ì9 ps|
Z.Z, Zß ps|
Z lersons
3. Schedu|ed Ma|ntenance
Ma|ntenance Chart
lerlorm re¿u|ar ma|ntenance, accord|n¿ to
ma|ntenance Handbook.
l: lnspect, c|ean, |ubr|cate, add hx or rep|ace
wHen necessarv.
/: /djust B: C|ean C: bep|ace 0: 1|¿Hten
3. lore lreuuent rep|acement |s reuu|red |l tHe
veH|c|e |s subjected to sever use, sucH as Heavv
|oad operat|on, |on¿ tr|ps or operat|on |n ra|n.
ºlor saletv reasons, |t |s recommended tHat
serv|ce be perlormed bv a dea|er.
Ncte:
ì. lor m||ea¿e H|¿Her tHan wHat |s spec|hed |n
tHe cHart, tHe ma|ntenance sHou|d be repeated
at tHe same |nterva| ||sted.
Z. lore lreuuent ma|ntenance |s reuu|red |l
tHe veH|c|e |s used |n dustv areas or |n ra|n.
Wh|chever
ccmes hrst
Note 3
Note Z, 3
C|ean everv 3CCCbm bep|ace wHen necessarv
Ln¿|ne o||
Ln¿|ne o|| h|ter
lue| h|ter screen
0ear o||
Va|ve ¿ap
Carburetor
/|r h|ter
3park p|u¿
Brake svstem
0r|ve be|t
3uspens|on
3crews and nusts
1|re
3teer|n¿ stem bear|n¿
Frequency
Item
km
ìCCC
/ / / /
l
l b b
l l
b b b b b b b
C C
b
b
b
b
b b b
l l l
l
l
l l
l l
l l
l
l
l
l l l l
l
l
l
M||eage (Km)
km
ZCCC
km
3CCC
km
4CCC
km
bCCC
km
bCCC
km
/CCC
km
ßCCC
km
9CCC
km
ìCCCC
km
ììCCC
km
ìZCCC
m|
bZC
m|
ìZ4C
m|
ìßbC
m|
Z4ßC
m|
3ìCC
m|
3/ZC
m|
434C
m|
49bC
m|
bbßC
m|
bZCC
m|
bßZC
m|
/44C
tHe hrst
3CCkm/
ìßb m|
new b
3CCkm/
ìßb m|
3CCkm/
ìßb m|
3. Schedu|ed Ma|ntenance
Fue| F||ter
ì. bemove |u¿¿a¿e box |Z·Zì
Z. CHeck lue| ||ne lor a¿e|n¿ or dama¿e.
3. bep|ace w|tH a new one |n case dama¿ed
or |eak|n¿.
Thrctt|e Lever Dperat|cn
ì. CHeck tHrott|e lor proper operat|on.
Z. CHeck tHrott|e ¿r|p lree p|av.
lree p|av: Z·bmm |.C/ß |n.·.Z3b |n.ì.
3. /djust lree p|av us|n¿ tHe adjust|n¿ nut |n
tHe tHrott|e cab|e and tHe adjuster at tHe
carburetor.
ºlajor adjustment sHou|d be made at
carburetor.
º/djust |t bv |oosen|n¿ tHe jam nut and rotat|n¿
adjust|n¿ nut.
ºl|ne adjustment sHou|d be made at tHe tHrott|e
¿r|p.
ºbemove outer cover, |oosen jam nut and
rotate adjust|n¿ nut to adjust |t.
3. Schedu|ed Ma|ntenance
A|r F||ter
F||ter Rep|acement
ì. bemove a|r h|ter cap, hx
screw and remove tHe a|r h|ter
cap.
Z. CHeck h|ter lor d|rt or
dama¿e. bep|ace as necessarv.
0o not attempt to c|ean tHe
h|ter e|ement.
Rep|ac|ng Frequency
ì. lore lreuuent rep|acement
|s reuu|red |l veH|c|e |s dr|ven on
dustv roads or |n tHe ra|n.
Z. lake sure tHe a|r h|ter
cover |s secure|v |n p|ace.
Spark F|ug
ì. bemove spark p|u¿.
Z. CHeck spark p|u¿ lor
burn|n¿, d|rt or depos|t.
3. C|ean |t w|tH a spark·p|u¿
c|eaner or stee| brusH |n case
ol d|rt or carbon depos|ts.
3pec|hed spark p|u¿:
N0b: C/H3/ CHamp|on
CHeck spark p|u¿ ¿ap
0ap: C.b·.C/mm |.CZZ·.CZ4 |n.ì
4. CHeck p|u¿ lor d|rt, carbon
bu||d·up or crack|n¿ ol |nsu|ator.
C.b·.C/mm
.CZZ·.CZ4 |ncH
CYllN0Lb
HL/0 C0VLb
/lb lll1Lb C/l
/lb lll1Lb
3l/bb
ll00
lN30l/10b Cb/Cb
CHLCblN0
ì
ì
Z
0/l, 0lb1Y C/bB0N
B0ll0·0l CHLCblN0
l0lL 3CbLw
Va|ve Adjustment
/|wavs cHeck and adjust w|tH
en¿|ne temperature |ower tHan
3b`C |9b`lì
ì. bemove cv||nder Head cover.
Z. botate coo||n¿ lan to camsHalt. locate
mark at center top, a||¿n|n¿ ma¿neto
Nv wHee| mark w|tH tHat on crankcase.
la¿neto "1' mark and box cranksHalt
mark.
Va|ve gap check|ng and
adjustment va|ve gap:
lN: C.Cbmm |.CCì9/ |n.ì
L/: C.Cbmm |.CCì9/ |n.ì
3. 1o adjust tHe va|ve ¿ap, |oosen am nut
and rotate adjust|n¿ nut.
Va|ve Adjustment Wrench
Be sure to cHeck va|ve ¿ap a¿a|n,
alter |ock|n¿ jam nut.
Carburetcr Id|e Speed
ld|e adjustment sHou|d be made
w|tH tHe en¿|ne warmed up.
ì. bemove cover.
Z. /lter tHe en¿|ne warms up, connect |t
to an en¿|ne revo|ut|on counter.
3. /djust |d|e screw unt|| spec|hed
revo|ut|on |s obta|ned.

Minimum idlinç speed. 1900+190rpm
4. beadjust tHe screw |l tHe |d|e speed
|s not steadv or lue| cannot be
proper|v app||ed.
Z
3
H0lL lN C/l 0L/b
/w/Y lb0l LN0lNL
C/l3H/l1
CH/lN 0L/b
`1` l/bb
CYllN0Lb
HL/0 C0VLb
ì
3
3. Schedu|ed Ma|ntenance
3. Schedu|ed Ma|ntenance
Ign|t|cn T|me
Luu|pped w|tH C0l, tHere |s no need
lor |¿n|t|on sett|n¿.
CHeck |¿n|t|on svstem |l |¿n|t|on t|me
|s |ncorrect.
ì. 0|smount r|¿Ht bodv cover.
Z. bemove |¿n|t|on t|m|n¿ |nspect|on.
3. CHeck |¿n|t|on t|m|n¿ us|n¿ tHe t|m|n¿ ||¿Ht.
Crankcase mark must be a||¿ned w|tH mark
"l' on NvwHee| wH||e en¿|ne |s at |d|e
speed. 1He t|m|n¿ sHou|d advance as tHe
bll |s |ncreased.

1He t|m|n¿ mark sHou|d a||¿n w|tH tHe
crankcase mark at 3CCC bll.
Cy||nder Fressure
ì. leasure cv||nder pressure w|tH tHe en¿|ne
warmed up.
Z. 0|smount m|dd|e |u¿¿a¿e box and m|dd|e
cover |Z·Zì.
Remcve spark p|ug.
ì. lnsta|| cv||nder pressure ¿au¿e.
Z. w|tH tHrott|e va|ve lu||v open, start starter
motor to measure cv||nder pressure. |Zì3ps|ì
3. Compress|on pressure: ìbk¿/cmZ
·bCCrpm.
4. ll tHe pressure |s excess|ve|v |ow, cHeck lor
tHe lo||ow|n¿:
ºVa|ve |eaka¿e
ºVa|ve ¿ap too t|¿Ht
ºCv||nder Head ¿asket dama¿ed
ºl|ston r|n¿ worn
ºl|ston or cv||nder worn
b. CHeck combust|on cHamber and p|ston top
lor excess|ve depos|t |l compress|on pressure
|s too H|¿H.
l0Nl1l0N 1lllN0
lN3lLC1l0N
l/bb `l`
lb0lLblY /ll0NL0
3
Z
1b/N3ll33l0N BLl1
Z
0ll 0b/lN/0L B0l1
/N0 w/3HLb
0L/b 0ll lNlL1
H0lL/CHLCb H0lL
F|na| check cf gear eng|ne c|| reduct|cn
CHeck|n¿ o|| vo|ume, bu||d up ma|n loot
rest so tHat bu||d up bodv becomes
vert|ca| on p|a|n ¿round.
ì. 0|smount ¿ear o|| adjust|n¿ bo|t alter
stopp|n¿ en¿|ne.
Z. 1He o|| |eve| sHou|d be just under tHe
re¿u|at|on screw bo|t Ho|e. /dd ¿ear o|| wHen o||
|eve| |s too |ow.
º0ear o|| recommended: 3/L 9Cw
3. Bu||d up ¿ear o|| re¿u|ator screw bo|t.
4. Conhrm wHetHer or not tHe pack|n¿ wasHer
|s broken.
Chang|ng Gear D||
ì. bemove ¿ear o|| adjust|n¿ bo|t and dra|n o||.
Z. Conhrm wHetHer or not pack|n¿ wasHer |s
broken.
3. /dd recommended ¿ear o||.
º0ear o|| capac|tv: C.ìZ|·4CL3
ºBo|t toruue: C.9k¿·m /ßC |bs.
4. CHeck |l tHere |s anv |eaka¿e alter work |s
perlormed.
Transm|ss|cn ße|t
ì. 0etacH tHe |elt crankcase cover |9·Zì.
Z. CHeck wHetHer tHere |s wear and tear ol
transm|ss|on be|t.
3. CHan¿e w|tH new one wHen necessarv or
dur|n¿ t|me|v ma|ntenance.
ì
3. Schedu|ed Ma|ntenance
3. Schedu|ed Ma|ntenance
Rear ßrake Arm
ì. CHan¿e new peda| wHen brake bar |s pu||ed
to stopp|n¿ pos|t|on and tHe sparrow ol brake
arm |s |n a||¿nment w|tH tHe brake p|ate mark.
ßrake System-Frcnt ßrake
ì. CHeck lree ¿ap ol lront brake bar.
ºlree ¿ap: ìC·ZCmm |C.b |n.ì.
Z. botate adjust|n¿ nut to re¿u|ate lree ¿ap ol
brake bar.
Rear ßrake
ºCHeck lree ¿ap ol rear brake bar.
ºlree ¿ap: ìC·ZCmm |C.b |n.ì.

b01/1L N01
3. Schedu|ed Ma|ntenance
Frcnt Lamp Adjustment
ì. botate nut to adjust lree ¿ap wHen |t
exceeds proper adjustment.
Z. 1urn ma|n sw|tcH to "on' and start
en¿|ne.
3. botate adjust|n¿ screw ol lront |amp
to a|m tHe ||¿Ht.
C|utch Engagement
ì. 3tart en¿|ne and |ncrease bll s|ow|v
to cHeck perlormance ol c|utcH.
ºC|utcH sHou|d en¿a¿e at ZZCC
bll.
º3erv|ce and rep|ace c|utcH as
necessarv sHou|d s||ppa¿e occur.
Frcnt Suspens|cn
ì. lu|| lront brake bar t|¿Ht|v and
compress lront lor up and down to cHeck
|ts perlormance.
Z. CHeck lor |eaka¿e ol lront lor and/or
solt spr|n¿s.
Rear Suspens|cn
ì. Compress rear sHocks up and down
to cHeck perlormance.
Z. CHeck lor |eaka¿e ol rear sHock or
solt spr|n¿s.
3. 3uspend rear wHee| and pusH |t |elt
and r|¿Ht to cHeck en¿|ne suspens|on
s|eeve lor wear.
ì
/0J031lLN1 3CbLw
UNDERSIDE DF CDVER
Z

3. Schedu|ed Ma|ntenance
Nut and ßc|t T|ghtness
ì. CHeck a|| nuts and bo|ts lor proper t|¿Htness.
Z. /djust toruue as necessarv.
Cc||ar R|m T|re
ì. CHeck t|re pressure.
leasure t|re pressure wHen t|re |s co|d.
A|r Fressure
T|re Standards
ºlront t|re: 3.CC x ìC
ºbear t|re: 3.CC x ìC
ì. CHeck |l lront wHee| ax|e Has s|ack.
Z. CHeck |l rear wHee| ax|e nut Has s|ack.
3. 1|¿Hten wHen necessarv to st|pu|ated toruue |l
tHere |s s|ack.
]oroue.
ºlron! wheel axle nu! 4.0·b.0 kç·m 28·32 í! lbs
ºRear wheel axle nu! 8.0·10.0 kç·m bb·6b í! lbs
lront 1|re ì./bk¿/cm ì/ps|
bear 1|re Z.CCk¿/cm Z3ps|

#(%#+4)2%
02%3352%
3. Schedu|ed Ma|ntenance
Steer|ng
ì. 3w|n¿ Hand|ebars |elt and r|¿Ht
to cHeck |l tHere |s |nterlerence
lrom tHe w|res.
Z. 0rasp Hand|ebars and rotate
lrom |elt to r|¿Ht wH||e Ho|d|n¿ tHe
lront wHee| stra|¿Ht. 1Here sHou|d
be s||ppa¿e.
3. CHeck steer|n¿ bear|n¿
adjustment. lork sHou|d turn lree|v
w|tH p|av |n bear|n¿.

4. Lubr|cat|ng System
Lubr|cat|ng System
Cb/Nb3H/l1
b0CbLb /bl
lll1Lb 3CbLLN
LN0lNL 0ll l0ll
4. Lubr|cat|ng System
Tcp|c Fage
0vera|| en¿|ne reuu|rements 4·Z
lrob|em d|a¿nos|s 4·Z
Ln¿|ne o||/h|ter screen 4·3
0|| Vo|ume 4·3
0|| CHan¿ed 4·3
Tcp|c Fage
Ln¿|ne 0|| lump bemova| 4·4
0|| lump 0|sassemb|v 4·b
CHeck|n¿ 4·b
/ssemb||n¿ 4·b
lnsta||at|on 4·b
Dvera|| Eng|ne Requ|rements
Spec|a| Attent|cn
0se proper motor o|| 3/L ìCw 3C.
0se on|v c|ean, lresH o||.
0o not rebu||d o|| pump. bep|ace w|tH a new pump wHen needed.
CHeck lor |eaka¿e alter rep|ac|n¿ pump.
Frcb|em D|agncs|s
Lcss cf eng|ne c||
ºLn¿|ne o|| natura| consumpt|on.
ºLn¿|ne o|| |eaka¿e.
ºl|ston r|n¿ wear, bad assemb|v.
ºVa|ve ¿u|de o|| sea| |s worn.
Nc c|| pressure
ºlump worn.
º0se ol wron¿ o||.
º0|| |eve| |ow.
Eng|ne burn|ng excess|ve c||
ºB|ocked o|| passa¿e.
º0se ol wron¿ o||.
ºworn r|n¿s.
ºVa|ves worn or dama¿ed.
ßas|c Mater|a|
Item
Ln¿|ne o|| pump
0ap between |nner rotator and externa| rotor
0ap between externa| rotor and pump bodv
0ap between and surlace ol rotor and pump bodv
···
···
C.ìZmm .CCb|n
C.ìZmm .CCb|n
C.Zmm .CCß|n
Nunmu| va|ue Rep|ace at
C.Cb·C.ìCmm
.CCì·.CC4|n
4. Lubr|cat|ng System
Eng|ne D||/F||ter Screen
D|| Vc|ume
ì. CHeck o|| w|tH scooter parked on |eve|
¿round on center stand.
3cooter must be on center stand
wHen o|| vo|ume |s cHecked.
bun en¿|ne lor two or tHree m|nutes
and tHen turn |t oll. /lter two to tHree
m|nutes, cHeck tHe o|| |eve|.
Z. CHeck tHe o|| |eve| wHen tHe o|| d|pst|ck |s
unscrewed and out.
3. /dd o|| to upper ||m|t |eve| on tHe d|pst|ck.
D|| Changed
lt |s eas|er to dra|n o|| wHen motor |s
warm.
ì. bemove dra|n bo|t to comp|ete|v dra|n o||.
Z. 0|sassemb|e tHe o|| h|ter screen cover
and take oll tHe o|| h|ter screen. 0se
H|¿H·pressure a|r to c|ean tHe h|ter screen.
wasH w|tH so|vent and drv belore re|nsta|||n¿.
3. CHeck o·r|n¿ lor dama¿e. bep|ace |l
necessarv.
4. /ssemb|e en¿|ne o|| h|ter screen and h|ter
screen cover.
º1ors|on va|ue: ì.4k¿·m
ì3CC lt |bs
b. /dd ass|¿ned o|| to determ|ned vo|ume.
ºLn¿|ne o|| capac|tv: C.ßl
º3ZCL3
b. CHeck lor o|| |eaks.
/. bun en¿|ne lor ì·Z m|nutes at |d|e speed.
ß. 1urn en¿|ne oll and cHeck o|| |eve|. /dd
o|| |l needed.
0ll31lCb
Z
ì
3
0b/lN B0l1
C·blN0
Cll lll1Lb 3CbLLN
4. Lubr|cat|ng System
D|| Fump Remcva|
ì. bemove en¿|ne r|¿Ht outer
cover lan ma¿netor.
Z. bemove a|ternator rotor.
3. bemove stator pu|es co||.
4. bemove e|¿Ht bo|ts ol
r|¿Ht cranksHalt case cover
and take oll cranksHalt case
cover.
b. bemove wasHer and hxed
p|n.
b. bemove tHe hxed nut ol
tHe ¿ear |n tHe o|| pump.
/. 1ake oll tHe ¿ear ol tHe o||
pump.
ß. bemove hxed bo|ts ol o||
pump modu|e bodv.
9. 1ake oll o|| pump.
ìC. 1ake oll two o·r|n¿s.
ìì. CHeck o·r|n¿s lor
dama¿e.
ìZ. bep|ace |l necessarv.
/
b
b
0L/b
w/3HLb
ll/L0 N01
ß
ìC
9
0ll l0ll
0·blN03
4. Lubr|cat|ng System
D|| Fump D|sassemb|y
ì. bemove tHree hxed screws |n o|| pump
bodv.
Z. 0|sassemb|e o|| pump.
Check|ng
ì. CHeck tHe ¿ap between tHe o|| pump modu|e
bodv and tHe externa| rotator.
º0sed ||m|t: C.ìZmm |.CCb |n.ì.
Z. CHeck tHe ¿ap between tHe surlace ol tHe
rotator and tHe bodv.
º0sed ||m|t: C.Zmm |.CCß |n.ì.
0ll l0ll B00Y
0ll l0ll B00Y
ll/L0 3CbLw3
L/1LbN/l b010b
L/1LbN/l b010b
lN1LbN/l b010b
4. Lubr|cat|ng System
Assemb||ng
ì. /ssemb|e |nner and outer
rotators and o|| pump
sHalt.

Be carelu| ol
a||¿nment between
pump bear|n¿ unh||ed
corner and |nner
rotator unh||ed corner.
Z. /ssemb|e pump cover
and t|¿Hten screws.
Insta||at|cn
ì. l|rst put two o·r|n¿s at
tHe o|| pump seat.
Z. lut o|| pump |n tHe
cranksHalt case.
l|rst add o|| to pump
and tHen assemb|e.
3. 1|¿Hten tHe tHree hxed
screws.
L/1LbN/l b010b
lN1LbN/l b010b
l0ll 3H/l1
3
ì
Z
ì
0ll l0ll
0·blN03
4. Lubr|cat|ng System
b
l0l3L C0ll
4. lnsta|| ¿ear ol o|| pump and
tHen hx nut.
º1ors|on va|ue: C.ß·ì.Zk¿·m
º/·ßlt |bs
b. /ssemb|e r|¿Ht cranksHalt
case cover, ß screws and t|¿Hten.
b. /ssemb|e pu|se co||, stator
and rotor.
/. lnsta|| lan and cover.
/
/
b
l/0NL10b C0ll
l/N
l/N C0VLb
l0l3L C0ll
b010b
4
0L/b
w/3HLb
ll/L0 N01
b. Fue| System
w
bL00l/10b
bL3l310b
LNblCHlLN1
w wHl1L Y YLll0w 0/B 0bLLN/Bl/Cb
Y
0/B
b 0Hl
b w
b. Fue| System
Tcp|c Fage
0enera| |nlormat|on b·Z
1roub|esHoot|n¿ b·3
0|sassemb|v ol Carburetor b·4
CHeck|n¿ /uto·cHoke b·4
/|r cutoll va|ve b·b
/ssemb||n¿ b·b
Vacuum CHamber·Break 0own b·/
/ssemb|v ol Vacuum CHamber b·/
l|oat bow| and 0|sassemb|v b·ß
CHeck|n¿ l|oat Va|ve b·9
Tcp|c Fage
0|sassemb|v ol /cce|erator lump b·ìC
CHeck|n¿ /cce|erator lump b·ìC
/ssemb|v ol carburetor b·ìì
0|sassemb||n¿ lue| tank b·ìZ
/ssemb|v ol lue| 1ank b·ìZ
Carburetor /djustment b·ì3
/utomat|c lue| Va|ve b·ì4
lue| leter 3end|n¿ 0n|t b·ì4
/|r l||ter lnspect|on b·ìb
Genera| Infcrmat|cn
Warn|ng|
work on tHe lue| svstem |n a
we||·vent||ated area tHat |s lree ol
sparks or open Names. 0o not breatHe
tHe vapors lrom tHe ¿aso||ne. wear
protect|ve ¿|oves to prevent sk|n
|rr|tat|on.
º0pen tHe bow| dra|n and a||ow a|| ¿aso||ne |n
tHe carburetor to dra|n |nto an appropr|ate
conta|ner pr|or to remov|n¿ or serv|c|n¿ |t.
ºbemove contro| cab|es and w|res carelu||v to
prevent dama¿e.
ºCHeck a|| o·r|n¿s lor dama¿e. bep|ace as
necessarv.
ºbemove carburetor lrom tHe scooter belore
attempt|n¿ to serv|ce tHe lue| bow| or vacuum
can|ster.
ºwHen c|ean|n¿ tHe carburetor, remove tHe
vacuum d|apHra¿m belore us|n¿ a|r or so|vents
lor c|ean|n¿. 1H|s w||| prevent dama¿e to tHe
d|apHra¿m.
ºwHen stor|n¿ tHe scooter lor a per|od ol t|me
exceed|n¿ one montH, use a uua||tv lue|
stab|||zer to prevent deter|orat|on ol tHe lue|
and dama¿e to tHe carburetor.
Repa|r|ng mater|a|
Spec|hcat|cn
Constant ve|oc|tv·CVb
ì/mm |.b/ |n.ì
mm
.Z/ mm |.ìZ |n.ì
ìbCC bll
bmm |.ìZb |n.ì
3 turns out
Carburetor tvpe
Ventur| Bore
lue| leve|
la|n jet
ld|e jet
ld|e speed
1Hrott|e lree p|av
l|xture screw sett|n¿
Standard va|ve
b. Fue| System
Trcub|eshcct|ng
Eng|ne |s hard tc start
ºNo spark
ºlow compress|on
ºNo lue| |n carburetor
·B|ocked lue| ||ne
·B|ocked lue| h|ter
·B|ocked vacuum ||ne
·leakv vacuum ||ne
·0|rtv Noat need|e
·l|oat set too H|¿H
Tcc much fue| tc eng|ne
·B|ocked a|r h|ter
·lan|lo|d a|r |eak
·Bad auto cHoke
·B|ocked a|r passa¿e |n carburetor
A|r/fue| m|xture tcc r|ch cr tcc |ean
ºBad auto cHoke
ºl|u¿¿ed |d|e jet
ºl|oat need|e stuck or d|rtv
ºl|oat He|¿Ht too H|¿H or too |ow
ºB|ocked a|r passa¿e |n carburetor
º0|rtv a|r h|ter
º/|r |eak at carburetor or man|lo|d
M|shre under acce|erat|cn
ºloor spark
º/|r m|xture screw too |ean
ºBad acce|erator pump
Fccr dr|vab|||ty
ºweak spark/bad |¿n|t|on svstem
ºB|ocked lue| ||ne
ºB|ocked lue| h|ter
ºBad lue|
ºwater |n lue|
º/|r |eak at carburetor or man|lo|d
ºlmproper Noat |eve|
ºBad auto cHoke
º0bstructed jet |n carburetor
ºVacuum s||de stuck
º0ama¿ed vacuum d|apHra¿m
º0|rt |n carburetor
b. Fue| System
D|sassemb|y cf carburetcr
ì. bemove seat and He|met
stora¿e tub.
Z. bemove r|¿Ht s|de bodv pane|.
3. 0|sconnect cab|e connector lor
auto cHoke.
4. loosen carburetor dra|n screw
and dra|n lue| lrom Noat bow|.
b. loosen c|umps |n |ntake tube
and ma|n lo|d.
b. loosen tHrott|e cab|e and
remove lrom support and lrom
tHrott|e contro| p|ate.
/. bemove lue| ||ne lrom
carburetor.
ß. bemove a|r |n|et tube lrom
carburetor and pu|| carburetor
stra|¿Ht back out ol |ntake man|lo|d.
9. bemove auto cHoke lrom
carburetor.
Check|ng Autc Chcke
ì. CHeck res|stance vo|ume.
Z. 3tandard va|ue be|ow b wHen
co|d.
3. Connect auto cHoke to ìZV
batterv.
4. l|un¿er sHou|d extend 3/ß |ncH
|n b m|nutes.
/lb lNlL1 10BL
/010 CH0bL
1Hb011lL 3CbLw
/lb 3CbLw
ß
9
3
4
/
b
1Hb011lL C/BlL
l0Ll llNL
C/bB0bL10b 0b/lN
3CbLw l0C/1L0
0N0LbNL/1H ll0/1 B0wl
b. Fue| System
b. CHeck p|n and seat lor
wear.
b. bep|ace |l necessarv.
/. l|ace auto cHoke |n
mount|n¿ |ocat|on and press
down hrm|v.
ß. lut |ock r|n¿ |n pos|t|on and
lasten screw
/010 CH0bL
l00N1lN0 l0C/1l0N
ß
b
/
ll/ ll/1L
l0Cb blN0
3CbLw
llN
b. Fue| System
Z
3
/lb C010ll
V/lVL C0VLb
0·blN0
3lblN0
V/C00l ll/1L
A|r Cut Dff Va|ve
ì. 0|sassemb|e two screws |n lue|
¿u|de hxed p|ate and remove hxed
p|ate.
Z. 0|sassemb|e two screws |n a|r
cut oll va|ve.
3. 1ake oll spr|n¿ and vacuum
p|ate.
4. CHeck lor wear on p|ate, rep|ace
|l necessarv.
b. C|ean tHe passa¿e wav to
remove d|rt or varn|sH.
Assemb||ng
ì. lnsta|| p|ate to carburetor.
Z. lnsta|| spr|n¿ and cover ol a|r
cut·oll va|ve.
3. Bu||d up lue| ¿u|de ||ne hxed p|ate
and t|¿Hten two screws.

Be sure tHat lurrow ol vacuum
p|ate |s a||¿ned w|tH tHe
carburetor ¿|ove.

lake sure tHat cover t|¿Htens
|nto p|ace.
ì
l0Ll 00l0L
ll/L0 ll/1L
b. Fue| System
Vacuum Chamber-ßreak dcwn
ì. bemove two screws and take oll
cover.
Z. bemove spr|n¿, d|apHra¿m p|ston.
3. bemove lue| p|n and s||de.
1ake spec|a| care not to
dama¿e d|apHra¿m. bep|ace
|l dama¿ed.
Check|ng
ì. CHeck p|n lor wear and rep|ace |l
necessarv.
Assemb||ng
ì. lnsta|| p|ston or p|ate to bodv ol
carburetor.
Z. lusH tHe button ol tHe p|ston to
vacuum cHamber s|de and keep open
comp|ete|v. lnsta|| spr|n¿ and cover.
3. lnsta|| screw.
Be sure to Ho|d s||de and
p|ston |n up pos|t|on wHen
|nsta|||n¿ cover and t|¿Hten
screw.
C0VLb
3lblN0
l0Ll llN
0l/lHb/0l
ll310N
ì
Z
3
Z
b. Fue| System
F|cat ßcw|
D|sassemb||ng
ì. 0|sassemb|e tHree screws and
take oll Noat bow|.
Z. bemove Noat p|n spr|n¿.
3. bemove H|¿H·speed jet, |ow·speed
jet and lue| vo|ume contro| screw.
Be carelu| not to break tHe
lue| jets and contro| screw.
Count tHe turns wHen remov|n¿
tHe lue| vo|ume contro| screw.
wHen re|nsta|||n¿ jets and
screws, do not over t|¿Hten.
4. C|ean jets w|tH so|vent and
compressed a|r.
b. C|ean bodv ol carburetor bv
b|ow|n¿ a|r tHrou¿H a|| passa¿es.
ll0/1 B0wl
ll0/1 llN
ll0/1 /bL/
ì
Z
3
l0Ll llN
l/lN l0Ll JL1
l0Ll llN
3lb/Y N0//lL
l0w 3lLL0
JL1
l0Ll V0l0lL
bL00l/1l0N
3CbLw
b. Fue| System
Check|ng
ì. CHeck Noat va|ve and va|ve seat
lor dama¿e.
Z. CHeck Noat va|ve and va|ve seat
wear, p|tt|n¿ or bu||dup ol d|rt.
3. /nv |eaka¿e ol tHe va|ve or a
bu||dup ol d|rt w||| allect tHe lue| |eve|
|n tHe Noat bow| and cause dr|vab|||tv
prob|ems.
4. /ssemb|e tHe |ow speed jet, lue|
p|n sprav nozz|e, lue| p|n sprav seat
and ma|n jet |nto tHe bottom ol tHe
carburetor Hous|n¿.
b. 3et tHe lue| |eve| |n tHe bow| bv
adjust|n¿ tHe lue| re¿u|at|on screw. 1He
standard sett|n¿ |s Z turns, p|us or
m|nus a ì/4 turn.
b. /ssemb|e tHe Noat va|ve, Noat and
Noat p|n to tHe bottom ol tHe
carburetor us|n¿ tHe reta|ner p|n.
/. CHeck tHe operat|on ol tHe Noat
and va|ve. /|| parts sHou|d move lree|v
and not b|nd.
ß. /lter assemb||n¿ tHe Noat, cHeck
lor proper lue| |eve| us|n¿ a sma|| ru|er
or a Noat ¿a¿e. 1He proper lue| |eve|
|s ZC.bmm |.ßC/ |n.ì.
ll0/1 llN
b
ll0/1
ll0/1
V/lVL
4
l0Ll llN
l/lN l0Ll JL1
l0Ll llN
3lb/Y N0//lL
l0w 3lLL0
JL1
l0Ll V0l0lL
bL00l/1l0N
3CbLw
b. Fue| System
ì
Z
C0VLb
0·blN0
3lblN0
/CCLlLb/1l0N
l0ll ll/1L
Acce|eratcr Fump
ì. bemove two screws on pump
and take oll cover.
Z. 1ake oll spr|n¿ and acce|erat|on
pump p|ate.
Check|ng
ì. CHeck acce|erat|on pump p|ate
lor cracks or Harden|n¿ ol tHe rubber.
bep|ace as necessarv.
Z. CHeck lor b|ocked lue| passa¿es.
3. C|ean bv H|¿H pressure a|r.
4. beverse steps to reassemb|e.
b. 1ake spec|a| care w|tH tHe
acce|erator pump p|ate to avo|d
dama¿e.
b. Fue| System
Assemb|y cf Carburetcr
ì. 3||de carburetor carelu||v
|nto tHe man|lo|d, mak|n¿ sure to
a||¿n tHe tab on tHe man|lo|d w|tH
tHe notcH on tHe carburetor.
3ecure|v t|¿Hten tHe c|amp screw
to hx tHe carburetor |n p|ace. 0o
not over t|¿Hten tHe screws as
tH|s can cause dama¿e to tHe
man|lo|d.
Z. /ttacH tHe |n|et p|pe to tHe
rear ol tHe carburetor and
t|¿Hten tHe c|amp screw.
3. /ttacH tHe tHrott|e cab|e to
tHe tHrott|e bv |nsta|||n¿ tHe cab|e
|u¿ |nto tHe notcH on tHe tHrott|e
p|a¿e. lnsert tHe outer cas|n¿ ol
tHe tHrott|e cab|e |nto tHe cab|e
support bracket. lake sure to
a||¿n tHe "0' sHape ol tHe
adjust|n¿ s|eeve w|tH tHe '0'
sHape Ho|e ol tHe bracket.
4. 0se tHe adjust|n¿ nut and
stop nut to set tHe cab|e tens|on.
Correct adjustment sHou|d a||ow
ì/4 |ncH ol lree p|av |n tHe
cab|e.
b. /ttacH tHe lue| ||ne lrom tHe
tank to tHe |n|et on tHe
carburetor and c|amp secure|v.
b. Connect tHe w|r|n¿ Harness
lrom tHe auto cHoke to tHe
proper connect|on on tHe ma|n
w|r|n¿ Harness.
/. /lter start|n¿ tHe en¿|ne, set
tHe |d|e speed us|n¿ tHe |d|e
adjust|n¿ screw.
/lb lNlL1 10BL
1Hb011lL 3CbLw
/lb 3CbLw
Z
b
3
1Hb011lL C/BlL
l0Ll llNL
b
b. Fue| System
D|sassemb||ng Fue| Tank
ì. 0|sassemb|e tHe bodv cover.
Z. 0|sconnect tHe w|r|n¿ Harness
lrom tHe lue| |eve| send|n¿ un|t.
3. 0|sconnect tHe lue| ||ne and
vacuum ||ne lrom tHe auto lue|
va|ve.
4. bemove tHree bo|ts and nuts
to |oosen tHe lue| tank.
b. bemove tHe lue| tank lrom tHe
lrame.
Assemb|y cf Fue| Tank
ì. beverse steps lor reassemb|v.
3
4
V/C00l llNL
l0Ll llNL
C0N1b0l V/lVL
l0Ll 1/Nb
AIR INLET TUBE
AIR SCREW
2
3
IDLING SPEED
ADJUSTMENT SCREW
3
Carburetcr Adjustment
lt |s ¿enera||v not necessarv
to adjust tHe m|xture screw
on tHe s|de ol tHe
carburetor. 1H|s screw |s
preset at tHe lactorv and
w||| Have ||tt|e ellect on tHe
perlormance ol tHe
carburetor.
ì. ll tH|s screw Has been removed
lor c|ean|n¿ ol tHe carburetor, |t
sHou|d be reset carelu||v. 1He
standard sett|n¿ |s two turns out,
p|us or m|nus ì/4 turn.
Z. 1o set tH|s pos|t|on, run tHe
en¿|ne unt|| warm and a||ow |t to
|d|e. 1urn tHe screw |n or out a ||tt|e
at a t|me and measure tHe |d|e
bll. 1He correct sett|n¿ |s
acH|eved wHen tHe |d|e speed |s
max|m|zed.
3. /djust tHe |d|e speed ol tHe
en¿|ne once tHe en¿|ne Has been
warmed up.
4. 3et tHe warm |d|e speed to
ì9CCbll, p|us or m|nus ìCCbll.
b. CHeck lor en¿|ne return to |d|e
speed alter runn|n¿ at part tHrott|e.
b. lake sure tHat tHe tHrott|e
cab|e a||ows tHe tHrott|e contro|
p|ate to return to tHe stop screw.
/. ll needed, readjust tHe m|xture
screw to He|p stab|||ze |d|e
perlormance.
ì
l0Ll V0l0lL
bL00l/1l0N
3CbLw
NDTE: 30lL C0ll0NLN13
bLl0VL0 l0b Cl/bl1Y.
b. Fue| System
b. Fue| System
Autcmat|c Fue| Va|ve
ì. 0|sconnect tHe lue| ||ne and tHe vacuum ||ne
lrom tHe contro| va|ve and lrom tHe carburetor
and |ntake man|lo|d. Carelu||v |nspect tHese
||nes. /nv b|ocka¿e, deter|orat|on, dama¿e, or
crack|n¿ ol tHese ||nes can cause |mproper
lunct|on|n¿ ol tHe lue| va|ve. bep|ace tHese
||nes as necessarv.
Z. /|wavs make sure tHat tHe c|amps work
proper|v wHen rep|ac|n¿ tHese ||nes |n order to
assure a t|¿Ht sea| ol tHe ||nes at tHe htt|n¿s on
tHe va|ve, carburetor and man|lo|d.
3. 1o cHeck tHe operat|on ol tHe va|ve, app|v a
vacuum to tHe |nput htt|n¿ ol tHe va|ve. lue|
sHou|d Now lree|v wHen tHe vacuum |s app||ed
and stop wHen |t |s removed.
4. Never attempt to c|ean tHe va|ve w|tH H|¿H·
pressure a|r. 1H|s w||| dama¿e tHe va|ve and
reuu|re rep|acement.
Fue| Meter Send|ng Un|t
ì. 0|sconnect tHe send|n¿ un|t w|r|n¿ Harness.
Z. 0|sconnect lour mount|n¿ screws.
3. l|lt and turn tHe send|n¿ arm to a||ow tHe
Noat arm and Noat to be removed lrom tHe lue|
tank. 1ake care not to bend or dama¿e tHe Noat
arm as tH|s can cause |mproper read|n¿s.
4. CHeck tHe movement ol tHe arm. lt sHou|d
move lree|v w|tHout b|nd|n¿ or Hes|tat|on. CHeck
tHe cont|nu|tv ol tHe co||. ll |t |s open, tHe un|t
needs rep|acement. wHen reassemb||n¿ tHe
send|n¿ un|ts, make sure tHat tHe ¿asket |s not
dama¿ed to avo|d |eaka¿e.
ì
V/C00l llNL
l0Ll llNL
C0N1b0l V/lVL
3
b. Fue| System
A|r F||ter Inspect|cn
ì. bemove a|r h|ter cover
screws.
Z. bemove cover.
3. bemove a|r h|ter e|ement.
4. bemove c|amp on a|r |n|et
tube.
b. 0|sconnect a|r tube lrom
carburetor.
b. bemove a|r box. lake sure
tHat tHe e|ement |s c|ean and lree
ol d|rt and o||. Lxcess|ve d|rt and
o|| on tHe e|ement can reduce
en¿|ne perlormance.
/. 0ur|n¿ reassemb|v, make sure
tHat tHe cover and tube
connect|ons are t|¿Ht and do not
|eak. /|r h|ter box |eaka¿e can
reduce en¿|ne perlormance.
/lb lll1Lb C0VLb
/lb lllL
/lb lll1Lb
ì
Z
3
b. Eng|ne Remcva| and Insta||at|cn
Tcp|c Fage
3pec|a| reuu|rements b·ì
Ln¿|ne remova| b·Z
Ln¿|ne |nsta||at|on b·4
Spec|a| Requ|rements
ºbemove a|| bodv pane|s carelu||v to prov|de
ease ol access to tHe en¿|ne.
º0se care wHen d|sconnect|n¿ tHe batterv
cab|es and lue| ||nes.
º0se protect|ve c|otH|n¿ sucH as ¿|oves and
saletv ¿|asses to protect vour bodv.
b. Eng|ne Remcva| and Insta||at|cn
Eng|ne Remcva|
ì. 0|sconnect tHe batterv
¿round w|re.
Z. bemove bodv pane|s to
expose en¿|ne.
3. 0|sconnect tHe en¿|ne
¿round w|re.
4. bemove tHe spark p|u¿
cab|e lrom tHe spark p|u¿ and
tHe |¿n|t|on co||.
b. 0|sconnect tHe auto cHoke
lrom tHe w|r|n¿ Harness.
b. 0|sconnect tHe ma¿neto
w|res and starter motor w|res.
/. 0|sconnect tHe lue| ||ne
lrom tHe carburetor and tHe
vacuum ||ne lrom tHe |ntake
man|lo|d.
ß. 0|sconnect tHe tHrott|e
cab|e lrom tHe carburetor.
9. bemove tHe a|r h|ter box.
b
1Hb011lL 3CbLw
V/C00l
llNL
/lb 3CbLw
1Hb011lL C/BlL
l0Ll llNL
/
/
ß
b. Eng|ne Remcva| and Insta||at|cn
ìC. 0|sassemb|e tHe brake
contro| cab|e lrom tHe
brake contro| arm.
ìì. bemove tHe rear sHock
absorber.
ìZ. bemove tHe en¿|ne
support bo|t and move tHe
cHass|s up tHe lorwards.
ì3. 3upport tHe cHass|s |n
pos|t|on temporar||v.
ì4. bemove tHe s|de stand
spr|n¿ and s|de stand.
ìb. bemove tHe lront
en¿|ne support bo|t to
d|sconnect tHe en¿|ne lrom
tHe cHass|s.
ìb. 3eparate tHe en¿|ne
lrom tHe cHass|s.
ì/. CHeck tHe cond|t|on ol
tHe en¿|ne support
|so|at|on mounts. ll tHev
are worn or dama¿ed,
rep|ace tHem dur|n¿ tHe
en¿|ne |nsta||at|on
process.
ìZ
LN0lNL
30ll0b1 B0l1
CH/3l3
UNDERSIDE DF SCDDTER
ìb
b. Eng|ne Remcva| and Insta||at|cn
Eng|ne Insta||at|cn
ì. /ttacH lront en¿|ne support
bo|t |nto pos|t|on and t|¿Hten to
bk¿·m |3b lt·|bsì.
Z. 3||de cHass|s to tHe rear to
a||¿n tHe rear mount and |nsta||
tHe mount|n¿ bo|t. 1|¿Hten to b
k¿·m |3b lt·|bsì.
3. /ttacH tHe rear sHock
absorber and t|¿Hten to 4 k¿·m
|Zß lt·|bsì.
4. Comp|ete tHe rema|nder ol
tHe assemb|v process |n reverse
order ol tHe d|sassemb|v.
b. wHen assemb|v |s comp|ete,
make sure to cHeck tHe tHrott|e
adjustment and brake
adjustment belore attempt|n¿ to
r|de tHe scooter.
ìb
LN0lNL
30ll0b1 B0l1
CH/3l3
UNDERSIDE DF SCDDTER
ìa
7. Cy||nder Head Va|ve
7. Cy||nder Head Va|ve
Tcp|c Fage
lmportant |nlormat|on /·Z
1roub|e d|a¿nos|s /·3
CamsHalt 0|sassemb|v /·4
CHeck|n¿ ol CamsHalt /·/
Bear|n¿ bocker /rm
Cv||nder Head 0|sassemb|v /·/
Cv||nder Head Break 0own /·9
CHeck|n¿ Cv||nder Head /·9
Va|ve and Va|ve 0u|de /·ìC
Tcp|c Fage
Va|ve 3eat CHamler Cutt|n¿ 1oo|s /·ìZ
Va|ve 3eat Cutt|n¿ /·ìZ
Bu||d|n¿ up ol Cv||nder Head /·ì3
lnsta|||n¿ Cv||nder Head /·ì4
CamsHalt /ssemb|v /·ìb
CamsHalt CHa|n be¿u|ator /ssemb||n¿ /·ìb
Impcrtant Infcrmat|cn
ºwHen work|n¿ on tHe cv||nder Head and va|ve
tra|n, a|wavs use en¿|ne o|| to |ubr|cate s||d|n¿
parts wHen assemb||n¿. Never assemb|e drv
parts |nto tHe va|ve tra|n.
º1He camsHalt |s |ubr|cated bv en¿|ne o||
supp||ed v|a an o|| passa¿e |n tHe cv||nder
Head. lake sure tHat tH|s passa¿e |s c|ean and
open wHen vou reassemb|e tHe Head.
ºwHen measur|n¿ parts to determ|ne wear,
wasH tHe parts w|tH so|vent and drv tHem |n
order to ¿et accurate measurements.
ºwHen d|sassemb||n¿ tHe va|ve components,
keep tHem |n order and re|nsta|| tHem |n tHe
reverse order.
Item
|C.C4ì C.Cb
|C.C4ì C.Cb
ìbk¿/cm
Z
·bCCrpm
Zb,/bì
Zb,bC4
ìC,CCC·ìC.Cìb
ìC,CCC·ìC.Cìb
9,9/Z·9,9ß/
9,9/Z·9,9ß/
ì.C
ì.C
4,9/b·4,9CC
4.9bb·4,9/C
b,CCC·b,CìZ
b,CCC·b,CìZ
C.CìC·C.C3/
C.C3C·C.Cb/
Z9.ì
33.b
C.Cb
Zb.bßì
Zb.Z4
ìC.ìC
ìC.ìC
9.9ì
9.9ì
ì.ß
ì.ß
4.9
4.9
b.3
b.3
C.Cß
C.ìC
Zb.ì
3C.b
lN
L/
lN
L/
lN
L/
lN
L/
lN
L/
lN
L/
lN
L/
lN
L/
lnner spr|n¿
0uter spr|n¿
Va|ve ¿ap |co|dì
Cv||nder Head compressed pressure
Cv||nder Head surlace tw|st|n¿
CamsHalt cover an¿|e He|¿Ht
Va|ve rocker arm |nner d|ameter
Va|ve rocker arm bear|n¿ outer d|ameter
Va|ve seat an¿|e
Va|ve bar outer d|ameter
Va|ve ¿u|de p|pe |nner d|ameter
0ap between va|ve bar and ¿u|de p|pe
Va|ve spr|n¿
Standard va|ve Used L|m|t
7. Cy||nder Head Va|ve
Tcrque Va|ue
ºCamsHalt bo|t ìb lt |bs
ºlubr|cate tHreads w|tH o||
ºVa|ve ¿ap adjust|n¿ screw cap / lt |bs
Genera| tcc|s
ºVa|ve spr|n¿ compressor
º4b de¿rees lN/L/
ºVa|ve seat reamer Z4.bmm
ºl|ane reamer 3C de¿rees lN
ºVa|ve seat reamerZbmm
ºl|ane reamer 3Z de¿rees L/
ºVa|ve seat reamer ZZmm
ºl|ane reamer bC de¿rees lN/L/
ºVa|ve seat reamer Zbmm
ºbeamer damp|n¿ hxture bmm
Spec|a| tcc|s
ºVa|ve spr|n¿ compressor accessor|es
ºVa|ve ¿ap re¿u|atorv spanner
ºVa|ve ¿u|de screwdr|ver
ºVa|ve ¿u|de reamer
Trcub|e D|agncs|s
ºConhrm poor operat|on ol cv||nder Head bv
measur|n¿ pressure or bv no|se produced
bv en¿|ne upper end.
S|cw Speed H|tch
Compress|on pressure too |ow
Bad va|ve ¿ap
Burn|n¿ or curv|n¿ ol va|ve
Bad va|ve t|m|n¿
Broken va|ve spr|n¿
Bad va|ve seat
leaka¿e ol cv||nder Head ¿asket
warped cv||nder Head surlace or crack|n¿
Bad spark p|u¿
Ccmpress|cn Fressure Tcc H|gh
º1oo mucH carbon bu||dup |n combust|on
cHamber
Wh|te Smcke frcm Exhaust F|pe
ºwear|n¿ ol va|ve ¿u|de
ºBroken o|| sea|
Abncrma| Nc|se
ºBad va|ve ¿ap
ºBroken or burn|n¿ ol va|ve or va|ve spr|n¿
ºwear|n¿ and break|n¿ ol camsHalt
ºwear|n¿ ol |nner cHa|n adjust|n¿ p|ate
ºwear|n¿ ol cam sHalt and va|ve rocker arm
7. Cy||nder Head Va|ve
D|sassemb||ng cf Camshaft
ì. 0|sassemb|e m|dd|e cover. |Z·Zì
Z. bemove lour bo|ts and two nuts, take oll
va|ve cover.
3. 0|sassemb|e cam cHa|r adjust|n¿ bo|t and
spr|n¿.
4. 0se tHe k|ck·start |ever to s|ow|v turn en¿|ne
unt|| "1' mark on NvwHee| ||nes up w|tH |nd|cator
on crankcase. CHeck pos|t|on ol camsHalt to
hnd |l botH va|ves are c|osed. 1He Ho|e |n tHe
cam ¿ear sHou|d be awav lrom tHe en¿|ne. ll
tH|s |s not correct, rotate tHe crank one
revo|ut|on to acH|eve tH|s a||¿nment.
b. bemove lour bo|ts and remove camsHalt
caps.
4
b
Z
3
3
H0lL lN C/l 0L/b
/w/Y lb0l LN0lNL
C/l3H/l1
CH/lN 0L/b
`1` l/bb
CYllN0Lb
HL/0 C0VLb
7. Cy||nder Head Va|ve
b. bemove rocker arms and p|vots.
/. bemove camsHalt ¿ear lrom camsHalt
cHa|n.
ß. bemove camsHalt.
9. CHeck CamsHalt
ìC. CHeck cam ||lt.
º0se ||m|t: lN: Zb.bßìmm be|ow cHan¿e
ºL/: Zb.bZ4mm be|ow cHan¿e
ìì. CHeck surlace ol cam |obes lor wearv
surlace breakdown, sculhn¿ or crack|n¿.
ìZ. CHeck camsHalt and bear|n¿ lor |oose ht or
dama¿e.
ì3. ll anv excess|ve wear or dama¿e |s lound,
rep|ace tHe camsHalt.
ba
bb
ß 9
b0CbLb /bl3
llV013
C/l3H/l1
C/l3H/l1
BL/blN0
7. Cy||nder Head Va|ve
4,46
7. Cy||nder Head Va|ve
Check|ng cf Camshaft ßear|ng Rccker Arm
ì. CHeck |l camsHalt bear|n¿ hxed seat and
camsHalt rocker arm and camsHalt rocker
bear|n¿ |s worn or broken.
Z. leasure outer d|ameter ol camsHalt
bear|n¿ hxed seat and camsHalt rocker arm.
0sed ||m|t: 9.9ìmm |.39C |n.ì. CHan¿e |l worn
|ar¿er.
ºlnner d|ameter ol camsHalt rocker arm.
0sed ||m|t: ìC.ìCmm |.39ß |n.ì. CHan¿e |l
worn |ar¿er.
º0uter d|ameter ol camsHalt rocker arm
bear|n¿ and camsHalt rocker arm.
0sed ||m|t: 9.9ìmm |.39C |n.ì.CHan¿e |l
worn |ar¿er.
º1He ¿ap between camsHalt rocker arm
and camsHalt rocker arm bear|n¿.

0sed ||m|t: C.ìCmm |.CC4 |n.ì. CHan¿e |l
worn |ar¿er.
D|sassemb|y cf Cy||nder Head
ì. bemove camsHalt bear|n¿. |/·4ì
Z. bemove carburetor |b·4ì
3. bemove exHaust p|pe. |Z·4ì
3. bemove |n|et man|lo|d.
ì
Z
C/l3H/l1
ll/L0 3L/1
C/l3H/l1 b0CbLb
/bl BL/blN0
7. Cy||nder Head Va|ve
4. bemove lan cover.
b. bemove bo|t and screw
ol en¿|ne cover.
b. 0|sassemb|e and
remove en¿|ne cover.
/. lu|| up on cv||nder Head
to break ¿asket and s||de oll
cv||nder stands.
ß. 1ake oll |ocat|on p|n and
cv||nder Head ¿asket.
9. 1ake oll camsHalt cHa|n
¿u|de bar.
/
CYllN0Lb HL/0
ß
CYllN0Lb HL/0
0/3bL1
l0C/1lN0 llN
C/l3H/l1
CH/lN 00l0L B/b
7. Cy||nder Head Va|ve
ßreak|ng Dcwn cf Cy||nder Head
ì. 0se va|ve spr|n¿ compressor to take oll
|ock c||p and supporter and va|ve spr|n¿, spr|n¿
seat va|ve.
l|ace parts |n seuuence alter
d|sassemb||n¿ and assemb|e |n reverse
order dur|n¿ reassemb|v.
Z. C|ean carbon depos|ts lrom combust|on
cHamber.
3. bemove ¿asket mater|a| on cv||nder Head
surlace.
0on't dama¿e cv||nder Head sea||n¿
surlace.
Check|ng Cy||nder Head
ì. CHeck spark p|u¿ Ho|e lor dama¿e.
Z. CHeck va|ve spr|n¿ seats lor a||¿nment.

0sed ||m|t: C.Cbmm |.CCZ |n.ì above a||¿n
ºleasure |en¿tH ol |nner and outer spr|n¿s.

0sed ||m|t:
ºCHan¿e |l |nner spr|n¿ be|ow Zb.ìmm
|ì.C3 |n.ì.
ºCHan¿e |l outer spr|n¿ |s be|ow 3C.bmm
|ì.Z |n.ì.
Z
ì
Z
3lblN0
V/lVL
C0llbL330b
C0lB031l0N
CH/lBLb
7. Cy||nder Head Va|ve
Va|ve and Va|ve Gu|de
ì. CHeck |l va|ve |s beat, burnt or broken.
Z. CHeck |l va|ve and va|ve ¿u|de are b|ocked.
3. leasure everv va|ve stem's outer d|ameter.
º0sed ||m|t: CHan¿e |l be|ow 4.9mm.

bemove carbon depos|ts lrom va|ve
¿u|de us|n¿ a reamer.

botate reamer |n proper d|rect|on and
do not stop rotat|on to pusH |n or pu||
out.
4. leasure |nner d|ameter ol everv va|ve
¿u|de.

0sed ||m|t:
lN: CHan¿e |l above b.3mm.
L/: CHan¿e |l above b.3mm.
Va|ve gu|de rep|acement
ì. 0perate cv||nder at tHe temperature ol
about ìCC
`
C·ìb
`
C ZìZ
`
l.
Heat cv||nder Head uu|ck|v and even|v
to prevent warp|n¿.
Z. lress, cut or prv out tHe va|ve ¿u|de.
Be carelu| to not dama¿e cv||nder Head
surlace.
3
Z
ì
V/lVL lllL bL/lLb
V/lVL 00l0L
3CbLw 0blVLb
10 lbY 001
00l0L
7. Cy||nder Head Va|ve
3. lress |n tHe new va|ve ¿u|de. 3pread en¿|ne
o|| on new o·r|n¿ and bu||d up new va|ve ¿u|de
p|pe. lake sure cv||nder Head |s st||| warm
wHen press|n¿ |n new ¿u|des.
4. 3|ze va|ve ¿u|de w|tH reamer alter |nsta|||n¿.
0se cutt|n¿ o|| on reamer. botate
reamer |n proper d|rect|on and do not
stop rotat|on to puncH |n or pu|| out.
b. C|ean cv||nder Head and ¿et r|d ol cut b|ts ol
meta| and dust.
3pec|a| too|s
ºVa|ve ¿u|de p|pe reamer
ºVa|ve 3eat CHeck|n¿ and Correct|n¿
ºVa|ve 3eat CHeck|n¿
b. bemove carbon depos|t lrom combust|on
cHamber va|ves.
/. 3pread emerv on seat surlace between
va|ve and va|ve seat. 0se po||sH|n¿ bar to wear
|n va|ve.
ß. 1ake out va|ve and cHeck va|ve seat surlace.
CHan¿e |l va|ve surlace |s course or lac|a|
po||sHed.
\alve sea! suríace wid!h checkinç
Used limi!. above 1.8mm (.07 in.) correc!.
9. Correct va|ve seat w|tH cHamlered too| |l
surlace w|dtH |s not even, too w|de or too
narrow.
4
9
3
V/lVL lllL bL/lLb
V/lVL 00l0L
3CbLw 0blVLb
10 lbY 001
00l0L
ì.ßmm
|.C/ |n.ì max
V/lVL 3L/1
30bl/CL wl01H
7. Cy||nder Head Va|ve
Va|ve Seat Chamfer Cutt|ng Tcc|s
beler to va|ve cHamlered too| Handbook lor
deta||s.
ì. lress and rotate w|tH 4·bk¿ ìC·ìZ |b lorce
to po||sH and cut wHen correct|n¿.
0se cHamlered too| alter spread|n¿
en¿|ne o|| on |t.
Va|ve Seat Cutt|ng
ì. 0o not po||sH or cut excess|ve|v.
Z. Cut pr|marv surlace w|tH 4bC cutt|n¿ Head.
3. CHamler |nner ed¿e w|tH 3ZC cutt|n¿ Head.
4. Correct |nner surlace bv s|xtv·de¿ree
cHamlered too|.
60•
45•
CORSE SURFACE
IN, EX: (30mm)
IN, EX: (32mm)
IN: (24.5mm)
EX: (27.5mm)
32•
VALVE SEAT SURFACE WIDTH
VALVE SEAT SURFACE WIDTH
32•
60•
7. Cy||nder Head Va|ve
b. 1r|m va|ve seat to ass|¿ned
seat w|dtH and va|ve seat w|dtH
w|tH 4b de¿ree cHamlered cutt|n¿
too|.
3tandard va|ve: ì.C mm |.393 |n.ì
CHeck contact p|ace ol va|ve
seat.
b. lo||sH w|tH 3C·de¿ree
cHamlered cutt|n¿ too| |l He
contact p|ace |s too H|¿H. 1r|m to
ass|¿ned w|dtH w|tH 4b·de¿ree
cHamlered cutt|n¿ too|. lo||sH
va|ve contact surlace w|tH emerv
and po||sH|n¿ bar alter correct|n¿
bar.
/. wasH and c|ean cv||nder and
va|ve alter po||sH|n¿ and ¿r|nd|n¿.
botate and press solt|v
wHen po||sH|n¿. 0on't put
emerv |nto va|ve and va|ve
¿u|de p|pe wHen po||sH|n¿.
ß. 3pread red |nk on 4b·de¿ree
seat surlace and conhrm |l tHe
center ol tHe contact surlace ol
tHe va|ve |s even alter correct|on.
ßu||d|ng Up cf Cy||nder Head
ì. Bu||d 0p 3pr|n¿ 3eat
0se new o|| sea|s wHen
reassemb||n¿.
Z. 3pread en¿|ne o|| on va|ve
stem and put |nto va|ve ¿u|de.
3. Bu||d up |nner and outer va|ve
spr|n¿ and put |n va|ve co||ar
us|n¿ spr|n¿ compressor.
V/lVL 3L/1
30bl/CL wl01H
V/lVL 3L/1
30bl/CL wl01H
3Z`
ì.Zmm
|.C4/ |n.ì
4b`
bC`
3
ba
b
bb
3lblN0
V/lVL
C0llbL330b
CDNTACT FLACE
TDD HIGH
CDNTACT FLACE
TDD LDW
7. Cy||nder Head Va|ve
4. 0se va|ve spr|n¿ compressor
accessorv to make va|ve contact w|tH
va|ve co||ar. 1ap w|tH p|ast|c ma||et two or
tHree t|mes, solt|v, on tHe ends ol tHe
va|ve to seat co||ars.
wHen us|n¿ ma||et, be carelu| to
not dama¿e va|ves.
Insta|||ng Cy||nder Head
ì. lnsta|| |ocat|n¿ p|n and ¿asket.
Z. lnsta|| cam cHa|n adjuster p|ate.
3. 3||de cv||nder Head over studs and
|nto p|ace.
3
Z 3
3lblN0
V/lVL
C0llbL330b
CYllN0Lb HL/0
0/3bL1
l0C/1lN0 llN
CYllN0Lb HL/0
C/l3H/l1
CH/lN 00l0L B/b
Camshaft Assemb|y
ì. /ssemb|e rocker arm
and rocker sHalt.
lake a||¿nment
between sHalt end
and hxed screw
bo|t Ho|e ol
camsHalt seat
wHen va|ve rocker
sHalt |s assemb|ed.
Z. lnsta|| tHe camsHalt |nto
tHe cv||nder Head. 3eat tHe
camsHalt |nto tHe hxed
seat and cHeck a||¿nment.
3. lnsta|| camsHalt hxed
seat.
4. botate NvwHee| and
a||¿n "1' mark on NvwHee|
w|tH cranksHalt mark.
b. /||¿n tHe camsHalt
cHa|n ¿ear round Ho|e awav
lrom en¿|ne.
b. lnsta|| camsHalt cHa|n
on camsHalt ¿ear.
/. /ssemb|e hxed studs.
ß. /ssemb|e camsHalt
seat, space and nut |nto
cv||nder Head. 1|¿Hten
cv||nder Head nut and bo|t
secure|v.
]oroue valve.
Lamshaí! íxed nu!.
2.0kç·m 1b í! lbs
Z
4 ß
ìa
b0CbLb /bl3
C/l3H/l1
3
ìb
b0CbLb 3H/l1
C/l3H/l1
ll/L0 3L/1
H0lL lN C/l 0L/b
/w/Y lb0l LN0lNL
C/l3H/l1
CH/lN 0L/b
`1` l/bb
7. Cy||nder Head Va|ve
7. Cy||nder Head Va|ve
Camshaft Cha|n Regu|atcr
Assemb||ng
ì. l|rst, bu||d up camsHalt
cHa|n re¿u|ator and spacer.
3econd, |ock two hxed bo|ts.
1H|rd, put spr|n¿ |nto camsHalt
cHa|n re¿u|ator. last, assemb|e
tHe o·r|n¿ and hxed bo|t.
lress down re¿u|ator
master jaw and dr|ve
down dr|v|n¿ bar
wHen camsHalt cHa|n
re¿u|ator |s
assemb|ed.
]orsion valve. 0.3·0.b kç·m
Reçula!e valve çap. (3·b)
Z. CHan¿e tHe r|n¿ ol He
cv||nder Head cover and
assemb|e tHe cv||nder Head
cover.
lut o·r|n¿ |nto lurrow.
ì
Z
0N0Lb3l0L 0l
CYllN0Lb HL/0 C0VLb
0·blN0
l0bb0w
C0VLb
7. Cy||nder Head Va|ve
3. lock hxed screw bo|t ol cv||nder
Head cover.
]orsion valve. 0.8·1.2 kç·m
4. 3pread ¿rease on tHread|n¿
pos|t|on ol camsHalt hxed seat
screw bo|t.
b. lock two or tHree t|mes at
d|a¿ona| ol camsHalt hxed seat
screw cap.
3
CYllN0Lb
HL/0
C0VLb
ß. Cy||nder and F|stcn
ß. Cy||nder and F|stcn
Tcp|c Fage
later|a| ß·Z
1roub|esHoot|n¿ ß·Z
bemov|n¿ tHe cv||nder ß·3
CHeck|n¿ tHe Cv||nder ß·b
Tcp|c Fage
bemov|n¿ tHe p|ston ß·3
/ssemb||n¿ tHe p|ston ß·/
/ssemb||n¿ tHe cv||nder ß·ß
Impcrtant Fc|nts
º1He work on tHe cv||nder and p|ston can be done on tHe en¿|ne w|tHout comp|ete d|sassemb|v.
º/lter tak|n¿ tHem apart, c|ean and drv tHe cv||nder and p|ston w|tH tHe compressed a|r belore measur|n¿ and test|n¿.
Trcub|eshcct|ng
ºln case ol d|lhcu|tv start|n¿ or unsteadv runn|n¿ at
|ow speeds, cHeck |l tHere |s wH|te smoke com|n¿
out ol tHe a|r Ho|e p|pe ol tHe crankcase. ll tHat |s
tHe case, tHe p|ston r|n¿ |s worn, burnt or broken.
Lcw Ccmpress|cn Fressure
º1He p|ston r|n¿ |s worn, burnt or broken.
º1He p|ston/cv||nder |s worn or dama¿ed.
Ccmpress|cn Fressure |s Tcc H|gh
ºCarbon depos|ts on tHe p|ston and tHe combust|on
cHamber.
Wh|te Smcke Ccm|ng Dut cf the Exhaust F|pe
º1He p|ston r|n¿ |s worn or dama¿ed.
º1He p|ston/cv||nder |s worn or dama¿ed.
bnock|n¿ No|se bv tHe l|ston
º1He cv||nder, tHe p|ston or tHe p|ston r|n¿ |s worn.
º1He p|ston p|n and |ts Ho|e are worn.
ltem
|C.C4ì C.Cb
C.Cìb·C.Cbb
C.Cìb·C.Cbb
C.Cß·C.ZC
C.Cb·C.ZC
C.ZC·C./C
3ß.9ßC·3ß./ßC
9mm awav lrom sk|rt
C.CìC·C.C4C
ì3.CCZ·ì3.CCß
ìZ.994·ì3.CCC
C.CCZ·C.Cì4
ì3.Cìb·ì3.C34
39.ìC
C.Cb
C.Cb
C.Cb
C.C9
C.C9
C.4b
C.4b
3ß./
C.ì
ì3.C4
ìZ.9b
C.CZ
ì3.Cb
Cv||nder
l|ston
l|ston r|n¿
00 ol tHe p|ston p|n
C|earance between tHe p|ston p|n and tHe Ho|e
l0 ol tHe sma|| end ol tHe connect|n¿ rod
l0
0|stort|on
Cv||ndr|c|tv
0ut·ol·roundness
C|earance between
tHe r|n¿ and tHe r|n¿ ¿roove
00 ol p|ston
CHeck po|nt ol 00
C|earance between p|ston and cv||nder
l0 ol tHe p|ston p|n Ho|e
Compressed ¿ap
Norma| s|ze lax. 3erv|ce
/||owance
un|t: mm
ß. Cy||nder and F|stcn
Remcv|ng the Cy||nder
ì. 0etacH tHe cv||nder Head |reler to /·bì.
Z. bemove tHe cHa|n ¿u|de ol tHe cam
cHa|n.
3. bemove tHe cv||nder.
4. bemove tHe cv||nder ¿asket and tHe
|ocat|n¿ p|n lrom tHe top ol tHe cv||nder
and tHe base ol tHe cv||nder.
Remcv|ng the F|stcn
ì. bemove tHe p|ston p|n snap r|n¿.
Attent|cn:
0on't drop tHe snap r|n¿
|nto tHe crankcase.
Z. 1ake out tHe p|ston p|n and tHen tHe
p|ston.
3. lusH tHe p|ston p|n lrom tHe s|de
oppos|te tHe removed snap r|n¿.
4. 0se a sma|| puncH or dr|lt p|n |l
necessarv and top ¿ent|v w|tH a solt·laced
bummer.
0se caut|on to keep lrom
scratcH|n¿ tHe p|ston surlaces.
ì
Za
ì
CYllN0Lb HL/0
0/3bL1
l0C/1lN0 llN
ll310N llN
ll310N
3N/l
blN0
Zb
N01L: CH/lN bLl0VL0 lb0l
lll031b/1l0N l0b Cl/bl1Y.
ll310N
ß. Cy||nder and F|stcn
ì
ll310N llN
ll310N
3N/l
blN0
ll310N
b
ll310N
blN0 0/l
CHeck|n¿ tHe p|ston, tHe p|ston p|n and tHe
p|ston r|n¿.
Attent|cn:
0on't dama¿e or break tHe r|n¿.
ì. bemove a|| ol tHe carbon depos|ts
lrom tHe r|n¿ ¿roove.
Z. lount tHe r|n¿ and measure tHe
c|earance ol tHe r|n¿ ¿roove.
lax|mum serv|ce a||owance:
1He top r|n¿: bep|ace wHen |t ¿oes
bevond C.C9mm |.C3b |n.ì.
1He second r|n¿: bep|ace wHen |t
¿oes bevond C.C9mm |.C3b |n.ì.
3. bemove tHe p|ston r|n¿s.
lnsta|| tHe p|ston r|n¿s |nto tHe bottom ol
tHe cv||nder.
Attent|cn:
0se tHe p|ston Head to press tHe
r|n¿s |nto p|ace |n tHe cv||nder.
4. leasure tHe p|ston r|n¿ ¿ap |n bore.
lax|mum serv|ce a||owance:
bep|ace wHen |t ¿oes bevond
C.4bmm |.Cìß |n.ì.
b. leasure tHe l0 ol tHe p|ston p|n Ho|e.
lax|mum serv|ce a||owance:
bep|ace wHen |t ¿oes bevond
ì3.C4mm |.bì |n.ì.
ß. Cy||nder and F|stcn
b. leasure tHe 00 ol tHe p|ston p|n.

Maximum service allowance.
Replace when i! is below 12.96 mm, (.b1 in.).
/. leasure tHe 00 ol tHe p|ston.
Attent|cn:
leasure |t |n a pos|t|on wH|cH lorms 9C de¿ree w|tH
tHe center ol tHe p|ston p|n and wH|cH |s 9mm awav
lrom tHe sk|rt.

Maximum service allowance.
Replace when i! is below 38.7 mm (1.b2 in.).
ß. leasure tHe c|earance between tHe p|ston p|n and tHe p|n
Ho|e.

Maximum service allowance.
Replace when i! çoes beyond 0.02 mm (.0008 in.).
Check|ng the Cy||nder
ì. CHeck wHetHer |t's scratcHed, worn or dama¿ed |n |ts |nner
surlace.
Z. leasure |ts l0 |n tHree pos|t|ons |upper, m|dd|e and |owerì
wH|cH lorm 9C de¿rees |x·v d|rect|onì w|tH tHe p|ston Ho|e.

Maximum service allowance.
Repair or replace when i! çoes beyond 0.1mm (.004 in.).
]he diííerence be!ween X and Y direc!ions is
ou!·oí·roundness.
1He cv||ndr|c|tv |s tHe l0 d|llerence |between / and Y
d|rect|onsì, measur|n¿ at tHree pos|t|ons |upper, m|dd|e and
|owerì. 1He |ar¿est measured va|ue w||| be cons|dered tHe
resu|t. 1H|s |nd|cates a taper ol tHe cv||nder.

Maximum service allowance.
Uu!·oí·roundness.
Repair or replace when i! çoes beyond 0.0bmm (.002 in.).
Lylindrici!y.
Repair or replace when i! çoes beyond 0.0bmm (.002 in.).
ll00lL
0llLb
lN L/
l0wLb
Y
/
ll310N llN
b
/
Z
ß. Cy||nder and F|stcn
3. CHeck tHe d|stort|on ol tHe
cv||nder.
lax|mum serv|ce a||owance:
bepa|r or rep|ace wHen |t ¿oes
bevond C.Cbmm |.CCZ |n.ì.
4. leasure tHe l0 ol tHe sma|| end
ol tHe connect|n¿ rod.
lax|mum serv|ce a||owance:
bep|ace wHen |t ¿oes bevond
ì3.Cbmm |.bì |n.ì.
Attent|cn:
0on't scratcH tHe p|ston or
break tHe p|ston r|n¿.
wHen rep|ac|n¿ tHe r|n¿,
keep tHe surlace w|tH tHe "1'
mark up.
/lter assemb||n¿, make sure
tHat tHe r|n¿ can be turned
lree|v |n tHe r|n¿ ¿roove.
b. l|¿Ht|v coat tHe r|n¿s w|tH en¿|ne
o|| belore |nsta|||n¿ tHem on tHe
p|ston.
b. lake sure to keep r|n¿ end ¿aps
rotated at ìZC
`
|ncrements.
/. Cover p|ston and r|n¿s w|tH a
||¿Ht coat ol en¿|ne o||.
Z
4
b
ìZC`
ìZC` ìZC`
ZCmm
|./9 |n.ì
ZCmm
|./9 |n.ì
10l blN0
ZN0 blN0
3l0L blN0
L/l/N0lN0 blN0
3l0L blN0
10l blN0
3LC0N0 blN0
0ll blN0
C0NNLC1lN0
b00
ß. Cy||nder and F|stcn
ß. lnsta|| tHe cHa|n ¿u|de |ever ol tHe cam.
Attent|cn:
lake sure tHat tHe |u¿ ol tHe ¿u|de
|ever enters tHe notcH ol tHe cv||nder.
Assemb||ng the F|stcn
ì. 3crape awav tHe ¿asket adHer|n¿ on tHe
surlace ol tHe crankcase.
Attent|cn:
Be sure not to |et anv matter drop
|nto tHe crankcase.
Z. /ssemb|e tHe p|ston and tHe p|ston p|n.
Attent|cn:
wHen assemb||n¿, keep tHe mark "|n'
|on tHe top ol tHe p|stonì toward tHe
|n|et va|ve.
Be sure not to |et tHe p|ston p|n snap
r|n¿ la|| |nto tHe crankcase. 0se a
c|otH to keep debr|s out ol tHe
crankcase.
3a
Z
ß
ll310N llN
ll310N
3N/l
blN0
3b
ll310N
ß. Cy||nder and F|stcn
Assemb||ng the Cy||nder
3. lnsta|| tHe |ocat|n¿ p|n and tHe
¿asket to tHe crankcase.
4. Coat tHe |nner surlace ol tHe
cv||nder, tHe p|ston and tHe p|ston r|n¿
w|tH o||.
b. wHen assemb||n¿ tHe p|ston r|n¿s,
tHev must be compressed |nto tHe
cv||nder.
Attent|cn:
0on't dama¿e or break tHe
p|ston r|n¿.
Be sure not to make tHe
pos|t|on ol tHe r|n¿ ¿ap po|nt
to tHe |n|et and out|et va|ves
and para||e| w|tH tHe
p|ston r|n¿.
9. Dr|v|ng ße|t Dev|ce & The Start|ng Lever
Tcp|c Fage
lmportant lo|nts 9·Z
1roub|esHoot|n¿ 9·Z
0etacH|n¿ tHe lelt Crankcase Cover 9·3
bemov|n¿ tHe 3tart|n¿ l|vot 9·3
CHeck|n¿ tHe 3tart|n¿ l|vot 9·4
lnsta|||n¿ tHe 3tart|n¿ /ssemb|v 9·4
/ssemb||n¿ tHe lelt Crankcase Cover 9·b
CHeck|n¿ tHe 0r|v|n¿ Be|t 9·b
bep|ac|n¿ tHe 0r|v|n¿ Be|t 9·b
/ssemb||n¿ tHe 0r|v|n¿ Be|t 9·/
1He 0r|v|n¿ lu||ev·0|smount|n¿ 9·/
1ak|n¿ tHe 0r|v|n¿ lu||ev /part 9·/
CHeck|n¿ tHe 0r|v|n¿ lu||ev 9·ß
/ssemb||n¿ tHe 0r|v|n¿ lu||ev 9·9
1He 0verrunn|n¿ C|utcH bemova| 9·9
CHeck|n¿ and /ssemb||n¿ 9·9
tHe 0verrunn|n¿ C|utcH
Tcp|c Fage
1He C|utcH/1ransm|ss|on lu||ev 9·ìC
bemov|n¿ tHe C|utcH/
1ransm|ss|on lu||ev
0|sassemb||n¿ tHe C|utcH/ 9·ìC
1ransm|ss|on lu||ev
CHeck|n¿ tHe C|utcH 9·ìì
1ransm|ss|on lu||ev
bep|ac|n¿ tHe transm|ss|on pu||ev 9·ìZ
and tHe bear|n¿
1He C|utcH/1ransm|ss|on 9·ì3
lu||ev /ssemb|v
/ssemb||n¿ tHe C|utcH Hous|n¿ 9·ì4
9. Dr|v|ng ße|t Dev|ce & The Start|ng Lever
Impcrtant Fc|nts
º1H|s cHapter |s about tHe dr|v|n¿ un|t, tHe
c|utcH/dr|ven un|t and tHe start|n¿ |ever.
º1He work on tHem can be done on tHe en¿|ne,
w|tHout tHe d|sassemb|v.
º1He surlace ol tHe dr|v|n¿ be|t and tHe dr|ve un|ts
are not a||owed to Have o|| adHer|n¿ to tHem. ll
tHere |s anv, remove |t to m|n|m|ze tHe s||p
between tHe be|t and tHe dr|ve un|ts.
Tcrque
1He nut ol tHe dr|v|n¿ p|ate
3.ßk¿/m Zßlt |bs
1He nut ol tHe c|utcH Hous|n¿
b.bk¿/m 4Clt |bs
1He bo|t ol tHe dr|v|n¿ p|ate
C.3k¿/m 4C|n |bs
1He nut ol tHe c|utcH/dr|v|n¿ p|ate
C.4bk¿/m 4C|n |bs


º0n|versa| stand
Trcub|eshcct|ng
1He motorcvc|e doesn't run alter tHe en¿|ne |s
started
º1He dr|v|n¿ be|t |s worn
º1He dr|v|n¿ p|ate |s broken
º1He brake ||n|n¿ |s worn or broken
º1He spr|n¿ ol tHe dr|ven p|ate |s lractured
Sudden breakdcwn dur|ng runn|ng
º1He spr|n¿ ol tHe brake ||n|n¿ |s lractured
Fcwer can't deve|cp fu||y
º1He dr|v|n¿ be|t |s worn
º0|stort|on ol tHe dr|ven be|t spr|n¿
º1He ro||er |s worn
º1He dr|v|n¿ p|ate surlace |s d|rtv
Tech Cr|ter|cn
l0 ol tHe s|eeve ol tHe s||d|n¿ dr|v|n¿ p|ate
00 ol tHe Hub ol tHe s||d|n¿ dr|v|n¿ p|ate
w|dtH ol tHe dr|v|n¿ be|t
1H|ckness ol tHe c|utcH brake ||n|n¿
l0 ol tHe c|utcH Hous|n¿
lree |en¿tH ol tHe dr|ven be|t spr|n¿
00 ol tHe dr|v|n¿ p|ate
l0 ol tHe s||d|n¿ dr|v|n¿ p|ate
00 ol tHe ro||er
Item Ncrma| S|ze Max. Ser|ce A||cwab|e
Z3.9ß9·Z4.Cb·
ZC.CìC·ZZ.CZb
ìß
ìC/.C·ìC/.ZZ
9ß.ì
33.9bb·33.9ßb
34.C·34.Zb
ì3.C
Z4.Z4
ì9.9/
ì/
Z.C
ìC/.b
ìC/.b
9Z.ß
34.Cb
ìZ.4
ºCompress|n¿ dev|ce lor
c|utcH spr|n¿
º3ocket |39mmì lor
3ocket |39mmì lor tHe hx nut
ºBear|n¿ dr|ver

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JL50QT-18 JL50QT-X1/8 JL50QT-14 .

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7 .

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3 IDLING SPEED ADJUSTMENT SCREW AIR INLET TUBE 2 3 AIR SCREW .

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IN.5mm) 45• CORSE SURFACE VALVE SEAT SURFACE WIDTH 32• VALVE SEAT SURFACE WIDTH 60• . EX: (32mm) 32• IN: (24. EX: (30mm) 60• IN.5mm) EX: (27.

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