Transcription

SERVICE MANUAL150cc Engine

TABLE OF CONTENTSCHASSIS NUTS AND BOLTS1ENGINE3LUBRICATION SYSTEM18FUEL SUPPLY SYSTEM22TRANSMISSION COMPONENTS27ELECTRICAL STARTING SYSTEM30BELT DRIVE CVT MECHANISM36CLUTCH40REAR TRANSMISSION SYSTEM45ELECTRICAL SYSTEM50IGNITION SYSTEM56

CHASSIS NUTS AND BOLTSNote: ,QVSHFW WKH ¿UVW ZHHN DQG WKHQ HYHU\ PRQWK WKHUHDIWHU.Always pay attention to the unit s nuts and bolts. Some loosening after use is normal. Check toensure that all nuts and bolts are tight.Torque Tightening ChartBoltDiameter45681012141618Conventional Marked BoltN.mKg.mIb-ft1 20.1 0.20.7 1.51 40.2 0.41.5 3.04 70.4 0.73.0 5.010 161.0 1.67.0 11.522 352.2 3.516.0 25.535 503.5 5.525.5 4050 805.0 8.036.5 5880 1308.0 13.058 94130 19013.0 19.094 137.5N.m1.5 33 68 1218 2840 6070 100110 160170 250200 2808.8 Marked BoltKg.mIb-ft0.15 0.31.0 2.00.3 0.62.0 4.50.8 1.26.0 8.51.8 2.813.0 20.04.0 6.029.0 43.57.0 10.050.5 72.511.0 16.079.5 115.517.0 25.123.0 181.020 28.0144.5 202.5FUEL SWITCH (PETCOCK) Periodically clean the petcock externally with grease remover and water. Check for any leaks or seeping fuel. Replace the petcock if there are any leaks found.This vehicle has a manually operated fuel valve. There are three positions.“ON” positionThe normal operating position for the fuel valve lever is the “ON” position. In this position, fuel willÀRZ WR WKH FDUEXUHWRr.“RES” positionIf the fuel level in the fuel tank becomes too low for the engine to operate with the fuel valve leverin the “ON” position, turn the lever to the “RES” position to use the reserve fuel supply, and refuelas soon as possible.“OFF” positionThe closing position for the fuel valve is the “OFF” position.When the vehicle is not in use, always make sure the petcock is in the “OFF” position.

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ENGINEENGINE COMPONENTS INSPECTION AND SERVICINGENGINE COMPONENTS AND CRANK CONNECTING RODMECHANISM INSPECTION AND SERVICINGENGINE COMPONENTS: CYLINDERCYLINDER REMOVALThe removal can be done on the vehicle body. Remove cylinder head. Remove cylinder. Remove cylinder gasket, bolts Clean cylinder gasket and remove any debris.Caution!Do not damage the cylinder area. Make sure not to drop anything,including cylinder gasket material, into the crankcase.CYLINDER INNER WALL WEAR INSPECTIONUse a bore diameter dial gauge to measure the degree of wear.The measure point is divided into three sectional planes in the axial direction: upper, middle andlower; measure every plane each time on the mutually perpendicular directions (X, Y), the measured least dimension is the cylinder bore; at the most upper position measured is the largestdiameter, and the lowest position measured is the smallest diameter, their difference is the cylindricity of the cylinder. At the same cross section, measure the difference of diameter between twopoints mutually perpendicular; which is the circularity of the cylinder.In order to make the measuring point perpendicular with the bore axis of the cylinder, and to ensure the precision of the measurement, the bar of the gauge canbe slightly swung in the direction of the gauge bar, and take the smallest readingnumber as the result.In the situation without a dial gauge, a feeler gauge can be used to make relativity measurement.put a new piston into the cylinder, and use the feeler gauge to measure the gap between thepiston skirt and the cylinder wall. T hen ¿gure out the abrasion loss of the cylinder. If the circularity of the cylinder exceeds the limit, then a cylinder reboring machine should be used to reborethe cylinder, and enlarge its diameter by 0.5mm or 1.00mm, then ¿t the piston and piston ringwhich size are also enlarged. If the wear is too severe and cannot be reworked, then a new cylinder should be installed.Cylinder boreCylindricityCircularity57.4mm0.05mm0.05mm3

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CRANKSHAFT AND CRANKCASE INSPECTION Replace the whole set of the crankshaft if serious wear is found while inspecting. Measure theaxial trend clearance of the big end of the connecting rod. When measuring, put the large end of the connecting rod close to the crank, and insert the feelergauge between the other side and the crank, for the correct end play.Service Limit0.55mm Measure the radial trend (X,Y) clearance of the big end of the connecting rod.Service Limit0.05mm Measure the main shaft journal jump of the crankshaft.If this measurement is too great, it will cause the engine to shake abnormally, shortening thelife of the engine It must be examined carefully when inspecting.Service Limit0.10mm(A 90)0.10mm(B 105) Examine if there is any loose, or unusual sound when the crank journal bearing turns. If there is,the whole set should be changed. After cleaning the crankcase, inspect if there is any damage. Inspect whether the joint face of the crankcase is smooth and clean. While reassembling, notice if itwill affect the sealing performance between the left and right crankcase. IWHU WKH DERYH LQVSHFWLRQ LI WKH FUDQNFDVH KDV VRPH VXUIDFH GDPDJH XVH RLOVWRQH WR refinish it.If damage is too severe, replace the cover.Because the right and left crankcase axle hole must be concentric, theyshould be replaced at the same time.CRANKSHAFT AND CRANKCASE INSTALLATION Mount the crankcase oil seal. Put the cam chain into the left crankcase. Put the crankshaft into the left crankcase.Pay attention to avoid damaging the oil seal with the cam chain.7

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