Scooters Haynes

Twist and Go

(automatic transmission)

50 to 250 cc with carburettor engines Haynes Service and Repair Manual

o.2 Contents Introduction A c k n o w le d g e m e n ts

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A b o u t th is m anual

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Id e n tific a tio n num be rs

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B u ying s p a re parts

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S a fe ty first!

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Daily (pre-ride checks) Engine oil level ch e c k

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C o o la n t level c h e c k (liq u id -c o o le d engines)

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S u spe nsio n a n d s te ering che c k s

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Fuel ch e c k

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B rake flu id level ch e c k

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Legal and s afety c h e c k s

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T y re c he c k s

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MAINTENANCE

Routine maintenance and servicing

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REPAIRS AND OVERHAUL

T w o -s tro k e e n gin es

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F o u r-s tro k e e ngines

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C o o lin g s y s te m s (liq uid c o o le d engines)

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Fuel a n d e x h a u s t s yste m s

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Ig n itio n s y s te m s

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F ram e a n d susp en sion

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B rake s, w he els an d ty res

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B o d y w o rk

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Electrical systems

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Engine and associated systems

Transmission D rive c o m p o n e n ts a n d ge arb ox

Chassis components

REFERENCE

D a ta s he ets

P a ge

T o o ls an d W o rk s h o p T ips

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M O T te s t c he c k s

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C on v ers ion fa c to rs

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In d e x

expert22

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DATA«1

A ckn ow ledgem en ts Thanks are due to Piaggio VE SpA, Italy, and to Mitsui Machinery Sales (UK) Ltd fo r perm ission to reproduce artw o rk from their publications. We would also like to thank NGK Spark Plugs (UK) Ltd for supplying colour spark plug condition photos and Draper Tools fo r some o f the workshop tools shown. We are grateful to the m anufacturers o r im porters w ho supplied

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material fo r th e Data section at th e end o f this manual, particularly th e UK importers fo r Sym, Malaguti, Peugeot, Gilera, Piaggio and Vespa. For anyone we have inadvertently om itted, please a cce pt our apologies. Special thanks are due to VE (UK) Ltd, suppliers o f scooter parts and accessories to th e trade, fo r help and advice given.

About this manual The aim o f this manual is to help you get the best value from your scooter. It can do so in several ways. It can help you decide what work m ust be done, even if you choose to have it done by a dealer; it provides inform ation and procedures fo r routine m aintenance and servicing; and it offers diagnostic and repair procedures to follow when trouble occurs. We hope you use the manual to tackle the work yourself. For many sim pler jobs, doing it yourself m ay be qu icker th an arranging an appointm ent to get the scooter into a dealer and making the trips to leave it and pick it up. More importantly, a lot o f money can be saved by avoiding the expense th e shop m ust pass on to you to cover its labour and overhead costs. An added benefit is th e sense of satisfaction and accom plishm ent th a t you feel after doing th e job yourself. References to th e left o r right side of the scooter assume you are sitting on the seat, facing forward.

We ta k e g re a t prid e in th e ac c u ra c y o f in fo rm a tio n given in th is m an ua l, b u t m a n u fa c tu re rs o fte n m a k e a lte ra tio n s and d e sign c ha ng es du rin g th e p ro d u c tio n ru n o f a p a rtic u la r m a c h in e o f w h ic h th ey do n o t info rm us. No lia b ility can be a c ce pted by th e a u th o rs o r p u b lis h e rs fo r lo s s , dam age o r in ju ry cau sed b y any e rrors in, o r o m issions fro m , th e info rm a tion given.

Illegal Copying It is th e policy, o f Haynes Publishing to actively protect its Copyrights and Trade Marks. Legal actio n w ill be taken against anyone who unlawfully copies the cover or contents o f this Manual. This includes all form s o f unauthorised copying including digital, mechanical, and electronic in any form . A uthorisation from Haynes Publishing will only be provided expressly and in writing. Illegal copying will also be reported to th e appropriate statutory authorities.

Identification numbers and buying spare parts Frame and engine num bers The frame serial number, or VIN (Vehicle Identification Number) as it is often known, is stamped into th e frame, and also appears on the identification plate. The engine number is stamped into the rear o f the transmission casing. Both of these numbers should be recorded and kept in a safe place so they can be furnished to law enforcem ent officials in th e event of a theft. The frame and engine numbers should also be kept in a handy place (such as with your driving licence) so they are always available when purchasing o r ordering parts fo r your scooter. Each model type can be identified by its engine and frame number prefix.

Buying spare parts When ordering new parts, it is essential to ide ntify exactly the machine fo r w hich the parts are required. While in som e cases it is sufficie nt to ide ntify th e m achine by its title, eg, ‘G ilera Runner’ or ‘Yamaha Neo’s ’, any m odifications made to components mean that it

is usually essential to identify the scooter by its year o f production, or better still by its frame or engine number prefix. To be absolutely certain of receiving the correct part, not only is it essential to have the scooter engine or frame number prefix to hand, but it is also useful to take th e old part for comparison (where possible). Note that where a m odified component has superseded th e original, a careful check m ust be made th at there are no related parts w hich have also been m odified and m ust be used to enable th e new to be correctly refitted; where such a situation is found, purchase all the necessary parts and fit them, even if this means renewing apparently unworn items. Purchase parts from an authorised dealer o r som eone w ho specialises in scooter parts; they are more likely to have th e parts in stock or can order them quickly from th e importer. Pattern parts are available fo r certain com ponents; if used, ensure these are o f recognised quality brands which w ill perform as well as th e original. Expendable items such as lubricants, spark plugs, some electrical com ponents, bearings, bulbs and tyres can usually be obtained at lower prices from accessory shops, m otor factors o r from specialists advertising in th e national motorcycle press.

0-4 S afety First! Professional mechanics are trained in safe w orking procedures. However enthusiastic you may be about getting on with th e job at hand, take the tim e to ensure that your safety is not put at risk. A moment's lack o f attention can result in an accident, as can fa ilure to observe simple precautions. There w ill always be new w ays o f having accidents, and th e follow ing is not a com prehensive list o f all dangers; it is intended rather to make you aware of th e risks and to encourage a safe approach to all work you carry ou t on your bike.

Asbestos • C ertain friction , insulating, sealing and other products - such as brake pads, clutch linings, gaskets, etc. - contain asbestos. Extreme care m ust be taken to avoid inhalation of dust from such products since it is hazardous to health. If in do ub t, assume that they do contain asbestos.

Fire • Remember at all times that petrol is highly flammable. Never smoke or have any kind of naked flam e around, when w orking on th e vehicle. But the risk does no t end there - a spark caused by an electrical short-circuit, by tw o metal surfaces contacting each other, by careless use o f tools, or even by static electricity built up in your body under certain conditions, can ignite petrol vapour, which in a confined space is highly explosive. Never use petrol as a cleaning solvent. Use an approved safety solvent.

Remember... X D o n ’t sta rt th e engine w itho ut first ascertaining th at th e transm ission is in neutral. X Don’t suddenly remove the pressure cap from a hot cooling system - cover it w ith a cloth and release the pressure gradually first, or you may get scalded by escaping coolant. X D o n ’t attem pt to drain oil until you are sure it has cooled sufficiently to avoid scalding you. X D o n ’t grasp any part o f th e engine or exhaust system w itho ut firs t ascertaining that it is cool enough not to burn you. X D on’t allow brake fluid or antifreeze to contact the machine’s paintw ork or plastic components. X D on’t siphon to xic liquids such as fuel, hydraulic fluid or antifreeze by m outh, or allow them to remain on your skin. X D on’t inhale dust - it may be injurious to health (see Asbestos heading). X D o n ’t allow any spilled oil or grease to remain on the floor - wipe it up right away, before someone slips on it. X D o n ’t use ill-fittin g spanners o r other tools which m ay slip and cause injury. X Don’t lift a heavy component which may

• Always disconnect the battery earth terminal before working on any part of the fuel or electrical system, and never risk spilling fuel on to a hot engine or exhaust. • It is recommended that a fire extinguisher of a type suitable for fuel and electrical fires is kept handy in the garage or workplace at all tim es. Never try to extinguish a fuel or electrical fire with water.

Fumes • Certain fu mes are highly to x ic and can quickly cause unconsciousness and even death if inhaled to any extent. Petrol vapour com es into this category, as do th e vapours from certain solvents such as trichloroethylene. Any draining o r pouring o f such volatile fluid s should be done in a well ventilated area. • When using cleaning fluids and solvents, read the instructions carefully. Never use materials from unmarked containers - they may give off poisonous vapours. • Never run th e engine o f a m otor vehicle in an enclosed space such as a garage. Exhaust fumes contain carbon m onoxide w hich is extremely poisonous; if you need to run the engine, always do so in th e open air or at least have the rear o f th e vehicle outside the workplace.

• Always disconnect th e battery ground (earth) terminal before working on th e fuel or electrical systems (except where noted). • If possible, loosen th e filler plugs or cover when charging th e battery from an external source. Do not charge a t an excessive rate or th e battery may burst. • Take care when topping up, cleaning or carrying the battery. The acid electrolyte, evenwhen diluted, is very corrosive and should not be allowed to contact the eyes or skin. Always wear rubber gloves and goggles or a face shield. If you ever need to prepare electrolyte yourself, always add the acid slowly to th e water; never add the water to the acid.

E lectricity

• Never cause a spark, o r allow a naked light near the vehicle’s battery. It w ill normally be giving off a certain am ount o f hydrogen gas, which is highly explosive.

• When using an electric pow er tool, inspection light etc., always ensure that the appliance is correctly connected to its plug and that, where necessary, it is properly grounded (earthed). Do not use such appliances in dam p conditions and, again, beware o f creating a spark or applying excessive heat in th e v icinity o f fuel or fuel vapour. Also ensure that th e appliances meet national safety standards. • A severe electric shock can result from touching certain parts o f th e electrical system, such as the spark plug wires (HT leads), when th e engine is running o r being cranked, particularly if com ponents are dam p o r th e insulation is defective. Where an electronic ignition system is used, the secondary (HT) voltage is much higher and could prove fatal.

be beyond your capability - get assistance. X D o n ’t rush to finish a jo b or take unverified short cuts. X Don’t allow children o r animals in or around an unattended vehicle. X D o n ’t inflate a tyre above the recomm ended pressure. A part from overstressing th e carcass, in extreme cases the tyre may blow off forcibly. ✓ Do ensure that the machine is supported securely at all tim es. This is especially important when the machine is blocked up to aid wheel or fork removal. ✓ Do take care when attempting to loosen a stubborn nut or bolt. It is generally better to pull on a spanner, rather than push, so th at if you slip, you fall away from th e machine rather than onto it. ✓ Do wear eye protection when using pow er to ols such as drill, sander, bench grinder etc. ✓ Do use a barrier cream on your hands prior to undertaking dirty job s - it w ill protect your skin from infection as well as making th e dirt easier to remove afterwards; but make sure your hands aren’t left slippery. Note that long-term contact with used engine oil can be a health hazard. ✓ Do keep loose clothing (cuffs, ties etc. and long hair) well out o f the way o f moving

mechanical parts. ✓ Do remove rings, wristw atch etc., before w orking on th e vehicle - especially th e electrical system. ✓ Do keep your w ork area tid y - it is only to o easy to fall over articles left lying around. ✓ D o exercise caution when compressing springs fo r removal or installation. Ensure that the tension is applied and released in a controlled m anner, using suitable tools which preclude the possibility of th e spring escaping violently. ✓ Do ensure that any lifting tackle used has a safe w orking load rating adequate fo r the job. ✓ Do get someone to check periodically th at all is well, when working alone on the vehicle. ✓ Do carry out work in a logical-sequence and check that everything is correctly assembled and tightened afterwards. ✓ Do remember that your vehicle’s safety affects th at of yourself and others. If in doubt on any point, get professional advice. • If in spite o f following these precautions, you are unfortunate enough to injure yourself, seek medical attention as soon as possible.

The battery

Daily (pre-ride) c h e c k s 0.5 Note: The Daily (pre-ride) checks outlined in you r owner's manual covers those items which should be inspected on a daily basis.

Two-stroke engine il level check Before you s ta rt ✓ Make- sure you have a supply o f th e correct oil available. ✓ Support th e machine in an upright position whilst checking th e level. Make sure it is on level ground.

• If th e engine is run w itho ut oil, even fo r a short time, serious engine damage and engine seizure w ill occur. It is advised that a bottle of engine oil is carried in th e storage compartm ent at all times.

S cooter care

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2

• If you have to add oil frequently, you should check whether you have any oil leaks, and check th e oil pump adjustment (see Chapter 1).

The c o rre c t oil • Keep th e oil ta n k to pp ed up w ith a good quality tw o-s troke oil suitable fo r injector systems. C ertain scooters require a specific grade o f tw o-stroke oil - see Data section at the end o f this manual. • Don’t rely on th e oil level warning light to (tell you that th e oil needs topping-up. Get into the habit o f checking the oil level a t th e same tim e as you fill up w ith fuel.

Remove th e fille r cap to che ck the oil level.

If the level is low, to p -u p w ith th e recommended grade and type o f oil, then refit th e filler cap securely.

Four-stroke engine oil level check Before you sta rt

The c o rre ct oil

✓ Make sure you have a supply o f th e correct oil available. ✓ Support th e machine in an .upright position whilst checking the level. Make sure it is on level ground.

• M odem engines place great dem ands on their Oil. It is very important to use th e correct oil fo r your engine. • Always to p-up w ith a good quality oil o f th e s pecified typ e and viscosity - see Data section a t the end o f this manual.

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Either check th e level th rough the sight g la ss. . .

• Check the oil level carefully. Make sure you know th e correct level fo r your scooter.

S cooter care • If you have to add oil frequently, you should check whether you have any oil leaks.

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If the level is low, to p -u p w ith the recommended grade and type o f oil, then refit th e filler c ap securely. Never overfill th e oil.

0.6 Daily (pre-ride) c h e c k s

Coolant level check (liquid-cooled engines)

A

W arning : DO N O T leave op en conta in ers o f coo lan t about, as i t is poisonous. PEUCE

Before you sta rt ✓ M ake sure you have a supply o f coolant available (a mixture o f 50% distilled water and 50% corrosion inhibited ethylene glycol antifreeze is needed). ✓ Alw ays che ck th e coolant level when the engine is cold. ✓ Support the machine in an upright position w hilst checking the level. Make sure it is on level ground.

Scooter care • Use only th e specified coolant mixture. It is important that antifreeze is used in th e system all year round, and not just in th e winter. Do not top-up the system with water only, as the coolant will become to o diluted. • Make sure you know the correct level fo r your scooter - refer to your scooter handbook fo r details. If there are no minimum and maximum marks, to p-up th e coolant level to just below th e bottom o f th e filler neck. • Do not overfill the reservoir tank. Any surplus should be siphoned or drained o ff to prevent th e possibility o f it being expelled under pressure. • If the coolant level falls steadily, check the system fo r leaks (see Chapter 1). If no leaks are found and th e level continues to fall, it is recommended that th e machine is taken to a scooter dealer fo r a pressure test.

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On many scooters you w ill need to detach a body panel to view the coolant reservoir.

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On other scooters th e coolant reservoir has level marks on its side which are visible through slots in the body p a n e l. . .

4

. . . and topping up is done via a filler cap at th e to p o f the panel.

Suspension and steering checks • Check that th e fron t and rear suspension operates smoothly without binding.

• C heck th at th e steering moves sm oothly from lock-to-lock.

Fuel check • This m ay seem obvious, but check that you have enough fuel to com plete your journey. Do not rely on the fuel gauge or warning light to te ll you that th e level in th e ta nk is low before filling up.

• If you notice any fuel leaks you must rectify the cause immediately.

• Ensure you use th e correct grade unleaded petrol, minimum 95 octane. Note that th e use o f unleaded petrol will increase spark plug life and have obvious benefits to th e environment.

Daily (pre-ride) c h e ck s 0.7 Brake fluid level check W arning : B ra ke h y d ra u lic flu id can h a rm y o u r eyes a n d dam age p a in te d surfaces, so use extrem e c a u tio n w he n h a n d lin g a n d pouring i t a n d c o ve r su rro u n d in g s urfaces w ith rag . Do n o t use flu id th a t ha s be en standing open fo r som e tim e, as i t absorbs m oistu re fro m th e a ir w h ic h can ca u s e a * dangerous loss o f bra kin g effectiveness.

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Before you sta rt ✓ Support th e machine in an upright position on level ground and turn th e handlebars until the hydraulic reservoir is as level as possible remember to che ck both reservoirs if your scooter is equipped with fron t and rear disc brakes. ✓ Make sure you have a supply o f DOT 4 hydraulic fluid. ✓ Access to the reservoir is restricted on most models by the upper handlebar cover. Remove the cover if the reservoir requires topping-up. ✓ Wrap a rag around th e reservoir to prevent any hydraulic fluid com ing into contact with painted o r plastic surfaces.

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The brake fluid level is visible through the sightglass in th e reservoir body - it must be half w ay up th e glass when th e reservoir is level.

2

Remove th e reservoir c a p screw s and rem ove th e cover, th e diaphragm plate and the diaphragm.

T op -u p w ith new DOT 4 hydraulic fluid until the level is half w ay up th e sightglass. Do not overfill and take care to avoid spills (see W arning above).

4

Ensure th a t th e diaphragm is correctly seated before installin g th e pla te and cover. Tighten the cover screws securely.

Scooter care • The fluid in the hydraulic reservoir w ill drop slightly as th e brake pads wear down. • If the reservoir requires repeated toppin gup this is an indication o f a flu id leak somewhere in th e system, w hich should be investigated immediately. • Check fo r signs o f fluid leaks from th e brake hoses and com ponents - if foun d, rectify immediately. • Check th e operation o f th e brake before riding the machine; if there is evidence o f air in the system (a spongy feel to the lever), it must be bled as described in Chapter 8.

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Legal and safety checks Lighting and signalling

Safety

• Take a m inute to che ck th a t th e headlight, ta il light, brake light, instrument lights and turn signals all w ork correctly. • Check that th e horn sounds when the switch is operated. • A working speedometer graduated in mph is a statutory requirement in the UK.

• C heck that th e throttle tw istgrip rotates sm oothly and snaps shut when released, in all steering positions. • Check that th e stand return spring holds th e stand securely up when retracted. • C heck th a t both brakes w ork correctly when applied and free o ff when released.

o-8 Daily (pre-ride) c h e c k s

Tyre checks The co rre c t pressures • The tyres must be checked when cold, not im m ediately after riding. Note th a t low tyre pressures may cause th e tyre to slip on th e rim o r come off. High tyre pressures will cause abnormal tread wear and unsafe handling. • Use an accurate pressure gauge. • P roper air pressure w ill increase tyre life and provide maximum stability and ride comfort. • Refer to the Data section at the end of this manual for the correct tyre pressures fo r your model.

Tyre care • C heck th e tyres carefully fo r cuts, tears, em bedded nails or other sharp objects and excessive wear. Operation o f th e scooter with excessively worn tyres is extremely hazardous, as tractio n and handling are directly affected. • Check the condition o f the tyre valve and ensure th e dust cap is in place. • Pick ou t any stones or nails w hich may have become embedded in th e tyre tread. If left, they will eventually penetrate through the casing and cause a puncture. • If tyre damage is apparent, or unexplained loss of pressure is experienced, seek th e advice o f a tyre fitting specialist without delay.

Tyre tread depth • At the tim e o f writing, for machines with an engine size greater than 50 cc, UK law

requires th a t tread depth m ust be at least 1 mm over 3/4 of the tread breadth all the way around the tyre, with no bald patches. Many riders, however, consider 2 mm tread depth minimum to be a safer limit. • For m achines w ith an engine size not greater than 50 cc, UK law states that tread depth may be less than 1 mm if th e tread pattern is clearly visible across the whole of the tread breadth all the way around the tyre. • Many tyres now incorporate wear indicators in th e tread. Identify the triangular pointer on the tyre sidewall to locate th e indicator bar and renew th e tyre if the tread has worn down to the bar.

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Check the tyre pressures when the tyres are cold and keep them properly inflated.

Tyre tread wear indicator bar and its location marking (usually either an arrow, a triangle o r th e letters TWI) on th e sidewall (arrowed).

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Chapter 1 Routine maintenance and servicing Contents Air filte rs-cle a n and renewal ............................................................... 3 Battery - check ....................................................................................... 4 Brake cable - check, adjustm ent and lu b ric a tio n ............................... 7 Brake fluid - check ................................................................................. 8 Brake hose - c h e c k .............................................................................. .. 9 Brake lever pivots - lubrication .............................................................. 6 Brake pads - wear check ........................................................................10 Brake shoe cam - check and lubrication ..............................................12 Brake shoes - wear c h e c k ........................................................................11 Brake system - c h e c k .............................. .............................................. 5 Carburettor - clean .................................................................................. 15 Clutch pulley and bearing -r check and lubricate ................................ 26 Cooling system - c h e c k ............................................................................ 21 Cylinder head (two-stroke Engines) - d e c arb on is e .............................. 31 Drivebelt - c h e c k ...................................................................................... 22 Drivebelt - renewal ..................................................................................23 Engine oil and oil filter - change ............................................................ 18 Engine oil system - c h e c k ....................................................................... 17 Fuel system - check ................................................................................ 14 Gearbox oil - c ha n g e ................................................................................28

Gearbox oil level - check ........................................................................ 27 Headlight, brake light and horn - check .............................................. 33 Idle speed - check and a d justm e nt........... ........................................... 16 In tro d u c tio n .............................................................................................. 1 Kickstart gear and spindle bush - c h e c k .............................................. 25 Nuts and bolts - tightness check .........................................................39 Oil pump cable (two-stroke engines) - check and a d ju s tm e n t.........19 Oil pum p drivebelt (tw o-stroke engines) - r e n e w a l.............................20 Spark plug - re n e w a l.............................................................................. 30 Spark plug gap - check and a d justm e n t..............................................29 Speedometer cable and drive gear - lu b rica tio n .................................36 Stand - check and lu b ric a tion ............................................................... 35 Steering head bearings - check ...........................................................37 Suspension - c h e c k ................................................................................ 38 Throttle cable - check and a d ju s tm e n t................................................13 Typical service i te m s .............................................................................. 2 Valve clearances (four-stroke engines) - check and adjustment . . . 32 Variator pulley and rollers - check and lub rica te .................................24 Wheels and tyres - general c h e c k .........................................................34

Degrees of difficulty Easy, suitable for novice with little experience

Ss? IS ; ^

Fairly easy, suitable fo r beginner with som e experience

Fairly difficult, ^

suitable fo r competent ^ DIY mechanic ^

Difficult, suitable fo r experienced DIY mechanic

^ ^ ^

Very difficult,

^ suitable fo r expert DIY or professional ^

Specifications Refer to th e Data section a t th e end of this manual fo r servicing specifications.

1 Introduction

1 This Chapter is designed to help th e home mechanic maintain his/her scooter fo r safety, economy, long life and peak performance. 2 Whenever you ride you r scoo te r, and in some cases even when it is not in use, com ponents wear and deteriorate. To counteract this process, every machine has a service schedule - relating to either a period of tim e or mileage - w hich stipulates

w hen checks and adjustm ents should be made. 3 The majority o f service items are common to all scooters, but some, like th e radiator on a liquid-cooled model o r the valves on a fo urstroke engine, are spe cific to certain machines. The Data section at th e end o f this manual w ill help you identify th e various system s on you r scoo te r and their com ponents, and provide you w ith th e specifications necessary to ensure their continued reliable performance. 4 Deciding where to start or adopt a service schedule depends on several fa ctors. If the

w arranty pe rio d on you r s c oo te r has just expired, and if it has been m aintained according to the warranty standards, you will w ant to p ic k up routine m aintenance as it coincides w ith th e next mileage or calendar interval. If you have ow ned th e m achine fo r som e tim e but have never perform ed any maintenance on it, then you may want to start a t th e nearest interval and include some additional procedures to ensure th at nothing important is overlooked. If you have just had a major engine overhaul, then you w ill w ant to sta rt th e m aintenance routine from the beginning as w ith a new machine. If you have

1.2 R outine m ain ten an ce and servicin g p ro ced u res a used scooter and have no knowledge o f its history or m aintenance record, it w ould be best to com bine all th e checks into one large initial service, and then settle into a regular routine schedule. 5 Don’t w orry if you haven’t got a service schedule fo r your particular scooter; use the inform ation in th is Chapter to identify th e service item s on you r machine - air filter, battery, brakes, etc - then create your own service schedule based on th e examples we give. Note: Certain maintenance information is sometimes printed on decals attached to the

machine. If the inform ation on th e decals differs from that included here, use the information on the decal. 6 Before beginning any maintenance or repair, clean your scooter thoroughly, especially around th e suspension, brakes, engine and transmission covers. Cleaning will help ensure that dirt does not contaminate the w orking parts and w ill allow you to detect wear and damage that could otherwise easily go unnoticed. N ote 1: The ‘Daily (pre-ride) checks' detailed a t the beginning o f this manual cover those

item s w hich should be inspected on a daily basis. Always perform the pre-ride inspection at every m aintenance interval (in addition to the procedures listed). N ote 2: The intervals listed below are the intervals generally recom m ended by m anufacturers b u t are n o t specific to any make o r model. The ow ner's handbook fo r y o u r m odel may have different intervals to those shown. If available, always refer to the maintenance booklet supplied w ith the machine for the correct intervals.

Routine maintenance and servicing procedures Two-stroke engines 2 Typical service items

Identifying service item s 1 Use the accompanying list and the owner’s handbook to identify th e service items on your scooter and their locations (see illustrations). The service items have been grouped under headings which identify th e overall systems to which they belong. The headings also relate to th e Chapters in this manual. 2 N ot all the service item s under each heading w ill require attention at the same time, but when you are working on a particular system it is useful to note all th e parts that require servicing and check them at th e same tim e. For example, when th e drivebelt cover has been removed to inspect the variator and th e condition o f the belt, th e general condition of th e clutch and the kickstart mechanism can be checked. Also, if the belt has worn prematurely and is close to its service limit, a new one can be installed earlier than scheduled to prevent any damage caused by a broken belt.

□ □ □ □ □

Engine oil level. Oil filter. Oil pum p adjustment. Oil pum p drivebelt. Cylinder head decarbonising.

Four-stroke engines □ □ □ □ □

Engine oil level. Engine oil change. Oil filter. Engine oil pressure. Valve clearances.

Cooling system (air-cooled engines) □ □

Cooling fan. Engine cowling.

Cooling system (liquid-cooled engines) □ □ □ □

Coolant. Radiator. Water pump. Hoses. Draining, flushing and refilling.

Fuel and exhaust system □ □ □ □ □

A ir filters. Throttle cable. Carburettor. Fuel hose. Idle speed.

Ignition system □

Sparkplug.

Transmission □ □ □ □ □ □

Drivebelt. Variator. Kickstart mechanism. Clutch pulley. Gearbox oil change. Gearbox oil level.

Frame and suspension □ □ □ □

Front suspension. Rear suspension. Stand. Steering head bearings.

Brakes, wheels and tyres □ □ □ □ □ □ .□ □

Brake cable. Brake fluid (disc brake). Brake hose (disc brake). Brake levers. Brake pads (disc brake). Brake shoes and cam (drum brake). Wheel bearings. Tyre condition.

Bodywork □ □

Fasteners. Panel condition.

Electrical systems □ □ □ □ □

Battery. Headlight aim. Brake light. Horn. Speedometer cable.

General □

Nuts and bolts.

C om ponent locations

1.3

1.4

R outine m ain ten an ce and servicin g p ro ced u res

Two-stroke engine Note: Always perform the ‘Daily (pre-ride) checks’ before every service interval - see the beginning o f this Manual. Note: Severe conditions are regarded as intensive urban use, short journeys with cold engine o r use in dusty conditions. Note; The 2500 mile tasks should be included with the 5000 m ile service, etc.

Text section in this Chapter

Every 2500 miles (4000 km) or 12 months 1500 miles (2500 km) fo r severe conditions

3

✓

4

✓

Body panels and fasteners - check

40

✓

Brake cable - check and lubricate

7

/

Brake fluid - check

8

✓

Brake hose - check

9

Brake lever pivots - lubricate

6

✓

Brake pads - check

10

✓

Brake shoes - check

11

✓

Brake shoe cam - check and lubricate

12

Air filters - clean/renew Battery - check

Brake system - check

5

Carburettor - clean

15

Clutch pulley and bearing - check and lubricate

26

Cooling system - check

21

Cylinder head - decarbonise

31

Drivebelt - check

22

Drivebelt - renew

23

s

S ✓

✓ ✓

17

Fuel system - check

14

✓

Gearbox oil level -.check

27

✓

Gearbox oil - change

28

Headlight, brake light and horn - check

33

✓

✓ ✓ ✓

Kickstart mechanism - check

25

Nuts and bolts - tightness check

39

✓

Oil pump cable - check and adjust

19

✓

Oil pump drivebelt - renew

20 29

Spark plug - renew

30

Speedometer cable and drive gear - lubricate

36

Stand - check and lubricate

35

Steering head bearings - check and adjust

37

Suspension - check

38

Throttle cable - check and adjust

13

Variator pulley and rollers - check and lubricate

24

Wheels and tyres - check

34

✓»* ✓

✓

18

Spark plug - gap check and adjust

✓*

✓

Engine oil filter - change

16

Every 10,000 miles (16,000 km) or 3 years

✓*

Engine oil system - check

Idle speed - check and adjust

Every 5000 miles (8000 km) or 2 years 3000 miles (5000 km) fo r severe conditions

✓

✓ ✓ ✓ ✓ ✓ ✓

✓ ✓

' The brake fluid m ust be changed every 2 years and the brake hose renewed every 3 years, irrespective o f mileage ** Drain and refill a liquid-cooled system with fresh coolant every 2 years, irrespective o f mileage

R outine m ain ten an ce an d servicin g p ro c e d u re s

1.5

Four-stroke engine Note: Always perform the ‘Daily (pre-ride) checks’ before every service interval - see the beginning o f this Manual. Note: Severe conditions are regarded as intensive urban use, short journeys w ith cold engine o r use in dusty conditions. Note: The 2500 mile tasks should be included with the 5000 m ile service, etc.

Text section in this Chapter

Every 2500 miles (4000 km) or 12 months 1500 miles (2500 km) fo r severe conditions

Air filters - clean/renew

3

✓

Battery - check

4

✓

Body panels and fasteners - check

40

Brake cable - check and lubricate

7

✓

Brake fluid - check

8

✓

Brake hose - check

9

✓

Brake lever pivots - lubricate

6

✓

Brake pads - check

10

✓

Brake shoes - check

11

✓

Brake shoe cam - check and lubricate

12

Brake system - check

5

Carburettor - clean

26

Cooling system - check

21

✓

✓ ✓

22 23

Engine oil system - check

17

✓

Engine oil and filter - change

18

✓

✓

Fuel system - check

14

✓

Gearbox oil level - check

27

✓

Gearbox oil - change

28

Headlight, brake light and horn - chefik

33

✓

Idle speed - check and adjust

16

✓

Kickstart mechanism - check

25

Nuts and bolts - tightness check

39 29 30

Speedometer cable and drive gear - lubricate

36

Stand - check and lubricate

35

Steering head bearings - check and adjust

37

Suspension - check

38

Throttle cable - check and adjust

13

Valve clearances - check and adjust

✓**

✓ ✓

Drivebelt - renew

Spark plug - renew

✓*

v'

Drivebelt - check

Spark plug - gap check and adjust

Every 10,000 miles (16,000 km) or 3 years

v'

15

Clutch pulley and bearing - check and lubricate

Every 5000 miles (8000 km) or 2 years 3000 miles (5000 km) fo r severe conditions

✓

✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓

32

Variator pulley and rollers - check and lubricate

24

✓

Wheels and tyres - check

34

✓

* The brake fluid m ust be changed every 2 years and the brake hose renewed every 3 years, irrespective o f mileage " Drain and refill a liquid-cooled system w ith fresh coolant every 2 years, irrespective o f mileage

1.6 R outine m ain ten an ce and servicin g p ro ced u res

3.1c A typ ica l filte r elem ent panel

3.1a Undo th e a ir filte r cove r screw s (a rro w e d ). . .

Air filters -

c lea n a n d renew al

^

C a u tio n : I f th e m a ch in e is c o n tin u a lly rid d e n in c o n tin u o u s ly w e t o r d u s ty c o n d itio n s, th e filte rs s h o u ld b e ch e c k e d m ore frequently.

Engine a ir filter 1 Remove the screws securing the air filter cover and detach the cover (see illustration). Remove th e filte r element - note that some filter elements are fitted in a removable panel (see illustrations). 2 Some manufacturers recommend that the filte r element is renewed at every service interval - refer to your scooter handbook for details. However, foam filters can usually be cleaned and re-used if they are in good condition. 3 Wash th e filte r in hot soapy water, then blow dry using compressed air. 4 Soak the filter in dedicated air filter oil, or a mixture of petrol and 10% tw o-stroke oil or four-stroke engine oil, as recommended. Lay it on an absorbent surface and squeeze out th e excess liquid, m aking sure you do not damage th e filter by twisting it. 5 Allow the filter to dry fo r a while, then fit it back into the housing and install th e cover and tighten th e screws securely.

3.7 Undo th e plug (arrowed) and d ra in th e hose

6 If the filter is excessively dirty and cannot be cleaned properly, or is torn or damaged in any way, renew it. 7 If th e filter housing is fitte d w ith a drain, undo th e plug and release any trapped fluid (see illustration)

Transmission a ir filter 8 Some scooters have a filter fitted to the belt drive housing. Remove the filter unit and lift out the filter element (see illustrations). Clean and, if required, re-oil th e element as described in Steps 3 to 5.

Secondary a ir system 9 A secondary air system is fitte d to tw ostroke m odels w ith a catalytic converter exhaust system. The system sucks fresh air into the exhaust pipe to promote the burning o f unburnt gases, reducing the em ission of hydrocarbons into the atmosphere. 10 Remove any body panels as necessary to access th e system com ponents (see Chap­ te r 9). 11 Undo th e screw s securing the housing cover and detach th e cover, then lift out the reed valve and the filter element. Discard the cover O-ring or gasket if fitted as a .new one m ust be used on reassembly. 12 Where fitted, lever the breather cap out of th e drivebelt cover w ith a small screwdriver and carefully pull the filter element out of the cap.

3.8a Rem ove th e b e lt drive housing filte r u n it. . .

13 Wash th e filters in hot soapy water then blow them dry using com pressed air. Never w ring th e filters dry as they may tear. If the filters are excessively dirty and cannot be cleaned properly, or are torn or damaged in any way, fit new ones. 14 To check the condition of the reed valve, hold it up to th e light. The valve should be closed. If light can be seen around the edge of th e reed a new valve should be fitted. Clean th e reed carefully w ith a suitable solvent to remove any gum. 15 Install th e com ponents in th e reverse order o f disassem bly, rem em bering to fit a new O -ring or gasket to the filte r housing cover if required.

4 Battery -

check

*

|g>

1 C au tion : Be e x tre m e ly c a re fu l w hen h a n d lin g o r w o rk in g a ro u n d th e ba tte ry. The e le c tro ly te is very c a u s tic a n d an explosive g as (hydrogen) is g iven o f f when the b a tte ry is charging.

Conventional battery 1 Remove th e battery access panel and partially lift th e battery out o f its holder. Check the electrolyte level which is visible through the translucent battery case - it should be

. and lift o ut th e filte r elem ent

R outine m ain ten an ce and serv icin g p ro c e d u re s 1.7 occurs. If m oto r oil o r ligh t grease is being used, apply it sparingly as it may attract dirt (which c ou ld cause th e c on trols to bind or wear at an accelerated rate). Note: One o f the best lubricants fo r the control lever pivots is a dry-film lubricant.

7 Brake cable -

c heck, a d ju s tm e n t an d lu b ric a tio n

C heck and adjustm ent Drum brake

4.1 Check th e e le ctrolyte level th ro ug h th e b a tte ry case between the UPPER and LOWER level marks (see illustration). 2 If the electrolyte is low, disco nn ect th e battery terminals (see Chapter 10) and move the battery to the w ork bench. Remove th e cell caps and fill each cell to th e upper level mark with distilled water (see illustration). Do not use tap water (except in an emergency), and do not overfill. The cell holes are quite small, so it may help to use a clean plastic squeeze bottle with a small spout to add the water. Install th e battery cell caps, tightening them securely, then install the battery (see Chapter 10).

Maintenance-free battery 3 On machines fitted w ith a sealed battery, no maintenance is required. N o te : D o no t attempt to remove the battery caps to check the electrolyte level or battery specific gravity. Removal w ill dam age th e caps, resulting in electrolyte leakage and battery failure. All that should be done is to check that the battery terminals are clean and tig h t and th at th e casing is not dam aged. See C hapter 10 fo r further details.

5 Brake system

- check

!^>

1 A routine che ck o f the brake system w ill ensure that any problems are discovered and remedied before th e rid er’s safety is jeopardised. 2 Check that the brake levers are not loose or

lever freeplay

^

% 1

1 Check that there is no excessive freeplay in th e handlebar lever before th e brake takes e ffect (see illu s tra tio n ). The wheel should spin freely when the brake is off, b ut the brake should com e on before th e lever is pulled back against the handlebar. 2 To reduce freeplay in the lever, tu rn th e adjuster nut on the brake drum end o f th e cable clockwise; to increase freeplay, turn the adjuster nut anti-clockwise (see illustration). If there is a locknut on th e adjuster, tighten it securely on completion. 3 If the brake is binding w ith o u t th e lever being pulled, firs t che ck th at the lever is m oving freely (see Section 6). Next, disconnect the cable from th e handlebar lever (see C hapter 8) and check that th e inner cable slides sm oo thly in th e ou te r cable. If the action is stiff, inspect along the length of the outer cable fo r splits and kinks, and the ends of the inner cable fo r frays, and renew either one if necessary (see C hapter 8). 4 If there are no signs o f dam age, lubricate the cable (see Step 9). If th e cable is still stiff after lubrication, renew it (see Chapter 8). 5 If th e handlebar lever and brake cable are in good condition, che ck th e operation o f the brake cam (see Section 12).

1 The lever pivo ts should be lubricated periodically to reduce wear and ensure safe and trouble-free operation. 2 In order fo r th e lubricant to be applied w here it w ill d o th e m ost good, th e lever should be removed (see Chapter 8). However, if chain or cable lubricant is being used, it can be applied to the pivot jo in t gaps and w ill w ork its w ay into th e areas where friction

6 If the hydraulic master cylinder is activated by a cable from th e handlebar lever, remove the front panel (see Chapter 9) and check that there is no freeplay in th e cable. If there is, loosen the cable adjuster locknut and turn th e adjuster anti-clockwise until all th e slack is taken up, but make sure the lever arm is not activated and pressurising the system (see illustration).

damaged, and that the lever action is smooth w itho ut excessive play. Renew any w orn or damaged parts (see C hapter 8). 3 Make sure all brake fasteners are tigh t. Check the brake pads (disc brake) and brake shoes (drum brake) fo r wear (see Sections 10 and 11). 4 Where disc brakes are fitted, make sure the fluid level in th e hydraulic reservoir is correct (see Daily (pre-ride) checks). Look fo r leaks at the hose connections and check fo r cracks and abrasions in th e hoses and renew them if necessary (see Chapter 8). If the lever action is spongy, bleed the brakes (see Chapter 8). 5 W here drum brakes are fitte d, check the cable fo r dam age o r s tiff action (see Section 7). 6 Make sure th e brake light operates when each brake lever is pulled in. The brake light sw itches are no t adjustable. If they fa il to operate properly, che ck th em (see Chap­ te r 10, Section 6).

6 Brake lever pivots lu b ric a tio n

7.2 Brake cable a d juste r n u t (arrowed)

Disc brake

7.6 Loosen the lo c k n u t (A) and tu rn the a d ju s te r (B) as required

1*8 R outine m ain ten an ce and servicin g p ro ced u res

10.1 C heck brake pad w ea r a t the underside o f the c aliper TH77T3?! O ld b ra k e flu id is inv a ria bly m u c h d a rk e r in c o lo u r th an n e w flu id , m ak in g i t e asy to see w he n a ll o ld flu id has been e xpelled from th e system.

HiNT

7.9 Lu bricating a cable w ith a m akeshift funnel and m o to r oil 7 If th e brake is binding without the lever being pulled, turn th e adjuster clockw ise until th e lever arm is at rest but make sure that no freeplay is created in th e cable. Tighten the locknut securely on completion. To check the cable operation, follow the procedure in Step 3.

Lubrication 8 The cable should be lubricated periodically to ensure safe and trouble-free operation. 9 To lubricate th e cable, disconnect it at its upper end and lubricate it w ith a pressure adapter, or using th e set-u p shown (see illustration). 10 Reconnect the cable and ad just th e handlebar lever freeplay. 8 B r a k e f lu id - c he ck

1 The fluid level in th e hydraulic reservoir should be checked before riding the machine (see Daily (pre-ride) checks). 2 Brake fluid w ill degrade over a period of time. It should be changed every tw o years or whenever a new master cylinder or caliper is fitted. Refer to the brake bleeding and fluid change section in Chapter 8.

9 B ra k e h o s e - c h e c k

1 T w ist and flex the hose w hile looking fo r cracks, bulges and seeping fluid. Check extra carefully w here the hose connects to th e banjo fittin g s as th is is a com m on area for hose failure (see illustration). 2 Inspect the banjo fittings; if they are rusted, cracked or damaged, fit new hoses. 3 Inspect th e banjo union connections for leaking fluid. If they leak when tightened securely, unscrew the banjo bolt and fit new washers (see Chapter 8). 4 Flexible hydraulic hose w ill deteriorate with age and should be renewed every three years regardless o f its apparent condition (see Chapter 8).

1 The extent o f friction material wear can normally be checked by looking at the underside of the caliper (see illustration). If the

pads are dirty, or if you are in any doubt as to th e amount o f friction material remaining, remove the pads for inspection (see Chapter 8). 2 If the amount o f friction material remaining on the pads is below th e service lim it, new pads must be fitted. W arning: Brake p ads o ften wear a t d iffe re n t rates. I f there is any d o u b t a b o u t th e c o n d itio n o f e ith e r o f th e pa ds in a c alip er, rem ov e th e c a lip e r a n d check. B rake fa ilu re w ill r e s u lt i f th e fr ic tio n m a te ria l wears aw ay com pletely. 3 Refer to Chapter 8 fo r details o f pad removal, inspection and renewal.

A

11 B ra k e s h o e s - w ea r c h e c k

1 Drum brakes are normally equipped with a wear indicator (see illustration). 2 As th e brake shoes wear and th e cable is adjusted to compensate, th e indicator moves closer to th e index mark on th e casing. To check th e extent o f brake wear, have an assistant apply th e brake firm ly; if th e indicator aligns with th e index mark, the brake shoes are worn to th eir lim it and m ust be renewed (see Chapter 8, Section 9). 3 If th ere is no wear indicator, remove th e wheel to check'the amount o f friction material remaining on the brake shoes (see Chapter 8, Section 9). 4 If the amount of friction material remaining on th e shoes is below th e service limit, new shoes must be fitted.

12Brake shoe cam c h e c k a n d lu b ric a tio n

11.1 W ear in d icato r (A) and index m ark (B)

12.1 T ypical brake shoe a rrangem ent no te the b rake cam (arrowed)

^ ^

1 Remove th e wheel; on fro n t brakes, the brake shoes and brake cam are fitte d to the backplate, on rear brakes the shoes and cam are fitte d to th e back of the gearbox casing (see illustration). 2 Remove th e brake shoes, then remove the brake arm and pull the brake cam out o f the backplate or casing (see Chapter 8, Section 9).

Routine m aintenance and servicing procedu res 1.9 3 Clean th e shaft and cam and inspect the bearing surfaces fo r wear; renew the cam if necessary. 4 Apply some copper grease to the bearing surfaces of th e cam and the shaft before reassembly. Caution: D o n o t a p p ly to o m u ch gre ase otherwise th ere is a r isk o f i t co n ta m in atin g the brake d rum a n d shoe linings.

13

Throttle cable ch e ck a n d a d ju s tm e n t

^ Jk 13.3 T hrottle cable freeplay is m easured ir te rm s o f tw is tg rip rota tion

Twistgrip cable 1 Ensure the throttle tw istgrip rotates easily from fully closed t o . fu lly open w ith th e handlebars turned at various angles. The twistgrip should return automatically from fully open to fully closed when released. 2 If the throttle sticks, this is probably due to a cable fault. Remove th e cable _ (see •Chapter 4) and lubricate it follow ing the procedure in Section 7. 3 With the th rottle operating smoothly, check for a small am ount o f freeplay in th e cable, measured in terms of the amount o f twistgrip rotation before th e th ro ttle opens (see illustration). Compare the amount o f freeplay to the specifications in the Data section a t the end of this manual.

4 If there is insufficient or excessive freeplay, loosen the locknut on the cable adjuster, then tu rn th e adjuster until th e rig ht am ount of freeplay is evident, then retighten th e locknut (see illustration). If the adjuster has reached its limit, renew the cable (see Chapter 4). 5 Start th e engine and check th e idle speed. If th e idle speed is too high, this could be due to incorrect adjustm ent of the cable. Loosen the locknut and turn th e adjuster in - if the idle speed fa lls as you do, there is insufficient freeplay in th e cable. Reset th e adjuster (see S tep 4). N ote : The idle spe ed should no t change as the handlebars are turned. I f it does, th e throttle cable is rou ted incorrectly. Rectify the problem before riding the scooter (see Chapter 4).

13.4 Ad justin g th e th ro ttle cable freeplay

Oil pum p cable (two-stroke engines) Note: Two-stroke engines are fitted with either a cable-controlled o r centrifugal oil pum p. A quick visual check w ill confirm which p um p is fitte d to you r engine (see Section 17). 6 There should be no freeplay in th e cable from th e sp litte r to the carb urettor (see illustration). 7 Remove the air filter housing (see Chapter 4) and pull back th e boot on the cable adjuster on th e to p o f th e carburettor. 8 Screw th e adjuster in to th e to p o f th e carb urettor to crea te a sm all am ount of freeplay in th e cable, then screw the adjuster out until the c arburettor slide ju st begins to lift. N ow tu rn th e adjuster in a quarter turn (see illu stratio n). Refit the boot and th e filter housing. 9 Check th e adjustm ent o f the oil pump cable (see Section 19).

14

Fuel system -

check

W a rn in g : P e tro l is e x tre m e ly fla m m a b le , so ta ke e x tra p re c a u tio n s w h e n y o u w o rk on a n y p a r t o f th e fu e l syste m . D on’t s m oke o r a llo w o p en flam e s o r bare lig h t b u lb s n e a r th e w o rk a rea, a n d d o n ’t w o rk in a garage w he re a n a tu ra l g a s-type appliance is pre sen t. I f y o u s p ill a n y fu e l on y o u r skin, rin se i t o f f im m e diately w ith soap

A

13.8 A d justin g the cable a t th e c a rb urettor end

i.io R outine m ain ten an ce and servicin g p ro ced u res

14.2 Fuel ta p union c lip (A), fuel hose (B) and vacuum hose (C)

15.2 Keep th e c a rb urettor body and th ro ttle m echanism free fro m dirt. N ote th e idle speed a djuster (arrowed)

a n d w ater. W hen y o u p e rfo rm any k in d o f w o rk on th e fu e l syste m , w e a r s a fe ty g la sses a n d have a fire e x tin g u is h e r s u ita ble fo r a Class B typ e fire (flam m able liquids) on hand.

6 If your scooter is fitte d w ith a fuel pump, ensure the fuel and vacuum hoses are securely attached to the pump and check the pum p body for leaks. If you suspect that the pum p is damaged or faulty, fo llo w the procedure in Chapter 4 to test it. 7 If the carburettor gaskets are leaking, the c arburettor should be disassem bled and rebuilt using new gaskets and seals (see Chapter 4). 8 If th e fuel gauge is believed to be faulty, che ck th e operation o f the sender (see Chapter 10).

Check 1 Remove th e body panels as necessary to access th e fuel tank, ta p or pum p (as applicable to your scooter) and carburettor (see Chapter 9). Check th e fuel tank, th e tap or pump, and th e fuel hose fo r signs o f leaks, deterioration or damage; in particular check th at there are no leaks from th e fuel hose. Renew th e fuel hose if it is cracked or deteriorated. 2 If a fuel ta p is fitted to the tank, inspect the ta p -to -ta n k union and ensure th at th e hose clip around th e union is tig h t (see illu s tra tio n ). If th e union is leaking, remove the ta p and check th e condition o f the fuel tap O-ring (see Chapter 4). 3 The fuel ta p is vacuum -operated and should be' closed when th e engine is not running. Disconnect th e hose from the ta p to check that the valve inside is not leaking (see illu stra tio n 14.2). If the valve is leaking, fit a new ta p (see Chapter 4). 4 Cleaning o r renewal o f th e fuel filte r'is advised after a particularly high mileage has been covered, or if fuel starvation is suspected (see Chapter 4). 5 Check that th e fuel tank cap breather hole is clear. If th e hole becom es blocked, fuel starvation w ill occur.

16.4a Ad justin g the idle speed w ith a s c re w d riv e r. . .

15 Carburettor -

clean

1 1 Remove th e air filter housing (see Chap­ te r 4) and th e storage com partm ent (see Chapter 9) to access th e carburettor. 2 The exterior o f th e carburettor and the throttle mechanism should be kept clean and free o f road dirt (see illu s tra tio n ). Wash it carefully w ith hot soapy water, ensuring no water enters the carburettor body, and dry it w ith compressed air. Clean away any grit with a small ‘pa int brush. O il deposits can be removed w ith a rag soaked in a suitable solvent. Take care to ensure th e idle speed setting is not disturbed during cleaning. 3 Provided th e air filter element is kept clean (see Section 3) th e carburettor w ill give many

16.4b . . . o r d ire c tly on th e c arburettor

thousands o f miles of satisfactory service. However, dirt particles and varnish w ill gradually accumulate inside the body, and the carburettor should be removed and disassem bled periodically to avoid th e jets becoming blocked (see Chapter 4). 4 If th e scooter has not been used fo r a long period, a sticky residue may form in th e carburettor, jam m ing th e th ro ttle slide. Disassemble the c arburettor and clean th e com ponents w ith a suitable solvent or carburettor cleaner (see Chapter 4). N ote: If the carburettor is being disassembled, read through the entire procedure and make sure that you have obtained a new gasket set first.

16

Idle speedc h e c k a n d a d ju s tm e n t

1 The idle speed (engine running w ith th e throttle tw istgrip closed) should be checked and adjusted when it is obviously too high or to o low. Before adjusting th e idle speed, make sure th e throttle cable is correctly adjusted (see Section 13) and check th e spark plug gap (see Section 29). On four-stroke engines, the •valve clearances must be correct to achieve a satisfactory idle speed (see Section 32). 2 The engine should be at normal operating temperature, which is usually reached after 10 to 15 minutes of stop-and-go riding. Support th e scooter on its centre stand w ith the rear wheel clear of the ground. W arning : D o n o t a llo w e xh a u st ga ses to b u ild -u p in th e w o rk are a; e ith e r p e rfo rm th e ch e ck o u ts id e o r use an e xh a u s t gas extra ction system. 3 Although m ost m anufacturers specify idle speed in engine revolutions per m inute (rpm), fo r scooters not fitted with a tachometer it is sufficient to ensure that, a t idle th e engine speed is steady and does not falter, and that it is not so high that th e automatic transmission engages. 4 The idle speed adjuster screw is located on the carburettor or adjacent to the carburettor - refer to your scooter handbook fo r details. W ith th e engine running, turn th e screw clockw ise to increase idle speed, and an ti-clockw ise to decrease it (see illustrations). 5 Snap th e th ro ttle open and shut a few tim es, then recheck the idle speed. If necessary, repeat th e adjustm ent procedure. 6 If a smooth, steady idle can’t be achieved, the fuel/air m ixture may be incorrect (see Chapter 4) or th e c arburettor may need cleaning (see Section 15). If a satisfactory idle speed still cannot be achieved, have the. ignition timing checked (see Chapter 5). 7 W ith the idle speed correctly adjusted, recheck th e th ro ttle cable freeplay (see Section 13).

A

R outine m ain ten an ce an d serv icin g p ro c e d u re s th

17.4 T w o-stroke engine o il filte r - arrow ind icate s d irectio n o f o il flo w

17.5a Inspect th e o il hose con ne ction s (a rro w e d ). . .

warning ligh t in th e instrum ent cluster. The c h e cligh k t should com e on when the ignition is tu rned on as a check o f th e warning circuit, and then extinguish when th e engine is started. 8 If th e light stays on, o r comes on when the 1 A routine check o f th e engine oil system will scoo te r is being ridden, s to p the engine ensure that any problems are discovered and immediately. Check th e oil level and to p-up as remedied before th e engine is damaged. necessary. If the level is correct, check fo r a 2 Check th e engine oil level (see Daily (prefault in th e oil pressure w arning circuit. If the ride) checks). light doesn’t com e on at all, check the bulb Two-stroke engines and oil pressure warning circuit. Note: If there is any d o u b t ab ou t th e perform ance o f the 3 Check th e operation of th e oil level warning engine lubrication system, the oil pressure light in th e instrument cluster. The light should should be checked b y a scoo te r dealer. come on temporarily when th e ignition is first Serious dam age to th e engine w ill result if turned on as a check o f th e warning circuit, th ere is a failure in th e engine lubrication . and then extinguish. If the light stays on the oil system. level is low and should be topped-up. If the

17

Engine oil system -

light stays on when th e tank is full, check the oil level warning circuit (see Chapter 10). If the light doesn’t com e on at all, check the bulb and oil level warning circuit (see Chapter 10, Section 8). N ote : On m o st scooters th e oil level sensor is p a rt o f th e safety circuit which prevents th e engine sta rtin g i f there is insufficient oil in the oil tank. 4 If a filter is fitte d in the hose from th e oil tank to the pum p, insp ect th e filte r (see illustration). Air bubbles should be bled from the filter by tilting it to allow th e trapped air to rise through th e hose into the oil tank. Check for sediment in th e filter and renew the filter if necessary (see Section 18). 5 Check th e con ditio n o f the oil inlet and outlet hoses. In particular check that there are no leaks from th e hose connections to the oil tank, filter, oil pum p and carb urettor (see illu stratio n). Renew any hoses th at are cracked o r deteriorated and ensure they are properly secured by clips (see illustration). 6 Two-stroke engines are fitted with either a cable-operated or centrifugal oil pum p; th e pump can be either mounted externally or inside part o f the engine casing. On engines fitted with a cable-operated oil pump, check tfiat the reference m arks on the oil pump cam and pum p bo dy align w ith the th ro ttle fully open. If th e m arks do not align, adjust th e pump cable as necessary (see Section 19).

Four-stroke engines 7 Check the operation o f the oil pressure

18Engine oil and oil filter c ha ng e

Two-stroke engines 1 The oil filte r should be changed at th e specified service interval, o r sooner if there is sediment in it. 2 Remove any body panels or th e storage com partm ent as necessary to access the oil filter. Release th e clips securing th e inlet and outlet hoses to the filter and slide them along the hoses aw ay from the filte r (see illu s tra tio n 17.4). Detach the hoses and clam p them to prevent oil loss.

18.7 U nscrew th e oil fille r plug

17.5b . . . and e nsure th e y are s ecured by clips 3 The oil filter body is marked with an arrow indicating th e direction o f oil flow . C onnect th e hoses to th e filte r unions, ensuring the arrow points to wards th e oil pump, then install th e hose clips. 4 Ensure any trapped air is bled from the filter (see Section 17) before re fittin g 'th e body panels.

Four-stroke engines W a rn in g : B e c a r e fu l w he n d ra in in g th e oil, as th e e xh a u st p ip e , th e e n g in e , a n d th e o il its e lf can cause severe b urns. 5 Oil and filter changes are th e single m ost im portant m aintenance procedure you can perform on a four-stroke engine. The oil not only lubricates the internal parts o f the engine, but it also acts as a coolant, a cleaner, a sealant, and a protector. Because o f these dem ands, the oil takes a te rrific am ount of abuse and should be renewed a t th e specified service interval w ith oil of th e recommended grade and type. 6 Before changing th e oil, w arm -up th e engine so the oil w ill drain easily. Stop th e engine and turn th e ignition OFF. Support the scoo te r on its cen tre sta nd , and po sition a clean drain tray below th e engine. 7 U nscrew the oil .filler plug to vent th e crankcase and to act as a reminder that there is no oil in the engine (see illustration). 8 Unscrew the oil drain plug and allow the oil to flow into the drain tray (see illustrations). Discard the sealing washer o r O -ring on th e drain plug as a new one m ust be used on reassem bly. On som e engines, a gauze

A

18.8a O il d rain plug is s itua te d on the u n d e rs id e . . .

1.12 R outine m ain ten an ce and servicin g p ro ced u res

18.8b . . . o r th e side o f th e crankcase (A). N ote th e oil filte r (B)

18.8c W here fitte d, rem ove th e strainer (arrowed)

strainer is fitte d behind th e drain plug; w ithdraw th e strainer and clean it in solvent and remove any debris caught in th e mesh (see illustration). Check the gauze fo r splits or holes and renew it if necessary. 9 A separate oil strainer is fitte d on some engines; unscrew th e strainer plug and withdraw the strainer (see illustration). Clean and check the strainer as described in Step 8. Install the strainer, fit a new sealing washer or O-ring to th e plug as necessary, then install the plug and tighten it securely. 10 When the oil has completely drained, install the drain plug using a new sealing washer or O-ring. Tighten th e plug to the specified torque, if available (see the Data section at the end of this manual). Avoid overtightening, as damage to the threads will result. 11 Now place th e drain tray below th e oil filter. On some engines th e filte r element is fitted inside a cover; unscrew th e cover bolts, th en remove the cover, th e spring and the filter (see illu stra tio n s). Tip any residual oil into the drain tray. Discard any O-rings on the cover and in th e filter housing as new ones should be used. As required, fit the new housing O-ring, then install the new filter and fit th e spring and the cover, again using a new O-ring (see illu stra tio n 18.11b). Tighten the cover bolts securely.

12 Some engines have a spin-on type filter (see illu s tra tio n 18.8b). Unscrew th e filter and tip any residual oil into the drain tray. Smear clean engine oil onto th e seal o f the new filter, then install th e filter and tighten it securely by hand. 13 Refill the engine to the correct level using th e recommended type and amount of oil (see th e Data section at th e end of this manual). Install th e filler plug and tightening it by hand. 14 Start the engine and let it run fo r tw o or three minutes. Shut it off, wait five minutes, then check the oil level. If necessary, top-up the oil to th e correct level (see Daily (pre-ride) checks). Check around the drain plug and the oil filter/strainer for leaks. 15 The old oil drained from th e engine cannot C heck the o ld o il c are fully i f i t is very m eta llic coloured, th e n th e en gin e is e xp e rie n c in g w e a r fro m b re a k -in (ne w en gin e) o r fro m in s u ffic ie n t lub ric a tio n . I f th ere are flakes o r chips o f m e ta l in the oil, then s o m e th in g is d ra s tic a lly w ro n g in te rna lly an d the engine w ill have to be disassem bled fo r inspection a n d repair.

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be re-used and should be disposed of properly. Check w ith your local refuse disposal com pany, disposal facility or environmental agency to see whether they will accept the used oil fo r recycling. Don’t pour used oil into drains o r onto the ground.

0800 66 33 66

N ote: I t is a n tisocia l and ille ga l to dum p o il dow n th e drain. To fin d th e loca tion o f yo u r local o il recycling bank, ca ll this nu m be r free.

19Oil pump cable (two-stroke engines) - c h e c k and a d jus tm e nt 1 Where the oil pump is cable-controlled, the cable is connected to th e throttle tw istgrip via a splitter (see illu stratio n 13.6). 2 First ensure the th ro ttle tw istgrip rotates easily from fully closed to fully open with the handlebars tu rned at various angles, and

R outine m ain ten an ce and serv icin g p ro c e d u re s

19.3a E xternally-m ounted oil pum p. N ote index m arks (A) and a d ju ste r lockn uts (B)

check that th e th ro ttle cable freeplay is correct (see Section 13). 3 Remove any body panels o r th e storage compartment as necessary to access th e oil pump. Where th e pum p is located inside the drivebelt cover, rem ove th e inspection plug (see illustrations). 4 At the pump end, th e cable is connected to the pump cam. W ith th e cable correctly adjusted, an index m ark on the cam should align with a mark on th e pum p body, either with the throttle closed or with th e throttle fully open - check w ith your scooter handbook for details (see illu s tra tio n s 19.3a and 19.3c). Note: The oil pum p cable w ill stretch slightly in use, so only a small am ount o f adjustm ent should be necessary to re-align the marks. As a guide, there sho uld be no discernible freeplay in th e p u m p cable w ith th e throttle dosed and the pum p cam should turn as the throttle is opened. I f the cable is over-adjusted (too tight), to o m uch o il w ill b e fe d in to the engine causing a fouled spark p lu g a n d a smoky exhaust. If there is any doubt about the adjustment o f the p u m p cable co n su lt a scooter dealer. 5 If the marks are n o t aligned, loosen th e cable adjuster locknut and turn th e adjuster as required until th e marks align, then retighten the locknut. If th e adjuster has reached its limit of adjustm ent, renew th e cable (see Chapter 4, Section 12).

20 Oil pump drivebelt (twostroke engines) - ren ew al

^ ^

1 On some engines, th e oil pum p is driven by a small belt from either the left or right-hand side of the crankshaft. To access the belt it is necessary to remove either th e variator or the alternator. 2 Refer to you scoo te r handbook o r check with a scooter dealer to confirm th at belt renewal is a service item , then fo llo w the appropriate procedure in Chapter 2A to renew the drivebelt.

19.3b Rem ove th e plug in th e d riveb elt c o v e r. . .

1-13

19.3c . . . t o a ccess th e inte rna lly-m o un te d pum p. N ote index m ark s (A) and (B)

1 On air-coo le d m odels, a fa n m ounted on the alternator rotor forces air into the engine cow ling to coo l th e cylind er and cylinder head. 2 Check that the air intake in th e fan cowling is unobstructed and th a t the sectio ns o f the engine cow ling are fitte d to ge the r correctly and secured with their mounting screws (see illu s tra tio n ). N ote: I f any sectio ns o f the engine cow ling are missing the engine w ill not b e properly cooled.

3 Remove th e fan cowling and inspect th e fan (see illu s tra tio n ). If any o f the vanes are broken, renew th e fan. C heck th a t th e fan m ounting bolts are tight; if the b olts are loose or if the bolt holes are worn oversize, the fan will run ou t o f true and cause engine vibration. N ote : On som e engines, the holes fo r the mounting b olts in th e c ooling fan are oversize and i t is important to centralise th e fan on the bo lts be fo re tigh te ning them, otherw ise th e fan w ill run o u t o f true a n d cause engine vibration. Use tw o shouldered bolts, o r wrap a short length o f e lectrical tape tig h tly around tw o bolts, an d fit th em in op po site holes to centralise th e fan, then install tw o m ounting bo lts (see illu s tra tio n s ). Rem ove th e centralising bo lts an d insta ll the rem aining bolts.

21.2 Fan c o w ling (A) and e ngine cow ling sectio ns (B) a nd (C)

21.3a C heck th e fan f o r b ro ken vanes and e nsure th e b o lts (arrow ed) a re tig h t

21 Cooling system -

ch e c k

Air-cooled engines

1.14

Routine m ain ten an ce and servicin g p ro ced u res

21.5 Check th e entire length o f the coolant hoses between th e engine and th e radiator

Liquid-cooled engines

A

W arning: The en g in e m u s t be co o l b e fo re b e g in n in g th is procedure.

4 Check the coolant level (see Daily (pre-ride) checks). 5 The entire cooling system should be checked fo r evidence o f leaks. Remove any body panels as necessary and examine each coolant hose along its entire length (see illustration). Look fo r cracks, abrasions and other damage. Squeeze th e hoses at various points. They should feel firm, yet pliable, and return to their original shape when released. If they are hard or perished, renew them (see Chapter 3). 6 Check fo r evidence of leaks at each cooling system joint. Ensure th a t th e hoses are pushed fu lly onto their unions and th a t the hose clips are tight. Note: Check the tension o f any hose spring clips and renew them if they are loose. 7 Check the underside o f th e w ater pump for evidence of leaks (see Chapter 3). 8 Check th e radiator fo r leaks and other damage. Leaks in th e radiator leave tell-tale scale deposits or coolant stains on the outside of the core below the leak. If leaks are noted, remove th e radiator (see Chapter 3) and have it repaired or renew it. Caution: D o n o t use a liq u id leak stopping com pound to try to re p a ir leaks. 9 Inspect th e radiator fins fo r mud, dirt and insects w hich w ill impede th e flow of air th rough the radiator. If th e fin s are dirty, remove the radiator (see Chapter 3) and clean it using water or low pressure compressed air directed through the fins from the back. If the fins are bent or distorted, straighten them carefully w ith a screwdriver. If the air flow is restricted by bent or damaged fins over more than 30% of the radiator’s surface area, fit a new radiator. 10 Check the condition of the coolant in the reservoir. If it is rust-coloured o r if accumulations of scale are visible, drain, flush and refill th e system w ith new coolant (see Chapter 3). 11 Check th e antifreeze content o f th e coolant w ith an antifreeze hydrometer. Sometim es coolant looks like it’s in good

25.1 K ic k s ta rt lever rest p osition

26.2 Check fo r play in th e bearings o f the clutch pulley hub (arrowed)

condition, bu t is to o weak to offer adequate protection. If th e hydrometer indicates a weak mixture, drain, flush and refill the system (see Chapter 3). Note: The cooling system should be drained and refilled w ith fresh coolant every 2 years. 12 Start th e engine and let it reach normal operating temperature, then check fo r leaks again. 13 If th e coolant level is consistently low, and no evidence of leaks can be found, have the entire system pressure-checked by a scooter

centre nut and, where applicable, the variator housing O-ring, m ust be renew ed on reassembly.

22 Drivebelt -

che c k

% *

1 Referring to Chapter 6, remove the drivebelt cover and inspect th e belt. Some m anufacturers specify service lim its for drivebelt wear (see th e Data section at th e end of this manual). 2 If there is any doubt about the condition of the belt, renew it. In the event of premature belt wear, the cause should be investigated (see Chapter 6).

1 The drivebelt m ust be renewed at the specified service interval, o r earlier dependant on belt condition (see Chapter 6).

25

Kickstart gear and spindle bush -

check

^

1 The kickstart lever should move smoothly and return to the rest position under the tension of th e return spring (see illustration). It is good practice to periodically check the operation of the kickstart to ensure it is in good working order. 2 Referring to Chapter 6, remove th e drivebelt cover. Inspect th e com ponent parts o f the kickstart mechanism fo r damage and wear and renew any parts as necessary. Lubricate th e kickstart spindle w ith high-temperature grease before reassembly.

26

Clutch pulley and bearing c h e c k a n d lub ric a te

1 Referring to Chapter 6, remove the drivebelt cover. 2 The outer half o f the clutch pulley should slide outwards on the clutch hub, against the pressure o f the clutch centre spring. Next, grasp the pulley assembly and check for play in th e pulley hub bearings (see illustration). 3 To dism antle th e clutch and pulley assembly in order to check th e condition of th e clutch and to lubricate the pulley bearing surfaces, follow th e procedure in Chapter 6. Note: The self-locking clutch centre nut must be renewed on reassembly.

24 Variator pulley and rollers c h e c k a n d lu b ric a te

^

1 'R eferring to Chapter 6, remove th e drive pulley and th e variator. Disassemble th e variator and check all components for wear as described. If applicable, grease the rollers and the roller tracks in the variator housing before reassembly. N ote: The self-locking variator

1 Some scooters are fitte d w ith an integral gearbox filler cap and dipstick, w hile m ost have a filler plug which also acts as a level plug; the filler plug may be on th e rear of the

Routine m aintenance and servicing procedu res

1-15

\

27.1a Gearbox o il level plug on th e rear o f th e casing

27.1b Oil level p lu g (A) a nd d rain plug (B)

gearbox casing or on th e side facing th e rear wheel (see illustrations). On a few scooters, where the manufacturer does not require the oil level to be checked o r th e oil drained unless the gearbox is being overhauled, th e filler plug is inside the belt drive casing. 2 The oil level should be checked either with the machine supported upright on level ground, or w ith it supported on its centre stand. It is im p orta nt to clarify th e correct procedure fo r you r m achine. On gearboxes fitted with a d ipstick it is important to identify which mark on th e d ipstick is to be used and whether th e d ipstick should be screwed back into the casing o r not when th e level reading is being taken. Either refer to you r scoo te r handbook or a scooter dealer fo r details. W arning: I t is im p o rta n t to have th e r ig h t in fo rm a tio n fo r che cking th e gearbox o il level on y o u r m achine. D o n o t ris k u nde r­ filling o r o v e r-fillin g th e g e a rb o x a s a transmission se izu re o r d a n g e ro u s o il leakage m ay result. 3 Clean the area around the filler cap o r plug and then unscrew th e ca p o r plug from th e gearbox casing. Discard th e filler plug sealing washer as a new one should be used on reassembly. If you are using a dipstick, use a clean rag o r paper towel to w ipe off the oil.

4 On gearboxes with a level plug, th e oil level should come up to th e lower threads so that it is just visible on the threads (see illustration). On gearboxes w ith a dip stick, insert the dipstick and then read th e level on the stick in accordance w ith th e m anufacturer’s recommendations. 5 If required, to p th e gearbox up w ith the recommended grade and type o f oil (see the Data section a t the end of this manual). Use a pu m p-type oil can o r oil b o ttle to to p -u p gearboxes w ith a level plug (see illustrations). Do not overfill. 6 Install th e filler cap and tighten it securely by hand, o r fit a new sealing washer t o the level plug and tighten it securely. 7 If the oil level is very low, o r o il is leaking from th e gearbox, refer to Chapter 6 and inspect th e condition o f th e case seals and gaskets and renew them if necessary.

A

27.4 G earbox o il s hould be level w ith th e th re ad s

gearbox. Unscrew th e filler c ap o r level plug (as applicable) to vent the case and to act as a reminder that there is no oil in it. 3 U nscrew th e oil drain plug (see illu s ­ tra tio n 27.1b), and allow th e oil to flow into th e drain tray. Discard the sealing washers on th e drain and level plugs as new ones should be used. 4 When the oil has com pletely drained, fit the drain plug using a new sealing washer, and tighten it securely. Avoid overtightening, as damage to th e casing w ill result. If available, tighten th e drain plug to th e specified torque setting (see th e Data section a t the end of this manual) 5 Refill th e gearbox to th e proper level using th e recommended type and amount o f oil (see Section 27). Install th e filler cap and tighten it securely by hand, or fit a new sealing washer to th e level plug and tighten it securely. 6 Check th e oil level again after riding the scooter for a few minutes and, if necessary, add 28 Gearbox oil - c h a n g e §!$> more oil. Check around th e drain plug fo r leaks. 7 The old oil drained from the gearbox cannot be re-used and should be disposed of properly. C heck w ith y o u r local refuse 1 If required to gain access to the gearbox disposal com pany, disposal fa cility or drain plug, rem ove the rear w heel (see environmental agency to see w hether they will Chapter 8). accept th e used oil fo r recycling. Don’t pour 2 Position a clean drain tray below the used oil into drains o r onto the ground.

27.5a Use a p u m p-type can to to p up th e o i l .

27.5b . . . o r a bo ttle o f spe cified ge ar oil

Lie R outine m ain ten an ce and servicin g p ro ced u res 29

Spark plug gap - o ; ch e c k a n d ad ju stm e n t

W arning : A cce ss to th e sp a rk p lu g is e xtre m e ly r e s tric te d on som e s co o te rs. E n su re th e e n gin e a n d e xh a u st syste m are c o o l be fo re a tte m p tin g to rem ove the spark plug. 1 Make sure your spark plug socket is th e correct size before attempting to remove the plug - a suitable plug spanner is usually supplied in the scooter’s tool kit. 2 As required, rem ove th e engine access panel or side cover. Remove any access panel in th e engine cow ling (see illustrations). 3 Pull off th e spark plug cap, then ensure the spark plug socket is located correctly over the plug and unscrew th e plug from th e cylinder head. 4 Inspect th e electrodes fo r wear. Both th e centre and side electrode should have square edges and th e side electrode should be of uniform thickness. Look fo r excessive deposits and evidence o f a cracked or chipped insulator around the centre electrode. Compare your spark plug to the colour spark plug reading chart at the end of this manual. Check the condition o f the threads and washer, and the ceram ic insulator body fo r cracks and other damage. 5 If the electrodes are not excessively worn, and if the deposits can be easily removed with a wire brush, the plug can be regapped and re­ used (if no cracks or chips are visible in th e insulator). If in doubt concerning th e condition of the plug, renew it, as th e expense is minimal. 6 Cleaning a spark plug by sandblasting is permitted, provided you clean it w ith a high flash-point solvent afterwards. 7 Before installing the plug, make sure it is the correct type (see th e Data section at the end of this manual). Check th e gap between the electrodes (see illu stra tio n s ). Compare the gap to th at specified and adjust as necessary. If th e gap m ust be adjusted, bend the side electrode only and be very careful not to chip or crack th e insulator nose (see illustration).

A

29.7a Using a w ire typ e gauge to m easure the s pa rk plug ele ctrod e gap

29.2a Remove th e engine

th e spa rk plug panel in the engine cow ling

decarbonise the engine. However, some manufacturers still recommend decarbonising as part o f the routine service schedule, and if the machine is continually rid de n on short journeys which do n o t allow th e engine to reach and m aintain its norm al operating temperature, th e cylind er head should be decarbonised more frequently. 1 Remove th e cylind er head (see Chap­ ter 2A). 2 Remove all accum ulated carbon from A s trip p e d p lu g th re ad in the inside th e cylinder head using a blunt scraper. c y lin d e r head ca n be Small traces o f carbon can be removed repaired w ith a th re ad insert. w ith very fine abrasive paper o r a kitchen scourer. C aution: The cylin d e r h e ad a n d p is to n are m ade o f alum inium w hich is relative ly soft. Take g re a t care n o t to gouge o r score th e 30 Spark plug - ren ew al % surfa ce w hen scraping. 3 Press th e cylind er dow n against the crankcase to avoid breaking th e cylinder base 1 Remove th e old spark plug as described in gasket seal, then turn the engine over until the piston is at th e very top of its stroke. Smear Section 29 and install a new one. Ensure the grease all around th e edge o f th e piston to new plug is the correct typ e (see the Data trap any particles o f carbon, then clean th e section at th e end of this manual). Check the piston crow n, ta king care no t to score or gap betw een the electrodes and adjust it if gouge it or the cylinder bore. Finally, lower the necessary. piston and w ipe away th e grease and any remaining particles o f carbon.

8 Make sure th e washer is in place before installing the plug. Sm ear th e plug threads with a little copper-based grease then thread it into the head by hand until it is finger-tight. Since th e cylinder head is made o f aluminium which is soft and easily damaged, ensure the plug threads are not crossed before tightening it securely w ith th e spark pljjg socket. Reconnect the plug cap.

n

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I

31 Cylinder head (two-stroke engines) - d e c a rb o n is e s Note: The use o f modern, low ash engine oils specifically designed fo r use in tw o-stroke engines has considerably reduced the need to

29.7b Using a fe eler gauge to m easure the spark plug ele ctrod e gap

W ffiJ IT J Finish the p is to n c row n a n d c y lin d e r h e ad o f f u s in g a m e ta l polish. A s hin y surface is m o re re s is ta n t to th e bu ild -u p o f carbon deposits.

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29.7c A d jus t th e ele ctrod e gap by bending the side e lectrode only

R outine m ain ten an ce an d servicin g p ro c e d u re s 1.17 4 With the piston at th e bottom of its stroke, check the exhaust po rt in th e cylinder and pape away any carbon. If th e exhaust port is ^Bavily coked, rem ove th e exhaust system I and clean th e port and th e exhaust pipe I thoroughly (see Chapter 4). 5 Install the cylinder head (see Chapter 2A).

o r disco nn ect the coolant hoses in ord er to displace th e cover. If th ere is access, the po sition o f th 6 piston can be checked by inserting a screwdriver down th e spark plug hole. 5 Look fo r tim in g m arks on th e cam shaft sprocket and th e camshaft holder or cylinder head (see illustrations). Alternatively, look for tim ing marks on the alternator rotor and the (see illustrations). With th e piston 32 Valve clearances (four-crankcase §$> at TDC on its com pression stroke and the stroke engines) - ch e c k a nd tim in g marks aligned, th e valve clearances » adjustm ent ^ can be checked. Note: On some engines with options fo r two o r four valve heads there m ay 1 1 The engine must be completely cold fo r this be alternative timing marks. I maintenance procedure, so let th e m achine sit 6 Insert a feeler gauge o f th e same thickness ■ overnight before beginning. Remove any body as th e correct valve clearance between the I panels necessary to gain access to th e rocker arm and stem o f each valve (see the alternator and cylinder head (see Chapter 9). Data section at th e end o f this manual). The | 2 Remove the spark plug (see Section 29). feeler gauge should be a firm sliding fit - you I 3 Remove the valve cover (see Chapter 2B). should feel a slight drag when th e you pull the L Discard the cover gasket or O-ring as a new gauge out (see illustration). one must be fitted on reassembly. 4 The valve clearances are checked with the 7 If th e clearance is either to o small o r too large, loosen th e locknut and turn th e adjuster piston at to p dead centre (TDC) on its until a firm sliding fit is obtained, then tighten compression stroke (the valves are closed the locknut securely, making sure the adjuster and a small clearance can be fe lt at each does not turn as you do so (see illustration). rocker arm). Turn the engine in the normal • direction of rotation until the piston is a t TDC; Recheck the clearances. 8 A p ply som e engine oil to th e valve you can do this by rotating the crankshaft via assem blies, rockers and cam shaft before the alternator rotor or the variator centre nut. installing th e valve cover and fit a new cover Note: On liquid-cooled engines w ith the water pump located on the alternator cover i t should gasket o r O -ring. Install th e remaining not be necessary to remove the water pum p components in th e reverse order of removal.

(

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33

Headlight, brake light and horn -

check

k

N ote: A n im properly adjusted h eadlight m ay cause pro blem s fo r oncom ing traffic or provide poor, unsafe illumination o f the road ahead. Before adjusting the headlight aim, be sure to con sult w ith lo ca l traffic law s and regulations - fo r UK models refer to M OT Test Checks in the Reference section. 1 Before making any adjustm ent, check that th e tyre pressures are c o rre c t and the suspension is adjusted as required. Make any a djustm ents to the headlight aim w ith the scooter on level ground, w ith th e fuel tank half full and w ith an assistant sitting on the seat. If th e m achine is usually ridden w ith a passenger on th e back, have a second assistant to do this. 2 All headlight units have provision fo r vertical (up and dow n) adjustm ent. T he headlight a djuster screw will be located eith er a t the fro n t o f the unit, adjacent to the light, accessible through a hole or grille, o r behind a bo dy panel. Alternatively an adjuster at the rear o f the unit w ill be accessible th rough a hole in th e kick panel o r inside th e glovebox. Refer to your scooter handbook fo r details. 3 Position th e s c oo te r as de scrib ed in the M O T Test Checks in th e Reference section. Switch th e headlight main beam ON and turn

101 HI, 1 w m ark (a rro w e d ). . .

32.5b . . . o r a line on th e cam shaft s p ro c k e t (arrowed)

32.5c C heck fo r tim in g m arks on the alte rna tor r o to r (A) and cran kcase ( B ) . . .

32.5d . . . o r a lte rna tor r o to r (A) and inside the inspection hole (B) in th e e ngine side cove r

32.6 C hecking the valve clearance w ith a fe eler gauge

32.7 H old th e a d ju s te r (A) w hile tightening th e lo c k n u t (B)

1.18 Routine m ain ten an ce and servicin g p ro ced u res

36.1b . . . o r press th e c lips to release th e speedom eter cable

36.1a U nscrew th e knurled ring . . . the adjuster screw to move th e beam up or down as required. 4 The brake light should come on when either the front or rear brake levers are pulled in. If it does not, check the operation o f the brake light sw itch and tail/b rake ligh t bulb (see Chapter 10). Note: In m ost cases, check the operation o f the brake lig h t w ith th e engine running. 5 If the horn fails to work, check th e operation of the handlebar sw itch and th e horn itself (see Chapter 10). Note: In m ost cases, check the operation o f the horn w ith th e engine running.

34

Wheels and tyres - |§ ge ne ral ch e c k

Wheels 1 Wheels are virtually maintenance free, but they should be kept clean and corrosion-free and checked periodically fo r damage to the rims. C heck cast w heels fo r cracks. Also check th e wheel runout and alignm ent (see Chapter 8). Never attem pt to repair damaged cast wheels; they m ust be renewed. 2 Wheel bearings w ill wear over a period of time and result in handling problems. Support the machine on its centre stand and check for any play in th e bearings by pushing and pulling th e wheel against th e hub. Also rotate the wheel and check that it turns smoothly.

36.3a Loosen th e retaining plate b o l t .

3 If any play is detected in the hub, or if the wheel does no t rotate sm oothly (and this is no t due to brake or transmission drag), th e wheel bearings must be inspected for wear or damage (see Chapter 8).

Tyres

retracted when th e machine is in use. If the spring has sagged o r broken it m ust be renewed (see Chapter 7).

36Speedometer cable and drive gear - lu b rica tion

^

4 C heck th e tyre condition and tread depth thoroughly - see Daily (pre-ride) checks. Check th e valve rubber for signs of damage or deterioration and have it renewed if necessary. Also, make sure the valve stem cap is in place and tight.

Note: Some scooters are fitted with electronic speedometers. On these machines, only the drive gear needs lubricating. Do n o t attem pt to disconnect the electrical wire from the drive housing. 1 Displace the handlebar cover (see Chap­ 35 Stand - c h e c k a n d lu b ricater tion 9), then disconnect the speedometer cable from th e underside o f th e instrum ent panel (see illustrations). 2 W ithdraw th e inner cable from the outer 1 Since th e stand pivots are exposed to the cable and lubricate it with m otor oil or cable elements, they should be lubricated lubricant. Do not lubricate th e upper few periodically to ensure safe and trouble-free inches of the cable as th e lubricant may travel operation. up into th e instrument head. 2 In order for the lubricant to be applied where 3 On some scooters, th e drive gear is it w ill do th e m ost good, the com ponent contained within th e hub (see Chapter 8). On should be disassembled. However, if chain or some machines, th e drive gear is sealed and cable lubricant is being used, it can be applied requires no maintenance other than to check to the pivot joint gaps and will usually w ork its that the gear rotates smoothly when th e hub is w ay into the areas where friction occurs. If being overhauled. On others, th e drive gear is motor oil o r light grease is being used, apply it retained by a plate. Loosen th e bolt and sparingly as it may attract d irt (which could w ithdraw th e speedometer cable, then undo cause th e controls to bind o r wear at an the bolt and remove th e plate (see accelerated rate). illu stratio ns). Pull out th e drive gear and 3 The return spring m ust be capable of regrease it (see illustration). Install th e drive retracting the stand fu lly and holding it gear and cable in th e reverse order o f removal.

lb-

36.3b . . . and w ithd ra w th e cable

36.3c Remove the drive gear and regrease it

R outine m ain ten an ce and serv icin g p ro c e d u re s

36.4a Rem ove th e cap (a rro w e d ). . . 4 Some scooters are fitte d w ith a separate ! speedometer drive housing. Remove th e cap from the housing and press som e general , purpose grease into it (see illu s tra tio n s ). Refit the cap and tighten it securely.

36.4b . . . a nd p re ss som e grease in to th e housing

m ove it forw ards and backw ards (see illustration). Any freeplay in the steering head bearings will be fe lt as front-to-rear movement o f th e ste ering stem. N ote: On leading o r trailing link front suspension, grasp the lower end o f the suspension leg b y the suspension arm p ivot b o lt fo r this test. If play is felt in the 37 Steering head bearings bearings, fo llo w th e procedure described in I . check Chapter 7 to adjust them. * 5 Over a period o f tim e th e grease in th e bearings w ill harden or may be washed out. 1 Most scooters are equipped w ith ball Disassemble the steering head for regreasing steering head bearings which run in races at of th e bearings. Refer to C hapter 7 for. details. the top and bottom o f the steering head. The races can become dented o r rough during normal use and th e balls w ill gradually wear. Inextreme cases, worn o r loose steering head 1bearings can cause steering w ob ble - a condition that is potentially dangerous. 2 Place the scooter on th e centrestand. Raise the front wheel off th e ground either by having 1 The suspension com ponents m ust be [an assistant push dow n on th e rear or by m aintained in to p operating con ditio n to placing a support under the frame. Note: Do ensure rider safety. Loose, worn or damaged not rest the w eight o f the m achine on the suspension parts decrease the s c oo te r’s ; bodywork; i f necessary, rem ove th e belly stability and control. panel to expose the frame (see Chapter 9). Front suspension 3 Point the front wheel straight-ahead and 2 While standing alongside th e scooter, apply slowly turn the handlebars from side-to-side. the front brake and push on the handlebars to Any dents or roughness in th e bearing races compress th e suspension several times. See if will be felt and th e bars w ill not move i smoothly and freely. If the bearings are it moves up -and-dow n sm oo thly w itho ut binding. If binding is felt, the suspension damaged they m ust be renewed (see Chap­ should be disassembled and inspected (see ter 7). Chapter 7). 4 Next, grasp the front suspension and try to

%

37.4 Checking fo r play in th e ste ering head bearings

1-19

3 On m odels w ith leading or trailing link suspension, inspect th e shock fo r fluid leaks and corrosion on the damper rod. If th e shock is faulty it should be renewed (see C hapter 7). Check that th e shock m ounting b olts are tight. 4 On m odels w ith te le scop ic fo rks, inspect th e areia around th e du st seal fo r signs of grease o r oil leaks, then carefully lever o ff the dust seal using a flat-bladed screwdriver and inspect the area behind it (see illu stratio n). If corrosio n due to th e ingress o f w ate r is evident, th e seals m ust be renewed (see Chapter 7). The chromed finish on th e fo rks is prone to corrosio n and p ittin g, so it is advisable to keep them as clean as possible and to spray them regularly w ith a rust inhibitor, otherwise the seals w ill not last long. If corrosion and pitting is evident, tackle it as early as possible to prevent it getting worse. 5 C heck th e tigh tn ess o f all suspension nuts and bolts to ensure none have w orked loose.

R e ar suspension N ote : F or scooters fitte d w ith tw in rear shocks, bo th shocks m u st b e in g o od condition. I f either is found to be faulty, renew the shocks as a pair. 6 inspect the rear sho ck fo r fluid leaks and corrosion on th e dam per rod. If a sho ck is faulty it should be renewed (see Chapter 7). Check that th e shock mounting bolts are tight. 7 With th e aid of an assistant to support the scooter, com press the rear suspension several tim es. It should move up-and-dow n freely w itho ut binding. If any binding is felt, th e w orn o r fa ulty c om ponent m ust be identified and renewed. The problem could be due to either th e shock absorber or th e front pivot assembly. 8 Support th e scooter so that th e rear wheel is o ff the ground. G rab th e engine/ transmission unit at th e rear and attem pt to rock it from side-to-side - there should be no discernible freeplay fe lt between th e engine and frame. If there is movement, inspect the tightness o f th e rear suspension m ountings and the front engine m ounting, referring to the torque settings specified in th e Data section, then recheck for movement. If freeplay is felt,

i.2o Routine m ain ten an ce and servicin g p ro ced u res disconnect th e rear shock absorber lower mounting and displace th e shock and check again - any freeplay in th e fro n t engine mounting should be more evident. If there is freeplay, inspect th e m ounting bolts and brackets for wear (see Chapter 7). 9 Reconnect the rear shock, then grasp the top of the rear w heel and pull it upw ards there should be no discernible freeplay before the shock absorber begins to compress. Any freeplay indicates a w orn shock or shock mountings. The w orn com ponents m ust be renewed (see Chapter 7).

39 Nuts and bolts tig h tn e s s c h e c k

% ||

1 Since vibration te nds to loosen fasteners, all nuts, bolts, screws, etc, should be periodically checked for proper tightness. 2 Pay particular attention to the following: • Spark plug. • C arburettor clamps. • G earbox oil filler and drain plugs (where fitted).

• • • • • • •

Engine oil drain plug (four-stroke engines). Stand bolts. Engine mounting bolts. Suspension bolts. Wheel bolts. Handlebar clamp bolts. Brake caliper and disc mounting bolts (disc brakes). • Brake hose banjo bolts (disc brakes). • Exhaust system bolts/nuts. 3 If a torque wrench is available, use it along w ith th e to rq ue specifications given in th e Data section at the end o f this manual.

2A*1

Chapter 2 Part A: Two-stroke engines Contents Alternator - remdval and in sta lla tio n ....................................................10 Crankcase halves and main bearings .................................................13 Crankshaft assembly and big-end b e a rin g ........................................ 14 Cylinder - removal, inspection and insta lla tio n .................................. 7 6 Cylinder head - removal, inspection and installation ................... Disassembly and reassembly - general info rm a tio n ......................... 5 Engine - removal and installation ......................................................... 4 I General info rm a tion...................................................................... .. 1 [■ Idle speed..............................................................................see C hapter 1 [ Initial start-up after overhaul ................................................................ 15

[ I [ | I

Major engine repair - general in fo rm a tio n ............................................ 3 Oil pump - removal, inspection, installation and bleeding ............... 12 Operations possible with the engine in the fr a m e .............................. 2 Piston - removal, inspection and installation ..................................... 8 Piston rings - inspection and installation ............................................ 9 Recommended running-in p ro c e d u re .................................................. 16 Spark plug g a p ......................................................................see Chapter 1 Starter m o t o r ......................................................................see Chapter 10 Starter pinion assembly and starter clutch - removal, inspection and insta llatio n.....................................................................................11

Degrees of difficulty Easy, suitable for novice with little experience

-;s;

Fairly easy, suitable fo r beginner with som e experience

Fairly difficult, ^

suitable for competent ^ DIY mechanic ^

Difficult, suitable fo r experienced DIY mechanic

^ ^

Very difficult,

^ suitable fo r expert DIY o r professional ^

Specifications Refer to the Data section a t th e end o f this manual fo r servicing specifications.

1 General information

The engine is a single cylinder two-stroke, with either fan-assisted air cooling (see Chapter 1) or pum ped liquid cooling (see Chapter 3). The crankshaft assem bly is pressed together, incorporating th e connecting rod. The piston runs on a needle roller bearing fitte d in the sm all-end o f th e connecting rod. The crankshaft runs in caged ball main bearings.

The crankcase divides vertically - the lefthand crankcase is an integral part o f th e drivebelt casing and gearbox.

2 Operations possible with the engine in the frame

from th e fram e. However, access to some com ponents is severely restricted, and if a number o f areas require attention a t the same time, removal o f th e engine is recommended, as it is an easy task to undertake.

3 Major engine repair ge ne ral in fo rm a tio n

Most components and assemblies, with the obvious exception o f the crankshaft assembly and its bearings, can be w orked on w ithout having to remove the engine/transmission unit

1 It is not alw ays easy to determ ine if an engine should be completely overhauled, as a number o f factors m ust be considered.

2A*2 Two-stroke engines 2 High mileage is no t necessarily an indication th at an overhaul is needed, while low mileage, on th e other hand, does not preclude th e need for an overhaul. Frequency of servicing is probably th e single m ost important consideration. An engine that has regular and frequent maintenance w ill most likely give many m iles o f reliable service. Conversely, a neglected engine, or one which has not been run in properly, may require an overhaul very early in its life. 3 If the engine is making obvious knocking or rumbling noises, th e connecting rod and/or main bearings are probably at fault. 4 Loss o f power, rough running, excessive noise and high fuel consum ption rates may also po int to th e need fo r an overhaul, especially if th ey are all present at th e same time. If a complete service as detailed in Chapter 1 does not • rem edy th e situation, major mechanical w ork is th e only solution. 5 An engine overhaul generally involves restoring th e internal parts to th e specifications o f a new engine. This may require fitting new piston rings and crankcase seals, or, after a high mileage, renewing th e piston, cylinder and crankshaft assembly. The end result should be a like-new engine that will give as many trouble-free miles as th e original. 6 Before beginning the engine overhaul, read through th e related procedures to familiarise yourself w ith th e scope and requirements of the job. Overhauling an engine is not all that difficult, but it is tim e-consum ing. Check on th e availability o f parts and make sure that any necessary special tools and materials are obtained in advance. 7 M ost w ork can be done w ith typical workshop hand tools, although manufacturers often produce a num ber of service tools for specific purposes such as disassembling the clutch and separating th e crankcase halves. Precision measuring to o ls are required fo r inspecting parts to determine if they must be renewed. Alternatively, a dealer will handle the inspection o f parts and offer advice concerning reconditioning and renewal. As a general rule, tim e is th e prim ary c ost of an overhaul so it does not pay to install worn or substandard parts.

8 As a final note, to ensure maximum life and minimum tro u b le ' from a rebuilt engine, everything must be assembled with care in a spotlessly clean environment.

4 Engine rem oval an d in sta llatio n

Sk

C au tion : The e n g in e /tra n s m is s io n u n it is not heavy, h o w e v e r re m o v a l and in s ta lla tio n s h o uld b e carried o u t w ith th e a id o f a n a s s is ta n t; p e rs o n a l in ju ry o r dam age c o u ld o c c u r i f the e ngine falls o r is dropped.

Removal 1 Support the scooter securely in an upright position. Work can be made easier by raising th e machine to a suitable height on a hydraulic ramp or a suitable platform. Make sure it is secure and will not topple over. 2 Remove any body panels as necessary to access the engine (see Chapter 9). 3 Remove th e exhaust system (see Chap­ ter 4). 4 If the engine is dirty, particularly around its mountings, wash it thoroughly before starting any m ajor dism antling work. This w ill make work much easier and rule out th e possibility of dirt falling inside. 5 Disconnect th e battery negative term inal (see Chapter 10) and pull th e spark plug cap off the plug. 6 On liquid-cooled engines, disconnect the wire to th e temperature sender on the cylinder head (see illu s tra tio n ). Drain the cooling system and disconnect th e coolant hoses from th e unions on the water pump, cylinder and cylinder head (see Chapter 3). If fitted, undo th e screw securing th e carburettor heater union to the carburettor (see illustration). 7 Trace th e wiring from the alternator/ignition pulse generator coil and disconnect it at the connectors. Free th e wiring from any clips or ties on th e engine. Either remove the starter m otor o r disconnect the starter m otor leads (see Chapter 10). If fitted, disconnect the earth (ground) w ire betw een the fram e and th e engine.

8 If required, remove th e air filter housing and th e air intake duct (see Chapter 4). 9 Either remove the carburettor, leaving the th ro ttle cable attached if required, or just disconnect th e fuel hose and fuel tap vacuum hose from their unions on the carburettor and inlet manifold respectively, and disconnect th e th ro ttle cable (see Chapter 4). Where fitted, disconnect th e automatic choke wiring connector. 10 W here fitte d, disconnect th e fuel pum p vacuum hose from th e engine. 11 Where fitted, detach th e oil pump control cable from th e pum p pulley and detach the cable from its bracket (see Section 12). 12 Release th e clip securing the hose from th e oil ta nk to th e union on the oil pum p and detach the hose from the pum p (see Section 12). Clamp th e hose and secure it in an upright position to minimise oil loss. Wrap a clean plastic bag around the end to prevent dirt entering the system. 13 If required, remove th e rear w heel (see Chapter 8). N ote: On machines where the centre stand is bolted to the underside o f the engine unit, the rear wheel and stand provide a convenient s u p po rt fo r the u n it once i t is rem oved from the scooter. However, it is useful to loosen the rear w heel n u t a t this point before disconnecting the rear brake. 14 On models fitted with a drum rear brake, disconnect the brake cable from th e brake arm (see Chapter 8). Undo any screws securing the cable to the underside o f th e drivebelt casing and detach th e cable (see illustration). 15 On m odels fitted with a disc rear brake, displace th e brake caliper (see Chapter 8). Unclip th e brake hose from th e underside of the drivebelt casing (see illu stratio n 4.14). 16 C heck th a t all wiring, cables and hoses are clear of the engine/transmission unit. 17 W ith th e aid of an assistant, support the w eight o f th e machine on th e rear o f th e frame, then remove the bolt securing the rear shock absorber to the gearbox casing. If the rear wheel has been rem oved sup po rt th e gearbox on a wood block to prevent damage to th e casing. Undo th e nut securing th e upper end o f the shock to th e fram e and remove the shock. N ote: On scooters fitted with twin rear shocks, remove both shocks.

4.6a D isconnect the tem perature sender w iring connector

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brake cable

Two-stroke engines 2A»3

4.18c S eparate th e e ngine u n it fro m th e 18 Remove th e fro n t engine m ounting bolt (see illu stratio ns). Note th at on some scooters the engine is supported by a bracket on the top of the engine/transmission unit. If (hestand is fitted to th e frame, manoeuvre the engine unit back and ou t o f the frame. If the stand i& bolted to th e engine unit, lift th e frame away (see illustration). 19 If required, remove the stand (see Chap­ ter?) and the rear wheel (see Chapter 8).

Installation 20 Installation is the reverse o f removal, noting the following: • Make sure no wires, cables o r hoses ' become trapped between the engine and B the frame when installing the engine. • Tighten the front engine m ounting bolt R and shock absorber b o lt to the torque ■ settings specified in the Data section at [ the end o f this manual. • Make sure all wires, cables and hoses are B correctly routed and connected, and I secured by any clips o r ties. • On liquid-cooled engines, fill the cooling I system (see Chapter 3). t Bleed the oil pum p (see Section 12) and ■ check the adjustm ent o f th e oil pum p I- cable where fitted (see Chapter 1). • Check the operation o f the rear brake I before riding the machine (see Chapter 8).

5 Disassembly and reassembly general in fo rm a tio n

W arning : The use o f p e tr o l (ga so lin e ) as a c le a n in g a g e n t s h o u ld be a v o id e d be c au s e o f th e ris k o f fire. 2 When clean and dry, arrange the unit on the w orkbench, leaving suitable clear area fo r w orking. Gather a selection o f small containers and plastic bags so that parts can be grouped together in an easily identifiable manner. Some paper and a pen should be on hand to permit notes to be made and labels attached where necessary. A supply o f clean rag is also required. 3 Before commencing w ork, read through the appropriate section so that some idea o f the necessary procedure can be gained. When removing components it should be noted that great fo rc e is seldom required, unless specified. In many cases, a com ponent’s reluctance to be removed is indicative of an incorrect approach or removal m ethod - if in any doubt, recheck w ith th e text. 4 W hen disassem bling the engine, keep 'm ated' parts th at have been in contact with each other during engine operation together. These ‘m ated’ parts m ust be re-used or renewed as an assembly. 5 C om plete engine disassem bly should be done in th e fo llo w in g general order w ith reference to the appropriate Sections (refer to C hapter 6 fo r details o f transm ission components disassembly): • Remove the cylinder head. • Remove the cylinder. • Remove the piston. • Remove the alternator. • Remove the variator (see Chapter 6).

A

• • • • • •

Remove the starter m otor (see Chapter 10). Remove the o il pump. Remove the water pum p i f fitte d internally (see C hapter 3). Remove the reed valve (see C hapter 4). Separate the crankcase halves. Remove the crankshaft.

Reassem bly 6 Reassembly is accom plished by reversing the order of disassembly.

6 Cylinder head -

rem ov a l, in s p e c tio n a n d in s ta lla tio n

^ ^

Note: This procedure can be carried o u t with the engine in the frame. I f the engine has been removed, ignore the steps that do n ot apply. C a u tio n : The en g in e m u s t b e c o m p le te ly c o o l b e fo re b e g in nin g th is p ro c e d u re o r th e cy lin d e r h e ad m ay be com e w arped.

A ir-cooled engines R em oval 1 Remove th e body panels as necessary to access th e cylinder head (see C hapter 9). 2 Pull th e spark plug cap o ff th e spark plug. It w ill be necessary to rem ove the engine cowling, or part o f the cowling, to access the cylinder head. On some engines, th e cooling fan cowling forms part o f the engine cowling. C heck around th e cow ling and disconnect any w ires or hoses clipp ed to it, th en undo the bo lts securing th e cow ling and remove it, noting how it fits (see illu s tra tio n s ).

Disassembly 1 Before disassem bling the engine, th e external surfaces o f the unit should be thoroughly cleaned and degreased. This will prevent contamination o f th e engine internals, and will also make w orking a lot easier and [ cleaner. A high flash -po in t solvent, such as I paraffin can be used, o r bette r s till, a I proprietary engine degreaser such as Gunk. ' Use an old paintbrush to w ork th e solvent into the various recesses o f the engine casings. !I Jake care to exclude solvent or water from the »■ electrical com ponents and inlet and exhaust I ports.

6.2a U nclip a ny w ire s o r hoses

th en undo th e c o w ling fix in g b olts (arrowed)

2A»4 Two-stroke engines

6.3a Undo th e cylind er head n u ts . . . Note: Some cowlings are clipped together take care n ot to damage the fixing lugs when separating them. Remove any spacers fo r the cowling bolts for safekeeping if they are loose. 3 Remove th e spark plug, then unscrew the cylinder head bolts, or cylinder head nuts, evenly and a little at a time in a criss-cross sequence until they are all loose and remove them, together with any washers (see illustrations). Note: Some cylinder heads are secured by long bolts which pass down through the cylinder and screw into the crankcase, others are secures by nuts on long studs. In both cases, once the cylinder head is loose care m ust be taken not to break the cylinder base gasket seal otherwise a new base gasket w ill have to be fitte d before refitting the head (see Section 7). 4 Lift the head off the cylinder. If the head is stuck, ta p around th e join t face between the head and cylinder with a soft-faced mallet to free it. Do not attem p t to free th e head by inserting a screwdriver between the head and cylinder - you’ll damage th e sealing surfaces. 5 If fitted, remove th e cylinder head gasket and discard it as a new one m ust be used on reassembly.

6.3b . . . o r th e cylinder head bolts

Damaged or worn threads can be reclaimed using a thread insert (see Tools and Workshop Tips in the Reference section). M ost scooter dealers and small engineering firm s offer a service o f this kind. 9 Check th e mating surfaces on th e cylinder head and cylinder fo r signs o f leaks, which could indicate that the head is warped. 10 Using a precision straight-edge and a feeler gauge, check the head mating surface fo r warpage. N ote: Clean all traces o f old gasket m aterial from th e cylinder head and cylinder with a suitable solvent. Take care not to scratch o r gouge the soft aluminium. Lay the straight-edge across the surface and try to slip the feeler gauge under it on either side o f the combustion chamber. If the feeler gauge can be inserted between the straight-edge and the cylinder head, the head is warped and must be either machined or, if w arpage is excessive, renewed. Check vertically, horizontally and diagonally across th e head, m aking four checks in all (see illustration). If there is any doubt about the condition of th e head consult a scooter dealer or specialist engineer.

Install th e new head gasket i f required. N ote: The gasket may b e m arked to . identify which side should face up when it is in place, o r there may be a raised section around th e inner edge o f the gasket. I f so, fit the gasket with the raised section uppermost. • Tighten th e cylinder head fixings evenly and a little a t a tim e in a criss-cross pattern to th e to rque setting specified in the Data section. • Ensure th e engine cow ling is correctly secured. •

Liquid-cooled engines

Inspection

Installation

6 Refer to Chapter 1 and decarbonise th e cylinder head. 7 Inspect th e head very carefully fo r cracks and other damage. If cracks are found, a new head will be required. 8 Inspect the threads in th e spark plug hole.

11 Installation is th e reverse o f removal, noting the following: • Ensure bo th cylinder h ead and cylinder mating surfaces are clean. • Lubricate th e cylinder bore w ith the specified type o f two-stroke oil.

R em oval 12 Remove the body panels as necessary to access th e cylinder head (see Chapter 9). Remove any heat shield th at may prevent access to the head. 13 Disconnect the battery negative terminal (see Chapter 10). Pull th e spark plug cap off th e plug and disconnect the wire to th e temperature sender on the cylinder head (see illu stratio n 4.6a). 14 Drain the cooling system and disconnect the coolant hoses from the unions on the cylinder head (see illustration). If fitted, disconnect the carburettor heater hoses (see illustration 4.6b). 15 On some engines, th e thermostat housing is mounted on th e top o f the cylinder head; if required, undo th e bolts and rem ove th e housing, th en lift ou t the th erm ostat (see illustration).

6.10 C heck th e cylind er head fo r w arpage w ith a s traight-edge

6.14 D isconnect th e c oo lan t hoses fro m th e cylind er head

6.15 Remove th e th erm o sta t housing if required

Two-stroke engines 2A*5

Cylinder head cover Cover b o lt - 4 o ff Temperature sender Thermostat Cover seal O-ring Cylinder head Cylinder head n u t - 4 o ff 9 O-ring 10 Cylinder 11 Base gasket 12 Piston rings 13 Piston 14 Piston pin 15 Circlips 6.16 Liq uid -co oled e ngine w ith separate cylind er head cover

6.17 C om ponents o f a conventional liq u id -co ole d engine

16 Some engines are fitte d w ith a separate cylinder head cover w hich form s part of the engine cooling w ater jacket (see illustration). Undo the bolts and remove th e cover. Discard any gasket or O-ring as a new one m ust be used on reassembly. 17 Follow Steps 3 and 4 and rem ove th e cylinder head. Discard any gasket or

O -ring as new ones m ust be used (see illustration). 18 If th e therm ostat is fitte d inside th e cylind er head, lift o u t th e th erm ostat (see illustration).

Inspection 19 Follow Steps 6 to 10 to decarbonise and

6.19 T herm ostat bypass passage m ust be

check th e cylinder head. If the therm ostat is fitted inside the cylinder head, ensure that th e therm o sta t bypass passage is clear (see illu s tra tio n ). C heck th e con ditio n o f th e thermostat (see C hapter 3).

Installation 20 Installation is th e reverse o f removal, noting th e following: Ensure b o th cylinder he ad a n d cylinder • mating surfaces are clean. • Lubricate th e cylind er bo re w ith the specified type o f two-stroke oil. • Assem ble the com ponents w ith new gaskets and O-rings. • Tighten the cylinder head, and head cover where fitted, fixings evenly and a little a t a time in a criss-cross pattern to the torque setting specified in the Data section. • Ensure th e therm o sta t a n d coo lan t system hoses are fitte d c orrectly (see Chapter 3). • Refill the cooling system (see C hapter 1).

2A»6 Two-stroke engines

7.1 Detach th e coo lan t hose (arrowed) fro m th e cylinder

lifte d o ff

Inspection

7 Cylinder -

1 Remove the exhaust system (see Chap­ ter 4) and th e cylinder head (see Section 6). On liquid-cooled engines, where applicable, detach th e coolant hose from the cylinder (see illustration). 2 Lift th e cylinder up o ff th e crankcase, supporting the piston as it becomes accessible to prevent it hitting th e crankcase opening (see illu stra tio n ). If th e cylinder is stuck, ta p around th e join t face between the cylinder and th e crankcase with a soft-faced mallet to free it. Don’t attem pt to free th e cylinder by inserting a screwdriver between it and the crankcase - you’ll damage the sealing surfaces. When th e cylinder is removed, stuff a clean rag into th e crankcase opening around the piston to prevent anything falling inside. 3 Remove th e cylinder base gasket and discard it, as a new one m ust be fitte d on reassembly. 4 Scrape o ff any carbon deposits th at may have form ed in th e exhaust port, then wash the cylinder w ith a suitable solvent and dry it thoroughly. Com pressed air w ill speed the drying process and ensure that all holes and recesses are clean.

5 Check th e cylinder bore carefully for scratches and score marks. 6 If available, use a te lescoping gauge and m icrometer to measure th e diameter o f the cylinder bore to assess th e amount of wear, ta per and ovality (see Tools and Workshop Tips in the Reference section). Measure near the top (but below the level o f the to p piston ring at TDC), centre and bottom (but above the level o f the bottom ring at BDC) of the bore both parallel to and across th e crankshaft axis (see illu s tra tio n ). Calculate any differences betw een the m easurements taken to determine any taper or ovality in th e bore. 7 Now measure an unworn part of the cylinder bore (below the level of th e bottom ring at BDC) and compare the result to th e previous measurements to determine overall wear. 8 If th e bore is ta pered, oval, or worn excessively, o r badly scratched, scuffed or scored, th e cylinder and piston will have to be renewed. Note: If no service lim it specifications (see Data section) are available to assess cylinder wear, calculate the pistonto-bore clearance to determine whether the cylinder is useable (see Section 8). 9 If there is any doubt about the serviceability of th e cylinder, consult a scooter dealer. Note: On some engines, the surface o f the cylinder has a wear-resistant coating which, when damaged o r worn through, requires a new cylinder. On others, the cylinder can be rebored and an oversize piston fitted (see Data section). Oversize pistons are not necessarily marked as

and should a lw ays m atch

7.11 Ensure the n ew g asket is positioned c orrec tly on th e crankcase

rem oval, in sp e ctio n and insta llatio n

^

Note: This procedure can be carried o u t with the engine in the frame.

Removal

7.6 Measure th e c ylinder b ore in th e d irectio ns shown

such; in many cases the only way to determine if a cylinder has been rebored is to measure an unworn area o f the bore and compare the result w ith the specifications in the Data section. M ost manufacturers mark cylinders and pistons with a size code during production; the size code (usually a letter) is stamped into the cylinder gasket surface and the top o f the piston (see illu s tra tio n ). It is im portant that new parts have matching codes. 10 If applicable, inspect the cylinder head bolt threads in the crankcase (see Section 13). If the head is secured by studs, check that they are tight. If any are loose, remove them and clean their threads. Apply a suitable permanent thread locking compound and tighten them securely.

j I I I '

]

Installation Note: On some engines, cylinder base gaskets are available in a range o f thicknesses; the appropriate thickness depends on the height o f the piston crown at TDC in relation to the cylinder to p gasket surface. Consult a scooter dealer fo r details. In these instances, the correct gasket thickness m ust b e calculated before reassembly (see Steps 17 to 21). 11 Check th at the m ating surfaces o f the cylinder and crankcase are clean, then remove any rag from the crankcase opening. Lay the new base gasket in place on the crankcase m aking sure it is the correct way round (see illustration). 12 Check that’ th e piston rings are correctly positioned so that th e ring locating pins in the piston grooves are betw een the ring ends (see illustration).

7.12 Ring loca ting pins (arrowed) m ust be between the ring ends

I I I I I I I |

I

Two-stroke engines 2A«7

7.13 Position th e c ylind er ove r th e to p o f th e p isto n . . .

7.14 . . . then carefully feed th e p isto n into th e cylind er

7.15 C heck th a t th e c y lind er base g asket (arrow ed) h as n o t been d isplaced

13 Lubricate the cylinder bore, pisto n and piston rings, and th e connecting rod big and small ends, w ith th e specified typ e o f tw ostroke oil, then locate th e cylinder over th e to p , ofthe piston (see illustration). 14 Ensure th e piston enters the bore squarely and does not get cocked sideways. Carefully compress and feed each ring into th e bore as the cylinder is lowered, ta king care th at th e rings do not rotate o u t o f position (see illustration). Do not use force if th e cylinder appears to be stuck as th e piston and/or rings will be damaged. 15 When th e piston is correctly installed in the cylinder, check that th e base gasket has not been displaced, then press th e cylinder down onto the gasket (see illustration). 16 Install th e remaining com ponents in th e reverse order of removal.

18 Assemble th e cylind er on th e piston as described in Steps 12 to 14, b u t w itho ut a base gasket, and press the cylind er dow n onto th e crankcase. 19 Set th e dial gauge in the mounting plate, and w ith the mounting plate feet and gauge tip resting against th e cylind er to p gasket surface, zero th e gauge. Rotate the crankshaft so that th e piston is part way down th e bore. 20 C lam p th e m ounting plate diagonally across th e cylinder using th e cylinder fixings and tighten them to ensure that th e cylinder is held firmly against the crankcase. 21 R otate th e crankshaft via the alternator rotor nut so th e piston rises to th e to p o f its stroke (TDC). A t th is point read o ff the dial gauge (see illu s tra tio n 7.17). The reading represents th e distance between th e cylinder to p gasket surface and th e to p of th e piston crown. Use this measurement, together with th e manufacturer’s information, to identify the appropriate gasket thickness.

arrow which faces to wards th e exhaust. If this is not visible, mark th e piston accordingly so that it can be installed the correct w ay round. Note th at th e arrow may no t be visible until th e carbon deposits have been scraped off and the piston cleaned. 3 Carefully prise th e circlip out from one side o f th e piston using needle-nose pliers o r a small flat-bladed screwdriver inserted into the notch (see illu s tra tio n ). C heck fo r burring around the circlip groove and remove any with a very fine file o r penknife blade, th en push th e piston pin ou t from th e other side and rem ove th e piston from the connecting rod (see illu stratio n). Use a socket extension to push the piston pin ou t if required. Remove th e other circlip and discard them both, as new ones m ust be used on reassembly.

Cylinder base gasket thickness 17 To measure th e height o f th e piston crown at TDC in relation to th e cylinder to p gasket surface you w ill require a dial gauge and a mounting plate (see illustration).

Piston - rem oval, in s p e c tio n an d in s ta llatio n

I

Note: This procedure can be carried o u t with the engine in the frame.

Rem oval 1 Remove the cylinder and stuff a clean rag into the crankcase opening around th e piston to prevent anything falling inside (see Section 7). 2 The piston to p should be m arked w ith an

7.17 Set-up fo r calcu latin g th e th ickn ess of the c ylind er base gasket

8.3a Rem ove the c irc lip .

WWHS ““ J

To p re v e n t th e c irc lip fro m flying a w a y o r fro m dro pp in g n to th e c ran k c as e , p a s s a r o d o r s c re w d riv e r, w ith a g re a te r d ia m e te r th a n th e gap b etw een the c irc lip ends, th ro u g h the p is to n pin. This w ill trap th e c irc lip i f i t s pring s out.

HiNT

I f th e p is to n p in is a tig h t f it in th e p is to n bo sses, h e a t th e p is to n g e n tly w ith a h o t a ir g u n - th is w ill e xp an d the a llo y p is to n s u ffic ie n tly to relea se its g rip on th e pin.

HiNT

8.3b . . . th en push o u t th e p isto n pin

2A»8 Two-stroke engines

8.4 Remove th e sm all-end bearing

8.5 Remove th e piston rin gs carefully

4 The connecting rod small-end bearing is a loose fit in the rod; remove it for safekeeping, noting which way round it fits (see illustration). 5 Before the inspection process can be carried out, the piston rings m ust be removed and th e piston must be cleaned. Note: If the cylinder is being renewed o r rebored, piston inspection can be overlooked as a new one will be fitted. The piston rings can be removed by hand; using your thumbs, ease th e ends of each ring apart and carefully lift it o ff th e piston, taking care not to expand it any more than is necessary (see illu s tra tio n ). Do not nick or gouge th e piston in the process. 6 Note w hich way up each ring fits and in which groove, as they m ust be installed in their original positions if being re-used. The upper surface of each ring should be marked at one end (see Section 9). Some pistons have an expander fitted behind th e second ring (see illustration). Note: It is good practice to renew the pisto n rings when an engine is being overhauled. Ensure that the piston and bore are serviceable before purchasing new rings. 7 Clean all traces o f carbon from th e top of th e piston. A hand-held w ire brush or a piece o f fine emery cloth can be used once most of th e deposits have been scraped away. Do not, under any circum stances, use a w ire brush mounted in a drill m otor; the piston material is soft and is easily damaged. 8 Use a piston ring groove cleaning tool to rem ove any carbon deposits from the ring grooves. If a to ol is no t available, a piece broken off an old ring will do the job. Be very

careful to remove only th e carbon deposits. Do not remove any metal and do not nick or gouge the sides o f th e ring grooves. 9 Once the carbon has been removed, clean th e piston with a suitable solvent and dry it th oroughly. If th e identification previously marked on the piston is cleaned off, be sure to re-mark it correctly.

pisto n p in axis

10 Inspect the piston for cracks around the skirt, at th e pin bosses and at the ring lands. Check that the circlip grooves are not damaged. Normal piston wear appears as even, vertical wear on the thrust surfaces of the piston and slight looseness o f the top ring in its groove. If th e skirt is scored or scuffed, the engine may have been suffering from overheating and/or abnormal combustion, resulting in excessively high operating temperatures. 11 A hole in the top o f th e piston, in one extreme, or burned areas around the edge of the piston crown, indicate that pre-ignition or knocking under load have occurred. If you find evidence of any problems the cause must be corrected or the damage w ill occur again. Refer to Chapter 4 fo r carburation checks and Chapter 5 fo r ignition checks. 12 Check th e piston-to-bore clearance by measuring th e cylinder bore (see Section 7) and the piston diameter. Measure the piston approximately 25 mm down from th e bottom of the lower piston ring groove and at 90° to the piston pin axis (see illu s tra tio n ). Note: The precise p o int o f measurement differs between manufacturers and engines, bu t the

aim is to measure the piston in an area where it is worn. Subtract th e piston diameter from I the bore diameter to obtain the clearance. If it I is greater than the specified figure, check I whether it is the bore or piston that is worn the I m ost (see Data section at the end o f this I manual). If the bore is good, install a new piston and rings. Note: Oversize pistons fitted I in a rebored cylinder are not necessarily I marked as such; in many cases th e only way I to determine if a cylinder has been rebored is I to measure an unworn area o f th e bore and I compare the result with th e specifications in I the Data section. M ost m anufacturers mark I cylinders and pistons with a size code during I production; the size code (usually a letter) is I stamped into th e cylinder gasket surface and I the to p o f the piston (see illu stra tio n 7.9). It is I im p orta nt that new parts have matching I codes. It is essential to supply the size code I and any rebore specifications when I purchasing a new piston. 13 Use a micrometer to measure th e piston I pin in the middle, where it runs in the small- I end bearing, and at each end where it runs in I the piston (see illu s tra tio n ). If there is any I difference in th e m easurements th e pin is I worn and must be renewed. 14 If the piston pin is good, lubricate it with I clean tw o-stroke oil, then insert it into the I piston and check fo r any freeplay between the I tw o (see illu s tra tio n ). There should be no I freeplay. 15 Next, check th e condition o f the I connecting rod sm all-end bearing. A worn I sm all-end bearing w ill produce a metallic I

8.13 M easuring th e piston p in w here it runs in th e sm all-end bearing

8.14 C heck fo r freeplay between the piston and th e p isto n pin

Inspection

Two-stroke engines 2A«9

8.16 M easuring th e internal dia m e te r o f the c on ne cting rod sm all-end rattle, most audible when the engine is under load, and increasing as engine speed rises. This should not be confused w ith big-end bearing wear, which produces a pronounced knocking noise. Inspect the bearing rollers for flat spots and pitting. Install th e bearing in the connecting rod, then slide th e piston pin into the bearing and check fo r freeplay (see illustration). There should only be slightly discernible freeplay betw een the piston pin, the bearing and th e connecting rod. 16 .If there is freeplay, measure th e internal diameter of the connecting rod small-end (see illustration). Take several m easurements; if any difference betw een the iurements, the small end is worn and either a new connecting rod or crankshaft assembly will have to be fitted (see Section 14). Consult a scooter dealer about th e availability of parts. Note: If a new rod is available, fitting it is a specialist task which should be le ft to a scooter dealer o r automotive engineer. If a new rod is fitted, the b ig -e nd bearing should be renewedat the same time. 17 If the small-end is good, fit a new smallend bearing. Note: On some engines, a m ark on the connecting rod indicates the matching size code o f th e sm all end bearing - the bearing w ill have th e same m ark o r w ill be mcolour-coded. Refer to these m arks when purchasing a new bearing.

Installation 18 Install the piston rings (see Section 9). 19 Lubricate th e piston pin, th e pisto n pin bore in the piston and th e small-end bearing

9.2 M easuring installed ring end

with th e specified tw o-stroke oil and install the bearing in the connecting rod. 20 Install a new circlip in one side o f th e piston, line up th e piston on the connecting rod, making sure the arrow on th e piston to p faces tow ards th e exhaust, and insert th e piston pin from th e other side. Secure the pin with the other new circlip. When installing the circlips, compress them only just enough to fit them in th e piston, and make sure th ey are properly seated in their grooves with the open end away from th e removal notch. 21 Install the cylinder (see Section 7).

10

9 Piston rings in s p e c tio n a n d in s ta lla tio n

3 If th e gap is larger or smaller than specified, check to make sure that you have the correct rings before proceeding. If the gap is larger than specified it is likely th e cylinder bore is worn. If th e gap is to o small th e ring ends may com e in to con ta c t w ith each othe r during engine operation, causing serious damage. 4 Repeat the procedure fo r th e other ring. 5 Once th e ring end gaps have been checked, th e rings can be installed on th e piston. First identify th e ring loca ting pin in each pisto n ring groove - the ring m ust be positioned so th at th e pin is in between th e ends o f th e ring (see illu stratio n 7.12). 6 If th e piston has an expander fitted behind th e lower ring, fit th at first, ensuring th at the ends o f the expander do not overlap the ring locating pin (see illu s tra tio n 8.6). 7 The upper surface o f each ring should be marked at one end; make sure you fit th e rings th e right way up. Install the lower ring first. Do not expand the ring any m ore th an is necessary to slide it into place and check that th e locating pin is between th e ends o f th e ring (see illustration). 8 Install the to p ring. Always ensure that the ring end gaps are positioned each side o f the locating pins before fitting the piston into the cylinder.

A lternatorre m o v a l a n d in s ta lla tio n

^

^

1 New piston rings should be fitted whenever an engine is being overhauled. It is important that you get new rings of the correct size for your piston so ensure that any information relating to piston size, including rebore size, and sizecoding is available when purchasing new parts. 2 Before fitting the new rings onto th e piston, th e ring end gaps m ust be checked. Insert the to p ring into th e bottom o f the cylinder bore and square it up by pushing it in with the to p o f th e piston. The ring should be about 15 to 20 mm from th e bottom edge o f th e cylinder. To measure th e end gap, slip a feeler gauge between th e ends o f th e ring and compare the measurement to th e specification in the Data section a t th e end o f th is manual (see illustration).

9.7 U sing a th in blade to insta ll th e piston ring

N ote: This procedure can be carried o u t with the engine in the frame. I f the engine has been removed, ignore th e steps that do n o t apply.

Rem oval 1 Remove th e body panels as necessary to access th e alternator (see C hapter 9). If required, rem ove th e exhaust system (see Chapter 4). 2 On air-cooled engines, unclip any wiring or hoses from th e fan cow ling, th en undo the bolts securing the fan cowling and remove it (see illu stratio n). Note that on some models th e fan cow ling is clipp ed to th e engine cowling - take care not to damage th e fixing lugs when separating th em . Remove any spacers fo r the cowling bolts fo r safekeeping if they are loose. Undo th e bolts securing the

10.2 Rem ove th e fa n cow ling

2A*10 Two-stroke engines

ro to r cooling fan to the alternator rotor and remove the fan (see Chapter 1, Section 21). 3 On liquid-cooled engines where th e water pump is mounted on the outside o f the alternator cover, first drain th e coolant and disconnect all th e coolant hoses from the pump

10.4 L ift o ff th e side cove r and a lternator sta tor

10.5 H old the r o to r and undo th e centre nut (arrowed)

(see Chapter 3). Undo th e cover mounting bolts and lift o ff th e cover. Depending on th e tools available fo r removing th e alternator rotor, it may be necessary to unscrew the pump drive dampers (see illustration). 4 On some engines the alternator is located behind the right-hand engine side cover. N ote : I f the water pu m p is m ounted on the outside o f the engine side cover, first drain the coolant and disconnect all the coolant hoses from the pu m p (see C hapter 3). Trace th e wiring from the cover and disconnect it at the connector, then undo th e cover bolts and lift o ff th e cover (see illu s tra tio n ). Discard th e gasket as a new one m ust be fitte d and remove th e cover dow els fo r safekeeping if th ey are loose. If applicable, remove the starter pinion assembly (see Section 11). 5 To remove th e rotoi; centre nut it is necessary to stop th e rotor from turning; some manufacturers produce a service tool fo r this

purpose. If the rotor face is accessible, you can make up a tool which engages th e slots or holes (see illustration). Note: Take great care no t to damage the coils o f the alternator when locating any tools through the rotor.

10.8a T ypical service to o l fo r rem oving the ro to r

10.8c Using a tw o-leg ge d p u ller

10.8d Remove th e W ood ruff key fo r safekeeping

A r o to r h o ld in g to o l can e a s ily b e m ad e u sin g tw o s trip s of s te e l b o lte d to ge the r in th e m iddle, w ith a b o lt th ro u g h ea ch e n d w h ich lo ca te s in to the s lo ts o r h o les in th e ro to r. Do n o t a llo w th e b o lts to e x te n d to o fa r th ro u g h th e r o to r o th e rw is e th e coils cou ld be damaged. 6 If the alternator sta tor is located in the engine side cover, the rotor can be held with a strap wrench (see illustration). 7 W ith th e rotor securely held, unscrew the centre nut. 8 To remove the rotor from th e shaft it is necessary to use a puller - either a manufacturer’s service tool or a commercially available puller (see illustrations). To use the service tool, first screw th e body o f th e tool all the way into th e threads provided in the rotor. Hold the tool steady with a spanner on its flats and tighten th e centre bolt, exerting steady pressure to draw the rotor o ff the crankshaft. To use a puller, engage the puller legs either in the slots in th e rotor or thread them into the threaded holes in th e rotor, then tighten the centre bolt exerting steady pressure to draw th e rotor off th e crankshaft. Remove the W oodruff key from th e shaft for safekeeping, noting how it fits (see illustrations).

10.8e Note th e alignm ent o f th e key (A) and the s lo t in th e ro to r (B)

Two-stroke engines 2A»11

10.10a Undo the s ta to r screw s (A) and th e pulse g enerator coil s cre w s ( B ). . . 9 In most cases, th e alternator sta tor coils and ignition pulse generator coil are wired together and have to be rem oved as an assembly. If not already done, trace th e wiring back from the alternator and pulse generator, and disconnect it at the connectors. Free the wiring from any clips o r guides and fe ed it through to th e alternator. 10 Undo the screws securing th e stator and the pulse generator and lift them o ff together (see illu stra tio n ). W here fitte d , draw any rubber wiring bo ot ou t o f th e crankcase or engine side cover and carefully pull the wiring away, noting how it fits (see illustrations).

Installation }11 Installation is th e reverse o f removal, noting the following: 0 Ensure th e w iring is c orrectly rou ted before installing th e s ta to r a n d pulse generator. • Make sure that n o m etal ob jects have attached them selves to th e m agnets on the inside o f the rotor. • Clean th e ta pered end o f the crankshaft and the corresponding m ating surface on the inside o f th e ro to r w ith a suitable [ solvent. • Fit the W ood ruff key in to its s lo t in th e shaft, then install the rotor. • Tighten the ro to r centre nut to th e torque 1 setting specified in the Data section a t the end o f this manual. • Secure the wiring w ith any clips o r ties. • If applicable, refill the cooling system and bleed it (see Chapter 3).

11.1 Starter pinion assem bly is driven b y the sta rter m o to r sh a ft (arrowed)

10.10b . . . and rem ove th e a ssem bly no ting ho w th e w irin g fits

11 Starter pinion assembly and starter clutch - rem oval, in s p e c tio n a n d in s ta llatio n N ote 1: Two differen t set-u ps are used to transfer the starter m otor drive to the engine a sliding p in ion assem bly o r a starter (one­ way) clutch. The sliding p in ion assembly engages with th e driven gear on the variator pulley, o r a driven ge ar on th e crankshaft b e hin d the variator. The starter clutch is lo ca te d e ith er on th e back o f the alternator rotor o r on the crankshaft behind the variator. Note the point a t which the starter m otor shaft enters the engine case to loca te the appropriate assembly. N ote 2: This procedure can b e carried out with the engine in the frame.

S ta rter pinion assembly Removal 1 Note the position o f th e starter motor, then remove th e drivebelt cover (see Chapter 6) and locate th e pinion assem bly adjacent to the variator pulley (see illustration). 2 Where necessary, undo the bolts securing the starter pinion outer support and remove the support. 3 W ithdraw th e starter pinion assembly (see illustration).

10.10c N ote th e p o s itio n o f th e pulse gene rato r (A) and th e w irin g g ro m m e t (B) damage or deterioration, remove it. If a new boot is available, fit it on reassembly. 5 Check the starter pinion assembly fo r any signs o f dam age o r w ear, particularly fo r c hip pe d o r broken teeth on either o f th e pinions (see illu s tra tio n ). C heck th e corresponding teeth on th e starter m otor pinion and the variator driven gear. 6 Rotate th e outer pinion and check th a t it moves smoothly up-and-down th e shaft, and that it returns easily to its rest position. 7 The starter pinion assembly is supplied as a complete unit; if any o f the com ponent parts is worn or damaged, the unit w ill have to be renewed. 8 M ost m anufacturers recom m end th at th e starter pinion m echanism s hould no t be lubricated as any excess grease may contaminate the drivebelt and cause it to slip. H owever, a sm ear o f grease should be applied to both ends o f th e pinion shaft before reassembly.

Installation 9 Installation is th e reverse o f te m oval. Ensure the inner pinion engages w ith th e starter m otor shaft (see illu stratio n 11.1).

S ta rter (one-way) clutch Removal

4 Some pinion assem blies are fitte d w ith a rubber boot. If th e bo ot show s signs of

10 N ote th e position o f th e starter m otor, then remove either th e alternator cover (see Section 10) o r the driveb elt cover (see Chapter 6). 11 The operation o f th e starter clutch can be

11.3 Rem ove th e pinion assem bly, noting how it fits

11.5 C heck th e p in ion teeth. O u ter pinion should m ove s m o o th ly on sha ft

Inspection

2A«12 Two-stroke engines

S tarter idler ge ar (A) and driven ge ar (B)

11.14 Examine the idler gear teeth fo r w ear and damage

dm

11.15 Gear should rota te free ly in one d irection only

11.16a W ithdraw th e g ear fro m th e clutch

11.16b Undo th e bolts to rem ove the s ta rte r clutch from the a lte rna tor ro to r

checked w hile it is in place. Check th at the starter driven gear is able to rotate freely in the opposite direction to engine rotation, but locks when rotated in the other direction (see illu stratio n 11.13). If not, th e starter clutch is faulty and should be removed fo r inspection.

the rotor and undo the clutch mounting bolts (see illustration). 17 Inspect th e hub of th e driven gear fo r wear and scoring. Inspect th e clutch one-way mechanism; if a ring o f sprags is used, th e individual sprags should be smooth and free to rotate in th eir cage (see illu s tra tio n ); if individual sprags are spring-loaded, check that th e spring plungers are free to move.

mounted pum ps are generally either be lt- or gear-driven and rate o f o il delivery is either cable-controlled o r automatic. Note 2: This procedure can be carried ou t with the engine in the frame. If the engine has been removed, ignore the steps that do not apply.

Installation

1 Remove the body panels as necessary to access the oil pump (see Chapter 9). If required, remove the exhaust system (see Chapter 4). Note: On some engines, the externally-mounted pump is located behind a cover on the side of the crankcase; the pum p is driven, b y an extension o f the water pum p driveshaft. Remove the cover to access the pump. 2 On engines fitte d w ith a cable-operated pump, detach the cable from the pump pulley, then unscrew th e bolts securing th e cable bracket and remove th e bracket w ith the cable attached (see illustration).

R em oval 12 Remove the variator (see Chapter 6) or the alternator rotor (see Section 10) as appropriate. If the starter clutch is mounted on th e crankshaft behind th e variator, slide the clutch assembly o ff th e shaft. 13 Remove th e idler gear, noting how it fits (see illustration). In s p e c tio n 14 Inspect the teeth on th e idler gear and renew it if any are chipped o r w orn (see illustration). Check th e idler shaft and bearing surfaces fo r signs o f wear o r damage, and renew it if necessary. Inspect th e teeth of the driven gear. 15 Hold th e starter clutch assembly or the alternator rotor, as appropriate, and check that the starter driven gear rotates freely in one direction and locks in th e other direction (see illu s tra tio n ). If it doesn’t, the starter clutch is faulty and should be renewed. If individual com ponents are available, follow Steps 16 and 17 and check the condition of th e one-way mechanism. If there is any doubt about th e condition of th e starter clutch, have it tested by a scooter dealer. 16 Slowly rotate the driven gear and withdraw it from th e clutch (see illustration). If th e starter clutch is on the back o f the alternator rotor, use a strap w rench to hold

18 Installation is the reverse o f removal, noting th e following; • Apply a drop o f thread locking compound to the clutch mounting bolts. • Lubricate the driven gear hub with clean engine oil. • Rotate the driven gear to install i t in the starter clutch. • Ensure the idle r gear engages w ith the pinion on the starter m otor shaft.

12 Oil pump -

rem oval, in s p e c tio n , in sta llatio n a n d ble ed ing

sprags - th ey should be fla t on one side

Externally-m ounted pum p R em oval

^ ^ ^

N ote 1: Generally the oil pum p is located on the outside o f the crankcase, either in front or behind the cylinder, o r inside the engine unit eith er behind th e variator o r behind the alternator rotor. Externally-m ounted pum ps are generally driven via a shaft and worm gear on the crankshaft and the rate o f oil delivery is either cable-controlled (from th e throttle tw istgrip via a cable splitter - see Chapter 1) o r autom atic (centrifugal pump). Internally-

12.2 Remove th e oil pump cable and bracket

Two-stroke engines 2A«13

12.3 Detach th e o il hoses (arrowed) fro m the pum p unions

|3 On all models, release the clip securing the I oil inlet hose from th e oil tank to th e union on the pump and detach th e hose (see Illustration). Clamp th e hose and secure it in an upright position to m inimise oil loss. Releasethe clip securing the oil outlet hose to the union on the pump and detach th e hose. Wrap clean plastic bags around th e hose ends to prevent dirt entering th e system. Note: On some engines, th e inle t a n d outlet hoses are protected from the exhaust pipe by a heat-proof sheath. Remove th e sheath if Kassary but d o n’t fo rg et to re fit i t on reassembly. 4 On models fitted w ith a centrifugal pump (without cable operation), unscrew th e pump mounting bolts and remove th e bolts. 5 Withdraw the pump from th e crankcase and remove the wave washer (see illu s tra tio n ). Note how the ta b on th e back o f th e pum p locates in the slot in th e pump driveshaft. 6 Stuff a clean rag into th e crankcase opening to prevent dirt falling inside. 7 Remove the O -ring from the pum p body and discard it as a new one m ust be fitted on reassembly. 8 If fitted, remove the tw o nuts from the underside of th e pum p m ounting on the crankcase for safekeeping. 9 Ensure no dirt enters th e pum p body and clean it using a suitable solvent, then dry the pump thoroughly. Inspection 10 Check the pump body fo r obvious signs

12.12b Ensure tab (A) loca tes in s lo t (E

12.5 Rem ove th e w ave w asher

o f dam age especially around th e m ounting bolt holes. Turn th e pump drive by hand and check that th e pump rotates smoothly. Where fitted, check that the cable pulley turns freely and returns to rest under pressure o f th e return spring. 11 No individual internal com ponents are available fo r th e pump. If it is damaged or, if after bleeding th e operation o f th e pum p is suspect, renew it.

Installation 12 Installation is th e reverse o f removal, noting th e following: • F it a new O -ring on th e p u m p bo dy and lubricate i t w ith a sm ear o f grease (see illustration). • In stall th e wave washer, then insta ll the pump. • Ensure the ta b on th e b ack o f the pum p engages w ith th e s lo t in the driveshaft (see illustration). • Ensure the hoses are secured to the pum p unions with clips. • Bleed the pum p (see Step 24). • On m odels fitte d w ith a cable-operated pum p, check th e operation o f the cable (see Chapter 1). C a u tio n : A c c u ra te c a b le a d ju s tm e n t is im p o rta n t to e n s u re th a t th e o il p u m p d e liv e rs th e c o rre c t a m o u n t o f o il to th e e n gin e a n d is c o rre c tly s y nch ron ise d w ith th e thro ttle .

12.14 Remove th e pum p fro m the crankcase

12.12a Fit a new p u m p b o d y O -ring

Internally-m ounted pum p Removal 13 Trace the oil inlet hose from the oil tank to the engine unit and rem ove eith er th e drivebelt cover o r the alternator cover. Remove either the variator (see Chapter 6) or the alternator ro to r (see Section 10) as applicable. 14 Undo th e screw s securing th e oil pump, then w ithd ra w th e pum p (see illu s tra tio n ). W here fitte d, slide th e rubber grom m et securing th e hoses ou t o f its c u to u t in th e crankcase. 15 If the pum p is belt-driven, note how the drive ta b on the back o f the pump locates in th e slot in th e driven pulley. If th e pum p is being rem oved rather th an ju st being displaced fo r belt renewal, detach th e cable from the pump pulley noting how it fits. 16 Release th e clip securing th e oil inlet hose from the oil tank to the union on th e pump and detach the hose (see illu stratio n). Clamp the hose to m inimise oil loss. Release th e d ip securing th e oil outlet hose to th e union on the pum p and detach th e hose. W rap clean plastic bags around the hose ends to prevent dirt entering the system. 17 Ensure no dirt enters the pump body and clean it usincf a suitable solvent, then dry the pump thoroughly. 18 To remove th e pum p drivebelt, first undo th e screw securing the b e lt cover, w here fitte d, th en rem ove th e cover and th e plate

12.16 D etach th e o il hoses fro m th e pum p

2A»14 Two-stroke engines

12.18a Remove the p um p d rivebelt cover

12.18b Remove the b e lt. . .

12.18c . . . th en slide o ff th e d rive pulley

behind it noting how they fit (see illustration). If a spacer is fitted to the crankshaft, slide it off. Slip the belt o ff the pulleys, then slide off th e drive pulley noting which w ay round it fits (see illustrations). 19 Remove th e pump driven pulley and the thrustwasher behind it (see illu stratio n). On engines where the w ater pum p is located inside the crankcase halves, note how the oil pump drive locates on th e water pump shaft. 20 To remove th e pum p drive gear, use circlip pliers to remove the circlip, then slide the gear off th e shaft. If th e drive gear, or drive pulley, is retained by a ring nut, hold th e crankshaft to prevent it turning, th en use a peg spanner or punch to undo the ring nut. Note th e drive pin in the shaft and remove it for safekeeping if it is loose.

Slide the drive pulley onto the crankshaft with the shoulder innermost. In stall th e th rustw asher between the crankcase and the driven pulley. • Where fitted, secure the pum p drivegear with a new circlip. • Where fitted, fit a new O-ring on the pump bo dy an d lubricate it w ith a sm ear o f grease. • Ensure the hoses are secured to the pump unions with clips. • Bleed the pum p (see Step 24). • On m odels fitte d with a cable-operated pum p, check the operation o f the cable (see Chapter 1). C a u tio n : A c c u ra te c ab le a d ju s tm e n t is im p o rta n t to en sure th a t th e o il p u m p d e liv e rs th e c o r r e c t a m o u n t o f o il to the en gin e a n d is c o rre c tly synch ron ise d w ith th e throttle.

Disconnect th e oil o u tlet hose from th e carburettor and crank th e engine w ith th e kickstarter until oil, without any air mixed with it, flows out th e hose, then reconnect the hose and secure it with the clip. Alternatively, fill an auxiliary fuel tank with a 2% (50:1) petrol/twostroke oil m ix and connect it to the carburettor. Disconnect th e oil ou tlet hose from the carburettor, start the engine and run it until oil, without any air mixed with it, flows ou t the hose, then reconnect th e hose and secure it with the clip. W arning: N eve r r u n th e engine w ith o u t a n o il s u p p ly o r cra n k the e ngine on the e le ctric sta rte r w ith o u t an o il sup ply. N eve r cran k th e engine w ith th e ig n itio n ON and th e spa rk p lu g cap d isco nn ecte d fro m the spa rk p lu g as th e ig n itio n system m ay be damaged.

In s p e c tio n 21 Follow Steps 10 and 11 to check th e condition o f the pump. If the pum p is gear driven, check the condition of th e pump drive and driven gears and renew them if necessary. 22 If the pump is belt-driven, check along the length of th e pump drivebelt for splits, cracks or broken teeth and renew the belt if necessary. The belt should be renewed regardless of its condition at the service interval specified in Chapter 1, or during the course o f dismantling. In s ta lla tio n 23 Installation is th e reverse o f removal, noting th e following:

12.19 Rem ove th e pum p driven pulley

• •

Bleeding 24 Bleeding the pum p is th e process of removing air from it and allowing it to be filled w ith oil. First ensure that th e inlet hose from the oil tank and th e oil filte r are com pletely filled w ith oil. If necessary, detach the hose from th e pump and wait until oil flows from the hose, then reconnect it. 25 Loosen the bleed screw on the pump and w ait until oil, w ithout any air m ixed w ith it, flow s out the hole, then tighten th e screw (see illustrations). 26 Ensure the ignition sw itch is OFF.

12.25a Bleed screw on cable-operated pump

A

13 Crankcase halves and main bearings

^ «

N ote: To separate the crankcase halves, the engine unit m ust be rem oved from the frame.

Separation 1 Follow the procedure in Section 4 and remove the engine from th e frame. 2 Before the crankcase halves can be

12.25b Bleed screw on centrifug al pum p

Two-stroke engines 2A*15

13.3 Loosen th e c rankcase b o lts evenly in a cris s -c ro s s sequence separated the following components m ust be removed: ! • Alternator (see Section 10). • Variator (see Chapter 6). • Cylinder head (see Section 6). I t Cylinder (see Section 7). • Piston (see Section 8). | • Starter m otor (see Chapter 10). ■ • Oil pump (see Section 12). • Water pump (see Chapter 3). • Reed valve (see C hapter 4). 3 Tape some rag around the connecting rod to prevent it knocking against th e cases, then loosen the crankcase b olts evenly, a little a t a time and in a criss-cross sequence until they are all finger-tight, then rem ove them (see illustration). N ote: Ensure that all th e crankcase bolts have been rem oved before attempting to separate the cases.

I

•ISW31 M ake a c a rd b o a rd te m p late ih U M si 0f tfie cran kcase a n d pu n c h a hole fo r ea ch b o lt location. This w ill ensure a ll b o lts are installed c orrectly on reassem bly - th is is im portant as som e b o lts m a y b e o f different lengths.

HiNT

4 Remove the right-hand crankcase half from |the left-hand half by drawing it o ff the righthand end of the crankshaft. The cases will be a tight fit on th e crankshaft and m ost Lmanufacturers produce a service to o l to facilitate this procedure. Alternatively, use the

13.4 D raw in g th e rig ht-h an d cran kcase h a lf o ff th e c ran ksha ft

set-u p shown, ensuring equal pressure is applied on both sides of the puller arrangement at all times (see illu stratio n). If th e puller is placed across the end o f the crankshaft, thread th e old alternator centre nut on firs t to protect th e threads. N ote : I f the crankcase halves d o n o t separate easily, first ensure all fasteners have been removed. Apply steady pressure with the tools described and heat the bearing housings with a h o t air gun. Do n o t try and separate the halves by levering against the m ating surfaces as they are easily scored and w ill n ot seal correctly afterwards. Do n o t strike the ends o f the crankshaft with a hammer as damage to the end threads o r the shaft itself will result. 5 Now press the crankshaft assembly out of the left-hand crankcase half - again, a service to ol will be available. Alternatively, use th e set-u p shown (see illu s tra tio n ). Thread th e old variator nut onto th e end of th e crankshaft to pro tect the th reads and make sure th e crankshaft assembly is supported to prevent it dropping if it suddenly comes free. 6 If fitted, remove the crankcase gasket and discard it as a new one m ust be used on reassembly. 7 Remove th e dowels from either crankcase half fo r safekeeping if they are loose. 8 On engines where th e oil pump is driven off th e crankshaft, remove the pum p driveshaft and th e shaft bush. If necessary, heat th e crankcase around th e bush w hile applying pressure to th e shaft.

9 On engines w here th e w ate r pum p is located inside th e crankcase halves, remove th e circ lip from the ou te r end o f th e pum p shaft, then press th e shaft and its bearings out of th e crankcase. Check th e condition o f the bearings and renew them if necessary (see Tools a n d W orkshop Tips in th e Reference section). The pum p seal is located in the crankcase - have a new seal fitte d b y a scooter dealer or automotive engineer. 10 Note th e position o f the cran ksha ft oil seals and measure any inset before removing them (see illustration). Note which way round th e seals are fitte d. Rem ove th e seals by tapp in g th em gently on one side and then pulling them out with pliers (see illustration). Discard the seals, as new ones m ust be fitted on reassembly. 11 The main bearings w ill either remain in place in th e crankcase halves during disassembly or come ou t w ith the crankshaft assembly (see Section 14). If th e main bearings have failed, excessive rumbling and vibration w ill be fe lt when th e engine is running. Sometimes this m ay cause the oil seals to fail, resulting in a loss o f com pression and poor running. Check th e condition o f the bearings (see Tools and Workshop Tips in th e Reference section) and only rem ove them if th ey are unserviceable. Always renew both main bearings at the same time, never individually. 12 To rem ove the bearings from th e cases, heat the bearing housings w ith a hot air gun and ta p them ou t using a bearing driver or

2A«16 Two-stroke engines

___ cl___________ 13.12 Driving a m ain bearing o u t o f th e crankcase .

13.18 Inspect th e m ounting bushes (A) and th e main bearing housings (B)

13.22 Tap th e bearing o n to th e c rankshaft - do n o t use e xcessive fo rce

suitable socket (see illustration). Note which way round the bearings are fitte d . If the bearings are stu ck on th e crankshaft, they m ust be removed w ith an external bearing puller to avoid dam aging th e crankshaft assembly. N ote: On some engines th e main bearings are fitted in the crankcases p rio r to assembly, on others they are fitte d to the crankshaft. Consult a scooter dealer fo r details before installing new bearings. 13 If required, rem ove th e transmission assembly from th e left-hand crankcase half (see Chapter 6).

20 Inspect th e crankshaft assem bly and bearings (see Section 14).

14 Remove all traces o f old gasket from the crankcase m ating surfaces, taking care not to nick or gouge the soft aluminium if a scraper is used. Wash all the components in a suitable solvent and dry them w ith compressed air. C aution: B e very ca re fu l n o t to dam age the c ra n kca se m a tin g s u rfa c e s w h ic h m ay r e s u lt in lo ss o f cra n k c a s e p re ssure c a u sing p o o r e n gin e p e rfo rm a n c e . C heck b o th cra n kca se h a lve s v e ry c a re fu lly fo r cracks a n d da m aged threads. 15 Small cracks o r holes in aluminium castings can be repaired with an epoxy resin adhesive as a temporary measure. Permanent repairs can only be effected by welding, and only a specialist in this process is in a position to advise on the economy or practical aspect of such a repair. On some engines, the crankcase halves can be renewed individually, on others the tw o halves are only available together as a matching set consult a scooter dealer for details. 16 Damaged th reads can be econom ically

reclaimed by using a thread insert (see Tools and Workshop Tips in the Reference section). M ost scooter dealers and small engineering firm s offer a service o f this kind. Sheared screw s can usually be removed w ith screw extractors (see Tools and Workshop Tips in th e Reference section). If you are in any doubt about removing a sheared screw, consult a scooter dealer or automotive engineer. 17 Always wash th e crankcases thoroughly after any repair work to ensure no dirt or metal swarf is trapped inside when the engine is rebuilt. 18 Inspect the engine mounting bushes (see illu s tra tio n ). If they show signs of deterioration renew them all a t th e same time. To remove a bush, first note its position in the casing. Heat the casing w ith a ho t a ir gun, then support the casing and drive th e bush o u t w ith a hammer and a suitably-sized socket. Alternatively, use tw o suitably-sized sockets to press th e bush out in the jaws o f a vice. Clean th e bush housing with steel wool to rem ove any corrosion, th en reheat th e casing and fit the new bush. N ote: Always sup po rt the casing when removing o r fitting bushes to avoid breaking the casing. 19 If th e main bearings came out with th e crankshaft assembly, o r if they have been removed from th e cases fo r renewal, inspect the bearing housings (see illustration 13.18). If a bearing outer race has spun in its housing, the inside o f th e housing w ill be damaged. A bearing locking compound can be used to fix th e outer race in place on reassembly if the damage is not too severe. Note: If a bearing has spun in its housing the bearing itself is likely to be damaged internally and should be renewed.

13.23 Ensure th e n ew o il seals are installed correctly

13.25a Pulling th e cran ksha ft into the case w ith a service t o o l . . .

Inspection

Reassembly 21 If th e main bearings are to be fitte d into the crankcase halves, heat the bearing housings with a hot air gun, then install them using a bearing driver o r suitable socket which bears onto the outer race only. 22 If th e main bearings are to be fitted onto the crankshaft, heat them first in an oil bath to around 100°C, then press them onto th e shaft using a suitable length o f tu be th a t ju st fits over th e shaft and bears onto th e inner race only (see illu s tra tio n ). If th e bearings are difficult to fit they are not hot enough. W arning: This m u s t be done very c a re fu lly to a v o id th e r is k o f person al injury. 23 Fit th e new crankshaft oil seals into the crankcase halves and drive th em to the previously measured inset using a seal driver or socket (see Step 10). Ensure the seals are fitted th e right w ay round and that they enter the cases squarely (see illustration). 24 On engines where the w ater pum p is located inside th e crankcase halves, ensure the pum p com ponents are fitte d before joining th e cases (see Step 9). 25 Fit th e crankshaft assembly into th e lefthand crankcase half first, ensuring that the connecting rod is aligned w ifh the crankcase mouth. Lubricate th e shaft, seal and bearing with the specified two-stroke oil and tape some rag around th e connecting rod to prevent it knocking against the cases. If the main bearing is in the crankcase half, pull the assembly into

A

13.25b . . . and w ith a hom e-m ade to o l

Two-stroke engines 2A»17

13.26 Install the c rankcase d ow els (A) and gasket (B)

13.27 Installing the rig ht-h an d crankcase half

checked through oilw ays (arrowed) placeeither with a service tool or using th e setupshown (see illustrations). If the main bearing isonthe crankshaft, heat the bearing housing in thecrankcase with a hot air gun before fitting the crank assembly. Note: Avoid applying direct heat onto the crankshaft oil seal. If required, a freezespray can be used on the bearing itself to aidinstallation. Ensure the bearing is fitted fully intoits housing. 26 If applicable, allow th e case to cool, then wipe the mating surfaces of both crankcase halves with a rag soaked in a suitable solvent andfit the dowels. Fit th e crankcase gasket or apply a small amount o f suitable sealant to the mating surface of th e left-hand case as required (see illustration). 27 Now fit the right-hand crankcase half. Lubricate the shaft, seal and bearing with the r specified two-stroke oil. If th e main bearing is inthecrankcase half, press th e crankcase half intoplace, either with a service tool or with the

set-u p used in Step 25 (see illu s tra tio n ). If necessary, place a th ic k washer ove r th e centre of the right-hand crankcase to protect th e aluminium. If th e main bearing is on th e crankshaft, heat th e bearing housing w ith a ho t air gun before fittin g th e crankcase half and, if required, use a freeze spay on th e bearing. Note: Avoid applying direct heat onto the crankshaft oil seal. 28 Check th at th e crankcase halves are seated all the w ay round and th a t th e main bearings are pressed fully into their housings (see illu s tra tio n s ). If the casings are not c orrectly seated, heat th e bearing housings w hile applying firm pressure w ith th e assembly tools used previously. Note: Do not attem pt to p u ll the crankcase halves together using th e crankcase bolts as the casing w ill crack and be ruined. 29 Clean th e threads of th e crankcase bolts and install them finger-tight, then tighten them

seated on the gasket evenly a little at a tim e in a criss-cross sequence to th e torque setting specified in the Data section. Support the connecting rod and rotate th e crankshaft b y hand - if there are any signs o f undue stiffness, tig h t or rough spots, or o f any other problem, th e fault m ust be rectified before proceeding further. 30 If necessary, trim, th e crankcase gasket flush with th e mating surface fo r the cylinder (see illustration). 31 W here fitte d , lubricate the oil pum p driveshaft and install the shaft and th e shaft bush; ta p th e bush into its seat with a hammer and suitable-sized socket (see illu stratio ns). Rotate th e crankshaft to ensure th e oil pump drivegears are correctly engaged. 32 Install the rem aining com ponents in the reverse order of removal.

14 Crankshaft assembly and big-end bearing

1 To access th e crankshaft and th e big-end bearing, th e crankcase m ust be split into tw o parts (see Section 13). 2 The crankshaft assembly should give many thousands o f m iles o f service. The m ost likely problems to occur will be a w orn small or bigend bearing due to p o o r lubrication (see illu s tra tio n ). A w orn big -e nd bearing will produce a pronounced knocking noise, most audible when th e engine is under load, and increasing as engine speed rises. This should not be confused w ith small-end bearing wear,

® -4 € 13.31a Install th e oil pum p s h a ft. . .

^ A,

-

%

14.2 The c ra n k assem bly b ig -e nd (A) and m ain b earing s (B)

«A

2A*18 Two-stroke engines which produces a lighter, metallic rattle (see Section 8).

Inspection 3 To assess th e condition of the big-end bearing, hold th e crankshaft assembly firmly and push and pull on the connecting rod, checking fo r any up-and-dow n freeplay betw een the tw o (see illu s tra tio n ). If any freeplay is noted, th e bearing is w orn and either the bearing or the crankshaft assembly w ill have to be renewed. N ote : A small am ount o f b ig -e nd side clearance (side-toside m ovement) is acceptable on the connecting rod. C onsult a scoo te r dealer about th e availability o f parts. Note: If a new bearing is available, fitting it is a specialist task which should be le ft to a scoo te r dealer o r automotive engineer. 4 Inspect the crankshaft where it passes through the main bearings fo r wear and scoring. The shaft should be a press fit in the bearings; if it is w orn o r damaged a new assembly w ill have to be fitte d. Evidence of extreme heat, such as discoloration or blueing, indicates that lubrication failure has occurred. Be sure to check the oil pump and bearing oil ways before reassembling the engine. 5 If available, place the crankshaft assembly on V-blocks and check the runout at the main bearing journals (B and C) and at either end (A and D) using a dial gauge (see illustration). If the crankshaft is o u t-of-tru e it w ill cause excessive engine vibration. If there is any do ub t about th e condition of th e crankshaft have it checked by a scoo te r dealer or autom otive engineer. N ote : The crankshaft assem bly is pressed together and is easily damaged i f it is dropped. 6 Inspect th e threads on each end of the crankshaft and ensure that the retaining nuts for the alternator rotor and the variator are a good fit (see illustration). Inspect the splines for the variator pulley on th e left-hand end o f the shaft. Inspect th e taper and the slot in the right-hand end of the shaft for th e alternator Woodruff key (see illu stratio n). Damage o r wear that prevents the rotor from being fitted securely will require a new crankshaft assembly. 7 W here applicable, inspect th e oil pump drivegear teeth on the crankshaft and on the pum p driveshaft fo r damage or wear (see

14.3 Any freeplay indicates a w orn big-end bearing

14.5 C heck cran ksha ft runout a t po ints A, B, C and D

illu s tra tio n ). Inspect th e ends of pump driveshaft where it runs in its bearings. Renew any components that are worn or damaged.

especially th e brakes, function properly before road testing the machine. Refer to Section 16 fo r th e recommended running-in procedure. 8 Upon completion o f th e road test, and after th e engine has cooled-dow n completely, check fo r air bubbles in th e engine oil inlet and outlet hoses (see Section 12). On liquidcooled models, check th e coolant level (see Daily (pre-ride) checks).

Reassembly 8 Follow th e procedure in Section 13 to install the crankshaft assembly.

15

Initial start-up after overhaul 16

Recommended running procedure

1 Make sure the oil tank is a t least partly full and th e pum p is correctly adjusted (see Chapter 1) and bled o f air (see Section 12). 2 On liquid-cooled models, make sure the coo lan t level is correct (see Daily (pre-ride) checks). 3 Make sure there is fuel in the tank. 4 With the ignition OFF, operate the kickstart to check that the engine turns over easily. 5 Turn th e ignition ON, start th e engine and allow it to run at a slow idle until it reaches operating temperature. Do not be alarmed if there is a little smoke from the exhaust - this w ill be due to the oil used to lubricate the engine com ponents during assem bly and should subside after a while. 6 If the engine proves reluctant to start, remove th e spark plug and check that it has not become wet and oily. If it has, clean it and try again. If th e engine refuses to start, go through th e fault finding charts at th e end of this manual to identify th e problem. 7 Check carefully fo r fuel and oil leaks and m ake sure the transm ission and controls,

1 Treat th e engine gently fo r the first few miles to allow any new parts to bed-in. 2 If a new piston, cylinder o r crankshaft assembly has been fitted, th e engine will have to be run-in as when new. This means a restraining hand on th e throttle until at least 300 miles (500 km) have been covered. There's no point in keeping to any set speed limit - th e main idea is to keep from labouring th e engine and to gradually increase perform ance up to th e 600 m ile (1000 km) mark. Make sure that th e throttle position is varied to vary engine speed, and use full throttle only for short bursts. Experience is the best guide, since it’s easy to tell when an engine is running freely. 3 Pay particular attention to the D aily (pre­ ride) checks at th e beginning of this manual and investigate th e cause o f any oil or, on liquid-cooled models, coolant loss immediately. Check th e tightness o f all relevant nuts and bolts.

V ■

14.6a Inspect th e shaft end threads and th e v ariator pulley splines (arrowed)

14.6b Inspect the sha ft ta pe r and slot (arrowed) fo r th e W oodruff key

A 14.7 Inspe ct th e oil p um p drivegear teeth

I

2B*1

Chapter 2 Part B: Four-stroke engines Contents Alternator - removal and in s ta llatio n...................................................... 16 Camchain tensioner - removal, inspection and in s ta llatio n .............. 8 Camchain, blades and sprockets - removal, inspection and installation ........................................................................................... 9 Camshaft and rockers - removal, inspection and insta llatio n............. 10 Crankcase halves and main bearings ................................................... 19 Crankshaft assembly and big-end b e a rin g ...........................................20 Cylinder - removal, inspection and in s ta llatio n............. ....................13 Cylinder head - removal and installation................................................ 11 Cylinder head and valves - disassembly, inspection and reassembly.............................................................................................12 Disassembly and reassembly - general in fo rm a tion........................... 5 Engine- removal and installation ......................................................... 4 General information................................................................................. 1 Idlespeed............................................................................. see Chapter 1

Initial start-up after overhaul ................................................................. 21 Major engine repair - general info rm a tion.......................... .................. 3 Oil cooler and pipes - removal and installation .................................... 7 Oil pump - removal, inspection and installation ................................... 18 Operations possible w ith th e engine in the fr a m e ................................ 2 Piston - removal, inspection and installation ....................................... 14 Piston rings - inspection and installation ..............................................15 Recommended running-in p ro c e d u re .................................................... 22 Spark plug g a p ....................................................................... see Chapter 1 Starter motor ..................................................................... see Chapter 10 Starter pinion assembly and starter clutch - removal, inspection and in sta lla tio n ................................................................... 17 Valve clearances ...................................................................see Chapter 1 Valve cover - removal and installation ................................................. 6

Specifications Refer to the Data section a t the end o f this manual fo r servicing specifications.

2B

Degrees of difficulty Easy, suitable for novice with little experience

F airly easy, suitable fo r beginner with som e experience

1 General information

The engine is a single cylinder, overheadcamshaft four-stroke, with either fan-assisted f air cooling (see Chapter 1) or pum ped liquid cooling (see C hapter 3). The cam shaft is L Chain-driven off the crankshaft and operates the valves via rocker arms. | The crankshaft assem bly is pressed together, incorporating the connecting rod. [ The crankcase divides vertically - the left-

^ ^

Fairly difficult, suitable fo r competent ^ DIY mechanic ^

Difficult, suitable for experienced DIY mechanic

hand crankcase is an integral part of th e drivebelt casing and gearbox.

2 Operations possible with the engine in the frame

Most components and assemblies, w ith the obvious exception o f the crankshaft assembly and its bearings, can be w orked on w ithout having to remove th e engine/transmission unit from th e fram e. However, access to some com ponents is severely restricted ,'a nd if a

^ ^

V e ry d ifficu lt, \ suitable fo r expert DIY S j o r professional ^

number o f areas require attention at th e same time, removal o f the engine is recommended, as it is an easy task to undertake.

3

Major engine repair general information

1 It is no t alw ays easy to determ ine if an engine should be com pletely overhauled, as a number o f factors m ust be considered. 2 High m ileage is not necessarily an indication th a t an overhaul is needed, while

2B*2 Four-stroke engines low mileage, on th e other hand, does not preclude the need for an overhaul. Frequency of servicing is probably th e single most important consideration. An engine that has regular and frequent oil and filter changes, as well as other required maintenance, will most likely give many miles o f reliable service. Conversely, a neglected engine, or one which has not been run-in properly, may require an overhaul very early in its life. 3 Exhaust smoke and excessive oil consumption are both indications that the piston rings and/or valve guide oil seals are in need of attention. 4 If the engine is making obvious knocking or rumbling noises, th e connecting rod and/or main bearings are probably at fault. 5 Loss of power, rough running, excessive noise and high fuel consum ption rates may also point to the need fo r an overhaul, especially if they are all present at the same time. If a complete service as detailed in Chapter 1 does not remedy th e situation, major mechanical work is the only solution! 6 An engine overhaul generally involves restoring the internal parts to the specifications of a new engine. The piston and piston rings are renewed and th e cylinder is rebored. The valve seats are reground and new valve springs are fitted. If the connecting rod bearings are worn a new crankshaft assembly is fitted and, where possible, the main bearings in the crankcase are renewed. The end result should be a like-new engine that will give as many trouble-free miles as the original. 7 Before beginning the engine overhaul, read through the related procedures to familiarise yourself with the scope and requirements of the job. Overhauling an engine is not all that difficult, but it is time-consuming. Check on the availability of parts and make sure that any necessary special tools and materials are obtained in advance. 8 Most work can be done w ith typical workshop hand tools, although precision measuring tools are required fo r inspecting parts to determine if they must be renewed. Often a dealer w ill handle th e inspection of parts and offer advice concerning reconditioning and renewal. As a general rule, time is the primary cost of an overhaul so it does not pay to install worn or substandard parts. 9 As a final note, to ensure maximum life and minimum trouble from a rebuilt engine, everything must be assembled with care in a spotlessly clean environment.

4 Engine rem oval and insta llatio n

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C aution: The engin e/tra nsm ission u n it is n o t heavy, how eve r rem oval and installation should be carried o u t w ith the

a id o f a n a ss is ta nt; person al in ju ry o r damage could occu r i f the engine falls o r is dropped.

Removal 1 The procedure for removing the four-stroke engine is the same as for two-stroke models. If required, drain th e engine oil (see Chap­ ter 1). Note: There is no external oil feed or external oil pump on four-stroke engines. 2 Refer to Chapter 2A, Section 4, for the rest of th e procedure.

Installation 3 Installation is the reverse of th e procedure in Chapter 2A. Note that if the engine oil was drained, or if any oil has been lost during overhaul, th e engine must be filled with the specified quantity of oil (see Data section at the end o f this manual) and the oil level checked as described in Daily (pre-ride) checks.

5 Disassembly and reassembly general inform ation

each other during engine operation together. These ‘mated’ parts must be re-used or renewed as an assembly. 5 Complete engine disassembly should be done in th e following general order with reference to the appropriate Sections (refer to Chapter 6. for details of transmission components disassembly): • Remove the valve cover. • Remove the camshaft and rockers. • Remove the cylinder head. • Remove the cylinder. • Remove the piston. • Remove the alternator. • Remove the starter m otor (see Chapter 10). • Remove the water pump if fitted internally ] (see Chapter 3). • Remove-the oil pump. • Separate the crankcase halves. • Remove the crankshaft.

Reassembly 6 Reassembly is accomplished by reversing I the order of disassembly.

6 Valve cover rem oval and installation

Disassembly 1 Before disassembling th e engine, the external surfaces of the unit should be thoroughly cleaned and degreased. This will prevent contamination of the engine internals, and w ill also make working a lot easier and cleaner. A high flash-point solvent, such as paraffin, can be used, or better still, a proprietary engine degreaser such as Gunk. Use old paintbrushes and toothbrushes to work the solvent into the various recesses of th e engine casings. Take care to exclude solvent or water from the electrical components and intake and exhaust ports. W arning: The use o f p e tro l (gasoline) as a clea nin g ag en t s h o uld be avo ide d because o f the ris k o f fire. 2 When clean and dry, arrange the unit on the workbench, leaving suitable clear area for working. Gather a selection of small containers and plastic bags so that parts can be grouped together in an easily identifiable manner. Some paper and a pen should be on hand to permit notes to be made and labels attached where necessary. A supply o f clean rag is also required. 3 Before commencing work, read through the appropriate section so that some idea of the necessary procedure can be gained. When removing components it should be noted that great force is seldom required, unless specified. In many cases, a com ponent’s reluctance to be removed is indicative of an incorrect approach or removal method - if in any doubt, recheck with the text. 4 When disassembling th e engine, keep ‘mated’ parts that have been in contact with

A

Note: This procedure can be carried out with I the engine in the frame. If the engine has been I removed, ignore the steps that do no t apply.

Removal 1 Remove th e body panels as necessary to 1 access the cylinder head (see Chapter 9). 2 On some air-cooled engines, the engine I cowling covers the valve cover - pull the cap I off th e spark plug, then remove the screws I securing the engine cowling and remove it. [ Note that it may also be necessary to remove I th e fan cowling to access th e valve cover. [ Note: Some cowlings are clipped together - I take care not to damage the fixing lugs when | separating them. 3 Loosen the clips securing any breather I hose or PAIR valve hose to th e valve cover | and detach the hoses (see illustration). 4 Unscrew the bolts securing the valve cover I

6.3 Location o f breather hose (A) and P valve hose (B)

Four-stroke engines 2B»3 and remove them, together with any washers, then lift the cover o ff (see illustration). If the cover is stuck, ta p around the jo in t face between the cover and the cylinder head with Isoft-faced m allet to free it. Do not try to lever the cover o ff as th is may damage th e sealing surfaces. 5 Remove the gasket and discard it, as a new one must be used. Note th a t on some engines the gasket incorporates a camshaft endcap.

Installation 6 Clean the mating surfaces of th e cylinder head and th e valve cover w ith a suitable solvent to remove any traces o f old gasket or sealant. 7 Lay the new gasket on to th e valve cover, making sure it fits correctly into the groove (see illustration). If a cam shaft end cap is used, apply a suitable sealant around th e edgeof the cap before installing it. | Position th e valve cover on the cylinder head, making sure th e gasket stays in place. Install the cover bolts w ith th eir washers, if fitted, then tighten the bolts evenly and in a Icriss-cross sequence to th e to rq ue setting i specified in the Data section. [ 9 Install the remaining com ponents in th e reverse order of removal.

6.4 L ift o ff th e valve c ove r - note the gasket (arrowed) washers where fitted, and remove th e cooler and pipes. 5 If required, unscrew the banjo bolt securing each pipe to the cooler and detach the pipes. Discard the pipe sealing washers as new ones must be used.

Installation 6 Installation is th e reverse of removal, noting the following: • Always use new sealing washers on the pipe unions. • Tighten the banjo bolts securely. • Fill the engine with oil (see Chapter 1) and check the o il level (see D aily (pre-ride) checks).

1 Remove the body panels as necessary to access th e engine (see Chapter 9). 2 If necessary, displace th e c arburettor to access th e cam chain tensioner (see Chap­ ter 4). 3 On air-cooled engines, remove the screws

8.5a Rem ove th e c ap b o lt and spring . . .

8.5b . . . th en w ith d ra w th e tensioner

7 Oil cooler and pipes 11, removal a n d in sta lla tio n

;|x

Note: This procedure can be carried o u t with | theengine in the frame. If the engine has been ■ removed, ignore the steps that do not apply.

Removal 11 Remove the body panels as necessary to access the oil cooler (see Chapter 9). 1 2 Drain the engine oil (see Chapter 1). [ 3 On air-cooled engines, remove th e screws [ securing the engine cowling and remove the | cowling. 1 4 Unscrew the banjo bolt securing each pipe

7.4 Oil pipe b anjo bo lts (A) and cooler m ou ntin g 1)olts (B) securing th e engine cowling and remove the cowling. 4 Undo the tensioner ca p b o lt (see illu s tra tio n ). N ote any sealing w asher or O-ring fitte d to th e b o lt and discard it, as a new one m ust be fitted. 5 On some tensioners, the cap bolt retains a spring in th e te nsioner body; w ithd ra w th e spring, then unscrew the tensioner mounting bolts and w ithd ra w th e te nsioner from th e cylind er (see illu s tra tio n s ). On others, th e te nsioner is a sealed unit; to release th e te nsioner plunger before rem oving th e tensioner, insert a small flat-b lad ed screwdriver into th e end o f the tensioner so that it engages th e slotted plunger, then turn th e screw driver clockw ise to retract th e plunger. Hold th e screwdriver in this position w hile undoing th e te nsioner m ounting bolts

8 Cam chain tensioner -

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rem ova l, in s p e c tio n and in sta llatio n N ote: This procedure can be carried out with the engine in the frame. I f the engine has been removed, ignore th e steps that d o not apply.

Removal

2B*4 Four-stroke engines

8.5c Use a sm all screw driver to r etrac t th e p lu n g e r. . .

8.5d . . . w hile the te nsion er is rem oved

8.8 Release th e ratch et and che ck the operation o f th e plunger

and withdraw th e tensioner from th e cylinder (see illustrations). Release the screwdriver the plunger will be released, but it can easily be reset for installation. 6 Remove the gasket from th e base o f th e tensioner or from th e cylinder and discard it, as a new one must be used.

13 If th e tensioner is a sealed unit, retract the plunger as before w ith a small screwdriver, then hold it in this position while the tensioner is - installed and th e mounting bolts are tightened. The plunger should extend when the screw driver is withdraw n. Fit a new washer or O-ring to the cap bolt and tighten the bolt securely. 14 It is advisable to remove the valve cover (see Section 6) and check that the cam chain is tensioned. If it is slack, th e tensioner plunger did not release. Remove the tensioner and check th e operation o f the plunger again. 15 Install th e remaining com ponents in the reverse order of removal.

camshaft sprocket. On these engines, follow the procedure below to displace the sprocket and chain from the camshaft, but note that the camshaft itself m ust be removed in order to remove th e sprocket and chain from the engine (see Section 10). 3 If th e cam chain and, in some cases, the tensioner blade is being removed, access will be required to the crankcase and the crankshaft. If th e cam chain is on th e left-hand side of th e engine, refer to th e procedure in Chapter 6 and remove the variator. If the lefthand crankcase oil seal is fitted in a holder behind th e variator, remove the holder and the seal (see illu s tra tio n s ). If the oil pum p is driven by a chain from th e left-hand side of the crankshaft, remove the oil pum p driven sprocket, drive chain and drive sprocket (see Section 18). If the cam chain is on th e righthand side of the engine, remove th e alternator (see Section 16). If th e oil pump drive is on the right-hand side, remove th e oil pum p driven sprocket, drive chain and drive sprocket (see Section 18). 4 If not already done, remove th e spark plug. 5 Turn the crankshaft in the normal direction of rotation, using a spanner on the alternator rotor nut, until the piston is at to p dead centre (TDC) on th e com pression stroke (all valves are closed and a small clearance can be felt at each rocker arm). 6 Look fo r tim in g marks on the camshaft sprocket and the camshaft holder o r cylinder head, or alternatively, look fo r timing marks on the alternator rotor and the crankcase to confirm the position o f th e piston (see Chap­ te r 1, Section 32). Note the alignment of the tim ing marks. 7 Remove th e cam chain tensioner (see Section 8). 8 If an automatic decompressor mechanism is fitted to th e camshaft sprocket, follow the procedure in Steps 18 to 26 to remove, inspect and install the mechanism. 9 If th e camshaft is supported in a journal on the outside o f the cam shaft sprocket, undo the bolts securing th e journal and remove it. Remove any dow els fo r safekeeping if they are loose. 10 Unscrew the bolt(s) securing the camshaft sprocket to the cam shaft. To prevent the sprocket from turning, hold th e alternator or use a suitable holding to ol fitte d into the

Inspection 7 Examine th e te nsioner com ponents fo r signs of wear or damage. 8 Release th e ratchet mechanism from the tensioner plunger and check that the plunger moves freely in and out o f the tensioner body (see illustration). 9 Individual com ponents are generally not available - if the te nsioner or any o f its com ponents are worn or damaged, or if the plunger is seized in th e body, a new tensioner must be fitted.

Installation 10 Turn the engine in th e normal direction of rotation using th e kickstarter o r a spanner on th e alternator rotor nut. This removes all the slack betw een th e crankshaft and the cam shaft in th e fro n t run o f th e chain and transfers it to. th e back run w here it will be taken up by th e tensioner. 11 Fit a new gasket on the tensioner body. 12 If the spring has been removed from the tensioner, release th e ratchet mechanism and press the tensioner plunger all th e way into the tensioner body (see illustration 8.8). Install the tensioner in the cylinder and tighten the bolts. Fit a new sealing washer on the cap bolt, then install the spring and tighten the bolt securely.

9.3a If fitte d , rem ove th e o il seal h o ld e r.. .

9

Cam chain, blades and sprockets - rem oval, in s p e c tio n a n d in s ta llatio n

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N ote 1: This p rocedure can be carried out w ith th e engine in th e frame, although on some scooters access to the to p o f the engine is extremely restricted. N ote 2: The general procedure fo r removing the cam chain, blades and sprockets is the same fo r all engines. However, since the positioning o f the cam chain differs according to m anufacturer, i t w ill be necessary to rem ove com ponents from the le ft- o r righthand side o f the engine as applicable.

Removal 1 Remove the valve cover (see Section 6). 2 On some engines, the cam shaft is supported in a journal on th e outside o f the

9.3b . . . and lever o u t the seal

Four-stroke engines 2B«5

9.10 H old th e s p ro cke t and u ndo th e s p ro c k e t bo lts

9.11 D raw th e s p ro c k e t o ff the s ha ft and o u t o f th e chain

hole(s) in the spro cket (see illu s tra tio n ). Note: Some m anufacturers recom m end that new bolts and washers are use d on reassembly - check with a scooter dealer. 1 11 Draw the spro cket o ff th e end o f th e i camshaft, noting how it locates on th e shaft, and disengage it from th e cam chain (see illustration). W here fitte d , rem ove th e sprocket spacer fo r safekeeping. 12Mark the chain with paint so that if it is to be re-used it can be fitte d the sam e way round. Where fitted, remove th e thrustwasher from the end of th e crankshaft, then lower the cam chain dow n its tunnel, slip it o ff ,the sprocket on the crankshaft, and draw it out o f the engine (see illu s tra tio n s ). On some engines th e spro cket is a sliding fit on the

shaft; remove th e sprocket, noting how it fits (see illustration). 13 If required, undo the b o lt securing the cam chain tensioner blade and withdraw the blade, noting w hich w ay round it fits (see illustration). The guide blade can be removed when th e cylinder head has been removed (see Section 11).

from th e crankcases (see Sections 19 and 20). 15 C heck th e chain te nsion er blade and guide blade fo r w ear or dam age and renew them if necessary. Check the operation of the cam chain tensioner (see Section 8). 16 W here fitte d , che ck the com ponents of the automatic decompressor mechanism (see Step 22)

Inspection

Installation

14 C heck th e sprockets fo r w ear and damaged teeth, renewing them if necessary. If th e sprocket teeth are worn, th e chain is also worn and should be renewed. If the sprocket is a press-fit on th e crankshaft, pull it o ff with a bearing puller. If access is limited, it m ay be necessary to remove th e crankshaft assembly

9.12a Remove th e cran ksha ft thru stw ash er w he re fitte d

9.12b Lo w er th e cam chain dow n the tu n n e l. . .

17 Installation is th e reverse o f removal, noting the following: • Ensure the tensioner blade and guide blade are fitte d the correct way round. • Ensure any spacers and thrustwashers are installed correctly. • Ensure the p isto n is a t TDC on the com pression stroke and that a ll the tim ing marks align as described in Step 6. • Ensure any slack in the chain is in the back run where i t w ill be taken up b y th e tensioner. • Use new b o lts and washers to secure the camshaft sprocket i f recomm ended b y the manufacturer. C a u tio n : A f te r in s ta llin g th e c a m ch a in te n s io n e r, tu rn th e c ra n k s h a ft a n d c he ck th a t a ll th e tim in g m a rk s s t ill a lig n c o rre c tly . I f th e tim in g m a rk s a re n o t a lig n e d e x a c tly a s d e s crib e d , th e valve tim in g w ill be in c o rre c t a n d th e valves m ay s tr ik e th e p is to n , c a u s in g exte n sive dam age to th e engine.

9.12c . . . and d ra w it o u t o f th e engine

9.12d N ote h o w th e s p ro c k e t loca tes on th e pin (arrowed)

9.13 The te n s io n e r blade is s ecured by a piv o t b o lt (arrowed)

2B«6 Four-stroke engines

9.18b . . . and rem ove th e cover

Autom atic decompressor m echanism R em oval 18 Undo th e cam shaft sprocket centre bolt and lift o ff th e decom pressor mechanism cover (see illu stratio ns). Hold the alternator to prevent the sprocket from turning. 19 Undo the decompressor mechanism bolt, then hold the bob w eight return spring and w ithdraw the b o lt and sta tic w eight (see illustrations). 20 Lift o ff th e bo b w eight - note th e nylon bush on the back o f th e w eight and how it locates in th e slot in th e cam chain sprocket (see illu s tra tio n ). Remove the bush fo r safekeeping. 21 Lift the sprocket and its backing plate off the end o f the cam shaft, then disengage it from the camchain (see illustration).

In s p e c tio n 22 Inspect th e com ponents o f th e decom pressor mechanism. Check the nylon bush fo r wear and fla t spots and renew it if necessary. Tem porarily assemble th e mechanism on th e camshaft (see below) and check its operation - check the spring tension and ensure the bob weight does not bind on the cover. In s ta lla tio n 23 Check th at the piston is at TDC on the com pression stroke (see Step 6). Install the camshaft sprocket backing plate on th e end o f th e cam shaft (see illu s tra tio n ). Slip th e camshaft sprocket into the top of the chain, then take up the slack in th e lower run of the chain and fit the sprocket onto the camshaft, aligning th e timing mark on the sprocket with th e index mark on the camshaft holder (see

9.19a Undo th e a u to m a tic decom pressor

9.21 D isengage th e s pro c k et fro m the cam chain

illu s tra tio n ). N ote: To prevent th e backing plate falling o ff the end o f the camshaft while the sprocket is being installed, pass the blade o f a small screwdriver through th e centre of the sprocket, th e backing plate and the camshaft. 24 Apply some silicone grease to th e nylon bush and fit it onto th e back o f the cam timing bob w eight, then install th e bob w eight ensure th e bush locates in the slot in the cam chain sprocket (see illu stratio n 9.20). 25 Lift th e bob w eight return spring and install th e s ta tic weight, ensuring th at the spring is located over th e to p o f th e static w eight. Tighten the decom pressor mechanism b o lt to th e specified torque setting. Check the operation o f the mechanism - the bob w eight should move freely on its spindle and return to th e rest position under th e tension o f the spring. 26 Install the decom pressor mechanism cover, aligning th e small hole in the cover with the head o f the mechanism bolt. Fit the camshaft sprocket centre bolt and tighten it securely. Hold th e alternator to prevent the sprocket from turning.

10 Camshaft and rockers removal, inspection and installation

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Note: This procedure can be carried ou t with th e engine in th e frame, although on some scooters access to th e to p o f the engine is extremely restricted.

9.20 Note how the bush (arrowed) locates in the s lo t

is ta ll th e c am shaft s procket backing p la te . . .

9.23b . . . and th e c am sh aft spro cket

Four-stroke engines 2B*7 Removal Remove th e valve cove r (see Section 6). lere fitted, rem ove th e rubber insulating idfrom the to p o f th e cam shaft holder fo r ceeping, noting how it fits (see lustration). [Remove th e cam chain te nsioner (see Section 8). Where possible, rem ove th e cam shaft Brocket (see Section 9), then secure th e cam using a cable tie to prevent it dropping intothe engine. If th e camshaft is supported in journal on th e ou tside o f the cam shaft 10.1 Rem ove th e rub be r pad (where fitte d) sprocket, remove the journal, then displace e sprocket and lift o ff the chain (see Secchain; secure the chain to prevent it dropping n9). into th e engine. If th e cam shaft is in th e Stuff a clean rag into the cam chain tunnel camshaft holder, remove th e retaining plate or prevent anything fa llin g in to th e engine. circ lip and w ithd ra w th e cam shaft from th e Markthe end of th e camshaft so that it can be holder (see illu s tra tio n s ). N ote th a t th e refitted in the same position (TDC, all valves bearings m ay come out with the camshaft. closed) (see illustration). 6 If th e camshaft housing is an integral part of [On some engines, the cam shaft and th e cylinder head, remove th e retaining plate rockers are located in a separate holder. If the o r circ lip and w ithd ra w th e cam shaft (see ter is retained by long studs th a t also illu s tra tio n s ). Note th at th e bearings, where ire the cylinder head and cylinder to the fitted, may com e out w ith th e camshaft. kcases, check to see if the head is also 7 Mark the rocker arms so th at th ey can be ired by any smaller bolts, and if so, undo installed in their original positions. On some Km first (see illustration). Now unscrew the ishaft holder nuts o r bolts, evenly and a engines, th e rocker shafts are retained in the c am shaft housing by th e cam shaft housing i at a time in a cris s-cross pattern, until i are all loose and remove them. Lift off thebolts; on ce the housing has been removed, w ithdraw th e shafts carefully and remove the Ishaft holder (see illu s tra tio n ). If th e rockers, noting th e position o f any camshaft remains in th e cylinder head, lift it th rustw ashers on the shafts. On other ^ ja n d remove th e sprocket, then detach the

10.5a Camshaft h older is retained by fo u r nuts (A), b ut sm aller bo lts (B) m us t be loosened firs t

10.4 M ark th e e nd o f th e c a m s h a ft to aid reassem bly engines, the shafts are retained by a stopper b o lt o r circlip; rem ove the b o lt o r circlip, as applicable, and w ithd ra w th e shafts. Assemble the rockers and any thrustwashers on their shafts in th e correct order so that they can be installed in th e ir original positions. N ote : On som e engines th e rockers are located on one shaft, on others the intake and exhaust valve rockers have separate shafts. On engines w ith four-valve heads, th e rockers are fo rke d so th at th ey b e a r on tw o valves simultaneously.

Inspection 8 Clean all o f th e com ponents w ith a suitable solvent and dry them. 9 Inspect the cam shaft lobes fo r heat discoloration (blue appearance), score marks, c hipped areas, fla t spo ts and spalling.

10.5b L ift o ff th e c am sh aft h older

10.6a Rem ove the retaining

10 .6b

. . . a nd w ith d ra w th e c am sh aft

2B»8 Four-stroke engines frame to allow the head to be removed. If so, support the rear frame, then detach the lower end o f the rear shock absorber(s) and displace the shockfs). Raise the rear wheel until there is enough clearance to remove the head. C a u tio n : The en g in e m u s t be co m p le te ly coo l before be gin nin g th is proced ure o r the c ylind er head m ay becom e w arped.

Removal

10.12 insp ect th e c on ta c t surfaces (arrow ed) on th e r ocke r arm s fo r w ear and pittin g M easure each cam shaft lobe height w ith a micrometer and compare th e results with the specifications in th e Data section at the end of th is manual (see illu s tra tio n ). If dam age is noted o r wear is excessive, the camshaft must be renewed. 10 Check th e con ditio n o f th e cam shaft bearings and renew them if necessary (see Tools a n d Workshop Tips in the Reference section). If the bearing is on th e cam shaft it m ust be rem oved using a suitable bearing puller to avoid dam aging the shaft. If th e bearing is in the housing o r cylinder head, it may be possible to remove it w ith a bearing driver or suita ble socket th at bears on the outer race only. Alternatively, a puller will be required. N ote: Take great care when rem oving the bearings to avoid damaging othe r com ponents. I f necessary, consult a scooter dealer o r specialist engineer. 11 If th e camshaft runs directly in the cylinder head, inspect the bearing surfaces o f th e head and cam shaft holder and th e corresponding journals on the camshaft. Look fo r score marks, scratches and spalling. If damage is noted the relevant parts-m ust be renewed. 12 Blow th rough th e oil passages in th e rocker arms with compressed air, if available. Inspect th e fa ce o f th e rocker arm and th e contact area between the adjuster screw and the valve stem fo r pits and spalling (see illu s tra tio n ). Where fitte d, check th e articulated tip o f the adjuster screw for wear; the tip should move freely, but not be loose.

Check the rocker shaft fo r wear; if available, use a micrometer to measure th e diameter of th e shaft in several places; any difference in th e m easurements is an indication o f wear. Assemble th e rocker arm on its shaft - it should be a sliding fit w ith no discernible freeplay. Renew any com ponents th at are worn o r damaged.

11.5a Undo th e sm aller b o lts (arrowed) fir s t. . .

11.5b . . . th en u ndo th e m ain nuts (arrowed)

Installation 13 Installation is the reverse of removal, noting th e following: • Ensure th e pisto n is at TDC on the compression stroke before you start. • Lubricate th e shafts, bearing surfaces and bearings w ith clean engine oil before installation. • It is g o od pra ctice to use new circlips, where fitted. • Tighten the main cylinder head fixings before any smaller bolts. • Tighten the cylinder head fixings a little a t a time in a criss-cross sequence to the torque setting specified in the Data section. • Check the valve clearances (see Chapter 1).

11Cylinder head removal and installation

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N ote: On m ost scooters, this procedure can b e carried o u t with th e engine in the frame. However, in some cases there is insufficient clearance between the cylinder head and the

1 If fitte d, remove the oil cooler (see Sec­ tion 7). 2 Remove the carburettor and exhaust system (see Chapter 4). 3 On liquid-cooled engines, drain the cooling system (see Chapter 3). Detach th e coolant hoses from th e unions on the cylinder head, noting where they fit. Disconnect th e coolant tem perature sensor w iring connector. If required, remove the thermostat housing (see Chapter 3). 4 Remove the cam shaft and rockers (see Section 10). N ote: On some engines it is possible to remove the cylinder head with the camshaft and rockers in place, bu t in practice the camshaft and rockers m ust be removed in order to service the valves. The fixings fo r the camshaft holder may also secure the cylinder head. 5 Check to see which bolts secure the cylinder head; on some engines, in addition to th e main internal fixings, th e head is also secured by smaller, external bolts. Undo the smaller bolts first, then undo the main nuts or bolts, evenly and a little at a tim e in a criss­ cross pattern, until th ey are all loose and remove them (see illustrations). 6 Lift th e cylinder head o ff carefully, feeding th e cam chain down through the tunnel in the head (see illu s tra tio n ). If th e head is stuck, ta p around th e jo in t face betw een th e head and th e cylinder w ith a soft-faced m allet to free it. Do not try to lever th e head off as this may dam age the sealing surfaces. Note: A vo id liftin g th e cylinder o ff th e crankcase when the head is removed, otherwise a new cylinder base gasket will have to be fitte d (see Section 13). 7 Remove th e old cylinder head gasket and discard it, as a new one m ust be fitte d on reassembly; note any dowels in the head or

11.6 Lift o ff the c y lind er head

Four-stroke engines 2B»9

11.7a Discard th e o ld cylinder head g asket

I cylinder and remove them fo r safekeeping if theyare loose (see illu strations). 1 8 Secure the cam chain to prevent it dropping kitothe engine. 9 Inspect th e cylinder head gasket and the mating surfaces on th e cylind er head and cylinder fo r signs o f leaks, w hich could indicate that the head is warped. Refer to Section 12 and check th e head mating surface for warpage. 10 Clean all traces o f old gasket material from the cylinder head and cylind er w ith a suitable solvent. Take care not to scratch or gouge the soft aluminium. Be careful not to let any of th e gasket material fa ll into the crankcase, th e cylind er bore o r th e oil or coolant passages.

11.7b N ote the position o f dow els (arrow ed) in th e head . . .

11.7c . . . o r the c y lind er

12 Cylinder head and valves -

^

disassembly, inspection and reassembly

^ ^

Note: I f a valve spring compressor is available, th e hom e m echanic can rem ove th e valves from the cylinder head, grind in the valves and renew th e valve stem seal. If th e necessary measuring tools are available, you can assess the am ount o f wear on the valves and guides and measure the valve-to-seat contact areas.

Disassembly

1 Before you start, arrange to label and store th e valves and th eir related com ponents so th a t they can be returned to th eir original locations w itho ut getting mixed up (see Installation illustration). 11 Installation is th e reverse o f removal, 2 If not already done, clean all traces of old j noting the following: gasket material from th e cylinder head w ith a ■•Lubricate th e cylind er bore w ith clean suitable solvent. Take care not to scratch or I engine oil. gouge the s o ft aluminium . On liquid-cooled [ • Install a new head gasket - never re-use the engines, if th e th erm ostat is fitte d in th e I oldgasket. cylind er head, rem ove the therm o sta t (see • •Ensure the oil an d coo lan t holes in the Chapter 3). I gasket align with the cylinder. 3 Compress th e valve spring on th e first valve I $ Tighten the m ain cylinder head fixings first w ith a spring com pressor, m aking sure it is I before the smaller, external bolts. correctly located onto each end o f the valve I • Tighten the m ain cylinder he ad fixings assembly (see illustration). On the underside I evenly and a little a t a tim e in a criss-cross o f th e head, make sure th e plate on th e I pattern to the torque setting specified in the com pressor only contacts th e valve and not Data section. the soft aluminium o f th e head - if the plate is to o big fo r th e valve, use a spacer betw een $ On liquid-cooled engines, refill the cooling them. Do not compress th e spring any more I' system.

and rem ove th e collets

the guide, d e bu rr the area (1) above the c o lle t groove

th an is absolutely necessary to release th e collets. 4 Remove th e collets, using either needlenose pliers, a magnet or a screwdriver w ith a dab o f grease on it. Carefully release th e valve spring com pressor and rem ove th e spring retainer, noting w hich w ay up it fits, the spring, the spring seat, and th e valve from the head. If the valve binds in the guide (won’t pull through); push it back into th e head and deburr th e area around the collet groove with a very fine file (see illustration). Note: On some engines, two springs are fitted to each valve. 5 Once the valve has been removed, pull the valve stem oil seal off th e to p of th e valve guide with pliers and discard it, as a new one m ust be used on reassembly (see illustration).

12.1 Valve c om ponents

1 2 3

Collets 4 Spring seat Spring retainer 5 Valve Valve spring

12.5 Pull o ff th e o ld valve s tem o il seal (arrowed)

2B*10 Four-stroke engines

J

Safe

fc '

12.10 Check th e head fo r cracks. Inspect th e spark plug hole (A) and th e valve seats (B)

12.12 Check th e cylinder head f o r w arpage in th e directio ns s how n

12.14a M easuring th e valve stem diameter w ith a m icrom eter

6 Repeat the procedure fo r the remaining valve(s). Remember to keep th e parts fo r each valve together and in order so they can be reinstalled in th e correct location. 7 Next, clean th e cylinder head with solvent and dry it thoroughly. C om pressed air w ill speed th e drying process and ensure that all holes and recessed areas are clean. 8 Clean th e valve springs, collets, retainers and spring seats w ith solvent. W ork on the parts from one valve at a tim e so as not to mix them up. 9 Scrape off any carbon deposits that may have form ed on the valve, then use a motorised wire brush to remove deposits from the valve heads and stems. Again, make sure the valves do not get m ixed up.

warpage is excessive, renewed. Check vertically, horizontally and diagonally across th e head, m aking fo ur checks in all (see illu s tra tio n ). If there is any doubt about the condition o f the head consult a scooter dealer or specialist engineer. 13 Examine the valve seats in th e com bustion chamber. If they are deeply pitted, cracked or burned, it may be possible to have them repaired and recut by a specialist engineer, otherwise a new head will be required. The valve seats should be a uniform w idth all the w ay round (see illu stratio n 12.10). 14 If available, use a micrometer to measure th e valve stem diameter in several places (see illu s tra tio n ). Any difference in th e measurements is an indication of wear. Inspect th e valve face fo r cracks, p its and burned spots. Check th e valve stem and the c olle t groove area fo r cracks (see illu stratio n). Rotate th e valve and check for any obvious indication that it is bent. Check th e end of the stem for pitting and excessive wear. If any o f the above conditions are found, fit a new valve. If th e stem end is pitted or worn, also check th e con ta ct area o f the adjuster screw in the rocker arm. 15 Insert a known good valve into its guide it should be a sliding fit w ith no discernible freeplay. If th ere is freeplay, th e guide is probably worn. Have the guides checked by a scooter dealer or specialist engineer. If new valve guides are available, have them installed by a specialist w ho w ill also recut th e valve seats. If new guides are not available, a

specialist engineer may be able to bore out th e old ones and fit sleeves in them. Otherwise a new cylinder head will have to be fitted. Note: Carbon build-up inside the guide is an indication o f wear. 16 Check th e end of each valve spring for wear and pitting. Stand th e spring upright on a flat surface and check it fo r bend by placing a square against it (see illu s tra tio n ). If the spring is worn, o r th e bend is excessive, it m ust be renewed. Some manufacturers specify a service lim it fo r th e spring free length (consult a scooter dealer), but it is good practice to fit new springs when th e head has been disassem bled fo r valve servicing. Always fit new valve springs as a set. 17 Check the spring retainers and collets for obvious wear and cracks. Any questionable parts should not be re-used, as extensive damage w ill occu r in th e event o f failure during engine operation.

Inspection 10 Inspect the head very carefully for cracks and other damage (see illustration). If cracks are found, a new head will be required. 11 Inspect th e threads in th e spark plug hole. Damaged or worn threads can be reclaimed using a thread insert (see Tools and Workshop Tips in th e Reference section). M ost scooter dealers and small engineering firm s offer a service o f this kind. 12 Using a precision straight-edge and a feeler gauge, check th e head mating surface fo r warpage. Lay the straight-edge across the surface and try to slip the feeler gauge under it on either side o f th e combustion chamber. If th e feeler gauge can be inserted between the straight-edge and the cylinder head, the head is warped and must be either machined or, if

12.14b C heck the valve fa ce (A), stem (B) and c o lle t groove (C) fo r signs o f w ear and dam age

12.16 C heck th e valve springs fo r bending

Reassembly 18 Unless th e valve seats have been recut, before installing th e valves in th e head they should be ground-in (lapped) to ensure a positive seal between the valves and seats. This procedure requires coarse and fine valve grinding compound and a valve grinding tool. If a grinding tool is not available, a piece of rubber or plastic hose can be slipped over the valve stem (after the valve has been installed in th e guide) and used to turn the valve. 19 Apply a small amount of coarse grinding com pound to th e valve face, then slip the valve into th e guide (see illu stratio n).

12.19 Apply th e g rinding com pound sparingly, in sm all dabs, to th e valve face only

Four-stroke engines 2B *11

12.20a Rotate th e g rinding to o l b ack and forth between th e palm s o f you r hands

12.20b The v alv e fa ce a nd s ea t should sho w a un iform unbroken ring

Note: Make sure each valve is installed in its m eet guide a nd be careful n o t to g e t any grinding compound on the valve stem. 20 Attach th e grinding to o l (or hose) to th e valveand rotate the tool between th e palms of your hands. Use a back-and-forth motion (as though rubbing your hands together) rather than a circular m otion (ie, so th at the valve rotates alternately clockw ise and anti­ clockwise rather than in one direction only) (see illustration). Lift th e valve off th e seat and turn it at regular intervals to distribute the ■ grinding com pound properly. C ontinue th e grinding procedure until the valve face and seat contact areas are o f uniform w idth and j unbroken around the circum ference (see illustration). 21 Carefully remove the valve from the guide and wipe off all traces of grinding compound. Use solvent to clean th e valve and w ipe the seat area thoroughly w ith a solvent-soaked doth. 22 Repeat th e procedure w ith fine valve ’ grinding com pound, then repeat the entire procedure for the other valve(s).

23 W orking on one valve at a tim e, lay th e spring seat in place in the cylinder head, then install a new valve stem seal onto th e guide. Use an appropriate size deep socket to push the seal over th e end o f th e valve guide until it is felt to clip into place. Don’t tw ist or cock it, or it w ill not seal properly against the valve stem. Also, do n't remove it again or it will be damaged. 24 Lubricate th e valve stem w ith molybdenum disulphide grease, then install it into its guide, rotating it slow ly to avoid dam aging the seal. C heck th at th e valve moves up and down freely in the guide. Next, install th e spring, with its closer-wound coils facing down into th e cylinder head, followed by the spring retainer, w ith its shouldered side facing down so that it fits into th e to p of the spring. Note: On some engines, tw o springs are fitted to each valve. 25 A p ply a small am ount o f grease to the collets to hold them in place as the pressure is released from the spring. Com press the spring with th e valve spring com pressor and install the collets (see illu s tra tio n ). When compressing the spring, depress it only as far as is absolutely necessary to slip th e collets into place. Make certain th at th e collets are securely locked in their retaining grooves. 26 Repeat th e procedure fo r th e remaining valve(s). 27 Support th e cylinder head on blocks so th e valves can’t contact th e w orkbench top, then very gently ta p each of th e valve stems w ith a soft-faced hammer. This will help seat the collets in their grooves.

C heck fo r p ro p e r se a lin g o f ea ch valve b y p o u r in g a sm all a m o u n t o f solve nt in to th e valve p o r t w h ile h o ld in g the valve sh u t. I f th e s o lv e n t leaks past th e valve in to th e c o m b u s tio n chamber th e valve g rin d in g o p e ra tio n should be repeated.

13.3 Lift o u t th e cam chain g uide blade

13.4 Bolt (arrowed) secures th e cylind er to the crankcase

12.25 A sm all dab o f g rease helps to keep th e c o lle ts in p la ce du rin g insta llatio n

13C ylin d e r- removal,

inspection and installation

1^ SK,

N ote: On m ost scooters, this p rocedure can be carried o u t w ith th e engine in th e frame. However, in some cases there is insufficient clearance between the cylinder and the frame to a llo w th e cylind er to be rem oved. I f so, support the rear frame, then detach the lower end o f the rear shock absorber(s) and displace the shockfs). Raise the rear wheel until there is enough clearance to remove the cylinder.

Rem oval 1 Remove th e cylinder head (see Section 11). 2 On liqu id -co ole d engines, where applicable, detach th e coolant hose from the cylinder (see C hapter 3). 3 N ote th e location o f th e cam chain guide blade, then lift out th e blade (see illustration). 4 Where fitted, undo the bolt(s) securing the cylinder to the crankcase (see illustration). 5 L ift th e cylind er up o ff the crankcase, supporting th e piston as it becom es accessible to prevent it hitting the crankcase opening (see illu s tra tio n ). If the cylind er is stuck, ta p around th e join t face between the cylinder and th e crankcase w ith a soft-faced m allet to free it. D on’t a ttem p t to free th e cylinder by inserting a screwdriver between it and th e crankcase - you’ll damage th e sealing surfaces. When th e cylinder is removed, stuff a clean rag into th e crankcase opening around the piston to prevent anything falling inside.

13.5 Su pp ort th e p isto n as th e cylind er is rem oved

2B

2B*12 Four-stroke engines

13.8 Measure th e cylind er bo re in the directio ns shown 6 Remove th e cylinder base gasket and discard it, as new one m ust be fitte d on reassembly.

Inspection

surfa ce-to -p iston crow n relationship

7 Check the cylinder bore carefully fo r scratches and score marks. 8 If available, use a telescoping gauge and m icrom eter to measure th e diam eter o f the •cylinder bore to assess th e amount of wear, taper and ovality (see Tools and Workshop Tips in the Reference section). Measure near the to p (but below the level of the to p piston ring at"TDC), centre and bottom (but above the level of th e bottom ring at BDC) o f th e bore both parallel to and across the crankshaft axis (see illu stra tio n ). Calculate any differences between th e measurements to determine any ta per or ovality in th e bore. 9 Now measure an unworn part of th e cylinder bore (below the level of th e bottom ring at BDC) and com pare th e result to th e previous measurements to determine overall wear. 10 If th e bore is ta pered, oval, o r worn excessively, o r badly scratched, s cuffed 'o r scored, th e cylinder and piston will have to be renewed. N ote : I f no service lim it specifications (see Data section) are available to assess cylinder wear, calculate the pistonto-bore clearance to determ ine whether the cylind er is useable (see Section 14). Alternatively, check fo r a lip around the (unworn) top edge o f the cylinder bore as a rough indication o f wear. 11 If there is any do ub t about th e serviceability o f the cylinder, consult a scooter

dealer. Note: On some engines, the surface o f th e cylinder has a w ear-resistant coating which, when damaged o r w orn through, requires a new cylinder. On others, the cylind er can be rebored and an oversize pisto n fitte d (see Data section). Oversize pistons are n ot necessarily marked as such; in m any cases the only way to determ ine i f a cylinder has been rebored is to measure an unw orn area o f the bore and com pare the result w ith the specifications in the Data section. Some manufacturers mark cylinders a n d pistons w ith a size code during production; the size code (usually a letter) is stamped into the cylinder gasket surface and th e top o f the piston. It is important that new parts have matching codes. 12 Where fitte d, check th at all th e cylinder head studs are tight in th e crankcase halves. If any are loose, remove them and clean their th reads. Apply a suitable permanent thread locking compound and tighten them securely.

13.24 Zero th e gauge against th e cylinder to p gasket surface

13.25 M easuring th e piston h e igh t a t TDC

13 Check th at the mating surfaces o f the cylinder and crankcase are clean, then remove any rag from th e crankcase opening. Lay the new base gasket in place on the crankcase making sure it is the correct way round. 14 If required, install a piston ring clamp onto the piston to ease its entry into th e bore as the cylinder is lowered. This is not essential if the cylinder has a good lead-in enabling the piston rings to be hand-fed into th e bore. If possible, have an assistant to sup po rt the cylinder w hile th is is done. Check th at the piston ring end gaps are positioned as described in Section 15. 15 Lubricate th e cylinder bore, piston and piston rings, and the connecting rod big- and sm all-ends, w ith th e clean engine oil, then lower the cylinder down until the piston crown fits into the bore. 16 Gently push down on th e cylinder, making sure th e piston enters the bore squarely and does not get cocked sideways. If a piston ring clamp is not being used, carefully compress and feed each ring into the bore as the cylinder is lowered. If necessary, use a soft mallet to gently tap th e cylinder down, but do not use force if it appears to be stuck as the piston and/or rings w ill be damaged. If a clamp is used, remove it once the piston is in the bore. 17 When th e piston is correctly installed in the cylinder, check that th e base gasket has not been displaced, then press th e cylinder down onto the base gasket. 18 Install th e cylinder bolt(s) finger-tight only at this stage (see Step 4). 19 Install th e cam chain guide blade, then install th e cylinder head (see Section 11). 20 Tighten the cylinder bolt(s) and, on liquidcooled engines, install th e coolant hose on the cylinder and secure it with th e clip.

'

j

|

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I , ! i

Installation

C y lin d e r b a s e g a s k e t t h ic k n e s s

Note: On some engines, cylinder base gaskets are available in a range o f thicknesses; the appropriate thickness depends on the height o f the piston crown a t TDC in relation to the cylinder to p gasket surface. Consult a scooter dealer fo r details. In these instances, the correct gasket thickness m ust be calculated before reassembly (see Steps 21 to 25).

21 To measure th e height o f the piston crown at TDC in relation to th e cylinder top gasket surface you w ill require a dial gauge and a mounting plate (see illustration). 22 Assemble th e cylinder on th e piston as j described in Steps 13 to 16, but w ithout a base gasket, and press th e cylinder down I onto the crankcase. 23 Clamp the mounting plate across th e top o f the cylinder using th e cylinder fixings and» tighten them to ensure that the cylinder is held firm ly against th e crankcase. Rotate the crankshaft so that the piston is part way down the bore. 24 Set th e dial gauge on the m ounting piate, and w ith th e gauge tip resting against the cylinder to p gasket surface, zero th e gauge (see illustration). 25 Now rest the gauge tip against the top of the piston. Rotate th e crankshaft via the alternator rotor nut so th e piston rises to the top o f its stroke (TDC). A t this point read off the dial gauge (see illustration). The reading represents the distance between th e cylinder

| I I I

Four-stroke engines 2B*13

14.3b . . . th en push o u t th e pisto n pin

top gasket surface and th e to p o f the piston crown. Use this measurement, together with the manufacturer's information, to identify the appropriate gasket thickness.

14

Piston - removal, inspection and installation

I f th e p is to n p in is a tig h t fit in th e p is to n bo sses, h e a t th e p is to n g e n tly w ith a h o t a ir gun - th is w ill exp an d the a llo y p is to n s u ffic ie n tly to relea s e its g rip o n th e pin. ******

HiNT

I I

c ylind er is being rebored, p isto n inspection can be overlooked as a n ew one w ill be fitted. The pisto n rings can be rem oved by hand; using your thumbs, ease th e ends o f each ring Note: This procedure can be carried o u t with apart and carefully lift it o ff the piston, taking I the engine in the frame. care no t to expand it any more than is Removal necessary (see illu s tra tio n ). Do no t nick or gouge the piston in the process. I 1 Remove th e cylinder and stu ff a clean rag 5 N ote w hich w ay up each ring fits and in into the crankcase opening around th e piston which groove, as they m ust be installed in their I to prevent anything fa llin g inside (see Sec­ original positions if being re-used. The upper tion 13). of each ring should be marked at one 12 The top o f th e piston s hould surface be m arked end (see Section 15). Some pistons are fitted with an arrow or lettering (eg, IN on the intake with a three-piece third (oil control) ring; there ! side, nearest th e carburettor) to show w hich will be an upper and lower side rail and a way round it should be fitte d. If no m ark is central rail spacer. Note: It is good practice to I visible, scratch one lightly on th e to p o f the renew the piston rings when an engine is being I piston (see illu s tra tio n ). N ote th at th e overhauled. Ensure th at the p isto n and bore ■ manufacturer’s mark may not be visible until are serviceable before purchasing new rings. | the carbon deposits have been scraped o ff 6 Clean all traces o f carbon from th e to p of . and the piston cleaned. I 3 Carefully prise out the circlip on one side o f th e piston. A hand-held wire brush or a piece of fine emery cloth can be used once m ost of the piston using needle-nose pliers o r a small th e de po sits have been scraped away. Do : flat-bladed screwdriver inserted into th e notch not, under any circum stances, use a wire (see illu stratio n). C heck fo r burring around brush m ounted in a drill m otor; th e piston the circlip groove and remove any w ith a very material is soft and is easily damaged. fine file or penknife blade, then push th e 7 Use a piston ring groove cleaning to o l to I piston pin out from the other side and remove rem ove any carbon deposits from the ring the piston from th e connecting rod (see illustration). Use a socket extension to push the piston pin o u t if required. Remove th e . other circlip and discard them both, as new . ones must be used on reassembly. 4 Before th e inspection process can be carried out, the piston rings m ust be removed i and the piston m ust be cleaned. Note: If the To p re v e n t th e c irc lip fro m flying a w a y o r fro m d ro pp in g in to th e cran kcase , pa s s a ro d o r s c re w d riv e r, w ith s greater dia m e te r th an the g a p b etw een the circlip ends, th ro ug h th e p is to n pin. This w ill tra p th e c irclip i f i t sp rin g s out.

grooves. If a to ol is not available, a piece broken off an old ring will do th e job. Be very careful to rem ove only th e carbon deposits. Do not remove any metal and do no t nick or gouge th e sides o f the ring grooves. 8 Once the carbon has been removed, clean th e piston w ith a suitable solvent and dry it thoroughly. If th e ide ntifica tion previously marked on th e piston is cleaned off, be sure to re-mark it correctly (see illustration).

Inspection 9 Inspect th e pisto n fo r c racks around th e skirt, at th e pin bosses and at the ring lands. C heck th a t th e circ lip grooves are no t' dam aged. Norm al piston w ear appears as even, vertical wear on th e thrust surfaces of th e piston and slight looseness o f th e top ring in its groove. If the skirt is scored or scuffed, th e engine may have been suffering from overheating a n d /o r abnorm al com bustion, w hich caused excessively high operating temperatures. 10 A hole in th e to p o f th e piston, in one extreme, or burned areas around th e edge of th e piston crown, indicate that pre-ignition or k nocking under load have occurred. If you find evidence o f any problems th e cause must be corrected or the damage w ill occur again. Refer to C hapter 4 fo r carburation checks and C hapter 5 fo r ignition checks. 11 C heck the p is to n -to -b o re clearance by measuring th e cylinder bore (see Section 13) and th e piston diameter. Measure th e piston approxim ately 25 mm down from th e bottom o f the lower piston ring groove and at 90° to

“ *5“ “

HiNT

14.4 Rem ove th e p isto n rin gs care fully

14.8 M an ufa ctu re r’s m ark o n p isto n crow n

2B*14 Four-stroke engines

a m icro m e ter

pisto n pin

the piston pin axis (see illu s tra tio n ). Note: The precise p o in t o f m easurem ent differs between manufacturers and engines, b u t the aim is to measure the piston in an area where it is worn. Subtract th e piston diameter from the bore diameter to obtain the clearance. If it is greater than' the specified figure, check whether it is the bore o r piston that is worn the m ost (see Data section at th e end o f this manual). If th e bore is good, install a new piston and rings. Note: Oversize pistons fitted in a rebored cylind er are n o t necessarily marked as such; in many cases the only way to determine i f a cylinder has been rebored is to measure an unw orn area o f the bore and compare the result w ith the specifications in the Data section. Some m anufacturers mark cylinders and pistons with a size code during production; th e size code (usually a letter) is stamped into the cylinder gasket surface and the to p o f the piston. It is important that new parts have m atching codes. It is essential to supply th e size cod e a n d any rebore specifications when purchasing a new piston. 12 Use a m icrometer to measure th e piston pin in th e middle, where it runs in the smallend bearing, and a t each end where it runs in the piston (see illu s tra tio n ). If there is any difference in th e m easurem ents the pin is worn and must be renewed. 13 If th e piston pin is good, lubricate it w ith clean engine oil, then insert it into the piston and check fo r any freeplay between the two (see illu s tra tio n ). There should be no freeplay. 14 Next, check the c o n ditio n o f the connecting rod small-end. A worn small-end

w ill produce a m etallic rattle, m ost audible when the engine is under load, and increasing as engine speed rises. This should not be confused w ith big-end bearing wear, which produces a pronounced knocking noise. Lubricate th e piston pin with clean engine oil, then slide it into the small-end and check for freeplay (see illustration). There should only be slightly discernible freeplay betw een the piston pin and th e connecting rod. 15 If there is freeplay, measure th e internal diam eter o f the connecting rod sm all-end (see illu s tra tio n ). Take several measure­ ments; if there is any difference between the m easurements, th e sm all end is worn and either a new connecting rod or crankshaft assem bly w ill have to be fitted (see Section 20). C onsult a scooter dealer about the availability o f parts. N ote : I f a new ro d is available, fittin g i t is a specialist task which sh o uld be le ft to a scoo te r dealer o r automotive engineer. If a new rod is fitted, the b ig -e n d bearing should b e renew ed a t the same time. 16 If the small-end is good, fit a new piston pin. N ote: On some engines, the p isto n pin an d sm all-end are m arked with a size code durin g pro du ction ; look fo r identification marks o r colours on the components and refer to them when ordering new parts.

in the s m all-end to c h e c k fo r wear

Installation 17 Install th e piston rings (see Section 15). 18 Lubricate th e piston pin, th e piston pin bore in th e piston and th e connecting-rod small-end w ith clean engine oil. 19 Install a new circlip in one side o f th e

14.15 M easuring the internal dia m e te r of th e connecting rod sm all-end

14.13 C hecking f o r freeplay b etw een the piston and p isto n pin

piston, then line up th e piston on the connecting rod, making sure it is the right way round (see Step 2), and insert th e piston pin from th e other side. Secure th e pin with the other new circlip. When installing the circlips, compress them only just enough to fit them in the piston, and make sure they are properly ■ seated in th e ir grooves w ith th e open end away from th e removal notch. 20 Install th e cylinder (see Section 13).

15Piston ring sin s p e c tio n an d in s ta llatio n

^ ^

1 New piston rings should be fitted whenever | an engine is being overhauled. It is important that you get new rings o f the correct size for j your piston so ensure th a t any information j relating to piston size, including rebore size, J and size coding is available when purchasing new parts. 2 Before fitting the new rings onto the piston, I the ring end gaps m ust be checked. Insert the top ring into th e bottom of the cylinder bore j and square it up by pushing it in with the top of the piston. The ring should be about 15 to 20 mm from th e bottom edge of the cylinder, j To measure th e end gap, slip a feeler gauge between th e ends o f the ring and compare the measurement to the specification in the Data section at the end o f th is manual (see illustration). 3 If th e gap is larger or smaller than specified, check to make sure that you have th e correct rings before proceeding. If th e gap is larger

j

15.2 M easuring th e installed p isto n ring end gap

expert22 flna h t t p :// r u t r a c k e r . o r a

Four-stroke engines 2B«15

than specified it is likely the cylinder bore is wom. If the gap is too small th e ring ends may come into con ta ct w ith each other during engine operation, causing serious damage. 4 Repeat th e procedure fo r th e other tw o rings. Note: If the piston is fitted w ith a threepiece third (oil control) ring, check the end gap on the upper and low e r side rails only. The ends of the central rail spacer should contact each other when it is fitte d on the piston. 5 Once th e ring end gaps have been ' checked, th e rings can be installed on th e piston. Do not expand the rings any more than ' is necessary to slide them into place. Note: A ring installation to ol can b e used on th e two t. fompression rings, a n d on a one-piece oil control ring, if desired, b u t no t on the side rails ola three-piece oil control ring. 6 The oil control ring (lowest on the piston) is ! installed first. If a three-piece ring is used, fit the rail spacer into the groove, then install the lower side rail (see illu stratio ns). Place one end of the side rail into the groove between the spacer and th e lower ring land. Hold it ; firmly in place, then slide a finger around the piston while pushing the rail into th e groove. Install the upper side rail the same way. 1 Ensure the ends o f the spacer touch bu t do not overlap, th en check th a t both s.ide rails turn smoothly in the ring groove. 7 Next install the 2nd com pression ring, noting that there is usually a marking or letter near the gap to denote th e upper surface of

the ring. Finally install th e to p ring into its groove. 8 Once the rings are correctly installed, check they move freely w itho ut snagging, then stagger their end gaps before fitting the piston into th e cylinder (see illu strations).

16A lternator-

removal and installation

^

Note: This procedure can be carried o ut with the engine in the frame. I f the engine has been removed, ignore the steps that d o no t apply.

Removal 1 Remove th e body panels as necessary to access the alternator (see C hapter 9). If required, rem ove the exhaust system (see Chapter 4). 2 On some air-cooled engines, th e alternator is located behind the fan cowling. Unclip any w iring o r hoses from th e fa n cow ling, then undo th e bolts securing th e fan cow ling and rem ove it (see illu s tra tio n ). Note th at on some m odels th e fan cowling is clipped to the engine cowling - take care not to damage the fixing lugs when separating th em . Remove any spacers fo r the cow ling bo lts fo r safekeeping if they are loose. Undo the bolts securing the cooling fan to th e alternator rotor and rem ove th e fa n (see Chapter 1, Sec­ tion 21). 3 On liquid-cooled engines where th e water

15.8a If a on e-piece o il c o n tro l rin g is used, p o sition th e end ga ps a t 120 ° intervals

A B C

First (top) compression ring Second (middle) compression ring Oil control ring

pum p is m ounted on th e ou tside o f th e alternator cover, firs t drain the coo lan t and disco nn ect all the coo lan t hoses from th e pum p (see C hapter 3). Undo th e cover m ounting bolts and lift o ff the cover. Depending on the tools available for removing th e alternator rotor, it may be necessary to unscrew the pum p drive dam pers (see illustration). 4 On some engines th e alternator is located behind the right-hand engine s ide cover. N ote : I f th e water p u m p is m ou nte d on the outside o f the engine side cover, first drain the coolant a nd disconnect a ll the coolant hoses from th e pu m p (see C hapter 3). Drain th e engipe oil (see C hapter 1). Trace th e w iring from th e cover and disco nn ect it at th e

* used, position th e end gaps as show n top ring (1), o il ring low e r side rail (2), oil ring upper side rail (3), second rin g (4)

16.2 W here necessary, rem ove the fan cow ling

16.3 W ater pum p is driven b y dam pers on th e a lte rna tor ro to r

2B*16 Four-stroke engines

16.4 L ift o ff th e side cove r and a lte rna tor s ta to r

16.5 Hold the r o to r and u ndo the cen tre nu t (arrowed)

16.6 Using a s trap w re nch to hold th e ro to r

16.8c Using a tw o-leg ge d puller roto r connector, then undo th e cover b olts and lift o ff th e cover (see illu s tra tio n ). Discard the gasket, as a new one m ust be fitte d, and remove th e cover dow els fo r safekeeping if they are loose. If applicable, rem ove the starter pinion assembly (see Section 17). 5 To remove th e rotor centre nut it is necessary to stop the rotor from turning; some manufacturers produce a service tool fo r this A r o to r h o ld in g to o l can ea sily be m ad e u s in g tw o s trip s of s te e l b o lte d to g e th e r in th e m id dle , w ith a b o lt th ro ug h each e n d w hich locates in to th e s lo ts o r h o les in th e ro to r. Do n o t allo w th e b o lts to e x te n d to o fa r th ro u g h th e r o to r o th e rw is e th e co ils co u ld be damaged.

16.8d Rem ove th e W ood ruff k ey fo r safekeeping

purpose. If th e rotor face is accessible, you can make up a tool which engages the slots or holes (see illustration). Note: Take great care no t to damage the coils o f the alternator when locating any tools through the rotor. 6 If the alternator stator is located in the engine side cover, the rotor can be held with a strap wrench (see illustration). 7 W ith th e rotor securely held, unscrew the centre nut. 8 To remove the rotor from th e shaft it is necessary to use a puller - either a manufacturer’s service tool or a commercially available puller (see illustrations). To use the service tool, first screw the body o f th e tool all the way into th e threads provided in the rotor. Hold th e tool steady with a spanner on its flats and tighten th e centre bolt, exerting steady pressure to draw the rotor off the crankshaft. To use a puller, engage th e puller legs either

in th e slots in th e rotor or thread them into the threaded holes in th e rotor, then tighten the centre bolt exerting steady pressure to draw th e rotor o ff th e crankshaft. Remove the W oodruff key from the shaft for safekeeping, noting how it fits (see illustrations). 9 In m ost cases, th e alternator sta tor coils and ignition pulse generator coil are wired together and have to be removed as an assembly. If not already done, trace th e wiring back from th e alternator and pulse generator and disconnect it at the connectors. Free the w iring from any clips or guides and feed it through to th e alternator. 10 Undo th e screws securing th e stator and th e pulse generator and lift them o ff together. Where fitted, draw any rubber wiring boot out o f th e crankcase or engine side cover and carefully pull the w iring away, noting how it fits (see illustrations).

16.8e N ote th e alignm ent o f the key (A) and th e s lo t in th e ro to r (B)

16.10a Undo th e s ta to r screw s (A) and the pulse generator coil s crew s ( B ). . .

Four-stroke engines 2B«17

assembly nc

Installation 11 Installation is the reverse o f removal, noting the following: 1 Ensure the wiring is correctly routed before L installing the stator and pulse generator. •Mate sure th at no m etal ob jects have i attached themselves to the magnets on the t inside of the rotor. [ • Clean the ta pered e n d o f th e crankshaft [, and the corresponding m ating surface on i the inside o f th e ro to r w ith a suitable I solvent. • Fit the Woodruff key into its slot in the shaft, : then install the rotor. ■ • Tighten the ro to r centre n u t to th e torque ■ setting specified in the Data section at the | end of this manual. ■ •Secure the wiring with any clips o r ties, inapplicable, fill the engine with the correct |r type and quantity o f oil (see Chapter 1). i • II applicable, refill th e cooling system and I bleed it (see Chapter 3).

17 Starter pinion assembly and starter clutch - removal,

II

>w th e w iring fits

16.10c N ote the position o f th e pulse g ene rato r (A) and th e w iring gro m m et (B)

1 Remove either the variator (see Chapter 6) o r th e alternator ro to r (see Section 16) as applicable. 2 If th e pump drive sprocket is located on the crankshaft behind th e variator, rem ove th e cover (see illustration). 3 If the pump is located in a separate sump, rem ove th e sum p cove r and discard th e

gasket, as a new one m ust be fitte d on reassembly (see illu stratio n). Note: On some engines, th e lubrication system incorporates an o il pressure re lie f valve. I f th e valve is loca ted in the sump, rem ove i t fo r safekeeping, noting how i t fits. I f th e valve is fitted with an O-ring, discard i t a nd fit a new one on reassembly. 4 Where fitted, remove th e screw s securing the pum p drive chain cover and remove the cover (see illustrations). 5 Mark the chain so that it can be fitte d the same way round. 6 On som e pum ps, th e pum p spro cket is

18.2 Undo th e s crew s (arrow ed) and rem ove th e cover

18.3 Undo th e b o lts (arrow ed) and rem ove th e s um p cover

crankshaft. On some engines, the p um p drive sprocket is integral with the crankshaft. N ote 2: This procedure can b e carried ou t with the engine in the frame.

Removal

^

inspection and installation

Note: This procedure can be carried out with I theengine in the frame. [ 1 The procedure fo r removal, inspection and ■Installation o f either th e starter pinion | assembly or the starter (one-way) clutch is the same as fo r tw o-stroke engines (see [ Chapter 2A, Section 17). Note that details fo r i removal o f th e alternator on fo ur-stro ke engines are given in Section 16.

18 Oil pump - removal, | f inspection and installation

^

- Note 1: Generally, th e o il p u m p is located inside the engine unit and is chain-driven from i either the le ft- o r rig ht-h an d side o f the

18.4a Undo th e s crew s ( a rro w e d ). . .

18.4b . . . securing th e pum p dr

2B»18 Four-stroke engines

18.7b . . . and lift o ff the spro cket and chain

18.8b . . . th en rem ove th e s p ro c k e t. . .

10 Check the pum p body fo r obvious signs o f dam age especially around th e mounting

bolt holes. Turn the pump shaft by hand and check that the pump rotates smoothly. Some pum ps cannot be disassembled for inspection - if the operation o f the pum p is suspect, renew it. 11 Remove the screws securing the cover to the pum p body, th en remove cover (see illu s tra tio n s ). Note any reference marks on th e pum p rotors; even if th e rotors are not marked, it is essential that they are reassembled th e correct way round. Lift out the inner and outer rotor and the pump shaft (see illu s tra tio n ). Note th e location of any drive pin in the shaft. Note: On some pumps, th e rotors are secured by a circlip - use a new circlip on reassembly. 12 Clean th e pum p com ponents w ith a suitable solvent and dry them with compressed air, if available. Inspect th e pump body, rotors and shaft fo r scoring and wear. If any damage, scoring, uneven or excessive wear is evident, renew the pump (individual components are not available).

18.11a Rem ove th e s crew s . . .

18.11b . . . and lift o ff th e cover

retained b y the chain cover. W ithdraw the chain and spro ckets from the engine as an assem bly, then rem ove th e dowel and thrustwasher from the pump shaft. 7 If the pump sprocket is retained by a circlip, use circlip pliers to remove th e circlip, then w ithdraw the chain and sprocket(s) (see illu strations). 8 If th e sprocket is retained by a bolt, insert a pin punch or screwdriver through one of the holes in the sprocket and locate it against part of the casing to prevent the sprocket turning, then unscrew th e b o lt (see illu s tra tio n ). W ithdraw th e chain and sprocket(s) (see illustrations). 9 W here fitte d, undo th e pum p retaining bolts, then w ithdraw the pum p from the engine. If a gasket is fitted behind the pump, discard it, as a new one must be fitted.

Inspection

18.8a Undo the s pro c k et b o lt. . . 13 If th e pum p is good, reassemble all the components in th e correct order and lubricate them w ith clean engine oil. 14 Fit th e cover and tighten th e screws securely, then rotate the pump shaft by hand to check that the rotors turn smoothly and freely. 15 Inspect th e pum p drive chain and • sprockets fo r wear or damage, and renew them as a set if necessary. If th e drive sprocket is not a sliding fit on th e crankshaft, check to see if it is a press-fit or an integral part of the shaft. If the sprocket is a press-fit and needs to be renewed, measure its position from the end of the shaft, then pull it o ff w ith a bearing puller (see Tools and Workshop Tips in the Reference section). Heat the new sprocket in an oil bath to around 100°C, then press it onto the shaft using a suitable length o f tu be that ju st fits over the shaft. Ensure that th e sprocket is installed at th e correct distance from the end o f th e shaft,

I "

!

I , I j I

Installation 16 Installation is th e reverse o f removal, noting the following: • If required, fit a new gasket to the pump. • Where fitted, secure the p um p drive gear with a new circlip. • Ensure th e chain is fitte d the correct way round. • Where fitted, ensure the oil pressure relief valve is correctly installed. • Fit a new gasket to the sump. • If applicable, fill the engine with the correct j type and quantity o f oil (see Chapter 1).

Inner rotor Body screw Cover

j

Four-stroke engines 2B*19

^

19Crankcase halves | and main bearings

^

Note: To separate the crankcase halves, the enginemust be removed from the frame.

Separation Follow the procedure in Section 4 and removethe engine from th e frame. 2 Beforethe crankcase halves can be separated sfollowing components must be removed: Camchain, blades and sprockets (see Section 9). I Cylinder head (Section 11). t Cylinder (Section 13). Alternator rotor (Section 16). t Variator (Chapter 6). t Starter motor (Chapter 10). tOil pump (Section 18). 3Tape some rag around th e connecting rod j prevent it knocking against th e cases, then loosen the crankcase bolts evenly, a little a t a limeand in a criss-cross sequence until they areall finger-tight, th en rem ove th em (see illustration). N ote : Ensure th at all the crankcase bolts have been rem oved before tempting to separate the cases. M ake a c a rd b o a rd te m p late ■■“ " n o f th e crankcase a n d pu n c h hole fo r each b o lt location. 5——— ' This w ill e nsure all bo lts are installed correctly on reassem bly - th is _isimportant as som e b o lts m ay b e o f different lengths.

HiNT

v-

19.6 Draw ing th e right-hand crankcase half o ff the cran ksha ft

19.7 Pressing th e c ra n k s h a ft o u t o f th e left-h an d cran kcase h alf

4 On some engines, th e crankshaft is secured against the right-hand main bearing by a large nut. Lock the crankshaft by passing a bar through th e connecting rod sm all-end and resting it on tw o pieces o f wood to protect the cylinder gasket surface, then undo th e nut. 5 If th e crankshaft oil seals are fitte d to the outside o f th e crankcases, rem ove th e oil seals. Note th a t on some engines the seals are held in a fixing plate; undo th e bolts and remove the plate, do not try to rem ove th e seal from the plate. 6 Remove the right-hand crankcase half from th e left-hand half by drawing it o ff the righthand end o f the crankshaft. On most engines, th e cases will be a tight fit on the crankshaft and m ost m anufacturers produce a service tool to facilitate this procedure. Alternatively, use th e set-u p shown, ensuring equal pressure is applied on both sides o f th e puller arrangement at all tim es (see illu stratio n). If th e puller is placed across th e end o f th e crankshaft, th read th e old alternator centre nut on first to protect the threads. Note: i f the crankcase halves do no t separate easily, first ensure all fasteners have been removed. A p p ly steady pressure w ith th e tools described and heat the bearing housings with a h o t a ir gun. D o n o t try and separate the halves b y levering against the m ating surfaces as they are easily scored and w ill n o t seal correctly afterwards. Do n o t strike the ends o f the crankshaft with a hammer as damage to the end threads o r the shaft itself w ill result. 7 Now press th e crankshaft assembly ou t of the left-hand crankcase half - again, a service to o l w ill be available. Alternatively, use the

set-up shown (see illu s tra tio n ). Thread th e old variator nut onto the end of th e crankshaft to pro tect the th reads and make sure th e crankshaft assembly is supported to prevent it dropping if it suddenly comes free. 8 Note the position of the crankshaft oil seals (if not already removed) and measure any inset before removing them (see illustration). Note which way round the seals are fitted. Lever the seals out carefully with a large, flat-bladed screwdriver and a piece of wood, taking care not to damage the crankcase. Discard the seals, as new ones must be fitted on reassembly. 9 Remove any dowels from either crankcase half fo r safekeeping if they are loose. 10 The main bearings w ill either rem ain in place in th e crankcase halves during disassembly or come out w ith th e crankshaft assem bly (see illu s tra tio n ). If th e main bearings have failed, excessive rumbling and vibration w ill be fe lt when the engine is running. Check th e condition o f the bearings (see Tools and W orkshop Tips in th e Reference section) and only rem ove them if they are unserviceable. Always renew both main bearings at the same tim e, never individually. Note that on some engines, plain (non-roller) main bearings are fitte d in th e crankcases. These bearings are generally not renewable, and if th ey are w orn new crankcases w ill have to be fitted. Check the availability o f new parts w ith a scooter dealer. 11 To remove th e bearings from th e cases, heat th e bearing housings w ith a hot air gun and ta p them ou t using a bearing driver or suitable socket (see illustration). Note which w ay round the bearings are fitte d. If th e

19.10 C hecking the m ain bearing on the crankshaft

crankcase

2B

2B*20 Four-stroke engines

19.19a Installing the cran ksha ft assem bly in th e left-hand c rankcase half

19.19b C heck th e loca tion o f th e cran ksha ft bearing (arrowed)

19.20 Apply sealant to the crankcase m ating surface

bearings are stu ck on th e crankshaft, they m ust be rem oved w ith an external bearing puller to avoid dam aging th e crankshaft assembly. N ote: On some engines the main bearings are fitte d in the crankcases p rio r to assembly, on others they are fitte d to the crankshaft. Consult a scooter dealer for details before installing new bearings. 12 If required, remove th e transmission assem bly from th e left-hand crankcase half (see Chapter 6).

only. If the bearings are difficult to fit they are not hot enough. W arning: This m ust be done very c a re fu lly to a vo id th e ris k o f person al injury. 18 Fit th e new crankshaft oil seals into the crankcase halves and drive them to the previously-measured inset using a seal driver o r socket (see Step 8). Ensure th e seals are fitted the right w ay round and that they enter th e cases squarely. 19 Fit the crankshaft assembly into th e lefthand crankcase half first, ensuring th at the connecting rod is aligned with th e crankcase mouth. Lubricate the shaft, seal and bearing with clean engine oil and ta pe some rag around th e connecting rod to prevent it knocking against th e cases. If th e main bearing is in the crankcase half, pull th e assembly into place either with a service tool or using the set-up shown (see illustration). If the main bearing is on th e crankshaft, heat the bearing housing in th e crankcase with a hot air gun before fittin g th e crank assembly. N ote : Avoid applying direct heat onto the crankshaft o il seal. If required, a freeze spray can be used on th e bearing itself to aid installation. Ensure th e bearing is installed fully into its housing (see illustration). 20 If applicable, allow the case to cool, then w ipe th e mating surfaces o f both crankcase halves with a rag soaked in a suitable solvent and fit the dowels. Apply a small am ount of suitable sealant to th e mating surface o f the left-hand case (see illustration). 21 Now fit the right-hand crankcase half.

Lubricate th e shaft, seal and bearing with clean engine oil. If th e main bearing is in the crankcase half, press the crankcase half into place, either w ith a service tool o r with the set-up shown (see illu s tra tio n ). If th e main bearing is on the crankshaft, heat the bearing housing w ith a ho t air gun before fitting the crankcase half and, if required, use a freeze spray on th e bearing. N ote: A vo id applying direct heat onto the crankshaft oil seal. 22 Check that th e crankcase halves are seated all th e way round (see illustration). If the casings are not correctly seated, heat the bearing housings while applying firm pressure w ith the assem bly to ols used previously. N ote: Do no t a ttem p t to p u ll th e crankcase halves together using the crankcase bolts as the casing will crack and be ruined. 23 Clean th e threads of th e crankcase bolts and install them finger-tight, then tighten them evenly a little a t a tim e in a criss-cross] sequence to th e torque setting specified in the Data section. Support the connecting rod and rotate the crankshaft by hand - if there are any signs of undue stiffness, tig h t or rough spots, or o f any other problem, th e fault must be rectified before proceeding further. 24 W here fitte d, install th e crankshaft nut (see Step 4). The nut should be tightened to a specific torque setting - check w ith a scooter dealer for details. 25 On engines where th e crankshaft oil seals are fitted to the outside of th e crankcases (see S tep 5), lubricate the new seals w ith clean engine oil and install them in the cases. 26 Install th e remaining com ponents in the reverse order of removal.

Inspection 13 Remove all traces of old sealant from the crankcase m ating surfaces w ith a suitable solvent. Take care no t to nick or gouge the soft aluminium. Wash th e cases in a suitable solvent and dry them with compressed air. 14 The procedure fo r inspecting th e crankcase halves and repairing minor damage is th e same as fo r tw o-strok e engines (see Chapter 2A, Section 13). 15 Inspect th e crankshaft assem bly and bearings (see Section 20).

Reassembly 16 If the main bearings are to be fitted into th e crankcase halves, heat th e bearing housings w ith a hot air gun, then install them using a bearing driver or suitable socket which bears onto th e outer race only. 17 If the main bearings are to be fitted onto th e crankshaft, heat them first in an oil bath to around 100°C, then press them onto th e shaft using a suitable length o f tu be that ju s t fits over the shaft and bears onto th e inner race

A

20 Crankshaft assembly and big-end bearing

19.21 Installing th e right-hand crankcase half

19.22 Ensure the crankcase halves are correctly seated

& ^

1 To access th e crankshaft and the big-end bearing, the crankcase must be split into two parts (see Section 19). 2 The crankshaft assembly should give many thousands o f miles of service. The most likely problems to occur will be a worn small or big^ end bearing due to poor lubrication. A worn big-end bearing w ill produce a pronounced knocking noise, most audible when th e engim

Four-stroke engines 2B»21 load, and increasing as engine speed i. This should not be confused w ith smallbearing wear, w hich produces a lighter, allic rattle (see Section 14).

Inspection To assess th e condition o f th e big-end fing, hold the crankshaft assembly firm ly push-and-pull on th e connecting rod, m g for any up -and-dow n freeplay jifeen the tw o (see illu s tra tio n ). If any play is noted, th e bearing is w orn and sr the bearing or the crankshaft assembly have to be renewed. N ote: A small |unf o f big-end side clearance (side-to«Je movement) is acceptable on the ting rod. C onsult a scooter dealer nut the availability o f parts. Note: If a new ing is available, fitting it is a specialist task th should be le ft to a scoo te r dealer o r motive engineer. Inspect the crankshaft where it passes Ugh the main bearings fo r wear and ing - if required, rem ove the bearings fully with a bearing puller to avoid aging the shaft (see illu s tra tio n ). The i should be a press-fit in the bearings; if it worn or damaged a new assembly will have be fitted. Evidence o f extreme heat, such iloration o r blueing, indicates that irication failure has occurred. Be sure to the oil pump and bearing oilways in the before reassembling the engine, available, place th e crankshaft assembly V-blocks and check the runout at th e main fingjournals (B and C) and a t either end (A D) using a dial gauge (see illu stratio n), ite: The main bearings w ill have to be for this check. If th e crankshaft is outit will cause excessive engine vibration, tpe is any doubt about the condition o f the crankshaft have it checked by a scooter dealer . omotive engineer. Note: The crankshaft Ibly is pressed together and is easily i f it is dropped. Inspect the th reads on each end o f the shaft and ensure that the retaining nuts te alternator rotor and th e variator are a od fit. Inspect the splines fo r th e variator on th e left-hand end o f th e shaft. Inspect the taper and th e slot in the right-hand of the shaft fo r th e alternator W oodruff (see illu stratio n). Damage or wear that prevents the rotor from being fitte d securely [require a new crankshaft assembly. Where applicable, inspect the oil pump for the camshaft drive sprocket teeth on icrankshaft fo r dam age or wear (see itration 20.6). If th e sprocket is integral ithe shaft, a new crankshaft assembly will jto be fitted. If the sprocket is a press-fit needs to be renewed, measure its position from th e end o f th e shaft, then pull it bearing puller (see illu s tion 20.4). Heat th e new sprocket in an oil around 100°C, then press it o nto the A using a suitable length of tube that just ]over the shaft. Ensure that th e sprocket is

20.3 C heck fo r up-an d-do w n p la y in the big -e nd bearing

20.4 R em oving a m ain bearing u sing a bearing p u ller

20.5 Su pp ort th e c ran ksha ft on V-blo cks and che ck th e r un ou t at po ints A, B, C and D

20.6 In spe ct the c ran ksha ft ta p e r (A), lo ca tion o f th e W ood ruff k ey (B), th re ad (C) and s p ro c k e t te eth (D)

installed at the correct distance from the end of th e shaft.

especially the brakes, function properly before road testing th e machine. Refer to Section 22 fo r th e recommended running-in procedure. 8 Upon completion o f the road test, and after th e engine has c ooled dow n com pletely, recheck the valve clearances (see Chapter 1). Check the engine oil level and, on liqu id cooled models, check th e coolant level (see Daily (pre-ride) checks).

Reassembly 8 Follow th e procedure in Section 19 to install th e crankshaft assembly.

21Initial start-up after overhaul

22 1 Make sure th e engine oil level is correct (see Daily (pre-ride) checks). 2 On liquid-cooled models, make sure th e coolant level is correct (see Daily (pre-ride) checks). 3 Make sure there is fuel in th e tank. 4 With the ignition OFF, operate the kickstart a couple o f tim es to check th at th e engine turns over easily. 5 Turn th e ignition ON, sta rt th e engine and allow it to run a t a slow idle until it reaches operating temperature. Do no t be alarmed if there is a little smoke from the exhaust - this w ill be due to th e oil used to lubricate th e piston and bore during assembly and should subside after a while. 6 If th e engine proves reluctant to start, remove the spark plug and check that it has not become wet and oily. If it has, clean it and try again. If th e engine refuses to start, go through th e fault finding charts at th e end of this manual to identify th e problem. 7 C heck carefully fo r fuel and oil leaks and make sure th e transm ission and controls,

Recommended running-in procedure

1 T reat th e engine gently fo r the firs t few miles to allow any new parts to bed-in. 2 If a new piston, cylinder or crankshaft assembly has been fitted, the engine will have to be run-in as when new. This means a restraining hand on the throttle until at least 300 miles (500 km) have been covered. There’s no point in keeping to any set speed limit - the main idea is to keep from labouring the engine and to gradually increase performance up to the 600 mile (1000 km) mark. Make sure that the th ro ttle position is varied to vary engine speed, and use full throttle only fo r short bursts. Experience is th e best guide, since it’s easy to tell when an engine is running freely. 3 Pay particular attention to the Daily (pre­ ride) checks at th e beginning o f this manual and investigate the cause o f any oil or, on liquid-cooled m odels, coolant loss imm ediately. C heck th e tigh tn ess o f all relevant nuts and bolts.

3*1

Chapter 3 Cooling system (liquid-cooled engines) Contents Coolant hoses - removal and installation ..............................................10 Coolant level check .......................................see Daily (pre-ride) checks Coolant reservoir - removal and in sta lla tio n ........................................ 7 Cooling fan and switch ............................................. ............................. 5 Cooling system checks ......................................................see Chapter 1 Draining, flushing and r e fillin g ............................................................ .. 2

General in fo rm a tio n ................................................................................. Pressure c a p .......................................... .............................................. Radiator - removal and in sta lla tio n ....................................................... Temperature gauge and sender ........................................................... Therm ostat................................................................................................ Water pump - removal and in s ta llatio n................................................

1 3 8 4 6 9

Degrees of difficulty suitable for novicewith little

|S ;

Fairly easy, suitable fo r beginner with

% som e experience

^ ^

Fairly difficult, suitable fo r competent ^ DIY mechanic ^

D ifficult, suitable fo r experienced DIY mechanic

^

V e ry d iffic u lt, \ suitable fo r expert DIY a J o r professional

Specifications Referto the Data section at the end o f this manual for servicing specifications.

1 General information

The cooling system uses a water/antifreeze coolant to carry excess energy away from the engine in th e form o f heat. The coo lan t is contained w ithin a w ate r jacke t inside th e cylinder and cylinder head which is connected tothe radiator and th e w ater pum p by the coolant hoses. I,Coolant heated by the engine is circulated wthermo-syphonic action, and th e action of jhe pump, to the radiator. It flow s across the radiator core, w here it is cooled b y th e

passing air, then through the water pump and back to th e engine where th e cycle is repeated. A thermostat is fitted in the cylinder head to prevent the coolant flow ing to the radiator when the engine is cold, therefore accelerating th e speed at w hich the engine reaches normal operating te m perature. A coolant temperature sender m ounted in the cylinder head is connected to th e temperature gauge on the instrument panel. W arning : Do n o t rem ov e the rese rvo ir cap w hen the engine is h o t. S c a ld in g h o t c o o la n t a n d s te a m m a y b e b lo w n o u t unde r pressure, w hich c o u ld cause serious injury.

A

W arning: D o n o t a llo w antifreeze to c o m e in c o n ta c t w ith y o u r s k in o r p a in te d o r p la s tic s u rfa c e s of th e s co o te r. R inse o f f any s p ills im m e diately w ith ple n ty o f w ate r. A n tifre e z e is h ig h ly to x ic i f in g e s te d . N e v e r lea ve a n tifre e z e ly in g a ro u n d in an open c o n ta in e r o r in p u d d le s o n th e flo o r; c h ild re n an d p e ts a re a ttra c te d b y its s w e e t sm e ll a nd m ay d rin k it. C h e c k w ith th e lo ca l a u th o ritie s a b o u t d is p o s in g o f used a n tifre e z e . M a n y c o m m u n itie s w ill have c o lle c tio n c e n tre s w h ic h w ill see th a t antifreeze is disp ose d o f safely. Antifreeze is also com b ustib le , so d o n ’t s to re i t near open flames.

A

3*2 Cooling system (liquid-cooled engines) Caution: A t a ll tim es use th e spe cified type o f a n tifree ze, a n d alw a ys m ix i t w ith d is tille d w a te r in th e c o rre c t p ro p o rtio n . The a ntifreeze c ontains corrosion inh ibito rs w hich are essential to avoid dam age to th e c o o lin g system . A la c k o f these in h ib ito rs c o u ld lead to a b u ild-up o f corrosion which w o u ld b lo c k th e c o o la n t passages, resu ltin g in overheating a n d severe engine dam age. D is tille d w a te r m u s t be use d as opposed to tap w ate r to a void a b u ild-up o f scale w hich w ou ld also b lock th e passages.

2

Draining, flushing and refilling

%

W arning : A llo w th e en g in e to cool co m p le te ly be fo re p e rfo rm in g th is m a in te n a n ce o p e ra tio n . A lso, d o n ’t a llo w a n tifree ze to com e in to c o n ta c t w ith y o u r sk in o r th e p a in te d o r p la s tic su rfa ce s o f th e s co o te r. R inse o f f s p ills im m e d ia te ly w ith ple n ty o f water.

A

Draining 1 Remove any body panels as necessary to access the hose connection either to th e water pump or, if more easily accessible, the bottom o f th e radiator, and the coolant system filler cap (see Chapter 9). N ote: On some systems, the filler cap is on the radiator, on others it is on the coolant reservoir; refer to your scooter handbook fo r details. 2 Remove th e filler cap. If you hear a hissing sound as you unscrew it (indicating there is still pressure in the system), wait until it stops. 3 To drain th e coolant, first loosen th e clip securing th e coolant hose either to the union on th e w ater pum p o r th e bottom o f the radiator. Position a suitable container beneath the hose, then detach it and allow th e coolant to drain from the system (see illu stratio n). Note that some water pumps are fitted with a drain bolt (see illustration); if applicable, undo th e bolt to drain th e system without disturbing th e coolant hoses. Retain th e old sealing washer for use while flushing th e system. 4 W here fitte d , check th at the coolant has drained from th e coo lan t reservoir.. If

2.3a Drain th e c ooling system into a suitable c ontainer

2.3b W ater pum p drain b o lt (arrowed)

necessary, detach th e hose from th e bottom o f th e reservoir and drain th e coolant (see illustration).

10 S top th e engine. Let it cool fo r a while, j then remove the filler cap (see Step 2) and drain the system (see Step 3). 11 R econnect the coolant hoses and the i drain bolt as applicable, then fill th e system w ith clean w ater only and repeat the procedure in Steps 7 to 10. Where fitted, I check that th e w ater has drained from the I coolant reservoir.

Flushing 5 Flush th e system with clean ta p water by inserting a garden hose in the filler neck. Allow the water to run through the system until it is clear and flow s cleanly out o f either th e detached hose or the drain hole. If there is a lot o f rust in the water, remove the radiator and have it professionally cleaned (see Section 8). If th e drain hole appears to be clogged with sediment, remove the pump cover and clean the inside o f th e pump (see Section 9). If necessary, remove the coolant reservoir and rinse the inside with clean water, then refit it. 6 As applicable, attach th e coolant hoses and secure them w ith the clips, and install the drain bolt using the old sealing washer. 7 Fill the system with clean water mixed with a flushing com pound. N ote: Make sure the flushing com pound is com patible with aluminium com ponents and follow the m anufacturer's instructions carefully. If the system is fitted with a bleed valve, loosen the valve to release any trapped air, then tighten it securely (see illustration). Alternatively, rock the scooter from side-to-side and bleed any trapped air out through the filler neck. Install th e filler cap. 8 If necessary, fill th e coolant reservoir separately with clean water. 9 Start th e engine and allow it to reach normal operating temperature. Let it run for about five minutes.

Refilling

12 Ensure all the hoses are correctly j attached and secured w ith th eir clips. If applicable, fit a new sealing washer onto the drain bolt and tighten the bolt securely. 13 Fill th e system w ith the proper coolant mixture (see the Data section at the end of this manual). Note: Pour the coolant in slowly to m inimise th e am ount o f air entering the system. Release any trapped air as described in Step 7. If necessary, to p-up th e coolant reservoir. Install th e filler cap. 14 Start th e engine and allow it to idle for 2 to 3 minutes. Flick th e th ro ttle tw istgrip part open 3 o r 4 times, so that the engine speed rises, then sto p the engine. Release any trapped air (see Step 7) and check the system fo r leaks. W arning : M ake su re th a t the m ach in e is on its ce n tre stand a n d th a t the rea r w he el is o ff the g ro u n d be fo re b le e d in g the co o lin g syste m . I f necessary, p la ce a s u p p o rt u n d e r th e s ta n d to p re v e n t the rea r w he el co n ta cting th e ground. 15 Let th e engine cool and check the coolant level (see Daily (pre-ride) checks), then install the body panels (see Chapter 9). 16 Do no t dispose o f th e old coolant by pouring it down the drain. Pour it into a heavy plastic container, cap it tightly and take it into an authorised disposal site o r garage - see W arning in Section 1.

A

3 Pressure cap

2.4 D etach th e ho se (arrowed) to drain the reservoir

2.7 Release any trapped a ir th rough the bleed valve (arrowed)

I

1 Where fitted, the pressure cap is designed to retain a specific w orking pressure within the cooling system and, in extreme cases, to

Cooling system (liquid-cooled engines) 3*3

4.2 T em perature sender w iring con ne cto r gauge sender e before it becomes a danger tration). >r checking th e cooling system (see er 1), problems such as overheating or »f coolant still occur, have th e cap g pressure checked by a scooter th the special tester required for the jib.If the cap is defective, renew it. .

Iperature gauge Check 11Thecircuit consists o f the sender mounted h the cylinder head or th erm ostat housing and the gauge or warning light in th e instrument panel. If the system malfunctions, Ifrst check the coolant level (see Daily (pre Push th e n eedle up fro m th e b ottom

4*10 Fuel and exhaust systems rem ove it (see illu s tra tio n ). Discard the gasket, as a new one m ust be used. 6 On carburettors with an accelerator pump, either withdraw the accelerator pump spring and plunger from th e carburettor body, noting how it fits, or unscrew the accelerator pump assem bly from the floa t cham ber (see illustration). Discard the O-ring as a new one must be fitted. 7 Using a pair of th in-nose pliers, carefully withdraw th e float pin; if necessary, displace th e pin using a small punch or a nail (see illu s tra tio n ). Remove th e floa t and unhook th e float needle valve, noting how it fits onto th e ta b on th e float (see illustration). 8 Where fitted, undo the screw securing the float needle valve seat clamp, then withdraw th e valve seat (see illu strations). Discard the O-ring as a new one should be used. 9 Where fitted, remove the plastic jet cover. U nscrew th e pilo t je t and th e main je t (see illu s tra tio n s ). The main jet screw s into the base o f th e needle jet; if th e needle jet is slotted, unscrew it if required. 10 The pilo t screw can be rem oved if required, b u t note th a t its setting will be disturbed (see H aynes H int). U nscrew and remove the pilot screw along with its spring To re c o rd th e p ilo t s c re w ’s c u rre n t se ttin g , tu rn the screw in u n til i t seats lightly, cou ntin g th e n u m be r o f turns necessary to achieve this, then u nscrew i t fully. On installation, tu rn the screw in u n til i t seats, th e n ba c k i t o u t the nu m ber o f tu rn s y o u ’ve recorded.

H iN T

9.8b . . . and w ith d ra w the valve seat

9.5 Remove th e flo a t cham ber and O-ring, where fitted. Note: Do not remove the screws securing the throttle b u tte rfly to the throttle shaft.

9.6 W ithdraw th e a ccelerator pump assem bly

Inspection

C a u tio n : Use o n ly a p e tro le u m -b a s e d so lv e n t f o r ca rb u re tto r cleaning. D on’t use ca u s tic cleaners. 11 Follow Steps 11 and 12 in Section 8 to clean th e carburettor body and jets. If th e carburettor has an accelerator pum p, pay particular attention to th e fuel passage in the float chamber. On some carburettors, th e fuel passage is fitted with a one-way valve; blow through the fuel passage with compressed air from th e bottom of the pump piston housing. N ote: A vo id soaking the carburettor body in solvent i f any O-ring seals remain inside. C aution: N ever clean the je ts o r passages w ith a piece o f w ire o r a d rill bit, as th ey w ill b e en large d, c a u s in g th e fu e l a n d a ir m ete rin g rates to be upset.

12 If removed, check the tapered portion of th e pilot screw and the spring fo r wear or damage. Fit a new O-ring and renew the screw or spring if necessary. 13 Check the carburettor body, float chamber and to p cover fo r cracks, distorted sealing surfaces and other damage. If any defects are found, renew th e faulty com ponent, although renewal o f th e entire carburettor will probably be necessary. 14 Inspect th e piston diaphragm fo r splits, holes and general deterioration. Holding it up to a light w ill help to reveal problems of this nature. Insert th e piston in th e carburettor body and check th at th e piston moves upand-down smoothly. Check the surface of the piston fo r wear. If it’s w orn o r scored excessively o r doesn’t move smoothly, renew the components as necessary. 15 W here fitte d, check th at th e clip is

9.7b Note h o w th e needle valve fits on the flo a t tab

9.8a Remove th e clam p screw (arrowed)..,

Cleaning

9.9a Remove the je t c o v e r. . .

9.9b . . . then u n screw th e main je t (A) and th e p ilo t je t (B)

4*11 Fuel and exhaust systems

m 9,27 Insert th e needle in to th e piston

9.28 Ensure th e d iaphragm and th e ta b (arrowed) are c o rre c tly seated

tly positioned on th e needle (see Data ||on). If necessary, rem ove th e clip and ; the needle fo r straightness by rolling it Saflat surface such as a piece o f glass. Fit a (needle if it’s bent o r if the tip is worn. ■Relitthe clip for safekeeping. 16 Inspect the tip o f th e float needle valve. If it has grooves or scratches in it, o r is in any wayworn, it must be renewed. If th e valve seatis damaged, check th e availability o f new parts, otherwise a new carburettor body will have to be fitted. N ote : On scooters w ith a pumped and pressurised fuel system, a worn orrectly-sized carb urettor floa t needle i seat will not be able to shut o ff the fuel b/y sufficiently to pre ven t carburettor ling and excessive use o f fuel. 17 Operate the th ro ttle shaft to make sure thethrottle butterfly valve opens and closes | smoothly. If it doesn’t, cleaning th e throttle J linkage may help. Otherw ise, renew th e I carburettor. 18 Check the float for damage. This will usually tieapparent by th e presence of fuel inside the float. If the float is damaged, it must be renewed. 19 Inspect the automatic choke unit plunger and needle for signs of wear and renew the unit if necessary. To check the operation of thechoke unit see Section 5. 20 Inspect the accelerator pump piston and I itsseat in the float chamber fo r signs o f wear. Ensurethat the spring and th e rubber boot are not damaged or deformed and renew them if sary.

necessary, the carburettor float height should be checked at this point (see Section 10). 26 On carburettors with an accelerator pump, either install th e accelerator pump spring and plunger in th e carburettor body, o r fit a new O-ring to th e accelerator pump assembly, then screw the assem bly into th e floa t cham ber (see Step 6). Fit a new gasket onto the float chamber, making sure it is seated properly in its groove, then install the chamber onto the carburettor and tighten the screws securely. If necessary, th e carburettor fuel height should be checked at this point (see Section 10). 27 Check that the clip is correctly positioned on th e needle, then insert the needle into the piston (see illustration). If applicable, install the spring and spring seat, then fit needle retainer. 28 Insert th e piston assem bly into th e c arburettor body and push it dow n lightly, ensuring the needle is correctly aligned with th e needle jet. Align the ta b on the diaphragm w ith th e recess in th e carburettor body, then press th e diaphragm outer edge into its groove, making sure it is correctly seated (see illu s tra tio n ). C heck th e diaphragm is not creased, and that the piston moves smoothly up-and-down in its bore. 29 Install th e spring into the piston and fit the top cover to th e carburettor, making sure the spring locates over the raised section on the inside o f the cover, then tighten the cover screws securely (see illustration).

30 W here fitte d , install th e choke unit mounting w ith a new gasket. 31 Install th e autom atic choke unit and secure it w ith its clam p. If fitte d , install th e choke unit cover. 32 If removed, install the accelerator pump lever and return spring and secure them with th e screw. 33 Install the carburettor (see Section 7).

10 Fuel level and float height check

^

1 If th e carburettor floods when the scooter is in use, and the floa t needle valve and the valve seat are good, th e fuel o r flo a t height should be checked and the result compared to the specification in the Data section at the end o f this manual.

Fuel level check 2 If not already done, remove th e carburettor (see Section 7). 3 S upport th e c arburettor up rig ht in a vice and connect a length o f clear fuel hose to the drain union on the base of the float chamber. Secure the hose up against th e side o f the c arburettor and m ark it level w ith th e float cham ber-to -ca rb ure ttor body jo in t, or the level mark on th e side o f th e carburettor body' (see illustration).

Reassembly Note: When reassembling the carburettor, be sure to use new O -rings a n d seals. Do n o t | wertighten the carburettor jets and screws as j theyare easily damaged. 21 If removed, install th e pilot screw, spring andO-ring; adjust the screw to the setting as noted on removal (see Step 10). 22 If removed, install the needle jet. 23 Install the main jet and th e pilot jet; install theplastic jet cover where fitted. 24 If removed, install th e floa t needle valve seat using a new O -ring, then fit th e clam p andtighten the screw. 25 Hook the float needle valve onto the float b, then position the float assembly in the carburettor, making sure the needle valve enters itsseat. Install the pin, making sure it is secure. If

^

t-u p fo r m easuring th e fu el level in th e c a rb urettor

4*12 Fuel and exhaust systems

11Reed valve (two-stroke engines) - removal, inspection ^

and installation

SS

Removal

10.7 M easuring th e c a rb urettor flo a t height 4 Carefully pour a small am ount o f fuel into th e carburettor via the fuel hose union, then undo th e drain screw in the bottom o f th e float chamber enough to allow fuel to flow into the clear hose. Continue pouring fuel into th e carburettor until th e float needle valve shuts o ff the supply, at which point th e level in the clear hose should be at the specified height in relation to th e mark (see Data section at the end o f this manual). 5 If the fuel level is incorrect, remove the float chamber and check the float ta b for wear or damage (see Section 8 or 9). If th e float tab is m etal it can be adjusted carefully to correct th e fuel height, otherwise a new float will have to be fitted.

Float height check

1 Remove the carburettor, along w ith th e intake manifold (see Section 7). 2 W ithdraw th e reed valve from th e crankcase, noting w hich way round it fits (see illustration). 3 Discard any seals or gaskets, as new ones m ust be fitted.

12

Throttle cable and twis

- removal and installation

Js

W arning : R e fe r to the p re c a u tio n s g ive n in Se ction 1 be fo re proceeding. Note: A ll four-stroke engines and two-stroke engines fitted with centrifugal oil pumps (see Chapter 2A) are fitted with one-piece throttle cables. Two-stroke engines with cable-controlled oil pumps are fitted with three-piece cables.

A

One-piece cable

Inspection

R em oval

4 Check th e reed valve body closely fo r cracks, distortion and any other damage, particularly around the m ating surfaces between the crankcase and the intake manifold - a good seal m ust be maintained between th e com ponents, otherwise crankcase pressure and therefore engine performance will Be affected. 5 Check the reeds fo r cracks, distortion and any other damage. Check also that there are no d irt particles trapped betw een th e reeds and th eir seats. The reeds should s it flat against the valve body so that a good seal is obtained when th e crankcase is under pressure (see illu s tra tio n ). After prolonged use, the reeds tend to become bent and will not therefore seal properly, in which case the assembly should be renewed. A good way to check is to hold th e valve up to the light - if light is visible between the reeds and th e body they are not sealing properly. If the engine is difficult to start or idles erratically, this could be the problem. 6 Check that th e stopper plate retaining screws are tight; do not disassemble the reed valve unnecessarily as individual components are not available.

1 Remove th e upper or front handlebar cover, the engine access panel and any body panels as required on your scooter to access the cable (see Chapter 9). Where fitted, remove the carburettor cover, noting how it fits (see illu stratio n 7.1). 2 Disconnect th e cable from the twistgrip: (see Steps 20 to 23). 3 If necessary, release th e cable from the grom m et w here it passes through the handlebar cover (see illustration). 4 Detach the cable from the th rottle slide (see Section 8) o r th e carburettor pulley (see1 Section 9). 5 Ensure th e cable is free from any clips or guides, then w ithdraw it from the machine; noting th e correct routing.

6 If not already done, remove the carburettor (see Section 7). Remove th e floa t chamber (see Section 8 or 9). 7 Angle th e carburettor so th at th e float needle valve is resting against th e valve seat and measure the distance betw een th e float cham ber gasket face and the bottom o f the float (see illustration). 8 Compare the result with th e measurement in th e Data section. N ote : On some carburettors, i t is sufficie nt th at th e bottom straight-edge o f the floa t s hould be parallel w ith the gasket face. 9 If th e floa t height is incorrect, check th e float tab fo r wear o r damage (see Section 8 or 9). If th e float tab is metal it can be adjusted carefully to correct the fuel height, otherwise a new float will have to be fitted.

7 Installation is the reverse of removal, noting the following: • Ensure all m ating surfaces are clean and perfectly smooth. • Use new gaskets.

6 Installation is the reverse of removal, noting the following: • Lubricate the upper e nd o f the cable with grease before fitting i t into the twistgrip. j • Ensure th e cable is correctly routed anil clipped into place.

11.2 L ift o ff th e reed valve and g asket note th e ta b s (arrowed) fo r p ositioning

11.5 Reeds (A), valve body (B) and stopper pla te (C)

(arrowed)

Installation

EBS

W hen fittin g a n e w cable, ta p e th e lo w e r e n d o f the n e w c ab le to the up p e r end o f th e o ld cab le before rem o vin g i t fro m th e m ach in e. Slowly p u ll th e lo w e r e n d o f th e o ld cable out, g u id in g th e n e w ca b le do w n into position. Using th is m eth od w ill ensure th e cable is ro u te d correctly.

HiNT

In s ta lla tio n

7 Thethrottle cable consists o f three sections | -the main cable from th e tw istgrip goes into a | splitter, with separate cables from this going I tothe carburettor and oil pum p (see C hapI ter 1, Section 13). [ 8 If a cable problem is diagnosed, check the Iavailability of new parts - on some scooters it is possible to renew individual cables rather thanthe whole assembly. j 9 Remove the upper or front handlebar cover, theengine access panel and any body panels as required on you r scoo te r to access th e cables (see Chapter 9). Where fitted, remove Jthe carburettor cover, noting how it fits (see llustration 7.1). gO Disconnect th e cable from the tw istgrip (seeSteps 20 to 23). II If necessary, release the cable from th e grommet where it passes th rough th e handlebar cover (see illu stratio n 12.3). 12 Either detach th e cable from the throttle slide assembly and th e carburettor to p cover (see Section 8) or the carburettor pulley (see Section 9). 13 If required, to access th e cable at the oil pump, remove the plug in th e engine case or [ thepump cover on the engine side cover (see Chapter 1, Section 19). Loosen the cable adjuster locknut, then detach the cable end I fromthe pump pulley and detach the outer

4*13 Fuel and exhaust systems

12.17b . . . th en press in th e ta b s . . .

cable from its bracket or the engine c illustration). 14 If th e com plete cable assembly is being removed, ensure the cables are free from any clips or guides, then withdraw the assembly from the machine, noting th e correct routing. W hen fittin g a n e w cable, ta p e th e lo w e r e n d o f th e n e w c ab le to th e u p p e r e n d o f th e o ld c a b le be fo re r e m o v in g i t fro m th e m a ch in e. S lo w ly p u ll th e lo w e r e n d o f th e o ld cable out, g u id in g th e n e w c a b le d o w n in to po sition . Using th is m e th o d w ill ensure th e cable is r o u te d correctly. m

HiNT

15 If an individual cable is being removed, firs t detach the cable from the tw istgrip, c arburettor or oil pum p as applicable, then

12.18a Detach th e s p litte r (arrowed) from th e fram e . . .

detach the cable from th e splitter as follows. 16 Two types o f cable splitter are used. One operates w ith the throttle cable pulling on a pivoted cam, while th e other operates with the throttle cable pulling on a slider. 17 On models w ith the cam type splitter, first remove th e screw securing the splitter to its m ounting and draw th e cable covers off the splitter. Depress th e tabs on th e bottom o f the peg securing the splitter cover, then draw the peg ou t o f the splitter and remove the cover (see illustrations). Draw the outer cables out of their sockets, then lift the cam o ff its pivot and detach the cable ends from the cam as required, noting th eir relative positions (see illustrations). 18 On models with th e slider type splitter, first detach th e splitter holder from th e frame and draw th e covers off the splitter housing (see illustrations). Remove the cap from the splitter and pull the slider out o f the housing with the

12.18b . . . then pull o ff th e covers

4*14 Fuel and exhaust systems

12.18c Remove th e cap . . . throttle cable (see illu stratio ns). Detach the cable(s) from th e splitter as required, noting their relative positions (see illustration). C aution: B efore rem ovin g a cable, m ake a c a re fu l n o te o f its ro u tin g to ensure c o rre c t installation.

12.18d

. . . and pull o u t the slider

12.18e Detach th e cables from the splitter

twistgrip housing screws and separate the two halves of the housing (see illustrations). Detach th e cable end from its socket, then remove the cable from the housing, noting how it fits. 23 On models w ith a sliding tw istgrip, loosen

th e screw securing the end o f th e cable in the slider, th en draw th e cable ou t (see illu strations). Note the distance from the end of th e cable where th e screw located as an aid for correctly setting th e new cable.

12.22a Loosen the lo c k n u t (A) and thread the a djuster (B) fu lly in

12.22b Undo th e s crew s (arrowed) and rem ove the p la te . . .

12.22c . . . then detach the cable end (arrowed) from its socket

12.22d Undo th e s crew s (arrowed) and s p lit th e housing . . .

In s ta lla tio n 19 Installation is the reverse o f removal, noting th e following: • Lubricate the cable ends with grease. • Ensure the cables are correctly routed and clipped into place - they m ust not interfere with any other com ponent a nd should not be kinked o r bent sharply. • Adjust the cable freeplay and check the oil pum p setting (see C hapter 1). • Check the cable operation before riding the scooter.

Throttle twistgrip 20 T w o typ es o f tw istgrip are used. Some scooters have a m otorcycle typ e tw istgrip, where the end o f the inner cable fits into a socket in th e twistgrip. Others have a sliding typ e tw istgrip, where th e end o f th e inner cable is secured in a slider w ith a screw. The slider runs in a spiral track inside th e twistgrip. 21 To access the cable at th e tw istgrip, first remove th e upper o r fro n t handlebar cover (see Chapter 9). 22 On models with a motorcycle type twistgrip, loosen the cable adjuster locknut and thread the adjuster fully in to slacken th e cable (see illustration). Either pull back th e tw istgrip rubber, then remove the screws securing the cover plate and remove the plate, or undo the

. th en d etach th e cable end (arrowed)

12.23a Loosen th e cable clam p screw (arro w ed ). . .

4*15 Fuel and exhaust systems

13.3 Location of fu e l pum p - no te th e c lips r (arrowed) securing th e hoses

1Fuel pump - check and 1 renewal

A

& I

W arning: R e fe r to th e p re ca u tio n s g iv e n in S e c tio n 1 before proceeding.

13.5 C heck th e vacuum hose (arrowed) fro m th e crankcase hose, o r due to a s plit in th e vacuum hose from th e crankcase, before renewing th e pump (see illu stratio n). Check all th e hoses fo r splits, cracks and kinks, and check that they are securely connected on each end by a good clip. Check that any air vent for the fuel tank is not blocked. If th e filter and hoses are good, renew the pump.

Renewal

Check

6 Release th e clips securing th e fuel and When the engine is running, th e alternating vacuum hoses and detach them from th e n and pressure in the crankcase opens pump, noting which fits where. Be prepared to iloses a diaphragm in th e pump. catch any residue fuel in a suitable container. _ _ illy, the pump supplies fuel direct to the The fuel hoses should be clamped to prevent Carburettor, but on some scooters th e pump fuel leaks using any o f th e methods shown in lies fuel to a header tank which ensures Tools and Workshop Tips in the Reference mediate supply o f fuel to th e carburettor section. i the scooter has been standing unused. 7 Undo the pum p fixings and rem ove th e The most likely cause o f pum p failure w ill pump, noting w hich way up it fits. lasplit in the pump diaphragm. 8 Install th e new pum p, making sure th e Generally, the fuel pump is m ounted on the hoses are correctly attached and secured with jtne alongside th e fuel ta nk (see th e clips. If th e old clips are corroded or Illustration). Remove th e bo dy panels as deformed, fit new ones. required on your scooter to access the pump feeeChapter 9). 4 To check whether th e pum p is operating, 14Exhaust — the clip securing th e fuel supply hose system removal and installation carburettor, o r header tank as applicable, and detach th e hose. Place th e d in a container suitable fo r storing W arning: I f th e engine has been petrol. Turn the engine over on the starter ru n n in g th e e xh au st syste m w ill motor and check whether fuel flow s from the be very h ot. A llo w th e system to hoseinto the container. If fuel flows, th e pump I isworking correctly. c o o l b e fo re c a rry in g o u t an y work. 5 If no fuel flows from th e pump, first check N ote: Some scooters are fitte d w ith a onethat this is not due to a blocked filter or fuel

A

14.3b

. and th e tw o b o lts (arrowed)

i Undo th e tw o n u ts (a rro w e d ). . .

piece exhaust system. Follow th e procedure fo r removing the complete system.

Downpipe rem oval 1 Remove th e bo d y panels as required on you r scoo te r to access th e exhaust system and cylinder head (see C hapter 9). 2 On tw o-s trok e m achines fitte d w ith a secondary air system (see C hapter 1, Sec­ tion 3), loosen the clip securing the air hose to th e extension on th e exhaust dow npipe and disconnect th e hose.

HiNT o il

s eized. I t is a d v is a b le to spra y them w ith p e n e tra tin g be fo re a tte m p tin g to loosen the

3 Undo the nuts securing th e downpipe to the exhaust port in th e cylinder o r cylinder head, and the fixings securing the downpipe to the silencer and rem ove the do w np ipe (see illu s tra tio n s ). N ote : On systems where the do w npipe fits inside th e silen cer and is secured by a clamp it is necessary to remove th e silencer first (see Step 5). 4 Remove th e gasket from th e exhaust port and from the dow npipe-to-silencer join t and discard them, as new ones m ust be used (see illustrations).

S ilencer rem oval 5 Undo the fixing securing the silencer to the do w npipe (see illu s tra tio n 14.3b) and th e

4»16 Fuel and exhaust systems

14.5 Silencer is secured to th e fram e (A) and to the dow npipe (B)

bolts securing th e silencer, o r silencer bracket, to the engine or frame, and remove the silencer (see illu stra tio n ). Where fitted, remove the gasket from the silencer-todownpipe join t and discard it, as a new one m ust be used.

Complete system removal 6 Follow Steps 1 to 3 to access the exhaust system and disconnect the exhaust pipe from th e cylinder or cylinder head. Where fitted, disconnect the secondary air system. 7 Loosen th e bolts securing th e silencer, or silencer bracket, then support the exhaust system and remove the bolts. Lift the system off th e scooter (see illustrations). 8 Remove th e gasket from the exhaust port and discard it, as a new one m ust be used (see illu stratio n 14.4a). 9 The exhaust system o f restricted 50 cc tw ostroke machines is fitted w ith a resonator tube

14.7a Undo the b olts securin g the silen cer . . .

(see illu s tra tio n ). If your scooter has been de-restricted and the resonator tube has been removed, check around th e welded patch on th e exhaust fo r gas leaks. De-restricting requires a number of m odifications to the engine and should only be undertaken by a scooter dealer.

Installation 10 Installation is the reverse o f removal, noting th e following: • Clean the exhaust po rt studs and lubricate them with a suitable copper-based grease before reassembly. • Clean the join ting surfaces o f th e exhaust po rt and the pipe. • Smear th e p o rt gasket w ith grease to ho ld it in place while fittin g th e exhaust system.

14.7c . . . and lift o ff th e com plete system

14.7b . . . o r silen cer b r a c k e t. . . • Leave all fixings finger tight until the system has been installed a n d correctly aligned, then tighten the exhaust p o rt nuts first. • Run the engine and check that there are no exhaust gas leaks.

14.9 Resonator tube on r e stricted 5 0cc exhaust system

5*1

Chapter 5 Ignition systems Contents General information.................................................................................. 1 HTcoil and spark plug cap - check, removal and installation ......... 3 Ignition (main) switch ......................................................see Chapter 10 Ignitioncontrol unit (ICU) - check, removal and in s ta lla tio n ............... 6 Ignitionsystem - c h e c k ............................................................................ 2

Ignition timing - general information and c h e c k ................................. Immobiliser system - general information and c h e c k ........................ Source coil and pick-up coil - check and renewal ............................ Spark p lu g ............................................................................see Chapter

7 4 5 1

Degrees of difficulty Easy, suitable for novicewith little

&

Fairly easy, suitable fo r beginner with som e experience

^ ^

Fairly difficu lt, |k , suitable for competent DIY mechanic ^

D ifficult, suitable fo r experienced DIY mechanic

;~k ^

V e ry difficu lt, ^ suitable fo r expert DIY 3 ^ o r professional ^

Specifications Referto the Data section a t th e end o f this manual fo r servicing specifications.

1 General information

f All scooters covered by th is manual are fitted with a fu lly-transistorised electronic ignition system. The components w hich make upthe system are th e alternator source coil, ignition trigger, pick-up coil, ignition control unit (ICU), HT coil and spark plug (see illustration overleaf). The ignition trigger, which is on the outside surfaceof the alternator rotor, operates the pick­ upcoil as the crankshaft rotates, sending a signal totheICU which in turn supplies the HT coil with 8iepower necessary to produce a spark at the plug. The alternator source coil produces the powerfor the ignition system when th e engine is

running, and on m ost machines th e battery provides the power for initial starting. In the typical ignition circuit shown overleaf, th e solid black wires show the connection between th e ignition system components described above. The role o f the ignition switch is to complete the power feed to the starter motor circuit when in the ON position (see the circuit diagram on page 10.8) and to divert residual alternator source coil output to earth when turned to the OFF position. The hatched black wires illustrate th e ignition switch function. On som e scooters the HT coil is integral with the ignition control unit (see Section 3). The ICU incorporates an ignition advance system controlled by signals from the pick-up coil. This varies the timing o f th e ignition spark depending on engine speed. A lthough th e ignition tim in g can be checked on m ost

m achines (see Section 7), there is no provision fo r adjusting the timing. Depending upon th e m odel specification, m ost ignition system s incorporate a safety circuit which prevents th e engine from being started unless one of th e brake levers is pulled in and/or the side stand is up (refer to your scooter handbook fo r details). For security, many scooters are fitte d w ith an ignition immobiliser (see Section 4). Due to th eir lack o f mechanical parts, the components of the ignition system are totally maintenance-free. If ignition system troubles occur, and th e fa ulty com ponent can be isolated by a series o f checks, th e only cure is to renew it. Keep in mind that m ost electrical parts, once purchased, cannot be returned. T o avoid unnecessary expense, make sure th e fa ulty c om ponent has been positively identified before buying a new one.

5*2

n

Regulator/rectifier

1.1 W iring diag ra m fo r a typ ica l ig n itio n system (highlighted) R efer to Section 1 on the previous pa g e for an explanation o f system operation

Alternator

Auto choke

Ignition systems

Carburettor Starter heater m otor

Instrument panel

Ignition systems 5*3

Earth the spark plug and operate the starter

I Ignition system - check

Warning: The e n e rg y leve ls in electronic syste m s ca n b e very high. On n o a cc o u n t s h o u ld th e ■ ignition be s w itc h e d o n w h ils t heplug or plug cap is b e ing h e ld - shocks the HT c irc u it ca n b e m o s t unpleasant. Secondly, i t is v ita l th a t th e lineis not tu rn ed ove r w ith th e p lu g cap inved, and th a t th e p lu g is so u n d ly ithed when th e syste m is c h e c k e d fo r tking. The ign ition system com ponents anbe seriously dam aged i f th e H T circ u it

--------

1Asno means of adjustment is available, any preofthe system can be traced to failure of a p i component or a simple wiring fault. Of itwo possibilities, the latter is by far the most jy. Inthe event of failure, check th e system in peal fashion, as described below. Ssconnect the HT lead from the spark ig. Connect the lead to a new plug o f the rect specification and lay the plug on the (ne with the thread earthed (see JpBtion). If necessary, hold the spark plug nthan insulated tool, i Warning: D o n o t rem ove th e A spark p lu g fro m th e en g in e to perform th is c h e c k - a to m is e d fu el b e in g p u m p e d o u t o f th e openspark plug hole c o u ld ign ite, causing re injury!

2.4 M easuring the resistance o f th e spark plug 3 Having observed the above precautions, turn the ignition sw itch ON and turn the engine over on th e starter motor. If th e system is in good condition a regular, fa t blue spark should be evident betw een the plug electrodes. If the spark appears thin or yellowish, o r is non-existent, further investigation w ill be necessary. Before proceeding further, turn th e ignition OFF. C a u tio n : Som e ig n itio n syste m s are d e sig n e d fo r th e co m b in e d re sista n ce o f th e s p a rk p lu g a n d s p a rk p lu g cap. To a vo id th e ris k o f dam aging th e ICU, a spark te sting to o l sh o uld n o t be used. 4 If required, spark plug resistance can be checked with a multimeter. Remove the plug and clean the electrodes (see Chapter 1). Set th e m ultim eter to th e K-ohm s scale and connect th e meter probes to th e term inal at th e to p o f the plug and th e central electrode (see illustration). Compare the result with the reading from a new plug o f the correct specification. If there is a great deal o f variance between th e readings, discard the old plug. 5 Ignition faults can be divided into tw o categories, namely th ose where th e ignition system has failed com pletely, and th ose w hich are due to a partial failure. The likely faults are listed below, starting with the most probable source o f failure. W ork through the list systematically, referring to the subsequent s ectio ns fo r fu ll details o f the necessary checks and tests. Note: Before checking the following items ensure that the battery is fullycharged and th a t all fuses are in g o od condition.

3.4a D isconnect the p rim ary c irc u it con ne cto rs fro m th e coil

and p rim ary c irc u it w irin g te rm ina ls (D) • Loose, co rrod ed o r dam aged w iring connections, broken o r sho rted w iring between any o f the com ponent parts o f the ignition system (see illu s tra tio n 1.1). • Faulty spark p lu g w ith dirty, w orn o r corroded plug electrodes, o r incorrect gap between electrodes (see Chapter 1). • Faulty HT coil o r spark plug cap. • Faulty ign ition (main) sw itch (see Chap­ ter 10). • Faulty imm obiliser (where fitted). • Faulty source coil. • Faulty pick-up coil. • Faulty ICU. 6 If the above checks don’t reveal th e cause o f th e problem , have the ignition system tested by a scooter dealer.

3 HT coil and spark plug cap -

^

check, removal and installation ^

Check 1 Trace the HT lead back from the spark plug c ap to th e HT coil and rem ove any body panels as required for access to th e coil (see C hapter 9). Disconnect th e battery negative (-ve) lead (see Chapter 10). 2 Pull the spark plug cap o ff the plug and inspect th e cap, HT lead and coil fo r cracks and other damage (see illustration). 3 On some scooters th e ICU and HT coil are integrated in one unit (see illu stratio n). If no te s t specifications are available in th e Data section, the only w ay to determ ine conclusively th a t th e unit is defective is to sub stitu te it w ith a know n go od one. If th e fault is rectified, th e original unit is faulty. 4 The con ditio n o f th e coil prim ary and secondary w indings can be checked w ith a multim eter. Note th e position o f the primary circu it w iring connectors, then disconnect them (see illu stratio n). N ote: If there is only one prim ary circ u it w ire th en th e co il is earfhed th rough its m ou ntin g - use the m ou ntin g as a substitute fo r th e earth wire te rm inal in this check. Set the m ultim eter to the appropriate ohms scale and connect the m eter probes to th e prim ary circu it w iring

5*4 Ignition systems

COIL MOUNTING

3.4b HT co il prim ary w ind in g check

3.5 HT co il secondary w ind in g check

term inals (see illu s tra tio n ). This w ill give a resistance reading fo r th e coil prim ary windings which should be consistent with the specifications in th e Data section. If , th e reading is outside th e specified range, it is likely th e coil is defective. 5 Set the m ultimeter to th e K-ohms scale and connect the meter probes to th e earth primary c ircu it w iring term inal and th e spark plug terminal inside the plug cap (see illustration). This will give a resistance reading fo r the coil secondary w indings. If the reading is not within th e specified range, unscrew th e plug cap from the HT lead and connect th e probes to the earth primary circuit wiring terminal and the core of the lead. If the reading is now as specified, the plug cap is suspect. If th e reading is still outside the specified range, it is likely that th e coil is defective. 6 Should any o f th e above checks not produce th e expected result, have your findings confirmed by a scooter dealer. If the coil is confirm ed to be fa ulty, it m ust be renewed; th e coil is a sealed unit and cannot be repaired. 7 To check th e condition o f th e spark plug cap, set th e m ultim eter to th e appropriate ohms scale and connect the meter probes to the HT lead and plug terminals inside the cap (see illustration). If th e reading is outside the specified range, th e cap is defective and a new one m ust be fitte d. If the reading is as specified, th e cap connection may have been fa ulty. Remake th e connection betw een the cap and the HT lead and check th e resistance

reading for th e coil secondary windings again (see Step 5).

3.7 M easuring th e resistance o f th e spark plug cap

Removal 8 Remove any bo dy panels as required fo r access (see Chapter 9). Disconnect the battery negative (-ve) lead (see Chapter 10). 9 Note the position of the prim ary circu it wiring connectors, then disconnect them (see illu s tra tio n 3.4a). Disconnect th e HT lead from th e spark plug. 10 Unscrew th e fixings securing the coil to the frame and remove it.

Installation 11 Installation is the reverse of removal. If the coil is earthed through its mounting, ensure th e mounting is clean and free from corrosion. Make sure th e wiring connectors and HT lead are securely connected.

4 Immobiliser system -

general information and check G eneral information C a u tio n : The use o f th e c o rre c t re s is to r type, sp a rk p lu g a n d su p p re sse r cap is esse n tia l to p re ve n t in te rfe re n ce w ith th e im m o b ilis e r syste m a n d po ssib le loss o f ke y program m ing. 1 The system com prises a security-coded ignition key w ith integral transponder, the immobiliser and transponder aerial. When the

a T ransponder aerial (arrowed) is clipped to th e ignition sw itch

key is inserted into th e ignition sw itch the security code is transmitted from th e key to the immobiliser via the aerial which is located around th e switch. The code deactivates th imm obiliser and th e warning LED on t instrument panel stops flashing. When the k« is removed, th e immobiliser is activated and th e warning LED starts flashing. Note: To minimise battery discharging, the warning LED goes ou t after a pe rio d o f tim e although the im m obiliser system remains active. Disconnecting the battery does no t deactivate the immobiliser system. 2 One master key and several ignition service keys are supplied w ith each machine from new. The keys and the imm obiliser are encoded by the fa ctory. The master key, should be kept in a safe place and not used on a day-to-day basis. 3 If an ignition key is lost, obtain a new oi from a scooter dealer and have th e system recoded. The dealer w ill require the master key fo r this purpose. Once th e system is recoded th e lost key w ill not deactivate the immobiliser. 4 The ignition keys can lose their code. If the machine w ill not sta rt w ith the ignition switched ON, and the LED continues to flf use a spare service key o r th e m aster key ar have th e system, including the key that has lost its code, recoded by a scooter dealer.

Check 5 Insert th e ignition key into th e switch and turn the sw itch ON. Once the LED stops flashing, th e im m obiliser has deactivated; if the machine will not start, the problem lies elsewhere. If the LED continues to flash, and using another key does not; deactivate the imm obiliser (see Step 4), the immobiliser is suspect. 6 ■Remove the bo dy panel to access the transponder aerial (see Chapter 9) and disconnect the battery negative (-ve) termini Trace the transponder aerial wiring from th ignition sw itch to th e imm obiliser f disconnect the w iring (see illustrations) C heck th e resistance in th e aerial with multimeter set to th e appropriate ohms seal Connect th e meter probes to th e terminals! the connector and compare th e result with tHT specifications in th e Data section (s|

4.6b D isconnect th e aerial w iring conne cto r fro m th e im m obiliser

Ignition systems 5*5 on). If the reading is not w ithin the n, fit a new aerial and try starting te again. | machine still will not start, the er should be checked by a scooter Note: It is not possible to substitute an w from another machine, oraseconds this will no t recognise the from your ignition key. w (uncoded) immobiliser is fitted, 6 that it is w orking before encoding it. p ignition ON and start the engine; the n b u t w ill no t rev above |jm. If the engine runs, th e immobiliser 4.6c M easuring th e resistance in the jded using th e master key. Note: tran spo nd er aerial jg the immobiliser is irreversible - only and disco nn ect it at the connector (see w immobiliser once y ou are sure illu s tra tio n ). N ote : On som e scooters, the jmis working correctly. w iring w ill c onnect directly into th e ICU, on fieengine does not start, the problem lies others there w ill be a m ulti-pin connector w here i t jo in s th e main w iring loom. If eck the LED, remove the instrument available, use your scooter’s w iring diagram Irand test fo r continuity betw een th e to identify the appropriate wires. Alternatively, linals (see illustration). There should check th e colour-coding o f th e w ires a t the nuity in one direction only. If there is source coil (on th e alternator stator) and the feiuity, or continuity in both directions, pick-up coil adjacent to th e alternator rotor. BheLED. 3 Using a multim eter set to th e appropriate function codes ohms scale, measure th e source coil resistance by connecting the meter probes between the B LED should flash once when th e coil term inals on the alternator side o f the p is switched ON. If the LED continues connector. Now reset th e m ultim eter and ih and then stays on permanently to measure the pick-up coil resistance by Ijian ignition fault, try using th e master connecting the meter probes betw een the Eto turn the ignition ON. If this works, the pick-up terminals in th e connector. feekey has lost its programme. If the fault 4 Compare th e readings obtained with those Kts, refer to your scooter handbook for given in th e Data section. If th e readings afeofmalfunction codes. obtained d iffer greatly from those given, particularly if th e m eter indicates a short I Source coil and pick-up coil circuit (no measurable resistance) o r an open (-check and renewal c irc u it (infinite, o r very high resistance), th e alternator sta tor and pic k -u p coil assembly m ust be renewed. However, first check that the fault is not due to a damaged o r broken heck wire from th e coil to th e connector; pinched or jo check the condition o f th e source coil broken wires can usually be repaired. nl the pick-up coil it is first necessary to 5 Some scooters are fitted w ith a motorcyclethe w iring fo r the individual typ e alternator w ith three yellow w ires from j&ients. Remove th e body panels and the stator. Using a m ultimeter set to the ohms ratbr or engine cover as required scale, measure resistance o f each coil by raihg to model (see C hapter 9) and connecting th e m eter probes betw een th e ectthe battery negative (-ve) lead. yellow w ire te rm inals in the connector. See the source coil and pick-up coil Compare th e result with the specifications in hgfrom the back o f th e alternator housing the Data section. Also che ck fo r continuity

Disconnect th e a lte rn a to r/p ick -u p coil w iring con ne cto r

6.2a Undo th e ICU fix in g s . . .

4.10 LED te rm ina ls (arrow ed) on the in stru m e nt c lu s te r c irc u it between each te rm inal and earth - there should be no continuity. 6 On some scooters, th ere is a short w iring loom between th e m ulti-pin connector and the ICU. To check th e con ditio n o f th is loom, disconnect th e ICU wiring connector and test fo r continuity between the terminals in th e ICU connector and th e alte rna tor/p ick-u p coil m ulti-pin connector.

Renewal 7 The source coil and p ick-up coil are integral with the alternator stator. Refer to th e relevant Section o f C hapter 2 fo r the rem oval and installation procedure.

6 Ignition control unit (ICU) -

^

check, removal and installation SjK Check 1 If the tests shown in th e preceding sections have failed to isolate the cause of an ignition fault, it is possible that th e ICU itself is faulty. In order to determine conclusively that the unit is defective, it should be substituted with a known good one. If the fault is rectified, th e original unit is faulty. Note: The ICU unit will be damaged i f a non-resistor type spark plug o r spark plug cap are fitted. When fitting a n ew IC U unit, always ensure the spark plug and cap are of the correct specification before starting the engine.

Removal 2 Remove the bo dy panels as required according to m odel (see C hapter 9) and

6.2b . . . o r u n clip i t fro m its holder (arrowed)

5

5*6 Ignition systems disconnect the battery negative (-ve) lead. Disconnect th e w iring connector(s) from th e ICU. Unscrew the nuts and bolts securing the unit to th e frame, or unclip it from its fixing, and remove th e unit (see illustrations).

Installation 3 Installation is th e reverse o f removal. Make sure the w iring connector is correctly and securely connected. Note: Some scooters are fitte d w ith a com bined IC U and ignition immobiliser. When a new unit is fitte d it must be encoded b y a scoo te r dealer using your ignition master key.

7 Ignition timing - general information and check

^ ^

remains indistinct. If possible, one o f th e more precise xenon tu be lamps should be used, pow ered by an external source of th e appropriate voltage. N ote: Do n o t use the m achine’s own battery as an incorrect reading m ay result from stray impulses within the m achine's electrical system. 3 Every engine has tw o marks - a static mark, either on th e alternator cover or on the inside o f an inspection hole, and a mark on th e alternator rotor or cooling fan (see illustrations). Refer to your scooter handbook fo r the exact location of th e timing marks and th e engine speed at which the marks should align.

Check 4 Warm th e engine up to normal operating temperature then turn it OFF. 5 Connect th e timing lamp to the spark plug HT lead as described in the manufacturer’s

G eneral inform ation 1 Since no provision exists fo r adjusting the ignition tim in g and since no com ponent is subject to mechanical wear, there is no need fo r regular checks; only if investigating a fault such as a loss of power or a misfire, should the ignition timing be checked. 2 The ignition tim ing is defined by th e relationship between tw o timing marks - one on th e alternator rotor and a static mark on the engine. The alignment of th e tw o marks is checked w ith th e engine running (dynamically) using a stroboscopic lamp. The inexpensive neon lamps should be adequate in theory, but in practice may produce a pulse of such low intensity th a t th e tim in g m ark on th e rotor

7.3a Static tim in g m ark on the a lternator cover

6 Start th e engine and aim the light at the static tim in g mark. W ith th e machiiS running at th e specified speed, th e timinc mark on th e rotor should align with th e idli timing mark.

The tim in g m a rks ca n be h ig h lig h te d w ith w h ite paint to m ake th e m m ore visible un d e r th e stroboscope light.

7 Slowly increase th e engine speed whilst observing th e tim ing mark. The tim ing mart should move anti-clockw ise, increasing ill relation to th e engine speed until it reache) the full advance m ark (where present). 8 If th e ignition tim ing is incorrect, a suspected of being incorrect, one of tht ignition system com ponents is at fault, ano the system m ust be tested as described in tw preceding Sections o f this Chapter.

7.3b Tim ing m ark on th e a lternator rotor (arrowed)

6*1

Chapter 6

Transmission: Drive components and gearbox ntents chand clutch pulley - removal, inspection and in s ta lla tio n ----- 6 sit-inspection and renewal ...................................................... 5 cover - removal and insta llatio n........................................... 2 - removal, inspection and installation.................................. 7

General info rm a tion................................................................................ Kickstart mechanism - removal, inspection and insta llatio n............. Variator - removal, inspection and installation ....................................

1 3 4

grees of difficulty Easy, suitable for novicewith little ©perience

Fairly easy, suitable fo r beginner with som e experience

^

Fairly difficult, suitable fo r competent DIY mechanic ^

D ifficult, suitable fo r experienced DIY mechanic

^ ^

Ve ry difficu lt, ^ suitable fo r expert DIY ^ o r professional ^

Specifications 9ferto the Data section a t th e end o f this manual fo r servicing specifications.

General information

Hie transmission on all scooters covered this manual is fully-automatic in operation.

Power is transm itted from the engine to the rear w heel by belt, via a variable-size drive pulley (the variator), an autom atic clutch on th e driven pulley, and a reduction gearbox, T he variator and th e autom atic clutch both w ork on th e principal o f centrifugal force. N ote : On some scooters th e internal

com ponents o f th e transm ission may d iffer slightly to those de scrib ed o r shown. When dism antling, always no te th e fitte d position, order and way round o f each com ponent as it is removed. The transm ission can be w orked on with th e engine in th e frame.

6*2 Transmission: Drive components and gearbox

2 Drivebelt cover -

';>■

removal and installation

Removal 1 Remove any body panels as required for access to th e transm ission casing (see C hapter 9). If required, rem ove th e air filter housing (se Chapter 4). 2 Undo th e screw securing th e rear brake cable o r hydraulic hose bracket to th e underside o f th e transm ission casing and remove th e bracket (see illustration). 3 Where fitte d, detach th e air cooling duct from th e front o f the cover (see illustration). On fo ur-stro ke engines, where th e oil filler plug passes th rough the cover, remove the plug (see illustration).

2.3a Detach th e a ir cooling d u c t (arrowed)

2.3b If necessary, rem ove th e o il fille r plug

4 Some scooters have a plastic trim fitted over the main belt cover. If necessary, remove th e kickstart lever (see Section 3), then undo the screws securing th e trim and remove it. Refit the kickstart lever - this is to prevent the kickstart shaft being accidentally knocked th rough th e cover and dislodging the mechanism return spring. 5 On some scooters, th e gearbox input shaft passes through th e drivebelt cove r and is supported by a bearing in the cover. To undo th e nut on th e outer end o f the shaft, first unclip th e plastic cap on th e clutch bearing housing (see illu s tra tio n ). The clutch drum m ust be locked against th e belt cover to prevent the shaft turning w hile the nut is undone. Either use a service tool to hold the clutch drum, or insert tw o large screwdrivers through the holes in the belt cover to engage th e holes in th e clutch drum. Have an

assistant hold the screwdrivers while the nutj is undone (see illustration). Remove the nut and washer. 6 Working in a criss-cross pattern, loosen the drivebelt cover retaining bolts and remove the bolts noting th e position o f any clips. Note: On scooters fitted with a kickstart lever it is not necessary to rem ove the lever before removing the cover.

2.5a Rem ove th e c lutch bearing cap

2.7 L ift o ff the d riveb elt cover

2.8 Note th e spacer on the shaft

M ake a ca rd bo ard template , o f th e c o v e r a n d punch a ho le fo r each b o lt location. This w ill e nsure all b o lts are insta lle d correctly on reassem bly - this is im p o rta n t a s som e b o lts m ay be of d iffe re n t lengths. 7 Lift off th e cover and note the position of any locating dow els (see illustration). Remove th e dowels fo r safekeeping if they are loose. Note: Sealant should n o t be used on the cover, b u t i f it will not lift away easily, tapft gently around th e edge with a soft-faci hammer. Some scooters have a cover m anufactured from com posite material: fitted w ith a gasket. If the gasket is damaged, discard it and fit a new one oil reassembly. 8 On models where the gearbox input shaj passes through the belt cover, note the spacer on th e shaft (see illustration). 9 Where fitted, note th e position of the kickstart quadrant and th e engaging pinion (see illu s tra tio n 3.2). If the starter motor engages with the variator, note how the outer end o f th e starter m otor pinion assembl) locates in the cover. 10 If fitted, undo the retaining bolt for the air cooling duct and remove the duct. Inspect#! duct filter element (see Chapter 1). 11 Clean any dust or dirt from th e inside (I th e casing w ith a suitable solvent, taking cai to avoid contact w ith th e belt and the drW faces of the pulleys. Any evidence of oil ins* the casing suggests a worn seal either on # crankshaft or the gearbox input shaft whk m ust be rectified. Evidence of grease insid the casing suggests worn seals either in tli variator or th e clutch centre which should m be rectified.

Transmission: Drive components and gearbox 6»3 foliation filiation is the reverse o f removal, ingthe following: 1, fit the dowels in the cover. f t required, apply a smear o f grease to the f t of the starter m oto r pinion and to the tads of the cover bolts. pdels where th e gearbox input shaft |es through th e b e lt cover, ensure the eris in place on the shaft. re fitted, ensure th e kickstart quadrant hdengaging pinion are correctly located in pecover. igMen the cover bo lts evenly in a crissbs pattern. ■e fitted, crank th e kickstart lever to Ssure the mechanism engages correctly Ith the kickstart driven gear and that the 9f returns to its p ro p e r rest po sition wards.

3

Kickstart mechanism -

removal, inspection and installation

% *

Removal 1 Remove the drivebelt cover (see Section 2). Where fitted, remove the mechanism cover from the inside of the drivebelt cover (see illustration). 2 Pull the engaging pinion o u t o f its recess in th e cover, noting how the spring locates (see illustration). Remove th e washer from behind the pinion. 3 Note the rest position o f the kickstart lever, then undo th e lever pin ch-bo lt and pull the lever off the shaft (see illustration). 4 Remove th e circlip and washer (if fitted) from the kickstart shaft on th e outside o f the cover (see illustration).

5 Ease th e kickstart shaft out of th e cover and release the tension on th e k ickstart return spring. Unhook th e spring from th e kickstart quadrant and rem ove the sha ft (see illustration). 6 Note how th e return spring locates inside th e cover and rem ove th e spring (see illu s tra tio n ). If it is a loose fit, lift o u t th e kickstart bush (see illustration). 7 Clean all the com ponents w ith a suitable solvent.

Inspection 8 Check th e dogs on the end o f th e engaging pinion and the corresponding dogs on th e kickstart driven gear (see illu s tra tio n ). Inspect th e teeth on th e engaging pinion and th e teeth on the k ickstart quadrant (see illustration). C heck th e shafts o f the engaging pinion and the kickstart quadrant, and th e

3.2 K ic k s ta rt quad ran t (A) and engaging pinion (B) are located in th e cover

3.3 Undo th e p in c h -b o lt and rem ove the k ic k s ta rt lever

3.5 Release th e tension in th e spring and unho ok i t fro m the q uadrant

3.6a U nhook th e sp rin g fro m th e p o st (a rro w e d ). . .

3.8a C heck th e d o gs on th e engaging pin ion and th e d o gs on th e driven gear

3.8b Inspe ct th e teeth (A) and the splines (B) on th e k ick sta rt q uadrant

6*4 Transmission: Drive components and gearbox

3.11 Q uadrant should b u tt a gainst th e sto p (arrowed) on th e inside o f the case

3.13 Operate th e k ic k s ta rt lever to draw th e pinion into th e case

4.2a Variator pulley te eth engage in notch (arrowed)

quadrant bush, for signs o f wear, and inspect th e splines on the end o f the quadrant shaft fo r damage. Renew any components that are worn o r damaged. 9 Ensure th e spring on the engaging pinion is a firm fit and inspect th e kickstart return spring fo r cracks and wear at each end. When fitte d, th e return spring should return th e kickstart lever to the rest position and hold.it there; if not, it has sagged and should be renewed.

th en fit the pinion into th e case. Align th e spring w ith the detent in the case, then operate the kickstart lever to engage th e pinion w ith th e kickstart quadrant and draw th e pinion into th e case (see illu s tra tio n ). Check th e operation o f th e mechanism. 14 Where fitted, install the mechanism cover (see illustration 3.1). 15 Refit th e drivebelt cover (see Section 2).

on reassembly - check with a scooter dealer. On some scooters, the kickstart driven gear is; held in place by the nut - note how the gear locates on the outer face of the pulley (see illu s tra tio n ). Remove the outer half of the

Installation 10 If removed, press the kickstart bush into the cover, then install the return spring with its long end innerm ost. H ook th e long end around the post on the inside o f th e cover (see illu stratio n 3.6a). 11 Lubricate the kickstart shaft with a smear o f molybdenum disulphide grease and insert it through the bush, then hook th e outer end of the return spring onto the quadrant. Rotate the sha ft anti-clo ckw ise against th e spring tension until th e quadrant can be butted against th e stop on the inside o f th e case (see illu stra tio n ). Ensure th e shaft is pressed all the way into the case, then install the washer (if fitted) and circlip. 12 Fit th e kickstart lever in the rest position and tighten th e pinch-bolt securely. Operate the lever to check that it turns smoothly and returns to its rest position under spring pressure. 13 Lubricate the shaft o f th e engaging pinion with a smear o f grease and install the washer,

4.2b Lo ck the c ran ksha ft w ith th e to o l (A) and undo th e n ut (B)

4 Variator - removal, inspection

and installation

^

Removal 1 Remove the drivebelt cover (see Section 2). 2 To remove the variator centre nut, th e crankshaft must be locked to stop it turning. O n engines with a toothed variator pulley, a service tool which bolts onto the engine case and locates between the teeth on the pulley is available to do this. Alternatively a similar tool can be made (see illustrations). On engines with cooling fan blades on the variator pulley, locate a suitable holding tool in the holes provided in th e pulley (see illu s tra tio n ). A holding tool can be made from tw o strips of steel (see Tool Tip). Note: The variator centre n u t is tigh t - to avoid damage, ensure the variator pulley is held firmly before attempting to undo the nut. 3 Undo th e variator centre nut. Note: Some m anufacturers recomm end fitting a new nut

4.2c Using th e h olding to o l to u ndo th e variator c entre nut

A h o ld in g to o l c an b e m ade using two s trip s o f s te e l b o lte d to g e th e r in the m iddle, a n d w ith a n u t a n d b o lt through each e n d w hich loca te in to th e holes in

Transmission: Drive components and gearbox 6*5 or pulley (see illu s tra tio n ). M ove the de - unless you are removing the jhassembly, leave th e belt on th e clutch K.Mark the belt w ith a directional arrow if smoved so th a t it can be refitted the get way round (see illustration), er hold the variator assem bly and aw the centre sleeve, then pull the ir assembly o ff the crankshaft (see rations), or pull the com plete variator jjnbly off th e shaft (see illu s tra tio n ). nil the variator is ju s t b eing displaced, theassembly so that the ramp plate at the ckis held into the variator bo dy as you te it, otherwise th e rollers inside w ill fall toll their ramps and the variator w ill have to sembled to reposition them. ive the w asher (if fitte d) from the shaft. Where fitted, remove th e screw s o r bolts

4.3b Rem ove th e o u te r h alf o f th e pulley

4.3c M ark th e d irec tio n o f ro ta tio n on the drivebelt

O-ring and discard it, as a new one m ust be fitted on reassembly (see illustrations). Some restricted 50 c c m achines have a restrictor pla te fitte d in th e variator - lift ou t the restrictor plate (see illustration).

7 Lift out th e ramp plate, noting how it fits, and rem ove the ram p guides (see illu strations). 8 Lift out the rollers, noting which way round they fit (see illustration).

4.4c Hold th e ram p p la te (arrow ed) to keep th e r ollers in place

4.6b . . . and lift o ff the cover. D iscard th e O -ring (arrowed)

4.7a Lift o u t th e ram p plate . . .

plate

4.8 L ift o u t th e rollers

6*6 Transmission: Drive components and gearbox

4.9 Clean th e c om ponents o f th e variator th orou gh ly

4.10 Measure th e d iam eter o f each roller

4.13 C heck th e splines (arrowed) fo r wear and th e surface o f th e pulley fo r blueing

9 Clean all th e com ponents using a suitable solvent (see illu s tra tio n ). N ote: Some m anufacturers lubricate th e rollers with high m elting-point grease - refer to y o u r scooter handbook for details.

where they fit in th e variator body and fit new components as necessary. 12 Inspect th e surface o f the variator sleeve fo r wear and fit a new one if necessary. 13 Check the condition of the splines in the centre of the outer half o f the variator pulley and inspect th e inner face o f th e pulley for signs of overheating or blueing, caused by the pulley running out o f alignm ent (see illu s tra tio n ). Renew the pulley half if it is

fitte d on the ramp plate and install th e plate (see illu stratio n 4.7b). 16 On restricted 50 cc machines, fit the restrictor plate. 17 Where fitted, fit a new O-ring in th e groove around the variator body, th en install the cover, taking care not to dislodge the. O-ring, and tighten th e cover screw s or bolts securely. 18 Install th e washer (if fitted) c crankshaft. Grip the variator so that the ramp plate is held into th e bo dy and install the assembly and th e centre sleeve (see Step 4). Note: If the ramp plate moves and the rollers are dislodged, disassemble th e variator and reposition the rollers correctly. 19 Clean both inner faces of the variator pulley with a suitable solvent, then compress the clutch pulley centre spring and press the drivebelt into the clutch pulley to facilitate fitting it over the variator pulley (see illustrations). 20 Install the outer half o f th e variator pulley, ensuring the splines align w ith the crankshaft If required, install th e kickstart driven gear (see Step 3). Fit th e centre nut finger tight. N ote: A new centre n u t should be fitted it recom m ended b y th e m anufacturer. Make sure the outer pulley half bu tts against the centre sleeve and is not skewed by the belt. 21 Install the locking tool used on remova (see Step 2) and tighten the centre nut to the specified torque setting. 22 Measure th e distance between the crankcase face and the edge of th e outf pulley half, then rotate the crankshaft and repeat th e measuring procedure several times to ensure the outer pulley half is not skewi (see illustration). 23 Ease the drivebelt out o f the clutch pulli to reduce th e slack in the belt (see illustration), then fit the cover (see Section2)

Inspection 10 Measure th e diameter o f each roller; they should all be the same size (see illustration). Inspect the surface of each roller fo r flat spots. If any rollers are worn below th e size specified in th e Data section, or have worn flat, renew all th e rollers as a set. Note: Variator rollers are n o t interchangeable between different models. Always specify the year and m odel o f you r scooter when buying new rollers. 11 Inspect th e surface o f th e ram ps in the variator body and th e ramp plate for wear or damage. Check th e slots in th e ramp guides

4.19a Clean th e inner faces o f th e variator p u lle y . . .

Installation 14 If required, lubricate the rollers and the ramps w ith high melting-point grease, then fit th e rollers into th e variator bo dy (see illu s tra tio n 4.8). Note: Too m uch grease in the variator will make it run out o f balance and cause vibration. 15 Check that the ramp guides are correctly

,19b . . . th en press th e belt into th e clutch pulley and fit i t onto th e variator pulley

5 Drivebelt -

inspection and renewal

Inspection 4.23 Ease th e b elt into place between the tw o pulleys

1 M ost m anufacturers specify intervals fo r drivebelt inspection and service limits fo r the w idth of the belt, but it is gai

Transmission: Drive components and gearbox 6*7

6 Clutch and clutch pulley -

removal, inspection and installation

^

Rem oval

5.2a Check th e b e lt fo r dam age check th e con ditio n o f th e (henever th e cover is rem oved (see jn2). sck along the entire length of th e belt for ks, splits, fraying and damaged teeth and h the belt if any such damage is found. ! the belt w idth and com pare th e t with th e specification in th e Data at the end o f th is manual (see itions). FtThebelt will wear during the normal course ^fuseand dust w ill accum ulate inside th e yt, However, a large am ount o f du st or 5 inside th e cover is an indication of il wear and the cause, such as high n the pulleys or th e pulleys running out jnment, should be investigated. [Hote: Drivebelts are no t interchangeable sen different models. Always specify the

year and m odel o f your scooter when buying a new belt. I f in doubt, check the p a rt number m arked on the belt. 4 Oil or grease inside th e casing w ill contaminate the belt and prevent it gripping th e pulleys (see Section 2).

Renewal 5 The drivebelt m ust be renewed at th e specified service interval, or earlier dependant on belt condition (see Step 2). Remove th e outer half o f th e variator pulley (see Section 4) and lift the belt o ff th e crankshaft and th e clutch pulley w itho ut disturbing th e variator assembly. 6 Fit the new belt, m aking sure any directional arrows point in th e direction of normal rotation, then install the variator outer pulley half (see Section 4).

1 Remove th e drivebelt (see Section 5). 2 To rem ove th e c lu tc h centre nut it is necessary to hold th e clutch to prevent it turning. On some scooters, a holding tool that locates in th e holes in the clutch drum can be used (see Section 4 T o o l Tip)] alternatively you can use a strap w rench (see illustrations). N ote 1: On machines where the gearbox inp ut shaft passes through th e driveb elt cover, th e clu tch centre n u t w ill already have been removed. Note any spacer on th e gearbox in p u t shaft and rem ove it. N o te 2: Some m anufacturers recom m end fitting a new nut on reassembly - check w ith a scooter dealer. 3 Remove th e clutch drum (see illu s ­ tration). 4 Draw th e clutch and pulley assembly off the gearbox input shaft (see illu s-tra tion ). 5 To disassem ble the c lu tc h and pulley assem bly, th e cen tre spring m ust be com pressed w hile the assem bly nu t is undone (see illu s tra tio n s ). M ost m anufacturers produce a service tool to d o this. Alternatively, use th e set-up show n, ensuring no pressure is applied to the rim o f th e pulley and th a t th ere is

6.2a Prevent the c lu tch fro m tu rn ing w ith a J hom e-m ade t o o l. . .

iH!|S 6.4 . .. then pull the c lu tch and pulley o ff th e shaft

/

6.5a To u ndo th e c lu tc h assem bly nut (arro w ed ). . .

6.5b . . . th e cen tre spring (arrowed) m ust be com pressed

6*8 Transmission: Drive components and gearbox

6.5c A hom e-m ade clam p fo r disassem bling the c lutch

th e rim (arrowed) o f the pulley

and u ndo th e nut

adequate room to undo the nu t (see illustrations). 6 Fit a strap w rench around th e clutch shoes to hold th e assembly while th e nut is

undone, then release th e spring pressure gradually by undoing the clam p (see illustration). 7 Remove th e clutch shoes and backplate,

then remove th e spring seat, th e spring and the centre sleeve (see illustrations). 8 Note th e tw o O -rings fitte d to the pulley outer half and remove them carefully (see illu s tra tio n ). N ote: If the O-rings are damaged, o r i f grease from th e clutch centre has w orked its way pa st th e O-rings, they should be renewed. 9 Withdraw the guide pins and separate the pulley halves (see illustrations). 10 Clean all th e components with a suitable solvent.

Inspection

6.7a L ift o ff th e spring s ea t (A) and spring (B ). . .

6.8 Rem ove th e O -rin gs c arefully

6.9b

. and separate th e pulley halves

6.9a W ithdraw th e g uide pins ..

6.11 Measure th e internal diam eter o f th e drum as described

11 Check th e inner surface o f th e clutch drum for damage and scoring and inspect the splines in th e centre; renew it if necessary. Measure the internal diameter of the drum at several points to determine if it is worn or outof-round (see illustration). If it is worn or outof-round, renew it. 12 Check the am ount of friction material remaining on th e clutch shoes (see illu stratio n). If the friction material has worn to th e service lim it specified in th e Data section, down to th e shoe, or the shoes are worn unevenly, fit a new shoe assembly. 13 Inspect the shoe springs for wear, cracks and stretching. Ensure that th e shoes are not seized on their pivot pins and that the retaining circlips, where fitted, are secure on the ends of th e pins (see illu stratio n 6.12). K any parts are worn or damaged, fit a new shoe assembly. 14 Check the condition of the centre spring.

6.12 C heck the c lu tc h fric tio n m aterial (A), shoe springs (B) and retaining clips (C)

Transmission: Drive components and gearbox 6*9

y ■

6.17 Inspect th e pulley internal seals (arrowed) j is bent or appears weak, renew it. jsure the free length o f the spring and (pare the result with th e figure in the Data Son. Fit a new spring if it has worn to less (the service limit. Inspect the inner faces of th e clutch pulley signs of overheating or blueing, caused by ipulley running out of alignment. Inspect the guide pins and th e pin slots Check the seals inside th e pulley outer I (see illustration). If th e seals are worn or imaged, grease w ill pass onto the face of ipulley. On m ost scooters, tw o bearings fitted in th e hub o f the pulley inner half; iispect the rollers of the inner bearing fo r flat Is and ensure the outer sealed ball___ ring turns sm oothly (see Tools and Workshop Tips in the Reference section). If of the clutch pulley internal components iworn or damaged, they must be renewed. ;k with a scoo te r dealer as to the ability o f new parts - details o f bearing seal renewal are given in Tools and Workshop Tips. If individual components are available, or if a number o f com ponents iworn, fit a new clutch pulley assembly.

Installation 18Assemble th e tw o halves o f th e clutch pulley and install the guide pins and the Orings. Lubricate th e pin slots w ith molybdenum disulphide grease, th en fit th e centresleeve, th e centre spring and th e spring seat. 19 Position the shoe assembly on th e spring

7.4 L ift away th e gearbox cover

•

'

7.2 Gearbox fille r plug (A) and drain plug (B)

7.3 Undo th e g earbox cove r b olts

seat and compress th e spring using th e same m ethod as fo r disassem bly (see S tep 5). Ensure the flats on the shoe backplate are aligned w ith th e pulley hub and install th e assembly nut finger tight. Hold th e assembly with a strap wrench around th e clutch shoes and tighten the nu t to th e to rq ue setting specified in the Data section, then release the clamp (see illu stratio n 6.6). 20 Lubricate the needle bearing in th e hub of th e pulley inner half w ith m olybdenum disulphide grease and install th e clutch and pulley assembly on the input shaft. Install the clutch drum, ensuring the splines align with th e shaft. 21 Install th e remaining com ponents in the reverse order of removal, noting th e following: • Where fitted, insta ll th e spacer on the gearbox shaft (see Step 2). • If required, use a new clutch centre nut. • Tighten th e centre nu t to the specified torque setting. • Clean both inner faces o f the clutch pulley with a suitable solvent before installing the drivebelt (see Section 5).

rear brake, rem ove the rear w heel; on machines fitted w ith a disc rear brake, remove the rear wheel, hub and brake d isc (see Chapter 8). 2 If a drain plug is fitted to th e machine, drain th e gearbox oil (see illu s tra tio n ). Note: Remove th e filler plug to assist oil drainage. 3 U nscrew th e bo lts securing the gearbox cover and rem ove them (see illu s tra tio n ). N ote : D epending upon th e design o f y o u r scooter, the gearbox cover is fitte d e ither on the left-hand side o f the transmission casing, behind the clutch, o r on the rig ht-h an d side b e hin d th e rear wheel. The cove r bo lts are usually p o sition ed on the same side as th e cover, although on som e m achines w ith a right-hand cover, the bolts pass through the casing from the left.

7 Gearbox - removal,

inspection and installation

1 Remove th e clutch and clutch pulley (see Section 6). On machines fitte d w ith a drum

7.6a O utput shaft (A), intermediate shaft (B), input shaft (C) and cover dow els (D)

M ake a c a rd b o a rd te m p la te o f th e g e a rb o x c o v e r an d p u n c h a h o le fo r each b o lt loc a tion . T his w ill en sure a ll b o lts a re in s ta lle d c o rre c tly on reassem bly - th is is im p o rta n t as som e bo lts m ay be o f d iffe re n t lengths.

HiNT

4 Carefully ease th e cover away from th e casing and remove it (see illustration). If the cover is stuck, tap around th e jo in t face between the cover and the casing w ith a softfaced mallet to free it. Do not try to lever the cover o ff as th is may dam age th e sealing surfaces. N ote : On gearboxes n o t fitted with a drain plug, position a tray beneath the casing to catch the oil when the cover is removed. 5 If any of the gearbox shafts com e o ut with th e cover, take care not to damage any seals as th e sha fts are pulled through. N ote th e po sition o f any dow els on th e cover and remove them for safekeeping if they are loose. Discard the gasket, as a new one m ust be fitted on reassembly. 6 All th e scooters covered by this manual have three gearbox shafts - th e input shaft which carries the clutch, th e ou tp ut shaft which carries th e rear wheel, and an intermediate shaft (see illu s tra tio n ). Check the shafts for any thrustwashers or wave washers and remove them, noting where they fit, then lift out

6*10 Transmission: Drive components and gearbox

7.6b Note the position o f any wave washers (A) o r thrustw ashers (B) on th e shafts the shafts (see illustrations). Note: The input shaft is often a press-fit in its bearing and should n o t be rem oved unless th e shaft, the bearing o r the oil seal is to be renewed. 7 Check th e casing and cover fo r any remaining washers and remove them, noting where they fit (see illustration). 8 Do not remove th e gear pinions from the shafts unnecessarily - th ey should only be removed if components are being renewed.

Inspection 9 Clean all traces of old gasket material from th e case and cover m ating surfaces, ta king care no t to scratch o r gouge the soft aluminium . Wash all the com ponents in a suitable solvent and dry th em with compressed air. 10 Check the pinion teeth fo r cracking, chipping, pitting and other obvious wear or damage, th en check fo r signs o f scoring or blueing on the pinions and shafts caused by

overheating due to inadequate lubrication (see illustration). 11 Ensure that all th e pinions are a tight fit on their shafts. 12 Inspect the splines and threads on the input and output shafts. 13 Renew any damaged or worn components. In some cases, the pinions are a press-fit on the shafts, or are retained by circlips allowing components to be renewed individually (see illustration). Some pinions are an integral part of the shaft and on some scooters shafts are only supplied as matched items. Check with a scooter dealer as to the availability of components. 14 To remove th e input shaft, firs t fit the clutch centre nut to protect th e threads, then drive th e shaft out using a soft-faced mallet on the clutch end. 15 Check the intermediate shaft thrustwashers and renew them if they are damaged or worn. Fit new ones if in any doubt. 16 Check the condition of the shaft oil seals

7.7 N ote th e loca tion o f any inner washers and threads (C) fo r w ear and dam age

Pinion is retained on th e shaft by th e circ lip (arrowed)

7.16a Check th e con ditio n o f th e oil seals (A) and bearings (B)

(see illustration). Some gearboxes are fitted with drain holes - if a seal fails, oil w ill drain o u t to the underside o f th e casing (see illustration). Any loss of gearbox oil must be remedied imm ediately to avoid expensive damage or seizure. If the input shaft oil seal fails, oil will run out of th e drain hole, if fitted, or into the drivebelt case behind the clutch. If either o f th e shafts has been removed, it is good practice to fit a new seal (see Tools and Workshop Tips in th e Reference section). 17 Inspect the bearings (see Tools and Workshop Tips in the Reference section). Note: Bearings that are fitted into b lind holes require an internal bearing puller to extract them without damaging the case; consult a scooter dealer or a specialist engineer if they need removing.

I n s t a lla t io n 18 Installation is th e reverse o f removal, noting the following: • Ensure any washers are fitted to the shafts before assembly. • Lubricate bo th ends o f th e intermediate shaft with m olybdenum disulphide grease before installation. • Fit any dowels into the cover. • Use a new cover gasket. • Smear the inside o f the oil seals with grease before installing the shafts. • Tighten th e cover bo lts evenly and in s criss-cross pattern to the to rque setting specified in the Data section. • If a gearbox drain plug is fitted, ensure it is tightened to the specified torque setting. • F ill the gearbox with the specified amouii and type o f oil (see Chapter 1). ■

7*1

hapter 7 rame and suspension ntents I-inspection and r e p a ir............................................................... 2 ;engine mounting - removal, inspection and installation .........10 isuspension - disassembly, inspection and reassembly ......... 8 gl information . .............................................................................. 1 irs - removal and installation.................................................. 4 fetlock absorber - removal, inspection and in sta llatio n ............. 9

Stands - removal and installation ........................................................ Steering head bearings - adjustm ent .................................................. Steering head bearings - inspection and ren ew al............................... Steering stem - removal and insta llatio n.............................................. Suspension - c h e c k .............................................................see Chapter

3 5 7 6 1

egrees of difficulty Easy, suitable fo r novicewith little Kperience

^ ^

Fairly easy, suitable for beginner with som e experience

^

Fairly difficult,

Difficult, suitable for

Very difficult,

suitable for competent ^ DIY mechanic ^

experienced DIY mechanic

suitable fo r expert DIY o r professional ^

^

Specifications fertothe Data section at the end o f this manual fo r servicing specifications.

General information

Ancillary item s such as stands handlebars are covered in this Chapter.

and

2 Frame - inspection and repair j k I; All scooters covered by th is manual are fitted with a tubular and pressed steel onepieceframe. Theengine and transmission unit is linked to Hieframe by a pivoting assembly at the front andby the rear shock absorber(s), making the lit an integral part of the rear suspension. Front suspension is by a leading or trailing ink arrangement w ith a single shock absorber, or by conventional or upside-down telescopic forks.

I

1 The fram e should not require attention unless accident damage has occurred. In m ost cases, fram e renewal is the only satisfactory remedy fo r such damage. A few fram e specialists have the jig s and other equipm ent necessary fo r straightening th e frame to the required standard o f accuracy, bu t even th en th ere is no simple w ay of

assessing to what extent the frame m ay have been over-stressed. 2 A fter a high mileage, th e fram e should be exam ined closely fo r signs o f cracking or s plittin g at the w elded join ts. Loose engine m ount and suspension bo lts can cause ovaling or fracturing o f the mounting points. M inor dam age can often be repaired by specialist w eldin g, depending on th e extent and nature o f the damage. 3 Remember th at a fram e w hich is out of alignm ent w ill cause handling problem s. If misalignment is suspected as the result of an accident, it w ill be necessary to strip th e machine com pletely so th e fram e can be thoroughly checked.

y ■

7*2 Frame and suspension

3.3 U nscrew th e n ut (arrowed) and w ithd ra w th e p iv o t b o lt

extends while th e m achine is in motion. II necessary, fit a new spring.

Side stand

3.4 Remove th e s tand assem bly

3.8 Unhook th e s pring and rem ove the pivot b o lt (arrowed)

1 Support the scooter securely in an upright position using an auxiliary stand. Note: Do not re st th e w eight o f th e machine on the bodywork; remove the belly panels to expose the frame (see Chapter 9). Alternatively, have an assistant support the machine. 2 Unhook the stand spring, noting how it fits, and rem ove the spring plate, if fitte d (see illu strations). 3 Unscrew the pivot bolt nut and remove the washer, then w ithdraw th e pivot bolt and remove the stand (see illustration). 4 On scooters w ith a stand bracket bolted to

the underside of th e engine, unscrew the nuts and withdraw the bolts securing the bracket, then remove the stand and bracket as an assembly (see illustration). 5 Thoroughly clean th e stand and remove all road dirt and old grease. Inspect th e pivot b o lt and th e pivot holes in the bracket for wear and renew them if necessary. Inspect the spring; if it is sagged or is cracked a new spring must be fitted. Inspect the rubber stop on the stand and renew it if it is worn or perished. 6 Installation is th e reverse of removal, noting the following; • Apply grease to the p ivot b o lt and all pivot points. • Tighten the nuts securely. • Ensure that the spring holds th e stand up securely when it is n ot in use - an accident is alm ost certain to occu r i f th e stand

4.3 Loosen bar end w eig ht c entre screw (A) to release nu t (B)

4.5 D isconnect th e brake ligh t sw itch w iring c onnectors

3 Stands -

removal and installation

Centre stand

7 Support the scooter securely in an upright position using an auxiliary stand (see Step 1), 8 Unhook the stand spring, noting how it fits (see illustration). 9 Unscrew th e stand pivot bolt and remove the bolt, washer and stand (see illus­ tra tio n 3.8). Note how th e contact plate on the stand locates against the safety switch plunger when the stand is lowered. 10 Installation is th e reverse o f removal, noting th e following: • Apply grease to the pivot bolt. • Ensure that the stand con ta ct plate actuates the stand switch when the stand is lowered. • Check the spring tension - it m ust hold the stand up when it is n ot in use. If necessaiy, fit a new spring. • Check the operation o f the sidestand switch (see Chapter 10, Section 8).

4 Handlebars -

removal and installation

if

•• 11

*

Removal 1 Remove th e handlebar covers and any body panels as necessary to access the steering stem (see Chapter 9). 2 If required, th e handlebars can be displaced from th e steering stem fo r access to the bearings without having to detach any cables, hoses o r main w iring looms, ti remove the switches, brake levers or master cylinders. If this is the case, ignore the Steps which do not apply. 3 Where fitted, loosen th e centre screws for the bar end weights and withdraw the weight! from th e handlebars. Take care not to undo the screws to o far and lose th e nuts on the end of the screws (see illustration). 4 Undo the throttle tw istgrip housing screws and slide th e tw istgrip o ff the end of the! handlebar (see Chapter 4). 5 Disconnect th e wiring from each brake light switch (see illustration).

Frame and suspension 7*3

4.10 Rem ove th e nu t (A), w ash er (B) and spacer (C) Undo the handlebar switch housing screws aiddisplace the housing. Check that no other electrical components a mounted on the handlebars and detach fan if necessary. Unscrew th e brake m aster cylinder assembly clam p bolts and po sition the ssembly clear of the handlebar, making sure •strain is placed on th e hydraulic hose (see Chapter 8). Keep th e m aster cylinder reservoir fright to prevent air entering th e system. Note: Some scooters are fitte d with ilraulically-operated fron t a nd rear brakes, n others only the front brake is hydraulically-

4.11 Undo the nu t (A) a nd w ith d ra w th e p in c h -b o lt (B)

Installation 13 Installation is the reverse o f removal, noting the following: • Tighten th e handlebar stem b o lt to the torque setting specified in the Data section. • Use a suitable adhesive to secure the lefthand grip on the handlebar. • D o n 't fo rg e t to reconnect the brake ligh t switch wiring connectors. 0 Check the operation o f the brakes before riding the scooter.

5 Steering head bearings -

%

adjustment Remove the left-hand grip; peel the grip off theend of the bar, o r if necessary cut it off. 10 On scooters w ith th e handlebars secured bya stem bolt, undo the nut on th e stem bolt and remove th e nut, washer and shaped {pacer, noting how they fit (see illustration). Support the handlebars and w ithdraw th e bolt, then lift th e bars o ff th e steering stem. 11 On scooters with th e handlebars secured bya clamp and pinch-bolt, undo the nut and It,then lift off th e bars (see illustration). 12 If the handlebar com ponents have been left attached, po sition the bars so th a t no slain is placed on any o f th e cables, hoses or !»iring, and protect th e body panels to prevent

5.4 Locknut (A), w ash er (B), a djuster nu t (C)

1 Su pp ort th e machine on the centrestand w ith the fron t w heel raised o ff the ground. Note: Do not rest the weight o f th e machine on the bodywork; remove th e b elly panels to expose the frame (see Chapter 9). 2 Remove the handlebar covers and any b ody panels as necessary to access th e steering stem (see Chapter 9). 3 If required, displace the handlebars (see Section 4). 4 Some scooters are fitted with one locknut above the bearing adjuster nut, others have tw o locknuts. The locknut and the adjuster nut are usually held in place w ith a lock washer

5.6 Rem ove th e lo c k n u t (arrowed) and disca rd th e lockw asher

(see illustration). Check carefully and refer to your scooter handbook fo r details. 5 If the lock washer has tabs w hich locate in notches in the locknut, first prise the tabs out o f the notches. N ote: A tabbed lock washer should n o t be re-used; rem ove the lockn ut and fit a new w asher a fte r adjusting the bearings. 6 If one lockn ut is fitte d , loosen it using a suitable spanner, C -spanner o r d rift (see illustration). 7 If tw o locknuts are fitted, unscrew th e to p nut then lift the tab washer o ff the remaining tw o nuts, noting how it fits (see illustration). Unscrew th e second locknut. A rubber washer is fitted between the second locknut and the adjuster nut. Discard it if it is crushed or damaged and fit a new one on reassembly. 8 Using either a spanner, C-spanner o r drift, loosen th e adjuster nu t sligh tly to take pressure o ff th e bearing then tighten th e nut until all freeplay is removed. Check th a t the steering still tu rn s freely from side -to-side . The object is to set th e adjuster nut so that the bearings are under a very ligh t loading, just enough to remove any freeplay. C a u tio n : Take g re a t c a re n o t to a p p ly excessive pre ssure because th is w ill cause p re m a tu re fa ilu re o f th e bearings. 9 W ith th e bearings c orrec tly adjusted, the adjuster nut m ust be held to prevent it from

5.7 Location o f th e ta b w asher

7*4 Frame and suspension

bearings

5.11b Hold the a djuster nut and tighten th e lo c k n u t w ith th e special tool

moving while th e locknut is tightened. Where prevent it turning and tighten the top locknut necessary, firs t install a new lockwasher securely. If the special tool is available, tighten ensuring th e tabs locate correctly in th e th e locknut to th e specified torque setting adjuster nut. (see illustrations). 10 Where one locknut is fitte d, tighten the 12 Check the bearing adjustm ent and locknut securely, then bend th e remaining re-adjust if necessary, then install the lockw asher ta bs up to secure the locknut. remaining components in the reverse order of removal. N ote: Some m anufacturers specify a torque setting fo r the locknut (see the Data section at the end o f this manual); however to apply this . 6 Steering stem a service tool o r a suitable fabricated tool (see illu s tra tio n 5.11a) is required an d the removal and installation handlebars m ust be displaced (see Section 4). 11 Where tw o locknuts are fitted, install the rubber washer and then th e second locknut, R em oval tightening it finger-tight. Hold the adjuster nut to prevent it turning, then tighten the second 1 Remove the front wheel and, if applicable, locknut only enough to align its notches with the brake caliper (see Chapter 8). On the notches in the adjuster nut and install the machines where the wheel can be removed ta b washer (see illu s tra tio n 5.7). Install the leaving th e hub in place, remove th e hub. to p locknut, th en hold th e adjuster nut to 2 If the front mudguard or mudguard liner are

6.5 Low er th e s teering stem o u t o f th e steering head

6.10 H old the low e r race ball-bearings in place w ith grease

6.7 T op bearing in th e to p o f th e steering head

11a L ift th e ste ering stem into place . . .

m ounted on the fron t suspension, remove them (see Chapter 9). 3 Remove th e handlebars (see Section 4). Note: The ball-bearings in the lower steering \ head race may n o t be retained b y a cageplace a clean rag on th e flo o r beneath the steering head to catch the ball-bearings i f they are loose when the steering stem is removed. 4 Unscrew and remove th e bearing adjuster locknut(s) and washer (see Section 5). 5 Support th e steering stem, then unscrew the bearing adjuster nut and carefully lower the stem out o f th e steering head illu s tra tio n ). Note which way round the adjuster nut fits. 6 The ball-bearings in the lower rac either fall out of the race or stick to the lower inner race on th e steering stem. The top inner race and top bearing will remain in the top of the steering head. 7 If not already done, lift out th e to p inner race and the to p bearing (see illustration)) N ote: On som e scooters, th e to p inner bearing race is integral w ith the adjuster nut The balls o f the to p bearing m ay be loc they may be'housed in a cage. 8 Remove all traces of old grease from the ball-bearings and races and inspect them for wear or damage (see Section 7). Note: Do noI attem p t to remove th e ou te r races from the steering head o r the lower bearing inner race from the steering,stem unless they are to be renewed.

I n s t a lla t io n 9 Apply a liberal quantity of grease to the bearing inner and outer races and install th| top bearing (see illustration 6.7). 10 Assemble the lower race ball-bearings on the lower inner race on th e steering stem;® they are a loose assembly they will be retained by th e grease (see illustration). I 11 Carefully lift the steering stem up through the steering head, ensuring the lower ra?i ball-bearings remain in place. Either threa the combined top inner bearing race/adjust^ nut onto the stem or install the inner race and thread the adjuster nut onto th e stem (see illustrations). Ensure th e adjuster nut is fitted the right way round. 12 Install the remaining com ponents in the reverse order o f removal.

6.11b . . . and install th e adjuster nut

Frame and suspension 7*5

7.3a Inspect th e races in th e to p ..

7.3c L o w er inn er race on th e ste ering stem

7.3b . . . and b o tto m o f th e ste ering head

Steering head bearings -

§§>

inspection and renewal

Sk

Inspection Remove th e steering stem (see Section 6). Remove all traces o f old grease from th e ings and races and check them for wear The races should be polished and free from is (see illustrations). The outer races steering head, th e to p inner race is feher integral with the bearing adjuster nut or it rests on top o f the top bearing, and the lower inner race is on the steering stem. Inspect the 1-bearings fo r signs o f wear, pitting or rosion, and examine th e bearing retainer cagefor signs of cracks or splits, where fitted. If thereare any signs of wear or damage on any of above components both upper and lower ing assemblies m ust be renewed as a set. Only remove the races from the steering head the stem if they need to be renewed - do lot re-use them once they have been removed.

Renewal The outer races are an interference fit in the frame and can be tapped from position w ith a suitable drift (see illustration). Tap firm ly and evenly around each race to ensure th at it is squarely. It may prove (antageous to curve the end of the drift slightly to improve access. Alternatively, the races can be pulled out using a slide-hammer w ith internal expanding :extractor. The new outer races can be pressed into the frame using a drawbolt arrangement (see Istration), o r by using a large diameter tubular drift w hich bears on ly on th e outer edge of th e race. Ensure th a t th e draw bolt d rift (as applicable) bears only on outer edge o f th e race and does not {contact the working surface. In s ta lla tio n o f n e w b e a rin g o u te r ra ce s is m ad e m uch e a s ie r i f th e ra c e s a re le ft o ve rn ig h t in th e freezer. This causes th e m to c o n tra c t s lig h tly them a loo ser fit.

HiNT

a b rass d rift 7 To rem ove th e low er inner race from th e steering stem, first drive a chisel between the base of th e race and th e bottom yoke. Work the chisel around the race to ensure it lifts squarely. Once there is clearance beneath the race, use tw o levers placed on opposite sides o f the race to w ork it free, using blocks of w ood to im prove leverage and pro tect th e yoke. If the race is firm ly in place it w ill be necessary to use a bearing puller. 8 Fit th e new lower inner race on to the steering stem. A length o f tubing w ith an internal diam eter slightly larger th an the steering stem w ill be needed to ta p th e new bearing into position. Ensure th at the d rift bears only on th e inner edge o f the race and does not contact its working surface. 9 Install the steering stem (see Section 6).

8 Front suspension -

disassembly, inspection and reassembly

7.6 U sing a dra w b o lt to f it th e o u te r races in th e s teering head

1 2 3

Long b o lt o r threaded bar Thick washer Guide fo r low er race

arm. Support th e arm and w ithdraw the bolt (see illustration). 3 Undo the nut securing the upper end o f the sho ck absorber, th en pull o ff th e shock. If required, rem ove the uppe r m ounting bolt, noting the position o f any spacers. 4 C ounterhold the b o lt and undo th e nut securing the brake caliper bracket to rque arm to the suspension leg, then remove the nut,

jk ^

Note: Some suspension assemblies use self­ locking nuts which should be discarded after use. Always use new self-locking nuts when reassembling the suspension.

Leading link o r m onolever Disassembly 1 Remove th e fron t w heel, hub, caliper bracket and axle (see C hapter 8), and th e mudguard (see Chapter 9). 2 Undo th e nut and bolt securing th e lower end of the shock absorber to th e suspension

8.2 Remove the bra cket (A) and w ithd ra w th e low e r sho c k b o lt (B)

7*6 Frame and suspension

8.4 Remove th e n u t (A), w asher (B) and to rq ue a rm (C)

8.6a Undo the p ivot b o lt n u t. . .

8.6b . . . and rem ove any washers . . .

washer and torque arm (see illu s tra tio n ). Remove th e bolt from the suspension leg if it is loose. 5 On some scooters th e suspension arm pivots on rubber bushes in th e bottom o f the suspension leg, on others the arm turns on a pair o f bearings. Before separating the arm from th e suspension leg, check the condition of the bushes or bearings by moving the arm laterally against th e suspension leg. If any play is fe lt betw een th e arm and th e leg, th e bushes o r bearings m ust be renewed. Also move th e arm up-and-down. If any roughness is felt or th e arm does not move smoothly and freely, th e bushes, bearings or pivot bolt must be renewed. If there is no play or roughness in the suspension arm m ovement there is no need to disassemble th e suspension further. Note: Suspension rubber bushes are generally a very tigh t fit w hich requires a press fo r

removal and fitting. Consult a scooter dealer o r specialist engineer i f th e bushes need renewing. 6 To remove the suspension arm, counterhold th e pivot b o lt and undo the nut on the opposite end. Remove th e nut, noting the position o f any washers, spacers or brackets, then withdraw the pivot bolt and arm from the suspension leg (see illu s tra tio n s ). The bolt should be a press-fit in the arm and should not be removed unnecessarily. 7 Remove any dust caps, spacers and seals from either side of th e suspension leg, then remove any sleeve from inside th e bearings (see illustrations).

obvious signs o f wear such as heavy scoring, j or for damage such as cracks or distortion, 9 Check the condition of the bearings in the suspension leg (see Tools and Workshop Tips in th e Reference section). N ote: If ball­ bearings are fitte d they can be removed for cleaning and inspection, b u t needle roller bearings should only be removed i f they are going to be renewed. Check carefully for any retaining circlips before attempting to remove th e bearings and note th e position of the bearings and any sleeves or spacers. 10 Inspect the pivot bolt for wear and remove any corrosion with steel wool. Check the bolt fo r straightness w ith a straight-edge. If the bolt is worn, press it ou t o f th e suspension arm carefully to avoid damaging th e locating hole and fit a new bolt. If the bolt is bent, cut o ff th e damaged section and press the remainder-out of th e arm.

Inspection 8 Clean all components thoroughly, removing all traces o f dirt, corrosion and grease. Inspect all com ponents closely, looking fo r

8.6d . . . then w ithd ra w the p ivot b o lt and arm from the suspension leg

8.7b . . . and a ny seals .

j

j

8.7a Remove the d u st cap . . .

Frame and suspension 7*7

6.13 Inspect th e s ho ck spring (A), dam per rod (B) and m ountings (C)

8.24 Undo th e screw (arrowed) t o rem ove th e cover and pull o ff th e trim

8.25 Rem ove th e c irc lip (arrow ed) and slide th e b ra c k e t o ff

11 Inspect the condition o f th e bearing seals andrenew them if they show signs o f wear or deterioration. 12 Inspect the sho ck absorber fo r obvious physical dam age and th e shock spring fo r looseness, cracks o r signs o f fatigue. 13 Inspect th e dam per rod fo r signs of tending, pitting and oil leaks, and check the mountings at the to p and bottom o f th e shock for wear or damage (see illu stratio n). If any parts are w orn o r dam aged, a new shock must be fitted.

17 If removed, install th e b o lt fo r th e brake caliper bracket to rque arm in th e suspension leg, then install th e arm, washer and nut (see illu stratio n 8.4). Tighten th e nut sufficiently to allow final alignment o f the torque arm when all th e components have been installed. 18 Install th e lower end o f the shock absorber in the bracket on th e monolever arm, then install th e bolt. Tighten th e bolt fingertight. 19 Ensure any spacers on the upper shock mounting bolt are correctly positioned, then fit th e shock onto th e bolt and install th e nut. Counterhold th e bolt and tighten th e nut to the specified torque setting. 20 Install the m udguard (see Chapter 9). If not already done, tighten the pivot bolt nut to the specified torque setting. 21 Install the axle and caliper bracket (see Chapter 8). Counterhold the bolt and tighten th e nut securing th e caliper bracket torque arm to the suspension leg to th e specified torque setting. 22 Tighten th e lower shock mounting bolt to th e specified torque setting. 23 Install th e hub and fro n t wheel (see Chapter 8).

25 On d isc brake models, check fo r any play in th e bearings betw een th e trailing link arm and th e brake calip er m ounting bracket. Remove the circlip and slide the bracket o ff th e arm to inspect th e bearings (see illustration). 26 On som e scooters, the bo tto m o f th e shock absorber is secured by tw o bolts, and a bracket on the to p o f th e shock is held by tw o nuts (see illu s tra tio n s ). Alternatively, th e shock is secured to p and bottom by a single bolt. Undo the fixings as appropriate, noting the position o f any washers or spacers, then lift the shock o ff (see illustration). 27 Before separating th e trailing link arm from the suspension leg, check the condition o f the bearings by m oving th e arm laterally against th e leg. If any play is fe lt between the arm and the leg, th e bearings and spacer pin m ust be renewed. Also m ove th e arm up-anddown. If any roughness is fe lt o r th e arm does no t m ove sm oothly and freely, the bearings and spacer pin m ust be renewed. If there is no play o r roughness in th e suspension arm m ovem ent there is no need to disassem ble th e suspension further. 28 To rem ove th e suspension arm, first remove the wheel hub assembly (see Chap­ ter 8). 29 On som e scooters, th e suspension arm turns on a p ivot bolt; counterhold the bolt and undo th e nut on th e op po site e n d ' Remove th e nut, noting th e position of any washers or spacers, then w ithdraw th e p ivot bolt and arm from the suspension leg.

Reassembly 14 If the bearings have been removed, ensure the bearing housings are thoroughly dean, then install the bearings (see Tools and Workshop Tips in the Reference section). Note: Where a bearing is retained by a circlip, drive it in only as far as is necessary to install the circlip. Ensure any bearing spacers are in place and lubricate needle roller bearings with golybdenum disulphide grease. 15 Install any seals, spacers and dust caps as necessary, then smear th e pivot b o lt w ith grease and install it through th e bearings, ensuring the seals remain in position. Check that the suspension arm is fitted on the correct side of the leg, then install the washers and spacers as necessary and the pivot bolt nut. 16 If the pivot bolt nut retains the mudguard assembly, tighten the nut sufficiently to allow final positioning o f the m udguard bracket when the m udguard is fitte d . Otherwise, tighten the nut to the torque setting specified inthe Data section a t th e end o f this manual.

8.26a Undo th e tw o b o lts (a rro w e d ). . .

Trailing link monoshock Disassembly 24 Remove th e fron t wheel and, on disc brake models, th e hub assembly (see Chap­ te r 8). W here applicable, rem ove th e suspension cover and the trailing link trim (see illustration).

7*8 Frame and suspension

8.46 T ypical te le s c op ic fo rk com ponents 30 Alternatively, th e arm turns on a pin which is secured at each end by a push-in cap. The caps can be removed either by hitting them centrally w ith a suitable punch or drift, which should be w ide enough to cover the raised inner section of th e cap, or be levering up the outer ta ngs of th e cap w ith a screwdriver. Discard the caps, as new ones must be used. 31 Drive or press ou t the pivot pin from the middle of the arm and separate the arm from the leg. Note the position o f any O-rings and seals.

Inspection 32 Clean all com ponents thoroughly, removing all traces o f dirt, corrosion and grease. Inspect all com ponents closely, looking fo r obvious signs o f wear such as heavy scoring, or for damage such as cracks or distortion. 33 Check th e con ditio n o f the suspension arm and brake caliper m ounting bracket bearings (see Tools and Workshop Tips in the Reference section). Note: If ball-bearings are fitted they can be rem oved fo r cleaning and inspection, but needle roller bearings should only be rem oved i f they are going to be renewed. Check carefully fo r any retaining circlips before attem pting to remove the bearings and note th e position o f the bearings and any sleeves or spacers. 34 Inspect th e shock absorber fo r obvious physical dam age and the shock spring fo r looseness, cracks or signs o f fatigue. 35 Inspect the dam per rod fo r signs of bending, pitting and oil leaks (see illu s ­ tratio n 8.13). 36 Inspect th e m ountings at the to p and bottom o f th e shock for wear or damage. 37 On some machines, th e shock absorber can be disassem bled and individual com ponents renewed (see illu s tra tio n ) check th e availability of parts with a scooter dealer. Com press the spring to rem ove the

pressure on th e spring seat at th e top, then unscrew the to p nut. Lift off the components o f th e upper mounting, noting the order in which they are fitte d, then carefully release th e pressure on the spring. Remove th e spring, noting which way up it fits. Install the new components and reassemble the shock in the reverse order of disassembly.

Reassembly 38 If th e bearings have been removed, ensure th e bearing housings are thoroughly clean, then install the bearings (see Tools and Workshop Tips in th e Reference section). Note: Where a bearing is retained by a circlip, drive it in only as far as is necessary to install the circlip. Ensure any bearing spacers are in place and lubricate needle roller bearings with' molybdenum disulphide grease 39 Lubricate th e pivot pin with molybdenum disulphide grease. Align th e suspension arm with the leg, ensuring it is th e right way round, then press the pin into place. 40 Fit new dust seals and O-rings as necessary. 41 Fit the new push-in caps and drive them into place using a piece o f tubing that bears on ly on th e area betw een the raised inner section and the raised outer tangs. 42 Install the shock absorber and tighten the nuts and bolts to th e specified torque settings. 43 On disc brake models, slide th e brake caliper mounting bracket onto the suspension arm and secure it with th e circlip, making sure it s its properly in its groove (see Step 25). Install the hub assembly (see Step 24). 44 Install the front wheel (see Chapter 8) and the covers, where applicable.

Conventional telescopic fork N ote 1: Two types o f conventional telescopic fork are fitted to the scooters covered by this manual. On th e first type, the tubes are an

integral part o f the fork yoke (Steps 45 to on th e second, m otorcycle-type fork, tu bes are clam ped in th e yoke and be rem oved individually fo r disassembly (Steps 63 to 92). N ote 2: Always dism antle th e fork separately to avoid interchanging parts. Check th e availability o f parts and th e type and quantity o f fo rk oil required w ith a scooter dealer before disassembling the forks. Note that on some scooters the forks are lubricated, with grease.

Disassembly 45 Remove th e steering stem (see Section 6). 46 Place a suitable oil drain tray below fork, then unscrew th e bolt in th e bottom of the fork slider. Discard the sealing washer, as a new one must be used on reassembly. Pull the slider o ff the fork tube, then pull the dust seal off the slider and, if applicable, drain the oil from th e slider (see illustration). 47 Remove the circlip from inside the top of the slider, then carefully prise out the oil seal, taking care not to gouge the rim of the slider when doing this. Discard th e seal, as s one must be fitted on reassembly. 48 Remove th e com pression limiting from inside th e bottom o f th e slider, noting which way round it fits. 49 To remove the spring, unscrew the bolt the top of the fork tu be and draw th e spring out of the tube. Hold th e spring to prevent it from turning w ith the bolt. Some fo rks are fitted with a sealed damper unit. Unscrew the to p bolt, then unscrew th e damper rod from th e to p bolt and rem ove dam per unit and spring together. Note: Various combinatioi o f spring a nd dam per u n it are used - some forks have only one unit fitte d in one o f the legs, others have a damper unit in both Some forks have a damper u n it fitted in one leg and a spring in the other.

Frame and suspension 7»9 Inspection $0 Clean all parts in a suitable solvent and diythem with compressed air, if available. 1 Inspect the fo rk tubes fo r score marks, pitting or flaking o f th e chrom e finish and xcessive or abnormal wear. C heck th e Iraightness o f th e tubes w ith a straight-edge, either o f th e tu be s is dam aged, w orn or bent, fit a new fork yoke assembly. 52 Inspect the springs fo r cracks, sagging and other dam age. No service da ta is available for the springs, bu t ensure they are both the same length. If one spring is defective renew both springs as a pair. 53 If fitted, check the operation o f th e (temper unit. Compress th e dam per rod into £ cartridge, then pull it out. Movement of the rodshould be slow and gradual - if there is no Ifemping action, o r th e movement is jerky, fit a new unit. N ote: If tw o units are fitte d they should be renewed as a pair. 54 The dust seals should be a sliding fit on thefork legs. Discard th e dust seals if they are worn or perished and fit new ones (it is good practice to renew the du st seals when the forksare disassembled). Reassembly 55 Install the compression limiting cone. 56 Lubricate the new oil seal with fork oil or grease, then press it squarely into the slider jrsing a suitable piece of tubing or a socket until the circlip groove is visible above th e seal.

59 If applicable, carefully po ur th e correct quantity o f the specified fork oil into the slider (see N ote 2). 60 Fit the dust seal and apply some fork oil to the lips o f the seal, then insert the top of the spring into the bottom of the fork tube. Ensure the fork tube fits squarely through th e oil seal and into th e slider, and install th e slider onto the tube until the spring contacts the top o f the tube. Hold the slider in position, then install the bolt in th e to p of th e fork tube and thread it into the plug in th e to p o f the spring. Alternatively, extend th e dam per rod fully, then install th e slider onto the tube and thread the damper rod into th e to p bolt and tighten it securely. 61 Tighten th e to p bolt securely. 62 Install th e steering stem (see Section 6).

M otorcycle-type fork N ote 1: Two types o f conventional telescopic fork are fitte d to the scooters covered b y this manual. On th e first type, th e tu bes are an integral part o f the fork yoke (Steps 45 to 62), on the second, motorcycle-type fork, the tubes are clam ped in the yoke and can be removed individually fo r disassembly (Steps 63 to 92). N ote 2: Always dismantle the fork legs separately to avoid interchanging parts. Check the availability o f parts and the type and quantity o f fork oil required with a scooter dealer before disassembling the forks. Note that on some scooters the forks are lubricated with grease.

I f th e fo rk le g s are seized in th e yoke s, s p ra y th e area w ith p e n e tra tin g o il a n d a llo w tim e fo r i t to so a k in be fo re try in g again.

Installation 68 Remove all traces o f corrosion from the fork tu bes and the yokes. Install each fork leg individually. Slide th e leg up through th e yoke until the to p edge o f th e fork tu be is level w ith th e to p edge o f the yoke. W here applicable, ensure the location groove fo r the clam p bolt is correctly aligned. N ote : If the fo rk to p b o lt has n o t been fu lly tightened, fo llow th e p rocedure in Step 66 to tighten it before positioning the leg in the yoke. Tighten th e clam p bolts in th e yoke to the torque setting specified in the Data section a t th e end of this manual. 69 Install the remaining components in the reverse order o f removal. Check th e operation of th e front forks and brake before taking the scooter out on th e road.

Disassembly 70 Remove the fork leg (see Steps 63 to 67). Always dism antle th e fork legs separately to avoid .interchanging parts. Store all com ponents in separate, clearly-m arked containers (see illustration).

Removal j HAYNES

Place a suitably-sized w asher on to p o f th e o il s e a l to p r o te c t i t w he n p re s s in g i t in to place.

SI Once the seal is installed, fit the circlip, making sure it is correctly located in its groove. Note: If th e fork is lub rica ted with grease, apply the grease to th e inside o f the slider below the level o f the seal. 58 As required, check that both plugs are in the endsof the spring, then insert th e spring into the slider; alternatively, install the damper unit and spring into the slider. Fit a new sealing washer to the bottom bolt, then install th e bolt into the bottom of the slider and thread it into the plug in the base of the spring or into the damper unit. Press down on the spring to prevent it from turning and tighten the bolt securely.

63 Remove the front wheel and, if applicable, the brake caliper (see Chapter 8). 64 If th e front mudguard is mounted on the front suspension, remove it (see Chapter 9). 65 Remove each fork leg individually. 66 If th e fork leg is going to be disassembled or the fork oil is going to be changed, loosen th e fork to p bolt while the leg is still clamped in th e fork yoke (see illustration). To do this, first undo th e fork leg clam p bolts and push th e leg a short distance up through th e yoke, then temporarily tighten the clamp bolts. Now loosen th e to p bolt. N ote : Som e fork legs have a location groove fo r one o f the clamp bolts - remove th e b o lt before attem pting to move the leg. 67 Undo th e fork clamp bolts and remove the fork leg by twisting it and pulling it downwards (see illustration).

a

n [L % llh /

8.70 Typical m oto rc y c le -ty pe fo rk c om ponents

8.66 Fork leg clam p b o lts (A) and fo rk to p b o lt (B)

8.67 Pull th e leg dow n - no te th e groove (arrowed)

1 2 3 4 5 6

Top bolt Spring Fork tube Sealing ring Damper Rebound spring

7 8 9 10 11 12

Spring seat Dust seal Circlip Oil seal Fork slider Damper bolt

7*10 Frame and suspension

8.74 W ithdraw th e fo rk spring

8.76 Remove the dam per b o lt and sealing washer (arrowed)

8.78 W ithdraw th e dam per and rebound spring

71 The dam per bolt should be loosened at this stage. Invert th e fork leg and compress th e fork tu be in th e slider so that th e spring exerts m axim um pressure on th e damper head, then loosen th e bolt in th e base of the fork slider (see illu stratio n 8.76). 72 If the fork to p bolt was not loosened with th e fo rk on th e scooter, carefully clam p the fork tu be in a vice equipped w ith soft jaws, ta king care not to overtighten o r score the tube’s surface, and loosen the to p bolt. 73 Unscrew the to p bolt from the to p of the fork tube. If a damper rod is attached to the to p bolt, loosen the locknut and unscrew the rod. Note any O-ring fitted to the top bolt; if it is damaged, fit a new one on reassembly. W arning : The fo rk sp rin g is p re s s in g o n th e fo rk to p b o lt w ith co n s id e ra b le pre ssure. U nscrew th e b o lt very carefully, ke e p in g a d o w n w a rd p re s s u re on i t a n d relea se i t s lo w ly a s i t is lik e ly to sp rin g

clear. I t is advisable to w ear some fo rm o f eye an d face p ro tectio n when carrying o u t th is operation. 74 Slide the fo rk tu be dow n into the slider and w ithdraw th e spring (see illu s tra tio n ). Note which way up th e spring is fitted. 75 Invert th e fork leg over a suitable container and pump the fo rk vigorously to expel as much fork oil as possible. 76 Remove the previously-loosened damper bolt and its sealing washer from the bottom of th e slider (see illu s tra tio n ). Discard the sealing washer, as a new one m ust be used on reassembly. If th e dam per b o lt was not loosened before dism antling the fork, temporarily install the spring and press down on it to prevent th e damper from turning. 77 Pull the fork tube out of the slider. 78 W ithdraw th e dam per and, if fitted, the rebound spring and spring seat from inside the fork tube (see illustration). 79 Carefully prise out th e dust seal from the

to p o f th e slider, then remove th e retaining clip and prise th e oil seal ou t o f the slider. Discard th e seals, as a new ones m ust be used on reassembly.

A

Inspection 80 Follow the procedure in Steps 50 to 54 to clean and check the fo rk components. If either o f th e fo rk tubes appears bent, have them both checked by a scooter dealer or specialist engineer. If necessary, fit new fork tubes, do not have them straightened. 81 Where fitted, check the condition of the rebound spring as well as th e main spring. 82 On some forks, no damper rod is fitted - a sealing ring is fitted around the damper which restricts the flow of oil through th e fork tube. Inspect th e surface o f the ring and renew it if il is scored, pitted or w orn (see illustration). Note: Do n o t remove the ring from the piston unless it requires renewal.

Reassembly 83 Where fitte d, slide th e rebound spring onto the damper, then insert the damper into th e bottom o f the fo rk tu be and install the spring seat on the bottom of th e damper (see illustration). 84 Lubricate the fork tube with th e specified fork oil and insert the assembly into the slider. Fit a new sealing washer to the damper bolt and apply a few drops of a suitable, non-permanent: thread-locking compound, then install the bolt into the bottom o f the slider. Tighten the bolt to the specified to rque setting. If the damper rotates inside th e tube, hold it with spring pressure as on disassembly (see Step 76). 1 85 Push the fork tu be fu lly into th e slider, then lubricate the inside o f the new oil seal with fork oil and slide it over the tube with its markings facing upwards (see illustration), Press th e seal into place in the slider. If necessary, use a suitable piece o f tubing to tap th e seal carefully into place; th e tubing, m ust be slightly larger in diameter than the fork tube and slightly smaller in diameter than the seal recess in the slider. Take care not to scratch the fork tube during this operation;! the fork tube is pushed fully into th e slider any accidental scratching is confined to the area above the seal. 86 Fit the retaining clip, making sure it is correctly located in its groove (see illustration).

Frame and suspension 7*11

8.88 Measure th e o il level w ith th e leg fu lly com pressed 87 Lubricate the inside of the new dust seal then slide it down the fo rk tube and press it intoposition (see illustration). 88 Slowly pour in th e correct quantity of the 1specified grade of fork oil and carefully pump thefork to distribute the oil evenly; th e oil level should also be m easured and adjustm ent made by adding o r s ubtracting oil - refer to your scooter handbook fo r details. Fully compress the fo rk tu be into th e slider, then measure the fork oil level from the to p o f the tube(see illustration). 89 Pull the fork tu be out o f th e slider to its full [extension; if applicable, pull th e dam per rod out also. Install th e spring. 90 If necessary, fit a new O-ring to th e fork top bolt. If applicable, thread the bolt onto the damper rod and tighten th e locknut. 91 Keep the fork leg fully extended and press down on the spring w hilst threading th e top bolt into the to p o f th e fork tube. Turn th e bolt I carefully to ensure it is no t cross-threaded. Note: The to p b o lt can be tigh te ne d to the specified torque setting when th e fork has been installed an d is securely he ld in the bottomyoke. " W arning: I t w ill b e necessa ry to com press th e sp rin g b y pressing i t dow n w ith th e to p b o lt in o rd er

A

■ to engage th e th re ad s o f th e to p bolt with th e fo rk tube. This is a p o te ntia lly dangerous o p e ra tio n a n d s h o u ld b e performed w ith care, u sin g an a ssista n t i f necessary. Wipe o f f an y excess o il b e fo re starting to p re v e n t th e p o s s ib ility o f slipping. 92 Install the fork leg (see Steps 68 and 69).

8.94b Lever o ff th e d u s t seal

Upside-down fork Seal renewal 93 Remove the front wheel and, if applicable, th e brake caliper (see Chapter 8). 94 W here fitte d, unscrew the b o lt from the base o f the fo rk slider w hich retains the axle/brake caliper bracket and draw th e bracket o ff th e slider (see illu s tra tio n ). Where fitted, lever the dust seal off the bottom o f the fo rk tu be and rem ove it (see illustration). 95 Where fitted, remove the circlip, then prise the oil seal out of th e bottom of the fork tube, taking care not to gouge th e tu be o r th e surface o f the slider. 96 Clean the bottom o f the slide r and th e inside o f the axle/brake caliper bracket and remove any traces o f corrosion. 97 Sm ear th e new oil seal w ith fo rk oil or grease, then fit it over the slider and press it in to position on th e bottom o f th e tube. If applicable, fit th e circlip. 98 If applicable, smear the inside o f the new

dust seal with fork oil o r grease and install the seal. 99 Install th e axle/brake caliper bracket and tighten th e retaining bolt securely. 100 Install the. remaining com ponents in the reverse order of removal.

Disassembly Note: Some designs o f upside-down forks are difficult to disassemble. I f th e fork is worn o r the fork action is suspect, consult a scooter dealer - it may be more practical to renew the whole assembly. On some scooters, the forks are m aintenance-free and no parts are available. Check the availability o f parts and the type and quantity o f fork oil required with a scooter dealer before disassembling the forks. N ote th a t on som e scooters the forks are lubricated with grease. 101 Remove the steering stem (see Sec­ tion 6). Alw ays dism antle the fo rk legs separately to avoid interchanging parts. Store all com ponents in separate, clearly m arked containers (see illustration).

7»12 Frame and suspension 2 The shock absorber is secured to the frame j at th e to p and the transmission casing at the bottom. To access the upper mounting, remove the body panels as necessary according to . model (see Chapter 9). If necessary, remove the air filter housing (see Chapter 4). 3 Undo and remove th e nut, o r the nut and bolt, securing the top of the shock absorber to the frame (see illustration). 4 Undo th e nut and bolt securing th e bottom o f the shock absorber to th e transmission; casing; sup po rt th e shock and remove the bolt, then manoeuvre the shock away from the machine (see illustrations).

• 8.103 R em oving the c irclip

9.3 U pper rear suspension m ounting

102 Remove the dust and oil seals (see Steps 94 and 95). 103 Remove the lower circlip from inside the bottom o f th e fork tube (see illustration). Pull th e slider o ut o f the fork tube, together with th e lower bush and rebound spring. Note the order o f the fork components for reassembly. If applicable, drain th e fork oil out of th e slider. 104 Remove th e upper bush circlip, then draw o u t th e upper bush and remove the upper circlip. Discard the circlips, as new ones m ust be fitted on reassembly. 105 W ithdraw th e washer (where fitted), compression spring and buffer from the tube.

specified fork oil into the slider; alternatively, lubricate th e inside o f the fork tube and the outside o f th e slider with grease. 111 Install the buffer, compression spring and washer (where applicable) into the fork tube. Fit th e new upper bush and circlips using a suitable piece o f tu bing to ensure they are squarely positioned inside the fork tube. Install the upper circlip for th e lower bush inside the fork tube. Install the lower bush and spring on the slider, then fit th e slider into the tube pushing it up into place. Press the lower bush into place against its upper circlip, then secure it with the lower circlip. 112 Install th e remaining com ponents in the reverse order o f removal.

Inspection

Inspection 106 Clean all parts in a suitable solvent and dry them with compressed air, if available. 107 Inspect th e fork sliders fo r score marks, pittin g or flaking o f th e chrome finish and excessive o r abnormal wear. Check th e straightness o f th e sliders w ith a straight­ edge. If either of th e sliders is damaged, worn or bent, fit a new fork yoke assembly. 108 Inspect th e springs fo r cracks, sagging and other damage. No service data is available fo r th e springs, but ensure both springs in each pair are the same length. If one spring is defective renew both springs as a pair. 109 Examine th e w orking surfaces o f each bush; if they are worn o r scuffed, renew the bushes as a set.

Reassembly 110 Install the various com ponents into the fo rk tube in the reverse order o f removal. If required, po ur th e correct quantity o f the

9.4a Undo th e low e r rear suspension m ounting . . .

9 Rear shock absorber -

removal, inspection and installation

>>

5 Inspect th e shock absorber fo r obvious physical dam age and the shock spring for looseness, cracks or signs of fatigue. 6 Inspect th e dam per rod fo r signs of bending, pitting and oil leaks and check the mountings at the to p and bottom o f th e shock for wear or damage (see illu stratio n 8.13). 7 On some scooters, th e shock absorber can be disassembled and individual components renewed (see illu s tra tio n ) - check the availability o f parts w ith a scooter dealer. Compress th e spring to remove the pressure on th e spring seat at the top, then unscrew the to p nut. Lift o ff the com ponents of the upper m ounting, noting th e order in which] they are fitte d, then carefully release the pressure on the spring. Remove th e spring, noting w hich way up it fits . Install th e new

^ ^

N ote: M ost scooters covered b y this manual have a single rear shock absorber. On machines w ith twin rear shocks, the lower end o f the right-hand shock is supported b y a subframe which bolts to the engine case and the rear wheel axle (see Chapter 8).

Removal 1 S upport th e m achine on its centre stand and position a support under the rear wheel so th a t the engine does not drop when th e shock absorber is removed, but also making sure that th e weight of the machine is o ff the rear suspension so that th e shock is not compressed.

9.4b . . . th en lift o ut th e shock

9.7 Rear sho ck absorber components

Frame and suspension 7*13

10.2a Removing a ‘hanger b ra ck et’ from the e ngine unit

10.2b W ithdraw th e piv o t b o lt . . .

10.2c . . . and rem ove th e b ra c k e t fro m the fram e

mponents and reassemble the shock in the reverseorder of disassembly.

all traces o f dirt, corrosion and grease. 4 Inspect th e silentbloc bushes closely, looking for obvious signs o f deterioration such as compression and cracks, or distortion due to accid en t dam age (see illu s tra tio n ). The bushes are generally a very tig h t fit which requires a press fo r rem oval and fittin g. Consult a scooter dealer or specialist engineer if the bushes need renewing. 5 Where th e m ounting bracket bolts to th e fro n t edge o f the crankcase it should be necessary to compress th e damping rubber in order to remove and install the engine bracket to frame bolt. If the bracket is not a tigh t fit, renew th e damping rubber (see illustration).

6 On th e hanger bra cket typ e m ounting, check for wear on th e dam ping rubbers. If the rubbers have worn, allowing m etal-to-m etal contact, renew them. 7 C heck the bolts fo r wear and che ck the holes in th e engine bra cket fo r w ear. If the bolts are not a precise fit in th e bracket the components m ust be renewed.

Installation ilnstallation is th e reverse o f removal, lightenthe shock absorber m ounting bolts to especified torque settings.

10Front engine mounting -

^

■removal, inspection and Iinstallation

^

Removal

Installation 8 Installation is th e reverse o f removal. Smear som e grease on th e engine bracket bolts. Tighten all m ounting bo lts to the to rq ue setting specified in th e Data section at the end o f this manual.

Bote: On some scooters th e fro n t engine minting is bolted to the front, lower edge o f b crankcase, on others a ‘hanger bra cket’ Ms to the top o f the crankcase. In a ll cases, fte mounting em ploys rub ber-in-torsion tHentbloc' bushes a n d d am ping rubbers to strict movement. Remove the engine/transmission unit (see Chapter 2A or 2B). Counterhold the engine bracket bolt(s) and mdothe nut(s), then withdraw the bolt(s) and remove the engine m ounting (see lustrations).

Inspection Thoroughly clean all components, removing

10.4 Inspe ct th e b ushes c a re fu lly . . .

10.5 . . . and c h e c k th e c o n ditio n o f th e da m per rubbers

expert22 fl/ia h ttp ://ru tra c k e r.o rg

8*1

Chapter 8 Brakes, wheels and tyres Contents fakecable - re n e w a l............................................................... .........10 Brakefluid level ............................................. see Daily (pre-ride) checks irakehoses and unions - inspection and re n e w a l............................ 7 levers - removal and in s ta llatio n............................................... 11 shoe/pad w e a r............................................................ see Chapter 1 Brake system - bleeding and fluid c h a n g e ......................................... 8 system c h e c k .............................................................. see Chapter 1 Drumbrakes - inspection, shoe removal and in sta llatio n ................. 9 front brake caliper - removal, overhaul and in sta llatio n................... 3 Front brake disc - inspection, removal and installation ................... 4 front brake master cylinder - removal, overhaul and installation . . . 5

Front brake pads - removal, inspection and in s ta llatio n.................... 2 Front wheel and hub assembly - removal and installation ............... 14 General in fo rm a tio n .............................................................................. .. 1 Rear disc brake - inspection, removal and insta lla tio n ...................... 6 Rear wheel and hub assembly - removal and installation..................15 Tyres - general information and fitting ................................................17 Tyres - pressure, tread depth and condition .. .see Daily (pre-ride) checks Wheel bearings - check and renewal ..................................................16 Wheels - alignment c h e c k ......................................................................13 Wheels - general c h e c k ...................................................... see Chapter 1 Wheels - inspection and r e p a ir ................. ....................................... 12

Degrees of difficulty suitablefor novicewith little experience

^

Fairly easy, suitable for beginnerwith f: some experience

%

Fairly difficult,

suitablefor competent ^ DIYmechanic

Difficult, suitablefor experienced DIY mechanic

% £

Very difficult,

suitablefor expert DIY or professional

Specifications Referto the Data section a t th e end o f this manual fo r servicing specifications.

General information

The scooters covered by th is manual are ftted with either hydraulic disc brakes, cablejoperated drum brakes, or a com bination of Sscfront and drum rear brakes. ■ Generally, th e hydraulic m aster cylinder is integral with the brake lever, although asionally the master cylinder is remotelymted and operated by a cable from the

In view of the broad variety o f wheel types and tyre sizes covered, owners are advised to refer to their scooter handbook or consult a tyre specialist fo r tyre choice and fitment. C a u tio n : D is c b ra k e c o m p o n e n ts ra re ly re q u ire disassem bly. D o n o t disa ssem ble c om p on en ts unless a b s olu tely necessary. I f a hy d ra u lic b ra k e ho se is loosened, th e e n tire sy s te m m u s t b e disa ssem ble d, d ra in e d , c le a n e d a n d th e n p ro p e rly fille d a n d b le d u p on rea ssem bly. Do n o t use s o lv e n ts on in te rn a l b ra k e com p o n e n ts . S olvents w ill cause the seals to s w e ll a n d d is to rt. U se o n ly c le a n b ra k e flu id , a

d e d ic a te d b ra k e c le a n e r o r d e n a tu re d a lc o h o l fo r c le a n in g . Use c a re w hen w o rk in g w ith b ra k e flu id as i t c a n in ju re y o u r eyes; i t w ill a lso da m a g e p a in te d surfaces a n d p la s tic parts.

Front brake pads - removal,

§|>

inspection and installation

*

A f '| \

W arning : The d u s t c re a te d b y th e b ra k e sys te m m a y c o n ta in asb estos, w h ic h is h a rm fu l to

8*2 Brakes, wheels and tyres

2.1 Remove th e pad cover

2.3c . . . a nd w ith d ra w th e p in - note the po sition o f th e pad spring

2.3a W ithdraw the spring w ire pins

2.3d D rift o u t the pin and spring clip

2.3e U nscrew th e pin plugs (arrowed) y o u r h e a lth . N eve r b lo w i t o u t w ith c om p re ssed a ir a n d d o n ’t inh ale any o f it. A n a p proved filte rin g m ask s h o u ld be worn when w orking on th e brakes.

1 W here fitte d, remove the pad cover from the caliper (see illustration). 2 If necessary, unscrew the brake caliper m ounting bolts and slide th e caliper o ff the

2.4a L ift o u t th e pads

2.4b Note th e position o f springs (arrowed) inside th e caliper

2.3b Remove th e E -clip . . .

disc (see Section 3). Note: Do no t operate the brake lever while the caliper is o ff the disc. 3 The pads are retained in th e caliper by pad pins. Some calipers have spring wire pins; w ithdraw th e pins, noting how th ey fit (see illu stratio n). Some calipers have pressed-in steel pins - if the pin is secured with an E-clip, remove the clip and withdraw the pin, noting th e position o f the pad spring (see illu s tra tio n s ). If the pin is secured with a spring clip, drift out the pin (see illustration)' Some calipers have screw-in pins - unscrew th e pin plug, then unscrew the pin and withdraw it (see illustrations). 4 If not already done, note the position of any pad springs and remove them, then lift out the pads (see illu stratio n). Note th e position of any pad springs inside th e caliper (see illustration). 5 Inspect th e surface o f each pad for contam ination and check th at th e frictioni material has no t w orn to or beyond the minimum thickness specified in the Data section at the end o f th is manual (see illustration). If either pad is worn down to, or beyond, th e service limit, is fouled with oil or grease, or heavily scored o r damaged, both pads m ust be renewed. Note: It is not possible to degrease th e friction material; il the p a ds are contam inated in any way they m ust be renewed. 6 If th e pads are in go od condition, clean them carefully using a fine wire brush which is completely free o f oil and grease to remove all traces o f road dirt and corrosion. Spray the caliper w ith a dedicated brake cleaner to

Brakes, wheels and tyres 8*3 Dve any du st and rem ove any traces of osion w hich m ight cause sticking o f the ler/pad operation. Remove all traces of corrosion from th e pad i. Inspect th e pins fo r damage and, where applicable, loss o f spring tension, and renew themif necessary. If the pins are secured by is, ensure th e clips are a tight fit on the pin, 3 fit new clips on reassembly. Remove all traces of corrosion from th e pad ngs; if the springs are badly worn or aged, fit new springs. Check the condition of the brake disc (see (Ction 4). I If new pads are being installed, slowly push each piston as far back into th e caliper spossible using hand pressure or a piece of wood for leverage. This w ill displace brake fluid back into th e hydraulic reservoir, so it f.be necessary to rem ove th e reservoir cap, plate and diaphragm and syphon out somefluid (depending on how much fluid was ;here in the first place and how fa r th e ions have to be pushed in). If a piston are icult to push back, attach a length of clear ose to the bleed valve and place the open . suitable container, th en open th e alve and try again. Take great care not to drawany air into the system and don’t forget totighten the valve once the piston has been ifficiently displaced. If in do ub t, bleed th e brakes afterwards (see Section 8). Caution: Never leve r the c alip er ag ain st th e ake disc to p u sh a p is to n b a c k in to the iliper as dam age to th e d isc w ill result, | Smear the pad pins and th e backs of the pads with copper-based grease, making sure that none gets on th e fro n t o r sides o f th e pads. 12 Installation is the reverse o f removal, noting the following: mil applicable, ensure any pa d springs are in place inside the caliper. 9 Fit the pads into the caliper so th a t the friction material faces the disc, whstall the pad pins and, where applicable, thepad spring. 9 Check that the pins are correctly locked o r dipped in place. the caliper an d operate th e brake iever several times to bring th e p ads into contact with the disc. 9 Check the brake flu id level and to p -u p i f j necessary (see Daily (pre-ride) checks). |:13 Check the operation o f the brake before ridingthe scooter.

•

•

3.1a Undo th e c alip er m ou ntin g b olts

brake s ystem m ay con ta in asbestos, w hich is h a rm fu l to y o u r health. N eve r b lo w i t o u t w ith com p re ssed a ir a n d d o n ’t in h ale any o f it. An ap pro ved filte rin g m ask s ho uld be w orn w hen w orking o n the brakes. Do not, un d e r any circu m stan ces, use p e tro le u m based solvents to clean brake p arts. Use a d e d ic a te d b ra ke c le a n e r o r de n a tu re d a lc o h o l only, as d e scrib e d . To p re v e n t da m ag e fro m s p ille d b ra ke flu id , alw a ys c o v e r p a in tw o rk w he n w o rk in g o n the bra kin g system. Note: On some scooters, the front wheel must be rem oved before th e caliper can be removed (see Section 14).

Removal 1 Unscrew the brake caliper mounting bolts and slide the caliper off the disc (see illustrations). Note: Do no t operate the brake lever while the caliper is o ff the disc. 2 If the caliper is ju s t being displaced, th e brake pads can be left in place. Support the caliper w ith a cable tie to ensure no strain is placed on the hydraulic hose. 3 If the caliper is being cleaned and inspected, rem ove the brake pads (see S ection 2). N ote: It is n o t necessary to disco nn ect th e brake hose to clean and inspect the caliper. 4 To remove th e caliper from the machine, first note the alignment o f th e banjo fitting on th e caliper, then unscrew the banjo bolt and separate th e hose from th e caliper (see illustration). Discard th e sealing washers, as new ones must be used on installation. Wrap a plastic bag tig h tly around th e end o f th e

3 Front brake caliper-

I. removal, overhaul and K installation W arning: I f a c a lip e r in d ic a te s th e n e e d fo r re n e w a l (u su ally due to le a k in g flu id o r s tic k y op era tion ), a ll o ld b ra k e flu id should be flu sh e d fro m th e syste m a t th e same time. A lso, th e d u s t c re a te d b y th e

A

3.4 U nscrew th e b o lt (arrowed) to d etach th e hose

3.1b . . . and slide th e c alip er o ff hose to prevent dirt entering th e system and secure th e hose in an upright position to m inimise fluid loss. Note: If you are planning to overhaul th e calip er an d d o n o t have a source o f com pressed a ir to b lo w o u t the piston, ju st loosen the banjo b o lt a t this stage and retighten i t lightly. The hydraulic system can then be used to force the piston out o f the caliper. Disconnect the hose once th e piston has been sufficiently displaced.

Overhaul 5 Clean th e exterior o f th e caliper w ith denatured alcohol o r brake system cleaner. In spect th e caliper fo r signs, o f damage, especially around th e mounting lugs and the bleed screw, and renew it if necessary. If hydraulic fluid is leaking from around the edge of th e piston, the internal piston seal has failed (see illu s tra tio n ). If new seals are available the calip er can be overhauled as follow s, otherwise a new caliper will have to be fitted. Note: The scooters covered b y this manual are fitted with single piston, opposed pisto n o r d ouble pisto n calipers. I f there is more than one piston in the caliper, mark each pisto n head an d the calip er bo dy w ith a suitable m arker to ensure that the pistons can be m atched to th e ir origin al bores on 6 Displace the piston from its bore using either compressed air o r by carefully operating the front brake lever to pump it out. If th e piston is being displaced hydraulically, it may be necessary to to p-up th e hydraulic reservoir during the procedure. Also, have some clean rag ready to catch any spilled hydraulic fluid

8*4 Brakes, wheels and tyres

3.9 Remove th e seals w ith a s o ft wooden o r plastic to ol - a pencil w o rk s well when the piston reaches th e end o f the bore. Where two pistons are fitted, ensure that they both move freely and evenly. N ote: If the compressed air m ethod is used, direct the air into the fluid inlet on the caliper. Use only low pressure to ease the piston ou t - i f th e air pressure is to o high and the piston is fo rced out, the caliper and/or piston may be damaged. W arning : N eve r p la c e y o u r fing ers in fro n t o f a p is to n in an a tte m p t to c a tc h o r p r o te c t i t w hen a p p lyin g com p re ssed air, as serious in ju ry c o u ld result. 7 If a piston sticks in its bore, try to displace it w ith compressed air (see Step 6). Where two pistons are fitted, remove the free piston first, then pack its bore w ith clean rag and try to displace the stuck piston. If the stuck piston cannot be displaced, a new caliper w ill have to be fitted. C aution: D o n o t t r y to rem ove a pisto n by le v e rin g i t o u t, o r b y u s in g p lie rs o r any o th e r grips. 8 On opposed piston calipers, it may not be possible to force th e pistons all th e way out of their bores. Unscrew the caliper joining bolts and separate the caliper halves, noting the position o f any O-rings. Discard the O-rings, as new ones must be fitted on reassembly. 9 Remove the dust seal and the piston seal from th e piston bore using a soft wooden or plastic tool to avoid scratching th e bore (see illu stratio n). Discard th e seals, as new ones must be fitted. 10 Clean th e piston and bore w ith clean brake fluid o r brake system cleaner. If com pressed air is available, blow it through

A

4.2a Look fo r thickn ess s tam ped on d isc

th e fluid galleries in the caliper to ensure they are clear and use it to dry the parts thoroughly (make sure it is filtered and unlubricated). C aution: D o n ot, unde r any circum stances, use a p e tro le u m -b a s e d so lv e n t to clean bra ke parts. 11 Inspect th e bore and piston fo r signs of corrosion, nicks and burrs and loss o f plating. If surface defects are present, the caliper assembly must be renewed. If the caliper is in bad shape th e master cylinder should also be checked. 12 Lubricate the new piston seal w ith clean brake fluid and install it in the groove in the caliper bore. 13 Lubricate th e new dust seal w ith clean brake fluid and install it in the groove in th e caliper bore. 14 Lubricate th e piston with clean brake fluid and install it, closed-end first, into the caliper bore. Using your thumbs, push th e piston all the way in, making sure it enters the bore squarely. . 15 On opposed piston calipers, smear th e new caliper body O-rings with clean brake fluid and install them in one half of th e caliper. Assemble th e caliper halves and tighten the joining bolts - if required, th e bolts can be tightened fu lly once th e caliper has been installed on the scooter.

Installation 16 If the brake pads have been removed, install th e pads (see Section 2). If the caliper has just been displaced, install the caliper on the brake disc (see illu stratio n 3.1b). 17 Install the caliper mounting bolts, and tighten them to th e torque setting specified in the Data section. If required, tighten the caliper joining bolts (see Step 15). 18 If the caliper was removed from the machine, or a new caliper is being fitted, connect the brake hose to th e caliper, using new sealing washers on each side of the banjo fitting. Align th e banjo fitting as noted on removal. Tighten the banjo bolt to th e specified to rque setting and to p-up th e hydraulic reservoir (see Daily (pre-ride) checks). Bleed the hydraulic system (see Section 8). 19 Check fo r fluid leaks and check the operation o f th e brake before riding the scooter.

4.2b M easuring th e thickn ess o f a d isc w ith a m icrom eter

4 Front brake disc - inspection,

removal and installation

«

Inspection 1 Visually inspect th e surface of the disc for score marks and other dam age. Light scratches are normal after use and won't affect brake operation, but deep grooves and heavy score marks w ill reduce braking efficiency and accelerate pad wear. If a disc is badly grooved it m ust be machined or renewed. 2 The disc must not be machined or allowed to wear dow n to a thickness less than the service limit, either as listed in th e Data section at the end o f th is manual, or as stamped on the disc (see illustration). Check the th ickness o f th e disc w ith a micrometer and renew it if necessary (see illustration). 3 To check disc warpage, position the machine upright so that the wheel is raised off the ground. A ttach a dial gauge to the suspension with the tip o f the gauge touching the surface o f th e disc about 10 mm from the outer edge. Rotate the wheel and watch the gauge needle; a small amount of movement is acceptable. If excessive movement is indicated, first check th e wheel bearings for play (see Section 14). If the bearings are good, the disc is warped and should be renewed.

Removal 4 Remove th e front wheel (see Section 14). On some scooters it may also be necessary to remove th e hub assembly. C a u tio n : Do n o t lay th e w h e e l dow n and a llo w i t to re s t on th e d isc - th e disc could becom e w arped. 5 If you are not renewing th e disc, mark the relationship of the disc to the wheel so that it can be installed in th e same position.. Unscrew the disc retaining bolts, loosening' them a little at a tim e to avoid distorting the disc, then remove th e disc (see illustration).

Installation 6 Before installing the disc, make sure there is no dirt or corrosion where the disc seats on th e hub. If the disc does not sit flat when it is

4.5 Unscrew the bolts (arrowed) to remove the disc

Brakes, wheels and tyres 8*5

■V.’vv' '■______ Med down, it will appear to be warped when liecked or when th e front brake is used. Install th e disc, m aking sure th at the ectional arrow, if applicable, points in the ection o f normal w heel rotation (see lustration). Align th e previously applied (sgister marks, if you are reinstalling the ■iginal disc. Install th e b olts and tighten them venly and a little at a tim e to th e torque settingspecified in th e Data section. Clean the feeusing acetone o r brake system cleaner. If anew brake disc has been installed, remove any protective coating from its w orking surfaces. I#applicable, install th e hub assembly, and liefront wheel (see Section 14). Operate the brake lever several tim es to bong the pads into con ta ct w ith th e disc. Checkthe operation o f th e brake before riding liescooter.

5 Front brake master cylinder

- removal, overhaul and installation

^

^ ^

H andlebar-m o un te d Removal ['Remove the handlebar covers fo r access seChapter 9).

5.2 U nscrew th e c lam p b o lts (arrowed)

5.4 Brake h ose b anjo b o lt (A), s ealing w ashers (B) and b a njo fittin g (C)

2 If th e m aster cylinder is ju s t being displaced, ensure th e fluid reservoir cover is secure. Unscrew th e master cylinder clam p bolts and remove the back o f the clamp (see illu s tra tio n ) . Position th e assembly clear of th e handlebar, making sure no strain is placed on th e brake hose and th e brake light switch w iring. Keep th e fluid reservoir upright to prevent air entering the hydraulic system. 3 If the master cylinder is being removed, disconnect the brake ligh t sw itch w iring connector and, if required unscrew the brake light switch. 4 U nscrew th e brake hose banjo b o lt and detach th e banjo fitting, noting its alignment with the m aster cylinder (see illustration). 5 Once disconnected, secure the hose in an upright position to minimise fluid loss. Wrap a clean plastic bag tigh tly around th e end to prevent dirt entering th e system. Discard the sealing washers, as new ones m ust be fitted on reassembly. 6 Undo the master cylinder clamp bolts and rem ove th e back o f th e clam p (see illu s tra tio n 5.2). Lift the master cylinder and reservoir away from th e handlebar. 7 Undo the reservoir cover retaining screws and lift off th e cover, th e diaphragm plate and th e diaphragm (see illu s tra tio n ). Drain the brake fluid from th e reservoir into a suitable container. Wipe any remaining fluid out o f the reservoir with a clean rag.

8 If required, rem ove th e brake lever (see Section 11).

5.7 Master cylind er cover, diaphragm pla te and diaphragm

Overhaul N ote : If the m aster cylinder is leaking fluid, or i f the lever does n o t produce a firm feel when the brake is applied, bleeding the brakes does n o t help (see S ection 8), a n d the hydraulic hoses are all in g o o d con ditio n, th en the m aster cylinder m ust be overhauled o r a new one m ust be fitted. Check th e availability o f parts w ith a scooter dealer. 9 Before disassembling the master cylinder, read through th e entire procedure and make sure that you have obtained all th e new parts required including som e new DOT 4 brake fluid, som e clean rags and internal circlip pliers. C a u tio n : D isasse m b ly, o v e rh a u l an d re a s s e m b ly o f th e b ra k e m a s te r c y lin d e r m u s t b e d o ne in a s p o tle s s ly -c le a n w o rk are a to a v o id c o n ta m in a tio n a n d p o ssible fa ilu re o f th e b ra k e h y d ra u lic syste m c o m p o n e n ts . To p re v e n t da m a g e to th e p a in t fro m s p ille d bra ke fluid, alw ays c ove r th e fu e l ta n k a n d fa irin g w hen w o rkin g on th e m a s te r cylinder. 10 Follow Steps 3 to 8, then carefully remove th e du st b o o t from th e m aster cylind er to reveal th e pushrod retaining circ lip (see illustration). 11 Depress th e piston and use circlip pliers

5.10 Rem ove the d u s t b o o t to a ccess the pushrod c irclip

8*6 Brakes, wheels and tyres disassembly. Depress th e piston and install th e new circlip, m aking sure it is properly located in th e groove. 16 Fit the dust boot, m aking sure th e lip seated properly in the groove. 17 Inspect th e hydraulic reservoir ca diaphragm plate and diaphragm and renew any parts if they are damaged o r deteriorated.

Installation 18 Installation is th e reverse of removal, noting the following: • Connect th e brake hose to th e master cylinder, using new sealing washers oi each side o f the banjo union. • Align the banjo union as noted on removal. • Ensure the brake ligh t wirihg is connected securely. • Fill the fluid reservoir with new brake fluid (see Daily (pre-ride) checks). • Bleed the air from the system (see Section 8). • Ensure the reservoir diaphragm is correctly I seated and th a t th e cover screws tightened securely. 19 Check th e operation of the brake before riding th e scooter.

Rem otely-m ounted Removal

to remove th e circlip, then slide out th e piston assembly and th e spring, noting how they fit (see illu s tra tio n ). If they are diffic u lt to remove, apply low pressure compressed air to the fluid outlet. Lay th e parts out in the proper order to prevent confusion during reassembly. 12 Clean all parts w ith clean brake fluid orbrake system cleaner. If com pressed air is available, blow it through the fluid galleries to ensure they are clear and use it to dry th e parts thoroughly (make sure the air is filtered and unlubricated). C aution: Do n o t, un d e r any circum stances, use a p e tro le u m -b a s e d s o lv e n t to clean brake parts.

13 Check th e bore inside the m aster cylinder fo r corrosion, scratches, nicks and score marks. If damage o r wear is evident, the m aster cylinder m ust be renewed. If the master cylinder is in poor condition, then the caliper should be checked as well. 14 The dust boot, circlip, piston assembly and spring are included in th e m aster cylinder rebuild kit. Use all o f the new parts, regardless of the apparent condition of the old ones. Fit them according to th e layout of th e old piston assembly. 15 Lubricate the piston assembly with clean brake fluid and install the components in the m aster cylinder in th e reverse order of

5.21 Remove th e E-clip and d raw o u t th e

5.22 U nscrew th e brake hose union (arrowed)

20 On some scooters, th e master cylinder is mounted on the steering stem w ith a separate hydraulic reservoir. The master cylinder is activated by a cable from th e brake lever. Remove th e handlebar covers and the front bo dy panels as necessary fo r access Chapter 9). 21 Remove the E-clip on the cable pivot pin, then draw out th e pin and detach the cable from the m aster cylinder lever arm (see illustration). 22 Unscrew th e brake hose from the master cylinder (see illustration). Secure the hose in an upright position to m inimise fluid loss. Wrap a clean plastic bag tigh tly around the end to prevent dirt entering the system. 1 23 Unscrew the reservoir cap and remove the diaphragm plate and diaphragm. Drain the brake fluid from the reservoir into a suitable container. J 24 Release th e clip securing th e hose to the union on the m aster cylinder, thenj detach the hose from the union (see illustration). Wipe any remaining fluid out of the reservoir with a clean rag.

Brakes, wheels and tyres 8*7

S.25 Master cylind er m ounting bolts (arrowed) nscrew th e master cylinder m ounting and remove th e m aster cylinder (see ration),

7 Brake hoses and unions -

inspection and renewal

lerhaul [the necessary parts fo r overhauling the |r Cylinder are available, fo llo w the ocedure in Steps 9 to 17, otherw ise fit a tester cylinder, illation Istallation is th e reverse o f removal, I the following: sure the reservoir hose is secured with clip - if the o ld clip has weakened, fit a w one. sE-clip should be a tight fit on th e pivot i- fit a new one i f necessary, the fluid reservoir w ith new brake fluid x Daily (pre-ride) checks). the air from the system (see Section 8). the reservoir diaphragm is correctly ted and th at th e cove r is tightened jreiy. |leck the operation o f the brake before the scooter.

ife I

Inspection 1 Brake hose condition should be checked regularly and the hose(s) renewed at th e specified interval (see Chapter 1). 2 Remove the body panels as necessary (see Chapter 9). 3 Tw ist and fle x the hose w hile looking fo r cracks, bulges and seeping fluid. Check extra carefully where th e hose connects to th e banjo fittin g s o r hose unions, as these are common areas for hose failure. 4 Inspect th e banjo fittings and hose unions; if they are rusted, cracked o r damaged, fit new hoses.

Renewal

5 Most brake hoses have banjo fittings on each end. Cover the surrounding area with plenty of rags and unscrew the banjo bolt, noting th e alignment of the fitting with the master cylinder or brake caliper (see illustration). Free the hose from any clips o r guides and remove it, noting Rear disc brake - inspection, ^ its routing. Discard the sealing washers. On ■removal and installation ^ some hoses, one end is secured by a union nut; hold the hose to prevent it twisting while the nut is being undone (see illustration 5.22). Note: ieprocedures fo r removal, inspection and Do n o t operate the brake lever while a brake lallation of th e rear d isc brake pads, hose is disconnected. disc and master cylinder are the same 6 Position the new hose, making sure it is not for the front brake. N ote: The rear wheel tw isted or otherwise strained, and ensure that it is correctly routed th rough any clips or be displaced before th e caliper can be (see Section 15). guides and is' clear o f all moving components. Note the routing o f the rear brake hose 7 Check that the fittings align correctly, then e displacing the caliper, then undo any install the banjo bolts, using new sealing its securing th e hose bracket to the w ashers on both sides o f the fittin gs (see 3elt cover and remove th e bracket (see illu s tra tio n 5.4). Tighten the banjo bolts ■ation). securely. If th e hose is secured by a union nut be caliper is secured to th e transmission at one end, install th a t end firs t to avoid by two bolts (see illustration). tw isting th e hose w hile the nut is being Jthecaliper is just being displaced, secure tightened. Take care not to overtighten th e |he machine w ith a cable tie to avoid union nut. ing the hose. Note: Do no t operate the 8 Flush the old brake fluid from the system, lever while the caliper is o ff the disc, refill w ith new brake fluid and bleed th e air er working on any com ponent in the from the system (see Section 8). i system, always check th e operation of 9 Check the operation o f th e brakes before Brake before riding the scooter. riding th e scooter.

8 Brake system -

bleeding and fluid change

s

^

C au tion : S u p p o rt th e s c o o te r in a u p rig h t p o s itio n a n d e n s u re th a t th e h y d ra u lic re s e rv o ir is le v e l w h ile c a rry in g -o u t these procedures.

Bleeding 1 Bleeding th e brakes is sim ply the process o f removing air from the brake fluid reservoir, m aster cylinder, th e hose and th e brake caliper. Bleeding is necessary w henever a brake system connection is loosened, or when a com ponent is renewed. Leaks in th e system may also allow air to enter, but leaking brake fluid w ill reveal their presence and warn you o f th e need fo r repair. 2 To bleed the brake, you w ill need some new DOT 4 brake fluid, a small container partiallyfilled w ith new brake fluid, a length o f clear vinyl or plastic hose, some rags and a spanner to fit the brake caliper bleed valve. 3 Remove th e handlebar covers or body panels fo r access to th e fluid reservoir (see Chapter 9) and cover any painted com ponents to prevent damage in th e event that brake fluid is spilled. 4 Remove th e reservoir cover, diaphragm plate and diaphragm , and slow ly pum p th e brake lever a few tim es until no air bubbles can be seen floating up from th e holes in the bottom of th e reservoir. This bleeds air from the m aster cylinder end o f th e system. Temporarily refit the reservoir cover.

7.5 N ote th e a lignm ent o f the fittin g (A) be fo re undoing the b o lt (B)

8*8 Brakes, wheels and tyres

5 Pull th e dust cap off the caliper bleed valve (see illustration). Attach one end o f the clear hose to th e bleed valve and subm erge th e other end in th e brake fluid in the container (see illu stra tio n ). Note: To avoid damaging the bleed valve during the procedure, loosen it and then tighten i t tem porarily w ith a ring spanner before attaching the hose. With the hose attached, the valve can then be opened and closed with an open-ended spanner. 6 Check th e fluid level in th e reservoir. Do not allow th e fluid level to drop below th e half-way mark during th e procedure (see illustration). 7 Carefully pump the brake lever three or four times and hold it in while opening the caliper bleed valve. When the valve is opened, brake fluid w ill flow out o f the caliper into the clear hose and th e lever w ill move toward th e handlebar. 8 Tighten the bleed valve, then release the brake lever gradually. Repeat the process until no a ir bubbles are visible in th e brake fluid leaving th e caliper and th e lever is firm when applied. On completion, disconnect the hose, ensure th e bleed valve is tightened securely and fit th e dust cap. 9 Top-up the reservoir, install the diaphragm, diaphragm plate and cover, and wipe up any spilled brake fluid. Check th e entire system for fluid leaks.

I f i t ’s n o t p o ssible to produce a firm fe e l to th e le v e r the flu id m ay be a erated. L e t the b ra ke flu id in th e system s ta b ilis e fo r a fe w h o u rs a n d th en re p e a t th e p ro c e d u re w h e n th e tin y bubbles in th e system have s e ttle d out. To speed th is pro cess up, tie the fro n t brake leve r to th e hand leb ar so th a t the system is pressurised.

Fluid change Note: Some manufacturers recommend back­ filling the hydraulic system with a syringe to avoid troublesom e air locks (see Steps 16 to 22). 10 C hanging th e brake fluid is a similar process to bleeding the brakes and requires th e same m aterials plus a suitable tool for

8.5b S et-up fo r bleeding th e brakes

8.6 C heck th e fluid level regularly

syphoning th e fluid ou t o f th e hydraulic reservoir. Also ensure that th e container is large enough to take all the old fluid when it is flushed out of the system. 11 Follow the procedure in Step 5, then remove th e reservoir cap, diaphragm plate and diaphragm and syphon the old fluid out of the reservoir. Fill the reservoir with new brake fluid, then follow th e procedure in Step 7. 12 Retighten the bleed valve, then release the brake lever gradually. Keep th e reservoir topped-up with new fluid at all times or air may enter the system and greatly increase the length of the task. Repeat the process until new fluid can be seen emerging from the bleed valve.

ring spanner before attaching the hose. With the hose attached, the valve can then be opened and closed with an open-ended spanner. 19 Open the bleed valve and carefully inject fluid into th e system until the level in the reservoir is up to th e half-way mark. Tighten the bleed valve, disconnect th e hose and refit the dust cap. 20 Operate th e brake lever carefully several times to bring the pads into contact with the disc; then check the fluid level in the reservoir and topup if necessary (see Daily (pre-ride) checks), j 21 Install th e diaphragm , diaphragm plate and cover, and w ipe up any spilled brake fluid. Check th e system for fluid leaks. 22 Check the operation o f the brakes before* riding th e scooter.

O ld b ra ke flu id is in va ria b ly m uch d a rk e r in c o lo u r th an n e w flu id , m a kin g i t easy to see w hen a ll o ld flu id has been e xpelled from th e system.

13 Disconnect the hose, ensure the bleed valve is tightened securely and install the dust cap. 14 T op-up the reservoir, install th e diaphragm, diaphragm plate and cover, and w ipe up any spilled brake fluid. Check th e entire system for fluid leaks. 15 Check the operation of the brakes before riding the scooter. 16 If, after changing the brake fluid, it proves im possible to obtain a firm feel at the brake lever, it may be necessary to back-fill th e system. To back-fill the hydraulic system, remove the reservoir cover, diaphragm plate and diaphragm and syphon the old fluid out of th e reservoir. Tem porarily refit the reservoir cover but do not tighten the fixing screws. 17 Remove th e brake caliper and slowly push th e pistons as fa r back into th e caliper as possible using hand pressure or a piece of wood fo r leverage, then syphon any residual fluid from th e reservoir. Leave th e cover o ff th e reservoir. Refit th e brake caliper. 18 Fill a suitable syringe w ith approximately 40 ml o f new brake fluid and connect a short length of hose to the syringe. Bleed any air from th e syringe and hose, then connect the hose to the caliper bleed valve. Note: To avoid damaging the bleed valve during the procedure, loosen it and then tighten it temporarily with a

9 Drum brakes - inspection,

^

shoe removal and installation &

%

W arning : The d u s t created bl th e b ra ke syste m m ay contain asbestos, w h ich is harmful to y o u r h e a lth . N eve r b lo w it out w ith com p re ssed a ir a n d d o n ’t inhale artf o f it. An approved filte rin g m ask should Ix w orn w hen w orking on th e brakes.

A

Inspection 1 Some scooters are fitted w ith a brake wes indicator; if the wear indicator aligns with III index mark when the brake is applied, I shoes should be renewed (see illustration),

Brakes, wheels and tyres 8*9

I 9.2 Check th e fric tio n m aterial (A) and spring s (B)

9.6 C heck the s urface o f th e brake drum (arrowed)

9.8 Brake arm (A), spring (B) and pin c h -b o lt (C)

ffilternatively, rem ove the w heel (see n 14 or 15). On some front suspension ^S, the brake backplate will remain on the nsion arm, on others it will be necessary inove the backplate from th e wheel. ;kthe amount o f friction material on the te shoes and compare the result with the Bpation in the Data section at the end o f ^manual (see illu s tra tio n ). If th e friction I has worn dow n to the minimum ess, fit new brake shoes. ie friction m aterial fo r imination. If it is fouled with oil or grease, javily scored o r dam aged, both shoes st be renewed as a set. Note that it is not e to degrease th e friction material; if «s are contaminated in any way they st be renewed. [if the shoes are in good condition, clean mcarefully using a fine wire brush w hich is letely free o f oil and grease to remove all 3S of dust and corrosion, feck the condition o f the brake shoe s; they should hold th e shoes tightly in e against th e operating cam and pivot st (see illustration 9.2). Remove the shoes (eSteps 11 to 12) and renew the springs if eyappear weak or are obviously deformed imaged. n Clean the surface of the brake drum using kesystem cleaner. Examine th e surface for Ipring and excessive wear (see illustration), le light scratches are to be expected, any iy scoring will impair braking and there is tisfactory way o f removing them; in this

event the wheel should be renewed, although you could consult a specialist engineer w ho m ight be able to skim the surface. 7 Measure the internal diameter of the brake drum w ith a vernier caliper; take several m easurem ents to ensure th e drum has not w orn ou t-of-round. If the drum is ou t-ofround, fit a new wheel. 8 To check and lubricate the brake cam, first remove th e brake shoes (see Steps 11 to 12). Note the position o f th e brake arm and spring, then loosen the brake arm pinch-bolt and pull the cam out of the backplate or casing (see illustration). Clean all traces o f old grease off the cam and shaft. If the bearing surfaces of the cam or shaft are worn th e cam should be renewed. 9 Lubricate the shaft with a smear o f copper grease; position the brake arm and spring and install th e cam in th e backplate or casing, then tighten the pinch-bolt securely. Lubricate th e cam and th e pivot post w ith a smear of copper grease and install th e brake shoes.

13 To install th e shoes, first lubricate th e cam and the pivot po st w ith a sm ear o f copper grease and hook th e springs into the shoes (see illustration). Position the shoes in a V on the cam and pivot post, then fo ld them down into position. Operate th e brake arm to check that th e cam and shoes w ork correctly. 14 Install the wheel and test the operation of the brake before riding the scooter.

19,12 Fold the shoes as show n to release th e spring tension

9.13 Assem ble th e shoes and spring s as show n - fla t en ds (A) and rounded ends (B)

Shoe rem oval and installation 10 Remove the wheel (see Section 14 o r 15). 11 If the shoes are not going to be renewed they m ust be installed in th eir original positions; mark them to aid reassembly. Note how the springs are fitted. 12 Grasp the outer edge o f each shoe and fo ld them inw ards tow ards each other to release the spring tension and remove the shoes (see illustration). Remove the springs from the shoes.

10 Brake cable - renewal

5

§ .

I

1 Remove th e body panels as necessary (see Chapter 9). 2 Fully unscrew th e adjuster on the lower end o f the cable, then release th e cable from the stop on the backplate. Disconnect th e cable from th e brake arm (see illustration). 3 Free the cable from any clips o r guides. 4 Pull th e ou te r cable out o f th e handlebar lever bracket and free the inner cable end from its socket in th e underside o f th e lever (see illu strations). 5 Withdraw the cable from th e scooter, noting its routing. 6 Installation is the reverse of removal. Make sure the cable is correctly routed and clipped into place. Lubricate th e cable nipple at the handlebar end w ith grease before fitting it into th e lever and ad just the cable freeplay (see Chapter 1).

10.2 Release the cable from th e brake arm

8«10 Brakes, wheels and tyres

11.1 Brake lever p ivot b o lt locknut

[W W JfW When fittin g a n e w cab le, ta p e th e lo w e r e n d o f the n e w c ab le to th e up p e r e n d o f th e o ld c a b le be fo re re m o v in g i t fro m th e m a ch in e. S lo w ly p u ll th e lo w e r e n d o f th e o ld cable out, g u id in g th e n e w ca b le d o w n in to position. Using th is m e th o d w ill ensure the cable is ro u te d correctly.

HiNT

7 Check th e operation o f th e brake before riding th e scooter.

11 Brake levers -

removal and installation

Removal 1 Unscrew th e lever pivot bolt locknut, then withdraw th e pivot bolt and remove the lever (see illu stratio n). Where applicable, slacken the brake cable and detach it from the underside o f th e lever as you remove it.

Installation 2 Installation is the reverse of removal. Apply grease to the pivot bolt shank and th e contact areas between th e lever and its bracket, and to th e brake cable nipple (where applicable).

12

Wheels-

inspection and repair

*?■

1 In order to carry out a proper inspection of th e wheels, it is necessary to support the scooter upright so th a t the wheel being inspected is raised off the ground. Clean the wheels thoroughly to remove mud and dirt th a t may interfere w ith th e inspection procedure or mask defects. Make a general check o f the wheels (see Chapter 1) and tyres (see Daily (pre-ride) checks). 2 If available, attach a dial gauge to the suspension (front) or the transmission casing (rear) w ith th e tip of th e gauge touching th e side o f th e rim. Spin the wheel slow ly and check the axial (side-to-side) runout of the rim (see illustration). 3 In order to accurately check radial (out-of­ round) runout with th e dial gauge, th e wheel should be removed from the machine, and the ty re removed from th e wheel. W ith th e axle clam ped in a vice o r jig and the dial gauge positioned on the to p of th e rim, the wheel can be rotated to check th e runout. 4 An easier, though slightly less accurate, method is to attach a stiff wire pointer to the front suspension or transmission casing with the end of th e pointer a fraction o f an inch from th e edge o f th e wheel rim where the wheel and tyre join. If the wheel is true, the distance from th e pointer to th e rim w ill be constant as th e wheel is rotated. N ote: If w heel runout is excessive, check th e wheel bearings very carefully before renewing the wheel (see Section 16). 5 The wheels should also be visually inspected for cracks, flat spots on th e rim and other damage. Look very closely fo r dents in

the area where th e tyre bead contacts the rim. Dents in this area may prevent complete sealing of th e tyre against the rim, which leads to deflation o f the tyre over a period of time. If damage is evident, or if runout is excessive, th e wheel w ill have to be renewed. Never attempt to repair a damaged cast al wheel.

1 M isalignm ent o f the w heels can c strange and potentially serious handling problems and will m ost likely be due to bent frame or suspension com ponents as the result of an accident. If th e frame or suspension are at fault, repair by a frame specialist or using new parts are the only options. 2 To check wheel alignment you will need an assistant, a length o f string o r a perfecttyfl straight piece o f wood and a ruler. A plumb bob or spirit level fo r checking that the wheels are vertical will also be required. Support the scooter in an upright position on its centre stand. 3 If a string is used, have your assistant hold one end o f it about halfway between the foot and th e centre o f th e rear wheel, with the string touching the back edge o f the rear tyre sidewall. 4 Run the other end of th e string forward and pull it tight so that it is roughly parallel to ttq floor. Slowly bring the string into contact the front sidewall o f th e rear tyre, then tumthe fron t wheel until it is parallel with the st Measure th e distance (offset) from the froi tyre sidewall to th e string (see illustratioi

c String heldtaut

round) runout (A) and a xial (side-to-side) run ou t (B)

13.4 W heel alignm ent che ck using s tring

Brakes, wheels and tyres 8*11

14.2a Lever o ff th e cen tre cover

14.2b Rem ove th e s p lit pin

wheels still may be out of alignment vertically. 9 Using a plumb bob o r spirit level, check the rear w heel to make sure it is vertical. To do this, hold the string of the plumb bob against the tyre upper sidewall and allow th e weight to settle just o ff the floor. If th e string touches both the upper and lower tyre sidewalls and is perfectly straight, th e wheel is vertical. -If it is not, adjust the centre stand by using spacers under its feet until it is. 10 Once th e rear wheel is vertical, check the fro n t wheel in the same m anner. If both w heels are not perfectly vertical, the frame and/or m ajor suspension com ponents are bent.

nut, then rem ove the w asher and draw th e wheel of the axle (see illustrations). 3 On some scooters, the wheel is secured on a kno ck-ou t axle; counterhold the axle and undo the axle nut, then support th e wheel and w ithd ra w th e axle. Note how the brake backplate locates against the suspension arm and how th e speedom eter drive gearbox locates in the hub. 4 Check the condition o f the wheel bearings (see Section 16). 5 If applicable, clean the axle and remove any corrosion using steel w ool. Check th e axle for straightness by rolling it on a flat surface such a piece o f plate glass. If th e axle is bent, renew it. 6 Installation is the reverse o f rem oval ensure all th e components align, then tighten the hub o r axle nut to th e torque specified in the Data section a t the end o f th is manual. Where applicable, fit a new split pin to secure the cage nut. Adjust the front brake cable (see Chapter 1).

14 Front wheel and hub assembly - removal and installation 13.6 Wheel a lignm ent che ck using a straight-edge Me: Where the same size tyre is fitte d front vim , there should be no offset. Repeat the procedure on th e other side of machine. The distance from th e front tyre Uewall to the string should be equal on both ties. I previously mentioned, a perfectly teght length of wood or metal bar may be substituted for the string (see illustration). Ifthe distance between th e string and tyre greater on one side, o r if the rear wheel ypears to be out o f alignm ent, have your achinechecked by a scooter dealer. Ifthefront-to-back alignment is correct, the

^

Leading and trailing link suspension Drum brake wheel 1 Support the machine in an upright position with th e front wheel off the ground. If required, disco nn ect th e fro n t brake cable from th e brake arm and backplate (see Section 10). 2 On some scooters, th e wheel is secured on a fixed axle; lever o ff th e hub centre cover using a small flat-b lad ed screw driver (see illustration). Where fitted, remove th e split pin from th e end o f th e axle then remove th e cage nut (see illustration). Discard the split pin, as a new one must be used. Undo th e hub centre

. and rem ove th e w asher

Drum brake hub assembly N ote : On scooters w ith a separate hub assembly, th e assem bly incorporates the brake backplate. 7 Remove the wheel (see above). 8 Remove th e suspension sho ck absorber (see Chapter 7). 9 If necessary, disconnect th e speedometer cable from the hub. 10 The hub assembly is secured by a circlip; remove the circlip and washer, they draw the assembly o ff the axle. 11 Check th e condition o f th e bearings in the

8*12 Brakes, wheels and tyres

14.14 F ront w heel is retained by b olts (arrowed)

14.22a Remove the s p lit pin (arro w ed ). . .

hub (see Section 16). Examine th e hub seals fo r wear and dam age - if grease is passing the seals they should be renewed (see Tools and Workshop Tips in the Reference section). Clean the axle and rem ove any corrosion using steel wool. 12 Installation is th e reverse o f removal, noting the following: • Lubricate th e axle, bearings and speedometer drive w ith grease. • Ensure the circlip is p roperly seated in its groove.

to the hub assembly; undo the bolts securing the wheel to th e hub and lift th e wheel off (see illu s tra tio n ). Installation is the reverse of removal - tighten the wheel bolts to th e torque specified in th e Data section. 15 On some scooters, th e wheel is secured on a knock-out axle; counterhold th e axle and undo the axle nut, then support the wheel and withdraw the axle. Lower th e wheel and lift off the speedometer drive gearbox, noting how it fits. Disengage th e brake disc from the caliper and remove the wheel. Note: Do not operate the brake lever while the caliper is o ff the disc. 16 Note th e position of any axle spacers and remove them from the wheel for safekeeping. 17 Check th e condition o f the wheel bearings (see Section 16). 18 Clean the axle and remove any corrosion using steel wool. Check th e axle fo r straightness (see Step 5). 19 Installation is th e reverse o f removal ensure th e speedom eter drive gearbox is

D is c b r a k e w h e e l

C a u tio n : D o n ’t la y th e w h e e l do w n a n d a llo w i t to r e s t on the d isc - th e d isc could b e co m e w arpe d. S e t th e w h e e l on w oo d b lo c k s so th e d is c d o e s n ’t s u p p o rt the w e ig h t o f th e wheel. 13 S upport th e m achine in an upright position with the front wheel off th e ground. 14 On some scooters, th e wheel is secured

14.24 Pull the hub a ssem bly o ff the axle

14.25a N ote h o w th e speedom eter drive ta b s (arro w ed ). . .

14.25b . . . locate in th e speedom eter gearbox (arrowed)

14.22b . . . and the c ag e nut correctly located and th e axle spacers are in place. Tighten th e axle nut to th e torque specified in th e Data section. 20 Check th e operation o f th e fron t brake before riding th e scooter. D is c b r a k e h u b a s s e m b ly 21 Remove the wheel (see above). 22 Where fitted, remove th e split pin from the: end of the axle then remove the cage nut (see illustrations). Discard th e split pin, as a new one m ust be used. Have an assistant apply th e fro n t brake, then loosen th e hub centre nut. Undo th e brake caliper mounting bolts and displace the caliper (see Section 3). Note: D o n o t operate the brake lever while the caliper is o ff the disc. 23 Unscrew the hub centre nut and remove the nut and washer (see illustration). 24 Draw th e hub assembly o ff the axle (see illustration). 25 If applicable, note how th e speedomete( drive tabs on th e back o f th e hub locate in the speedom eter gearbox in th e brake caliper bracket (see illustrations). 26 Check th e condition o f the hub bearings and seals, and th e axle (see Step 11). J 27 If applicable, disconnect the speedometer cable from th e speedom eter gearbox in the brake caliper bracket. N ote : On some scooters-, th e speedom eter is electronic^ activated and the ele ctrica l wire and dm housing are a one-piece unit. Do n ot attemi disconnected them. Undo th e bolt securing the brake to rque arm to the caliper bracket then slide the bracket o ff the axle (a illustration).

Brakes, wheels and tyres 8*13 stallation is th e reverse o f removal, ithe following: icate th e axle, bearings and m eter drive w ith grease, ure the speedom eter drive tabs are ■ectly located. rten the hub n u t and brake caliper bolts the torque specified in the Data section. ire applicable, fit a new s p lit p in to ire the cage nut.

\escopic fork leel rem ova l tion: D on’t la y th e w h e e l d o w n a n d it to re st on th e d isc - th e d isc cou ld me w arped. S e t th e w h e e l on w oo d so th e d is c d o e s n ’t s u p p o rt th e fit of th e w heel. Support the m achine in an upright with the front wheel off the ground. In drum brake m odels, disco nn ect the cable (see Section 10). Jnscrew the brake caliper m ounting bolts Gsplace the caliper (see Section 3). Note: operate the brake lever while the eris o ff the disc. | required,, disconnect th e speedometer 3 from th e speedom eter gearbox (see (ration). N ote: On som e scooters, the eedometer is electronically-activated and lectrical wire and drive housing are a unit. Do n o t attem pt disconnected

14.32 D isconnect the s peedom eter cable

14.33b . . . th en s u p p o rt th e w heel and w ith d ra w th e axle

On m odels w ith a cable-activated speedometer, apply some grease to the inside o f the speedom eter gearbox. Install the Jounterhold th e axle and undo the axle speedom eter gearbox, ensuring it locates hen support th e wheel and w ithdraw the correctly on the wheel hub (see illustrations). lefrom the wheel and front suspension (see 38 Lubricate th e axle with a smear o f grease. itrations). Lower th e wheel o u t o f the L ift the wheel into place between th e forks Is and lift o ff th e speedom eter gearbox and install any axle spacers. Check th a t the «illustration). speedom eter gearbox is located correctly I Note the position of any axle spacers and against th e inside o f th e fo rk (see we them from th e wheel fo r safekeeping. illu stratio n). On drum brake models, ensure n the axle and remove any corrosion th e brake backplate is located correctly jigsteel wool. Check the axle for straightness against the inside o f the fork. lolling it on a flat surface such as a piece of 39 Slide th e axle in carefully ensuring all the 3. If the axle is bent, renew it. components remain in alignment. Check the condition o f th e wheel bearings 40 Install the axle nut and tighten it to the eSection 16). to rque setting specified in the Data section. H in s ta lla tio n 41 As necessary, install th e brake caliper, 37 Manoeuvre th e wheel into position, m aking sure th e pads s it squarely on each J a n g sure the directional arrow on the tyre side o f the disc (see Section 3). Connect the speedometer cable. On drum brake models, pointing in th e normal direction of rotation.

14.37b . . . locate a gain st ta bs on the w heel h ub (arrowed)

14.33c L ift o ff th e speed om e ter gearbox connect the brake cable (see Section 10) and adjust it (see C hapter 1). 42 Move th e scooter off its stand, apply the fro n t brake and pum p the fro n t fo rks a few times to settle all components in position. 43 C heck the operation o f the fro n t brake before riding the scooter.

15 Rear wheel and hub assembly - removal and installation

;|§ ^

N ote: It m ay n o t b e p ossible to rem ove the rear wheel with the exhaust system in place. If necessary, remove th e com plete system - do n o t rem ove the exhaust system m ounting bolts and a ttem p t to lever the w heel b ehind the silen cer w ith th e exhaust m anifold still connected; damage to the m anifold studs and cylinder w ill result.

14.38 Note h ow th e speedometer gearbox (A) locates against th e fork slider (B)

8*14 Brakes, wheels and tyres

15.3 B o lt (A) secures sho ck to subfram e; bo lts (B) secure subfram e to engine

Drum brake models W heel 1 Position the scooter on its centre stand and support it so that the rear wheel is off the ground. 2 If necessary, remove th e exhaust system (see Chapter 4). 3 On scooters w ith 'tw in rear shock absorbers, undo th e b o lt securing th e lower end of the right-hand shock to th e subframe and displace th e shock, then, undo the bolts securing th e subfram e to th e engine casing (see illustration). 4 Lever th e centre cover o ff w ith a small flatbladed screwdriver. Where fitted, remove the split pin from the end o f th e axle then remove th e cage nu t (see illu s tra tio n s 14.22a and 14.22b). Discard th e split pin, as a new one m ust be used. 5 Have an assistant apply th e rear brake, then unscrew th e hub centre nut and remove the nut and washer (see illustration).

15.8 In spe ct the splines fo r w ear and dam age

15.6 L ift o ff th e rear subfram e 6 If applicable, lift o ff the rear subframe and slide any spacers off the axle (see illustration). Check the condition of the bearing and seals in the subframe (see Tools and Workshop Tips in the Reference section). If there is any doubt about the condition o f the bearing, renew it. 7 Slide the wheel off th e axle and manoeuvre it ou t o f th e back of the machine (see illustrations). 8 Inspect th e splines on th e axle and on the inside of the hub fo r wear and damage (see illu s tra tio n ). If th e splines are worn, both com ponents should be renewed. To renew the axle th e gearbox m ust first be disassembled (see Chapter 6). 9 Installation is th e reverse o f removal - slide the wheel onto th e axle carefully to avoid disturbing th e alignment of the brake shoes. Tighten th e hub centre nut to th e to rque setting specified in the Data section at the end o f th is m anual. Where applicable, fit a new split pin to secure the cage nut.

10 Check th e operation o f th e rear brake before riding th e scooter.

Disc brake models W heel 11 Position th e scooter on its centre stand and support it so that the rear wheel is off th( ground. 12 If necessary, remove the exhaust system (see Chapter 4). 13 Have an assistant apply th e rear brake, then undo the bolts securing the wheel to the hub assem bly and remove th e wheel (see illustration). Note: On scooters with twin red shocks, follow the procedure in Steps 3 antfS to remove the subframe. 14 Installation is the reverse o f removal tighten th e wheel bolts to the to rque setfiri specified in the Data section. H u b a s s e m b ly 15 If required, remove the wheel. 16 Lever th e centre cover o ff w ith a smal flat-bladed screwdriver. Where fitted, remov the s plit pin from the end o f the axle thel remove the cage nut (see illustrations 14.22a and 14.22b). Discard th e split pin, as a ne* one must be used. 17 Have an assistant apply th e rear brak? then loosen the hub centre nut. 18 Undo th e brake caliper mounting bM and displace th e caliper (see Section 3). Note: Do n o t operate th e brake lever while ra caliper is o ff the disc. 19 Undo the hub centre nut and remove 18 nut, then draw the hub assembly off the an (see illustration).

15.19 rem ove th e n u t (A), hub a ssem bly (C)

Brakes, wheels and tyres 8*15

>A 1v 120a Inspect th e splines on the axle . . . Inspect th e splines on the axle and on the Heof the hub fo r wear and damage (see drations). If th e splines are worn, both raonents should be renewed. To renew i axle th e gearbox m ust first be assembled (see Chapter 6). Installation is the reverse o f rem oval the hub centre nut to th e torque ling specified in th e Data section. Where pable, fit a new split pin to secure th e emit. Check th e operation o f the rear brake riding th e scooter.

16Wheel bearings check and renewal

^

The fron t w heel bearings are located the wheel hub and, where applicable, the separate hub assembly. There are 3r wheel bearings as such, the rear (gearbox output shaft bearings are located the gearbox (see C hapter 6). On s with twin rear shock absorbers, also theck the condition o f th e bearing in the rear (see Section 15).

15.20b . . . and inside th e hub (arrowed)

Renewal 5 If not already done, lever out th e bearing seal. Check fo r any retaining c irclips and remove them (see illustration). 6 To rem ove th e bearings from th e hub assembly, stand th e assembly on a suitable spacer to allow the bearings to be driven out. N ote th e position o f the bearings before removing them. C a u tio n : D o n ’t s u p p o rt th e h u b on th e bra ke d isc w hen d rivin g o u t th e bearings. 7 To remove a caged ball-bearing, use a metal rod (preferably a brass d rift punch) inserted through the centre of the bearing on one side of the wheel hub or hub assembly, to ta p evenly around the outer race o f th e bearing on th e other side (see illustrations). T he bearing spacer w ill com e out w ith th e bearing. Use a drawbolt to remove a needle roller bearing (see Tools and Workshop Tips in th e Reference section). 8 Turn the hub over and rem ove th e

16.2a Rem ove a ny spacers . . . remaining bearing using the same procedure. 9 Thoroughly clean the bearing housings with a suitable solvent and insp ect them fo r scoring and wear. If a housing is damaged, indicating th a t th e bearing has seized and spun in use, it may be possible to secure the new bearing in place w ith a suitable bearing locking solution. 10 Install a new bearing into its seat in one side o f th e hub, w ith th e m arked o r sealed side fa cin g outw ards (see Tools and Workshop Tips in the Reference section), then turn th e hub over, install th e bearing spacer and install the other new bearing. N ote: N eedle ro ller bearings sho uld be installed using a drawbolt. 11 If applicable, secure th e bearing w ith the circ lip and ensure th e circlip is. properly located in its groove. 12 Install new bearing seals. 13 Install th e hub assembly a nd/or th e wheel as applicable (see Section 14).

Check love th e w heel and, if a pplicable, th e assembly (see Section 14). Caution: D on’t la y th e w h e e l d o w n a n d m it to rest o n th e b ra ke d isc - i t c ou ld Income w arped. S e t th e w h e e l on w o o d Hocks so th e w h e e l rim s u p p o rts th e neight o f the wheel. Remove any spacers and du st caps from wheel hub (see illu strations). Inspect the bearings (see Tools and irkshop Tips in th e Reference section). If Bcessary, lever out th e bearing seals with a d screwdriver to gain access to the brings and fit new seals on reassembly, needle roller bearings w ith a suitable ^ it so th a t th ey can be inspected roperly. Note: C aged b all-bearings can be moved for checking and re-used i f they are good, but needle roller bearings m ust be renewed once they have been removed. If there is any doubt about th e condition of , renew it. Note: Always renew the ' wheel bearings in sets, never individually.

16.5 Rem ove th e c irc lip (arrowed)

16.7a Driving a bearing o u t o f the hub

16.7b Locate th e rod as shown when driving o u t a bearing

8*16 Brakes, wheels and tyres Fitting new tyres 17 T y re s - general in fo rm a tio n a n d fittin g

General inform ation 1 Tyre sizes and tyre pressures are given in the Data section at the end o f this manual. 2 Refer to D aily (pre-ride) checks at th e beginning o f this manual fo r tyre maintenance.

3 When selecting new tyres, refer to the tyre inform ation given in the owners handbook. Ensure th at fro n t and rear tyre types are c om patible, th e correct size and correct speed rating. If necessary seek advice from a tyre fitting specialist. 4 It is recommended that tyres are fitted by a tyre specialist rather than attem pted in the home workshop. This is particularly relevant in

the case of tubeless tyres because the forct required to break th e seal between th e whee rim and tyre bead is substantial, and is usualI) beyond th e capabilities o f an individua w orking with normal tyre levers. Additionally the specialist w ill be able to balance thi wheels after tyre fitting. 5 Note th a t although punctured tubeless tyres can in some cases be repaired, some manufacturers do not recommend th e use o: repaired tyres.

Chapter 9 lodywork o n te n ts ypanels - removal and insta llatio n............................................... 8 and oil tanks - removal and insta llatio n....................................... 7 ial inform ation................................................................................ 1 elfasteners - removal and installation ......................................... 5

Panel r e p a ir ............................................................................................. Passenger footrests - removal and insta llatio n................................... Rear view mirrors - removal and installation....................................... Seat and storage compartm ent - removal and insta llatio n...............

6 3 2 4

egrees of difficulty asy, suitable for mice with little

Fairly easy, suitable fo r beginner with som e experience

General information

Imost all th e functional components o f the liters covered by this manual are enclosed jody panels, m aking removal o f relevant necessary part o f m ost servicing and aintenance procedures. Panel removal is ihtforward, and as well as facilitating is to mechanical components, it avoids risk of accidental damage to th e panels. Most panels are retained by screw s and

2.1a Slacken th e n u t ..

^

Fairly difficult,

Difficult, suitable for

suitable for competent ^ DIY mechanic ^

experienced DIY mechanic

inter-locking ta bs, although in some cases trim clips are used (see Section 5). Always check the details in your scooter handbook and fo llow the advice given at th e beginning of Section 8 before removing the panels.

2

Rear view mirrors -

removal and installation

I

Removal Note: If the m irror stem is covered b y a rubber

2.1b . . . th en un screw th e m irror

Very difficult, ^

^

suitable fo r expert DIY < or professional ^

boot, p u ll b ack the low e r end o f th e b o o t to expose the top o f the fixing. 1 W here the m irror th reads into a housing, slacken th e locknut then unscrew th e mirror (see illu strations). 2 W here the m irror passes th ro ug h a bore and is secured by a nut, unscrew th e nut from the underside and rem ove th e m irror (see illustration).

Installation 3 Installation is the reverse o f removal. Position the mirror as required, then hold it in place and tighten the nut.

9*2 Bodywork

' 2.4 Rear view m irror ad juste r screw s

4 Some m irrors have screw fixings on th e back of the mirror head. To adjust th e angle of the mirror, pull back th e upper end o f th e boot on the stem to expose the adjuster screws (see illustration). Loosen th e screws and set th e m irror to th e required position, then tighten th e screws and refit the boot.

3 Passenger footrests removal and installation

|^> |j5

N o te : Some scooters are fitte d w ith fold ing passenger footrests. D ifferent m ethods o f securing the footrests are em ployed - study the design before attem pting to rem ove the footrest.

3.1 Remove th e s p lit pin (A) to release th e pivot pin. Note the de te nt plate (B) and ball (C)

Removal 1 If applicable, remove th e s plit pin and washer or spring clip from th e bottom o f the footrest pivot pin, then withdraw th e pivot pin and remove th e footre st (see illu s tra tio n ). Som e footrests are hel'd in position w ith a detent plate, ball and spring; note how they are fitted and take care that they do not spring out when removing the footrest. 2 On some scooters the footrest is secured by a pivot bolt. Counterhold the bolt and undo the nut on th e underside of the footrest (see illu s tra tio n ). N ote: It may be necessary to remove a cover o r lift a floor m at to access the bolt. Withdraw the bolt and slide the footrest out o f the bracket.

Installation 3 Installation is th e reverse of removal.

4.2 Undo th e hinge b o lts to rem ove th e seat

4.3a Latch m echanism is actuated either by rod . . .

4.3b . . . o r by cable

4.3c U nclip th e cable from th e s to p on the p a n e l. . .

Apply a smear o f grease to th e pivot pin or] bolt and ensure any washers o r spacers ar* fitte d on th e bolt before it is installed. Hj applicable, tighten the nut enough t| allow the footrest to pivot w ithout binding in the bracket. Alternatively, install th e spring clip, ensuring it is a firm fit, or fit a new spii pin.

4 Seat and storage compartment removal and installation Seat 1 Release th e seat catch and swing the seal upright. 2 The seat is retained by th e hinge at the frort of th e seat base (see illu s tra tio n ). Support the seat and undo the hinge bolts, then lift the seat away. 3 The seat latch mechanism is actuated either by a rod o r cable from th e seat lod (see illustrations). To remove the seat lock, first remove th e storage compartmenj (see Steps 7 to 10). Unclip the rod from the lock or unclip th e cable from the back o f th e side panel and th e lock (see illustrations), then remove the side panel (see Section 8). 4 The lock is retained in a recess in the panel by a spring clip. Pull off thi spring clip, note how th e lock locates in the

Bodywork 9*3

I Pull o ff th e c lip to rem ove the lock

recess, then rem ove the lock (see ition). Check th e operation o f the latch schanism and lubricate it w ith a sm ear of stallation is th e reverse of removal. W arning : E n su re th e a c tu a tin g ro d o r ca b le is p ro p e rly c o n n e c te d to th e lo c k b e fo re clo sin g th e seat, o th e rw is e you w ill have no w ay o f relea sing the latch.

Storage com partm ent Unlock th e seat and sw ing it upright. illy, an engine access panel is fitted in (bottom of the compartm ent, although this limited access to th e engine; fo r better s remove th e storage com partm ent as s. Note: On m ost scooters, the storage mpartment can be rem oved w ith the seat tached. Where fitted, rem ove any sealing collars around the fuel and oil tank filler'necks be necessary to unscrew the tank caps remove the collars (see illu stratio n). Refit itank caps. Undo the screw s or flange nuts securing storage com partm ent to th e fram e edge illustrations). N ote th a t on some scooters, the screws also secure some body Check that no electrical com ponents Kh as relays o r fuseboxes are clipp ed to n compartment, th en lift it bu t (see ustration). Installation is th e reverse o f removal.

4.9b . . . o r by flan ge nuts

4.10 D etach any e le ctrica l com p on en ts fro m th e c om p artm en t

On some panels, fasteners are located inside glove com partm ents or fuel fille r flaps, or behind blanking plugs (see illu s tra tio n s ). N ote: A d jace nt panels are often jo in e d together by tabs and slots (see Step 16). 3 Note all the fasteners and associated fittings removed with the panel to be sure of returning everything to its correct place on installation.

4 Before installing a panel, che ck th a t all fasteners and fittin g s are in good condition and renew any that are damaged. 5 Tighten th e fasteners securely, bu t be careful not to overtighten any o f them or th e panel may break (not always im m ediately) due to uneven stress. Take particular care when tightening self-tapping s crew s into plastic lugs on th e backs of panels - if th e lugs break the panel will have to be renewed.

M ake a c a rd b o a rd te m p late o f th e pa ne l an d pu nch a hole fo r each fa s te n e r loc a tion . This w ill e nsure a ll fasteners are in s ta lle d c o rre c tly on reassem bly th is is im p orta nt as som e fasteners m ay b e o f d iffe re n t sizes o r lengths.

HiNT

Trim clips 6 T w o types o f trim clip s are used. If the centre pin is flush w ith th e head o f the trip clip, push the centre into th e body, then draw th e clip o u t o f th e panel (see

!5 Panel fastenersremoval an d in sta llatio n

t Before removing any body panel, study it josely, noting th e position o f th e fasteners ii associated fittings. 2 Once th e evident fasteners have been wed, try to remove th e panel but DO NOT FORCE IT - if it w ill no t release, check that all fasteners have been removed.

5.2a C heck fo r fasten ers inside c o m p a rtm e n ts . . .

5.2b . . . o r behind blanking plugs

9*4 Bodywork

‘

^

#■

i

‘ ■*& «, - f 5.6a Trim c lip rem oval

A B

Clip installed Clip with centre pin pushed in ready for removal

illustration). Before installing th e this type of trim clip, first push th e centre back ou t so that it protrudes from th e to p o f the clip (see illu s tra tio n ). Fit the clip into its hole, then push th e centre in so that it is flush with the to p o f th e clip. 7 Alternatively, if th e centre pin has a raised head, pull th e pin out, then draw the clip out of the panel (see illu stra tio n ). To install the clip, fit th e clip into its hole, then push the centre in until it clicks into place.

Quick-release screws 8 To undo a quick-release screw, turn it anti­ clockwise until resistance is felt - the screw will normally turn between 90° and 180°. As the panel is removed, note the alignment between the screw and its retaining mechanism. 9 To install a quick-release screw, first ensure it is correctly aligned, then turn it clockwise

5.6b Trim c lip installation

A B

Clip ready fo r installation Clip being secured in panel

until resistance is felt - th e screw should now be locked.

Self-tapping screws 10 When th e panel is removed, note the loca tion of th e screws. If they engage in plastic lugs on the back o f an adjacent panel, check th& condition o f each lug and ensure it is not split or the thread stripped. If necessary, repair a damaged lug with a proprietary repair kit (see Section 6). 11 If the screws engage in U-clips, check that the clips are a firm fit on th e mounting lug and that they are not sprained (see illustration). If necessary, fit new U-clips.

Shouldered screws 12 Shouldered screws are designed to retain a panel in conjunction with a spacer or rubber bush (see illu s tra tio n ). Ensure the correct

sr

5.7 Pull o u t the cen tre pin to remove the clip components are in place on the screw before installing it, otherw ise the panel w ill not be held firmly. Do not pack a shouldered screw with washers - this w ill place undue pressure on the panel and cause cracking.

Wellnuts 13 W ellnuts have a metal th read retained inside a rubber bush; th e bush is a firm pressfit in a body panel o r windscreen (see illustration). Avoid overtightening the screw, otherwise the bush will tw ist in the panel and damage th e locating hole.

Peg and grom m et 14 Ease the panel back and exert firm, even pressure to pull th e peg ou t o f the rubber grommet (see illustration). If th e peg is a tight fit, use a lubricating spray to release it. Do not rock the panel as the peg may snap. 15 If th e grommet has split or hardened wiffi' age, renew it.

N ote th a t a sm all am ount of lu b ric a n t (liq u id soap or sim ila r) a p p lie d to rubber m o u n tin g g ro m m e ts will a s s is t th e lu g s to enga ge w ith o u t the need fo r undue pressure.

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/ k

-a ?

5.11 U -clip (arrowed) s hould be a firm fit

5.12 Shouldered screw and rubber bush

rubber bush

5.14 Peg (A) is secured in rubber grom m et (B)

Tab and slot 16 The edges o f adjacent panels are often joined by tabs and slots - once all the fixing screws have been removed, slide these panels apart rather th an pull them (see illustration).

5.16 H ooked ta b (A) locates in slot (B)

Bodywork 9*5

Panel repair

the case of damage to th e body panels, it ually necessary to rem ove th e broken I and use a new (or second-hand) one. i are how ever som e shops that ialise in ‘plastic w eld in g’, so it may be iwhile seeking the advice o f one o f these ialists before scrapping an expensive ponent. bprietary repair kits can be obtained for drof small components (see illustration).

6.2 A typical rep air k it

into a suitable container. The fuel hose should be clamped to prevent fuel leakage using any Fuel and oil tanks o f the m ethods shown in Tools and Workshop removal an d in s ta llatio n Tips in the Reference section. 6 Undo the fixings securing th e ta nk t o th e fram e, noting th e location o f any washers, i W arning : R e fe r to th e then lift out th e tank. Note the routing of any V pre ca u tio n s g ive n in C h a p te r 4, tank vent hoses. ^ Section, 1 be fo re proceeding. W arning : I f th e fu e l ta n k is re m o v e d fro m th e sco o te r, i t iel tank s h o u ld n o t b e p la ce d in an area ienerally, th e fuel ta nk is located w h e re sp a rks o r op e n flam e s imeath th e seat, although on some c o u ld ig n ite th e fu m e s c o m in g o u t o f th e iters th e ta nk is underneath th e floo r tank. B e esp ecia lly c a re fu l insid e garages J. The location of th e fuel filler is a good w h e re a n a tu ra l g a s -ty p e a p p lia n ce is Meto the location o f th e tank, located, because the p ilo t lig h t co u ld cause move th e body panels as necessary on an explosion. [ scooter to access th e ta nk (see Sec7 Installation is the reverse of removal, noting 1 8 ). the following: disconnect th e battery negative (-ve) lead • Ensure no w iring is trap pe d b etw een the disconnect th e fuel gauge sender w iring tank and the frame. inector (see Chapter 10). • Tighten the fixings securely. If the tank is located underneath th e seat, • Ensure the fuel a n d vacuum hoses are a Jflow to th e carburettor w ill be controlled tight fit on their unions. i a tap on the underside o f th e tank, • Ensure any vent hoses are correctly connect th e fuel and vacuum hoses from routed. unions on the ta p (see Chapter 4). Drain Oil tank r residual fuel in the fuel hose into a itable container. 8 Generally, th e oil tank is located underneath |fthe tank is located underneath th e floor th e seat, either alongside or below th e fuel anel, fuel flow to the carb urettor w ill be tank. If necessary, remove th e fuel tank (see Itrolled by a pump mounted on th e frame above). jngside th e fuel tank. Disconnect th e fuel 9 Disconnect the oil level warning light sensor sebetween th e tank and th e pum p at the wiring connector. imp, and drain any residue fuel in th e hose 10 Release the clip securing th e oil hose from

A

8.6a Handlebar c overs are u sually screw ed t o g e th e r. . .

the ta nk to the oil filter and detach the hose from th e filter. Clamp the hose to prevent oil loss (see S tep 5). W rap a clean plastic bag around the oil filter to prevent dirt entering the system and secure th e filte r in an upright position to m inimise oil loss. 11 Undo the tank fixings, noting th e location o f any washers, then lift ou t th e tank. 12 Installation is th e reverse o f removal, noting the following: • Ensure n o w iring is trap pe d b etw een the tank and th e frame. • Tighten the fixings securely. • Ensure the oil hose is pushed fully onto the union on the filter and secure it with the clip. • Bleed any a ir trap pe d in th e filte r (see Chapter 1).

8 Body panels rem ova l a n d in s ta lla tio n

^

1 In m ost cases, adjacent body panels are linked together with some form of fixing and it is usually necessary to remove panels in a specific order - refer to your scooter handbook for details. Removing service panels, rear carriers and the under seat storage compartment often allows access to concealed panel fixings. 2 In some cases th e aid o f an assistant will be required when removing panels, to avoid the risk o f straining tabs or damaging paintwork. Where assistance was required to remove a panel, make sure your assistant is on hand to install it. 3 Check th a t all m ounting brackets are straight and repair or renew them if necessary before attempting to install the a panel. 4 The follow in g information is intended as a general guide to panel removal.

H andlebar covers 5 Remove the handlebar covers to gain access to th e instrum ent cluster, brake master cylinders) and, where applicable, the headlight unit. 6 The covers are usually screwed and clipped together - remove th e fixings and ease them apart carefully (see illustrations).

9*6 Bodywork

—

v :

I

I

I

r -

8.11a F ront panel fixings in the kic k p a n e l. . . 7 If th e instrument cluster is located in th e to p cover, ease the cover up and disconnect the speedom eter cable and w iring connectors before removing the cover. 8 Note any c u t-o u t in the covers fo r th e th rottle cable. 9 On some scooters, th e handlebar switches are located in th e covers - take care not to strain the sw itch w iring when removing th e covers. 10 On some scooters, the handlebars must be rem oved in order to remove the lower cover (see Chapter 7).

Front panel 11 Generally, th e fron t panel is secured by fixings th rough th e kick panel and, where fitted, th e glove compartm ent. Also check for fixings underneath the fron t of th e panel

(arrowed) above th e front wheel (see illustrations). 12 If th e headlight unit is located in th e front panel, ease the panel forward and disconnect the light w iring connectors before removing the panel. 13 On some liquid-cooled scooters, th e radiator is located behind the front panel. The grille in th e fro n t panel should be kept free from obstructions.

Front m udguard 14 On some scooters, th e mudguard is mounted on the front suspension, on others it is secured to the fron t body panels (see illustration). 15 It may be necessary to remove th e front wheel before removing the mudguard. 16 Note th e location o f any guides fo r the speedom eter cable and fron t brake

hose/cable on th e mudguard. Ensure the cables are correctly routed on installation. 1

Kick panel 17 Generally, th e kick panel is secured to the main fram e tu be and is clipped to the floor panel along its lower edge (see illustration). 18 Remove th e kick panel to gain access to the main headlight/ignition w iring loom and the th ro ttle cable. On some two-strokffl scooters with a cable-operated oil pump, the cable s plitte r is located behind the kick panel.

Belly panel 19 The belly panel may be either a one or tw o-piece assembly; check along the centre of th e panel underneath the scooter for joining screws. 20 On som e scooters, th e top edge of the belly panel is secured to the floor panel with ta bs and slots; check carefully before removing th e panel to avoid breaking the tabs (see illustrations).

Side panels

8.17 C heck fo r ta b s (arrowed) b etw een th e flo o r and kic k panels

21 Remove the side panels to gain access to the engine, fuel tank and carburettor, and upper rear suspension mounting(s). 22 On some scooters, th e side panels can be removed as an assembly once the seat and| storage compartm ent have been removed; on, others, a separate rear cowling is fitted (see illustrations). 23 Note the location of the tail light unit. On

Bodywork 9*7

:c Some scoo te rs have a s eparate rear cow ling

8.26a C heck fo r flo o r panel fixing s behind blanking plugs . . .

18.26c . . . and on the underside o f th e

8.29 M udguard fix in g s (arrowed). N ote th e tu rn signals and n u m ber pla te lig h t are pa rt o f the a ssem bly

IB scooters th e tail ligh t is located in a Idy panel assembly; disconnect th e light mg connectors before rem oving th e snbly. On some scooters, it is necessary « the light lens to access panel fixing

lock and disconnect th e latch mechanism before removing th e appropriate panel (see Section 4).

Floor panel

J If applicable, note the position o f th e seat

25 The flo o r panel is secured to the main fram e tu be and sup po rt brackets. On m ost

scooters, it is necessary to remove som e of the adjacent panels before the floor panel will lift off. Check fo r ta b and s lo t fixings t o th e kick panel, belly panel and th e side panels. 26 Panel fixings are often located underneath rubber m ats, metal trim panels o r behind blanking plugs; also check on th e underside of th e floor panel (see illustrations). 27 It may be necessary to rem ove th e passenger fo otrests before the floor panel will lift o ff (see Section 3). 28 On installation, ensure no cables, hoses o r w iring are trapped between th e panel and th e frame.

R ear m udguard 29 On m ost scooters th e m udguard is secured to th e rear of th e fram e underneath th e side panels o r rear cow ling (see illustration). 30 Check th e location o f th e rear turn signals and, where fitted, th e number plate light, and disco nn ect th e w iring if applicable before removing th e mudguard.

10*1

Chapter 10 Electrical systems Contents iator - removal and installation ....................see Chapter 2A or 2B Battery- charging .................................................................................. 4 Battery- removal, installation and checks ......................................... 3 jing system - check ..................................................................... 9 Coolant temperature gauge and sender .......................... see Chapter 3 Electrical systems - fault fin d in g .......................................................... 2 and level sender - check and renewal ............................ 12 - check and re n e w a l................................................................... 5

General in fo rm a tio n ................................................................................ 1 Headlight ad justm e nt.............................................................see Chapter 1 Horn - check and ren ew al......................................................................11 Ignition (main) switch - check, removal and in s ta lla tio n ....................10 Ignition s y s te m ...................................................................... see Chapter 5 Lighting system - check ........................................................................ 6 Starter system - check .......................................................................... 8 Turn signal system - c h e c k .................................................................... 7

Degrees of difficulty Easy, suitable fo r

Difficult, suitable fo r suitable for competent ^ DIY mechanic ^

novicewith little

I

som e expenence

experienced DIY mechanic

^ v

Very difficult,

^

suitable fo r expert DIY

Specifications Refer to the Data section at the end o f this manual for servicing specifications.

1 General information

2 Electrical systems fa u lt fin d in g

W arning: To p re v e n t th e ris k o f II the scooters covered by th is manual s ho rt circu its, th e ig n itio n (main) 312 volt electrical systems charged by a s w itc h m u s t a lw ays be OFF a nd e-phase alternator w ith a separate the b a tte ry n e ga tiv e (-ve) ___ ilator/rectifier. The regulator m aintains the term inal should be disconnected before any charging system ou tp ut w ithin a specified o f th e scooter’s o th e r electrical com ponents range to prevent overcharging, and th e are disturbed. D on’t fo rg e t to reconnect the rectifier converts th e AC (alternating current) term inal securely once w o rk is finish ed o r if iitput of the alternator to DC (direct current) ba tte ry p o w e r is needed fo r c irc u it testing. power th e lights and other com ponents, andto charge th e battery. Tracing faults The four electrical systems covered in this 1 A typical electrical circu it consists o f an lighting, signalling, starting and electrical component, th e switches, relays, etc, irging - are each illustrated by a general related to that component, and the wiring and Ing diagram which shows how th e system connectors th at link th e com ponent to both iponents are linked to gether. Follow the th e battery and th e frame. To aid in locating diagrams when tracing faults and com pare any electrical problem, refer to th e relevant Biemwith the wiring diagram in your scooter system wiring diagram in this manual and then [book, noting any additional features to th e diagram in your scooter handbook. specific to your scooter. 2 Study the wiring diagram thoroughly to get a The location o f electrical com ponents complete picture of what makes up each such as relays, resistors and diodes individual circuit. Trouble spots, fo r instance, varies enormously; refer to the w iring can often be narrowed down by noting if other diagram in your handbook and trace th e components related to that circuit are operating wiring to the com ponent, rem oving any properly or not. If several components or circuits body panels as necessary to gain access fail a t one time, chances are the fault lies in the system fuse or earth connection. Chapter 9). N ote : Keep in m ind that 3 Electrical problems often stem from simple electrical parts, once purchased, cannot causes, such as loose or corroded connections jje returned. To avoid unnecessary or a blown fuse. Prior to any electrical fault expense, make very sure the faulty component finding, always check the condition of the fuse, lias been positively identified before buying a wires and connections in the problem circuit. impart.

A

Intermittent failures can be especially frustrating, since you can’t always duplicate th e failure when it’s convenient to test. In such situations, a good practice is to clean all connections in the affected circuit, whether o r not they appear to be good. All of the connections and wires should also be wiggled to check for looseness which can cause intermittent failure. 4 If testing instruments are going to be used, use the w iring diagram to plan where you will make th e necessary connections in order to accurately pinpoint th e trouble spot.

Using te s t equipm ent 5 The basic tools needed fo r electrical fault finding include a battery and bulb test circuit, a continuity tester, a test light, and a jumper wire. A m ultim eter capable of reading volts, ohm s and am ps is also very useful as an alternative to th e above, and is necessary for performing more extensive tests and checks (see illustration).

2.5 A m ultim ete r is capable o f reading ohm s, am ps and volts

10*2 Electrical systems w ith y o u r skin, o r p a in te d o r plastic surfaces o f the scooter. Rinse o f f any spills im m e d ia te ly w ith p le n ty o f w ate r. Check w ith the lo c a l a u th o ritie s a b o u t disposing o f an o ld b a tte ry. M an y c o m m un ities will have c olle ction cen tres w hich w ill set batte rie s are disposed o f safely.

Removal and installation

2.6a A te s t lig h t.. 6 Voltage checks should be perform ed if a circuit is not functioning properly. Connect one lead o f a te st light or voltm eter to either the negative battery term inal or a known good earth (see illu stra tio n s). Connect th e other lead to a connector in the circuit being tested, preferably nearest to the battery or fuse. If the bulb lights, voltage is reaching th at point, which means th e part o f the circuit between that connector and the battery is problem-free. Continue checking the remainder of the circuit in the same manner. When you reach a point where no voltage is present, th e problem lies between th ere and th e last good test point. Most of the tim e th e problem is due to a loose connection. Keep in mind that some circuits only receive voltage when the ignition is ON. 7 One m ethod o f finding short circuits is to remove th e fuse and connect a te s t light or voltm eter to the fuse terminals. There should be no load in th e circuit (it should be switched off). Move the w iring harness from side -toside while watching the test light. If the bulb lights, there is a short to earth somewhere in that area, probably w here insulation has rubbed o ff a wire. The same te s t can be performed on other components in the circuit, including the switch. 8 An earth check should be done to see if a c om ponent is earthed properly. Disconnect the battery and connect one lead o f a selfpowered te st light (continuity tester) to a known good earth (see illu s tra tio n s ). C onnect th e other lead to th e w ire or earth connection being tested. If the bulb lights, the

ba tte ry p ow ered t e s te r .,

2.6b . . . o r buzzer can be used f o r simple voltage checks 9 A continuity check is performed to see if a circuit, section o f circu it or individual com ponent is capable o f passing electricity th rough it. Disconnect th e battery and connect one lead of a self-powered test light (continuity tester) to one end o f th e circuit being tested and th e other lead to th e other end o f the circuit. If th e bulb lights, there is continuity, which means the circuit is passing electricity through it properly. Switches can be checked in the same way. R em em ber th a t a ll e le ctrica l c irc u its are d e sign ed to c o n d u c t e le c tric ity fro m th e ba tte ry , th ro u g h th e wires, s w itc h e s , relays, e tc, to th e ele c tric a l c om ponent (lig ht bulb, m otor, etc). From th ere i t is dire c te d to th e fram e (earth) w he re i t is p assed b ack to th e battery. E le c tric a l p ro b le m s are b a s ically an in te rru p tio n in th e flo w o f e le c tric ity from th e ba tte ry o r back to it.

3 Battery -

rem oval, in sta llatio n an d c he c k s

a A V

W arning : B e e x tre m e ly c a re fu l w hen h a n d lin g o r w o rk in g around the b attery. Do n o t allow e le c tro ly te to c om e in c o n ta c t

1 Refer to your scooter handbook and remove the battery access panel. 2 Undo the negative (-ve) terminal screw fir and disconnect th e lead from th e battery, then unscrew th e positive (+ve) terminal screw and disconnect the lead (see illustration). 3 Undo the battery strap or displace the strap and lift th e battery from its holder. 4 Before installation, clean th e battery terminals, term inal screws, nuts and l< ends w ith a wire brush, knife o r steel wool to ensure a good electrical connection. 5 Install the battery, then reconnect the leads, connecting the positive (+ve) lead first, and secure th e battery strap.

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B a tte ry corro s io n can be k e p t to a m in im u m by applying a lay e r o f petroleum je lly to th e te rm in a ls after >have been connected.

6 Fit the battery access panel.

Inspection and maintenance C o n v e n tio n a l b a tte r y 7 The battery fitted to m ost scooters covered ’ by this manual is of th e conventional lead-acid type, requiring regular checks of the electrolyte level (see Chapter 1) in addition to) those detailed below. 8 Check th e battery terminals and leads for tightness and corrosion. If corrosion isj evident, undo th e term inal screws and d isconnect th e leads from th e battery, disconnecting the negative (-ve) terminal first Wash the term inals and lead ends in a solution o f baking soda and hot water and dry them thoroughly. If necessary, further clean the terminals and lead ends with a wire brush, knife o r steel w ool. Reconnect the leads, connecting th e negative (-ve) terminal last,

3.2 D isconnect th e negative (-ve) lead firs t, then the positive (+ve) lead

Electrical systems 10*3 measurement, w ait a t least 30 minutes after any charging has taken place (including running the engine). 13 If battery condition is suspect, connect the m ultim eter to th e battery te rm inals as before (see Step 12), turn the ignition ON and press th e starter button. If the meter reading drops below 8 volts a new battery is required. M a in te n a n c e - fr e e (M F) b a tte r y

3.12 M easuring b a tte ry o p en -circu it voltage Iapply a th in coat o f petroleum jelly to the ;tions to slow further corrosion, battery case should be kept clean to it current leakage, which can discharge battery over a period o f tim e (especially l it sits unused). Wash the outside o f the with a solution o f baking soda and water, iethe battery thoroughly, then dry it. Look for cracks in the case and renew the fery if any are fo un d. If acid has been on th e battery holder o r surrounding lywork, neutralise it w ith a baking soda water solution, d ry it thoroughly, then ti up any damaged paint. If the machine is not used fo r long periods disconnect th e leads from the battery iminals, negative (-ve) terminal first. Refer to ction 4 and charge th e battery once every to six weeks. The condition o f the battery can be by measuring th e voltage present at battery term inals w ith a m ultim eter, inect the meter positive (+ve) probe to th e psry positive (+ve) term inal, and the agative (-ve) probe to the battery negative (•*e) terminal (see illustration). Compare the leading with th e spe cificatio ns given in the Datasection at the end o f this manual. If the ige falls below 12 volts th e battery must bremoved, disconnecting th e negative (-ve) linal first, and recharged as described iWin Section 4. N ote: Before ta king the

43If the charger has no b u ilt-in am m eter, connect one in series as show n. DO NOT connect th e am m eter b etw een th e battery [' term inals o r it w ill be ruined

14 If your scooter is fitted with an MF battery, inspect th e terminals and case as fo r a conventional battery (see Steps 8 to 10). If the machine is not used fo r long periods of time, disconnect the leads from th e battery terminals and charge the battery periodically (see Step 11). 15 Battery con ditio n can be assessed as fo r a conventional battery (see Steps 12 and 13).

C a u tio n : Be e x tre m e ly c a re fu l w hen h a n d lin g o r w o rk in g a ro u n d th e ba tte ry . The e le c tro ly te is v e ry c a u s tic a n d an explosive gas (hydrogen) is given o f f when th e b a tte ry is charging. 1 Ensure th e charger is suitable fo r charging a 12V battery. 2 Remove th e battery (see Section 3). Connect th e charger to th e battery BEFORE switching th e charger on. Make sure that the positive (+ve) lead on the charger is connected to the positive (+ve) terminal on the battery, and th e negative (-ve) lead is connected to th e negative (-ve) terminal. 3 Refer to your, scoo te r handbook fo r the recomm end battery charging rate manufacturers generally recommend a rate of no more than 0.5 amps. Exceeding this figure can cause th e battery t o overheat, buckling th e plates and rendering it useless. Few ow ners w ill have access to an expensive current con trolled charger, so if a normal dom estic charger is used check th at after a possible initial peak, the charge rate falls to a safe level (see illu s tra tio n ). If th e battery

becomes ho t during charging STOP. Further charging w ill cause damage. 4 When charging .a maintenance-free battery, make sure th at you use a regulated battery charger. 5 If the recharged battery discharges rapidly if left disconnected it is likely that an internal short caused by physical dam age or sulphation has occurred. A new battery w ill be required. A sound item w ill te nd to lose its charge at about 1 % per day. 6 Install the battery (see Section 3).

1 The electrical system s are protected by fuses; on some scooters, only one (main) fuse is fitte d , on others th e individual electrical system s are pro tected by th eir own (secondary) fuses. Refer to th e Data section and to your scooter handbook fo r details and fo r th e location o f th e fuse holders. 2 A blown fuse is easily identified by a break in th e element - pull the fuse o u t o f its holder to che ck it visually (see illu s tra tio n s ). The fuse is clearly marked w ith its rating and must only be renewed w ith a fu se o f th e correct rating. It is advisable to carry spare fuses on the scooter at all times. W arning: N eve r p u t in a fuse o f a h ig h e r ra tin g o r b rid g e th e te rm in a ls w ith any o th e r s u b s titu te , h o w ev e r te m p orary it m ay b e. S e rio us da m ag e m a y b e do n e to th e c ircu it, o r a fire m ay start. 3 If the fuse blow s, be sure to check th e w iring circuit very carefully fo r evidence o f a short-circuit. Look fo r bare wires and chafed, m elted o r burned insulation. If th e fuse is renewed before the cause is located, the new fuse will blow immediately. 4 Occasionally the fuse w ill blow or cause an open-circuit for no obvious reason. Corrosion of the fuse ends and fuse holder terminals may occur and cause poor fuse contact. If this happens, remove the corrosion with a wire brush or steel wool, then spray the fuse ends and fuse holder terminals with electrical contact cleaner.

A

U U 5.2a Rem ove the fuse to c he c k it

104

Electrical systems

Electrical systems 10*5

6.3a C hecking th e h e adlight bu lb term inals . . .

6 Lighting system - check

^

The lighting system consists o f th e idiight, sidelight, ta il light, brake light, Jument panel lights, handlebar switches Ifuse (see illu stratio n opposite). On most of th e scooters covered by this hual, the engine must be running for any of i lights to work. If none of the lights work, (ays check th e fuse (where fitte d) and jmator lighting coil before proceeding (see Jion 9). If applicable, check th e condition fthe lighting resistor (see Step 11).

lights

Instrum ent panel lights

k To remove the bulbs, refer to you r iter handbook for details. If a light fails to work, first check th e bulb (the terminals in th e bulbholder or th e bulb tig connector (see illustrations). Note: If | headlight bu lb is o f th e quartz-halogen e, do not touch the bulb glass as skin acids \shorten the bulb's service life. If the bulb is tcidentally touched, i t should be w iped illy when co ld w ith a rag soaked in ethylated spirit and dried before fitting.

A

6.3b . . . and th e ta il lig h t te rm ina ls (arrowed)

4 Next check fo r voltage on th e supply side of the bulbholder or wiring connector with a test light o r m ultim eter w ith th e light sw itch ON. Don’t forget that the engine may have to be running to do th is check (see Step 2). When checking th e headlight, select either high o r low beam at the handlebar sw itch. When checking the brake light, pull the brake lever in. 5 If no voltage is indicated, check th e wiring between th e bulbholder and th e light switch, then check th e switch (see Steps 12 to 16). 6 If voltage is indicated, check fo r continuity between th e earth wire terminal and an earth po int on the scoo te r fram e. If th ere is no continuity, check th e earth circuit fo r a broken or poor connection.

W arning: A llo w th e bu lb tim e to c o o l b e fo re re m o v in g i t i f th e he ad ligh t has ju s t been on.

N ote : On som e scooters, th e panel is illuminated with LEDs. I f an LED fails, it m ay be necessary to renew th e com plete panel circu it - check the availability o f parts with a scooter dealer. 7 If one light fails to work, check the bulb and the bulb terminals (see illustration). If none of the lights work, refer to the wiring diagram in your scooter handbook, then check fo r voltage on th e supply side of th e instrument cluster wiring connector, if necessary w ith the engine running and light sw itch ON (see illustration). 8 If no voltage is indicated, check the wiring

6.7b In strum ent c luste r w iring c onnectors

betw een th e connector, the light switch and th e ignition sw itch, then check th e switches themselves. 9 If voltage is indicated, disco nn ect the connector and check fo r continuity between th e pow er supply w ire te rm inal on th e instrum ent c luste r and th e corresponding term inals in the bulbholders; no continuity indicates a break in the circuit. 10 If continuity is present, check for continuity betw een th e earth wire terminal in th e wiring connector and an earth point on the scooter frame. If there is no continuity, check th e earth circ u it fo r a broken o r poor connection.

Lighting system resistor 11 On some scooters, th e lighting system is protected by a resistor (see illu stratio n). To te st th e resistor, sub stitu te it w ith a known good one or have th e resistance checked by a scooter dealer.

H andlebar switches 12 Generally speaking, the sw itches are reliable and trouble-free. M ost problems, when they d o occur, are caused by dirty or corroded contacts, but wear and breakage of internal parts is a possibility th at should not be overlooked when tracin g a fault. If breakage does occur, the entire switch and related wiring harness will have to be renewed as individual parts are not available.

6.11 A ty p ic a l ligh ting system resistor

10*6 Electrical systems

6.14a T race the w iring to the c on ne cto rs . . .

6.14b . . . and disconnect them to te s t the handlebar switches

6.17a Pull b a ck th e b o o t (A) and disco nn ect th e w ires (B)

6.17b Testing th e c on tinu ity o f th e brake ligh t switch

13 The sw itches can be checked fo r continuity using a m ultimeter o r test light and battery. Always disco nn ect th e battery negative (-ve) lead, w hich w ill prevent the possibility of a short circuit, before making the checks. 14 Remove the body panels as necessary to trace th e w iring from the sw itch in question back to its connector (see Chapter 9). Disconnect the relevant wiring connector (see illustrations). Refer to the wiring diagram in your scooter handbook and check for continuity between the terminals o f th e switch wiring with the switch in the various positions (ie, switch OFF - no continuity; switch ON continuity). 15 If th e checks indicate a problem exists, remove the sw itch housing and spray the switch contacts w ith electrical contact cleaner. If they are accessible, the contacts can be scraped clean carefully w ith a knife or polished w ith crocus cloth. If switch components are damaged o r broken, it will be obvious when th e switch is disassembled. 16 Clean th e inside o f th e sw itch body th oroughly and smear th e contacts with suitable grease before reassembly.

Brake light switches 17 Remove th e handlebar cover (see Chap­ te r 9), then disconnect th e sw itch w iring connectors (see illu s tra tio n ). Using a

c ontinuity te ster, connect a probe to each terminal on the switch. With the brake lever at rest, th ere should be no continuity. Pull th e brake lever in - th ere should now be continuity (see illu stratio n). If not, fit a new switch. 18 If th e sw itch is good, refer th e wiring diagram in your scooter handbook to check the brake light circuit using a m ultim eter or test light (see Section 2).

7 Turn signal system - check

1 The turn signal system consists of the turn signal lights, instrument panel light, handlebar sw itch, relay and fuse (see illu s tra tio n opposite). 2 On m ost of th e scooters covered by this manual, th e engine m ust be running fo r the turn signal lights to work. If none of the lights work, always check the fuse (where fitted) and alternator lighting coil before proceeding (see Section 9).

Follow th e procedures described in Section to check th e bulbs and the sockets, operation o f the turn signal switch and turn signal warning light in the instru cluster.

Turn signal relay 4 If the bulbs and sockets are good, pow er supply to th e turn signal relay (se* illu s tra tio n ). Disconnect th e relay connector and check fo r voltage at the wire terminal in the connector with the running, using a m ultim eter or test connected to a good earth. Turn the OFF. If there is no voltage, use the diagram in your scooter handbook to th e supply circuit.

Turn signal lights 3 Most turn signal problems are th e result of a failed bulb o r corroded socket. This is especially true when the turn signals function properly in one direction, but not in the other.

7.4 A typical tu rn signal relay

Electrical systems

10*7

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10*8

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Electrical systems

Fuse

Fusebox

Dfodestarter relay

Regulator/rectifier

Alternator

8 . 1 W ir in g d ia g r a m f o r a t y p i c a l s t a r t e r s y s t e m ( h ig h lig h t e d ) T h e h a t c h e d b l a c k w i r e s s h o w t h e f e e d f r o m t h e b a t t e r y , t h r o u g h t h e m a in f u s e a n d ig n it io n s w i t c h t o t h e f u s e b o x c o n t a i n i n g t h e c ir c u i t f u s e s . T h e s o li d b l a c k w i r e s i ll u s t r a t e t h e s t a r t e r c ir c u i t : P o w e r i s f e d f r o m t h e s t a r t e r c ir c u i t f u s e , v i a t h e o il l e v e l s e n s o r t o t h e b r a k e l e v e r s w i t c h e s . C l o s i n g e i t h e r b r a k e l e v e r s w i t c h a l l o w s c u r r e n t t o f lo w t o t h e s t a r t e r s w i t c h o n t h e h a n d l e b a r . W h e n t h e s t a r t e r s w i t c h i s c l o s e d , c u r r e n t f l o w s t o t h e c o i l o f t h e s t a r t e r r e l a y a n d t h e n t o e a r t h , c o m p l e t in g t h e c ir c u i t a n d a c t iv a t i n g t h e r e l a y c o n t a c t s t o b r i d g e t h e h e a v y g a u g e c a b l e s b e t w e e n t h e b a t t e r y a n d s t a r t e r m o t o r . A n additional feature on m any two-stroke engined scooters is the link with the oil level warning light. W hen the starter switch is closed (button pressed), p o w e r is also fed to the warning light via a diode. This serves as a check o f the warning light bulb. In norm al operation (engine running) if the oil level sensor contacts close due to the oil level dropping to a low level, current is routed from the starter circuit fuse side o f the circuit to the oil level warning light.

Electrical systems 10*9 there is voltage, reconnect the w iring ctor to th e relay and use a test light to for voltage on the ou tp ut side of th e wiring con ne cto r w ith th e engine g. The light should flash; if it does not, lew relay.

starter system consists of th e starter ih, starter motor, battery, relay and fuse illu stratio n o p po site). On some ters, one or both o f the brake light and, where fitte d , th e side stand h, are part o f a safety circ u it w hich nts the engine starting unless th e brake j on and the side stand is up. most tw o-stroke engined scooters, a links the starter circuit w ith th e oil level iing light; th is serves to che ck th a t th e ig light bulb is sound. A similar system also be fitted to check that the fuel level light bulb is sound, ithe starter circuit is faulty, first check the (see Section 5). Also che ck th a t th e is fully-charged (see Section 3).

irter relay locate the starter relay, either trace the from the positive terminal of the battery the relay, o r trace th e lead back from the motor to th e relay (see illustration), onnect the starter m otor lead from the I. With the ignition switch ON, press the ter switch. The relay should be heard to Switch the ignition OFF. the relay wasn’t heard to click in the test remove it from th e scooter fo r further ing. Ensure th at th e ignition is OFF and

8.4 S tarter m o to r relay disconnect the battery negative (-ve) lead beforehand. Take note o f th e wire connections to the starter relay, then disconnect th e heavy gauge battery and starter m otor cables from the relay term inals, follow ed by th e wire connector. Move th e relay to th e bench fo r testing. Connect a multi-meter set to th e ohms (resistance) range across th e b a tte ry and starter motor terminals of the relay (these are the term inals fo r the heavy gauge cables). Using a fully charged battery (the scooter’s battery w ill do) and short jum per wires, connect th e other terminals of the relay to the battery (see illustration). If the relay if working correctly, continuity should be indicated on the m eter when battery power is applied. Note that the wire terminal numbers shown on the illustration may be stam ped on the relay, particularly on European models. 7 If the relay is good, refer to the w iring diagram in your scooter handbook and check the other components in th e starter circuit as described below. If all components are good, check th e w iring betw een th e various components.

cluster should come on temporarily when the starter bu tto n is pressed as a check o f the warning bulb. If th e light fails to come on, first check th e bulb (see Section 6), then check the wiring between the instrument cluster and the diode. 9 The diode will only allow current to pass in one direction. This is usually represented by an arrowhead on th e diode housing and may also be shown on the wiring diagram. 10 Unplug the diode from the wiring harness, ta king note o f th e w ire locations. Use a m ultim eter set to the ohm s o r diode test function, connect its probes across th e two term inals o f the diode. C ontinuity (zero resistance) should be indicated when connecting th e probes one w ay, th en no con tinu ity (infinite resistance) should be shown when reversing th e probes. 11 If the tests indicate the same condition in both directions, the diode is faulty.

Side stand switch 12 The side stand switch is mounted on the stand bracket (see illu s tra tio n ). To te st the switch, trace the wiring back to the connector and disconnect it. 13 C onnect a m ultim eter o r continuity tester to th e term inals on th e sw itch side of the connector. W ith the sidestand up there should be con tinu ity (zero resistance) betw een th e term inals, w ith th e stand down th ere should be no c on tinu ity (infinite resistance). 14 If the switch does not w ork as expected, check that th e fault is not caused by a sticking switch plunger due to the ingress o f road dirt; spray th e sw itch w ith a w ate r dispersant aerosol. If th e switch still does not w ork it is defective and must be renewed.

Oil level w arning light and diode

S ta rte r m otor

8 The oil level warning light in the instrument

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10*10 Electrical systems

8.15 D isconnect the w ire from th e s ta rte r m o to r term inal

disconnect th e battery negative (-ve) lead. If accessible, disconnect th e w ire from , the starter m otor term inal (see illu s tra tio n ). Alternatively, trace th e w ire from th e starter m otor term inal and disco nn ect it at the connector. 16 U nscrew th e tw o bolts securing the starter m oto r to the crankcase; note any earth w ire secured b y the bolts (see illustration). 17 Withdraw th e starter motor. If not already done, disco nn ect th e w ire from th e m otor terminal. Remove th e O-ring from th e end of

8.16 Remove th e tw o b olts, n o ting th e earth cable w here fitted

th e motor body and discard it, as a new one m ust be fitte d on reassem bly (see illustration). 18 Installation is the reverse o f removal. W here fitte d, apply a smear o f engine oil to th e new body O-ring and secure the earth wire with one o f th e mounting bolts. 19 The parts o f th e starter m otor that are m ost likely to wear are th e brushes, the commutator and the bearings. If the motor is suspect, it can be inspected as follows. Note: A num ber o f different starter motors are fitted across the range o f scooters coyered b y this

manual. Before disassem bling the mofor.j check th e availability o f new parts with a scooter dealer. If parts are not available itmnj be w orthwhile consulting an auto-electricim before buying a new m otor, as sometimesm depending on the nature o f the fault, they cat be repaired. When disassembling the motor, carefully note th e correct fitte d position m each com ponent before removing it, as the procedure given be low is general and does no t cover th e specific com ponents o f each type o f motor. 20 Remove th e starter m otor (see Steps 1i to 17), then undo th e screws or bolts securing the housing to th e end cover and draw the] housing off, leaving th e armature in place in the cover (see illu s tra tio n s ). Note th? position o f any housing seals and remove them carefully. Note: I f there is oil inside thi starter m otor the internal cover seal has tM - check the availability o f a new seal or cow I assembly with a scooter dealer. 21 W ithdraw th e arm ature from the cover, noting any shims or washers on either or boft ends o f th e armature shaft, and noting ho* the brushes locate onto the commutator (sn illustration). 22 Slide the brushes out from their holders

8.21 W ithdraw the armature, noting how i t fits

Electrical systems 10*11

j D isplace th e brushes . . .

. and rem ove th e brush springs

te the position o f th e brush springs and te them fo r safekeeping if they are loose |eeillustrations). |3 Check th a t th e brushes are firm ly (ached to their terminals. If the brushes are essively worn, cracked o r chipped, they d be renewed, otherwise a new starter >r must be fitted. Note that some starter jjtors are fitte d w ith separate brush plates eeillustration). t th e com m utator bars on the mature fo r scoring, scratches and coloration (see illu s tra tio n ). The Snmutator can be cleaned and polished J h crocus cloth, but do not use sandpaper Iremery paper. After cleaning, wipe away any lesidue with a cloth soaked in electrical m cleaner or denatured alcohol. ^ Using an m ultim eter or te s t ligh t and ry, check fo r continuity betw een the jimmutator bars (see illustration). Continuity to resistance) should exist betw een each id all of th e others. * » Also, check fo r con tinu ity betw een the mmutator bars and the armature shaft (see justration). There should be no continuity e resistance) betw een th e com m utator shaft. If th e checks indicate wise, the armature is defective.

27 Check the front end of th e armature shaft fo r w orn o r chipped teeth. C heck the condition o f the bearing which may be either on the arm ature o r in th e m oto r cover (see illustration). 28 Reassemble th e starter m otor in the reverse order o f disassem bly, noting the following: • Press the brushes into their holders against th e pressure o f th e ir springs, then fit the arm ature in to th e en d cove r carefully to avoid damaging the seal. • Ensure each brush is pressed a gainst the

8.25 Continuity should exist b etw een the com m uta to r bars

8.26 There should be no c on tinu ity between th e c om m uta to r bars and the a rm ature shaft

Brushes m ounted on s eparate brush

com m uta to r b y its sp rin g a n d is free to move easily in its holder. ft Lubricate the bush in the end o f th e housing with a smear o f grease.

9 Charging system - check

1 If the performance o f the charging system is suspect, th e system as a whole should be checked first, fo llo w ed by te sting o f th e

8.24 Inspe ct th e c om m uta to r bars (arrowed)

10*12 Electrical systems

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Electrical systems 10*13 sud de n s u rg e in c u rre n t w ill b lo w th e m e te r’s fuse. 6 While manufacturers figures may vary, if the current leakage indicated exceeds 1 mA, there is probably a short circuit in the wiring. Disconnect the meter and reconnect the negative (-ve) lead to the battery, tightening it securely, 7 If current leakage is indicated, refer to the wiring diagram in your scooter handbook and systematically disconnect individual electrical com ponents and repeat th e te st until the source is identified.

Alternator Regulated output test 8 Start th e engine and warm it up to normal operating temperature, then stop the engine and turn the ignition OFF. 9 Support the scooter on its centre stand with com ponents and circu its (see Before th e rear wheel clear of th e ground. o p p o site ). N ote : 10 To check th e regulated voltage output, set make sure the battery is th e multimeter to the 0 to 50 volts DC scale and that all circuit connections (voltmeter). Connect th e meter positive (+ve) probe to th e battery positive (+ve) terminal, ecking the output o f th e charging system and th e negative (-ve) probe to the battery perform ance o f th e various negative (-ve) terminal. ponents w ithin the charging system 11 Start the engine and slowly increase the |uires the use of a m ultim eter - if a engine speed to a fast idle; the regulated meter is not available, have th e system voltage should be as specified in the Data a scooter dealer or auto-electrician, i making the checks, fo llo w th esection at th e end o f this manual. Now turn the headlight ON and note th e reading - there edures carefully to prevent incorrect should be no significant change in the output ections or short circuits, as irreparable voltage. Note: As a general rule, i f a regulated lage to electrical system components may voltage is n o t specified, th e m eter reading {ult if short circuits occur. should be between 13 to 16 volts. gakage te s t 12 If th e voltage is no t w ithin these limits, there is a fault either in th e regulator/rectifier ^connect th e battery negative (-ve) or the alternator itself. If available, substitute inal. the regulator/rectifier w ith a known good one |i Set the multimeter to th e amps function and and test again; if the voltage is still outside the ect its negative (-ve) probe to th e battery specified lim its, check th e alternator coil p iv e (-ve) te rm inal, and positive (+ve) o the disconnected negative (-ve) leadresistance (see Steps 14 to 17). 13 Some m anufacturers only specify an » illustration). Always set th e meter to a unregulated alternator output. This check jh amps range initially and then bring it requires a wring diagram and test details mto the mA (milliAmps) range; if there is a jh current flow in the circuit it m ay blow the 's fuse. C lues to a fa u lty re g u la to r on: A lw ays c o n n e c t an a m m e te r in a re c o n s ta n tly b lo w in g s, ne ver in p a ra lle l w ith th e ba tte ry , b u lbs, w ith b rig h tn e s s jfierw/se i t w ill b e dam aged. Do n o t tu rn ie ignition ON o r o p e ra te th e s ta rte r engine speed, a n d ba tte ry overheating. lofor when th e m e te r is c o n n e c te d - a

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specific to your scooter, and is best undertaken by a scooter dealer or auto-electrician.

Coils resistance test 14 Disconnect th e battery negative (-ve) terminal. Trace the w iring from th e alternator cover and disconnect it at th e connector. 15 Refer to the wiring diagram in your scooter handbook and identify the wire terminals for the charging coil and lighting coil in the alternator side of the connector. Note: For alternators with three charging co il wires o f the same colour code, see Step 16. Set the multimeter to the ohms x 1 scale and connect the meter probes to the charging coil wire terminal and to earth, and then to the lighting coil terminal and earth. This will give resistance readings for the coils which should be consistent with the specifications in the Data section (see illustration). 16 Alternatively, set th e m ultim eter to th e ohm s x 1 scale and check th e resistance betw een one pair o f w ire term inals at a tim e and note the three readings obtained. Also check for continuity between each terminal and earth. The readings should be consistent with the specifications in the Data section and there should be no continuity (infinite resistance) between any of th e terminals and earth. 17 If th e readings obtained differ greatly from those given in the Data section, particularly if the meter indicates a short circuit (no measurable resistance) o r an open circuit (infinite, or very high resistance), the alternator stator assembly must be renewed. However, first check that the fault is not due to a damaged o r broken wire from the alternator to the connector; pinched or broken wires can usually be repaired. 18 Refer to the procedure in C hapter 2A o r 2B, as applicable, fo r details o f alternator removal and installation.

10 Ignition (main) switch -

check, removal and installation \

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W arning: To p re v e n t th e ris k o f s h o r t c irc u its , d is c o n n e c t th e b a tte ry n e g a tiv e (-ve) le a d b e fo re m a k in g a n y ig n itio n (main) s w itc h checks.

Check 1 Remove any body panels as required fo r access (see Chapter 9). Ensure th e battery negative (-v e ) lead is disconnected, then pull back th e b o o t on th e w iring connector and disconnect the connector (see illustration). 2 Refer to th e wiring diagram in your scooter handbook, then using a m ultim eter or continuity tester, check th e continuity of the connector term inal pairs. C ontinuity should exist between th e connected terminals when the switch is in th e indicated position. 3 If the switch fails any o f the tests, renew it.

Removal 9.15 C hecking the resistance in th e a lte rna tor coils

10.1 D isconnect the ignition s w itc h w iring con ne cto r

4 Disconnect th e battery negative (-ve) lead -f Q and th e switch wiring connector (see Step 1). }

10*14 Electrical systems

10.4 W here fitte d , unclip th e im m obiliser ring

10.5 Ignition sw itch is secured by a shear b o lt (arrowed)

If applicable, unclip th e imm obiliser transponder aerial from th e front o f th e switch (see illustration). 5 The sw itch is secured to th e fram e by a shear bolt (see illu stra tio n ). To remove the bolt, drill off th e bolt head, then remove the switch. The threaded section o f the bolt can then be unscrewed w ith pliers.

battery positive (+ve) terminal and th e other horn term inal to th e battery negative (-ve) te rm inal. If the horn sounds, check th e handlebar switch .(see Section 6) and the wiring between the switch and th e horn. 4 If the horn doesn’t sound, renew it.

Installation 6 Installation is the reverse of removal. Operate th e key to ensure the steering lock mechanism is correctly aligned w ith the frame and steering stem before tightening the shear bolt, then tighten the bolt until the head snaps off. 7 Reconnect th e battery negative (-ve) lead once all electrical connections have been made to the switch.

Renewal 5 Disconnect th e wiring connectors from the horn, then unscrew the bolt securing the horn and remove it. 6 Install th e horn and tighten the mounting bolt securely. Connect the wiring connectors and test th e horn.

12Fuel gauge and level sender - check and renewal

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11.2 Horn w iring c onnectors (A) and m ounting b o lt (B)

Fuel gauge C heck 1 Disconnect the wiring connector from the to p of th e fuel level sender (see illustration). 2 Connect a jum per w ire between the term inals on the w iring loom side of the cpnnector. W ith the ignition switched ON, the fuel gauge should read FULL. If it doesn’t,' check the wiring between the connector and th e gauge. If th e w iring is good, then the gauge is confirm ed fa ulty. N ote: On most scooters, th e fuel gauge is integral with the instrum ent cluster, fo r w hich no individual parts are available. If the fuel gauge is faulty, the entire cluster m ust be renewed.

Fuel level sender C heck

11H orncheck and renewal

Check 1 Remove any bo dy panels as required for access to th e horn (see Chapter 9). 2 Disconnect the wiring connectors from the horn and ensure that the contacts are clean and free from corrosion (see illustration). 3 To test th e horn, use jum per w ires to con ne ct one o f the horn term inals to the

W arning : P e tro l (gasoline) is e xtre m e ly flam m ab le, so ta ke e x tra p re c a u tio n s w hen yo u w o rk on an y p a r t o f th e fu e l system . D o n ’t sm oke o r a llow open flam es or ba re lig h t bulbs n e a r th e w ork area, and d o n ’t w o rk in a ga rag e w he re a n a tu ra l g a s-typ e a p plia nce is pre sen t. I f y o u sp ill an y fu e l on y o u r skin, rin s e i t o ff im m e d ia te ly w ith soap a n d w ate r. When y o u p e rfo rm an y k in d o f w o rk on th e fu e l system, w ear s afety glasses an d have a fire extin gu ishe r suita ble fo r a class B type fire (flam m able liquids) on hand.

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3 Disconnect the w iring connector from the fuel level sender (see Step 1), then unscrew! the sender from the ta nk and remove the sender unit (see illustration). Note: On some scooters the sender is retained by a locking ring. W arning : B lo c k th e opening in th e ta n k to p re v e n t the escape o f p e tr o l fu m e s a n d accidental fu e l spillage. 4 Check the operation of the sender; the arm should move freely w itho ut binding. Also check th at th e flo a t is held securely on the arm and th at it is not damaged. This will usually be apparent by th e presence of fuel inside th e float. If any o f the component parts are faulty o r damaged, fit a new sender., 5 If th e sender is good, check the wiring; between the sender and th e gauge. 6 If a fault persists w ith the fuel gauge and both th e gauge and sender appear good, have th e sender resistance checked by a scooter dealer.

A

R enew al

12.1 Fuel level sender w irin g conne cto r

7 Check th e condition o f the sender O-ring and fit a new one if it is deformed o r perished! Insert the sender carefully into the tank, tha lock it in position.

Data section Contents Note: The specifications available a t the time o f writing are given on the Data Sheets; consult a scooter dealer for any other settings. Piaggio Zip 50 S P ............................................ DATA 50

Aprilia Leonardo 1 2 5 ........................................ DATA 2

MBK Skyliner 1 2 5 ....................... ...................DATA 73

Aprilia Rally 50 ................................................. DATA 3

MBK Stunt 5 0 .................................................. DATA 68

Piaggio Zip 125

Aprilia Sonic FT and G P .................................DATA 4

MBK Thunder 125

Suzuki AN 1 2 5 ............

Aprilia SR50 (1994 to 1999)

Peugeot Elyseo 50 .......................................... DATA 24

.

..................... DATA 5

.........................................DATA 70

...............................................DATA 51 ................................... DATA 52

Suzuki A P 5 0 ......................................................DATA 53

6

Peugeot Elyseo 100 ........................................DATA 25

Suzuki AY50 K a ta n a ........................................DATA 54

Gilera Runner 5 0 ............................................... DATA 7

Peugeot Elyseo 125 ........................................DATA 26

Suzuki UH125 B u rg m a n .................................DATA 55

Gilera Runner FX125 and FXR180................ DATA 8

Peugeot Looxor 5 0 .......................................... DATA 27

Sym DD50 City T r e k ........................................DATA 56

Gilera Runner VX125 and VXR180/200 ____DATA 9

Peugeot Looxor 1 0 0 ........................................DATA 28

Sym Jet 50 and 1 0 0 ........................................DATA 57

Gilera SKP50 (Stalker)......................................DATA 10

Peugeot Looxor 125 and 1 5 0 ........................DATA 29

Sym Shark 5 0 ................................................... DATA 58

Honda FES125 P a n th e o n ...............................DATA 11

Peugeot Speedfight 5 0 .................................. DATA 30

Sym Super Fancy and City H o p p e r..............DATA 59

Honda FES250 Foresight ...............................DATA 12

Peugeot Speedfight 2 50 liquid-cooled . . . .

DATA 31

Vespa ET2 50 ................................................... DATA 60

Honda NES125 @ 1 2 5 ..................................... DATA 13

Peugeot Speedfight and Speedfight 2100 .

DATA 32

Honda S F X 5 0 ................................................... DATA 14

Peugeot Trekker 5 0 .......................................... DATA 33

Vespa ET4 1996 to 1998 .................................DATA 62

Honda SGX50 Sky .......................................... DATA 15

Peugeot Trekker 1 0 0 ........................................DATA 34

Vespa ET4 with LEADER e n g in e ...................DATA 63

Honda S H 5 0 ......................................................DATA 16

Peugeot Vivacity 50 ........................................DATA 35

Vespa GT 1 2 5 ....................................................DATA 64

Honda SH12 5 ....................................................DATA 17

Peugeot Vivacity 100 ..................................... DATA 36

Vespa GT 200 ....................................................DATA 65

Honda SZX50 (X8R-S and X 8R -X )................ DATA 18

Peugeot Z e n ith ................................................ DATA 37

Yamaha CS50 JogR ........................................DATA 66

Malaguti F12 50 Phantom air-cooled

. . . . . DATA 19

Piaggio B125 (Beverly) .................................. DATA 38

Yamaha CW / B W .......................................... * DATA 67

Malaguti F12 50 Phantom liquid-cooled . . . DATA 20

Piaggio Hexagon 1 2 5 ..................................... DATA 39

Yamaha EW50 Slider ......................................DATA 68

Malaguti F12 50 Spectrum ............................ DATA 21

Piaggio Super Hexagon 1 2 5 ..........................DATA 40

Yamaha XN125 Teo’s ..................................... DATA 69

Malaguti F15 50 Firefox .................................DATA 22

Piaggio Super Hexagon 1 8 0 ..........................DATA 41

Yamaha XQ125 M a x s te r.................................DATA 70

Malaguti Madison 125 and 1 5 0 ..................... DATA 23

Piaggio Liberty 1 2 5 .......................................... DATA 42

Yamaha YN50 Neo’s ........................................DATA 71

MBK Doodo 1 2 5 ...............................................DATA 69

Piaggio NRG 50 ...............................................DATA 43

Yamaha YN100 Neo’s ..................................... DATA 72

MBK Mach G 5 0 ............................................... DATA 66

Piaggio Skipper ...............................................DATA 44

Yamaha YP125 Majesty .................................DATA 73

MBK Nitro 5 0 ................................................... DATA 75

Piaggio Skipper ST12 5 ................................... DATA 45

Yamaha YP250 Majesty .................................DATA 74

MBK Nitro 100 ................................................. DATA 76

Piaggio Typhoon 50 and 80

Yamaha YQ50 Aerox

MBK Ovetto 5 0 ................................................. DATA 71

Piaggio Typhoon 125 ..................................... DATA 47

Gilera Ice 5 0 ......................................................DATA

..........................DATA 46

MBK Ovetto 1 0 0 ...............................................DATA 72

Piaggio X9 1 2 5 ................................................. DATA 48

MBK R o c k e t......................................................DATA 67

Piaggio Zip 50 ................................................. DATA 49

Vespa ET2 50 4 T .............................................DATA 61

......................................DATA 75

Yamaha YQ100 A e ro x ......................................DATA 76

D a ta 2

A p rilia L e o n a r d o 125 E n g in e ................................................................................................. Cooling s y s te m .............................................................................. Fuel system ................................................................................... Ignition s y s te m ......................................................................... T ra n s m is s io n ..................................................................................... S u s p e n s io n ....................................................................................... B r a k e s ................................................................................................. Tyres ................................................................................................... W heelbase ....................................................................................... W e ig h t ................................................................................................. Fuel ta n k c a p a city .........................................................................

Ign itio n system

Engine

Coolant capacity .............. ............

NGK CR8E 0.6 mm 1600 rpm SAE 5W 40 four-stroke motorcycle oil 1.1 litres 56.4 x 50 mm 50% distilled water, 50% corrosion inhibiting ethylene glycol anti-freeze 1.2 litres

Throttle tw istgrip fre e p la y .............. Main je t .............................................

2 to 3 mm 107.5

Spark plug t y p e ................. Electrode g a p ..................... Idle speed (rp m )................. Engine o i l .............................

124 cc single-cylinder four-stroke Liquid-cooled Mikuni BS26 CV carburettor CDI Variable speed automatic, belt-driven Upside-down telescopic front, swingarm with twin adjustable shock rear 220 mm disc front, 190 mm disc rear 130/70 x 12 front, 140/70 x 12 rear 1320 mm 136 kg 9.5 litres

............ ............ ............ ............

Oil capacity ........................ ............ Bore x s tr o k e ..................... ............ Coolant ............................... ............

P ilo t je t : .................................................... S t a r te r j e t .................................................... N e e d le ty p e /c lip p o s i t i o n ................. p|lot

4 2 .5 25 4 D X 8 - 3 (3 rd g ro o v e fromtop)

HT coil primary resistance . . . . HT coil secondary resistance (without plug cap) ................... Pick-up coil re sis ta n c e ..............

0.5 to 2.0 ohm 4.8 to 7.2 K-ohms 192 to 288 ohms

1 Transm ission Gearbox oil .......................... Gearbox oil capacity .........

SAE 75W/90 API GL4 oil 90 ml

Tyre pressures Front

28 psi (1.9 bar) 29 psi (2.0 bar)

E lectrical system | Battery Capacity ........................................ | Alternator O utput (regulated) ........................ Charging coil re sista nce.............. Fuse (main) ...................................... Fuse (se co nd ary)............................. Bulbs Headlight (m ain/dipped).............. Sidelight ........................................ Brake/tail l i g h t ............................... Turn signal lig h t s .......................... Instrument and warning lights . .

12 V, 12 Ah 13 to 15 V (DC) 0.1 to 1.0 ohms 20 Amps 15 and 7.5 Amps 35/35 W 3 W 21/5 W 10W 2 and 1.2 W

Torque w ren ch se ttin g s Engine mounting b o lt ........................................ Exhaust manifold n u t s ...................................... Exhaust system mounting b o l t ........................ Engine oil drain plug ........................................ Oil filter cover b o l t ............................................. Gearbox oil drain p l u g ...................................... Rear shock absorber mountings Lower b o lt ......................................................... Upper b o lt ......................................................... Rear subframe b o lts ........................................... Steering head bearing lo c k n u t........................ Handlebar stem bolt ........................................ Front fork leg clamp bolts ............................... Front axle n u t ...................................................... Front axle pinch-bolt ........................................ Rear hub nut ...................................................... D is c b ra k e c a lip e r m o u n tin g b o lts ..................

50 30 27 15 12 15

Nm Nm Nm Nm Nm Nm

O ise m ounting bolts....................................................

27 N m

20 Nm 20 Nm 27 Nm 110 Nm 35 Nm 25 Nm 50 Nm 12 Nm 110 Nm 27 N m

Aprilia Rally 50

Data 3

E n g in e ................................................................................................. Cooling s y s te m ............................................................................. Fuel system .................................................................................. Ignition s y s te m .............................................................................. T ra n s m is s io n ..................................................................................... S u s p e n s io n ....................................................................................... B r a k e s ................................................................................................ Tyres ................................................................................................... W heelbase ....................................................................................... W e ig h t................................................................................................. Fuel ta n k c a pa city .........................................................................

Spark plug type Air-cooled e n g in e .............. ........... Liquid-cooled e n g in e ................... Electrode g a p ................................... Idle speed (rpm) . . . . .................... Oil tank capacity ............................ Bore x s tr o k e ................................... Coolant ............................................

Coolant capacity ............................

NGK BR7 HS NGK BR8 HS 0.5 to 0.6 mm 1700 to 1900 rpm 1.3 litres 40.0 x 39.2 mm 50% distilled water, 50% corrosion inhibiting ethylene glycol anti-freeze 0.8 litres

Fuel system Throttle twistgrip freeplay . Main jet ............................... Pilot jet ............................... Starter j e t ............................ Needle type / - clip position Pilot screw s e tt in g ............ Float height .......................

2 to 3 mm 90 50 46 3SI12 - 3/5 1 1 /2 turns out 12 to 17 mm

49 cc single-cylinder two-stroke Air or liquid-cooled Dell’Orto PHBN 12 slide carburettor CDI Variable speed automatic, belt-driven Upside down telescopic front, swingarm with single shock rear 190 mm disc front, 190 mm disc o r 110 mm drum rear 120/80 x 12 front, 130/80 x 12 rear 1250 mm 94 kg 6.0 litres

HT coil primary resistance ............ HT coil secondary resistance (without plug cap) ....................... Source coil resistance ................... Pick-up coil re sis ta n c e ...................

. . .. .... ____ ____

Disc brake Fluid type ................................. Pad minimum th ic k n e s s......... Disc thickness (service limit) . Drum brake Brake shoe lining thickness Service lim it .......................... Brake lever fre e p la y ................

.

Front ................................. .............. R e a r................................... ..............

17 psi (1.2 bar) 22 psi (1.5 bar)

E lectrical system Battery Capacity ........................................ Alternator Output (regulated) ........................ Fuse (main) ...................................... Bulbs Headlight (m ain/dipped).............. Sidelight ........................................ Brake/tail lig h t ..................... Turn signal lig h t s .......................... Instrument and warning lights . .

12 V, 4 Ah 13 to 15 Volts (DC) 7.5 Amps 35/35 W 3W 10/5 W 10 W 1.2 W

0.56 to 0.84 ohms 4.5 to 7.5 K-ohms 640 to 960 ohms 400 to 600 ohms

Transmission Variator roller diameter (service lim it ) ........................ Belt width (service limit) . . . . Gearbox oil . . ........................ Gearbox oil capacity ............

Tyre pressures

14.5 mm 15.5 mm SAE 75W/90 API GL4 oil 110 ml

DOT 4 1.0 mm 3.2 mm

1.0 mm 10 mm

Engine mounting b o lt ........................................ Exhaust manifold n u t s ...................................... Exhaust system mounting b o l t ........................ Cylinder head n u ts ............................................. Spark p lu g ........................................................... Alternator rotor nut .......................................... Starter m otor b o lt s ............................................. Clutch assembly nut ........................................ Variator centre n u t ............................................. Crankcase bolt ................................................. Gearbox oil drain plug ...................................... Gearbox cover bolts ........................................ Rear shock absorber mountings Lower b o lt ......................................................... Upper b o lt ......................................................... Handlebar stem bolt ........................................ Front axle n u t ...................................................... Front axle pinch-bolt ........................................ Rear hub n u t ...................................................... Rear wheel bolts (disc b ra k e ).......................... Disc brake caliper mounting bolts F r o n t.................................................................. Rear .................................................................. Disc mounting b o lt s ..........................................

50 Nm 12 Nm 25 Nm 10 Nm 20 Nm 38 Nm 13 Nm 50 Nm 33 Nm 9 Nm 18 Nm 12 Nm 25 Nm 50 Nm 50 Nm 50 Nm 12 Nm 110 Nm 50 Nm 25 Nm 27 Nm 27 Nm

Data 4

Aprilia Sonic FT and GP E n g in e ................................................................................................ Cooling s y s te m ............................................................................. Fuel system .................................................................................. Ignition s y s te m ............................................................................. T ra n s m is s io n ..................................................................................... S u s p e n s io n ....................................................................................... B r a k e s ................................................................................................ Tyres ................................................................................................... Wheelbase ....................................................................................... W e ig h t................................................................................................ Fuel ta n k ca pa city .........................................................................

Ign itio n system

Engine Spark plug type Air-cooled e ng in e ................ Liquid-cooled e n g in e ......... Electrode g a p .......................... Idle speed (rp m )..................... Oil tank capacity ................... Bore x s tr o k e .......................... Coolant ...................................

49 cc single-cylinder two-stroke Air o r liquid-cooled Dell’Orto PHBN 12 slide carburettor CDI Variable speed automatic, belt-driven Telescopic front, swingarm with single shock rear 155 mm disc front, 110 mm drum rear 100/90 x 10 front, 100/90 x 10 rear 1180 mm 87 kg 8.0 litres

____ .... .... ____ .... .\ . . ....

Coolant capacity ................... . . . .

NGK BR8 HS NGK BR8 HS 0.5 to 0.6 mm 1700 to 1900 rpm 1.6 litres 40.0 x 39.2 mm 50% distilled water, 50% corrosion inhibiting ethylene glycol anti-freeze 1.0 litres

Throttle twistgrip fre e p la y .............. Main j e t .............................................

2 to 3 mm 90

P ilo t j e t ....................................................... Starter j e t ....................................................

50 46

HT coil primary resistance ......... HT coil secondary resistance (without plug cap) ..................... Source coil resistance ................ Pick-up coil re sis ta n c e ................

0.56 to 0.84 ohms

Tyre pressures Front ................................................. R e a r....................................................

25 psi (1.7 bar) 28 psi (1.9 bar)

E lectrical system Battery Alternator Output (regulated) ..................... Fuse (main) ................................... Bulbs Headlight (m ain/dipped)............ Sidelight ...................................... Brake/tail li g h t ............................ Turn signal lig h t s ........................ Instrument and warning lights .

.

12 V, 4 Ah

. .

13 to 15 Volts (DC) 7.5 Amps

. . . . .

35/35 W 3W 10/5 W 10 W 1.2 W

4.5 to 7.5 K-ohms 640 to 960 ohms 400 to 600 ohms Torque w ren ch se ttin g s Engine mounting b o lt ............................... Exhaust manifold n u t s ............................ Exhaust system mounting b o l t .............. Cylinder head n u t s ...................................

Transm ission Variator roller diameter (service lim it ) ............................... Belt width (service lim it ) .............. Gearbox oil ................................... . Gearbox oil capacity ................... .

Disc brake Fluid type ................................... . Pad minimum th ic k n e s s ............ . Disc thickness (service limit) . . Drum brake

14.5 mm 15.5 mm SAE 75W/90 API GL4 oil 110 ml

DOT 4 1.0 mm • 3.2 mm

Brake shoe lining thickness mm

Alternator rotor nut ................................. Starter m otor bolts .................................... Clutch assembly nut .............................. Variator centre n u t ................................... Crankcase bolt ........................................ Gearbox oil drain plug ............................ Gearbox cover bolts .............................. Rear shock absorber mountings Lower b o lt ............................................... Upper b o lt ............................................... Handlebar stem bolt .............................. Front axle n u t.............................................

.... ____ ____ . ... ____ .. .. ____ . . ____ ____ ____ ____

60 Nm 10 Nm 25 Nm 10 Nm 20 Nm 38 Nm 13 Nm 50 Nm 33 Nm 9 Nm 18 Nm 12 Nm

____ ____ ____ ____ ____

18 Nm 32 Nm 50 Nm 50 Nm 110 Nm

Disc brakecaliper m ounting bolts .... . . . .

27 N m

Aprilia SR50 (1994 to 1999) Engine .

49 cc single-cylinder two-stroke Minarelli engine with horizontal cylinder Air o r liquid-cooled Dell’Orto PHBN 12 slide carburettor CDI Variable speed automatic, belt-driven Telescopic front, swingarm with single shock rear 190 mm disc front, 190 mm disc or 110 mm drum rear 130/60 x 13 front, 130/60 x 13 rear 1250 mm 99 kg 8.0 litres

Cooling system . . Fuel system . . . . Ignition system . . T ra n s m is s io n ......... S u s p e n s io n ............ Brakes ..................... Tyres ....................... W heelbase ............ W e ig h t ..................... Fuel ta n k ca pa city

Ign itio n system

Engine Spark plug type Air-cooled e n g in e ................ Liquid-cooled e n g in e ......... Electrode g a p .......................... Idle speed (rp m )..................... Oil tank capacity ................... Bore x stroke . . ...................... Coolant ...................................

Data 5

____ ____ .... ____ .... .... ....

Coolant capacity ................... . . . .

NGK BR7 HS NGK BR8 HS 0.5 t o 0.6 mm 1700 to 1900 rpm 1.6 litres 40.0 x 39.2 mm 50% distilled water, 50% corrosion inhibiting ethylene glycol anti-freeze 1.2 litres

Fuel system Throttle twistgrip freeplay . . . Main je t ........................ .. Pilot je t .......................... .. Starter j e t .......................... .. Needle type/ - clip position . . . . . Pilot screw s e ttin g ..................... . . Float height ................................. . .

2 to 3 mm 90 50 46 3SI12 - 3/5 1 1 /2 turns out 12 to 17 mm

HT coil prim ary resistance . . . . HT coil secondary resistance (without plug cap) ................... Source coil resistance .............. Pick-up coil re sis ta n c e ..............

.... . . .. ____ ____

Disc brake Fluid type ............................... Pad minimum thickness . . . . Disc thickness (service limit) Drum brake Brake shoe lining thickness Service lim it ........................ Brake lever freeplay . . . . . . .

25 psi (1.7 bar) 28 psi (1.9 bar)

E lectrical system Battery Capacity ...................................... Alternator Output (re g u la te d )..................... Fuse (main) ................................... Bulbs Headlight (m ain /dipp e d)............ Sidelight ...................................... Brake/tail li g h t ............................ Turn signal lig h t s ........................ Instrument and warning lights .

.

12 V, 4 Ah

.

13 to 15 Volts (DC) 7.5 Amps

. . . . .

35/35 W 3W 10/5 W 10 W 1.2 W

0.56 to 0.84 ohms 4.5 to 7.5 K-ohms 640 to 960 ohms 400 to 600 ohms

Transm ission Variator roller diameter (service lim it ) ........................ Belt width (service limit) . . . . Gearbox oil ............................ Gearbox oil capacity ............

Front ................................. .............. R e a r................................... ..............

14.5 mm 15.5 mm SAE 75W/90 API GL4 oil 110 ml

DOT 4

1.0 mm 3.2 mm

1.0 mm 10 mm

Torque w ren ch se ttin g s Engine mounting b o lt ............................... . . . 50 Nm Exhaust manifold n u t s ............................ . . . 12 Nm • Exhaust system mounting b o l t .............. . . . 25 Nm Cylinder head n u t s ................................... . . . 10 Nm Spark p lu g ................................................. . . . 20 Nm Alternator rotor nut ................................. . . . 38 Nm Starter motor b o lt s ................................... . . . 1 3 N m Clutch assembly nut ............................... . . . 50 Nm Variator centre n u t ................................... . . . 33 Nm Crankcase bolt ........................................ . . . , 9 Nm Gearbox oil drain p l u g ............................ . . . 18 Nm Gearbox cover bolts ............................... . . . 12 Nm Rear shock absorber mountings Lower b o lt ............................................... . . . 25 Nm Upper b o lt ............................................... . . . 50 Nm Handlebar stem bolt ............................... . . . 50 Nm Front axle n u t ............................................. . . . 50 Nm Front axle pinch-bolt ............................... . . . 12 Nm Rear hub nut ............................................. . . . 110 Nm Rear wheel bolts (disc b ra k e )................. . . . 50 Nm Disc brake caliper mounting bolts F r o n t......................................................... . . . 25 Nm Rear ......................................................... . . . 27 Nm Disc mounting b o lt s ................................. ____ 27 Nm

Data 6

Gilera Ice 50 Engine no. p r e f ix ............................................................................. Frame no. p re fix ............................................................................. E n g in e ................................................................................................ Cooling s y s te m .............................................................................. Fuel system .................................................................................. Ignition s y s te m ............................................................................. T ra n s m is s io n .................................................................................... S u s p e n s io n ....................................................................................... B r a k e s ................................................................................................ Tyres ................................................................................................... W heelbase ........................................................................................ W e ig h t................................................................................................ Fuel ta n k ca pa city .........................................................................

C301M ZAPC3 49 cc single cylinder two-stroke Air-cooled Weber 18 OM / Dell’Orto PHVA 17.5 RD carburettor CDI Variable speed automatic, belt driven Telescopic front, swingarm with single adjustable shock rear 200 mm disc front, 110 mm drum rear 120/90 x 10 front and rear 1220 mm 92 kg 6.5 litres

Engine

1 Ign itio n system

Spark plug t y p e ............................... Electrode g a p ................................... Idle speed (rp m )............................... Engine o i l .......................................... Oil tank capacity ............................ Bore x s t r o k e ................................... Piston oversizes available ............ Piston to bore clearance (standard) . Piston ring installed end gap S ta n d a rd ........................................

Champion RN2C 0.6 to 0.7 mm 1700 to 1900 rpm Two-stroke injector oil 1.6 litres 40.0 x 39.3 mm + 0.20 and + 0.40 mm 0.055 to 0.069 mm 0.10 to 0.25 mm

Fuel system Throttle twistgrip fre e p la y .............. Main jet W e b e r ............................................. Dell’Orto ........................................ Pilot jet W e b e r ............................................. Dell’Orto ........................................ Starter j e t .......................................... Needle type / position W e b e r ............................................. Dell’Orto ........................................ Pilot screw setting W eber....................................................... DelTO rto .................................................

2 to 6 mm 60 56

19 psi (1.3 bar) 26 psi (1.8 bar)

E le ctrical system

800 to 1100 ohms 90 to 140 ohms

...

17.5 mm

Torque w ren ch settings

.. . ...

18.5 mm lithium soap grease

Source coil resistance ......... . . . . Pick-up coil re sis ta n c e ......... . . . .

.

12 V, 3.6 Ah

.

25 to 30 V (AC) 7.5 Amps

. . . . .

35/35 W 3W 21/5 W 10 W LEDs

Transm ission Belt width (service lim it ) ......... Variator rollers diameter Service lim it ............................ Recommended lubricant . . . Clutch lining thickness (service lim it ) .......................... Clutch spring free length (service lim it ) .......................... Gearbox oil .............................. Gearbox oil capacity ..............

...

1.0 mm

... ... ...

110 mm SAE 80W/90 API GL3 oil 75 ml

E s s m

2 1/2 turns out 11/2 turns out

Front ................................................. Rear .................................................

Battery Capacity ...................................... Alternator Output (unregulated) ................. F u se ................................................. Bulbs Headlight (m ain /dipp e d)............ Sidelight ...................................... Brake/tail li g h t ............................ Turn signal lig h t s ........................ Instrument and warning lights .

30 32 50 AK (3rd notch from top) A22 (1st notch from top)

Tyre pressures

Disc brake Fluid type ...................................... Pad minim um th ic k n e s s .............. D is c th ic k n e s s (s e rv ic e lim it) Drumbrake

. . .

DOT 4 1.5 mm 3 .5 m m

Cylinder head n u t s ............................................. Crankcase b o lt s .................................................. Engine mounting b o lt ........................................ Exhaust system mounting b o lt ........................ Alternator rotor nut .......................................... Variator centre n u t ............................................. Clutch centre n u t ............................................... Clutch assembly nut ........................................ Rear shock absorber mountings Lower b o lt ......................................................... Upper b o lt ......................................................... Steering head bearing lo c k n u t........................ Handlebar stem bolt ........................................ Front fork leg clamp bolts ............................... Front fork leg top nuts (where fitted) ............ Front fork leg bottom bolts ............................ Front axle n u t ...................................................... Rear hub nut ...................................................... Disc brake caliper mounting bolts .................. Disc mounting b o lt s ..........................................

11 13 41 24 44 44 44 60

Nm Nm Nm Nm Nm Nm Nm Nm

41 Nm 25 Nm 40 Nm 50 Nm 25 Nm 25 nm 20 Nm 50 Nm 126 Nm 2 5 Nm e.5 Nm

Gilera Runner 50 (except PUREjet model) Engine no. p r e f ix .............................................................................. Fram e no. p re fix .............................................................................. E n g in e ................................................................................................. Cooling s y s te m .............................................................................. Fuel system ................................................................................... Ignition s y s te m .............................................................................. T ra n s m is s io n ..................................................................................... S u s p e n s io n .................................................................... .................. B r a k e s ................................................................................................. Tyres ................................................................................................... W heelbase ....................................................................................... W e ig h t ................................................................................................. Fuel ta n k c a p a city .........................................................................

Engine Spark plug t y p e ............................... Electrode g a p ................................... Idle speed (rp m )............................... Engine o i l ........................................... Oil tank capacity ............................ Bore x s t r o k e ................................... Piston oversizes available ............ Piston to bore clearance (standard) . Piston ring installed end gap S ta n d a rd ........................................ Coolant .............................................

Coolant capacity ............................

Data 7

C141M ZAPC 49 c c single-cylinder two-stroke Liquid-cooled Weber 12 OM slide carburettor CDI Variable speed automatic, belt-driven Upside-down telescopic front, swingarm with single adjustable shock rear 220 mm disc front, 110 mm drum o r 220 mm disc rear 120/70 x 12 front, 130/70 x 12 rear 1290 mm 98 kg 8.5 litres

Battery Capacity ........................................ Alternator Output (unregulated) ................... F u s e .................................................... Bulbs Headlight (m ain/dipped).............. Sidelight ........................................ Brake/tail l i g h t ............................... Turn signal lig h t s .......................... Instrument and warning lights . .

17 psi (1.2 bar) 23 psi (1.6 bar)

12 V, 4 Ah 25 to 30 V (AC) 7.5 Amps 35/35 W 5W 21/5 W 10 W 1.2 W

Ign itio n system Champion N84 0.5 mm 1800 rpm Two-stroke injector oil 1.8 litres 40.0 x 39.3 mm + 0.20 and + 0.40 mm 0.04 to 0.05 mm 0.10 to 0.25 mm 50% distilled water, 50% corrosion inhibiting ethylene glycol anti-freeze 0.9 litres

Source coil resistance ................... Pick-up coil re sista n ce ...................

800 to 1100 ohms 90 to 140 ohms

Transm ission Belt width (service lim it ) ......... . . . Variator rollers Recommended lubricant . . . . . . Gearbox oil ............................... . . . ' Gearbox oil capacity .............. . . .

17.5 mm lithium soap grease SAE 80W/90 API GL3 oil 75 ml

Fuel system Throttle twistgrip freeplay . . Main je t ................................. Pilot jet ................................. Needle type / position Pilot screw s e ttin g .............. Fuel le v e l............................... Automatic choke resistance

Front ................................................. R e a r....................................................

2 to 6 mm 100

34 L U (2nd notch from top) 2 1/4 turns out 3.5 mm 35 ohms

Brakes Disc brake Fluid type ................................. . . Pad minimum th ic k n e s s ......... Drum brake Brake shoe lining thickness Service lim it ..........................

DOT 4 1.5 mm

1.5 mm

Cylinder head n u t s ............................................. Crankcase b o lt s ................................................. Engine mounting b o lt ........................................ Exhaust manifold n u t s ...................................... Exhaust system mounting b o l t ........................ Thermostat housing bolt ................................. Alternator rotor nut .......................................... Variator c e n t r e jiu t ............................................. Clutch centre n u t ............................................... Clutch assembly nut ........................................ Gearbox oil drain plug ...................................... Rear shock absorber mountings Lower b o lt ......................................................... Upper b o lt ......................................................... Steering head bearing lo c k n u t........................ Handlebar stem bolt ........................................ Front fork leg top n u t s ...................................... Front fork leg bottom bolts ............................ Front axle n u t ...................................................... Rear wheel bolts ............................................... Rear hub nut ...................................................... Disc brake caliper mounting bolts ................ Disc mounting b o lt s .......................................... Brake hose banjo bolts ...................................

10 Nm 12 Nm 41 Nm 10 Nm 24 Nm 4 Nm 44 Nm 44 Nm 44 Nm 60 Nm 5 Nm 41 Nm 25 Nm 40 Nm 70 Nm 25 Nm 25 Nm 50 Nm 25 Nm 125 Nm 25 Nm 15 Nm 18 Nm

Data 8

Gilera Runner FX125 and FXR180 E n g in e n o . p r e f ix F X 1 2 5 .............................................................................................. FX R 180............................................................................................

M071M M081M

F r a m e n o . p r e f ix F X 1 2 5 .............................................................................................. FX R 180............................................................................................ E n g i n e ................................................................................................. Cooling s y s te m .............................................................................. Fuel system ................................................................................... Ignition s y s te m .............................................................................. T r a n s m i s s i o n ..................................................................................... S u s p e n s i o n .......................................................................................

B r a k e s ................................................................................................. T y r e s ................................................................................................... W h e e l b a s e ....................................................................................... W e i g h t ................................................................................................. F u e l t a n k c a p a c i t y .........................................................................

Fuel system

Engine Spark plug t y p e ............................... Electrode g a p ................................... Idle speed (rp m )............................... Engine o i l ........................................... Oil tank capacity ............................ Bore x stroke FX125 ............................................. FXR180 ........................................... Piston oversizes available FX125 only ................................... Piston to bore clearance (standard) FX125 ............................................. FXR180 ........................................... Piston ring installed end gap S ta n d a rd ............................ : . . . . Coolant .............................................

Coolant capacity ............................

ZAPM 070 ZAPM 080 123 cc single cylinder two-stroke Liquid-cooled Mikuni VM20 slide carburettor CDI Variable speed automatic, belt driven Upside-down telescopic front, swingarm with single adjustable shock rear 220 mm disc front, 140 mm drum rear o r 240 mm disc rear 120/70 x 12 front, 130/70 x 12 rear or 130/60 x 13 rear (1999-on) 1303 mm 115 kg 9 litres or 12 litres (1999-on)

Champion RN2C 0.6 to 0.7 mm 1400 to 1600 rpm Two-stroke injector oil 1.8 litres 55.0 x 52 mm 65.6 x 52 mm + 0.20, + 0.40 and + 0.60 mm 0.05 to 0.06 mm 0.04 to 0.05 mm 0.20 to 0.35 mm 50% distilled water, 50% corrosion inhibiting ethylene glycol anti-freeze 1.74 litres

Main jet FX125 ........................................ FXR180 ...................................... Pilot jet FX125 ........................................ FXR180 ...................................... Starter jet ................................... Needle type / position FX125 ........................................

.. ..

85 97.5

.. ..

35 27.5 gs 40

Pilot screw s e tt in g ..................... Fuel level ...................................... Automatic choke resistance . . . . .

3CK01 (3rd notch from top) 3DJ8 (3rd notch from top) 1 1 /4 turns out 6.5 mm 35 ohms

Transm ission ..

1.5 mm

E le ctrical system Battery capacity FX125 ........................................... FXR180 ........................................ Alternator Output (unregulated) ................. Fuse (main) ................................... Fu seh o lde r...................................... Bulbs Headlight (m ain /dipp e d)............ Sidelight ...................................... Brake/tail li g h t ............................ Turn signal lig h t s ........................ Instrument and warning lights .

. .

12 V, 9 Ah 12 V, 12 Ah

.

27 to 31 V (AC) 25 Amps 10 and 7.5 Amps

. . . . .

55/55 W 5W 21/5 W 10 W 1.2 W

.. .. . .

lithium soap grease SAE 80W/90 API GL3 oil 80 ml

0 .5 ohm 4.55 to 5.05 K-ohms Front .............................................................

Cylinder head cover bolts ..................... Cylinder head n u t s ................................... Crankcase b o lt s ........................................ Engine mounting bolt . .......................... Exhaust manifold n u t s .............. .............. Exhaust system mounting b o lt .............. Thermostat housing bolt ........................ Alternator rotor nut ................................. Variator centre n u t ................................... Clutch centre n u t ...................................... Clutch assembly nut ............................... Gearbox oil drain p l u g ............................ Rear shock absorber mountings Lower b o lt ...............................................

20.5 mm

ig n itio n system H T c o il p rim a ry re s is ta n c e ............... HTcoil secondary resistance .. . .

DOT 4 1.5 mm

Torque w ren ch se ttin g s

FXR180 ......................................

Belt width (service lim it ) ............ Variator rollers diameter Recommended lubricant Gearbox oil ................................. Gearbox oil capacity .................

Disc brake Fluid type ...................................... Pad minim um th ic k n e s s .............. Drum brake Brake shoe lining thickness Service lim it ...............................

20 psi (1.4 bar)

Steering head bearing lo c k n u t.............. Handlebar stem bolt ............................... Front fork leg top n u t s ............................ Front fork leg bottom bolts ................... Front axle n u t ............................................. Rear wheel bolts ...................................... Rear hub n u t ............................................. Disc brake caliper mounting bolts . . . . Disc mounting bolts.........................................

____ ____ ____ ____ ____ ____ .... ____ ____ ____ ____ ....

10 Nm 10 Nm 12 Nm 41 Nm 10 Nm 24 Nm 4 Nm 56 Nm 80 Nm 56 Nm 60 Nm 5 Nm

____ .... ____ ____ ____ ____ ____ ____ ____

41 Nm 25 Nm 40 Nm 70 Nm 25 Nm 25 Nm 50 Nm 25 Nm 130 Nm 25 Nm

__ ....

15 N m

—

i I

-

W -------

E n g in e n o . p r e f i x . . F ra m e n o . p r e fix . . E n g i n e ....................

M 2 4 1 M (V X 1 2 5 ), M 2 4 2 M ( V X R 1 8 0 ), M 2 4 2 10 1 (V X R 2 0 0 )

ZAPM 24 Single cylinder, four valve, four-stroke Liquid-cooled Walbro CV carburettor WVF-7C (VX125), WVF-7D (VXR180), WVF-7H (VXR200) Inductive discharge with electronic variable advance Variable ratio automatic, belt driven Telescopic front, swingarm with twin adjustable shocks rear 220 mm disc front, 200 mm disc rear 120/70 x 12 front, 130/70 x 12 rear 1350 mm 132 kg 12 litres

Cooling system . . Fuel system . . . . Type ................. Ignition system . .

T r a n s m i s s i o n ......... S u s p e n s i o n ........... B r a k e s .................... T y r e s ....................... W h e e l b a s e ........... W e i g h t .................... F u e l ta n k c a p a c ity

Ign itio n system

Engine Spark plug t y p e ............................... Electrode g a p ................................... Idle speed (rp m )............................... Engine o i l ..........................................

NGK CR 8EB 0.7 to 0.8 mm 1600 to 1700 rpm SAE 5W /40 synthetic four-stroke oil 1.0 litre

Oil capacity ...................................... Bore x stroke VX125 ............................................. 57.0 x 48.6 mm VXR180 .......................................... 69.0 x 48.6 mm VXR200 .......................................... 72.0 x 48.6 mm Piston oversizes (VX125 only) . . . . +0.20, +0.40 +0.60 mm Piston to bore clearance (standard) VX125 ............................................. 0.045 to 0.059 mm VXR180 and VXR200 ................... 0.030 to 0.044 mm Piston ring installed end gap (standard) VX125 and VXR180 Top r i n g ...................................... 0.20 to 0.40 mm 0.10 to 0.30 mm Second r i n g .............................. Oil control r i n g .......................... 0.15 to 0.35 mm VXR200 Top r i n g ...................................... 0.15 to 0.30 mm Second and oil control ring . . 0.20 to 0.40 mm Valve clearance Intake ............................................. 0.10 mm Exhaust .......................................... 0.15 mm Camshaft lobe height (standard) Intake ............................................. 30.285 mm E x h a u s t.......................................... 29.209 mm Coolant ................ 50% distilled water, 50% corrosion inhibiting ethylene glycol anti-freeze Coolant capacity 0.9 litre

HT coil primary resistance . . . . HT coil secondary resistance . . Spark plug cap resistance . . . . Pick-up coil re sista n ce ..............

0.4 t o 0.5 ohm 2.7 to 3.3 K-ohms 5 K-ohms 105 to 124 ohms

Fuel system Main jet V X 1 2 5 ........................................ Pilot jet VX125 ........................................ Starter jet ................................... Needle type / position VX125 ........................................ VXR180 ...................................... VXR200 ....... .......................... Pilot screw s e tt in g ..................... Float level ................................... Automatic choke resistance . . .

V X 12 5

V X R 180 /20 0

..

108

118

.. ..

36 50

34 50

..

51C (2nd notch from top) 465 (3rd notch from top) 465 (2nd notch from top) 3 turns out Parallel to gasket face 30 ohms (cold)

Transm ission Belt width (service limit) VX125 ............................................. VXR180 and VXR200 ................... Variator rollers Standard d ia m e te r........................ Service lim it ................................... Recommended lu b r ic a n t............ Clutch lining thickness (service limit) Clutch spring free length (standard) . Gearbox oil ...................................... Gearbox oil capacity .....................

Disc brake Fluid type ............................... . . . Pad minim um thickness . . . . . . .

21.5 mm 19.5 19.1 mm 18.5 mm Do not lubricate 1 mm 106 mm SAE 80W/90 API GL3 oil 150 ml

DOT 4 1.5 mm

sn m Front ................................................. Rear .................................................

20 psi (1.4 bar) 23 psi (1.6 bar) solo, 26 psi (1.8 bar) with pillion

E le ctrical system Battery Capacity ...................................... . Alternator Output (regulated) ..................... Charging coil re sistance............ F u s e ................................................. Bulbs Headlight (separate lights) . . . . Sidelight ...................................... Brake/tail l i g h t ............................ Turn signal lig h t s ........................ Instrument and warning lights .

12 V, 10 Ah 15.2 V (DC) 0.7 to 0.9 ohms 2 x 1 5 and 4 x 5 Amps 55 W main. 55 W dip 5W 21/5 W 10 W 1.2 W

Torque w ren ch se ttin g s Valve cover b o lt s ........................................ . . . Cylinder head n u ts ...................................... . . . Cylinder head bolts ................................... . . . Cam chain tensioner spring cap bolt . . . . . . Camshaft sprocket b o l t ............................ . . Engine oil drain plug ................................. . . Engine mounting b o lt ................................. . . Exhaust manifold n u t s ............................... . . Exhaust system mounting b o l t ................. . . Alternator rotor nut ................................... . . Variator centre n u t ...................................... . . Clutch centre n u t ........................................ . . .. Clutch assembly nut ............................ . Crankcase b o lts .......................................... . . Gearbox oil drain plug .............................. . . Gearbox cover bolts ................................. . . Rear shock absorber mountings Lower b o lt ................................................. . . Upper b o lt ................................................. . . Steering head bearing lo c k n u t................ . . Handlebar stem bolt ................................. . . Front fork leg top n u t s ............................... . . Front fork leg bottom bolts ..................... . . Front axle n u t ............................................... . . Rear wheel bolts ........................................ . . Rear hub n u t ............................................... . . . Disc brake caliper mounting bolts ......... . . . Disc mounting bolts F r o n t ........................................................... . . . Rear ........................................................... . . . Brake hose banjo bolts ............................ . . .

11 to 13 Nm 27 to 29 Nm 11 to 13 Nm 5 to 6 Nm 11 to 15 Nm 30 Nm 41 Nm 18 Nm 27 Nm 54 to 60 Nm 83 Nm 60 Nm 60 Nm 12 Nm 15 Nm 27 Nm 41 Nm 25 Nm 40 Nm 50 Nm 25 Nm 25 Nm 50 Nm 25 Nm 126 Nm 25 Nm 13 Nm 17 Nm 25 Nm

DATA

Gilera SKP50 (Stalker) Engine no. p r e f ix .............................................................................. Fram e no. pre fix .............................................................................. E n g in e ................................................................................................. Cooling s y s te m .............................................................................. Fuel system ................................................................................... Ignition s y s te m .............................................................................. T ra n s m is s io n ..................................................................................... S u s p e n s io n .......................................................................................

Data 10

B r a k e s ................................................................................................. Tyres ................................................................................................... W heelbase ....................................................................................... W e ig h t ................................................................................................. Fuel ta n k c a p a city .........................................................................

C131M ZAPC13 49 cc single-cylinder two-stroke Air-cooled Weber 12 OM slide carburettor CDI Variable speed automatic, belt-driven Upside-down telescopic front, swingarm with single adjustable shock rear 190 mm disc front, 110 mm drum or 175 mm disc rear 120/90 x 10 front, 130/90 x 10 rear 1230 mm 87 kg 6.0 litres

Engine

I Ign itio n system

Tyre pressures Front R e a r.

18 psi (1.2 bar) 23 psi (1.6 bar)

E le ctrical system Battery Capacity ...................................... Alternator O utput (unregulated) ................. F u se .................................................. Bulbs Headlight (m ain /dipp e d)............ Sidelight ...................................... Brake/tail l i g h t ............................ Turn signal lig h t s ........................ Instrument and warning lights .

.

12 V, 4 Ah

.

25 to 30 V (AC) 7.5 Amps

. . . . .

35/35 W 5W 21/5 W 10 W 1.2 and 2 W

Torque w ren ch se ttin g s Spark plug t y p e ............................... Electrode g a p ................................... Idle speed (rp m )............................... Engine o i l ........................................... Oil tank capacity ............................ Bore x s tr o k e ................................... Piston oversizes available ............ Piston to bore clearance (standard) . Piston ring installed end gap S ta n d a rd ........................................

Champion N2C 0.5 to 0.6 mm 1800 to 2000 rpm Two-stroke injector oil 1.2 litres 40.0 x 39.3 mm + 0.20 and + 0.40 mm 0.045 to 0.055 mm 0.10 to 0.25 mm

Source coil resistance ......... . . . . Pick-up coil re sis ta n c e ......... . . . .

800 to 1100 ohms 90 to 140 ohms

Transm ission Belt width (service lim it ) ......... Variator rollers Recommended lubricant . . . Gearbox oil ............................... Gearbox oil capacity ..............

. ..

17.5 mm

... ... ...

lithium soap grease SAE 80W/90 API GL3 oil 75 ml

Fuel system T h r o ttle tw is tg rip f r e e p l a y ............ M a in je t

..................................................

P ilo t je t

..................................................

.. .. ..

S t a r te r j e t .............................................. N e e d le t y p e / p o s itio n .................. Pilot screw setting.......................... . . ..

2 t o 6 mm 72 34 50 V (3 rd n o tc h fro m to p ) 2 3 / 4 tu rn s o u t 3.Sm m

Disc brake Fluid type ...................................... Pad minimum th ic k n e s s .............. Drum brake Brake shoe lining thickness

DOT 4 1.5 mm

Cylinder head n u t s ............................................. Crankcase b o lts ................................................. Engine mounting b o lt ...................................... Exhaust manifold n u t s ...................................... Exhaust system mounting b o lt ........................ Alternator rotor nut ........................................... Variator centre n u t ............................................. Clutch centre n u t ............................................... Clutch assembly nut ........................................ Gearbox oil drain plug ...................................... Rear shock absorber mountings Lovyer b o l t ......................................................... Upper b o l t ......................................................... Steering head bearing lo c k n u t........................ Handlebar stem bolt ........................................ Front fork leg top n u t s ...................................... Front fork leg bottom bolts ............................ Front axle n u t ...................................................... Rear wheel bolts ............................................... Rear hub nut ...................................................... Disc brake caliper mounting bolts ................. Disc mounting bolts F r o n t .................................................................. R ear .................................................................................

11 Nm 12 Nm 41 Nm 10 Nm 24 Nm 44 Nm 44 Nm 44 Nm 60 Nm 4 Nm 41 Nm 25 Nm 40 Nm 21.5 Nm 25 Nm 25 Nm 50 Nm 25 Nm 110 Nm 25 Nm 15 Nm 6.5 N m

Data 11

Honda FES125 Pantheon E n g i n e ................................................................................................ Cooling s y s te m .............................................................................. Fuel system .................................................................................. Ignition s y s te m ............................ ................................................. T r a n s m i s s i o n ..................................................................................... S u s p e n s i o n ....................................................................................... B r a k e s ................................................................................................ T y r e s ................................................................................................... W h e e l b a s e ....................................................................................... W e ig h t ( d r y ) ....................................................................................... F u e l t a n k c a p a c i t y . ....................................................................

124 cc single-cylinder two-stroke liquid-cooled PB20 slide carburettor CDI Variable speed automatic, belt-driven Telescopic front, swingarm with single adjustable shock rear Disc front, drum rear 110/90 x 12 front, 130/70 x 12 rear 1450 mm 149 kg 12 litres

E le ctrical system Battery Capacity ...................................... Voltage (fully c h a rg e d ).............. Alternator Output (re g u la te d )..................... Charging coil re sistance............ Fuse (main) ................................... Fuse (secondary) .......................... Bulbs Headlight (m ain/dipped)............ Sidelight ...................................... Brake/tail li g h t ............................ Turn signal lights ........................ Instrument and warning lights .

. .

12 V, 8 Ah 13 to 13.2 V

.

14.5 to 15.3 V (DC) 0.1 to 0.5 ohms 30 Amps 2 x 15 and 3 x 10 Amps

. . . . .

55/55 W 5W 21/5 W 21 W 1.7 and 2 W

Engine Spark plug t y p e .............................. Electrode g a p ................................... Idle speed (rp m ).............................. Engine o i l .......................................... Oil tank capacity ............................ Bore x s tr o k e ................................... Piston diameter (s ta n d a rd )............ Piston to bore clearance (standard). Piston ring installed end gap (service limit) ................................. Coolant .............................................

Coolant capacity ............................

NGK BR8ES 0.7 to 0.8 mm 1500 rpm Two-stroke injector oil 1.2 litres 54.0 x 54.5 mm 53.93 to 53.95 mm 0.06 to 0.07 mm 0.65 mm 50% distilled water, 50% corrosion inhibiting ethylene glycol anti-freeze 1.2 litres

Fuel system Throttle twistgrip freeplay . . Main jet . . . t ....................... Pilot jet ................................. Pilot screw s e ttin g .............. Float height .......................... Automatic choke resistance

2 to 6 mm 108 40 1 3/4 turns out 8.8 mm 1.5 to 5.6 ohms

Belt width (service lim it ) ................. Variator rollers diameter S ta n d a rd ........................................ Service lim it ................................... Clutch lining thickness (service lim it ) ................................. Clutch spring free length (service lim it ) ................................. Gearbox oil ...................................... Gearbox oil capacity .....................

21.5 mm

Fluid t y p e .......................................... Disc brake Disc thickness (service limit) . . . Drum brake Drum internal diameter (service limit) ............................ Brake lever fre e p la y .....................

DOT 4

Front.................................................... R e a r....................................................

25 psi (1.75 bar) 29 psi (2.0 bar)

23.08 mm 22.50 mm 2.0 mm 99.6 mm S AE 10W -30oil 180 ml

3.5 mm

161 mm 10 to 20 mm

Torque w rench settings Cylinder head n u t s ............................... Cylinder base n u t s ............................... Crankcase b o lt s ................................... Engine mounting b o lt .......................... Exhaust manifold n u t s ........................ Exhaust system mounting bolts 8 m m .................................................... 10 m m ................................................. Water pump impeller n u t ................... Alternator rotor nut ............................ Alternator stator bolts ........................ Variator centre n u t ............................... Clutch centre n u t ................................. Clutch assembly nut .......................... Gearbox oil filler p lu g .......................... Gearbox oil drain p l u g ........................ Gearbox cover bolts .......................... Rear shock absorber mounting bolts Steering head bearing lo c k n u t......... Handlebar stem bolt .......................... Front fork leg clamp bolts ................. Front fork leg bottom bolts .............. Front axle n u t ........................................ Rear hub n u t ........................................ Disc brake caliper mounting bolts . . Disc mounting b o lt s ............................ Brake hose banjo bolts .....................

22 22 10 62 29

Nm Nm Nm Nm Nm

34 Nm 49 Nm 10 Nm 64 Nm 12 Nm 93 Nm 74 Nm 78 Nm 13 Nm 13 Nm 22 Nm 39 Nm 74 Nm 59 Nm 40 Nm 20 Nm 69 Nm 118 Nm 31 Nm 42 Nm 34 Nm

DATA

Honda FES250 Foresight E n g in e ................................................................................................. Cooling s y s te m .............................................................................. Fuel system ................................................................................... Ignition s y s te m .............................................................................. T ra n s m is s io n ..................................................................................... S u s p e n s io n ....................................................................................... B r a k e s ................................................................................................. Tyres ................................................................................................... W heelbase ....................................................................................... W e ig ht ( d r y ) ....................................................................................... Fuel ta n k c a p a city .........................................................................

Data 12 249 cc single-cylinder four-stroke liquid-cooled VE3BB CV carburettor CDI Variable speed automatic, belt-driven Telescopic front, swingarm with single adjustable shock rear Disc front, drum rear 110/90 x 12 front, 130/70 x 12rear 1450 mm 150 kg 12 litres

Fuel system Throttle twistgrip fre e p la y ............ Main je t .......................................... . Pilot je t .......................................... . Pilot screw setting ........................ Float height ................................... Automatic choke resistance

Engine Spark plug t y p e ............................... Electrode g a p ................................... Idle speed (rp m )............................... Engine o i l ..........................................

NGK DPR7EA-9 0.8 to 0.9 mm 1500 rpm SAE 10W/40 fourstroke motorcycle oil 1.3 litres 72.7 x 60.0 mm 72.65 mm 73.01 mm

Oil capacity ...................................... Bore x s tr o k e ................................... Piston diameter (service limit) . . . . Cylinder diameter (service limit) . . Piston to bore clearance (service lim it ) ................................. 0.10 mm Piston ring installed end gap (service limit) Top r i n g ........................................... 0.50 mm Second r in g ................................... 0.65 mm Oil control r in g ............................... 0.90 mm Valve clearance ............................... Refer to handbook Valve spring free length (service limit) Inner spring (intake and exhaust) .. 29.5 mm Outer spring (intake and exhaust) . 38.4 mm Camshaft lobe height (service limit) Intake ............................................. 34.181 mm Exhaust ........................................... 34.062 mm Coolant ............................................. 50% distilled water, 50% corrosion inhibiting ethylene glycol anti-freeze

2 to 6 mm 105 40 2 1/8 turns out 18.5 mm 10 K-ohms

Tyre pressures Front .................................................. R e a r....................................................

25 psi (1.75 bar) 29 psi (2.0 bar)

E lectrical system Battery Capacity ...................................... Voltage (fully c h a rg e d ).............. Alternator Output (regulated) ..................... Charging coil re sista nce ............ Fuse (main) ................................... Fuse (s e c o n d a ry ).......................... Bulbs Headlight (m ain /dipp e d)............ Sidelight ...................................... Brake/tail l i g h t ............................ Turn signal lig h t s ........................ Instrument and warning lights .

. .

12 V, 10 Ah 13 to 13.2 V

.

14.5 to 15.3 V (DC) 0.1 to 0.5 ohms 30 Amps 2 x 15 and 3 x 10 Amps

. . . . .

55/55 W 5W 21/5 W 21 W 1.7 and 3 W

Torque w ren ch se ttin g s Transm ission Belt width (service lim it ) ......... Variator rollers diameter S ta n d a rd ................................. Service lim it ............................ Clutch lining thickness (service lim it ) .......................... Clutch spring free length (service lim it ) .......................... Gearbox oil ............................... Gearbox oil capacity ..............

Fluid t y p e .................................... Disc brake Pad minimum thickness . . . . Disc thickness (service limit) Drum brake Drum internal diameter (service limit) ..................... B ra k e s h o e lin in g th ic k n e s s Service limit .

...

22.3 mm

... ...

23.08 mm 22.50 mm

...

0.5 mm

... ... ...

127.8 mm SAE 10W-30 oil 200 ml

To wear lim it indicator 3.5 mm

Towear limit indicator

Cylinder head cap nuts ............................ Cam chain tensioner cap bolt ................ Engine mounting b o lt ................................. Engine bracket to frame bolt ................... Engine bracket pivot b o l t .......................... Engine tension rod n u t ............................... Exhaust manifold n u t s ............................... Exhaust system mounting b o lt s .............. Water pump impeller nut .......................... Alternator rotor nut ................................... Alternator stator bolts ............................... Variator centre n u t ...................................... Clutch centre n u t ........................................ Clutch assembly nut ................................. Gearbox oil filler p lu g ................................. Gearbox oil drain p l u g ............................... Gearbox cover bolts ................................. Rear shock absorber mounting bolts . . . Steering head bearing lo c k n u t................ Handlebar stem bolt ................................. Front fork leg bottom bolts ..................... Front axle n u t ............................................... Rear hub nut ............................................... Disc brake caliper mounting bolts ............ Disc mounting bolts............................................

.. .. .. .. .. .. .. .. .. . .. .. .. . . .. . . . . .. .. .. .. .. .. .. ..

24 Nm 22 Nm 59 Nm 78 Nm 62 Nm 20 Nm 29 Nm 34 Nm 12 Nm 116 Nm 12 Nm 93 Nm 74 Nm 78 Nm 13 Nm 13 Nm 25 Nm 39 Nm 74 Nm 88 Nm 20 Nm 69 Nm 1113 Nm 31 Nm 42 N m

E n g in e .

1 2 4 c c s in g le -c y lin d e r f o u r -s tro k e

Cooling system . Fuel system . . . Ignition system . Transm ission S u s p e n s io n ......... B r a k e s ................... Tyres ..................... W heelbase ......... W eight ( d r y ) .........

Liquid-cooled VK4AA CV carburettor CDI Variable speed automatic, belt-driven Telescopic front, swingarm with twin adjustable shock rear Disc front, drum rear 110/90 x 13 front, 130/70 x 13 rear 1328 mm 131 kg

Ignition system Spark plug t y p e ............................... Electrode g a p ................................... Idle speed (rp m )............................... Engine o i l ..........................................

NGK CR8EH-9 0.8 to 0.9 mm 1500 rpm SAE 10W/40 fourstroke motorcycle oil 1.0 litre 52.4 x 57.8 mm 52.30 mm 52.44 mm

Oil capacity ...................................... Bore x s tr o k e ................................... Piston diameter service lim it.......... Cylinder bore service lim it ............ Piston to bore clearance (service lim it ) ................................. 0.10 mm Piston ring installed end gap (standard/service limit) Top r i n g .......................................... 0.15 to 0.30 mm/ 0.50 mm Second r in g ................................... 0.30 to 0.45 mm/ 0.65 mm Oil control r in g .............................. 0.20 to 0.70 mm/ 0.90 mm Valve clearance Intake ............................................. 0.16 mm E x h a u s t.............................. : . . . . 0.25 mm Valve spring free length S ta n d a rd ........................................ 36.2 mm Service lim it ................................... 34.4 mm Camshaft lobe height service limit Intake ............................................. 29.637 mm E x h a u s t.......................................... 29.395 mm Coolant ............................................. 50% distilled water, 50% corrosion inhibiting ethylene glycol anti-freeze Coolant capacity ............................ 0.95 litre

Throttle twistgrip fre e p la y .............. Main jet ............................................. Pilot jet ............................................. Pilot screw s e tt in g .......................... Float height ......................................

2 to 6 mm 112 35

1 7 /8 turns out 18.2 mm

Honda’s specified testing procedure for the ignition system components requires specialist equipment not available to the DIY mechanic.

Battery Capacity ...................................... Voltage (fully c h a rg e d ).............. Alternator Output (regulated) ..................... Charging coil re sistance............ Lighting coil resistance ............ Fuse (main) ................................... Fuse (secondary) .......................... Bulbs Headlight (m ain/dipped)............ Sidelight ...................................... Brake/tail lig h t ............................ Turn signal lig h t s ........................ Instrument and warning lights .

12 V, 6 Ah 13 to 13.2 V 15.5 V (DC) 0.1 to 0.5 ohms 0.1 to 0.5 ohms 30 Amps 1 x 15 and 4 x 10 Amps 55/55 W 5 W 21/5 W 21 W 1.7 W

Torque wrench settings T ransm ission Belt width (service lim it ) ......... Variator rollers Standard d ia m e te r................. Service lim it ............................ Clutch lining thickness (service limit) .......................... Clutch spring free length (standard) ............................... Gearbox oil ............................... Gearbox oil capacity ..............

...

21.5 mm

... ...

20.0 mm 19.5 mm

...

2 mm

... ... ...

143.3 mm SAE 90 hypoid gear oil 220 ml

Disc brake Fluid type ..................................... . Pad minim um th ic k n e s s .............. , Disc thickness (service limit) . .. Drum brake Drum internal diameter (service limit) ............................ Shoe lining minimum thickness .. . Brake lever fre e p la y .....................

DOT 4 To wear lim it indicator 3.5 mm

131 mm To wear lim it indicator 15 to 25 mm

Tyre pressures Front ................................................. R e a r....................................................

25 psi (1.7 bar) 29 psi (2.0 bar)

Valve cover b o lt s ............................................... Cylinder head n u ts ............................................. Cylinder head bolts .......................................... Cam chain tensioner b o lt s ............................... Camshaft sprocket bolts ................................. Engine oil drain plug ........................................ Engine mounting b o lt s ...................................... Exhaust manifold n u t s ...................................... Exhaust system mounting b o lt s ..................... Water pump cover b o lt s ................................... Water pump impeller nut ................................. Thermostat cover bolts ................................... Alternator rotor nut .......................................... Variator centre n u t ............................................. Clutch centre n u t ............................................... Clutch assembly nut ........................................ Crankcase b o lts ................................................. Gearbox oil filler p lu g ........................................ Gearbox oil drain plug ...................................... Gearbox cover bolts ........................................ Rear shock absorber mountings Lower b o lt ........................................................ Upper b o lt ........................................................ Rear sub frame b o lt s ........................................ Steering head bearing lo c k n u t........................ Handlebar stem bolt ........................................ Front fork leg clamp bolts ............................... Front axle n u t ...................................................... Rear hub nut ...................................................... Disc brake caliper mounting bolts ................ Disc mounting b o lt s .......................................... Brake hose banjo bolts ...................................

12N m 27 Nm 12 Nm 12 Nm 9 Nm 20 Nm 49 Nm 9 Nm 49 Nm 12 Nm 12 Nm 10 Nm 116 Nm 59 Nm 49 Nm 54 Nm 12 Nm 13 Nm 27 Nm 27 Nm 25 Nm 39 Nm 40 Nm 68 Nm 39 Nm 40 Nm 68 Nm 118 Nm 30 Nm 42 Nm 34 Nm

DATA

Honda SFX50

Data 14

E n g in e ................................................................................................. Cooling s y s te m .............................................................................. Fuel system ................................................................................... Ignition s y s te m .............................................................................. T ra n s m is s io n ..................................................................................... S u s p e n s io n ....................................................................................... B r a k e s ................................................................................................. Tyres ................................................................................................... W heelbase ....................................................................................... W eight ( d r y ) ...................................................... ................................ Fuel ta n k c a pa city .........................................................................

Ign itio n system

Engine Spark plug t y p e ............................ Electrode g a p ................................. Idle speed (rp m )............................ Engine o i l ........................................ Oil tank capacity .......................... Bore x s tr o k e ................................. Piston diameter (service limit) . . . Cylinder diameter (service limit) . Piston to bore clearance (service limit) ............................... Piston ring installed end gap S ta n d a rd ...................................... Service lim it .................................

49 cc single-cylinder two-stroke Air-cooled PB2BN slide carburettor CDI Variable speed automatic, belt-driven Telescopic front, swingarm with single shock rear Disc front, drum rear 90/90 x 10 front, 90/90 x 10 rear 1215 mm 71 kg 6 litres

. .

. .

.

NGK BR6HSA 0.6 to 0.7 mm 1800 rpm Two-stroke injector oil 1.2 litres 39.0 x 41.4 mm 38.90 mm 39.05 mm 0.10 mm 0.10 to 0.25 mm 0.40 mm

HT coil primary resistance . . . . HT coil secondary resistance . . Spark plug cap resistance . . . . Pick-up coil re sis ta n c e ..............

0.1 t o 0.3 6.5 to 9.7 3.8 to 6.2 50 to 200

ohm K-ohms K-ohms ohms

Tyre pressures 18 psi (1.3 bar) 29 psi (2.0 bar)

E le ctrical system Battery Capacity ...................................... Voltage (fully c h a rg e d ).............. Alternator O utput (re g u la te d )..................... Charging coil re sista nce ......... Lighting coil resistance ............ F u s e ................................................. Bulbs Headlight (m ain /dipp e d)............ Sidelight ...................................... Brake/tail li g h t ............................ Turn signal lig h t s ........................ Instrument and warning lights .

12 V, 2.3 Ah 13 to 13.2 V 14 to 15 V (DC) 0.2 to 1.0 ohms 0.1 to 0.8 ohms 15 + 10 Amps 25/25 W 5W 21/5 W 10 W 2W

Torque w ren ch se ttin g s Transm ission Belt width (service lim it ) ......... Variator rollers diameter S ta n d a rd ................................. Service lim it ............................ Clutch lining thickness (service lim it ) .......................... Clutch spring free length (service lim it ) .......................... Gearbox oil ............................... Gearbox oil capacity ..............

Throttle twistgrip fre e p la y .............. Main jet ............................................. Pilot je t .............................................

2 to 6 mm 80 35

Disc brake Fluid type ............................... - Disc thickness (service limit)

N e e d le ty p e / p o s itio n ....................... Pilot screw s e ttin g ................................

J 6 3 S (3 rd n o tc h ) 11/8 turns out

Drum brake Drum internal diameter

...

17.5 mm

... ...

15.92 to 16.08 mm 15.40 mm

...

2 mm

.. . ... ...

92.8 mm SAE 10W-40 oil 100 ml

DOT 4 3.5 mm

Cylinder head bolts ........................................ Crankcase b o lts ................................................. Engine mounting b o lt ........................................ Exhaust manifold n u t s ...................................... Exhaust system mounting b o lt s ..................... A lternator rotor nut ........................................... Variator centre n u t ............................................. Clutch centre n u t ............................................... Clutch assembly nut ........................................ Gearbox oil filler p lu g ........................................ Gearbox oil drain plug ...................................... Rear shock absorber mountings Lower b o lt ......................................................... Upper b o lt ......................................................... Steering head bearing lo c k n u t ........................ Handlebar stem bolt ........................................ Front fork leg clamp bolts ............................... Front axle n u t ...................................................... Rear hub nut ...................................................... Disc brake caliper mounting bolts .................

Disc mounting bolts....................................................

10 10 50 16 27 40 42 40 55 12 12

Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm

25 Nm 40 Nm 70 Nm 40 Nm 27 Nm 45 Nm 120 Nm 3 2 Nm 43 M m

Data 15

Honda SGX50 Sky E n g i n e ................................................................................................. Cooling s y s te m .............................................................................. Fuel system ................................................................................... Ignition s y s te m .............................................................................. T r a n s m i s s i o n ..................................................................................... S u s p e n s i o n ....................................................................................... B r a k e s ................................................................................................. T y r e s ................................................................................................... W h e e l b a s e ....................................................................................... W e ig h t ( d r y ) ........................................................................................ F u e l t a n k c a p a c i t y .........................................................................

Ignition system

Engine Spark plug t y p e ............................ . Electrode g a p ................................. Idle speed (rp m )............................ Engine o i l ........................................ Oil tank capacity .......................... Bore x s tr o k e ................................. Piston diameter (service limit) . . . Cylinder diameter (service limit) . Piston to bore clearance (service limit) ............................... Piston ring installed end gap S ta n d a rd ...................................... . Service lim it .................................

NGK BR6HSA 0.6 to 0.7 mm 1800 rpm Two-stroke injector oil 1.2 litres 3 9 .0 x 4 1 .4 mm 38.90 mm 39.05 mm 0.10 mm 0.10 to 0.25 mm 0.40 mm

Fuel system Throttle twistgrip fre e p la y......... Main je t ............................... Pilot je t ............................... Needle type / position .............. Pilot screw s e tt in g ................. Float height ................................. Automatic choke resistance . ..

49 cc single-cylinder two-stroke Air-cooled PB2BN slide carburettor CDI Variable speed automatic, belt-driven Telescopic front, swingarm with single shock n Disc front, drum rear 2.50 x 16 front, 2.75 x 16 rear 1230 mm 72.2 kg 4.5 litres

.. .. .. .. .. ..

2 to 6 mm 72 35 J63U (3rd notch from top) 3 turns out 14.3 mm 3.2 to 5.6 ohms

HT coil secondary resistance . . Spark plug cap resistance . . . . Pick-up coil re sista nce ..............

550 to 650 ohms 4.95 to 5.05 K-ohms 150 to 200 ohms

Tyre pressures Front ................................. .............. R e a r................................... ..............

25 psi (1.75 bar) 33 psi (2.25 bar)

E le ctrical system Battery Capacity ........................................ Voltage (fully c h a rg e d )................. Alternator Output (re g u la te d )........................ Charging coil resistance.............. Fuse (main) ...................................... Fuse (se co n d a ry)............................ Bulbs Headlight (m ain /dipp e d).............. Sidelight ........................................ Brake/tail l i g h t ............................... Turn signal lig h t s .......................... Instrument and warning lights . .

12 V, 3 Ah 13 to 13.2 V 14 to 15 V (DC) 0.7 to 1.1ohms 15 Amps 10 Amps 35/35 W 5 W 21/5 W 10W 2 W

Transm ission Belt width (service lim it ) ............ Variator rollers diameter S ta n d a rd ................................... Service lim it ............................... Clutch lining thickness (service lim it ) ............................ Clutch spring free length (service lim it ) ............................. Gearbox oil ................................. . . Gearbox oil capacity ................. . .

Disc brake Fluid type ...................................... Disc thickness (service limit) . . . Drum brake Drum internal diameter (service limit) ............................ Brake shoe lining thickness Service lim it ............................... Brake lever fre e p la y .....................

17.0 mm 15.92 to 16.08 mm 15.40 mm 2 mm 92.8 mm SAE 10W-40 oil 100 ml

DOT 4 3.0 mm

111 mm 1.5 mm 10 to 20 mm

Cylinder head bolts .......................................... Crankcase b o lt s ................................................. Engine mounting b o lt ........................................ Exhaust manifold n u t s ...................................... Exhaust system mounting b o lt s ..................... Alternator rotor nut .......................................... Variator centre n u t ............................................. Clutch centre n u t ............................................... Clutch assembly nut ........................................ Gearbox oil filler p lu g ........................................ Gearbox oil drain p lu g ...................................... Rear shock absorber mountings Lower b o lt ......................................................... Upper b o lt ...................................................... .. Steering head bearing lo c k n u t........................ Handlebar stem bolt ........................................ Front fork leg clamp bolts ............................... Front axle n u t ...................................................... Rear hub nut ...................................................... Disc brake caliper mounting bolts ................ Disc mounting b o lt s .......................................... Brake hose banjo bolts ...................................

10 10 50 16 27 40 42 40 55 12 12

Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm

25 Nm 40 Nm 70 Nm 40 Nm 27 Nm 45 Nm 120 Nm 32 Nm 43 Nm 30 Nm

DATA

Honda SH50

Data 16

E n g in e ................................................................................................ Cooling s y s te m .............................................................................. Fuel system .................................................................................. Ignition s y s te m .............................................................................. T ra n s m is s io n ..................................................................................... S u s p e n s io n ....................................................................................... B r a k e s ................................................................................................ Tyres ................................................................................................... W heelbase ....................................................................................... W eight ( d r y ) ....................................................................................... Fuel ta n k c a pa city .........................................................................

49 cc single-cylinder two-stroke Air-cooled PB2BR slide carburettor CDI Variable speed automatic, belt-driven Telescopic front,swingarm with twin shock rear Disc front, drum rear 2.50 x 16 front, 2.75 x 16 rear 1267 mm 83.8 kg 6.3 litres

Transm ission Spark plug t y p e ............................ . Electrode g a p ................................. Idle speed (rp m )............................ Engine o i l ........................................ Oil tank capacity .......................... . Bore x s tr o k e ................................. Piston diameter (service limit) . . . Cylinder diameter (service limit) . Piston to bore clearance (service lim it ) ............................... . Piston ring installed end gap S ta n d a rd ...................................... Service lim it.................................

NGK BR6HSA 0.6 to 0.7 mm 1800 rpm Two-stroke injector oil 1.2 litres 3 9 .0 x 4 1 .4 mm 38.90 mm 39.05 mm

Belt width (service lim it ) ......... Variator rollers diameter S ta n d a rd ................................. Service lim it ............................. Clutch lining thickness (service lim it ) .......................... Clutch spring free length (service lim it ) .......................... Gearbox oil ............................... Gearbox oil capacity ..............

0.10 mm

...

17.0 mm

... ...

15.92 to 16.08 mm 15.40 mm

...

2 mm

... ... ...

92.8 mm SAE 10W-40 oil 100 ml

0.10 to 0.25 mm 0.40 mm B rakes Disc brake Fluid type ................................... . Disc thickness (service limit) . . Drum brake Drum internal diameter (service limit) .......................... Brake shoe lining thickness Service lim it ............................. Brake lever fre e p la y ...................

Fuel system Throttle twistgrip fre e p la y ............ Main je t ........................................... Needle type / position ................ Pilot screw s e tt in g ........................ Float height ................................... Automatic choke resistance . . . .

1

2 to 6 mm 82 J63U (3rd notch from top) 1 3/8 turns out 8.6 mm 3.2 to 5.6 ohms

DOT 4 3.0 mm

111 mm 1.5 mm 10 to 20 mm

Ign itio n system H T co il p rim a ry re s is ta n c e H T co il s e c o n d a ry re s is ta n c e . . Spark plug cap resistance .... . .

'

0 1 to 0 3 o h m 2 . 7 to 3 . 5 K -o h m s 3.8 to 6.2 K-ohms

-

............................. ................................

2 5 p s i ( 1 .7 5 b ar) 3 3 p s i ( 2 .2 5 b ar)

E le ctrical system Battery Capacity ...................................... Voltage (fully c h a rg e d ).............. Alternator Output (regulated) ..................... Charging coil re sista nce ............ Lighting coil resistance ............ Fuse (main) ................................... Fuse (se co n d a ry).......................... Bulbs Headlight (m ain/dipped)............ S idelight ...................................... Brake/tail lig h t ............................ Turn signal lig h t s ....................... Instrument and warning lights .

12 V, 2.3 Ah 13 to 13.2 V 14 to 15 V(DC) 0.2 to 1.0 ohms 0.1 to 0.8 ohms 15 Amps 10 Amps 35/35 W 5W 21/5 W 10 W 2W

Torque w ren ch settings Cylinder head bolts ........................................... Crankcase b o lt s .................................................. Engine mounting b o lt s ...................................... Exhaust manifold n u t s ...................................... Exhaust system mounting b o lt s ..................... Alternator rotor nut .......................................... Alternator stator bolts ...................................... Variator centre n u t ............................................. Clutch centre n u t ............................................... Clutch assembly nut ........................................ Gearbox oil filler p lu g ........................................ Gearbox cover bolts ........................................ Rear shock absorber mountings Lower b o lt ......................................................... Upper b o lt ......................................................... Steering head bearing lo c k n u t........................ Handlebar stem bolt ........................................ Front fork leg clamp bolts Upper ................................................................ Lower ................................................................ Front fork leg bottom bolts ............................ Front axle n u t ...................................................... Rear hub nut ...................................................... Disc brake caliper mounting bolts ................. Disc mounting b o lts ...........................................

18 10 50 12 27 40 10 42 40 55 12 10

Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm

24 39 68 44

Nm Nm Nm Nm

26 Nm 18 Nm 20 Nm 58 Nm 118 Nm 32 Nm 42 Nm

..................................................................................................... 1- - ' "

E n g in e ................................................................................................. Cooling s y s te m .............................................................................. Fuel system .................................................................................. Ignition system .............................................................................. T ra n s m is s io n ..................................................................................... S u s p e n s io n ....................................................................................... B r a k e s ................................................................................................. Tyres ................................................................................................... W heelbase ....................................................................................... W e ig h t .................................................................................................

Ign itio n system

Engine Spark plug t y p e ................... Electrode g a p ....................... Idle speed (rp m )................... Engine o i l ...............................

124 cc single-cylinder four-stroke Liquid-cooled VK4AA CV carburettor CDI Variable speed automatic, belt-driven Telescopic front, swingarm with twin adjustable shock rear Disc front, drum rear 100/80 x 16 front, 120/80 x 16 rear 1335 mm 131 kg

....... .... ....

NGK CR8EH-9 0. 8 t o 0.9 mm 1500 rpm SAE 10W/40 four-stroke motorcycle oil 1.0 litre 52.4 x 57.8 mm 52.30 mm 52.44 mm

Oil capacity .......................... . . . . Bore x s tr o k e ....................... . . . . Piston diameter service limit . . . . Cylinder bore service lim it . . . . . Piston to bore clearance (service lim it ) ..................... . . . . 0.10 mm Piston ring installed end gap (standard/service limit) Top r i n g ..................... . . . . 0.15 to 0.30 mm/0.50 mm Second r in g ........................ ......... 0.30 to 0.45 mm/0.65 mm Oil control r in g ................... ......... 0.20 to 0.70 mm/0.90 mm Valve clearance Intake ................................. ......... 0.16 mm Exhaust ............................... ......... 0.25 mm Valve spring free length S ta n d a rd ............................ ......... 36.2 mm Service lim it ........................ ......... 34.4 mm Camshaft lobe height service limit Intake ................................. ......... 29.637 mm E x h a u s t............................... ......... 29.395 mm Coolant ................................. ......... 50% distilled water, 50% corrosion inhibiting ethylene glycol anti­ freeze Coolant capacity ................. ......... 0.95 litre

Honda’s specified testing procedure fo r the ignition system components requires specialist equipment not available to the DIY mechanic.

Transm ission Belt width service lim it ................. Variator rollers Standard d ia m e te r........................ Service lim it ................................... Clutch lining thickness service limit . Clutch spring free length (standard) ...................................... Gearbox oil ...................................... Gearbox oil capacity .....................

Disc brake Fluid type ................................... . Pad minim um th ic k n e s s ............ Disc thickness (service limit) . . Drum brake Drum internal diameter (service limit) .......................... Shoe lining minimum thickness . Brake lever fre e p la y ...................

21.5 mm 20.0 mm 19.5 mm 2 mm 143.3 mm SAE 90 hypoid gear oil 220 ml

DOT 4 To wear lim it indicator 3.5 mm

131 mm To wear limit indicator 15 to 25 mm

2 to 6 mm

112 35 1 7/8 turns out 18.2 mm

12 V, 6 Ah 14.5 to 15.3 V 15.5 V (DC) 0.1 to 0.5 ohms 0.1 to 0.5 ohms 30 Amps 2 x 15 and 5 x 10 Amps 55/55 W 5W 21/5 W 21 W 1.7 W

Torque w rench se ttin g s

Fuel system Throttle tw istgrip freeplay Main jet ............................ Pilot je t ............................ Pilot screw s e tt in g ......... Float h e ig h t .....................

Battery Capacity ...................................... Voltage (fully c h a rg e d ).............. Alternator O utput (regulated) ..................... Charging coil re sista nce ............ Lighting coil resistance ............ Fuse (m a in ),................................... Fuse (se co n d a ry).......................... Bulbs Headlight (m ain /dipp e d)............ Sidelight ...................................... Brake/tail lig h t ............................ Turn signal lig h t s ........................ Instrument and warning lights .

Tyre pressures Front ................................................. . R e a r.................................................

25 psi (1.75 par) 25 psi (1.75 bar)

Valve cover b o lt s ...................................... Cylinder head n u t s ................................... Cylinder head bolts ................................. Cam chain tensioner b o lt s ..................... Camshaft sprocket bolts ........................ Engine oil drain plug ............................... Engine mounting b o lt s ............................ Exhaust manifold n u t s ............................ Exhaust system mounting b o lt s ............ Water pump cover b o lt s .......................... Water pump impeller n u t ....................... Oil pump mounting b o l t s ....................... Thermostat cover bolts .......................... Alternator rotor nut ................................. Variator centre n u t ................................... Clutch centre n u t ...................................... Clutch assembly nut .............................. Crankcase b o lts ........................................ Gearbox oil filler p lu g .............................. Gearbox oil drain plug ............................ Gearbox cover bolts .............................. Rear shock absorber mountings Lower b o lt ............................................... Upper b o lt ............................................... Rear sub frame b o lt s .............................. Steering head bearing lo c k n u t.............. Handlebar stem bolt ............................... Front fork leg clamp bolts ............ Front axle n u t ............................................. Rear hub nut ............................................. Disc brake caliper mounting bolts . . . . Disc mounting b o lt s ................................. Brake hose banjo bolts ..........................

____ ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ .... ____ ____

12 Nm 27 Nm 12 Nm 12 Nm 9 Nm 20 Nm 49 Nm 9 Nm 49 Nm 12 Nm 12 Nm 12 Nm 10 Nm 116 Nm 59 Nm 49 Nm 54 Nm 12 Nm 13 Nm 27 Nm 27 Nm

____ ____ ____ ____ ____ ____ .... ____ ____ ____ ____

25 Nm 39 Nm 40 Nm 68 Nm 39 Nm 40 Nm 68 Nm 118 Nm 30 Nm 42 Nm 34 Nm

Honda SZX50 (X8R-S and X8R-X) E n g in e ................................................................................................. Cooling s y s te m .............................................................................. Fuel system ................................................................................... Ignition s y s te m .............................................................................. T ra n s m is s io n ..................................................................................... S u s p e n s io n ....................................................................................... B r a k e s ................................................................................................ Tyres Model S ......................................................................................... Model X ......................................................................................... W heelbase ....................................................................................... W eight ( d r y ) ....................................................................................... Fuel ta n k ca pa city .........................................................................

Data 18

49 cc single-cylinder two-stroke Air-cooled PHVA 12FS slide carburettor CDI Variable speed automatic, belt-driven Telescopic front, swingarm with single shock rear Single disc front, single disc rear 120/70 x 13 front, 140/60 x 13 rear 120/80 x 12 front, 120/80 x 12 rear 1265 mm 97 kg 6 litres

Electrical system Battery Capacity ........................................ Voltage (fully c h a rg e d )................. Alternator Output (regulated) ........................ Charging coil resistance.............. Fuse (main) ...................................... Fuse (se co n d a ry)............................ Bulbs Headlight (m ain /dipp e d).............. Sidelight ........................................ Brake/tail l i g h t ............................... Turn signal lig h ts .......................... Instrument and warning lights . .

12 V, 2.3 Ah 13 to 13.2 V 14 to 15 V (DC) 0.7 to 1.1 ohms 15 Amps 10 Amps 25/25 W 5W 21/5 W 10 W 2W

Transm ission Spark plug t y p e .............................. Electrode g a p ................................... Idle speed (rp m ).............................. Bore x s t r o k e ................................... Piston diameter (service limit) . . . . Cylinder diameter (service limit) . . Piston to bore clearance (service lim it ) ................................. Piston ring installed end gap S ta n d a rd ........................................ Service lim it ...................................

Throttle tw istgrip fre e p la y .............. Main je t ............................................. Pilot je t ............................................. Needle type / position ................... Pilot screw s e tt in g .......................... Float height ...................................... Automatic choke re s is ta n c e .........

NGK BR6HSA 0.6 to 0.7 mm 1800 rpm 39.0 x 41.4 mm 38.90 mm 39.05 mm 0.10 mm 0.10 to 0.25 mm 0.40 mm

2 to 6 mm 72 35 A30 (2nd notch) 3 turns out 14.3 mm 3.2 to 5.6 ohms

Belt width (service lim it ) ......... Variator rollers diameter S ta n d a rd ................................. Service lim it ............................. Clutch lining thickness (service lim it ) .......................... Clutch spring free length (service lim it ) .......................... Gearbox oil ............................... Gearbox oil capacity ..............

...

17 mm

... ...

15.92 to 16.08 mm 15.40 mm

...

2 mm

... ... ...

92.8 mm SAE 10W-40 oil 100 ml

Disc brake Fluid type ...................................... Disc thickness (service limit) Front ........................................... R e a r.............................................

DOT 4 3.0 mm 2.5 mm

Tyre pressures

HT coil primary resistance ............ HT coil secondary resistance . . . .

0.1 to 0.3 ohm 6.5 to 9.7 K-ohms

S p a r k p lu g c a p r e s i s t a n c e ............... Pick-up coil resistance ...............

3 . 8 t o 6 . 2 K -o h m s S Oto 200 ohm s

F ro n t. • Model S .......................... .............. Model X .......................... .............. Rear Model S .......................... Model X .......................... ..................

25 psi (1.75 bar) 18 psi (1.25 bar) 25 psi (1.75 bar)

Cylinder head bolts ........................................... Crankcase b o lts ................................................. Engine mounting b o lt ........................................ Exhaust manifold n u t s ...................................... Exhaust system mounting b o lt s ..................... Alternator rotor nut .......................................... Variator centre n u t ............................................. Clutch centre n u t ............................................... Clutch assembly nut ........................................ Gearbox oil filler p lu g ........................................ Gearbox oil drain plug ...................................... Rear shock absorber mountings Lower b o lt ......................................................... Upper b o lt ......................................................... Steering head bearing lo c k n u t........................ Handlebar stem bolt ........................................ Front fork leg clamp bolts ............ .............. Front axle n u t ...................................................... Rear wheel n u ts ................................................. Rear hub nut ...................................................... Disc brake caliper mounting bolts ................ Disc mounting b o lt s ..........................................

10 10 50 16 32 40 42 40 55 12 12

Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm

26 Nm 18 Nm 78 Nm 44 Nm 39 Nm 59 Nm 64 Nm 118 Nm 31 Nm 42 Nm

Brake hose banjo bolts ............................................

30 N m

Data 19

Malaguti F12 50 Phantom air-cooled 50cc E n g in e ................................................................................................. Cooling s y s te m .............................................................................. Fuel system ................................................................................... Ignition s y s te m .............................................................................. T ra n s m is s io n ..................................................................................... S u s p e n s io n ....................................................................................... B r a k e s ................................................................................................ Tyres ................................................................................................... W heelbase ....................................................................................... W eight (d r y ) ....................................................................................... Fuel ta n k ca pa city .........................................................................

Spark plug t y p e .......................... . .

.

NGK BR8HS or Champion RL 78/C 0.5 to 0.6 mm 1600 to 1800 rpm 0 8 City Bike Ultra 1.4 litres 40.0 x 39.2 mm 39.97 mm ' None 0.034 mm 0.047 mm 0.15 to 0.35 mm

Belt width S ta n d a rd ................................. Service lim it ............................. Variator rollers Standard d ia m e te r................. Service lim it ............................. Clutch lining thickness S ta n d a rd ................................. Service lim it ............................. Clutch spring free length S ta n d a rd ................................. Service lim it ............................. Gearbox oil capacity ..............

... ...

16.8 mm 15.5 mm

... ...

15.0 mm 14.5 mm

... ...

4.0 mm 2.5 mm

... ... ...

121.7 mm 106.7 mm 120 ml

Fuel system Throttle twistgrip fre e p la y ......... Main jet ........................................ Pilot jet ........................................ Starter j e t ...................................... Needle t y p e ..........................

. . . .

1 to 3 mm 78 38 48 F12

Disc brake Fluid type ...................................... Pad minim um th ic k n e s s .............. Disc minim um thickness ............ Drum brake Brake lining minim um thickness . Brake lever fre e p la y .....................

DOT 4 2.0 mm 2.0 mm 2 mm 10 mm

Ignition system HT coil primary resistance . . . . HT coil secondary resistance . . Spark plug cap resistance . . . . Pick-up coil re sista nce ..............

E lectrical system Battery Capacity ................................. Alternator Output (unregulated) ............ Charging coil resistance . . . . Lighting coil resistance . . . . Fuse (main) ............................... Bulbs Headlight (main/dipped) . . . . Sidelight ................................. Brake/tail lig h t ........................ Turn signal lig h ts ................... Instrument lights ................... Warning lig h ts ........................

...

12 V, 4 Ah

... ... ... ...

55 V (AC) 0.80 ohms 0.60 ohms 10 Amps

... ... . .. ... ... ...

35/35 W 5W 21/5 W 1 0W 1.2 W LED panel

Transm ission

Engine

Electrode g a p ............................... Idle speed (rp m ).......................... Engine o i l ...................................... Oil tank capacity ........................ Bore x s tr o k e ............................... Piston diameter (standard) . . . . Piston oversizes available . . . . Piston to bore clearance S ta n d a rd ................................... Service lim it ............................... Piston ring installed end gap . .

49 cc single-cylinder two-stroke Air-cooled Dell’Orto PHVA 12 slide carburettor CDI Variable speed automatic, belt-driven Telescopic forks front, swingarm with single adjustable shock rear 190 mm disc front, 110 mm drum or 190 mm disc rear 120/70 x 12 front, 130/70 x 12 rear 1240 mm 88 kg 8.5 litres

0.30 to 0.50 ohm 4.2 to 5.2 K-ohms 5.3 K-ohms 116 to 118 ohms

I Tyre pressures Front ................................. .............. R e a r................................... ..............

26 psi (1.8 bar) 28 psi (1.9 bar)

Torque w ren ch se ttin g s Cylinder head n u t s ............................................. Crankcase b o lt s ................................................. Engine mounting b o lt s ...................................... Intake manifold b o l t s ........................................ Exhaust manifold n u t s ...................................... Exhaust system mounting bolts 8 m m .................................................................. 6 m m .................................................................. Oil pump mounting b o lt s .............. .............. Alternator rotor nut .......................................... Alternator stator bolts ...................................... Variator centre n u t ............................................. Clutch centre n u t ............................................... Clutch assembly nut ........................................ Gearbox oil filler p lu g ........................................ Gearbox oil drain p l u g ...................................... Gearbox cover bolts ........................................ Rear shock absorber Upper mounting b o l t ...................................... Lower mounting b o l t ...................................... Steering head bearing adjuster locknut . . . . Handlebar stem bolt ........................................ Front axle ........................................................... Front axle pinch-bolt ........................................ Rear hub nut ...................................................... Disc brake caliper mounting bolts ................ Brake hose banjo bolts ...................................

15 Nm 12 Nm 62 Nm 8 Nm 8 Nm 25 Nm 8 Nm 4 Nm 38 Nm 9 Nm 33 Nm 40 Nm 50 Nm 12 Nm 12 Nm 12 Nm 40 Nm 24 Nm 140 Nm 50 Nm 45 Nm 24 Nm 100 Nm 30 Nm 28 Nm

DATA

Malaguti F12 50 Phantom liquid-cooled E n g in e ................................................................................................. Cooling s y s te m .............................................................................. Fuel system .................................................................................. Ignition s y s te m .............................................................................. T ra n s m is s io n ..................................................................................... S u s p e n s io n ....................................................................................... B r a k e s ................................................................................................. Tyres ................................................................................................... W heelbase ....................................................................................... W eight ( d r y ) ....................................................................................... Fuel ta n k ca pa city .........................................................................

Engine Spark plug t y p e .......................... . . Electrode g a p ............................... Idle speed (rp m ).......................... Engine o i l ...................................... . . Oil tank capacity ........................ Bore x s tr o k e ............................... Piston diameter (standard) . . . . Piston oversizes available . . . . Piston to bore clearance S ta n d a rd ................................... Service lim it ............................... Piston ring installed end gap . . Coolant ........................................ . .

Coolant capacity ........................ . .

Data 20

49 cc single-cylinder two-stroke Liquid-cooled Dell’Orto PHVA 12 slide carburettor CDI Variable speed automatic, belt-driven Telescopic forks front, swingarm with single adjustable shock rear 190 mm disc front, 110 mm drum or 190 mm disc rear 120/70 x 12 front, 130/70 x 12 rear 1240 mm 92 kg 8.5 litres

Ign itio n system NGK BR8HS or Champion RL 78/C 0.5 to 0.6 mm 1600 to 1800 rpm 0 8 City Bike Ultra 1.4 litres 40.0 x 39.2 mm 39.97 mm None 0.029 mm 0.042 mm 0.15 to 0.35 mm 50% distilled water, 50% corrosion inhibiting ethylene glycol anti-freeze 1.1 litres

Fuel system Throttle twistgrip fre e p la y .......... Main jet ........................................ . . Pilot jet ................................................. . .

1 to 3 mm 78 38

Starter jet..............................................

48

HT coil prim ary resistance ............ HT coil secondary resistance Spark plug cap resistance ............ Pick-up coil re sis ta n c e ...................

0.30 to 0.50 ohm 4.2 to 5.2 K-ohms 5.3 K-ohms 116 to 118 ohms

Transm ission Belt width S ta n d a rd ........................................ Service lim it ................................... Variator rollers Standard d ia m e te r........................ Service lim it .................................... Clutch lining thickness S ta n d a rd ........................................ Service lim it ............................... Clutch spring free length S ta n d a rd ........................................ Service lim it ................................... Gearbox oil capacity .....................

Disc brake Fluid type ...................................... Pad minim um th ic k n e s s .............. Disc minim um thickness ............ Drum brake Brake lining minimumthickness .

16.8 mm 15.5 mm 15.0 mm 14.5 mm 4.0 mm 2.5 mm 121.7 mm 106.7 mm 120 ml

DOT 4 2.0 mm 2.0 mm 2m m

Tyre pressures Front ................................. .............. R e a r................................... ..............

26 psi (1.8 bar) 28 psi (1.9 bar)

E le ctrical system Battery Capacity ........................................ Alternator Output (unregulated) ................... Charging coil re sista nce .............. Lighting coil resistance .............. Fuse (main) ...................................... Bulbs Headlight (m ain/dipped).............. Sidelight ........................................ Brake/tail lig h t ............................... Turn signal lig h t s .......................... Instrument lights .......................... Warning lig h t s ...............................

12 V, 4 Ah 55 V (AC) 0.80 ohms 0.60 ohms 10 Amps 35/35 W 5 W 21/5 W 10 W 1.2 W LED panel

Cylinder head n u t s ............................................. Crankcase b o lt s .................................................. Engine mounting b o lt s ...................................... Intake manifold b o lt s ........................................ Exhaust manifold n u t s ...................................... Exhaust system mounting bolts 8 m m .................................................................. 6 m m .................................................................. Oil pump mounting b o l t s ................................. Alternator rotor nut ........................................... Alternator stator bolts ...................................... Variator centre n u t ............................................. Clutch centre n u t ............................................... Clutch assembly nut ........................................ Gearbox oil filler p lu g ........................................ Gearbox oil drain p l u g ...................................... Gearbox cover bolts ........................................ Rear shock absorber mounting Upper b o lt ......................................................... Lower b o lt ......................................................... Steering head bearing adjuster locknut . . . . Handlebar stem bolt ........................................ Front axle ........................................................... Front axle pinch-bolt ........................................ Rear hub nut ......................................................

40 Nm 24 Nm 140 Nm 50 Nm 45 Nm 24 Nm 100 Nm

D is c b r a k e c a lip e r m o u n tin g b o lts

3 0 Nm

....................

15 Nm 12 Nm 62 Nm 8 Nm 8 Nm 25 Nm 8 Nm 4 Nm 38 Nm 9 Nm 33 Nm 40 Nm 50 Nm 12 Nm 12 Nm 12 Nm

Data 21

Malaguti F12 50 Spectrum E n g in e ................................................................................................. Cooling s y s te m ................................... .......................................... Fuel system .................................................................................. Ignition s y s te m ................................. \ ......................................... T ra n s m is s io n ..................................................................................... S u s p e n s io n ....................................................................................... B r a k e s ................................................................................................ Tyres ................................................................................................... W heelbase ....................................................................................... W e ig h t ................................................................................................ Fuel ta n k ca pa city .........................................................................

49 cc single-cylinder two-stroke Liquid-cooled DelPOrto PHVA 12 slide carburettor CDI Variable speed automatic, belt-driven Telescopic forks front, swingarm with single adjustable shock rear 200 mm disc front, 190 mm disc rear 120/70 x 12 front, 130/70 x 12 rear 1240 mm 86 kg 8.5 litres

Ign itio n system Spark plug t y p e ...............................

NGK BR8HS or Champion RL 78/C 0.5 to 0.6 mm 1600 to 1800 rpm Q8 City Bike Ultra 1.6 litres 40.0 x 39.2 mm 39.97 mm None

Electrode g a p ................................... Idle speed (rp m )............................... Engine o i l .......................................... Oil tank capacity ............................ Bore x s tr o k e ................................... Piston diameter (s ta n d a rd )............ Piston oversizes available ............ Piston to bore clearance S ta n d a rd ........................................ 0.029 mm Service lim it ................................... 0.042 mm Piston ring installed end gap . . . . 0.15 to 0.35 mm Coolant ............................................. 50% distilled water, 50% corrosion inhibiting ethylene glycol anti-freeze Coolant capacity ............................ 1.1 litres

HT coil primary resistance . . . . HT coil secondary resistance . . Spark plug cap resistance . . . . Pick-up coil re sis ta n c e ..............

0.30 to 0.50 ohm 4.2 to 5.2 K-ohms 5.3 K-ohms 116 to 118 ohms

Transm ission Belt width S ta n d a rd ................................. Service lim it ............................. Variator rollers Standard d ia m e te r................ Service lim it ............................ Clutch lining thickness S ta n d a rd ................................. Service lim it ............................ Clutch spring free length S ta n d a rd ................................. Service lim it ............................ Gearbox oil capacity ..............

...

16.8 mm 15.5 mm

... ...

15.0 mm 14.5 mm

... . ..

4.0 mm 2.5 mm

... ... ...

121.7 mm 106.7 mm 110 ml

Fuel system Throttle twistgrip freeplay . . . . Main je t ...................................... Pilot je t ...................................... Starter j e t ................................... Needle t y p e ...............................

... . .. . .. ... .. .

1 t o 3 mm 78 38 48 F12

Disc brake Fluid type ............................... . . Pad minim um thickness . . . . Disc minim um thickness . . .

DOT 4 2. 0 mm 2.0 mm

Tyre pressures Front ................................................. R e a r....................................................

26 psi (1.8 bar) 28 psi (1.9 bar)

E lectrical system ^322 Battery Capacity ........................................ Alternator Output (unregulated) ................... Charging coil resistance.............. Lighting coil resistance .............. Fuse (main) ...................................... Bulbs Headlight (m ain /dipp e d).............. Sidelight ........................................ Brake/tail lig h t ............................... Turn signal lig h t s .......................... Instrument lights .......................... Warning lig h ts ...............................

12 V, 4 Ah 55 V (AC) 0.80 ohms 0.60 ohms 10 Amps 35/35 W 5W 21/5 W 10W 1.2 W LED panel

Cylinder head n u ts ............................................. Crankcase b o lts ................................................. Engine mounting b o lt ........................................ Intake manifold b o lt s ........................................ Exhaust manifold n u t s ...................................... Exhaust system mounting bolts 8 m m .................................................................. 6 m m .................................................................. Oil pump mounting b o l t s ................................. Alternator rotor nut .......................................... Alternator stator bolts ...................................... Variator centre n u t ............................................. Clutch centre n u t ............................................... Clutch assembly nut ........................................ Gearbox oil filler p lu g ........................................ Gearbox oil drain p l u g ...................................... Gearbox cover bolts ........................................ Rear shock absorber Upper mounting b o l t ...................................... Lower mounting b o l t ..................................... Steering head bearing adjuster locknut . . . . Handlebar stem bolt ........................................ Front axle ........................................................... Front axle pinch-bolt ........................................ Rear hub nut ...................................................... Disc brake caliper mounting bolts ................ Brake hose banjo bolts ...................................

15 Nm 12 Nm 62 Nm 8 Nm 8 Nm 25 Nm 8 Nm 4 Nm 38 Nm 9Nm 33 Nm 40 Nm 50 Nm 12 Nm 12 Nm 12 Nm 40 Nm 24 Nm 140 Nm 50 Nm 45 Nm 24 Nm 100 Nm 30 Nm 28 Nm

Malaguti F15 50 Firefox E n g in e ................................................................................................ Cooling s y s te m .............................................................................. Fuel system .................................................................................. Ignition s y s te m .............................................................................. T ra n s m is s io n ..................................................................................... S u s p e n s io n ....................................................................................... B r a k e s ................................................................................................ Tyres ................................................................................ .................. W heelbase ....................................................................................... W eight ( d r y ) ....................................................................................... Fuel ta n k ca pa city .........................................................................

Data 22 49 cc single-cylinder two-stroke Liquid-cooled Dell’Orto PHVA 12 slide carburettor CDI Variable speed automatic, belt-driven Telescopic forks front, swingarm with single adjustable shock rear 190 mm disc front, 110 mm drum o r 190 mm disc rear 120/70 x 12 front, 130/70 x 12 rear 1268 mm 96 kg 7.0 litres

Ign itio n system Spark plug t y p e ...............................

NGK BR8HS or Champion RL 78/C 0.5 to 0.6 mm 1600 to 1800 rpm Q8 City Bike Ultra 1.6 litres 40.0 x 39.2 mm 39.97 mm None

Electrode g a p ................................... Idle speed (rp m )............................... Engine o i l .......................................... Oil tank capacity ............................ Bore x s tr o k e ................................... Piston diameter (s ta n d a rd )............ Piston oversizes available ............ Piston to bore clearance S ta n d a rd ........................................ 0.029 mm Service lim it ................................... 0.042 mm Piston ring installed end gap . . . . 0.15 to 0.35 mm Coolant ............................................. 50% distilled water, 50% corrosion inhibiting ethylene glycol anti-freeze Coolant capacity ............................ 1.1 litres

T h ro ttle tw is tg r ip f r e e p la y . M a in je t .............................. P ilo t je t ...................................... Starter je t...................................

1 to 3 m m 78

HT coil primary resistance . . . . HT coil secondary resistance . . Spark plug cap resistance . . . . Pick-up coil re sis ta n c e ..............

0.30 to 0.50 ohm 4.2 to 5.2 K-ohms 5.3 K-ohms 116 to 118 ohms

Transm ission Belt width S ta n d a rd ................................. Service lim it ............................ Variator rollers Standard d ia m e te r................. Service lim it ............................. Clutch lining thickness S ta n d a rd ................................. Service lim it ............................. Clutch spring free length S ta n d a rd ................................. Service lim it ............................. Gearbox oil capacity ..............

... ...

16.8 mm 15.5 mm

... ...

15.0 mm 14.5 mm

... ...

4.0 mm 2.5 mm

... ... ...

121.7 mm 106.7 mm 110 ml

D is c b r a k e F lu id t y p e .................................. P a d m in im u m t h i c k n e s s ........... D is c m in im u m t h i c k n e s s ......... Drumbrake Brake lining m inim umthickness .

DOT 4

2 .0 m m 2 .0 m m

Tyre pressures Front ................................................. R e a r....................................................

26 psi (1.8 bar) 28 psi (1.9 bar)

E lectrical system Capacity ........................................ Alternator Output (unregulated) ................... Charging coil re sista nce .............. Lighting coil resistance .............. Fuse (main) ...................................... Bulbs Headlight (m ain /dipp e d).............. Sidelight ........................................ Brake/tail l i g h t ............................... Turn signal lig h t s .......................... Instrument lights .......................... Warning lights ...............................

12 V, 4 Ah 55 V (AC) 0.80 ohms 0.60 ohms 10 Amps 35/35 W 5W 21/5 W 10W 1.2 W LED panel

Cylinder head n u t s ............................................. Crankcase b o lt s ................................................. Engine mounting b o lt ........................................ Intake manifold b o l t s ........................................ Exhaust manifold n u t s ...................................... Exhaust system mounting bolts 8 m m .................................................................. 6 m m .................................................................. Oil pump mounting b o l t s ................................. Alternator rotor nut ........................................... A lternator stator bolts ...................................... Variator centre n u t ............................................. Clutch centre n u t ............................................... Clutch assembly nut ........................................ Gearbox oil filler p lu g ........................................ Gearbox oil drain p l u g ...................................... Gearbox cover bolts ........................................ Rear shock absorber Upper mounting b o l t ...................................... Lower mounting b o l t ...................................... Steering head bearing adjuster locknut . . . . Handlebar stem bolt ........................................ Front axle ........................................................... Front axle pinch-bolt ........................................ Rear hub nut ......................................................

40 Nm 24 Nm 140 Nm 50 Nm 45 Nm 24 Nm 100 Nm

D is c b r a k e c a lip e r m o u n tin g b o lts

30 Nm

....................

15 Nm 12 Nm 62 Nm 8 Nm 8 Nm 25 Nm 8 Nm 4 Nm 38 Nm 9 Nm 33 Nm 40 Nm 50 Nm 12 Nm 12 Nm 12Nm

E n g in e ................................................................................................. Cooling s y s te m .............................................................................. Fuel system ................................................................................... Ignition system .............................................................................. T ra n s m is s io n ..................................................................................... S u s p e n s io n ....................................................................................... B r a k e s ................................................................................................. Tyres ................................................................................................... W heelbase ....................................................................................... W e ig ht ( d r y ) ....................................................................................... Fuel ta n k c a p a city .........................................................................

Single-cylinder four-stroke Liquid-cooled Teikei 224V - YD CV carburettor CDI Variable speed automatic, belt-driven Telescopic forks front, swingarm with twin adjustable shock rear 240 mm disc front, 220 mm disc rear 120/70 x 13 front, 130/60 x 13 rear 1445 mm 150 kg 12 litres

Fuel system Spark plug t y p e ............................... Electrode g a p ................................... Idle speed (rp m )............................... Engine o i l ...........................................

NGK CR8E 0.6 to 0.7 mm 1600 to 1800 rpm 10W 40 four-stroke motorcycle oil 1.4 litres

Oil capacity ...................................... Bore x stroke 125 c c ............................................. 53.7 x 54.8 mm 150 c c ............................................. 59.5 x 54.8 mm Cylinder bore service lim it ............ + 0.05 mm Piston to bore clearance S ta n d a rd ........................................ 0.025 to 0.035 mm Service lim it ................................... 0.15 mm Piston ring installed end gap (standard/service limit) 125 cc Top r i n g ...................................... 0.15 to 0.25 mm/ 0.40 to 0.45 mm Second r i n g ............................... 0.15 to 0.30 m m / 0.45 to 0.60 mm 150 cc Top r i n g ...................................... 0.15 to 0.30 m m / 0.40 to 0.45 mm Second r i n g ............................... 0.30 to 0.45 m m / 0.45 to 0.60 mm Oil control r in g ............................... 0.20 to 0.70 mm Valve clearance Intake ............................................. 0.10 to 0.14 mm E x h a u s t.......................................... 0.16 to 0.20 mm Valve spring free length service lim it ................................... 39.84 mm Camshaft lobe height service lim it 30.711 mm Coolant ............................................. 50% distilled water, 50% corrosion inhibiting ethylene glycol anti-freeze Coolant capacity ............................ 1 litre

Throttle twistgrip fre e p la y .............. Carburettor type ............................ Main je t 1 .......................................... Pilot je t ............................................. Starter je t ........................................ Needle t y p e ...................................... Pilot screw setting (turns out) Float height ...................................... Fuel level ..........................................

1 to 5 mm 125 c c 150 cc 5DS 5KD 116 114 39 36 50 47 4E31 4E32 2 1/3 3 27 mm 27 mm 5 to 6 mm below joint

Ignition system HT coil primary resistance ............ HT coil secondary resistance Pick-up coil re sista n ce ...................

0.40 to 0.60 ohm 7.5 to 8.5 K-ohms 110 to 115 ohms

T ransm ission Belt width Standard (service limit) .............. Variator rollers Standard dia. (service limit) ; . . . Recommended lu b r ic a n t............ Clutch lining thickness (service lim it ) ................................. Gearbox oil ...................................... Gearbox oil capacity .....................

22.0 mm (19.8 mm) 20.0 mm (19.5 mm) Shell BT No 3 1.0 mm T35 80W 140 ml

B rakes Disc brake Fluid type ...................................... Pad minimum th ic k n e s s .............. Disc thickness (service limit) . . . Drum brake Shoe lining minim um thickness . Brake lever fre e p la y .....................

DOT 4 2.0 mm 2.0 mm 2 mm 10 mm

e xpe rt2 2 arm http://rutracker.org

Front ........................ R e a r..........................

..................... .....................

29 psi (2.0 bar) 29 psi (2.0 bar) Solo, 32 psi (2.2 bar) with pillion

E le ctrical system Battery Capacity ................................. Alternator Output (unregulated) ............ Output (re g u la te d )................. Lighting coil resistance Fuse (main) ............................... Fuse (s e c o n d a ry )..................... Bulbs Headlight (main/dipped) Sidelight ................................. Brake/tail lig h t ........................ Turn signal lig h t s ................... Instrument l i g h t ..................... Warning lig h t s ........................

...

12 V, 9 Ah

... ... ... ... ...

85 to 90 V (AC) 13.5 V (DC) 0.8 to 0.9 ohms 15 Amps 5 Amps

... ... ... ... ... ...

35/35 W 3W 21/5 W 10W 2 W 1.2 W

Torque w rench settings Cylinder head n u t s ................................... Cylinder head bolts ................................. Cam chain tensioner cap bolt .............. Cam chain tensioner b o lt s ..................... Camshaft sprocket b o l t .......................... Engine mounting b o lt ............................... Intake manifold b o l t s ............................... Exhaust manifold n u t s ............................ Exhaust system mounting b o lt s ............ Alternator rotor nut ................................. Variator centre n u t ................................... Clutch centre n u t ...................................... Clutch assembly nut ............................... Crankcase b o lt s ........................................ Gearbox oil drain p lu g ............................ Gearbox cover bolts ............................... Rear shock absorber Upper mounting b o l t ............................ Lower mounting b o l t ............................ Rear sub frame b o lt s ............................... Steering head bearing lo c k n u t.............. Handlebar stem bolt ............................... Handlebar clamp b o lts ............................ Front fork leg clamp bolts ..................... Front fork leg bottom bolts ................... Front axle ................................................. Rear hub nut ............................................. Disc brake caliper mounting bolts . . . . Brake hose banjo bolts ..........................

____ ____ .... ____ ____ ____ .:.. .... ____ ____ ____ ____ ____ ____ ____ ____

22 Nm 12 Nm 8 Nm 10 Nm 25 Nm 32 Nm 10 Nm 8 Nm 42 Nm 70 Nm 55 Nm 60 Nm 90 Nm 10 Nm 22 Nm 16 Nm

.... ____ ____ ____ ____ ____ ... . ____ ____ ____ ____ ____

45 Nm 24 Nm 23 Nm 140 Nm 50 Nm 30 Nm 32 Nm 24 Nm 45 Nm 100 Nm 30 Nm 28 Nm

DATA

Data 24

Peugeot Elyseo 50 E n g in e ................................................................................................ Cooling s y s te m .............................................................................. Fuel system .................................................................................. Ignition s y s te m .............................................................................. T ra n s m is s io n ..................................................................................... S u s p e n s io n ....................................................................................... B r a k e s ................................................................................................ Tyres ................................................................................................... W heelbase ....................................................................................... W e ig h t................................................................................................ Fuel tan k ca pa city .........................................................................

49 cc single-cylinder two-stroke Air-cooled Gurtner PA390 slide carburettor CDI Variable speed automatic, belt-driven Upside down telescopic front, swingarm with single shock rear 190 mm disc front, 110 mm drum rear 120/70 x 12 front, 130/70 x 12 rear 1360 mm 99 kg 8.3 litres

Ign itio n system

Engine Spark plug t y p e ........................ Electrode g a p ............................ Idle speed (rp m )........................ Engine o i l ...................................

.. .. .. ..

. . . .

Oil tank capacity ..................... Bore x s tr o k e ............................ Piston diameter (standard) . . . Piston to bore clearance S ta n d a rd ................................. Piston rings Installed end g a p ...................

... ... ...

NGK BR7HS 0.6 mm 1600 rpm JASO FC, SAE 20 semi-synthetic 1.3 litres 40.0 x 39.1 mm 39.85 mm

...

0.15 mm

...

0.20 to 0.35 mm

HT coil primary re s is ta n c e ......... HT coil secondary resistance . . . Spark plug cap resistance ......... Source coil resistance AEC 400 system ........................ AC I 100 s y s te m .......................... Pick-up coil re sis ta n c e ................ Immobiliser transponder aerial resistance ...................................

N e e d le t y p e / p o s itio n .................. screw setting ................................

2 to 5 mm 72 42 45

L 3 0 3 5 H (to p n o tch ) 11/8 turns out

0.44 to 0.66 K-ohms 0.64 to 0.96 ohms 102 to 138 ohms 13.6 to 20.4 ohms

T ransm ission Variator rollers Standard d ia m e te r................. Recommended lubricant . . . . . Clutch spring free length . . . . Gearbox oil ............................... Gearbox oil capacity .............. . .

Throttle tw istgrip fre e p la y .............. Main jet ............................................. Pilot je t ............................................. Starter j e t ..........................................

0.15 to 0.25 ohm 3.6 to 4.5 K-ohms 4.5 to 5.5 K-ohms

Disc brake Fluid type ............................... Pad minim um thickness Disc thickness Standard ............................ Service lim it ...................

D ru m b r a k e D ru m in te rn a l d ia m e te r B r a k e s h o e lin in g t h ic k n e s s Standard

..........................

16 mm Esso SKF LGHT 3/0.4 103.5 mm 80W-90 scooter gear oil 120 ml

DOT 4 1.5 mm 3.5 mm 3.0 mm

I Tyre pressures Front ................................. .............. R e a r................................... ..............

19 psi (1.3 bar) 23 psi (1.6 bar)

E le ctrical system Battery Capacity ...................................... Voltage (fully c h a rg e d ).............. Alternator Output (unregulated) ................ Output (regulated) ..................... Charging coil re sista nce ............ Lighting coil resistance ............ Fuse (main) ................................... Bulbs Headlight (m ain /dipp e d)............ Sidelight ...................................... Brake/tail lig h t ............................ Turn signal lig h t s ....................... Instrument and warning lights .

. .

12 V, 4 Ah 14 to 15 V

. .

.

18 to 22 V (AC) 14 to 15 V (DC) 0.64 to 0.96 ohms 0.48 to 0.72 ohms 5 Amps

. . . . .

35/35 W 5W 21/5 W 10 W 1.2 W

Torque w rench se ttin g s Cylinder head bolts ........................................ Crankcase b o lts ............................................... Engine mounting b o lt ...................................... Intake manifold b o l t s ...................................... Exhaust manifold n u t s ................................... Exhaust system mounting b o lt s ................... Oil pum p mounting b o l t s .............. ................ . Alternator rotor nut .................•...................... Alternator stator bolts ................................... Variator centre n u t .......................................... Clutch centre n u t ............................................. Clutch assembly nut ...................................... Gearbox oil filler p lu g ...................................... Gearbox oil drain plug ................................... Gearbox cover bolts ...................................... Shock absorber mountings (front and rear) Lower b o lt ...................................................... Upper b o lt ...................................................... Steering head bearing adjuster nut Initial setting ................................................. Final s e ttin g .................................................... Steering head bearing lo c k n u t..................... Handlebar stem bolt ...................................... Front axle n u t .................................................... Rear hub n u t .................................................... . Disc brake caliper mounting bolts .................

15 Nm 12 Nm 60 Nm 10 Nm 16 Nm 25 Nm 8 Nm 40 Nm 10 Nm 40 Nm 45 Nm 50 Nm 12 Nm 12 Nm 10 Nm 25 Nm 50 Nm 40 Nm 23 Nm 80 Nm 40 Nm 70 Nm 120 Nm as 32

: £ ________

!

Peugeot Elyseo 100 E n g in e ................................................................................................ Cooling s y s te m .............................................................................. Fuel system .................................................................................. Ignition s y s te m .............................................................................. T ra n s m is s io n ..................................................................................... S u s p e n s io n ....................................................................................... B r a k e s ................................................................................................. Tyres ................................................................................................... W heelbase ....................................................................................... W e ig h t ................................................................................................ Fuel ta n k ca pa city .........................................................................

Oil tank capacity ..................... Bore x s t r o k e ............................ Piston diameter (standard) . . . Piston to bore clearance S ta n d a rd ................................. Piston rings Installed end g a p ...................

99 cc single-cylinder two-stroke Air-cooled DelPOrto 17.5 ES slide carburettor CDI Variable speed automatic, belt-driven Telescopic front, swingarm with single shock rear 226 mm disc front, 110 mm drum rear 120/70 x 12 front, 130/70 x 12 rear 1368 mm 113 kg 8.3 litres

Transm ission

Engine Spark plug t y p e ........................ Electrode g a p ............................ Idle speed (rp m )........................ Engine o i l ...................................

Data 25

. .. .. . .. . ... ... ... ...

NGK BR8ES 0.6 mm 1600 rpm JASO FC, SAE 20 semi-synthetic 1.3 litres 50.6 x 49.7 mm 50.45 mm

...

0.15 mm

...

0.30 to 0.45 mm

Variator rollers Standard diameter (models up to 1999) Standard diameter (2000-on m o d e ls ).............. Recommended lubricant . . . Clutch spring free length . . . . Gearbox oil ............................... Gearbox oil capacity ..............

...

19 mm

.. .. .. .. ..

. . . . .

18 mm Esso SKF LGHT 3/0.4 105.5 mm 80W-90 scooter gear oil 120 ml

.

DOT 4 1.5 mm

Fuel system Throttle twistgrip fre e p la y ......... Main je t ........................................ Pilot je t ........................................ Starter j e t ...................................... Needle type / position .............. Pilot screw s e tt in g ..................... Float height ................................. Automatic choke resistance . . .

.. .. .. ..

2 to 5 mm 81 30 65 A11 (2nd notch from top) 2 turns out Not adjustable approx. 5.0 ohms @ 20°C

Ignition system HT coil primary resistance ......... HT coil secondary resistance . . . Spark plug cap resistance ......... Source coil resistance AEC 400 system . . . AC1100 system . . . Pick-up coil resistance . . . Immobiliser transponder aerial resistance ................ .

0.15 to 0.25 ohm 3.6 to 4.5 K-ohms 4.5 to 5.5 K-ohms

Disc brake Fluid type ................................. Pad minimum th ic k n e s s ......... Disc thickness Standard ............................... Service lim it .......................... Drum brake Drum internal diameter ......... Brake shoe lining thickness Standard ............................... Brake lever fre e p la y .................

0.44 to 0.66 K-ohms 0.64 to 0.96 ohms 102 to 138 ohms

Tyre pressures

13.6 to 20.4 ohms

Front ............................................. R e a r...............................................

4.0 mm 3.5 mm 110 mm 4 mm 10 to 20 mm

19 psi (1.3 bar) 23 psi (1.6 bar)

E lectrical system Battery Capacity ...................................... Voltage (fully c h a rg e d ).............. Alternator Output (unregulated) ................ Output (regulated) ..................... Charging coil re sista nce ............ Lighting coil resistance ............ Fuse (main) ................................... Bulbs Headlight (m ain/dipped)............ Sidelight ...................................... Brake/tail lig h t ............................ Turn signal lig h t s ........................ Instrument and warning lights .

. .

12 V, 4 Ah 14 to 15 V

. .

18 to 22 V (AC) 14 to 1 5 V (DC) 0.64 to 0.96 ohms 0.48 to 0.72 ohms 5 Amps

. . . . .

35/35 W 5W 21/5 W 10 W 1.2 W

Cylinder head bolts ........................................... Crankcase b o lt s ................................................. Engine mounting b o lt ........................................ Intake manifold b o l t s ........................................ Exhaust manifold n u t s ...................................... Exhaust system mounting b o lt s ..................... Oil pump mounting b o l t s ................................. Alternator rotor nut .......................................... Alternator stator bolts ...................................... Variator centre n u t ............................................. Clutch centre n u t ............................................... Clutch assembly nut ........................................ Gearbox oil filler p lu g ........................................ Gearbox oil drain p lu g ...................................... Gearbox cover bolts ........................................ Shock absorber mountings (front and rear) Lower b o lt ......... ............................................... Upper b o lt ......................................................... Steering head bearing adjuster nut Initial setting .................................................... Final s e ttin g ...................................................... Steering head bearing lo c k n u t........................ Handlebar stem bolt ........................................ Front axle n u t...................................................... Rear hub nut ...................................................... Disc brake caliper mounting bolts ................. Brake disc mounting b o lt s ...............................

15 Nm 12 Nm 60 Nm 10 Nm 16 Nm 25 Nm 8 Nm 40 Nm 10 Nm 40 Nm 45 Nm 50 Nm 12 Nm 12 Nm 10 Nm 25 Nm 50 Nm 40 Nm 23 Nm 80 Nm 40 Nm 70 Nm 120 Nm 35 Nm 32 Nm

Data 26

Peugeot Elyseo 125 Engine no. p r e f ix .............................................................................. Fram e no. pre fix .............................................................................. E n g in e ................................................................................................ Cooling s y s te m .............................................................................. Fuel system ................................................................................ .. Ignition s y s te m .............................................................................. T ra n s m is s io n ..................................................................................... S u s p e n s io n ....................................................................................... B r a k e s ................................................................................................ Tyres .................................................................................................. W heelbase ....................................................................................... W e ig h t................................................................................................ Fuel ta n k c a pa city .........................................................................

FD1 VGAG2AB 124 cc single-cylinder four-stroke Liquid-cooled Mikuni BS26 CV carburettor CDI Variable speed automatic, belt-driven Telescopic front, swingarm with twin adjustable shock rear 226 mm disc front, 210 mm disc or 130 mm drum rear 120/70 x 12 front,130/70 x 12 rear 1368 mm 140 kg 8.5 litres

E le ctrical system Battery Capacity ...................................... Voltage (fully c h a rg e d ).............. Alternator Output (unregulated) ................. Output (regulated) ..................... Charging coil re sista nce............ Lighting coil resistance ............ Fuse (main) ................................... Bulbs Headlight (m ain /dipp e d)............ Sidelight ...................................... Brake/tail lig h t ............................ Turn signal lig h t s ........................ Instrument and warning lights .

. .

12 V, 4 Ah 14 to 15 V

. . .

18 to 22 V (AC) 14 to 15 V (DC) 0.64 to 0.96 ohms 0.48 to 0.72 ohms 5 Amps

. . . . .

35/35 W 5W 21/5 W 10 W 1.2 W

Transm ission

Engine Spark plug t y p e ................. Electrode g a p ..................... Idle speed (rp m )................. Engine o i l ............................

............ ............ ............ ............

Oil capacity ........................ Bore x s t r o k e ..................... Valve clearance Intake ............................... Exhaust ............................ Coolant ............................... Coolant capacity ..............

............ ............

NGK CR7E 0.6 mm 1600 rpm SAE 10W 40 four-stroke motorcycle oil 1.25 litres 57.0 x 48.9 mm

............ ............ ............ ............

0.10 mm 0.25 mm Procor 3000 or equivalent 1.5 litres

Fuel system Throttle twistgrip freeplay Main je t ...................................... Pilot je t ...................................... Starter j e t ................................... Needle type / position ............

... ... ... ... ...

Pilot screw s e tt in g ................... . . . Float height ............................... . . .

2 to 5 mm 125 35 25 4CZ3 (2nd notch from top) 2 turns out Not adjustable

Variator rollers (standard diameter) Gearbox oil ...................................... Gearbox oil capacity .....................

Disc brake Fluid type .............................. Pad minim um thickness Disc thickness Standard ............................ Service lim it ....................... Drum brake Drum internal diameter Brake shoe lining thickness Standard ............................ Brake lever fre e p la y ..............

20 mm 80W-90 scooter gear oil 120 ml

DOT 4 1.5 mm 4.0 mm 3.5 mm

4 mm 10 to 20 mm

Ign itio n system HT coil prim ary resistance . . . HT coil secondary resistance . Spark plug cap resistance . . . Source coil resistance AEC 400 system ................... A C I 1 0 0 s y s t e m .......................... Pick-up coil resistance .

0.15 to 0.25 ohm 3.6 to 4.5 K-ohms 4.5 to 5.5 K-ohms

0 .4 4 to 0 .6 6 K - o h m s 0 .6 4 t o 0 .9 6 o h m s 10 2 to 1 3 8 oh m s nSf? .........................................

.................

22 psi (1.5 bar)

Torque w ren ch se ttin g s Valve cover b o lt s ............................................... Cylinder head bolts ........................................... Cylinder head n u ts ............................................. Cylinder bolt ...................................................... Cam chain tensioner b o lt s ............................... Camshaft sprocket b o l t ................................... Engine oil drain plug ........................................ Engine mounting b o lt ........................................ Intake manifold b o l t s ........................................ Exhaust manifold n u t s ...................................... Exhaust system mounting b o lt s ..................... Oil pump mounting b o l t s ................................. Alternator rotor hut ........................................... Alternator stator bolts ...................................... Variator centre n u t ............................................. Clutch centre n u t ............................................... Clutch assembly nut ........................................ Crankcase b o lts .................................................. Gearbox oil filler p lu g ........................................ Gearbox oil drain p l u g ...................................... Gearbox cover bolts ........................................ Rear shock absorber mountings Lower b o lt ......................................................... Upper b o lt ......................................................... Steering head bearing adjuster nut Initial setting .................................................... Final s e ttin g ...................................................... Steering head bearing lo c k n u t........................ Handlebar stem bolt ........................................ Front axle n u t ...................................................... Rear hub nut ...................................................... Disc brake caliper mounting bolts ................

10 Nm 10 Nm 23 Nm 12 Nm 10 Nm 23 Nm 40 Nm 60 Nm 10 Nm 16 Nm 25 Nm 10 Nm 70 Nm 10 Nm 70 Nm 70 Nm 50 Nm 10 Nm 12 Nm 12 Nm 10N m 23 Nm 45 Nm 40 Nm 23 Nm 70 Nm 40 Nm 65 Nm 110 Nm 3 0 Nm

............... 3g

Peugeot Looxor 50 (except TSDI model) E n g in e ................................................................................................. Cooling s y s te m ............................................................................. Fuel system ................................................................................... Ignition s y s te m .............................................................................. T ra n s m is s io n ..................................................................................... S u s p e n s io n ....................................................................................... B r a k e s ................................................................................................. Tyres ................................................................................................... W heelbase ....................................................................................... W e ig h t ................................................................................................ Fuel ta n k ca pa city .........................................................................

Spark plug t y p e ............................... Electrode g a p ................................... Idle speed (rp m )............................... Engine o i l .......................................... Oil tank capacity ............................ Bore x s tr o k e ................................... Piston diameter (s ta n d a rd )............ Piston to bore clearance S ta n d a rd ........................................ Piston rings Installed end g a p ..........................

NGK BR7HS 0.6 mm 1600 rpm JASO FC, SAE 20 semi-synthetic 1.2 litres 40.0 x 39.1 mm 39.85 mm

Data 27

49 cc single-cylinder two-stroke Air-cooled Gurtner PA358 slide carburettor CDI Variable speed automatic, belt-driven Telescopic front, swingarm with single shock rear 226 mm disc front, 110 mm drum rear 80/80 x 16 front, 100/70 x 16 rear 1311 mm 100 kg 8.0 litres

HT coil primary resistance ............ HT coil secondary resistance . . . . Spark plug cap re s is ta n c e ............ Source coil resistance AEC 400 system .......................... ACI 100 s y s te m ............................ Pick-up coil re sista n ce ................... Immobiliser transponder aerial resistance ......................................

0.15 to 0.25 ohm 3.6 to 4.5 K-ohms 4.5 to 5.5 K-ohms

13.6 to 20.4 ohms

Transm ission Variator rollers Standard d ia m e te r................. Recommended lubricant . . . . . Clutch spring free length . . . . Gearbox oil ............................... Gearbox oil capacity .............. . .

16 mm Esso SKF LGHT 3/0.4 103.5 mm 80W-90 scooter gear oil 120 ml

R0S! Fuel system Throttle twistgrip freeplay . . Main jet ................................. Pilot jet ................................. Starter j e t .............................. Needle t y p e .......................... Pilot screw s e ttin g .............. Float height .......................... Automatic choke resistance

2 to 5 mm 52 36 50 L3035F 1 1/2 turns out Not adjustable approx. 5.0 ohms @ 20°C

Brakes Disc brake Fluid type ................................. Pad minimum th ic k n e s s ......... Disc thickness Standard ............................... Service lim it .......................... Drum brake Drum internal diameter ......... Brake shoe lining thickness Standard ............................... Brake lever fre e p la y ................

.

.

Battery Capacity ........................................ Voltage (fully c h a rg e d )................. Alternator Output (unregulated) ................... Output (regulated) ........................ Charging coil resistance.............. Lighting coil resistance .............. Fuse (main) ...................................... Bulbs Headlight (m ain/dipped).............. Sidelight ........................................ Brake/tail li g h t ............................... Turn signal lig h ts .......................... Instrument and warning lights . .

26 psi (1.8 bar) 29 psi (2.0 bar)

12 V, 4 Ah 14 to 1 5V 18 to 22 V (AC) 14 to 15 V (DC) 0.64 to 0.96 ohms 0.48 to 0.72 ohms 5 Amps 35/35 W 5W 21/5 W 1 0W 1.2 W

0.44 to 0.66 K-ohms 0.64 to 0.96 ohms 102 to 138 ohms

0.15 mm 0.20 to 0.35 mm

Front ................................... .............. R e a r............................ ....................

DOT 4 1.5 mm 4.0 mm 3.0 mm 110 mm 3 to 3.8 mm 10 to 20 mm

Cylinder head bolts .......................................... Crankcase b o lt s ................................................. Engine mounting b o lt ........................................ Intake manifold b o lt s ........................................ Exhaust manifold n u t s ...................................... Exhaust system mounting b o lt s ..................... Oil pump mounting b o lt s ................................. Alternator rotor nut ........................................... Alternator stator bolts ...................................... Variator centre n u t ............................................. Clutch centre n u t ............................................... Clutch assembly nut ........................................ Gearbox oil filler p lu g ........................................ Gearbox oil drain plug ...................................... Gearbox cover bolts ........................................ Shock absorber mountings (front and rear) Lower b o lt ......................................................... Upper b o lt ......................................................... Steering head bearing adjuster nut Initial setting .................................................... Final s e ttin g ...................................................... Steering head bearing lo c k n u t........................ Handlebar stem bolt ........................................ Front axle n u t ...................................................... Rear hub nut ...................................................... Disc brake caliper mounting bolts ................. Brake disc mounting b o lt s ...............................

15 Nm 12 Nm 70 Nm 10 Nm 16 Nm 25 Nm 8 Nm 40 Nm 10 Nm 40 Nm 45 Nm 50 Nm 12 Nm 12 Nm 10 Nm 25 Nm 50 Nm 40 23 80 40 70 120 35 32

Nm Nm Nm Nm Nm Nm Nm Nm

Data 28

Peugeot Looxor100 E n g in e ................................................................................................ Cooling s y s te m .............................................................................. Fuel system .................................................................................. Ignition s y s te m .............................................................................. T ra n s m is s io n ..................................................................................... S u s p e n s io n ....................................................................................... B r a k e s ................................................................................................ Tyres ................................................................................................... W heelbase ....................................................................................... W e ig h t ................................................................................................ Fuel ta n k ca pa city .........................................................................

99 cc single-cylinder two-stroke Air-cooled Gurtner PY slide carburettor CDI Variable speed automatic, belt-driven Telescopic front, swingarm with single shock rear 226 mm disc front, 190 mm disc rear 80/80 x 16 front, 100/70 x 16 rear 1311 mm 107 kg 8.0 litres

Ign itio n system

Engine Spark plug t y p e ........................ Electrode g a p ............................ Idle speed (rp m )........................ Engine o i l ................................... Oil tank capacity ..................... Bore x s tr o k e ............................ Piston diameter (standard) . . . Piston to bore clearance S ta n d a rd ................................. Piston rings Installed end g a p ...................

. . . .

. . . .

. . . .

.. . ... ...

NGK BR7HS 0.6 mm 1600 rpm JASO FC, SAE 20 semi-synthetic 1.2 litres 50.6 x 49.7 mm 50.45 mm

. ..

0.15 mm

...

0.30 to 0.45 mm

HT coil primary resistance ......... HT coil secondary resistance . . . Spark plug cap resistance ......... Source coil resistance AEC 400 system ........................ ACI 100 s y s te m .......................... Pick-up coil re sis ta n c e ................ Immobiliser transponder aerial resistance ...................................

0.15 to 0.25 ohm 3.6 to 4.5 K-ohms 4.5 to 5.5 K-ohms

Fuel system

.... . . .

Throttle twistgrip freeplay Main jet ...................................... Pilot jet ...................................... Starter j e t ................................... Needle t y p e ............................... P ilo t s c re w s e t t i n g .......................

...........

... ... ...

.. . ...

2 to 5 m m 88 45 62 L3035F 1 3 / 4 tu rn s o u t Not adjustable

Disc brake Fluid type ........................ Pad minim um thickness . Disc thickness Standard ..........................

..

..

Front ................................................. R e a r....................................................

26 psi (1.8 bar) 29 psi (2.0 bar)

E lectrical system Battery Capacity ...................................... Voltage (fully c h a rg e d ).............. Alternator Output (unregulated) ................ Output (re g u la te d )..................... Charging coil re sistance......... Lighting coil resistance ............ Fuse (main) ................................... Bulbs Headlight (m ain /dipp e d)............ Sidelight ...................................... Brake/tail lig h t ............................ Turn signal lig h t s ....................... Instrument and warning lights .

12 V, 4 Ah 14 to 15 V 18 to 22 V (AC) 14 to 15 V (DC) 0.64 to 0.96 ohms 0.48 to 0.72 ohms 5 Amps 35/35 W 5W 21/5 W 10 W 1.2 W

Torque w ren ch se ttin g s 0.44 to 0.66 K-ohms 0.64 to 0.96 ohms 102 to 138 ohms

18 mm Esso SKF LGHT 3/0.4 105.5 mm 80W-90 scooter gear oil 120 ml

Cylinder head bolts .......................................... Crankcase b o lt s ................................................. Engine mounting b o lt ........................................ Intake manifold b o l t s ........................................ Exhaust manifold n u t s ...................................... Exhaust system mounting b o lt s ..................... Oil pump mounting b o l t s ................................. Alternator rotor nut .......................................... Alternator stator bolts ...................................... Variator centre n u t ............................................. Clutch centre n u t ............................................... Clutch assembly nut ........................................ Gearbox oil filler p lu g ........................................ Gearbox oil drain plug ...................................... Gearbox cover bolts ........................................ Shock absorber mountings (front and rear)

DOT 4 1.5 mm

Upper b o lt ........................................................ Steering head bearing adjuster nut Initial setting .................................................... Final s e ttin g ...................................................... Steering head bearing lo c k n u t........................ Handlebar stem bolt ........................................ Front axle n u t......................................................

13.6 to 20.4 ohms

Transm ission Variator rollers Standard d ia m e te r................ Recommended lubricant . . . Clutch spring free length . . . . Gearbox oil ............................... Gearbox oil capacity ..............

Tyre pressures

Disc brake caliper mounting bolts

....................

15 Nm 12 Nm 70 Nm 10 Nm 16 Nm 25 Nm 8 Nm 40 Nm 10 Nm 40 Nm 45 Nm 50 Nm 12 Nm 12 Nm 10 Nm 25 Nm 50 Nm 40 Nm 23 Nm 80 Nm 40 Nm 70 Nm 120 Nm 3 5 Nm 32 ________I

125

Peugeot Looxor

and 150

E n g in e ................................................................................................. Cooling s y s te m .............................................................................. Fuel system ................................................................................... Ignition system .............................................................................. T ra n s m is s io n ..................................................................................... S u s p e n s io n ....................................................................................... B r a k e s ................................................................................................. Tyres ................................................................................................... W heelbase ....................................................................................... W e ig h t ................................................................................................. Fuel ta n k ca pa city .........................................................................

Data 29

Single-cylinder four-stroke Air-cooled Walbro CV carburettor CDI Variable speed automatic, belt-driven Telescopic front, swingarm with single shock rear 226 mm disc front, 200 mm disc rear 80/80 x 16 front, 110/80 x 14 rear 1311 mm 115 kg 8.5 litres

Ign itio n system Spark plug t y p e ............................... Electrode g a p ................................... Idle speed (rp m )............................... Engine o i l .......................................... Bore x stroke 125 c c ............................................. 1 5 0 c c ............................................. Piston rings installed end gap Top r in g .......................................... Second r in g ................................... Oil control r in g ............................... Valve clearance Intake ............................................. E x h a u s t..........................................

NGK CR7E 0.6 mm 1600 rpm SAE 15W 40 fourstroke motorcycle oil 57.0 x 48.6 6 2 .6 x 4 8 .6

mm mm

0.15 to 0.40 mm 0.20 to 0.50 mm 0.20 to 0.50 mm 0.10 mm 0.15 mm

HT coil primary resistance ......... HT coil secondary resistance . . . Spark plug cap re s is ta n c e ......... Source coil resistance AEC 400 system ....................... ACI 100 s y s te m .......................... Pick-up coil re sista n ce ................. Immobiliser transponder aerial resistance ................................... .

0.15 to 0.25 ohm 3.6 to 4.5 K-ohms 4.5 to 5.5 K-ohms 0.44 to 0.66 K-ohms 0.64 to 0.96 ohms 102 to 138 ohms 13.6 to 20.4 ohms

1 Transm ission Gearbox oil .......................... ......... Gearbox oil capacity .........

80W-90 scooter gear oil 120 ml

Fuel system Throttle twistgrip freeplay Main jet 125 c c ...................................... 150 c c ............................ Pilot jet 125 c c .......................... 150 c c .......................... Starter j e t .......................... Needle type / position 125 c c ................................... 150 c c ...................................... Pilot screw s e tt in g ...................

...

to 5 mm

.. . ...

84 82

... ... ...

33 34 48

... . .. ...

DCK (2nd notch from top) 52K (2nd notch from top) 2 1 /4 turns out

Disc brake Fluid type ............................... Pad minimum thickness . . . . Disc thickness Standard ............................ Service lim it ........................

.. . ...

DOT 4 1.5 mm

... ...

4.0 mm 3.5 mm

Tyre pressures Front ........................................... . . . R e a r............................................. . . .

26 psi (1.8 bar) 33 psi (2.3 bar)

E le ctrical system Battery Capacity ...................................... Voltage (fully c h a rg e d ).............. Alternator Output (unregulated) ................ Output (regulated) ..................... Charging coil re sista nce ............ Lighting coil resistance ............ Fuse (main) ................................... Bulbs Headlight (m ain /dipp e d)............ Sidelight ...................................... Brake/tail li g h t ............................ Turn signal lig h t s ........................ Instrument and warning lights .

12 V, 4 Ah 14 to 15 V 18 to 22 V(AC) 14 to 15 V(DC) 0.64 to 0.96 ohms 0.48 to 0.72 ohms 5 Amps 35/35 W 5 W 21/5 W 10 W 1.2 W

Valve cover b o lt s ............................................... Cylinder head bolts ........................................... Cylinder head n u ts ............................................. Cylinder bolt ...................................................... Cam chain tensioner b o lt s ............................... Camshaft sprocket b o l t ................................... Engine oil drain plug ........................................ Engine mounting b o lt ........................................ Intake manifold b o lt s ........................................ Exhaust manifold n u t s ...................................... Exhaust system mounting b o lt s ..................... Oil pump mounting b o l t s ................................. Alternator rotor nut .......................................... Alternator stator bolts ...................................... Variator centre n u t ............................................. Clutch centre n u t ............................................... Clutch assembly nut ........................................ Crankcase b o lts .................................................. Gearbox oil filler p lu g ........................................ Gearbox oil drain plug ...................................... Gearbox cover bolts ........................................ Rear shock absorber mountings Lower b o lt ......................................................... Upper b o lt ......................................................... Steering head bearing adjuster nut Initial setting .................................................... Final s e ttin g ...................................................... Steering head bearing locknut ........................ Handlebar stem bolt ........................................ Front axle n u t ...................................................... Rear hub nut ...................................................... Disc brake caliper mounting bolts ................. Brake disc mounting b o lt s ...............................

10 10 28 12 10 23 40 62 10 16 25 10 70 10 70 70 50 10 12 12 10

Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm

25 Nm 50 Nm 40 23 80 40 53 120 35 32

Nm Nm Nm Nm Nm Nm Nm Nm

Peugeot Speedfight 50 Engine no. p r e fix .............................................................................. Fram e no. p r e f i x .............................................................................. E n g in e ................................................................................................ Cooling s y s te m .............................................................................. Fuel system .................................................................................. Ignition s y s te m .............................................................................. T ra n s m is s io n ..................................................................................... S u s p e n s io n ....................................................................................... B r a k e s ................................................................................................ Tyres ................................................................................................... W heelbase ....................................................................................... W eight ( d r y ) ....................................................................................... Fuel ta n k ca pa city .........................................................................

Engine Spark plug t y p e ............................ . Electrode g a p ................................. Idle speed (rp m )............................ Engine o i l ........................................ . Oil tank capacity .......................... Bore x s tr o k e ................................. Piston diameter (s ta n d a rd )......... Piston to bore clearance S ta n d a rd ...................................... . Piston rings Installed end g a p ........................ Service lim it ................................. Coolant .......................................... .

Temperature sender resistance @ 20°C ........................................ @ 90°C ........................................ .

Data 30 FL1 VGAS1B 49 cc single-cylinder two-stroke Liquid-cooled Gurtner PA370 slide carburettor CDI Variable speed automatic, belt-driven Monolever front, swingarm with single shock rear 180 mm disc front, 110 mm drum 120/70 x 12 front, 140/70 x 12 rear 1225 mm 90 kg 7.2 litres

Ign itio n system NGK BR7HS 0.6 mm 1500 rpm JASO FC, SAE 20 semi-synthetic 1.3 litres 40.0 x 39.1 m m 39.85 mm

HT coil primary re s is ta n c e ......... HT coil secondary resistance . . . Spark plug cap re s is ta n c e ......... Source coil resistance AEC 400 system ........................ . AC1100 s y s te m .......................... Pick-up coil re sis ta n c e ................ Immobiliser transponder aerial resistance ................................... .

0.15 to 0.25 ohm 3.6 to 4.5 K-ohms 4.5 to 5.5 K-ohms 0.44 to 0.66 K-ohms 0.64 to 0.96 ohms 102 to 138 ohms 13.6 to 20.4 ohms

0.15 mm 0.24 mm 0.26 mm 50% distilled water, 50% corrosion inhibiting ethylene glycol anti-freeze 1.19 to 2.58 K-ohms 92 to 124 ohms

Throttle twistgrip freeplay .............. Main jet ............................................. Pilot jet ............................................. Starter j e t .......................................... Needle type / position ................... Pilot screw s e ttin g ..........................

2 to 5 mm 72 36 50 L3035H (top notch) 1 1 /8 turns out

Float height .............................................. Auloinallc choKgreslslonce . . - -

Not adjustable appro*. 5.0oH m sfc O 20°C

T ransm ission Variator rollers Standard d ia m e te r................... Recommended lubricant .. Clutch spring free length ......... . . Gearbox oil ................................. Gearbox oil capacity ................ . .

Disc brake Fluid type ................................. . . Pad minimum th ic k n e s s ......... Disc thickness Standard ............................... Service lim it .......................... Drum brake Drum internal diameter ......... Brake shoe lining thickness Standard ...................................... Brake lever freeplay.................... . .

16 mm Esso SKF LGHT 3/0.4 103.5 mm 80W-90 scooter gear oil 120 ml

DOT 4 1.5 mm 3.5 mm 3.0 mm 110 mm 4m m 1 oto 20 mm

Front ................................................. R e a r....................................................

19 psi (1.3 bar) 23 psi (1.6 bar)

E le ctrical system Battery Capacity ...................................... Voltage (fully c h a rg e d ).............. Alternator Output (unregulated) ................ Output (re g u la te d )..................... Charging coil re sista nce ............ Lighting coil resistance ............ Fuse (main) ................................... Bulbs Headlight (m ain /dipp e d)............ Sidelight ......... ........................ Brake/tail li g h t ............................ Turn signal lig h t s ........................ Instrument and warning lights .

12 V, 4 Ah 14 to 15 V 18 to 22 V(AC) 14 to 15 V (DC) 0.64 to 0.96 ohms 0.48 to 0.72 ohms 5 Amps 35/35 W 5W 21/5 W 10 W 1.2 W

Torque w ren ch se ttin g s Cylinder head bolts .......................................... Crankcase b o lt s ................................................. Engine mounting b o lt ........................................ Intake manifold b o lt s ........................................ Exhaust manifold n u t s ...................................... Exhaust system mounting b o lt s ..................... Oil pum p mounting b o l t s ................................. Water pump mounting b o lts ............................ Alternator rotor nut ........................................... Alternator stator bolts ...................................... Variator centre n u t ............................................. Clutch centre n u t ............................................... Clutch assembly nut ........................................ Gearbox oil filler p lu g ........................................ Gearbox oil drain plug ...................................... Gearbox cover bolts ........................................ Shock absorber m ountings (front and rear) Lower b o lt ......................................................... Upper b o lt ......................................................... Front monolever arm pivot bolt ..................... Steering head bearing adjuster nut Initial setting .................................................... Final s e ttin g ...................................................... Steering head bearing lo c k n u t........................ Handlebar stem bolt ........................................ Front and rear wheel b o lt s .............................. Front hub n u t ...................................................... Rear hub nut ...................................................... Disc brake caliper mounting bolts ................. Brake disc mounting bolts......................................

15 Nm 12 Nm 60 Nm 10 Nm 16 Nm 25 Nm 8 Nm 10 Nm 40 Nm 1 0N m 40 Nm 45 Nm 50 Nm 12 Nm 12 Nm 10 Nm 25 Nm 50 Nm 90 Nm 40 Nm 23 Nm 80 Nm 40 Nm 40 Nm 70 Nm 120 Nm 35 Nm 32 N m

Peugeot Speedfight 2 50 liquid-cooled Engine no. p r e fix .............................................................................. Fram e no. p r e f i x .............................................................................. E n g in e ................................................................................................. Cooling s y s te m .............................................................................. Fuel system ................................................................................... Ignition system ................................................................................... T ra n s m is s io n ..................................................................................... S u s p e n s io n ....................................................................................... B r a k e s ................................................................................................. Tyres ................................................................................................... Wheelbase ....................................................................................... W eight ( d r y ) ....................................................................................... Fuel ta n k c a pa city .........................................................................

Engine

Data 31

FL1 VGAS1B 49 cc single-cylinder two-stroke Liquid-cooled Gurtner PA370 slide carburettor CDI Variable speed automatic, belt-driven Monolever front, swingarm with single shock rear 180 mm disc front, 180 mm disc rear 120/70 x 12 front,140/70 x 12rear 1225 mm 90 kg 7.2 litres

Battery Capacity ...................................... Voltage (fully c h a rg e d ).............. Alternator O utput (unregulated) ................. O utput (regulated) ..................... Charging coil re sista nce............ Lighting coil resistance ............ Fuse (main) ................................... Bulbs Headlight (m ain/dipped)............ Sidelight ...................................... Brake/tail l i g h t ............................ Turn signal lig h t s ........................ Instrument and warning lights .

12 V, 4 Ah 14 to 15 V 18 to 22 V (AC) 14 to 15 V(DC) 0.64 to 0.96 ohms 0.48 to 0.72 ohms 5 Amps 35/35 W 5W' 21/5 W 10 W 1.2 W

Ign itio n system

Spark plug t y p e ............................ . Electrode g a p ................................. Idle speed (rp m )............................ Engine o i l ........................................ . Oil tank capacity .......................... Bore x s tr o k e ................................. Piston diameter (s ta n d a rd )......... Piston to bore clearance S ta n d a rd ...................................... Piston rings Installed end g a p ........................ Service lim it ................................. Coolant ..........................................

NGK BR7HS 0.6 mm 1500 rpm JASO FC, SAE 20 semi-synthetic 1.3 litres 40.0 x 39.1 mm 39.85 mm

HT coil primary re s is ta n c e .......... . HT coil secondary resistance . . . Spark plug cap re s is ta n c e ......... Source coil resistance AEC 400 system ........................ AC 1100 s y s te m .......................... Pick-up coil re sista nce ................. Immobiliser transponder aerial resistance ................................... .

0.15 to 0.25 ohm 3.6 to 4.5 K-ohms 4.5 to 5.5 K-ohms 0.44 to 0.66 K-ohms 0.64 to 0.96 ohms 102 to 138 ohms 13.6 to 20.4 ohms

0.15 mm 0.24 mm 0.26 mm 50% distilled water, 50% corrosion inhibiting ethylene glycol anti-freeze

Temperature sender resistance @ 20°C ........................................ . @ 90°C ........................................

1.19 to 2.58 K-ohms 92 to 124 ohms

T ransm ission Variator rollers Standard d ia m e te r................ . . Recommended lubricant . . . . . Clutch spring free length . . . . . . Gearbox oil ............................... Gearbox oil capacity .............. . .

16 mm Esso SKF LGHT 3/0.4 103.5 mm 80W-90 scooter gear oil 120 ml

B rakes

Fuel system Throttle twistgrip fre e p la y ............ Main j e t ........................ Pilot jet ................... Starter j e t ..................... Needle type / position .............. Pilot screw s e tt in g ........................ Float height ................................... Automatic choke resistance . . . .

E lectrical system

. . . .

2 to 5 mm 72 36 50 L3035H (top notch) 1 1/8 turns out Not adjustable approx. 5.0 ohms @ 20°C

Disc brake Fluid type ............................... Pad minim um thickness . . . . Disc thickness Standard ............................ Service lim it . . . .................

.. . ...

DOT 4 1.5 mm

... ...

3.5 mm 3.0 mm

I Tyre pressures Front ................................. .............. R e a r................................... ..............

19 psi (1.3 bar) 23 psi (1.6 bar)

Cylinder head bolts ........................................... Crankcase b o lt s ................................................. Engine mounting b o lt ........................................ Intake manifold b o lt s ........................................ Exhaust manifold n u t s ...................................... Exhaust system mounting b o lt s ..................... Oil pump mounting b o l t s ................................. Water pump mounting b o lts ............................ Alternator rotor nut .......................................... Alternator stator bolts ...................................... Variator centre n u t ............................................. Clutch centre n u t ............................................... Clutch assembly nut ........................................ Gearbox oil filler p lu g ........................................ Gearbox oil drain plug ...................................... Gearbox cover bolts ........................................ Shock absorber mountings (front and rear) Lower b o lt ......................................................... Upper b o lt ......................................................... Front monolever arm pivot bolt ..................... Steering head bearing adjuster nut Initial setting .................................................... Final s e ttin g ...................................................... Steering head bearing lo c k n u t........................ Handlebar stem bolt ........................................ Front and rear wheel b o lt s ............................... Front hub n u t ...................................................... Rear hub nut ...................................................... Disc brake caliper and disc mounting bolts F r o n t.................................................................. Rear ..................................................................

15 Nm 12 Nm 60 Nm 10 Nm 16 Nm 25 Nm 8 Nm 10 Nm 40 Nm 10 Nm 40 Nm 45 Nm 50 Nm 12 Nm 12 Nm 10N m 25 Nm 50 Nm 90 Nm 40 Nm 23 Nm 80 Nm 40 Nm 40 Nm 70 Nm 120 Nm 35 Nm 32 Nm

Peugeot Speedfight and Speedfight 2 100 Engine no. p r e f ix .............................................................................. Frame no. pre fix .............................................................................. E n g in e ................................................................................................. Cooling s y s te m .............................................................................. Fuel system .................................................................................. Ignition s y s te m .................................................................................. T ra n s m is s io n ..................................................................................... S u s p e n s io n ....................................................................................... B r a k e s ................................................................................................. Tyres ................................................................................................... W heelbase ....................................................................................... W eight ( d r y ) ....................................................................................... Fuel ta n k ca pa city .........................................................................

FB6 VGAS2A 99 cc single-cylinder two-stroke Air-cooled Dell’Orto PHVA slide carburettor CDI Variable speed automatic, belt-driven Monolever front, swingarm with single shock rear 180 mm disc front, 180 mm disc rear 120/70 x 12 front, 130/70 x 12 rear 1225 mm 94 kg 7.2 litres

E lectrical system Battery Capacity ...................................... Voltage (fully c h a rg e d ).............. Alternator Output (unregulated) ................. O utput (regulated) ..................... Charging coil re sista nce ............ Lighting coil resistance ............ Fuse (main) ................................... Bulbs Headlight (m ain /dipp e d)............ Sidelight ..................................... Brake/tail l i g h t ............................ Turn signal lig h t s ....................... Instrument and warning lights .

12 V, 4 Ah 14 to 15 V 18 to 22 V (AC) 14 to 15 V (DC) 0.64 to 0.96 ohms 0.48 to 0.72 ohms 5 Amps 35/35 W 5 W 21/5 W 10 W 1.2 W

Ign itio n system

Engine Spark plug t y p e ........................ Electrode g a p ............................. Idle speed (rp m )........................ Engine o i l ....................................

Data 32

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..

Oil tank capacity ..................... Bore x s tr o k e ............................. Piston diameter (standard) . . . Piston to bore clearance S ta n d a rd ................................. Piston rings Installed end g a p ................... Service lim it ............................

NGK BR8ES 0.6 mm 1600 rpm JASO FC, SAE 20 semi-synthetic 1.3 litres 50.6 x 49.7 mm 50.45 mm

HT coil primary re s is ta n c e ......... HT coil secondary resistance . . . Spark plug cap re s is ta n c e ......... Source coil resistance AEC 400 system ........................ AC1100 s y s te m .......................... Pick-up coil re sis ta n c e ................. Immobiliser transponder aerial resistance ...................................

0.15 to 0.25 ohm 3.6 to 4.5 K-ohms 4.5 to 5.5 K-ohms 0.44 to 0.66 K-ohms 0.64 to 0.96 ohms 102 to 138 ohms 13.6 to 20.4 ohms

0.15 mm 0.30 mm 0.45 mm

Throttle twistgrip fre e p la y .............. Main jet ............................................. Pilot je t ............................................. Starter j e t ........................................... Needle type / position ...................

2 to 5 mm 83 30 65 A11 (2nd notch from top)

P ilo t s c re w s e t t i n g ................................ F lo a t h e ig h t ............................................... Automatic choke resistance . . .

1 3 / 4 tu rn s o u t N o t a d ju s ta b le approx. 5-0ohm s