Service Manual 1

4 STROKE ENGINE
SERVICE AND REPAIR MANUAL

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Tab|e cf Ccntents
Chapter Tcp|c Fage
CH/l1Lb : lntroduct|on Z
CH/l1Lb Z: Body Cover and LxHaust 3ystem Z
CH/l1Lb 3: 3cHedu|ed la|ntenance 33
CH/l1Lb 4: lubr|cat|n 3ystem 4b
CH/l1Lb b: lue| 3ystem bZ
CH/l1Lb b: Ln|ne bemova| and lnsta||at|on b/
CH/l1Lb /: Cy||nder Head Va|ve /
CH/l1Lb : Cy||nder and l|ston
CH/l1Lb 9: 0r|v|n Be|t 0ev|ce & 1He 3tart|n lever 9b
CH/l1Lb C: 1He l|na| 1ransm|ss|on /ssemb|y C
CH/l1Lb : 1He Crankcase and tHe CranksHalt b
CH/l1Lb Z: 1He lront wHee|, lront Brake, Z4
lront Buller and tHe lront lork
CH/l1Lb 3: 1He bear wHee|, tHe bear Brake & bear 3Hock 4C
CH/l1Lb 4: 1He Battery and tHe CHar|n 3ystem 4b
CH/l1Lb b: ln|t|on 3ystem bC
CH/l1Lb b: 3tarter 3ystem bb
CH/l1Lb /: leters, 3w|tcHes and l|Ht|n 3ystem /3
lN0L/ C
I. Genera| Infcrmat|cn
lb/lL N0lBLb C01 l03l1l0N
LN0lNL N0lBLb C01 l03l1l0N
Tcp|c Fage
Ln|ne and lrame Number los|t|ons
lroduct 3pec|hcat|ons Z
and 1ecHn|ca| 0ata
1ecHn|ca| 1|ps 3
1orque 3ett|ns
Tcp|c Fage
1oo|s Z
0|| and 0rease 3upp|y CHart 3
Contro| Cab|es and w|r|n 0|aram 4
la||ure 0|anost|cs Z
Lccat|cn fcr: Eng|ne Number,Frame Number
Frcduct Spec|hcat|cns and Techn|ca| Data
Scccter Mcde| JL50QT-18
JL50QT-X1/8
JL50QT-14
Length bbmm |bb.b |ncHes
W|dth bbCmm |Zb |ncHes
He|ght C/Cmm |4Z |ncHes
Whee| base 9bmm |4/ |ncHes
Eng|ne type 4stroke 0HC
D|sp|acement 49.bcc
Fue| requ|rements leadlree aso||ne
Dry we|ght
lront 3bks |// |bs
bear bbks |Z3 |bs
1ota| 9ks |ZCC |bs
Curb we|ght
lront 3/ks |.b |bs
bear bCks |3Z |bs
1ota| 9/ks |Z3.b |bs
T|re s|ze
lront 3.CC x C
bear 3.CC x C
Grcund c|earance Cmm |3.Zb |ncHes
3topp|n d|stance 4m lrom 3Ckm/Hr
b lt lrom mpH.
1urn|n rad|us .bbm |b.b lt
Eng|ne Specs
1ype 4stroke 3l
3tart|n L|ectr|c/k|ck start
Cy||nders 3|n|e
Combust|on cHamber Hem|spHer|ca|
Va|ve tra|n 3|n|e 0HC
Bore 39mm |3.34 |ncHes
3troke 4.4mm |.b3 |ncHes
0|sp|acement 49.bcc
Compress|on rat|o C.b:
Compress|on pressure bk/cm
Zbps|

lower Z.Z Hl @ CCC bll
1orque 4.b lt |bs @ bCCC bll
lntake t|m|n b` B10CZ` /10C
LxHaust t|m|n 3` BB0Cb` B10C
Va|ve |asH .Cbmm
ld|e speed bC9CCbll
0|| system lressure/sp|asH
0|| pump lnterna| ear
0|| h|ter lu||Now h|ter and screen
0|| capac|ty .l |3Z oz
Coo||n 0ucted lorced a|r
A|r c|eaner loam and paper
Carburetcr type CVb bC
Ventur| mm
Thrctt|e mechan|sm ButterNy type
Ign|t|cn system C0l type
3`B10C @ ZCCC bll
3park p|u N0b C/H3/ CHamp|on
Z9Y
0ap .b.bmm |.CZZ.CZ4 |ncH
Battery ZV 4/H
Dr|ve system
C|utcH 0ry mu|t| p|ate
1ransm|ss|on CV1
3H|lt|n /utomat|c
l|na| 0r|ve 0oub|e reduct|on
st step 3.Z:
Znd step 3.4:
Steer tube ang|e b4`
Steer|ng ang|e 4b`
T|re pressure frcnt ./bk/cm |Zbps|
T|re pressure rear Z.Zbk/cm |3bps|
Frcnt brake Hydrau||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/Hydrau||c
Shcck abscrber rear Co|| over Hydrau||c sHock
Frame type 1ubu|ar space lrame
bep|ace a|| askets, or|ns, 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|aona| pattern to
un|lorm|y d|str|bute c|amp
lorce.
0se |ubr|cants recommended |n tH|s
manua| at a|| t|mes to assure peak
perlormance lrom tHe scooter.
0se on|y enu|ne rep|acement parts
wHen perlorm|n repa|rs to tHe scooter.
3pec|a| serv|ce too|s may be requ|red
to perlorm ma|ntenance and repa|rs on
tH|s scooter. /|ways use tHe proper too|s
to prevent damae to tHe scooter.
C|ean and |ubr|cate a|| en|ne parts
dur|n tHe d|sassemb|y and reassemb|y
process to prevent damae to tHe
en|ne.
Techn|ca| T|ps
wHen perlorm|n ma|ntenance on tHe
scooter, make sure tHat a|| mov|n parts
and contro|s move lree|y and return to
tHe|r proper pos|t|on.
wHen connect|n tHe battery, a|ways
connect tHe pos|t|ve term|na| hrst.
wHen d|sconnect|n tHe battery, a|ways
d|sconnect tHe neat|ve term|na| hrst.
lake sure tHat too|s and serv|ce
equ|pment do not come |n contact w|tH
botH battery term|na|s.
Cover botH battery term|na|s w|tH a
||Ht coat ol rease to prevent
corros|on.
Techn|ca| T|ps (ccnt|nued)
wHen rep|ac|n luses, a|ways use an
exact rep|acement. 0o not use luses ol
a H|Her amp rat|n|
bep|ace a|| rubber caps on w|re
connectors alter perlorm|n
ma|ntenance.
wHen d|sconnect|n w|re connectors,
press hrm|y on tHe |ock|n tab and pu||
tHe body ol tHe connectors. Never pu||
on tHe w|res
wHen assemb||n w|re connectors,
press hrm|y to assure tHe |ock tab lu||y
enaes.
lake sure tHat a|| w|re term|na|s are
proper|y |n p|ace belore attempt|n to
assemb|e any w|re connector.
YL3
N0
lake sure tHat a|| w|r|n connectors are lu||y
seated and |ock tubs enaed.
CHeck |l a|muce ol connector |s covered and
hxat|on |s t|Ht.
lake sure tHat a|| protect|ve covers are
proper|y |n p|ace over tHe w|r|n connectors.
Never reuse damaed w|re term|na|s or
connectors.
Never reuse damaed w|re term|na|s or
connectors.
bep|ace a|| rubber covers on w|re connectors
to prevent water lrom ett|n |nto tHe
connector.
3tr|p ol ma|n w|re must be hxed on ass|ned
pos|t|on.
lnsu|ator ol a|um|num str|p must be alhxed to
w|res.
lake sure tHat a|| w|r|n Harness reta|ners are
proper|y p|aced.
0o not over t|Hten w|r|n t|es to prevent
p|ncH|n ol w|res.
0o not a||ow w|r|n Harness to Han |n |oose
|oops.
lake sure tHat a|| w|re c||ps are
proper|y attacHed.
lake sure tHat tHe w|r|n Harness and
a|| w|res do not contact mov|n or
rotat|n parts ol tHe scooter.
a|| w|res do not contact Hot components
or surlace parts ol tHe scooter.
a|| w|res do not contact sHarp edes or
parts ol tHe scooter. 0se tape to prevent
damae to w|res on sHarp edes.
YL3
YL3 YL3
N0
N0
N0
N0
0o not pu|| w|res too t|Ht|y.
0se tape to protect aa|nst sHarp edes.
lake sure tHat a|| rubber rommets are |n
p|ace to protect tHe w|r|n Harness.
0o not reuse broken or lrayed w|res.
bepa|r or rep|ace w|res as necessary.
0o not tw|st or knot w|res wHen
perlorm|n ma|ntenance on tHe scooter.
lake sure tHe w|r|n Harnesses to tHe
Hand|ebars are not too t|Ht or too |oose
by 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.
lake sure tHat you understand tHe proper
use ol test equ|pment to perlorm
ma|ntenance on tHe scooter. 1H|s w|||
prevent acc|denta| damae to tHe
e|ectr|ca| system ol tHe scooter.
0se e|ectr|ca| contact c|eaner and
abras|ve paper to c|ean corros|on lrom any
w|re term|na|s.
1ake care to prevent |nadvertent damae
to w|r|n and cab|es.
YL3
N0
N0
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|| requ|red.

0rease requ|red.

Ln|ne o|| requ|red.

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

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

0anerous and |mportant,
spec|a| care requ|red.
Tcrque Sett|ngs
1orque
Standard Tcrque Sett|ngs
bmm Cap 3crew
bmm Cap 3crew
mm Cap 3crew
Cmm Cap 3crew
Zmm Cap 3crew
.b k/cm
k/cm
Z.Z k/cm
3.b k/cm
b.b k/cm
1orque lastener 1ype lastener 1ype
bmm 3ocket Head 3crew
bmm 3ocket Head 3crew
mm l|ane Head 3crew
Cmm l|ane Head 3crew
Zmm l|ane Head 3crew
.4 k/cm
.9 k/cm
.Z k/cm
Z./ k/cm
4.C k/cm
0enera| 1orque bequ|rements lor 3tandard lasteners
Number
0sed
Spec|a| Tcrque Sett|ngs
Cy||nder Bo|t /
Cy||nder Bo|t B
0|| l||ter 3creen Cap
LxHaust l|pe l|ane Bo|t
l|ane 3crew Be|t lu||ey
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
Z
4
Z
Z
3
1orque
k m ||n. |bs
Comments
0|a.
|mm
lastener 1ype
3C
b
b
b
Z
Z
b
b
Z
b
b
C
.9
.9
.b
.9
Z.C
.9
.C
.3
b.b
b.b
.C
.Z
b.b
.C
.b
.Z
lubr|cate w|tH Ln|ne 0||
lubr|cate w|tH Ln|ne 0||
1orque bequ|rements lor Ln|ne lasteners
Number
0sed
Cy||nder Bo|t /
Cy||nder Bo|t B
0|| l||ter 3creen Cap
LxHaust l|pe l|ane Bo|t
l|ane 3crew Be|t lu||ey
Va|ve /djusters
1orque
k m ||n. |bs
Comments
0|a.
|mm
lastener 1ype
Zb.4
C
4
C
b
Z
4b
C
34
Z3
.b
0se 3olt 3et lock1|te
1orque bequ|rements lor lrame lasteners
epa|r ol tHe
scooter, a comp|ete bas|c set ol metr|c s|zed
too|s |s requ|red. 1H|s sHou|d |nc|ude; 0penend
wrencHes, sockets and ratcHet, Hex keys, stra|Ht
and lH|||ps screw dr|vers, standard p||ers,
need|enosed 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|ety ol spec|a| too|s tHat
w||| be requ|red. 1Hese |nc|ude tHe lo||ow|n:
Va|ve spr|n compressor
Va|ve u|de reamer
lee|er ae set
3||de Hammer bear|n and sea| remover
Bear|n press
1orque wrencH
b|n compressor
C|utcH spr|n compressor
l|y wHee| pu||er
L|ectron|c mu|t| meter
Tcc| Requ|rements
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
cy||nder hxed screw bo|ts and nuts
around p|ston and p|ston r|n roove
around p|ston p|n
cy||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 ena|n |mat|n part
coundersHalt ear ena|n part
hna| ear ena|n part
eacH bear|n rotat|ona| part
or|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
/Cenerator connector
Item Lccat|cn Reccmmended Lubr|cant
3/L bw 3C Ln|ne 0||
/ll30 0rade Ln|ne 0||
o||
rease
o||
o||
o||
o||
o||
o||
o||
o||
o||
rease
o||
o||
o||
rease
o||
rease
adHes|ve
LN0lNL 0ll:
3lLL00lL1Lb
0blVL
0bL/3L:
3lLL0 lL1Lb llL/lBlL 3H/l1
lb0N1 wHLLl BL/blN0
Bb/bL C/l
ll/L0 llN
lb0N1 3H0Cb /B30bBLb B/3L
0bL/3L:
CLN1Lb 31/N0 llV01
0bL/3L:
bL/b wHLLl BL/blN0
0bL/3L:
bL/b Bb/bL lLVLb llV01
0bL/3L:
3L/1 l/1CH
0bL/3L:
bL/b Bb/bL
00l0L llNL
0bL/3L:
Bb/bL C/l
/N0 llN
/pp|y o|| to tHe lo||ow|n parts.
0se rease |n tHe parts otHer tHan spec|hed
ones.
/pp|y en|ne o|| or rease to tHe mov|n parts to
prevent abnorma| no|se and to ra|se durab|||ty.
Chass|s
Cab|e Rcut|ng D|agram
/010l/1lC BYl/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
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
l0Nl1l0N C0ll
l0Nl1l0N C/BlL
V/C00l llNL
b0CbLb C0VLb VLN1
Cb/NbC/3L VLN1
1Hb011lL
l0Ll llNL
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/lVL
3l/bb ll00
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
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
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
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
B
r
0
/
Y
l
B
l
0
r
Z
V

4
/
H
+
3
C
w
/
.
b
0
l
0
B
l/
w
B
l/
w
0
b
Y
Y
0
B
3
1
/
b
1
L
b
b
L
l
/
Y
3
1
/
b
1
L
b
l
0
1
0
b
l
0
/
Y
l
0
3
L
b
L
C
1
ll
lL
b
l0
N
l1
L
b
C
0
ll
3 l / b b l l 0 0
C
0
l
B
/
Y
3
l
L
L
0

l
ll
l1
|3
L
l
L
C
1
/
B
l
L

0
N
l1
l
/
0
L
N
1
/
B
l/
Y
B
b
b
:

b
e
d

0
:
0
r
a
n
e

Y
:

Y
e
||o
w

B
|:
B
|u
e

l
:
l
|n
k

0
:

0
a
r
k

r
e
e
n

0
r
:

0
r
e
y

B
r
:

B
r
o
w
n

l
0
:

l
|
H
t

r
e
e
n

0
:

0
r
e
e
n

B
|/
Y
:

B
|u
e
/
y
e
||o
w

B
/
b
:

B
|a
c
k
/
b
e
d

w
/
b
:

w
H
|t
e
/
r
e
d
Y
/
B
:

Y
e
||o
w
/
b
|a
c
k

B
|/
w
:

b
|u
e
/
w
H
|t
e

0
/
b
:

0
r
e
e
n
/
r
e
d

B
r
/
b
:

b
r
o
w
n
/
r
e
d

B
/
w
:

b
|a
c
k

0
/
Y
:

0
r
e
e
n
/
y
e
||o
w

w
:

w
H
|t
e

B
/
Y
:

b
|a
c
k
/
y
e
||o
w

l
B
l:

l
|
H
t

b
|u
e
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|y app|y
enouH 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 dry
|Ln|ne Hav|n |n|t|on
spark but not to start
bemove spark p|u aa|n and cHeck
No lue| |n tank
l|oat passae c|ocked
lassae 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|ty
lue| h|ter b|ocked
3park p|u bad
l|ckup co|| bad
3park p|u d|rty and broken
C.0.l. bad
ln|t|on co|| broken c|rcu|t
ln|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
Cy||nder p|ston or p|ston r|n bad
Va|ve too t|Ht
Va|ve set bad
Cy||nder asket |eak|n
Va|ve t|m|n |mproper
Va|ve burned
/utomat|c cHoke perlormance
Carburetor o|| quan|t|ty
/|r |n|et |mproper man|lo|d
ln|t|on t|me wron
reu|at|on screw bad
Carburetor o|| |eve| too H|H
1Hrott|e va|ve open|n too w|de
/utoenr|cH|n dev|ce start
enr|cHment lau|ty
Ln|ne bll 0b low Ln|ne bll
ln|t|on t|m|n correct ln|t|on t|m|n |ncorrect
3upp|y en|ne w|tH lue| and watcH
beu|ate |n|t|on t|me us|n t|m|n |amp
Va|ve reu|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
ln|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
Cy||nder or p|ston worn
0|| passae b|ocked
0|| pump de||very
Ln|ne o|| too mucH
Ln|ne o|| uncHaned
Ln|ne o|| too ||tt|e
Cy||nder asket |eak|n
Va|ve ap adjustment |mproper
Va|ve seat excess|ve|y worn
|va|ve out sHoot|n excess|ve|y
Compress|on pressure norma| Compress|on pressure too |ow
No b|ockae B|ocked
Not d|rty or d|sco|ored 0|rty or d|sco|ored
CHeck lor carburetor b|ockae
bemove spark p|u to cHeck
Norma| |eve| too mucH
CHeck en|ne o|| |eve| or qua||ty |n crank case
Norma| /bnorma|
CHeck cy||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 cy||nder worn
depos|t too mucH
l|xture excess|ve|y tH|n lue| |mproper
Combust|on cHamber carbon
ln|t|on t|me too ear|y
Combust|on cHamber
C|utcH s||pp|n
Carbon depos|t too mucH
lue| bad
l|xture weak
ln|t|on t|m|n too ear|y
(under speed, nc pcwer)
Trcub|e Shcct|ng Gu|de (under speed, nc pcwer)
Norma| /bnorma|
0ood Bad
/djust |n|t|on t|me
/djust carbureator adjust|n screw
CHeck lor carburetor asket a|r |eakae
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 screw
|to |oosen screw
l|xture
0ood Bad
0ood Bad
CHeck /.C.V.
Heat sH|e|d bad
Neat|ve pressure p|pe broken
Carburetor Ho|ddown nut |oose
Heat sH|e|d broken
3park p|u bad or d|rty
ln|t|on co|| bad
C0l bad
Battery d|scHared
|ead broken or sHort c|rcu|t
la|n sw|tcH bad spark p|u
/.C.V. bad
Neat|ve pressure p|pe damaed
/|r b|eeder b|ocked or damaed
(h|gh speed)
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|ockae
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
Trcub|e Shcct|ng Gu|de-Imprcper attery Charg|ng
(attery cverd|scharge cr cvercharge)
Battery vo|tae uncHared Norma| |Z.b4V
Norma| 1est va|ve too H|H
3tart en|ne and measure battery term|na|s lor ||m|ted vo|tae
1est /C manetor co|| res|stance va|ue
CHeck reu|ated rect|her. 1est vo|tae by connect|n red w|re
to pos|t|ve term|na| wH||e neat|ve term|na| body
CHeck rect|her connector lor |oosen
Vo|tae No vo|tae
Battery serv|ce ||le over
Battery bad
lau|ty reu|ated rect|her
lau|ty connector
Co|| bad
Ye||ow w|re broken c|rcu|t
lau|ty connector
Norma| /bnorma|
Battery w|tH ma|n sw|tcH on Hav|n no vo|tae w|tH ma|n sw|tcH |n `on`
1est vo|tae by connect|n reen w|re to and to body.
Norma| 3pr|n broken or lat|ued
CHeck reu|ated rect|her connector lor poor contact
bed w|re broken
/C0 bad
0reen w|re broken
Connector contact poor
beu|ated rect|her bad
lmproper|y cHared |overcHared
(nc spark)
3park weak or spark|ess 3park stron
lroper loose
bep|ace spark p|u and cHeck aa|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
ln|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
ln|t|on co|| bad
cdy Exp|cded V|ew
Z. cdy Ccver and Exhaust System
0o not use excess|ve lorce wHen remov|n body
pane|s. 0se a hrm, cons|stent lorce to d|senae
tHe tabs and remove tHe pane|s.
0o not pry or pound on tHe body pane|s. 1He
mount|n tabs are not des|ned to w|tHstand
pry|n, pound|n or tw|st|n.
larts to be removed and sequence ol remova|.
lront Head||Ht and meter cover.
Back Head||Ht and meter cover.
lront lender.
lront body cover.
lront body pane|.
3eat and He|met box.
bear HandHo|d and ta||||Ht assemb|y.
lootboard cover and battery cover.
lootboard and rear cover.
lront lrame cover.
Covers and body s|de pane|s.
Bottom cover.
1orque requ|rements
Body mount|n nuts and screws .Zkm
LxHaust p|pe bo|ts 3bkm
Tcp|c Fage
0enera| lnlormat|on Z
Body Cover bemova| ZZ
LxHaust 3ystem bemova| Z4
Genera| Infcrmat|cn
cdy Ccver Remcva|
Frcnt Fane| Remcva|
. 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 |4a.
and remove two screws on eacH
s|de ||elt and r|Ht |4b. 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.
. 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.
C. bemove tHe hx screw |n eacH
s|de ol rear Hand|ebar cover.
bemove rear Hand|ebar cover.
. 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
cdy Ccver Remcva|
. bemove m|dd|e |uae
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. |Z3
b. bemove tHree rearrack
screws.
b. bemove rear rack.
/. bemove screws |n rear ol
body pane|.
. bemove tHe two screws |n
tHe lront ol tHe body
pane|.
9. 0|sconnect seat |ock |ead.
C. bemove tHe remova|
order lor |nsta||at|on.
lake sure to connect
seat |ock |ead wHen
|nsta|||n body cover.
3
/
3L/1
ll00lL l000/0L B0/
CLN1Lb
C0VLb
b
b
l000/0L b/Cb
R|ght and Left S|de Mc|d
Remcva|
. bemove two rear body screws.
Z. bemove tHree screws |n e|tHer
s|de ol mo|d.
3. bemove |elt and r|Ht s|de
pane|s.
cdy under Ccver Remcva|
b. bemove rear body pane|.
b. bemove |elt and r|Ht s|de
pane|s.
/. bemove two nuts |n e|tHer s|de
ol body under cover.
. bemove body cover.
F|ccr Fane| Remcva|
. bemove battery cover,
d|sconnect battery |ead and
d|smount battery.
Z. 0|sconnect C.0.l. w|re and take
|t out ol battery box.
3. bemove body cover.
4. bemove tHe speed||m|t|n
overnor.
b. bemove lour cHeck bo|ts |n tHe
Noor pane|.
b. bemove Noor pane|.
Z
7 /
ll00b C0VLb
b
B00Y 0N0Lb C0VLb
N013
Frcnt cx Remcva|
. 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|y and upward|y.
Frcnt and Rear Fenders Remcva|
. 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 stay.
4. bemove tHe rear lender stay.
Exhaust F|pe Remcva|
. 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.
lns!all exhaus! pipe join! rin beore
ins!allin exhaus! pipe.
lns!all exhaus! pipe join! nu!s and as!en
!hem and !hen ins!all exhaus! pipe ca!ch
bol!s and as!en !hem.
!orque.
Lxhaus! pipe ca!ch bol! 3.bkm
Lxhaus! pipe join! jam nu! 1.2km
Use a new exhaus! pipe carrier rin when
reassemblin !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 1ype 3Z
la|ntenance CHart 33
lue| l||ter 34
1Hrott|e 0perat|on lever 34
/|r h|ter 3b
bep|ac|n lrequency 3b
3park l|u 3b
Va|ve /djustment 3b
Carburetor ld|e 3peed 3b
ln|t|on 1|m|n 3/
Cy||nder lressure 3/
bemov|n tHe 3park l|u 3/
l|na| beduct|on 0ear Ln|ne 0|| 3
Tcp|c Fage
0r|ve Be|t 3
bear Brake /rm 39
Brake 3ystem lront Brake 39
bear Brake 39
lront lamp /djustment 3C
C|utcH Lnaement 3C
lront 3uspens|on 3C
bear 3uspens|on 3C
Nut and Bo|t 1|Htness 3
Co||ar b|m 1|re 3
/|r lressure 3
1|re 3tandards 3
3teer|n 3ystem 3Z
Genera| Infcrmat|cn
Warn|ng
/|ways make sure you 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.
Frame
lront brake |ever lree p|ay: CZCmm
bear brake |ever lree p|ay: CZCmm
T|re type
lront: 3.CC xC
bear: 3.CC xC
1orque:
lront wHee| ax|e nut 4.Cb.Ck/m
bear wHee| ax|e nut .CC.Ck/m
1|re un|t: k/cm
Z
lerson
lront
bear
.b, / ps|
Z.C, Z3 ps|
./b, 9 ps|
Z.Z, Z ps|
Z lersons
Ma|ntenance Chart
lerlorm reu|ar ma|ntenance, accord|n to
ma|ntenance Handbook.
l: lnspect, c|ean, |ubr|cate, add hx or rep|ace
wHen necessary.
/: /djust B: C|ean C: bep|ace 0: 1|Hten
3. lore lrequent rep|acement |s requ|red |l tHe
veH|c|e |s subjected to sever use, sucH as Heavy
|oad operat|on, |on tr|ps or operat|on |n ra|n.
lor salety reasons, |t |s recommended tHat
serv|ce be perlormed by a dea|er.
Ncte:
. lor m||eae H|Her tHan wHat |s spec|hed |n
tHe cHart, tHe ma|ntenance sHou|d be repeated
at tHe same |nterva| ||sted.
Z. lore lrequent ma|ntenance |s requ|red |l
tHe veH|c|e |s used |n dusty areas or |n ra|n.
Wh|chever
ccmes hrst
Note 3
Note Z, 3
C|ean every 3CCCbm bep|ace wHen necessary
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 system
0r|ve be|t
3uspens|on
3crews and nusts
1|re
3teer|n stem bear|n
Frequency
Item
km
CCC
/ / / /
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
CCC
km
9CCC
km
CCCC
km
CCC
km
ZCCC
m|
bZC
m|
Z4C
m|
bC
m|
Z4C
m|
3CC
m|
3/ZC
m|
434C
m|
49bC
m|
bbC
m|
bZCC
m|
bZC
m|
/44C
tHe hrst
3CCkm/
b m|
new b
3CCkm/
b m|
3CCkm/
b m|
Fue| F||ter
. bemove |uae box |ZZ
Z. CHeck lue| ||ne lor ae|n or damae.
3. bep|ace w|tH a new one |n case damaed
or |eak|n.
Thrctt|e Lever Dperat|cn
. CHeck tHrott|e lor proper operat|on.
Z. CHeck tHrott|e r|p lree p|ay.
lree p|ay: Zbmm |.C/ |n..Z3b |n..
3. /djust lree p|ay us|n tHe adjust|n nut |n
tHe tHrott|e cab|e and tHe adjuster at tHe
carburetor.
lajor adjustment sHou|d be made at
carburetor.
/djust |t by |oosen|n tHe jam nut and rotat|n
adjust|n nut.
l|ne adjustment sHou|d be made at tHe tHrott|e
r|p.
bemove outer cover, |oosen jam nut and
rotate adjust|n nut to adjust |t.
A|r F||ter
F||ter Rep|acement
. bemove a|r h|ter cap, hx
screw and remove tHe a|r h|ter
cap.
Z. CHeck h|ter lor d|rt or
damae. bep|ace as necessary.
0o not attempt to c|ean tHe
h|ter e|ement.
Rep|ac|ng Frequency
. lore lrequent rep|acement
|s requ|red |l veH|c|e |s dr|ven on
dusty roads or |n tHe ra|n.
Z. lake sure tHe a|r h|ter
cover |s secure|y |n p|ace.
Spark F|ug
. bemove spark p|u.
Z. CHeck spark p|u lor
burn|n, d|rt or depos|t.
3. C|ean |t w|tH a sparkp|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.
4. CHeck p|u lor d|rt, carbon
bu||dup 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
Z
0/l, 0lb1Y C/bB0N
B0ll00l CHLCblN0
l0lL 3CbLw
Va|ve Adjustment
/|ways cHeck and adjust w|tH
en|ne temperature |ower tHan
3b`C |9b`l
. bemove cy||nder Head cover.
Z. botate coo||n lan to camsHalt. locate
mark at center top, a||n|n maneto
Ny wHee| mark w|tH tHat on crankcase.
laneto "1' mark and box cranksHalt
mark.
Va|ve gap check|ng and
adjustment va|ve gap:
lN: C.Cbmm |.CC9/ |n.
L/: C.Cbmm |.CC9/ |n.
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 aa|n,
alter |ock|n jam nut.
Carburetcr Id|e Speed
ld|e adjustment sHou|d be made
w|tH tHe en|ne warmed up.
. 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 idlin speed. 1900+190rpm
4. beadjust tHe screw |l tHe |d|e speed
|s not steady or lue| cannot be
proper|y 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
3
Ign|t|cn T|me
Lqu|pped w|tH C0l, tHere |s no need
lor |n|t|on sett|n.
CHeck |n|t|on system |l |n|t|on t|me
|s |ncorrect.
. 0|smount r|Ht body 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 NywHee| 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
. leasure cy||nder pressure w|tH tHe en|ne
warmed up.
Z. 0|smount m|dd|e |uae box and m|dd|e
cover |ZZ.
Remcve spark p|ug.
. lnsta|| cy||nder pressure aue.
Z. w|tH tHrott|e va|ve lu||y open, start starter
motor to measure cy||nder pressure. |Z3ps|
3. Compress|on pressure: bk/cmZ
bCCrpm.
4. ll tHe pressure |s excess|ve|y |ow, cHeck lor
tHe lo||ow|n:
Va|ve |eakae
Va|ve ap too t|Ht
Cy||nder Head asket damaed
l|ston r|n worn
l|ston or cy||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 body becomes
vert|ca| on p|a|n round.
. 0|smount ear o|| adjust|n bo|t alter
stopp|n en|ne.
Z. 1He o|| |eve| sHou|d be just under tHe
reu|at|on screw bo|t Ho|e. /dd ear o|| wHen o||
|eve| |s too |ow.
0ear o|| recommended: 3/L 9Cw
3. Bu||d up ear o|| reu|ator screw bo|t.
4. Conhrm wHetHer or not tHe pack|n wasHer
|s broken.
Chang|ng Gear D||
. 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||.
0ear o|| capac|ty: C.Z|4CL3
Bo|t torque: C.9km /C |bs.
4. CHeck |l tHere |s any |eakae alter work |s
perlormed.
Transm|ss|cn e|t
. 0etacH tHe |elt crankcase cover |9Z.
Z. CHeck wHetHer tHere |s wear and tear ol
transm|ss|on be|t.
3. CHane w|tH new one wHen necessary or
dur|n t|me|y ma|ntenance.
Rear rake Arm
. CHane 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.
rake System-Frcnt rake
. CHeck lree ap ol lront brake bar.
lree ap: CZCmm |C.b |n..
Z. botate adjust|n nut to reu|ate lree ap ol
brake bar.
Rear rake
CHeck lree ap ol rear brake bar.
lree ap: CZCmm |C.b |n..
b01/1L N01
Frcnt Lamp Adjustment
. 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
. 3tart en|ne and |ncrease bll s|ow|y
to cHeck perlormance ol c|utcH.
C|utcH sHou|d enae at ZZCC
bll.
3erv|ce and rep|ace c|utcH as
necessary sHou|d s||ppae occur.
Frcnt Suspens|cn
. lu|| lront brake bar t|Ht|y and
compress lront lor up and down to cHeck
|ts perlormance.
Z. CHeck lor |eakae ol lront lor and/or
solt spr|ns.
Rear Suspens|cn
. Compress rear sHocks up and down
to cHeck perlormance.
Z. CHeck lor |eakae ol rear sHock or
solt spr|ns.
3. 3uspend rear wHee| and pusH |t |elt
and r|Ht to cHeck en|ne suspens|on
s|eeve lor wear.
/0J031lLN1 3CbLw
UNDERSIDE DF CDVER
Z
Nut and c|t T|ghtness
. CHeck a|| nuts and bo|ts lor proper t|Htness.
Z. /djust torque as necessary.
Cc||ar R|m T|re
. CHeck t|re pressure.
leasure t|re pressure wHen t|re |s co|d.
A|r Fressure
T|re Standards
lront t|re: 3.CC x C
bear t|re: 3.CC x C
. CHeck |l lront wHee| ax|e Has s|ack.
Z. CHeck |l rear wHee| ax|e nut Has s|ack.
3. 1|Hten wHen necessary to st|pu|ated torque |l
tHere |s s|ack.
!orque.
lron! wheel axle nu! 4.0b.0 km 2832 ! lbs
Rear wheel axle nu! 8.010.0 km bb6b ! lbs
lront 1|re ./bk/cm /ps|
bear 1|re Z.CCk/cm Z3ps|
#(%#+4)2%
02%3352%
Steer|ng
. 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||ppae.
3. CHeck steer|n bear|n
adjustment. lork sHou|d turn lree|y
w|tH p|ay |n bear|n.
4. Lubr|cat|ng System
Lubr|cat|ng System
Cb/Nb3H/l1
b0CbLb /bl
lll1Lb 3CbLLN
LN0lNL 0ll l0ll
Tcp|c Fage
0vera|| en|ne requ|rements 4Z
lrob|em d|anos|s 4Z
Ln|ne o||/h|ter screen 43
0|| Vo|ume 43
0|| CHaned 43
Tcp|c Fage
Ln|ne 0|| lump bemova| 44
0|| lump 0|sassemb|y 4b
CHeck|n 4b
/ssemb||n 4b
lnsta||at|on 4b
Dvera|| Eng|ne Requ|rements
Spec|a| Attent|cn
0se proper motor o|| 3/L Cw 3C.
0se on|y c|ean, lresH o||.
0o not rebu||d o|| pump. bep|ace w|tH a new pump wHen needed.
CHeck lor |eakae alter rep|ac|n pump.
Frcb|em D|agncs|s
Lcss cf eng|ne c||
Ln|ne o|| natura| consumpt|on.
Ln|ne o|| |eakae.
l|ston r|n wear, bad assemb|y.
Va|ve u|de o|| sea| |s worn.
Nc c|| pressure
lump worn.
0se ol wron o||.
0|| |eve| |ow.
Eng|ne burn|ng excess|ve c||
B|ocked o|| passae.
0se ol wron o||.
worn r|ns.
Va|ves worn or damaed.
as|c Mater|a|
Item
Ln|ne o|| pump
0ap between |nner rotator and externa| rotor
0ap between externa| rotor and pump body
0ap between and surlace ol rotor and pump body
C.Zmm .CCb|n
C.Zmm .CCb|n
C.Zmm .CC|n
Nunmu| va|ue Rep|ace at
C.CbC.Cmm
.CC.CC4|n
Eng|ne D||,F||ter Screen
D|| Vc|ume
. 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.
. bemove dra|n bo|t to comp|ete|y dra|n o||.
Z. 0|sassemb|e tHe o|| h|ter screen cover
and take oll tHe o|| h|ter screen. 0se
H|Hpressure a|r to c|ean tHe h|ter screen.
wasH w|tH so|vent and dry belore re|nsta|||n.
3. CHeck or|n lor damae. bep|ace |l
necessary.
4. /ssemb|e en|ne o|| h|ter screen and h|ter
screen cover.
1ors|on va|ue: .4km
3CC lt |bs
b. /dd ass|ned o|| to determ|ned vo|ume.
Ln|ne o|| capac|ty: C.l
3ZCL3
b. CHeck lor o|| |eaks.
/. bun en|ne lor Z m|nutes at |d|e speed.
. 1urn en|ne oll and cHeck o|| |eve|. /dd
o|| |l needed.
0ll31lCb
Z
3
0b/lN B0l1
CblN0
Cll lll1Lb 3CbLLN
D|| Fump Remcva|
. bemove en|ne r|Ht outer
cover lan manetor.
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.
. bemove hxed bo|ts ol o||
pump modu|e body.
9. 1ake oll o|| pump.
C. 1ake oll two or|ns.
. CHeck or|ns lor
damae.
Z. bep|ace |l necessary.
/
b
b
0L/b
w/3HLb
ll/L0 N01
C
9
0ll l0ll
0blN03
D|| Fump D|sassemb|y
. bemove tHree hxed screws |n o|| pump
body.
Z. 0|sassemb|e o|| pump.
Check|ng
. CHeck tHe ap between tHe o|| pump modu|e
body and tHe externa| rotator.
0sed ||m|t: C.Zmm |.CCb |n..
Z. CHeck tHe ap between tHe surlace ol tHe
rotator and tHe body.
0sed ||m|t: C.Zmm |.CC |n..
0ll l0ll B00Y
0ll l0ll B00Y
ll/L0 3CbLw3
L/1LbN/l b010b
L/1LbN/l b010b
lN1LbN/l b010b
Assemb||ng
. /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
. l|rst put two or|ns 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
0ll l0ll
0blN03
b
l0l3L C0ll
4. lnsta|| ear ol o|| pump and
tHen hx nut.
1ors|on va|ue: C..Zkm
/lt |bs
b. /ssemb|e r|Ht cranksHalt
case cover, 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 bZ
1roub|esHoot|n b3
0|sassemb|y ol Carburetor b4
CHeck|n /utocHoke b4
/|r cutoll va|ve bb
/ssemb||n bb
Vacuum CHamberBreak 0own b/
/ssemb|y ol Vacuum CHamber b/
l|oat bow| and 0|sassemb|y b
CHeck|n l|oat Va|ve b9
Tcp|c Fage
0|sassemb|y ol /cce|erator lump bC
CHeck|n /cce|erator lump bC
/ssemb|y ol carburetor b
0|sassemb||n lue| tank bZ
/ssemb|y ol lue| 1ank bZ
Carburetor /djustment b3
/utomat|c lue| Va|ve b4
lue| leter 3end|n 0n|t b4
/|r l||ter lnspect|on bb
Genera| Infcrmat|cn
Warn|ng|
work on tHe lue| system |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.
0pen 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.
bemove contro| cab|es and w|res carelu||y to
prevent damae.
CHeck a|| or|ns lor damae. bep|ace as
necessary.
bemove carburetor lrom tHe scooter belore
attempt|n to serv|ce tHe lue| bow| or vacuum
can|ster.
wHen c|ean|n tHe carburetor, remove tHe
vacuum d|apHram belore us|n a|r or so|vents
lor c|ean|n. 1H|s w||| prevent damae to tHe
d|apHram.
wHen stor|n tHe scooter lor a per|od ol t|me
exceed|n one montH, use a qua||ty lue|
stab|||zer to prevent deter|orat|on ol tHe lue|
and damae to tHe carburetor.
Repa|r|ng mater|a|
Spec|hcat|cn
Constant ve|oc|tyCVb
/mm |.b/ |n.
mm
.Z/ mm |.Z |n.
bCC bll
bmm |.Zb |n.
3 turns out
Carburetor type
Ventur| Bore
lue| leve|
la|n jet
ld|e jet
ld|e speed
1Hrott|e lree p|ay
l|xture screw sett|n
Standard va|ve
b. Fue| System
Trcub|eshcct|ng
Eng|ne |s hard tc start
No spark
low compress|on
No lue| |n carburetor
B|ocked lue| ||ne
B|ocked lue| h|ter
B|ocked vacuum ||ne
leaky vacuum ||ne
0|rty 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 passae |n carburetor
A|r,fue| m|xture tcc r|ch cr tcc |ean
Bad auto cHoke
l|ued |d|e jet
l|oat need|e stuck or d|rty
l|oat He|Ht too H|H or too |ow
B|ocked a|r passae |n carburetor
0|rty a|r h|ter
/|r |eak at carburetor or man|lo|d
M|shre under acce|erat|cn
loor spark
/|r m|xture screw too |ean
Bad acce|erator pump
Fccr dr|vab|||ty
weak spark/bad |n|t|on system
B|ocked lue| ||ne
B|ocked lue| h|ter
Bad lue|
water |n lue|
/|r |eak at carburetor or man|lo|d
lmproper Noat |eve|
Bad auto cHoke
0bstructed jet |n carburetor
Vacuum s||de stuck
0amaed vacuum d|apHram
0|rt |n carburetor
b. Fue| System
D|sassemb|y cf carburetcr
. bemove seat and He|met
storae tub.
Z. bemove r|Ht s|de body 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.
. 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
. CHeck res|stance vo|ume.
Z. 3tandard va|ue be|ow b wHen
co|d.
3. Connect auto cHoke to ZV
battery.
4. l|uner sHou|d extend 3/ |ncH
|n b m|nutes.
/lb lNlL1 10BL
/010 CH0bL
1Hb011lL 3CbLw
/lb 3CbLw
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 necessary.
/. l|ace auto cHoke |n
mount|n |ocat|on and press
down hrm|y.
. lut |ock r|n |n pos|t|on and
lasten screw
/010 CH0bL
l00N1lN0 l0C/1l0N
b
/
ll/ ll/1L
l0Cb blN0
3CbLw
llN
b. Fue| System
Z
3
/lb C010ll
V/lVL C0VLb
0blN0
3lblN0
V/C00l ll/1L
A|r Cut Dff Va|ve
. 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 necessary.
b. C|ean tHe passae way to
remove d|rt or varn|sH.
Assemb||ng
. lnsta|| p|ate to carburetor.
Z. lnsta|| spr|n and cover ol a|r
cutoll 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.
l0Ll 00l0L
ll/L0 ll/1L
b. Fue| System
Vacuum Chamber-reak dcwn
. bemove two screws and take oll
cover.
Z. bemove spr|n, d|apHram p|ston.
3. bemove lue| p|n and s||de.
1ake spec|a| care not to
damae d|apHram. bep|ace
|l damaed.
Check|ng
. CHeck p|n lor wear and rep|ace |l
necessary.
Assemb||ng
. lnsta|| p|ston or p|ate to body ol
carburetor.
Z. lusH tHe button ol tHe p|ston to
vacuum cHamber s|de and keep open
comp|ete|y. 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
Z
3
Z
b. Fue| System
F|cat cw|
D|sassemb||ng
. 0|sassemb|e tHree screws and
take oll Noat bow|.
Z. bemove Noat p|n spr|n.
3. bemove H|Hspeed jet, |owspeed
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 body ol carburetor by
b|ow|n a|r tHrouH a|| passaes.
ll0/1 B0wl
ll0/1 llN
ll0/1 /bL/
Z
3
l0Ll llN
l/lN l0Ll JL1
l0Ll llN
3lb/Y N0ZZlL
l0w 3lLL0
JL1
l0Ll V0l0lL
bL00l/1l0N
3CbLw
b. Fue| System
Check|ng
. CHeck Noat va|ve and va|ve seat
lor damae.
Z. CHeck Noat va|ve and va|ve seat
wear, p|tt|n or bu||dup ol d|rt.
3. /ny |eakae ol tHe va|ve or a
bu||dup ol d|rt w||| allect tHe lue| |eve|
|n tHe Noat bow| and cause dr|vab|||ty
prob|ems.
4. /ssemb|e tHe |ow speed jet, lue|
p|n spray nozz|e, lue| p|n spray seat
and ma|n jet |nto tHe bottom ol tHe
carburetor Hous|n.
b. 3et tHe lue| |eve| |n tHe bow| by
adjust|n tHe lue| reu|at|on screw. 1He
standard sett|n |s Z turns, p|us or
m|nus a /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|y
and not b|nd.
. /lter assemb||n tHe Noat, cHeck
lor proper lue| |eve| us|n a sma|| ru|er
or a Noat ae. 1He proper lue| |eve|
|s ZC.bmm |.C/ |n..
ll0/1 llN
b
ll0/1
ll0/1
V/lVL
4
l0Ll llN
l/lN l0Ll JL1
l0Ll llN
3lb/Y N0ZZlL
l0w 3lLL0
JL1
l0Ll V0l0lL
bL00l/1l0N
3CbLw
b. Fue| System
Z
C0VLb
0blN0
3lblN0
/CCLlLb/1l0N
l0ll ll/1L
Acce|eratcr Fump
. bemove two screws on pump
and take oll cover.
Z. 1ake oll spr|n and acce|erat|on
pump p|ate.
Check|ng
. CHeck acce|erat|on pump p|ate
lor cracks or Harden|n ol tHe rubber.
bep|ace as necessary.
Z. CHeck lor b|ocked lue| passaes.
3. C|ean by 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
damae.
b. Fue| System
Assemb|y cf Carburetcr
. 3||de carburetor carelu||y
|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|y 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 damae 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 by |nsta|||n tHe cab|e
|u |nto tHe notcH on tHe tHrott|e
p|ae. 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
/4 |ncH ol lree p|ay |n tHe
cab|e.
b. /ttacH tHe lue| ||ne lrom tHe
tank to tHe |n|et on tHe
carburetor and c|amp secure|y.
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
. 0|sassemb|e tHe body 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
. beverse steps lor reassemb|y.
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||y not necessary
to adjust tHe m|xture screw
on tHe s|de ol tHe
carburetor. 1H|s screw |s
preset at tHe lactory and
w||| Have ||tt|e ellect on tHe
perlormance ol tHe
carburetor.
. ll tH|s screw Has been removed
lor c|ean|n ol tHe carburetor, |t
sHou|d be reset carelu||y. 1He
standard sett|n |s two turns out,
p|us or m|nus /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
9CCbll, p|us or m|nus CCbll.
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.
l0Ll V0l0lL
bL00l/1l0N
3CbLw
NDTE: 30lL C0ll0NLN13
bLl0VL0 l0b Cl/bl1Y.
b. Fue| System
b. Fue| System
Autcmat|c Fue| Va|ve
. 0|sconnect tHe lue| ||ne and tHe vacuum ||ne
lrom tHe contro| va|ve and lrom tHe carburetor
and |ntake man|lo|d. Carelu||y |nspect tHese
||nes. /ny b|ockae, deter|orat|on, damae, or
crack|n ol tHese ||nes can cause |mproper
lunct|on|n ol tHe lue| va|ve. bep|ace tHese
||nes as necessary.
Z. /|ways make sure tHat tHe c|amps work
proper|y wHen rep|ac|n tHese ||nes |n order to
assure a t|Ht sea| ol tHe ||nes at tHe htt|ns on
tHe va|ve, carburetor and man|lo|d.
3. 1o cHeck tHe operat|on ol tHe va|ve, app|y a
vacuum to tHe |nput htt|n ol tHe va|ve. lue|
sHou|d Now lree|y 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||| damae tHe va|ve and
requ|re rep|acement.
Fue| Meter Send|ng Un|t
. 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 damae tHe Noat
arm as tH|s can cause |mproper read|ns.
4. CHeck tHe movement ol tHe arm. lt sHou|d
move lree|y w|tHout b|nd|n or Hes|tat|on. CHeck
tHe cont|nu|ty 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
damaed to avo|d |eakae.
V/C00l llNL
l0Ll llNL
C0N1b0l V/lVL
3
b. Fue| System
A|r F||ter Inspect|cn
. 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|y, make sure
tHat tHe cover and tube
connect|ons are t|Ht and do not
|eak. /|r h|ter box |eakae can
reduce en|ne perlormance.
/lb lll1Lb C0VLb
/lb lllL
/lb lll1Lb
Z
3
b. Eng|ne Remcva| and Insta||at|cn
Tcp|c Fage
3pec|a| requ|rements b
Ln|ne remova| bZ
Ln|ne |nsta||at|on b4
Spec|a| Requ|rements
bemove a|| body pane|s carelu||y to prov|de
ease ol access to tHe en|ne.
0se care wHen d|sconnect|n tHe battery
cab|es and lue| ||nes.
0se protect|ve c|otH|n sucH as |oves and
salety |asses to protect your body.
Eng|ne Remcva|
. 0|sconnect tHe battery
round w|re.
Z. bemove body 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 maneto
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.
. 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
/
/

C. 0|sassemb|e tHe brake
contro| cab|e lrom tHe
brake contro| arm.
. bemove tHe rear sHock
absorber.
Z. bemove tHe en|ne
support bo|t and move tHe
cHass|s up tHe lorwards.
3. 3upport tHe cHass|s |n
pos|t|on temporar||y.
4. bemove tHe s|de stand
spr|n and s|de stand.
b. bemove tHe lront
en|ne support bo|t to
d|sconnect tHe en|ne lrom
tHe cHass|s.
b. 3eparate tHe en|ne
lrom tHe cHass|s.
/. CHeck tHe cond|t|on ol
tHe en|ne support
|so|at|on mounts. ll tHey
are worn or damaed,
rep|ace tHem dur|n tHe
en|ne |nsta||at|on
process.
Z
LN0lNL
30ll0b1 B0l1
CH/3l3
UNDERSIDE DF SCDDTER
b
Eng|ne Insta||at|cn
. /ttacH lront en|ne support
bo|t |nto pos|t|on and t|Hten to
bkm |3b lt|bs.
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
km |3b lt|bs.
3. /ttacH tHe rear sHock
absorber and t|Hten to 4 km
|Z lt|bs.
4. Comp|ete tHe rema|nder ol
tHe assemb|y process |n reverse
order ol tHe d|sassemb|y.
b. wHen assemb|y |s comp|ete,
make sure to cHeck tHe tHrott|e
adjustment and brake
adjustment belore attempt|n to
r|de tHe scooter.
b
LN0lNL
30ll0b1 B0l1
CH/3l3
UNDERSIDE DF SCDDTER
a
7. Cy||nder Head Va|ve
Tcp|c Fage
lmportant |nlormat|on /Z
1roub|e d|anos|s /3
CamsHalt 0|sassemb|y /4
CHeck|n ol CamsHalt //
Bear|n bocker /rm
Cy||nder Head 0|sassemb|y //
Cy||nder Head Break 0own /9
CHeck|n Cy||nder Head /9
Va|ve and Va|ve 0u|de /C
Tcp|c Fage
Va|ve 3eat CHamler Cutt|n 1oo|s /Z
Va|ve 3eat Cutt|n /Z
Bu||d|n up ol Cy||nder Head /3
lnsta|||n Cy||nder Head /4
CamsHalt /ssemb|y /b
CamsHalt CHa|n beu|ator /ssemb||n /b
Impcrtant Infcrmat|cn
wHen work|n on tHe cy||nder Head and va|ve
tra|n, a|ways use en|ne o|| to |ubr|cate s||d|n
parts wHen assemb||n. Never assemb|e dry
parts |nto tHe va|ve tra|n.
1He camsHalt |s |ubr|cated by en|ne o||
supp||ed v|a an o|| passae |n tHe cy||nder
Head. lake sure tHat tH|s passae |s c|ean and
open wHen you reassemb|e tHe Head.
wHen measur|n parts to determ|ne wear,
wasH tHe parts w|tH so|vent and dry tHem |n
order to et accurate measurements.
wHen d|sassemb||n tHe va|ve components,
keep tHem |n order and re|nsta|| tHem |n tHe
reverse order.
Item
|C.C4 C.Cb
|C.C4 C.Cb
bk/cm
Z
bCCrpm
Zb,/b
Zb,bC4
C,CCCC.Cb
C,CCCC.Cb
9,9/Z9,9/
9,9/Z9,9/
.C
.C
4,9/b4,9CC
4.9bb4,9/C
b,CCCb,CZ
b,CCCb,CZ
C.CCC.C3/
C.C3CC.Cb/
Z9.
33.b
C.Cb
Zb.b
Zb.Z4
C.C
C.C
9.9
9.9
.
.
4.9
4.9
b.3
b.3
C.C
C.C
Zb.
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|d
Cy||nder Head compressed pressure
Cy||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
Tcrque Va|ue
CamsHalt bo|t b lt |bs
lubr|cate tHreads w|tH o||
Va|ve ap adjust|n screw cap / lt |bs
Genera| tcc|s
Va|ve spr|n compressor
4b derees lN/L/
Va|ve seat reamer Z4.bmm
l|ane reamer 3C derees lN
Va|ve seat reamerZbmm
l|ane reamer 3Z derees L/
Va|ve seat reamer ZZmm
l|ane reamer bC derees lN/L/
Va|ve seat reamer Zbmm
beamer damp|n hxture bmm
Spec|a| tcc|s
Va|ve spr|n compressor accessor|es
Va|ve ap reu|atory spanner
Va|ve u|de screwdr|ver
Va|ve u|de reamer
Trcub|e D|agncs|s
Conhrm poor operat|on ol cy||nder Head by
measur|n pressure or by no|se produced
by 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
leakae ol cy||nder Head asket
warped cy||nder Head surlace or crack|n
Bad spark p|u
Ccmpress|cn Fressure Tcc H|gh
1oo mucH carbon bu||dup |n combust|on
cHamber
Wh|te Smcke frcm Exhaust F|pe
wear|n ol va|ve u|de
Broken o|| sea|
Abncrma| Nc|se
Bad va|ve ap
Broken or burn|n ol va|ve or va|ve spr|n
wear|n and break|n ol camsHalt
wear|n ol |nner cHa|n adjust|n p|ate
wear|n ol cam sHalt and va|ve rocker arm
D|sassemb||ng cf Camshaft
. 0|sassemb|e m|dd|e cover. |ZZ
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|ckstart |ever to s|ow|y turn en|ne
unt|| "1' mark on NywHee| ||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 away 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
b. bemove rocker arms and p|vots.
/. bemove camsHalt ear lrom camsHalt
cHa|n.
. bemove camsHalt.
9. CHeck CamsHalt
C. CHeck cam ||lt.
0se ||m|t: lN: Zb.bmm be|ow cHane
L/: Zb.bZ4mm be|ow cHane
. CHeck surlace ol cam |obes lor weary
surlace breakdown, sculhn or crack|n.
Z. CHeck camsHalt and bear|n lor |oose ht or
damae.
3. ll any excess|ve wear or damae |s lound,
rep|ace tHe camsHalt.
ba
bb
9
b0CbLb /bl3
llV013
C/l3H/l1
C/l3H/l1
BL/blN0
4,46
Check|ng cf Camshaft ear|ng Rccker Arm
. 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: 9.9mm |.39C |n.. CHane |l worn
|arer.
lnner d|ameter ol camsHalt rocker arm.
0sed ||m|t: C.Cmm |.39 |n.. CHane |l
worn |arer.
0uter d|ameter ol camsHalt rocker arm
bear|n and camsHalt rocker arm.
0sed ||m|t: 9.9mm |.39C |n..CHane |l
worn |arer.
1He ap between camsHalt rocker arm
and camsHalt rocker arm bear|n.

0sed ||m|t: C.Cmm |.CC4 |n.. CHane |l
worn |arer.
D|sassemb|y cf Cy||nder Head
. bemove camsHalt bear|n. |/4
Z. bemove carburetor |b4
3. bemove exHaust p|pe. |Z4
3. bemove |n|et man|lo|d.
Z
C/l3H/l1
ll/L0 3L/1
C/l3H/l1 b0CbLb
/bl BL/blN0
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 cy||nder Head
to break asket and s||de oll
cy||nder stands.
. 1ake oll |ocat|on p|n and
cy||nder Head asket.
9. 1ake oll camsHalt cHa|n
u|de bar.
/
CYllN0Lb HL/0
CYllN0Lb HL/0
0/3bL1
l0C/1lN0 llN
C/l3H/l1
CH/lN 00l0L B/b
reak|ng Dcwn cf Cy||nder Head
. 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 sequence alter
d|sassemb||n and assemb|e |n reverse
order dur|n reassemb|y.
Z. C|ean carbon depos|ts lrom combust|on
cHamber.
3. bemove asket mater|a| on cy||nder Head
surlace.
0on't damae cy||nder Head sea||n
surlace.
Check|ng Cy||nder Head
. CHeck spark p|u Ho|e lor damae.
Z. CHeck va|ve spr|n seats lor a||nment.

0sed ||m|t: C.Cbmm |.CCZ |n. above a||n
leasure |entH ol |nner and outer spr|ns.

0sed ||m|t:
CHane |l |nner spr|n be|ow Zb.mm
|.C3 |n..
CHane |l outer spr|n |s be|ow 3C.bmm
|.Z |n..
Z
Z
3lblN0
V/lVL
C0llbL330b
C0lB031l0N
CH/lBLb
Va|ve and Va|ve Gu|de
. CHeck |l va|ve |s beat, burnt or broken.
Z. CHeck |l va|ve and va|ve u|de are b|ocked.
3. leasure every va|ve stem's outer d|ameter.
0sed ||m|t: CHane |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 every va|ve
u|de.

0sed ||m|t:
lN: CHane |l above b.3mm.
L/: CHane |l above b.3mm.
Va|ve gu|de rep|acement
. 0perate cy||nder at tHe temperature ol
about CC
`
Cb
`
C ZZ
`
l.
Heat cy||nder Head qu|ck|y and even|y
to prevent warp|n.
Z. lress, cut or pry out tHe va|ve u|de.
Be carelu| to not damae cy||nder Head
surlace.
3
Z
V/lVL lllL bL/lLb

V/lVL 00l0L
3CbLw 0blVLb
10 lbY 001
00l0L
3. lress |n tHe new va|ve u|de. 3pread en|ne
o|| on new or|n and bu||d up new va|ve u|de
p|pe. lake sure cy||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 cy||nder Head and et r|d ol cut b|ts ol
meta| and dust.
3pec|a| too|s
Va|ve u|de p|pe reamer
Va|ve 3eat CHeck|n and Correct|n
Va|ve 3eat CHeck|n
b. bemove carbon depos|t lrom combust|on
cHamber va|ves.
/. 3pread emery on seat surlace between
va|ve and va|ve seat. 0se po||sH|n bar to wear
|n va|ve.
. 1ake out va|ve and cHeck va|ve seat surlace.
CHane |l va|ve surlace |s course or lac|a|
po||sHed.
\alve sea! surace wid!h checkin
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
.mm
|.C/ |n. max
V/lVL 3L/1
30bl/CL wl01H
Va|ve Seat Chamfer Cutt|ng Tcc|s
beler to va|ve cHamlered too| Handbook lor
deta||s.
. lress and rotate w|tH 4bk CZ |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
. 0o not po||sH or cut excess|ve|y.
Z. Cut pr|mary surlace w|tH 4bC cutt|n Head.
3. CHamler |nner ede w|tH 3ZC cutt|n Head.
4. Correct |nner surlace by s|xtyderee
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
b. 1r|m va|ve seat to ass|ned
seat w|dtH and va|ve seat w|dtH
w|tH 4b deree cHamlered cutt|n
too|.
3tandard va|ve: .C mm |.393 |n.
CHeck contact p|ace ol va|ve
seat.
b. lo||sH w|tH 3Cderee
cHamlered cutt|n too| |l He
contact p|ace |s too H|H. 1r|m to
ass|ned w|dtH w|tH 4bderee
cHamlered cutt|n too|. lo||sH
va|ve contact surlace w|tH emery
and po||sH|n bar alter correct|n
bar.
/. wasH and c|ean cy||nder and
va|ve alter po||sH|n and r|nd|n.
botate and press solt|y
wHen po||sH|n. 0on't put
emery |nto va|ve and va|ve
u|de p|pe wHen po||sH|n.
. 3pread red |nk on 4bderee
seat surlace and conhrm |l tHe
center ol tHe contact surlace ol
tHe va|ve |s even alter correct|on.
u||d|ng Up cf Cy||nder Head
. 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`
.Zmm
|.C4/ |n.
4b`
bC`
3
ba
b
bb
3lblN0
V/lVL
C0llbL330b
CDNTACT FLACE
TDD HIGH
CDNTACT FLACE
TDD LDW
4. 0se va|ve spr|n compressor
accessory 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|y, on tHe ends ol tHe
va|ve to seat co||ars.
wHen us|n ma||et, be carelu| to
not damae va|ves.
Insta|||ng Cy||nder Head
. lnsta|| |ocat|n p|n and asket.
Z. lnsta|| cam cHa|n adjuster p|ate.
3. 3||de cy||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
. /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 cy||nder Head. 3eat tHe
camsHalt |nto tHe hxed
seat and cHeck a||nment.
3. lnsta|| camsHalt hxed
seat.
4. botate NywHee| and
a||n "1' mark on NywHee|
w|tH cranksHalt mark.
b. /||n tHe camsHalt
cHa|n ear round Ho|e away
lrom en|ne.
b. lnsta|| camsHalt cHa|n
on camsHalt ear.
/. /ssemb|e hxed studs.
. /ssemb|e camsHalt
seat, space and nut |nto
cy||nder Head. 1|Hten
cy||nder Head nut and bo|t
secure|y.
!orque valve.
Lamsha! xed nu!.
2.0km 1b ! lbs
Z
4
a
b0CbLb /bl3
C/l3H/l1
3
b
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
Camshaft Cha|n Regu|atcr
Assemb||ng
. l|rst, bu||d up camsHalt
cHa|n reu|ator and spacer.
3econd, |ock two hxed bo|ts.
1H|rd, put spr|n |nto camsHalt
cHa|n reu|ator. last, assemb|e
tHe or|n and hxed bo|t.
lress down reu|ator
master jaw and dr|ve
down dr|v|n bar
wHen camsHalt cHa|n
reu|ator |s
assemb|ed.
!orsion valve. 0.30.b km
Reula!e valve ap. (3b)
Z. CHane tHe r|n ol He
cy||nder Head cover and
assemb|e tHe cy||nder Head
cover.
lut or|n |nto lurrow.
Z
0N0Lb3l0L 0l
CYllN0Lb HL/0 C0VLb
0blN0
l0bb0w
C0VLb
3. lock hxed screw bo|t ol cy||nder
Head cover.
!orsion valve. 0.81.2 km
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|aona| ol camsHalt hxed seat
screw cap.
3
CYllN0Lb
HL/0
C0VLb
. Cy||nder and F|stcn
Tcp|c Fage
later|a| Z
1roub|esHoot|n Z
bemov|n tHe cy||nder 3
CHeck|n tHe Cy||nder b
Tcp|c Fage
bemov|n tHe p|ston 3
/ssemb||n tHe p|ston /
/ssemb||n tHe cy||nder
Impcrtant Fc|nts
1He work on tHe cy||nder and p|ston can be done on tHe en|ne w|tHout comp|ete d|sassemb|y.
/lter tak|n tHem apart, c|ean and dry tHe cy||nder and p|ston w|tH tHe compressed a|r belore measur|n and test|n.
Trcub|eshcct|ng
ln case ol d|lhcu|ty start|n or unsteady 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
1He p|ston r|n |s worn, burnt or broken.
1He p|ston/cy||nder |s worn or damaed.
Ccmpress|cn Fressure |s Tcc H|gh
Carbon depos|ts on tHe p|ston and tHe combust|on
cHamber.
Wh|te Smcke Ccm|ng Dut cf the Exhaust F|pe
1He p|ston r|n |s worn or damaed.
1He p|ston/cy||nder |s worn or damaed.
bnock|n No|se by tHe l|ston
1He cy||nder, tHe p|ston or tHe p|ston r|n |s worn.
1He p|ston p|n and |ts Ho|e are worn.
ltem
|C.C4 C.Cb
C.CbC.Cbb
C.CbC.Cbb
C.CC.ZC
C.CbC.ZC
C.ZCC./C
3.9C3./C
9mm away lrom sk|rt
C.CCC.C4C
3.CCZ3.CC
Z.9943.CCC
C.CCZC.C4
3.Cb3.C34
39.C
C.Cb
C.Cb
C.Cb
C.C9
C.C9
C.4b
C.4b
3./
C.
3.C4
Z.9b
C.CZ
3.Cb
Cy||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
Cy||ndr|c|ty
0utolroundness
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 cy||nder
l0 ol tHe p|ston p|n Ho|e
Compressed ap
Norma| s|ze lax. 3erv|ce
/||owance
un|t: mm
Remcv|ng the Cy||nder
. 0etacH tHe cy||nder Head |reler to /b.
Z. bemove tHe cHa|n u|de ol tHe cam
cHa|n.
3. bemove tHe cy||nder.
4. bemove tHe cy||nder asket and tHe
|ocat|n p|n lrom tHe top ol tHe cy||nder
and tHe base ol tHe cy||nder.
Remcv|ng the F|stcn
. 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
necessary and top ent|y w|tH a soltlaced
bummer.
0se caut|on to keep lrom
scratcH|n tHe p|ston surlaces.
Za
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
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 damae or break tHe r|n.
. 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
beyond C.C9mm |.C3b |n..
1He second r|n: bep|ace wHen |t
oes beyond C.C9mm |.C3b |n..
3. bemove tHe p|ston r|ns.
lnsta|| tHe p|ston r|ns |nto tHe bottom ol
tHe cy||nder.
Attent|cn:
0se tHe p|ston Head to press tHe
r|ns |nto p|ace |n tHe cy||nder.
4. leasure tHe p|ston r|n ap |n bore.
bep|ace wHen |t oes beyond
C.4bmm |.C |n..
b. leasure tHe l0 ol tHe p|ston p|n Ho|e.
3.C4mm |.b |n..
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 deree w|tH
tHe center ol tHe p|ston p|n and wH|cH |s 9mm away
lrom tHe sk|rt.

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

Replace when i! oes beyond 0.02 mm (.0008 in.).
Check|ng the Cy||nder
. CHeck wHetHer |t's scratcHed, worn or damaed |n |ts |nner
surlace.
Z. leasure |ts l0 |n tHree pos|t|ons |upper, m|dd|e and |ower
wH|cH lorm 9C derees |xy d|rect|on w|tH tHe p|ston Ho|e.

Repair or replace when i! oes beyond 0.1mm (.004 in.).
!he dierence be!ween X and Y direc!ions is
ou!oroundness.
1He cy||ndr|c|ty |s tHe l0 d|llerence |between / and Y
d|rect|ons, measur|n at tHree pos|t|ons |upper, m|dd|e and
|ower. 1He |arest measured va|ue w||| be cons|dered tHe
resu|t. 1H|s |nd|cates a taper ol tHe cy||nder.

Uu!oroundness.
Repair or replace when i! oes beyond 0.0bmm (.002 in.).
Lylindrici!y.
Repair or replace when i! oes beyond 0.0bmm (.002 in.).
ll00lL
0llLb
lN L/
l0wLb
Y
/
ll310N llN
b
/
Z
3. CHeck tHe d|stort|on ol tHe
cy||nder.
bepa|r or rep|ace wHen |t oes
beyond C.Cbmm |.CCZ |n..
4. leasure tHe l0 ol tHe sma|| end
ol tHe connect|n rod.
3.Cbmm |.b |n..
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|y |n tHe r|n roove.
b. l|Ht|y coat tHe r|ns w|tH en|ne
o|| belore |nsta|||n tHem on tHe
p|ston.
b. lake sure to keep r|n end aps
rotated at ZC
`
|ncrements.
/. Cover p|ston and r|ns w|tH a
||Ht coat ol en|ne o||.
Z
4
b
ZC`
ZC` ZC`
ZCmm
|./9 |n.
ZCmm
|./9 |n.
10l blN0
ZN0 blN0
3l0L blN0
L/l/N0lN0 blN0
3l0L blN0
10l blN0
3LC0N0 blN0
0ll blN0
C0NNLC1lN0
b00
. 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 cy||nder.
Assemb||ng the F|stcn
. 3crape away tHe asket adHer|n on tHe
surlace ol tHe crankcase.
Attent|cn:
Be sure not to |et any 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|ston 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
ll310N llN
ll310N
3N/l
blN0
3b
ll310N
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
cy||nder, tHe p|ston and tHe p|ston r|n
w|tH o||.
b. wHen assemb||n tHe p|ston r|ns,
tHey must be compressed |nto tHe
cy||nder.
Attent|cn:
0on't damae 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 e|t Dev|ce & The Start|ng Lever
Tcp|c Fage
lmportant lo|nts 9Z
1roub|esHoot|n 9Z
0etacH|n tHe lelt Crankcase Cover 93
bemov|n tHe 3tart|n l|vot 93
CHeck|n tHe 3tart|n l|vot 94
lnsta|||n tHe 3tart|n /ssemb|y 94
/ssemb||n tHe lelt Crankcase Cover 9b
CHeck|n tHe 0r|v|n Be|t 9b
bep|ac|n tHe 0r|v|n Be|t 9b
/ssemb||n tHe 0r|v|n Be|t 9/
1He 0r|v|n lu||ey0|smount|n 9/
1ak|n tHe 0r|v|n lu||ey /part 9/
CHeck|n tHe 0r|v|n lu||ey 9
/ssemb||n tHe 0r|v|n lu||ey 99
1He 0verrunn|n C|utcH bemova| 99
CHeck|n and /ssemb||n 99
tHe 0verrunn|n C|utcH
Tcp|c Fage
1He C|utcH/1ransm|ss|on lu||ey 9C
bemov|n tHe C|utcH/
1ransm|ss|on lu||ey
0|sassemb||n tHe C|utcH/ 9C
1ransm|ss|on lu||ey
CHeck|n tHe C|utcH 9
1ransm|ss|on lu||ey
bep|ac|n tHe transm|ss|on pu||ey 9Z
and tHe bear|n
1He C|utcH/1ransm|ss|on 93
lu||ey /ssemb|y
/ssemb||n tHe C|utcH Hous|n 94
9. Dr|v|ng e|t Dev|ce & The Start|ng Lever
Impcrtant Fc|nts
1H|s cHapter |s about tHe dr|v|n un|t, tHe
c|utcH/dr|ven un|t and tHe start|n |ever.
1He work on tHem can be done on tHe en|ne,
w|tHout tHe d|sassemb|y.
1He 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 any, 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.k/m Zlt |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

0n|versa| stand
Trcub|eshcct|ng
1He motorcyc|e doesn't run alter tHe en|ne |s
started
1He dr|v|n be|t |s worn
1He dr|v|n p|ate |s broken
1He brake ||n|n |s worn or broken
1He spr|n ol tHe dr|ven p|ate |s lractured
Sudden breakdcwn dur|ng runn|ng
1He spr|n ol tHe brake ||n|n |s lractured
Fcwer can't deve|cp fu||y
1He dr|v|n be|t |s worn
0|stort|on ol tHe dr|ven be|t spr|n
1He ro||er |s worn
1He dr|v|n p|ate surlace |s d|rty
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 |entH 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
Z3.99Z4.Cb
ZC.CCZZ.CZb
C/.CC/.ZZ
9.
33.9bb33.9b
34.C34.Zb
3.C
Z4.Z4
9.9/
/
Z.C
C/.b
C/.b
9Z.
34.Cb
Z.4
Compress|n dev|ce lor
c|utcH spr|n
3ocket |39mm lor
3ocket |39mm lor tHe hx nut
Bear|n dr|ver

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4 STROKE ENGINE

SERVICE AND REPAIR MANUAL

b. Eng|ne Remcva| and Insta||at|cn

V/lVL lllL bL/lLb

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