Explorer GT 50 Installation and user guide

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Service and Maintenance Manual
(50ccm)

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PREFACE
The service manual has been specially prepared to provide all the necessary
information for the proper maintenance and servicing.
You have now a new type of scooter that has many techinal features such as:
V-belt drive automatic transmission
Forced air-cooling system
CDI ignition system
Electric starter system
Those who will be servicing the scooter should carefully review the manual before
performing any repair or services. Major modifications and changes incorporated
later will be advised to GENERIC product distributor in each market. Therefore, if
newest information is requested in the future, please contact the local GENERIC
distributor.
The scooters distributed in your country mignt differ in minor respects from the
standard specification and, if they do, it is because some minor modifications had to
be made to comply with the statutory requirements of your country.

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GENERAL INFORMATION
TYPE IDENTIFICATION
FUEL AND ENGINE OIL
BREAK-IN PROCEDURE
PRECAUTIONS AND GENERAL INSTRUCTIONS
SPECIFICATIONS
CONTENTS

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TYPE IDENTIFICATION
཰
ENGINE NUMBER
ENGINE NUMBER཰LVFDUYHGRQUHDUFUDQNFDVHDV 
6KRZQLQILJXUH
Both FRAME NUBER AND ENGINE NUMBER are
Designed specially for registering your scooter
and ordering spare parts.
FUEL AND ENGINE OIL
Be sure to use specified fuel and engine oil.
Some specifications are as follows:
FUEL
Unleaded, the minimum octane number is 95 or more.
ENGINE OIL
For GENERIC CCI SYSTEM, we recommend special engine oil, you can choose high quality two-stroke
engine oil (without being diluted) if without special oil.
GEAR OIL
Use high quality, all-purpose SAE90 engine oil for scooter.
BREAK-IN TIME
General requirements are as follows᧶
Limit break-in speed᧶
At the first 1000KMS᧤600 miles᧥mileage᧨play throttle less than 4/5 throttle᧷
After mileage exceeds 1000KMS᧤600 miles᧥᧨play full throttle᧷
Don’t run engine too long during break-in time, and try to change throttle position.

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PRECAUTIONS AND GENERAL INSTRUCTIONS
Correctly abide by the following items when disassembling and assembling scooter:
႒ Don’t run engine indoors without ventilation;
႒ Be sure to replace new bushings, circlips, O-rings and cotter pins with new ones᧷
CAUTION
It is forbidden to use the circlip removed from shaft, only use new one᧷
Be very carefull to install new circlip for fear that the end hatch of circlip exceeds required sliding surface for
shaft᧷
After installing circlip, inspect whether it has been completely clipped into the groove.
႒ Fix bigger diameter bolt first when tightening cylinder head or cylinder, and tighten to specified torque
gradually from inside to outside at diagonal order.
႒ Use special tools for some special requirements᧷
႒ Use original components and recommended engine oil᧷
႒ Keep each other’s safety when several persons do᧷
႒ Inspect looseness and operating state of components after reassembling them.᧷
႒ Take high care of gasoline, which is explosive, and never use gasoline as lotion.
The words like warning, notice, note may turn out incessantly in the manual, which means:
WARNING The personal safety of the rider may be involved. Disregarding the information could result
in injury to the rider.
CAUTION These instructions point out special service procedures or precautions that must be followed to
avoid damaging the machine.
NOTE it provides some special information, which keeps maintenance easier and important
instructions clearer..
REPLACEMENT COMPONENTS
Be sure to use genuine GENERIC components or their equivalent.. Genuine GENERIC components are high
quality parts which are designed specially for GENERIC vehicle.
CAUTION
Damage to the scooter may result from use of replacement components which are not
Equivalent in quality to genuine GENERIC parts, and it can lead to performance problems.

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SPECIFICATIONS
DIMENSION AND NET WEIGHT
OVERALL LENGTH 1830 mm
OVERALL LENGTH 695 mm
OVERALL HEIGHT 1160 mm
WHEELBASE 1295 mm
NET WEIGHT 92 kg
CHASSIS
Front shock absorber spring, no damp
Rear shock absorber spring, oil damp
Turning angle 48º
Front wheel 120/70-12
Rear wheel 130/70-12
Front brake Discij190
Rear brake Drumij110
ENGINE
Type two-stroke, air cooled
Intake system piston-reed valve
Cylinder QTY. 1
Bore 40.0mm
Stroke 39.6mm
Discharge 49.8mL
Compression ratio 6.9:1
Carburetor flat inhale stopper style
Air cleaner dry
Starting system electric and kicking start
Lubricating system pressure lubricating
ELECTRIC
Ignition mode CDI
Ignition timing 150at 1500RPM
Spark plug BP8HS
Storage battery YTX5L-BS
Generator AC magneto
Fuse 8A
Headlight 12V—55W
Turning light 12V/10W
Taillight 12V—21/5W
Meter light 12V/1.7W
Oil level signal indicator light 12V/3W
Turning signal indicator light 12V/3W
CAPACITY
FUEL TANK 5.2L
ENGINE OIL TANK 1L
GEAR OIL 0.1L
Transmission system
Clutch system dry auto a centric
Gearshift mechanism CVT stepless
Operating mode of gears shift mechanism
Automaticacentric
Step less shift range 0.86~2.64
*the above data may be modified without
any notification.

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Periodic maintenance and service
Periodic maintenance and service schedule
Maintenance and service procedures
Storage battery
Spark plug
Cylinder head nut and exhaust pipe bolt
Cylinder head and cylinder
Fuel level line
Air cleaner
Throttle cable
Engine idle speed
Oil pump
Gear oil
Braking
Tire
Steering
Front shock absorber
Rear shock absorber
Vehicle bolts and nuts
CONTENTTS

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Periodic maintenance and service schedule
The following table lists all required intervals for maintenance and service᧨following which, you are assured to
have your scooter perform in the best way.
Note
Do more frequent maintenance when often riding on bad road
Periodic maintenance table
Interval
(first 500 than
all 3000km)
Kilometer 500 3500 6500 9500 12500
Storage battery I I I I I
Cylinder head nut and
exhaust pipe bolt TT T T T
Cylinder head and cylinder
(change all 12000 km) ಧC R C R
Spark plug ಧR R R R
Air cleaner Clean every 3000KM(2000 miles)
Idle speed rpm I I I I I
Throttle cable play I I I I I
Oil pump I I I I I
Gear oil (75W90) R ಧR ಧR
I I I I
I
Fuel line Replace every 4 years
Brake I I I I I
I I I I I
Brake hose Replace every 4 years
I I I I I
Brake fluid Replace every 2 years
Steering I I I I I
Front fork I I I I I
Rear shock absorber I I I I I
Tire I I I I I
Vehicle body boot and nut T T T T T
Note
I=inspect᧨clean᧨adjust᧨lubricate᧨or replace if necessary᧷
A=adjust᧷C=clean᧷R=replace᧷T=tighten

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Maintenance and adjustment procedures
The section describes the servicing procedures for each item of the Periodic Maintenance requirements.
Storage battery
Inspect at initially 1000KM᧤600 miles᧨2 months᧥᧨and
every 6000KM᧤4000 miles᧨12 months᧥thereafter
႒ Uncover seat, and then remove the battery box cap in the
Middle of helmet barrel.
႒ Disconnect negative pole line end, positive end, and then remove battery᧷
႒ Measure the voltage between the two ends of battery with
voltage gauge᧨charge if the voltage is below 11,9V

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Cylinder head nuts and exhaust pipe bolts
Tighten at 500 km, and each service.
If cylinder head nuts are not tightened to the
specified torque, may result in leakage of
compressed fuel-air mixture and reduce output,
tighten the cylinder head nuts in the following
procedures:᧶
1᧪Remove the frame lower covers.
2᧪Remove the cylinder head cover bolt.
3᧪Remove spark plug cap.
4᧪Tighten the nuts evenly one by one to the
their specified torque. Tighten the nuts in the
order indicated.
Tightening torque᧶
Cylinder head nut᧶15-18N.m
Exhaust pipe bolt᧶15-18N.m
Cylinder and cylinder head
Remove carbon every 6000 km᧤4000
miles᧨12 months᧥
Carbon deposits in the combustion chamber and the
cylinder head will raise the compression ratio and may cause
preignition and overheating. Carbon deposited at the exhaust
port of the cylinder will prevent the flow of exhaust gases,
reducing the output. Remove carbon deposits periodically.

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SPARK PLUG
Neglecting the spark plug maintenance eventually leads to
difficult starting and poor performance. If the spark plug is used for a
long time, the electrode gradually burns away and carbon builds up
along the inside part. In accordance with the periodic table, the plug
should be removed for inspection, cleaning and to reset the gap.
zCarbon deposits on the spark plug will prevent good sparking
and cause misfiring. Clean the deposits periodically.
zIf the center electrode is fairly worn down, the plug should be
replaced and the plug gap set to the specified gap using a
thickness gauge.
Thickness gauge
Spark plug gap᧶0.6-0.7 mm (0.024-0.028 inch)
Check the spark plug for burnt condition. If abnormal replace the spark
plug as indicated in the chart.
NGK TROCH REMARKS
BPR7HS E8RTC
If the standard plug is apt to get wet,
replace with the plug.
BPR8HS E7RTC Standard
BPR9HS E6RTC If the standard plug is apt to
overheat, replace with the plug.
zTighten the spark plug to the specified torque.
Spark plug
Tightening torque:15-18N.m
NOTE:
zTo check the spark plug, first make sure that the fuel used is
unleaded gasoline, and if plug is either sooty with carbon or
burnt white, replace it.
zConfirm the thread size and reach when replacing the plug.
FUEL LINE
Inspect at initially 500 km and every service, replace every 4
years.

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AIR CLEANER
Clean every 3000KM᧤2000 miles᧥
If the air cleaner is clogged with dust, intake resistance will, be increased with a resultant decrease in power
output and an increase in fuel consumption. Check and clean the element in the following manner.
Remove clamp 1 and screw 2᧨take down air cleaner
Unscrew tapping screw 3᧨remove air cleaner cap 4
Fill a washing pan of a proper size with
Non-flammable cleaning solvent. Immerse the air
Cleaner in the cleaning solvent and wash them clean.
Squeeze the cleaning solvent out of the washed element
By pressing it between the palms of both hands: do not twist
or wring the air cleaner filter core element or it will develop tears.᧨
Immerse cleaned filter core of air cleaner
in CCI or CCI SUPER oil, and squeeze the oil out of
the core᧨which may be slightly wet with oil.
Install air cleaner filter core in the reverse
order of removal.

CAUTION᧶
Before and during the cleaning operation, inspect the core for tears. A tore core must be replaced
Be sure to position the filter core, so that no
incoming air will bypass it. Remember, rapid wear
of piston rings and cylinder bore is ofter caused by
defective or poorly fitted filter core.
ȺNon-flammable cleaning solvent
ȻCCI or CCI SUPER oil
THROTTLE CABLE
Adjust at initially 1000KM᧤600 miles᧨2 months᧥᧨and
every 6000 km᧤4000 miles᧨12 months᧥
Loosen locknut ᧨and adjust throttle cable play by turning adjuster in or
out to obtain the following cable play. After adjusting the calbe play᧨
tighten the locknut.
Cable play᧶0.5-1.0MM᧤0.02.-0.040 inch᧥
Engine idle speed
Adjust at initially 1000KM᧤600 miles᧨2 months᧥and every
6000 km᧤4000 miles᧨12 months᧥thereafter.
Adjust the throttle cable play.
warm up the engine.
Note᧶
Warm up engine for 10 minutes.

Connect an electric tachometer to the connecting protion of the
magneto lead wire as shown in the illustration. Use the selector key
“C’ position.
2
4
1
3

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Tachometer
Adjust the throttle stop screw to obtain the idle r/min as follows:
Idle speed᧶1400s100r/min
Finally adjust the throttle cable play.
OIL PUMP
Inspect at initially 500km and every year.
The engine oil is fed by the oil pump to the engine. The amount of oil fed to it is regulated by engine speed and oil
pump control lever which is controlled by amount of throttle opening.
Check the oil pump in the following manner to confirm correct operation for throttle valve full opening position.
Turn the throttle grip full open.
Check whether the red mark on the oil pump control lever
Is aligned with the index mark when the throttle valve is positioned as above.
If the marks are not aligned, loosen lock nuts and turn the adjuster in or out to align the marks.
After align the marks, tighten the locknuts.
Caution᧶
Oil pump calbe adjustment must be done after throttle cable
adjustment.

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GEAR OIL
Change as shown in the service schedule.
Inspect gear oil periodically as follows:
Remove the cover and hose
Remove the kicking starter lever
Remove clutch cover
Remove oil level bolt and inspect oil level, if oil level is below oil hole,
add oil until oil flows from the level hole.
Tighten oil level bolt to the specified torque.
Tightening toque᧶9-15N.m
᧤0.9-1.5 kg-m ᧨6.5-11.0 lb-ft᧥
BRAKES
Inspect at initially 500 km and every service, replace brake
fluid every 2 years, replace brake hose every 4 years.
Front brake fluid level
Keep the scooter upright and place the handlebar staight.
Check brake fluid level by observing the lower limit line
on the brake fluid reservoir.
When the level is below the lower limit line, replenish with
Brake fluid that meets the following specification.
Specification and classification᧶DOT4
WARNING᧶
The brake system of the scooter is filled with a glycol-based brake the lowest line
Fluid. Do not use or mix different types of fluid such as silicone-based and petroleum-based. Do not use any
brake fluid taken from old, used or unsealed containers. Never reuse the brake fluid left over from the last
servicing and stored for long periods.

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WARNING᧶
Brake fluid, if it leaks, will interfere with safe running and immediately discolor painted surfaces.
Check the brake hoses for cracks and hose joints for leakage before riding.
Brake pads
Wearing condition of brake pads can be checked by observing the limit
line ཰marked on the pad. When the wear exceeds the limit mark,
replace the pads with new ones.
Bleeding air from the brake fluid circuit
Air trapped in the fluid circuit acts like a cushion to absorb a large
proportion of the pressure developed by the master cylinder and thus
interferes with the full braking performance of the brake caliper. The
presence of air is indicated by “sponginess” of the brake lever and
also by lack of braking force. Considering the danger to which such
trapped air exposes the machine and rider, it is essential that, after
remounting the brake and restoring the brake system to the normal
condition, the brake fluid circuit be purged of air in the following manner:
Fill up the master cyliner reservoir to the upper end of the inspection
window. Replace the reservoir cap to prevent entry of dirt.
Attach a pipe to the caliper bleeder valve, and insert the free end of
The pipe into a receptacle.
႒Bleed air from the bleeder valve.
Squeeze and release the brake level several times in rapid succession. And squeeze the lever fully without
releasing it. loosen the bleeder valve by turning it a quarter of a turn so that the brake fluid runs into the
receptacles: the will remove the tension of the brake lever causing it to touch the handlebar grip. Then, close the
valve, pump and squeeze the lever, and open the valve. Repeat the process until the fluid flowing into the
receptacle no longer contains air bubbles.

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NOTE᧶when bleeding the braking system, replenish the brake fluid reservoir if necessary.
Make sure that there is always some fluid visible in the reservoir.
Close the bleeder vavle, disconnect the pipe. Fill the reservoir with brake fluid to the upper end of the
inspection window.
BLEEDER VALVE
TIGHTENING TORQUE: 6-9N.m(0.6-0.9kg-m,4.5-6.5lb-ft)
CAUTION᧶
Handle brake fluid with care: the fluid reacts
chemically with paint, plastics, rubber materials, etc.
Rear brake
Turn adjusting nut ཰ VRWKDWWKHWKHSOD\ ཱ RI 
%UDNHOHYHULV15-25MM as shown in the illustration.
Brake shoe wear᧶
The vehicle is equipped with the brake lining limit
Indicator  on the rear brake.
Inspect brake lining limit as follows᧶
1. First check if the brake system is properly
Adjusted.
2. when operating the brake, check to see that
the tip of indicator is within the range.
3. if the tip of indicator is beyond the range,
the brake shoe assembly should be raplaced with anew set of shoe.

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Tire
Inspect at initially 1000KM᧤600 miles᧨2 months᧥and every
6000KM᧤4000 miles᧨12 months᧥thereafter
Tire pressure᧶
If the pressure is too high, the scooter will tend to rede stiffly
and have poor traction. Conversely, if tire pressure is too low,
stability will be adversely affected. Thereafter, maintain the
correct tire pressure for good roadability and to prolong tire life.
CAUTION᧶
The standard air pressure of tires is 175/196Kpa, the use of other
than standard may cause handling instability. It is highly
recommended to use a GENERIC genuine tire.
Tire tread condition᧶
Operating the scooter with the excessively worn tires will decrease
riding stability and consequently invite dangerous situation. It is highly
recommended to replace the tire when the remaining depth of tire tread
reaches the following specification.
Front and rear᧶1.6MM᧤0.064IN᧥
Tire depth gauge
Steering
inspect at initially 500km and every service.
Steering should be adjusted properly for smooth turning of handlebars
and safe running. Too stiff steering prevents smooth turning of handlebars
and too loose steering will cause poor stability.
Check that there is no play in the front fork assembly by supporting the
machine so that the front wheel is off the ground, with wheel staight ahead,
grasp lower shock absorber near the axle and pull forward. If play is
found, perform steering bearing adjustment.

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Front shock absorber
Adjust at initially 500km and each service.
Inspect the front shock absorber for oil leakage or other damage, and replace the defective parts, if necessary.
Rear shock absorber
Adjust at initially 500km and each service.
Inspect front shock absorber for oil leakage and other damage, and replace the defective parts if necessary.
No. Item NವmKg-m
1 Front axle nut 55-60 5.5-6
2 Handle tightenging nut 37-44 3.7-4.4
3 Steering sterm locknut 37-44 3.7-4.4
4 Disc brake caliper fixing bolt 22-29 2.2-2.9
5 Disc brake master cylinder hose fixing bolt 22-29 2.2-2.9
6 Disc brake fixing bolt 5-9 0.5-0.9
7 Front shock absorber fixing bolt 37-44 3.7-4.4
8 Engine pivot fixing nut 55-60 5.5-6
9 Engine bracket fixing nut 37-44 3.7-4.4
10 Rear wheel fixing nut 100-130 10-13
11 Rear brake rocker arm fixing bolt 5-9 0.5-0.9
12 Rear shock absorber under fixing bolt 22-29 2.2-2.9
13 Start pedal mounting screw 15-20 1.5-2
14 Rear shock absorber top fixing bolt 37-44 3.7-4.4

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