Generic Trigger SM 50ccm User manual

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Contents
Contents ···················································································································································-1-
Preface ·····················································································································································-4-
Documents to be prepared ················································································································-5-
Inspection/adjustment ······················································································································-19-
1 Brake····················································································································································-32-
1.1 Maintenance instruction·············································································································-32-
1.2 Fault diagnosis···························································································································-32-
1.3 Front hydraulic brake·················································································································-33-
1.4 Rear hydraulic brake··················································································································-35-
2 Body cover ···········································································································································-38-
3 Front wheel/ front suspension···············································································································-42-
3.1 Preparation data ·························································································································-42-
3.2 Fault diagnosis···························································································································-42-
3.3 Front wheel································································································································-43-
3.4 Steering handle ··························································································································-45-
3.5 Front fork···································································································································-45-
4 Rear wheel/rear suspension ··················································································································-50-
4.1 Preparation data ·························································································································-50-
4.2 Fault diagnosis···························································································································-50-
4.3 Rear wheel·································································································································-51-
4.4 Rear shock absorber/rear rocker·································································································-52-
4.5 Driving chain ·····························································································································-53-
5 Battery/charging system ·······················································································································-56-
5.1 Preparation data ·························································································································-56-
5.2 Fault diagnosis···························································································································-57-
5.3 Battery ·······································································································································-58-
5.4 Charging system ························································································································-59-
5.5 Voltage and current regulator ·····································································································-60-
5.6 Charge coil of the alternator·······································································································-60-
5.7 Illuminating coil of alternator·····································································································-61-
5.8 Disassembly of alternator···········································································································-61-
6 Ignition system ·····································································································································-64-
6.1 Preparation data ·························································································································-64-
6.2 Fault diagnosis···························································································································-65-
6.3 Ignition system inspection··········································································································-66-
6.4 CDI group··································································································································-68-
6.5 Ignition coil ·······························································································································-68-
6.6 Trigger ·······································································································································-69-
7 Startup system ······································································································································-71-
7.1 Preparation data ·························································································································-71-
7.2 Fault diagnosis···························································································································-72-

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7.3 Start electric machinery··············································································································-72-
7.4 Start relay···································································································································-74-
8 Bulbs/ switch/instrument ······················································································································-75-
8.1 Preparation data ·························································································································-75-
8.2 Fault diagnosis···························································································································-75-
8.3 Replace the head light bulb ········································································································-75-
8.4 Replace bulb of the front turning light ·······················································································-76-
8.5 Replace the bulb of the taillight / license light / rear turning light ··············································-76-
8.6 Instrument··································································································································-77-
8.7 Main switch ·······························································································································-77-
8.8 Horn ··········································································································································-77-
8.9 Handle switch ····························································································································-77-
Table of torque value of engine fastener ··································································································-79-
9Lubrication system ·······························································································································-81-
9.1 Preparation data ·························································································································-81-
9.2 Fault diagnosis···························································································································-81-
9.3 Oil pump····································································································································-81-
10 Carburetor ··········································································································································-84-
10.1 Preparation data ·······················································································································-84-
10.2 Fault diagnosis·························································································································-84-
10.3 Disassembly of carburetor········································································································-85-
10.4 Carburetor cover ······················································································································-86-
10.5 Float chamber ··························································································································-87-
10.6 Installation of carburetor ··········································································································-87-
11 Cylinder cover/air cylinder/piston·······································································································-90-
11.1 Preparation data ·······················································································································-90-
11.2 Fault diagnosis ·························································································································-91-
11.3 Disassembly of air cylinder······································································································-91-
11.4 Disassembly and installation of the piston················································································-92-
11.5 Installation of the air cylinder···································································································-95-
11.6 Disassembly of cylinder cover ·································································································-95-
11.7 Installation of the cylinder cover ······························································································-96-
12 Crankcase/clutch/actuating lever ········································································································-98-
12.1 Preparation data ·······················································································································-98-
12.2 Fault diagnosis·························································································································-99-
12.3 Crankcase ································································································································-99-
12.4 Clutch ·····································································································································-100-
12.5 Actuating lever························································································································-103-
13 Crankshaft-connecting rod set and shift chamber···············································································-105-
13.1 Preparation data ······················································································································-105-
13.2 Crankshaft and connecting rod set···························································································-105-
13.3 Shift chamber··························································································································-107-
13.4 Shift shaft set ··························································································································-108-
13. 5 Main shaft and sub shaft ········································································································-109-

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14 Cooling system··································································································································-112-
14.1 Preparation data ······················································································································-112-
14.2 Fault diagnosis························································································································-112-
14.3 Water pump/water tank ···········································································································-112-
15 Exhaust emission and control system·································································································-118-
15.1 Warranty of Exhaust emission and control system ··································································-118-
15.2 Regular maintenance guideline ·······························································································-119-
15.3 Mechanical function of the exhaust control system ·································································-120-
15.4 Catalyst converter system ·······································································································-121-
15.5 Countermeasure of idle speed emission exceeding specified value（two-stroke)····················-122-

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Preface
This Manual explains the maintenance of Generic Trigger 50ccm
The documents to be prepared are the maintenance manual and all the operations are included in, please read the
manual prior to operation.
Inspection and Adjustment explains the gist of inspection and adjustment; the maintenance of safety of vehicle and
the performance of each part should come into force since regular inspection.
After Chapter I is the explanation of the gist of disassembly, assembly and inspection of engine, entire vehicle and
electric fittings.
There are exploded view, system diagram, maintenance, fault diagnosis and explanation before each chapter.
Notice：
For the universal parts of both types of motorcycle, this manual does not seperate the explanation.
There is no prior individual notification on the alteration of mode or structure of motorcycle and the actual product
shall prevail if there is discrepancy between the photos, pictures or explanation contained in this Manual and the
actual product.

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Documents to be prepared
Generalsafety Maintenanceregulation
Specififcationsheet Troubleshooting
General safety
Carbon monoxide
The engine should be started in ventilated area other than closed area.
Attention
The exhaust contains toxic gas, carbon monoxide, which can numb people and may result in death.
The engine should be started in an open area and the exhaust scavenging system should be applied if the engine
has to be started in a closed area.
Gasoline
The operation should be made in a ventilated area and smoking or lighting fires should be strictly forbidden in
working space or the place stored gasoline.

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Maintenance regulation
As maintaining this vehicle, the instrument of metric system should be applied as possible for the reason that the
application of incorrect instrument may demage this vehicle.
Before dismantling from the frame cover of vehicle to maintain the dirt of parts or external subassembly should be
purged in order to prevent that falling into engine, chasis or braking system.
After dismantling and before measuring attrition value, please
clean parts and purge it with compressor.
The operation should not be bended or distorted; otherwise it
will cause operational difficulties or demage ahead of time.
The rubber parts will be deteriorated due to aging which is
prone to be damaged by solvent or oil and it should be inspected
(if necessary, it should be replaced) before reinstallation.
Loosen the parts with multiple assemblies that should be made
from outside to inside and started from small one.
The complicated assembly, transmission case, for instance,
should be stored according to proper assembly sequence in order
to facilitate the assembly in the future.
error error error
cover

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For the important assembly position, it should be given special
attention before dismantling. The parts out of use should be
replaced before dismantling in time.
The length of bolts to assemblies and frame cover are different
which should be installed in correct position and the bolts may
placed in the hole to find out whether they are suitable if they
are mixed.
For the installation of oil seal, the grease should be filled in oil
seal groove; as installing oil seal, it should check the smoothness
of oil seal whether it will likely damage the oil seal.
For the installation of rubber hose (fuel, vacuum or coolant), the
ends of which should plug into the bottom of the joint in order to
ensure that there is enough space for hose clamp to clamp the
joint. The rubber or plastic soldering cup should restore its
original design position.
As dismantling ball bearing, please use the tool to withstand one
or two (internal and external) bearing runners. If the strength is
only applied onto a rolling ring (no matter internal or external),
the bearing may be damaged as dismantling and has to be
replaced.
In both instances, the bearings will
be broken

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Specififcation Sheet Trigger X 50ccm
Model Trigger 50ccm Engine Type 40-2 2-stroke engine
Full length mm 2060 Fuel type
Unleaded gasoline of 95
Octane above
Full width mm 890 Number of
cylinders 1
Full height mm 1230 Inside measure
* stroke 40.25*39mm
Wheelbase mm 1370 Total flow rate 49.6mm
Front
axle 53 Start mode Start by electricity/foot
Rear
axle 58 Cooling mode Water-cooling
Vehicle weight kg
Total 111 Lubrication Separated lubrication
Front
（internal）
Front
（external）
3.00-21 3.00-21
Engine oil
capacity 0.8L
Rear（internal）Rear（external）
Tyre specification
4.10-18 4.10-18 Air cleaner Sponge
Engine
Petrol capacity 10（+/-）0.2 L
Clutch type Wet multidisc brake Maximum
speed 45km/h
Climbing
capability
Maximum climbing angle
no less than 15 degree
Transmission Manual
Idling speed -
rpm 1400±100rpm/min
Gearing
Driving mode Chain drive Maximum
torque 2.60Nm/3000rpm
Battery
capacity/type 12V 3AH Maximum
horsepower 1.39KW/5500 rpm
Generator type 1E40MB-2 Compression
ratio 7.0：1
Spark plug BR8ES/F10KC
Performance
Cylinder
pressure 1.1-1.3Mpa/1400rpm
Spark plug gap 0.5-0.7mm
Front liquid
braking disc
unit（mm）
φ230mm
Electrical installation
Ignition mode CDI
Brake
Rear liquid
braking disc
unit（mm）
φ220mm

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Specififcation Sheet Trigger SM 50ccm
Model Trigger 50ccm Engine Type 40-2 2-stroke engine
Full length mm 2035 Fuel type
Unleaded gasoline of 95
Octane orabove
Full width mm 890 Number of cylinders 1
Full height mm 1230 Inside measure * stroke 40.25*39mm
Wheelbase mm 1390 Total flow rate 49.6mm
Front
axle 55 Start mode Start by electricity/foot
Rear
axle 60 Cooling mode Water-cooling
Vehicle weight kg
Total 115 Lubrication Separated lubrication
Front（external）
100/80-17 Engine oil capacity 0.8L
Rear（external）
Tyre specification
130/80-17 Air cleaner Sponge
Engine
Petrol capacity 10（+/-）0.2 L
Clutch type Wet multidisc brake
Maximum speed 45km/h
Climbing capability Maximum climbing angle
no less than 15 degree
Transmission Manual
Idling speed - rpm 1400±100rpm/min
Gearing
Driving mode Chain drive Maximum torque 2.60Nm/3000rpm
Battery
capacity/type 12V 3AH Maximum horsepower 1.39KW/5500 rpm
Generator type 1E40MB-2 Compression ratio 7.0：1
Spark plug BR8ES/F10KC
Performance
Cylinder pressure 1.1-1.3Mpa/1400rpm
Spark plug gap 0.5-0.7mm Front liquid braking disc
unit（mm）φ280mm
Electrical installation
Ignition mode CDI
Brake
Rear liquid braking disc
unit（mm）φ220mm
TRIGGER X 50ccm

- 9 -

- 10 -
TRIGGER SM 50ccm

- 11 -
Troubleshooting
Difficult to start or unable to start
Troubleshooting Tune-upinspection Failurecause
Enough oil to
carburator
No gasoline
to
carburator
Loosen the oil drain
bolt of carburator to
check whether there
is oil within the
carburator
Spark plug
has flashover
Weak spark or no
spark of spark
plug
Dismantle the spark
plug and put it into
spark plug cover to
connect engine and
check whether the
spark plug has
flashover
Compression
pressure
measurement
Compression
pressure too low,
no compression
p
ressure
Normal compression
pressure
No ignition
burst
phenomenon of
engine
With burst
phenomenon but
the engine failed
to start
Spark plug is
damp
Spark plug is
dry
Dismantle the spark plug
again to re-inspect
No gasoline in gasoline tank
Oil tube clog of gasoline tank carburator
Oil tube clog of float chamber
Conduit clog of evaporation control system of fuel tank
Gasoline filter clog
Auto oil ring is broken
Spark plug is broken
Spark plug is polluted
CDI group is broken
Trigger is broken
The lead of sparking coil is open circuit or short circuit
Sparking coil is open circuit or short circuit
Main switch is broken
Charge coil is broken
Start clutch is broken
Air cylinder piston and piston ring are
broken
Cylinder head leaks
Auto choke actuation is bad
Intaken air in intake manifold
Incorrect ignition time
Bad adjustment of adjustable bolt of
carburetor
Overhigh oil level of carburetor
Auto choke actuation is bad
Too big throttle opening

- 12 -
Improper gyration (impotent velocity)
Troubleshooting Tune-upinspection Failurecause
Winding number
of engine
increases
Engine revolution
unable to increase
completely
Start the engine
and slightly
accelerate
Correct ignition
time
Incorrect ignition
time
Adjust ignition
timing and use
ignition timing light
N
ormal compressio
n
pressure Compression pressure is too low
Bad timing
ad
j
ustment
No clog Clogged
With pollution
and discoloration
No pollution and no
discoloration
Dismantle the spark plug and re-inspect
Clog inspection of carburetor
Normal Abnormal
Without superheat Overheating
No phenomenon
of deton
ation
With phenomenon
of detonation
Accelerated drive or
operation
Engine overheat
Inspect the lubrication of
air c
y
linder head
Normal mobile
oil level Too much
mobile oil
Check whether the
mobile oil in crankcase is
too much or polluted
Air cleaner clogged
Bad gasoline
Conduit clog of evaporation control
system of firing chamber
Exhaust pipe clogged
Auto choke is bad
Carburetor vacuum module is broken
Auto oil ring is broken
CDI group is broken
Trigger is broken
Air cylinder piston and piston ring are
broken
Cylinder head leaks
Cleaning contamination
Cleaning contamination
Discrepancy of spark-plug heat value
Too much mobile oil
Too little mobile oil
No change of mobile oil
Piston，cylinder wear
Piston，cylinder wear
Bad gasoline
Too much carbon laydown in combustion chamber
Too early ignition time
Too much carbon laydown in combustion chamber
Bad gasoline
Slipping of clutch
Tenuity of gas mixture
Too early ignition time

- 13 -
Improper gyration（especially at low speed）
Troubleshooting Tune-upinspection Failurecause
Normal Abnormal
Ignition time
adjustment
Favorable
adjustment
Maladjusted
Adjust the
adjustable screw of
carburetor oil level
No intake air With intake air
Dismantle the spark plug
and put it into spark plug
cover to connect engine
and check whether the
spark plug has flashover
Favorable
spark plug
flashover
Bad spark plug
flashover
Bad
Favorable
Intake air in
carburetor shim
CDI group is broken
Trigger is broken
Rare gas mixture（loosen the bolt）
Too thick gas mixture （locking
screw）
Bad heat spacer shim
Loosen fixing nut of carburetor
Broken shock insulator
Broken suction line
Bad or polluted spark plug
Bad CDI
Bad sparking coil
The lead of spark plug is open circuit
or short circuit
Main switch is broken
Damaged suction line
Ventilation hole clogged

- 14 -
Improper gyration（high speed）
Troubleshooting Tune-upinspection Failurecause
Normal
Abnormal
Ignition time
adjustment
Normal Abnormal
No clog Clogged
Spring broken
and slack
elasticity
Favorable
Carburettor clogged
CDI group is broken
Trigger is broken
Too little gasoline in gasoline
tank
Gasoline filter of gasoline pipe
clogged
Conduit clog of evaporation
control system of fuel tank
Auto oil ring is broken
Purged
Bad spring

- 15 -
Improper charging (overdischarge or over charge of battery)
Troubleshooting Tune-upinspection Failurecause
No increase of
battery voltage
Battery voltage
rised to normal
value and restore its
original voltage
after killing engine
Measure the voltages
of the both ends of
battery, start the
engine
Normal Abnormal
Inspect whether the voltage regulator
p
lu
g
is slack
With voltage No voltage
Measuring alternator coil resistance value
Normal Abnormal
Normal voltage
Voltage
higher than
normal value
Start engine, the red line of voltage regulator
socket connects to avometer and positive and
negative line connects the voltage of
motorcycle
Check the voltage regulator socket,
the red line connects universal meter
and positive and negative line connect
the volta
g
e of motorc
y
cle
Improper charging
Normal Slack and improper
connection
Inspect whether the connection of
voltage regulator wiring is correct
Voltage regulator unit test
impedance
Expired battery
Bad battery
Bad contact of plug
Open circuit of red line of wiring
Voltage regulator
Open circuit of white line of
wiring
Bad coil
Bad contact of joint
White line of alternator
disconnected
Bad battery
Improper contact of joint and
imperfect earth of wiring
Bad voltage regulator

- 16 -
Spark plug has no flashover
Troubleshooting Tune-upinspection Failurecause
Weak or no
flashover of
spark plug
Strong spark
Replace new spark plug
and examine it again
No slack Slack
Inspect spark plug and examine it
again
Normal Abnormal
Check the conduction among each
terminal of CDI group line trap, and
measure the resistance value
Normal Abnormal
AbnormalNormal
Inspection of
related position
Inspect whether the CDI
group plug is slack
Normal Abnor
Abnormal
Check sparking coil by CDI tester
Check CDI group by CDI tester
Bad former spark plug
Slack spark plug cover
Bad contact of plug
Main switch is broken
Charge coil is broken
Trigger is broken
Bad sparking coil
Main wiring disconnected
Bad contact of joint and socket
CDI group is broken
Bad sparking coil

- 17 -
Inspection/adjustment
Preparation of documents Cylinder pressure
Check list of constant maintenance Gear mobile oil
Engine mobile oil/oil strainer Changing gear oil
Gasolinefilter Drivingchain
Inspection/adjustment of accelerator's pull wire Clearance of front/rear brake
Aircleaner Frontshoeblockabrasion
Sparkplug Headlighting
Battery Clutch
Carburator Front/rearsuspensionsystem
Ignitiontiming Bolt/nut/fixture
Rim/tyre Tyrespecification
Steering post bearing and handle fixture
Preparation requirement
General
Warning!
•Before starting engine, please confirm whether there is favorable ventilation and do not start engine in a closed
location for that the exhaust gas contains carbon monoxide which may numb or kill people.
•Under certain condition, gasoline is prone to volatilize and explode so that the working place should be ventilated
and kill the engine and should be free from smoking and lighting in the working area or oil storage.

- 18 -
Specification
Engine
Gyration speed at idle
speed 1400±100rpm/min
Spark plug gap 0.5-0.7mm Engine oil
capacity
0.8L
Spark plug specification BR8ES/F10KC
Compression pressure of
air cylinder
1.1-1.3Mpa/1400rpm
Firing time BTDC12 degree（+/-）1degree 1400±100rpm
Carriage
Free stroke of front brake
drawbar
20-30mm
Free stroke of rear brake
drawbar
20-30mm
Specification Tire pressure
Front wheel of
inside
3.00-21 2,25 Bar
Rear wheel of
outside
4.10-18 2,25 Bar
Front wheel 100/80-17 2,25 Bar
Tire pressure unit：Bar
Rear wheel 130/80-17 2,25 Bar
Front wheel
spindle
55-62 N·m
Torque
force
value Rear-wheel spindle
nut
85-98 N·m

- 19 -
Check list of constant maintenance
Every
300 KM
Every
1000
KM
Every 3000
KM
Every 6000
KM
Every
12000 KM
Every
14500 KM
Mileage and time of
maintenance
Inspection items
New
motorcy
cle
One
month 3 months 6 months A year 15 months
Tools
* Air cleaner I C C R C General purpose tool
* Gasoline filter I I R General purpose tool
* Oil cleaner C C C General purpose tool
Changing engine mobile oil R Changed every 1000KM General purpose tool
Tire pressure I I I I I I Pressure meter, inflator
Battery inspection I I I I I I Gravimeter, universal
meter
Clearance inspection I I I I I I General purpose tool
Handle inspection I I I General purpose tool
Shock absorber inspection I I I General purpose tool
Bolt inspection I I I I I I Torque spanner
Oil leak inspection of gear case I I I I I I General purpose tool
* Spark plug inspection or replacement I I R R I General purpose tool
* Replacement of gear case oil I Changed every 5000KM General purpose tool
Lubrication of each part L L Lubrication filler
Exhaust pipe I I I I I I General purpose tool
* Ignition timing I I I I I I Timing lamp
* Carburator A I A A A A
* Inspection of idle speed and exhaust gas A I A A A A
Tachometer, CO HC
analyser
* Accelerator inspection I I I I I General purpose tool
Fuel line inspection I I I I I General purpose tool
Lamplight, instruments, electric
installations I I I I I I Visual universal meter
Main rack, side rack I I I General purpose tool
Shock absorber I I I I General purpose tool
* Torque force of engine bolt I I I I I Torque spanner