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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Measure the inner diameter of the rocker arm.Service Limit10.04mm Measure the outer diameter of the rockshaft.Service Limit9.96mmROCKER ARM AND ROCKSHAFT INSTALLATION 噝 R ead the “ EX” mark on the camshaft holder, then mount the exhaust port rocker arm to the rockshaft. M ount the inlet port rocker arm to the rockshaft. Apply some oil to the rockshaft before mounting.CAM CHAIN TENSIONERThe chain tensioner must be in good working condition for proper chain tension.1. Cam chain2. Cam chain tensioner3. Cam chain tensioner lifter.4. Gasket5. Cam chain tensioner pivot6. Cam chain guide7. Bolt8. Nut9. O-ring10. O-ringThe operational principle of the tensioner is as shown in the picture.As for the adjustment of the cam chain tensioner, clockwisetightens, and counterclockwise loosens.12
VALVE AND VALVE SPRINGVALVE AND VALVE SPRING REMOVAL Remove cylinder head. Remove valve cotter pin and compressor. Remove upper spring race. Remove valve spring. Remove lower spring race. Remove valve stem oil seal. Remove valve.The removed parts should be placed in order toavoid confusion. It’s better to place the intake valveparts and exhaust valve parts separately.VALVE AND VALVE SPRING INSPECTION Inspect the valve for bending or burning. Inspect for smooth action between the valve and the valve guide. Measure the outer diameter of the valve stem.Service Limit4.94mm Measure the free length of the inner and outer valve spring.ValveInner springOuter springInlet valve31.2mm34.1mmExhaust valve31.2mm34.1mmVALVE AND VALVE SPRING INSTALLATION Mount the spring retainer, valve guide oil seal.It is recommended to replace the valve guide oil seal with a new one. After applying oil on the valve stem, mount it into the valve guide. Mount the inner and outer valve springs. Mount the valve locker with a spring compressor.When mounting, the twisting direction of the inner and outer springs must be opposite. Tap on the valve gently two or three times with a rubber hammer to make the valve and the valvelock connect well.Do not damage the valve.13
VALVE GUIDECarbon accumulation on the valve guide will make thevalve move roughly, causing the valve to notopen or close properly.Valve guide abrasion is one of the causes of white smoke from the exhaust pipe.TO CLEAN CARBON ACCUMULATION OFF THE VALVE GUIDE Remove the valve and springs etc. Clean the carbon accumulation with a valve guide reamer.Generally, only turn right when using the reamer, and do notpush in or out directly with the reamer.VALVE GUIDE INNER DIAMETER MEASUREMENTService Limit5.03mmCalculate the clearance between the valve stem and the valve guide(the inner diameter of the guide subtracted by the outer diameter of the valve stem).ValveService LimitInlet valve0.08mmExhaust valve0.10mmWhen the abrasion of the valve guide exceeds the service limit, it should be replaced; after replacing a new valve guide, the valve retainer must be adjusted.VALVE GUIDE REPLACEMENT Heat the cylinder head to 212 302 F (100 150 C)The cylinder head must be wholly and quickly heatedWR WKH VSHFL¿F GHJUHH DQG FDQQRW EH KHDWHG SDUWOy, orit will cause the cylinder head to distort. The temperature is very high, two technicians are recommended. Tap the valve guide out with a valve guide remover or similar tool.Do not damage the cylinder joint face14
After tapping the valve guide, you need to trim it with a reamer.When using the reamer, cutting oil must be used. The reamercan only be turned right; do not push in or out directly. Clean the cylinder head, and remove the scraps generated while ramming.VALVE SEATThe relative position between the valve seat and the working surface of the valve is very important forthe valve to seal properly.VALVE SEAT WIDTH MEASUREMENT Clean the carbon accumulation in the combustion chamber. Measure the width of the valve seat with a vernier caliper.StandardService Limit0.6-1.2mm1.8mmWhen abrasion causes the valve seat width to be uneven, too wide ortoo narrow, it will result in poor contact between the valve and the valveseat, and not seal tight. At this time it must be reamed with a customized valve seat milling cutter.The valve seat milling cutter is the customized trimming tool for thevalve seat, and it has three cutting angles: 32, 45, and 60.While trimming, press the valve seat milling cutter to make rotary motion with 40 50 N force.Some oil must be applied on the valve seat milling cutter, to eliminate scraping when trimming.VALVE SEAT FINISHING Ream out the defects on the working surface with a 45 coarsetooth milling cutter.Do not ream too much.15
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LUBRICATION SYSTEM INSPECTION AND SERVICINGGENERAL INTRODUCTIONThe picture shows the functional diagram of the lubrication system. After the lubrication oil crossesWKH ¿OWHU VFUHHQ, it is pumped by the rotator oil pump. Some of the oil goes into the big end of theconnecting rod and splashes on the cylinder wall and the small end of the connecting rod; the restgoes through some oil passages, such as the shaft neck of the camshaft, and splashes on thecam rockshaft and cam chain. The lubrication oil that falls back into the oil groove can be recirculated.18
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Mount the right crankcase cover positioning bolt. Mount the trigger winding and the stator coil. Tighten the right crankcase cover positioning bolt.The bolt should be gradually diagonally tightened intwo to three steps. IWHU ¿QLVKLQJ WKH LQVWDOODWLRQ LQspect for any oil leaks.FUEL SUPPLY SYSTEM INSPECTION AND SERVICINGCV CARBURETORThe CV carburetor is a constant vacuum carburetor. The picture shows the structure of the CVcarburetor.1. Gasket set2. Float valve set3. Needle jet set4. Float set5. Float chamber set6. Screw set A7. Screw set B8. Valve plate set9. Starter valve set10. Air cut valve set11. Compression coil spring12. Screw13. Carburetor assy.14. Top comp.15. Vacuum piston comp.16. Needle jet holder17. Plate clip18. Holder cap19. Tube A20. Tube B21. Screw22. Screw23. Washer screw24. Washer screw25. Washer screw26. Clip27. Clip28. Tube29. Main jet30. Slow jet41622
CARBURETOR IDLING ADJUSTMENTAIR ADJUSTING SCREW ADJUSTMENTStep one: T urn on the air adjusting screw in the turn out by the prescribed number of turns.Turn out number of turns2 3/4 – 2 1/4Step two: Adjust the throttle by adjusting the screw to the prescribed idle rpm.Step three: Left and right, adjust the air adjusting screw slightly to ¿nd the highest positionof the rpm.Increase throttle quickly and gently (the rpm is from low to high), and return throttle immediately,then observe 10 to 15 minutes, to observe if the idle remains the same.VACUUM CHAMBERThe picture shows the structure of the vacuum chamber of theCV carburetor.VACUUM CHAMBER REMOVAL Remove the body cover. Remove the automatic chokelead wire. Loosen the fuel drain bolt, and drain the fuel in the Àoatchamber. Remove the fuel line and the vacuum pipe. Loosen the throttle cable adjusting nut and positioning nut;remove the throttle cable. Loosen the carburetor air inlet vent clip and the inlet manifold clip;remove the carburetor. Remove the vacuum cover bolt, and remove the vacuum cover.Notice: move slowly to prevent the spring from ejecting. Take out the spring, the vacuum membrane and the plunger. Press down the holding clamp of the needle valve top, and turn leftto take out the clamp. Take out the spring and needle valve.Do not damage the vacuum membrane. Inspect the needle valve for wear. Inspect the vacuum membrane for damage. Inspect the plunger for damage.23
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Before removing ¿rst tighten the two screws gently, counting the number of turns Remove screws. Do not use excessive force to avoid damaging the air adjusting screwhead surface. Remove the main fuel injection nozzle and fuel injection needle seat.FLOAT CHAMBER INSTALLATION,QVSHFW WKH ÀRDW IRU DQ\ GDPDJH DQG IRU IXHO LQ WKH ÀRDW ,QVSHFW WKH ÀRDW YDOYH DQG Àoat valveseat for wear. If there is wear, it should be replaced.Clear every fuel line and air line on the carburetor body with compressed air.FLOAT CHAMBER INSTALLATION Install the main fuel injection nozzle and fuel injection needle seat. Install the air adjusting screw and choke adjusting screw, and turn them to the proper position according to the noted number of turns while removing. 0RXQW WKH ÀRDW YDOYH WKH ÀRDW DQG WKH ÀRDW SLQ TLJKWHQ WKH ÀRDW SLQ SRVLWLRQLQJ VFUHw.FUEL LEVEL INSPECTION Measure the fuel level height.Fuel level height18.5mm ,QVSHFW WKH ÀRDW IRU DQ\ GDPDJH DQG LQVSHFW WKH Àoat valve for excess we
service manual 150cc engine. 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
