Motos

SERVICE MANUAL
150cc Engine

TABLE OF CONTENTS
CHASSIS NUTS AND BOLTS

1

ENGINE

3

LUBRICATION SYSTEM

18

FUEL SUPPLY SYSTEM

22

TRANSMISSION COMPONENTS

27

ELECTRICAL STARTING SYSTEM

30

BELT DRIVE CVT MECHANISM

36

CLUTCH

40

REAR TRANSMISSION SYSTEM

45

ELECTRICAL SYSTEM

50

IGNITION SYSTEM

56

CHASSIS NUTS AND BOLTS
Note:

.Always pay attention to the unit s nuts and bolts. Some loosening after use is normal. Check to
ensure that all nuts and bolts are tight.

Torque Tightening Chart
Bolt
Diameter
4
5
6
8
10
12
14
16
18

Conventional Marked Bolt
N.m
Kg.m
Ib-ft
1~2
0.1 ~ 0.2
0.7 ~ 1.5
1~4
0.2 ~ 0.4
1.5 ~ 3.0
4~7
0.4 ~ 0.7
3.0 ~ 5.0
10 ~ 16
1.0 ~ 1.6
7.0 ~ 11.5
22 ~ 35
2.2 ~ 3.5
16.0~ 25.5
35 ~ 50
3.5 ~ 5.5
25.5 ~ 40
50 ~ 80
5.0 ~ 8.0
36.5 ~ 58
80 ~ 130
8.0 ~ 13.0
58 ~ 94
130 ~ 190
13.0 ~19.0
94 ~ 137.5

N.m
1.5 ~ 3
3~6
8 ~ 12
18 ~ 28
40 ~ 60
70 ~ 100
110 ~ 160
170 ~ 250
200 ~ 280

8.8 Marked Bolt
Kg.m
Ib-ft
0.15 ~ 0.3
1.0 ~ 2.0
0.3 ~ 0.6
2.0 ~ 4.5
0.8 ~ 1.2
6.0 ~ 8.5
1.8 ~ 2.8
13.0 ~ 20.0
4.0 ~ 6.0
29.0 ~ 43.5
7.0 ~ 10.0
50.5 ~ 72.511.0 ~ 16.0
79.5 ~ 115.5
17.0 ~ 25.
123.0 ~ 181.0
20 ~ 28.0
144.5 ~ 202.5

FUEL 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” position
The normal operating position forthe fuel valve lever is the “ON” position. In this position, fuel will
r.

“RES” position
If the fuel level in the fuel tank becomes too low for the engine to operate with the fuel valve lever
in the “ON” position, turn the lever to the “RES” position to use the reserve fuel supply, and refuel
as soon as possible.

“OFF” position
The 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.

unit

before

gear

2

ENGINE
ENGINE COMPONENTS INSPECTION AND SERVICING
ENGINE COMPONENTS AND CRANK CONNECTING ROD
MECHANISM INSPECTION AND SERVICING

ENGINE COMPONENTS: CYLINDER
CYLINDER REMOVAL
The 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 INSPECTION
Use 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 and
lower; 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 largest
diameter, 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 can
be slightly swung in the direction of the gauge bar, and take the smallest reading
number as the result.
In the situation without a dial gauge, a feeler gauge canbe used to make relativity measurement.
put a new piston into the cylinder, and use the feeler gauge to measure the gap between the
piston 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 rebore
the cylinder, and enlarge its diameter by 0.5mm or 1.00mm,...