User manual ETON ATV BXL 50 - SERVICE MANUAL

CONTENTS 1. INFORMATION............................................................2 2. MAINTENANCE..........................................................6 3. ENGINE REMOVAL AND INSTALLATION......................12 4. ENGINE FUEL SYSTEM.............................................14 5. ENGINE LUBRICATION AND COOLING SYSTEM...........18 6. ENGINE COMBUSTION SYSTEM.................................21 7. TRANSMISSION SYSTEM..........................................25 8. FRONT WHEEL AND STEERING SYSTEM....................29 9. REAR WHEEL SYSTEM.............................................42 10. FENDERS AND EXHAUST PIPE.................................45 11. HYDRAULIC DISC SYSTEM......................................48 12. ELECTRICAL SYSTEM.............................................53 13.TROUBLE SHOOTING.............................................57 1 1. INFORMATION 1.1 SAFETY 1.2 NOTES 1.3 SERIAL NUMBER 1.4 SPECIFICATION 1.5 TORQUE VALUES 1.1 SAFETY Gasoline is extremely flammable and is explosive under certain condition. Do not smoke or allow sparks or flames in your work area. Never run the engine in a closed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death. The battery electrolyte contains sulfuric acid. Protect your eyes, skin and clothing. If you contact it, flush thoroughly with water and call a doctor if electrolyte gets in your eyes. 1.2 NOTES All information, illustrations, directions and specifications included in this publication are base on the latest product information available at the time of approval for printing. JI-EE Industry Co., Ltd. reserves the right to make changes at any time without notice and without incurring any obligation whatever. No part of this publication may be reproduced without written permission. 2 1.3 SERIAL NUMBER The frame serial number is stamped on the right side of the frame. The engine serial number is stamped on the left side of the crankcase. Frame serial number Engine serial number 3 1.4 SPECIFICATION ENGINE Type Displacement Bore and Stroke Compression Maximum Torque Carburetor Ignition Starting Lubrication Oil Capacity Transmission Forced Air-Cooling 2-Stroke 49.3cc/95.6cc 40.0*39.2mm/52.0*45.0mm 6.8:1/7.8:1 4.8 N-m@6500rpm/8.0N-m@4500rpm Mikuni VM16 Capacitor Discharge Ignition Electric/Kick Starter Oil Pump Separate Supply 1. 0 liter Automatic (C.V.T V-belt) CHASSIS Overall Length Overall Width Overall Height Seat Height Wheel base Ground Clearance Dry Weight Fuel Tank Capacity 1600mm(62.9inch) 795mm(31.2inch) 1020mm(40.1inch) 700mm(27.5inch) 1020mm(40.1inch) 120mm(4.7inch) 141kg 6.5±0.2liter SUSPENSION Front Rear Dual Absorber& Swing arm Single Absorber& Swing arm BRAKES Front Rear Drum Hydraulic Disc TIRIES Front Rear 19"*7"-8" 19"*8"-8" Red / Blue / Silver COLORING Specifications subject to change without notice. 4 1.5 TORQUE VALUES ENGINE Item Cylinder head nut park plug Cylinder head bolt Alternator bolt N·m 28-30 12-19 20-30 8-12 Lbf-ft 20.7-22.1 8.9-14.0 14.8-22.1 5.9- 8.9 FRAME Item Handlebar upper holder bolt Steering shaft nut Steering shaft bushing holder nut Wheel rim bolt Tie rod lock nut King pin nut Handlebar lower holder nut Front wheel bolt Front axle castle nut Front brake arm nut Rear brake arm nut Rear axle castle nut Rear wheel bolt Exhaust muffler mounting bolt Engine hanger bolt N·m 24-30 50-60 24-30 18-25 35-43 30-40 40-48 24-30 40-60 4-7 7-12 40-60 24-30 30-35 24-30 Lbf-ft 17.7-22.1 36.9-44.3 17.7-22.1 13.3-18.4 25.8-31.7 22.1-29.5 29.5-35.4 17.7-22.1 30-45 3.0- 5.2 5.2- 8.9 30-45 17.7-22.1 22.1-25.8 17.7-22.1 5 2. MAINTENANCE 2.1 MAINTENANCE DATA 2.2 MAINTENANCE SCHEDULE 2.3 FUEL TUBE 2.4 THROTTLE OPERATION 2.5 THROTTLE CABLE ADJUSTMENT 2.6 AIR CLEANER 2.7 SPARK PLUG 2.1 MAINTENANCE DATA 2.8 IDLE SPEED 2.9 DRIVE CHAIN 2.10 BRAKE SYSTEM 2.11 WHEELS AND TIRES 2.12 STEERING SYSTEM 2.13 TOE-IN 2.14 GEAR OIL SPECIFICATION SPARK PLUG GAP: RECOMMENDED SPARK PLUGS: THROTTLE LEVER FREE PLAY: IDLE SPEED: BRAKE LEVER FREE PLAY: DRIVE CHAIN SLACK FRONT/REAR TIRE SIZE FRONT/REAR TIRE PRESSURE TOE-IN 0.6-0.7 mm NGK BPR7HS 5-10 mm 1800±100 rpm 15-25 mm 10-25 mm 19X7-8/19X8-8 12 psi (0.8 kgf/cm2) 5±10 mm TORQUE VALUES SPARK PLUG TIE-ROD LOCK NUT 25-30 N.m 35-43 N.m ENGINE OIL GEAR LUBRICATION OIL 2.2 MAINTENANCE SCHEDULE JASO FC Grade or same degree oil SAE 90 The maintenance internals in the follow table is based upon average riding, conditions. Riding in unusually dusty areas, require more frequent servicing INITIAL REGULAR SERVICE SERVICE EVERY YEAR (Every 30 (First week) operating days) FUEL LINE I THROTTLE OPERATION I I AIR CLEANER C SPARK PLUG I CARBURETOR IDLE SPEED I I DRIVE CHAIN I, L I, L BRAKE SHOE WEAR I BRAKE SYSTEM I I NUT, BOLT, FASTENER I I WHEEL I I STEERING SYSTEM I SUSPENSION SYSTEM I C.V.T. AIR FILTER C GEAR OIL R Note ­ I: Inspect and Clean, Adjust, Lubricate or Replace, if necessary C: Clean L: Lubricate R: Replace 6 2.3 FUEL TUBE Inspect the fuel lines for deterioration, damage or leakage and replace any parts if necessary. 2.4 THROTTLE OPERATION Inspect throttle lever for smooth full opening and automatic full closing in all steering positions. Inspect if there is no deterioration, damage or kinking in the throttle cable, replace it if occur any damage. Check the throttle lever, free play is 5-10 mm at the tip of the throttle lever. Disconnect the throttle cable at the upper end. Lubricate the cable with commercially lubricant to prevent from premature wear. 2.5 THROTTLE CABLE ADJUSTMENT Slide the rubber cap of the adjuster off the throttle Housing, loosen the lock nut and adjust the free play of the throttle lever by turning the adjuster on the throttle housing. Inspect the free play of the throttle lever. 2.6 AIR CLEANER Unscrew the air cleaner cover screws. Pull out the air filter element from the air cleaner case. Wash the element in non-flammable solvent, squeeze out the solvent thoroughly. Let it dry. Soak the filter element in gear oil and then squeeze out the excess oil. Install the element into air cleaner carefully. 7 2.7 SPARK PLUG This spark plug located at the front of the engine. Disconnect the spark plug cap and unscrew the spark plug. Inspect the spark plug electrodes for wear. Change a new spark plug if the electrodes and insulator tip appear unusually fouled or burned. Discard the spark plug if there is apparent wear or if the insulator is cracked or chipped. The spark plug gap shall keep in 0.6-0.7mm. With the sealing washer attached, thread the spark plug in by hand to prevent cross threading. Tighten the spark plug with 25-30 N.m 2.8 IDLE SPEED Connect an engine speedometer. Warm up the engine, 10 minutes are enough. Turn the idle-speed adjust screw on the carburetor to obtain the idle speed. "Turn in" (clockwise) will get higher speed. "Turn out" (counter clockwise) will get lower speed. IDLE SPEED: 1800±100 rpm ADJUST SCREW 2.9 DRIVE CHAIN Inspect the chain slack. The standard is 10-25mm. Adjust the chain slack. Loose the lock bolts (4 pcs) then adjust the drive chain slack by turn the adjusting nut. Tighten the four lock bolts. 8 When the drive chain becomes very dirty, it should be removed, cleaned and lubricated by specify lubricator. Using commercial chain lubricant to lubricate the drive chain. Clean the drive chain with kerosene and wipe it dry. Inspect the drive chain for possible wear or damage. Replace the chain, if it is worn excessively or damaged. Inspect the sprocket teeth, if it is excessive wear or damage, replace it. 2.10 BRAKE SYSTEM Inspect the front brake lever and cable for excessive play or other damage. Replace or repair if necessary. Measure the free play of the brake lever at the end of the brake lever. The standard of free play is 15-25 mm. Inspect the rear brake lever and cable for excessive play or other damage. Replace or repair if necessary. Measure the free play of the rear brake lever at the end of the lever. The standard is 10-20 mm. 2.11 WHEELS AND TIRES Inspect the tire surfaces for cuts, nails or other sharp objects. Check the tire surfaces at cold tire condition. The standard of tire pressure is 12 psi (0.8 kgf/cm2). 9 2.12 STEERING SYSTEM Check the free play of the steering shaft with the front wheels, turned straight ahead. When there is excessive play, inspect the tie-rod, kingpin bushing and ball joint. 2.13 TOE-IN Let the vehicle on level ground and the front wheels facing straight ahead. Mark the centers of the tires to indicate the axle center height. Measure the distance between the marks. Carefully move the vehicle back, let the wheels have turned 180 °, so the marks on the tires are aligned with the axle center height. Measure the distance between the marks. Calculate the difference in the front and rear measurements. Toe-in: 5±10mm If the toe-in is out of standard, adjust it by changing the length of the tie-rods equally by turning the tie-rod while holding the ball joint. Tighten the lock nuts. Torque: 35-43 N.m 10 2.14 GEAR OIL Gear oil needs to be changed every year. There is a gear oil release bolt at the rear of engine. Unscrew this release bolt and can let the dirty oil flow out. The re-add oil hole is on the engine case beside gearbox. OIL DRAIN BOLT FILL OIL 11 3. ENGINE REMOVALS AND INSTALLATION 3.1 SERVICE INFORMATION 3.2 ENGINE REMOVAL 3.3 ENGINE INSTALLATION 3.1 SERVICE INFORMATION Engine shall be removed in the conditions of necessary repairment or adjustment in the transmission and combustion system only. 3.2 ENGINE REMOVAL Remove the seat and rear fender. (Chapter 10) Remove the spark plug cap from the spark plug. Remove the rear tires first, and than disassemble the exhaust pipe. Caution: When remove the tailpipe before, be careful the temperature. Please wear the gloves to avoid the heat from tailpipe. 2.REMOVE TAILPIPE 1.REMOVE REAR TIRE Remove the drive chain cover. This is under the chain. Remove the drive chain retaining clip and master link, than remove the drive chain. 12 Remove the three engine hanger nuts and bolts. Two hanger nuts are outside and one is inside. Remove the engine from the left side of frame. ENGINE HANGER NUTS 3.3 ENGINE INSTALLATION Engine installation is essentially the reverse order of removal. The torque of engine hanger bolt is 24-30 Nm Route the wires and cable in reverse order properly. 13 4. ENGINE FUEL SYSTEM 4.1 TROUBLESHOOTING 4.2 FUEL TANK 4.3 CARBURETOR 4.4 ASSEMBLY 4.1 TROUBLESHOOTING ENGINE CAN NOT START NO FUEL IN TANK NO FUEL TO CARBURETOR TOO MUCH FUEL INTO CYLINDER NO SPARK AT PLUG AIR CLEANER CLOGGED ENGINE IDLES UNSTEADY, STALLS OR RUNS POORLY UNPROPER ADJUSTMENT TO THE IDLE SPEED SCREW IGNITION MALFUNCTION FUEL/AIR MIXTURE RATIO NOT GOOD AIR CLEANER DIRTY INSULATOR LEAKAGE FUEL TANK CAP BREATHING HOLE CLOGGED LEAN MIXTURE FUEL JET OF CARBURETOR CLOGGED FUEL TANK CAP BREATHING HOLE CLOGGED FUEL FILTER CLOGGED FUEL FLOWS IN THE TUBE UNSMOOTHLY FLOAT LEVEL IN CARBURETOR TOO LOW RICH MIXTURE FLOAT NEEDLE VALVE IN CARBURETOR FAULTY FLOAT LEVEL TOO HIGH AIR DUCT IN CARBURETOR IS CLOGGED AIR CLEANER DIRTY 14 4.2 FUEL TANK REMOVAL Remove the seat and rear fender. Disconnect the fuel line from the carburetor. Remove the fuel tank cap and front fender. Unscrew the fuel tank fixed bolts. Note: Keep gasoline away from flames or sparks. Wipe up spilled gasoline at once. 4.3 CARBURETOR REMOVAL Remove the air cleaner. Disconnect the fuel line and auto-choke electric wire. Unscrew the intake pipe mounting bolts at the carburetor then remove the carburetor. Note: Turn off the fuel pipe by turn the fuel cup (below fuel tank) to "off" position. DISASSEMBLY Remove the carburetor cap. Remove the throttle cable from the throttle valve while depressing the throttle valve spring. Remove the needle clip retainer, the jet needle and needle clip. Inspect the throttle valve and jet needle surface for wearness, scratches or dirt. 15 Unscrew the float chamber screws and remove the float chamber. Disassembly the float arm pin, float and float needle valve. Inspect the seat of the float needle valve for wear or damage. Disassembly the idle jet, main jet, idle speed adjust screw and idle mixtures adjust screw. Inspect all the jets and screws for wear or damage. Clean the passages and jets with compressed air. 16 4.4 ASSEMBLY Clean all parts in solvent and blow it dry with clean compressed air. Assembly is essentially the reverse order of disassembly. THROTTLE VALVE ASSEMBLY Install the needle clip on the jet needle. Install the jet needle into the throttle valve. Assemble the throttle cable, spring and the throttle valve. Align the throttle valve groove with the idle speed adjust screw and install the carburetor cap to the carburetor. 17 5. ENGINE LUBRICATION AND COOLING SYSTEM 5.1 ENGINE LUBRICATION SYSTEM 5.2 CAUTION 5.3 OIL PUMP 5.4 COOLING SYSTEM 5.5 TROUBLESHOOTING 5.1 ENGINE LUBRICATION SYSTEM The engine crankshaft drives the pump gears of oil pump. Pump gears rotate the plunger shaft in oil pump. This shaft sent the lubricating oil into the crankcase to mix with the mixture of air-fuel flow evenly. The oil drops and foam cover the cylinder inner wall, piston surface and piston rings. 5.2 CAUTION Having enough oil supply to engine is very important. If the oil quantity is not enough, this engine will be serious scratched, and then this engine will stop, even cannot work again. When this engine is serious scratched, you need to change the piston, piston rings and cylinder together. Also you need to check the combustion system and lubrication system carefully. 5.3 OIL PUMP The quantity of oil that deliver out from oil pump increased by the engine speed and the carburetor throttle open width. Oil pump is under the right side of the engine and connected by a control cable of throttle. 5.4 COOLING SYSTEM The engine-cooling fan sucks the air. The cooling fan is on the right side of engine. The air is forced to flow through cylinder fin and cylinder head. So, the cylinder and piston will not over heat. 18 5.5 TROUBLESHOOTING NO ENOUGH OIL SUPPLY TO ENGINE THE OIL LEVEL IN OIL TANK IS TOO LOW. OIL TUBES WERE NOT FIXED WELL. OIL HAS LEAKAGED FROM TUBE ENDS. OIL TUBES WERE BROKEN. OIL TUBES WERE CLOGGED. OIL PUMP CANNOT WORK. ALWAYS INSUFFICIENT OIL LEVEL IN LUBRICATE OIL TANK EXTERNAL OIL LEAKS WORN CYLINDE HEAD GASKET WORN PISTON RINGS 19 6. ENGINE COMBUSTION SYSTEM 6.1 TROUBLESHOOTING 6.2 CYLINDER AND PISTON REMOVAL 6.3 CYLINDER AND PISTON INSPECTION 6.4 INSTALLATION 6.1 TROUBLESHOOTING LOW COMPRESSION CYLINDER HEAD HEAD GASKET LEAKING OR DAMAGED WARPED OR CRACKED CYLINDER HEAD CYLINDER OR PISTON RINGS WORN OUT HIGH COMPRESSION EXCESSSIVE CARBON BUILD-UP ON PISTON HEAD OR IN COMBUSTION CHAMBER EXCESSIVE NOISE PISTON AND CYLINDER WORN OUT EXCESSIVE CARBON BUILD-UP EXCESS SMOKE CYLINDER OR PISTON RINGS WORN OUT IMPROPER INSTALLATION OF PISTON RINGS PISTON OR CYLINDER WALL SCORED OR SCRATCHED OVERHEATING EXCESSIVE CARBON BUILD-UP ON THE PISTON OR COMBUSTION CHAMBER ENGINE COOLING SYSTEM (FAN, CYLINDER COVER etc.) WORKS BADLY. OIL SUPPLY IS OUT OF ORDER. WRONG IGNITION TIMING 20 6.2 CYLINDER AND PISTON REMOVAL Remove the seat and rear fender. Remove the exhaust pipe. Remove the spark plug cap. Disconnect the wire. Drag out the engine. Disassembly the air cleaner and carburetor. Remove the intake pipe mounting bolts. Remove the cylinder bolt nuts. Remove the cylinder head. Remove the cylinder carefully, and then you can see the whole piston. Remove one piston pin clip. Remove the piston and piston pin. Spread each piston ring and remove it by lifting up at a point just opposite the gap. Note: Don't let the clip drop into engine crankcase. 6.3 CYLINDER AND PISTON INSPECTION Inspect the cylinder bore for wear or damage. Measure the cylinder inner diameter at three levels in X and Y-axis. Taper limit: 0.10 mm Out of round: 0.10 mm 21 Check the cylinder head mating surface for warp with a straight edge and feeler gauge. Service limit: 0.10 mm Insert each piston ring into the cylinder, and measure the end gap. Service limit: 0.5 mm Measure the clearance between ring and groove. Service limit: 0.09 mm Measure the piston outer diameter at 10 mm high from the skirt's bottom. Service limit: 39.9 mm (for 50cc engine) 51.9 mm (for 100cc engine) 22 Measure the piston pin bore, and the piston pin outer diameter. Pin outer diameter service limit: 9.96 mm (for 50cc engine) 11.6 mm (for 100cc engine) Pin bore service limit: 10.04 mm (for 50cc engine) 12.04 mm (for 100cc engine) Measure the connecting rod small end inner diameter with an inside micrometer. Service limit: 14.06 mm (for 50cc engine) 15.06 mm (for 100cc engine) 6.4 INSTALLATION Install the piston rings with the marks facing up. Do not damage the piston rings by spreading the ends too far. Clean the cylinder gasket surface being careful not to drop any gasket material into the crankcase. 23 Apply some oil to inside of the connecting rod small end. Install the piston, piston pin and clip. Install the piston with the arrow mark facing the exhaust pipe. Do not align the piston pin clip end gap with the piston cutout. Install a new cylinder gasket. Apply a thin coat of engine oil to the piston rings and cylinder wall. Install the cylinder, compressing the piston rings. Replace a new cylinder head gasket. Install the cylinder head. Tighten the cylinder-mounting bolt. The torque is 10-14N.m 24 7. TRANSMISSION SYSTEM 7.1 TROUBLESHOOTING 7.2 THE PARTS DRAWING OF TRANSMISSION SYSTEM 7.3 PATH OF POWER TRANSMISSION 7.4 AUTOMATIC CONTINUOUS VARIABLE TRANSMISSION 7.5 CONTINUOUS VARIABLE TRANSMISSION 7.6 GEAR BOX 7.7 ELECTRIC SELF-STARTER MECHANISM 7.8 DISASSEMBLY AND CHECK OF C.V.T. SYSTEM 7.1 TROUBLESHOOTING SCOOTER CAN NOT MOVE AFTER ENGINE START BELT WEARED FRONT PULLEY WEARED OR BROKEN LINING OF CLUTCH WEARED CAN NOT RUN AT HIGH SPEED BELT WEARED ROLLERS WEARED SPRING OF REAR PULLEY IS DISTORTED 7.2 THE PARTS DRAWING OF TRANSMISSION SYSTEM 25 7.3 PATH OF POWER TRANSMISSION The torque of crank-shaft drive the front pulley The torque (drive) pulley turn the belt The belt drive the rear (driven) pulley The force through the clutch shoe, clutch housing and drive shaft The drive shaft turn the idle gear in gearbox Turning speed reduced by final-gear and transmitted to rear-axle shaft to move rear wheel 7.4 AUTOMATIC CONTINUOUS VARIABLE TRANSMISSION This transmission is the combination of automatic centrifugal clutch and V-belt continuous variable transmission, which can change the transmission ratio automatically. When engine speed increase, the drive pulley will be push to belt by the centrifugal force from six rollers. Then the pitch circle of belt in drive pulley will be larger. The belt at driven pulley is forced to move to the center of shaft, then the radius of pitch circle is decreased. The transmission ratio is therefore altered by the alteration of pitch circle's radius. (In the drawing, "H" means high speed, "L" means low speed) 7.5 CONTINUOUS VARIABLE TRANSMISSION V-Belt Made of rubber fiber, resistant to head, pressure and abrasion. The inner side of the Belt is toothed. Drive Pulley Due to the increasing engine speed, the rollers push the movable drive face by centrifugal force. Then the belt is pressed and enlarge its turning radius. The aluminum fan is installed on the exterior of fixed drive face. It can reduce the belt temperature. 26 Driven Pulley Because the revolving radius of V-Belt at the Drive End is enlarged, the Face Comp Movable Drive is squeezed out by the V-Belt at the Driven End to shorten the revolving radius. There is a Torque Cam on the Movable Drive Face. Torque Cam is loaded from outside. When the outside load is higher than the engine's output, the pulley of fixed shaft and belt slip to make the Movable Drive Face move along the inner side of Cam and compensate to increase to high torque (toward to low speed) and make the engine maintain smooth running with original revolution. 7.6 GEAR BOX The torque received by the Drive shaft will be transmitted by the speed reduction of two sets to rear axle shaft. The first gear ratio is 36/13 (for 50cc engine), 47/15 (for 100cc engine). The second gear ratio is 48/12 (for 50cc engine), 31/11 (for 100cc engine). DISASSEMBLE TRANSMISSION BOX Unscrew fixing nut of rear wheel axle. Remove rear wheel. Unscrew oil-leaking bolt at the bottom of crankcase. Let the oil flow out from mission box. Unscrew six bolts of mission box cover. Remove the mission cover. Remove the gears from mission box. Lubricated oil is SAE 90 oil 110cc. Torque value: M6: 1.0 ­ 1.2 kgf-m M10: 3.5 ­ 4.0 kgf-m 27 7.7 ELECTRIC SELF-STARTER MECHANISM Starter Motor is installed on the upper side of engine. The starter motor can act only when the left hand brake is applied. 7.8 DISASSEMBLY AND CHECK OF C.V.T. SYSTEM Remove the engine clutch cover, by unscrew the fixed bolts. Check the belt for wear. If necessary, replace the belt. Disassembly the front drive pulley, check the six rollers for wear. If necessary, replace the rollers. 28 8. FRONT WHEEL AND STEERING SYSTEM 8.1 THE PARTS DRAWING OF FRONT WHEELS AND STEERING SYSTEM 8.2 TROUBLESHOOTING 8.3 HANDLEBAR 8.4 FRONT WHEEL 8.5 FRONT BRAKES 8.6 SPEEDOMETER 8.7 STEERING SYSTEM 8.1 THE PARTS DRAWING OF FRONT WHEELS AND STEERING SYSTEM FRONT WHEEL FRONT BRAKE STEERING SYSTEM HANDLEBAR 29 8.2 TROUBLESHOOTING HARD STEERING FAULTY TIRE STEERING SHAFT HOLDER TOO TIGHT INSUFFICIENT TIRE PRESSURE FAULTY STEERING SHAFT BEARINGS DAMAGED STEERING SHAFT BEARING FAULTY TIRE WORN FRONT BRAKE DRUM BEARING BENT RIM AXLE NUT NOT TIGHTENED PROPERLY INCORRECT BRAKE ADJUSTMENT STICKING BRAKE CABLE BENT TIE RODS WHEEL INSTALLED INCORRECTLY UNEQUAL TIRE PRESSURE BENT FRAME WORN SWING ARM PIVOT BUSHINGS BRAKE SHOES WORN WORN BRAKE DRUM IMPROPER BRAKE ADJUSTMENT FRONT WHEEL WOBBLING BRAKE DRAG STEERS TO ONE SIDE POOR BRAKE PERFORMANCE FRONT SUSPENSION NOISE HARD SUSPENSION LOOSE FRONT SUSPENSION FASTENERS BINDING SUSPENSION LINK FAULTY FRONT SWING ARM BUSHINGS IMPROPERLY INSTALLED FRONT SWING ARMS BENT FRONT SHOCK ABSORBER SWING ROD WEAK FRONT SHOCK ABSORBER SPRINGS WORN OR DAMAGE FRONT SWING ARM BUSHINGS SOFT SUSPENSION 30 PS: ADJUST THE SUSPENSION Both the suspension is soft or too hard. One must adjust the suspension to an appropriate elasticity position. See the top right of the picture for adjustment tool. 8.3 HANDLEBAR REMOVAL Remove the throttle lever housing on the right handle bar. Remove front brake cable. Remove the couple of brake switch assy. Remove engine switch housing on the left handle bar. Remove rear brake cable. Remove the bolts attaching the upper holder cover. There are two bolts on top and another two bolts on the both sides. 31 When take the three up toward screws, it can remove the handlebar holder and handlebar. INSTALLATION Put the handlebar on the lower holders. Make sure the handlebar punch mark with the tops of the handlebar lower holders. Install the handlebar upper holders with the L or R marks facing forward. Tighten the forward bolts first, and then tighten the rear bolts. Install the handlebar upper holder's cover. Install the switch housing, aligning the boss with the hole. Tighten the upper screw first then tighten the lower one. Install the rear brake lever bracket, aligning the boss with the hole. Tighten the screw securely. Aligning the split line of the throttle housing and holder with the punch mark. Tighten the screw securely 32 8.4 FRONT WHEELS REMOVAL Raise the front wheels off the ground by placing a block under the frame. Remove the front wheel nuts, washer and wheels. INSTALLATION Install and tighten the four-wheel castle nuts Torque: 40-60 N.m Remember put a cotter pin in the castle nut. 8.5 FRONT BRAKES FRONT BRAKE INSPECTION Remove the front wheel. Remove the brake drum. Measure the brake lining thickness. The minimum limit: 1.5 mm If they are thinner than the minimum limit, replace the brake linings. Measure the brake drum inner diameter. The maximum limit: 86 mm 86mm 33 Turn the inner race of each bearing with fingers. The bearings should turn smoothly and quietly. If the race does not turn smoothly or quietly, remove and discard the bearings. BRAKE PANEL REMOVAL Disconnect the brake cable from the brake arm. Remove the brake panel from the knuckle. Remove brake arm and cam. Remove indicator plate and felt seal. INSTALL BRAKE PANAL Apply grease to the brake cam and anchor pin and install the cam in the brake panel. Soak the felt seal in the engine oil and install the seal on the brake cam. 34 Install the brake arm on the cam by aligning the punch mark and the groove on the cam. Tighten the brake arm bolt and nut. Torque: 4-7 N.m Install the brake panel on the knuckle. Connect the brake cable to the brake arm. Install the brake arm cover. Tighten the screws securely. Position the brake shoes in their original locations and install the brake shoe spring. Install the brake drum and front wheel. Install the castle nut and cotter pin. When finish all steps of above, it must do some fine turnings on break system. First tune the adjuster screws of brake distributor. When the nuts tighten, loosen it about two teeth. Then tune the adjuster nuts of steering arm on both sides. It shall be tune to suitable. 35 Last, tune the nuts of handle bar on both sides. The steps just like above. FRONT BRAKE ADJUSTMENT HANDLEBAR RIGHTSIDE BRAKE ALLOT ASSEMBLY RIGHT FRONT BRAKE LEFT FRONT BRAKE PEDAL BRAKE Any parts of brake system were replaced, or poor brake force. The adjustment should be done. The brake adjustment steps are below; 1. Handlebar Brake Lever: It should tune up the brake allot assembly first, and then align the handlebar lever. 2. Front Brake: Tune the front brake up to normal and adjust the nut in the brake allots assembly. 3. Finally: Set the pedal brake to the position. And use the above steps to adjust the whole brake each other 36 8.6 SPEEDOMETER TROUBLESHOOTING INSTRUMENT PANEL LIGHT OFF PANEL LCD NOT DISPLAY BATTERY LOW/DISCHARGE METER MAIN WIRE NOT CONNECTED BATTERY LOW/DISCHARGE ADJUST SETTINGS METER MODLE BROKEN METER CABLE BROKEN METER SENSOR BROKEN DRUM MAGNET REMOVAL First disassemble the screws on top of the panel. There are seven screws which locate on the top, side and forward. Then the panel just can be taking apart. Second, some cables just connect with the panel. So let the those couplers are disassembled. When those two were taken apart, use open-end tool to unscrew the screws on the back of panel. So it can be checked and changed by oneself. 37 The speedometer sensor is located on the back of wheel hub. Use hexagon wrench to disassemble the nut. LEFT FRONT BRAKES INSPECTION Remove the left front wheel. Remove the brake drum. Make sure the magnet steady in the drum. Install front brake drum 38 Install the end of meter sensor on front brake panel. Be careful, when assemble the speedometer sensor and magnetic block, there are a distance about 1mm. Please use thickness gauge to make it be in place. 1mm Tie the wires of speedometer with front brake cable. 8.7 STEERING SYSTEM REMOVAL OF KINGPIN AND TIE-ROD Remove the front wheels and brakes drum. Remove the cotter pin on the kingpin. Remove the four self-lock nuts from the tie-rod ball joints and take off the two tie-rods. Unscrew the bolt and remove the kingpin. 39 TIE-ROD INSPECTION Inspect the tie-rod for damage or bending. Inspect the ball joint rubbers for damage, wear or deterioration. Turn the ball joints with fingers. The ball joints should turn smoothly and quietly. KINGPIN INSPECTION Inspect the kingpin for damage or cracks. STEERING SHAFT REMOVAL Remove the speedometer and handle bar cover. (see paragraph 8-1) Remove the front fender. (see paragraph 10-1) Unscrew the steering shaft fixed out below shaft. Pull steering shaft carefully. BUSHING INSPECTION Remove the steering shaft. Remove the bushing from the shaft. Inspect the bushing for damage or wear, replace if necessary. Measure the bushing inner diameter. Maximum limit: Ø22.8 mm 40 STEERING SHAFT INSPECTION Inspect the steering shaft for damage or cracks. Measure the steering shaft outer diameter in the location of the bushing. Minimum limit: Ø22.0 mm STEERING SHAFT BEARING INSPECTION Turn the shaft bearing with finger. The bearing is on the front part of frame. The bearing should turn smoothly and quietly. Also check that the bearing outer race fits in the holder. Replace the bearing if necessary. INSTALLATION OF STEERING SHAFT Install the steering shaft with the bushing. Apply grease to the bushing. Install the bushing holder and tighten the nuts. Torque: 24-30 N.m Install the steering shaft nut and tighten it. This nut is under this steering shaft. Torque: 50-60 N.m INSTALLATION OF TIE-ROD Install the ball joint with " L" mark on the steering shaft side. Install the tie-rod with the mark on the wheel side. 41 9. REAR WHEEL SYSTEM 9.1 THE PARTS DRAWING OF REAR WHEEL SYSTEM 9.2 TROUBLESHOOTING 9.3 DRIVE MECHANISM 9.4 INSTALLATION 9.1 THE PARTS DRAWING OF REAR WHEEL SYSTEM 42 9.2 TROUBLESHOOTING BAD BRAKE PERFORMANCE BRAKE SHOES ARE WORN BAD BRAKE ADJUSTMENT BRAKE LININGS ARE OILY, GREASY OR DIRTY BRAKE DISC IS WORN BRAKE ARM SETTING IS IMPROPERLY ENGAGE AXLE IS NOT TIGHTENED WELL BENT RIM AXLE BEARINGS ARE WORN FAULTY TIRES REAR AXLE BEARING HOLDER IS FAULTY INCORRECT BRAKE ADJUSTMENT STICKING BRAKE DISC STICKING BRAKE TUBE VIBRATION OR WOBBLE BRAKE DRAG 9.3 DRIVE MECHANISM REMOVAL AND INSPECTION Remove the rear wheel first. Then remove the drive chain cover. Disassembly the chain retaining clips and master link. Disassembly the driven sprocket, axle and sprocket collar. Check the driven sprocket for damage or wear. 43 Let the rear axle lie in V-blocks and check the run out. The run out limit is 0.5 mm Check the turning of bearing with fingers. The bearings should turn smoothly and quietly. Replace if necessary. 9.4 INSTALLATION Add grease to the dust seal lips and install dust seals. Assembly the rear axle and the driven sprocket. Assembly the drive chain on the driven sprocket. Assembly the master link and retaining clip. Note the retaining clip direction. Install the drive chain cover. Assembly the chain under cover. 44 10. FENDERS AND EXHAUST PIPE 10.1 FENDERS DRAWING 10.2 REAR FENDERS REMOVE 10.3 FRONT FENDER REMOVE 10.4 EXHAUST PIPE DRAWING 10.5 EXHAUST PIPE REMOVE 10.6 EXHAUST PIPE INSTALLATION 10.1 FENDERS DRAWING 10.2 REAR FENDERS REMOVE First, pull the "Seat Fixer Assembly" to take off the seat. This seat fixer assembly is under the right side of the rear fender. The next procedures of remove the rear fender is: Unscrew the three bolts that connect in the back bumper and four in front. (The actual positions please see the fenders drawing.) 45 INSIDE Last, unscrew the bolts of the footrest on both sides. Then it can take apart the front and rear fender away. 10.3 FRONT FENDER REMOVE Remove the rear fender and seat. (See 10-1 paragraph) Pull the front fender upward. Remove the handle bar assembly and handle bar cover. Unscrew the two fixed screws under the front fender, just above front wheels. Unscrew the two fixed screws beside the oil tank. Unscrew the fuel tank cap. Then the front fender can be remove. Remove the seat by pulling the seat fixer assembly under the rear fender. Remove the handle bar assembly headlight and handlebar cover. Unscrew the hexagon screws, which connect with footrest plate. Unscrew the four screws, which connect with the frame. Two screws are just behind the fuel tank; the other two screws are back of the fender. 46 10.4 EXHAUST PIPE DRAWING 10.5 EXHAUST PIPE REMOVE Do not service the exhaust pipe while they are hot. You must wait at least 15 minutes after turn off the engine. You need remove the seat, rear fender and footrest plate, before you take off the exhaust pipe. Unscrew the two exhaust pipe bolts that fixed with engine. Remove the exhaust pipe mounting bolts that fixed on the engine. Remove the exhaust pipe carefully. 10.6 EXHAUST PIPE INSTALLATION Installation is the reverse order of removal. Torque: Exhaust muffler bolts 30-35 N.m After installation, make sure that there are no exhaust leaks. 47 11. HYDRAULIC DISC BRAKE SYSTEM 11.1 TROUBLESHOOTING 11.2 REPLACE BRAKE DISC 11.3 REPLACE THE BRAKE SHOE 11.4 REPLACE THE BRAKE HYDRAULIC OIL 11.5 REAR BRAKE ADJUSTMENT 11.1 TROUBLESHOOTING POOR BRAKE PERFORMANCE Improper brake adjustment Worn brake shoes Brake linings oily, greasy or dirty Worn brake cam Worn brake drum Brake arm serrations improperly engaged Brake shoes worn at cam contact area 11.2 REPLACE BRAKE DISC Remove the rear left tire Unscrew the two bolts shown on the photo and remove caliper. 48 Unscrew the rear wheel axle nut and then remove the mounting seat of the disc. Unscrew bolts and remove the brake disc Check the thickness of disc and replace a new one if the thickness less than 3mm. 11.3 REPLACE THE BRAKE SHOE Remove the rear left tire Unscrew the two bolts shown and remove caliper. 49