KSR Moto TRIGGER 50 Operating instructions
REPAIR MANUAL
D01 - TRIGGER 50 Vers. 2015_01
It is important that you read this repair manual carefully before the start of work.
Only use GENERIC/ KSR spare parts.
KSR Motot Motorcycles is a registered brand by KSR Group GmbH.
This vehicle can only full the demands placed on it if the service work is made by qualied experts and in accordance
with the service schedule.
The repair manual was written to correspond to the current state of this model.
We reserve the right to make changes in this manuals in the interest of technical advancements and improvements
without a notice.
It is recommended that repair work will be done by a fully educated mechanic.
We will not provide descriptions of general workshop methods, safety rules that necessary in a workshop.
All specications refers to the current state and are nonbinding. KSR Group GmbH specically reserves the right to
modify the information in this manual without notice and without specifying reasons.
KSR Group GmbH accepts no liability deviations from illustrations and descriptions or misprints and other errors.
The models in this manual partly contain special equipment that does not belong to the regular scope of delivery fur-
ther the illustrations and pictures are symbolic images, and may differ from the actual components.
© 2012 by KSR Group GmbH, Krems Austria
All rights reserved
Reproduction of this manual is permitted only with the express written permission of the copyright owner.
Within the meaning of the international quality management standard ISO 9001, KSR Group GmbH uses quality as-
surance processes that lead to the maximum possible quality of the products.
KSR Group GmbH
A-3500 Krems, Austria
INTRODUCTION 2
IMPORTANT NOTES 6
LOCATION OF SERIAL NUMBERS
VIN (VEHICLE IDENTIFICATION NUMBER)
AND FRAME PLATE 7
ANTI TEMPERING LABEL 7
ENGINE NUMBER 7
DECRYPTING THE VEHICLE IDENTIFICATION NUMBER 7
GENERAL SPECIFICATIONS
VEHICLE SPECIFICATION 8
SPECIFIC TIGHTENING TORQUE 10
GENERAL TIGHTENING TORQUE 11
SPECIAL TOOLS
SPECIAL TOOLS 12
1. PERIODIC MAINTENANCE
PERIODIC MAINTENANCE CHART
CHECKLIST OF CONSTANT MAINTENANCE 15
IMPORTANT PREPARATION REFERENCES
IMPORTANT PREPARATION REFERENCES 18
FUEL SYSTEM
AIR CLEANER 21
CHANGING INTERVALS 21
THROTTLE WIRE INSPECTION/ ADJUSTMENT 21
IDLE ADJUSTMENT 22
CARBURETTOR ADJUSTMENT 22
FUEL HOSE INSPECTION 22
FUEL FILTERS CLEANING 23
ENGINE
ENGINE OIL LEVEL INSPECTION 23
ENGINE OIL LEVEL SENSOR INSPECTION 24
OIL PUMP INSPECTION 24
OIL PUMPADJUSTMENT 26
TRANSMISSION OIL LEVEL INSPECTION 27
SPARK PLUG INSPECTION 27
SPARKPLUG IMAGES AND ANALYSIS 28
SPARK PLUG REPLACEMENT 28
CYLINDER PRESSURE INSPECTION 28
CLUTCH
CLUTCH CABLE FREE PLAY ADJUSTMENT 29
ADJUSTING THE CLUTCH CABLE FREE PLAY
ON THE ENGINE SIDE 29
CLUTCH ADJUSTMENT 30
WHEELS
AIR PRESSURE INSPECTION 30
WHEEL BEARING AND WHEEL AXLE
DAMAGE INSPECTION 31
BRAKES
BRAKE FLUID LEAK INSPECTION FRONT 31
BRAKE FLUID LEAK INSPECTION REAR 31
BREAK OPERATION INSPECTION FRONT 31
BREAK OPERATION INSPECTION REAR 32
BRAKE FLUID LEVEL INSPECTION FRONT 32
BRAKE FLUID LEVEL INSPECTION REAR 32
FRONT BRAKE PADS INSPECTION 33
REAR BRAKE PADS INSPECTION 33
FRONT BRAKE DISC INSPECTION 34
REAR BRAKE DISC INSPECTION 35
FRONT BRAKE LEVER/ MASTER BRAKE
CYLINDER REPLACEMENT 35
FOOT BRAKE LEVER/ MASTER BRAKE
CYLINDER REPLACEMENT 36
FRONT BRAKE CALLIPER REPLACEMENT 36
REAR BRAKE CALLIPER REPLACEMENT 36
FRONT BRAKE HOSE REPLACEMENT 37
REAR BRAKE HOSE REPLACEMENT 37
FRONT BRAKE LEVER ADJUSTMENT 38
REAR BRAKE LEVER ADJUSTMENT 38
DRIVE CHAIN
DRIVE CHAIN SLACK INSPECTION 39
DRIVE CHAIN SLACK ADJUSTMENT 39
DRIVE CHAIN LUBRICATION 39
DRIVE CHAIN WEAR INSPECTION 40
SUSPENSION
FRONT FORK OPERATION INSPECTION 40
FRONT FORK OIL LEAK INSPECTION 40
REAR SHOCK OPERATION INSPECTION 41
REAR SHOCK OIL LEAK INSPECTION 41
STEERING
STEERING PLAY INSPECTION 41
STEERING BEARING LUBRICATION 42
ELECTRICAL SYSTEM
BATTERY INSPECTION/ CHARGING 43
FUSES 44
LIGHTAND SWITCHES OPERATION INSPECTION 44
HEADLIGHTAIMING INSPECTION 45
2. REPAIR AND DIAGNOSTIC
CHASSIS
EXPLODED VIEW / PART LOCATION - FRAME 47
EXPLODED VIEW / PART LOCATION - REAR
SWING ARM 48
EXPLODED VIEW / PART LOCATION - SEAT 48
FUEL SYSTEM
EXPLODED VIEW / PART LOCATION - FUEL SYSTEM 50
SPECIFICATION 51
CARBURETTOR
EXPLODED VIEW / PART LOCATION - CARBURETTOR 52
CARBURETTOR REMOVAL 53
CHOKE/ CABLE REMOVAL 53
CARBURETTOR UPPER COVER REMOVAL 54
CARBURETTOR ADJUSTMENT 54
FUEL SUPPLY
FUEL SUPPLY INSPECTION 54
FUEL TANK REMOVAL 55
FUEL COCK 56
ENGINE
EXPLODED VIEW / PART LOCATION - CYLINDER/
CYLINDER COVER 57
EXPLODED VIEW / PART LOCATION - CRANK
ASSEMBLY 58
EXPLODED VIEW / PART LOCATION - CRANKCASE 59
SPECIFICATION 60
TROUBLESHOOTING 61
ENGINE OVERHAUL/ REMOVAL 62
ENGINE PREPARATION 62
ENGINE REMOVAL 62
ENGINE TOP END
CYLINDER COVER REMOVAL 63
CYLINDER REMOVAL 63
PISTON REMOVAL 63
OIL PUMP REMOVAL 64
WATER PUMP REMOVAL 64
CRANKCASE (RIGHT) REMOVAL 64
CLUTCH REMOVAL 65
CRANKSHAFT GEARAND MAIN SHAFT GEAR REMOVAL 66
MEMBRANE 66
SPROCKET REMOVAL 66
CRANKCASE COVER (LEFT) REMOVAL 67
INDEX 3
INDEX 4
STARTER REMOVAL 67
STARTER GEAR REMOVAL 67
STATOR REMOVAL 67
CRANKCASE SEPARATION 68
CRANKSHAFT REMOVAL 68
TRANSMISSION DISASSEMBLY 69
INPECTION OF TRANSMISSIONAND GEAR SHIFT
MECHANISM 70
EXPLODED VIEW / PART LOCATION - PRIMARY
SHAFTASSY/ SECONDARY SHAFTASSY 71
EXPLODED VIEW / PART LOCATION - SHIFT
MECHANISM 72
EXPLODED VIEW / PART LOCATION - REDUCTION
GEAR 73
INSPECTION OF TRANSMISSIONAND SHIFT
MECHANISM 74
TRANSMISSION ASSEMBLING 75
CRANKSHAFT INSPECTION 76
TOP END PARTS INSPECTION 78
PISTON INSTALLATION 80
CYLINDER INSTALLATION 81
CYLINDER COVER INSTALLATION 81
LEFT CRANKCASE ASSEMBLING 82
SPROCKET INSTALLATION 83
MEMBRANE INSPECTION 83
MEMBRANE INSTALLATION
RIGHT CRANKECASE ASSEMBLING 83
CLUTCH INSPECTION 84
EXPLODED VIEW / PART LOCATION CLUTCH 85
CLUTCH ASSEMBLING 86
OUTWARD RELEASE LEVER ADJUSTMENT 87
ACTUATING LEVER INSPECTION 87
ACTUATING LEER ASSEMBLING 87
RIGHT CRANKCASE ASSEMBLING 87
ACTUATING LEVER ADJUSTMENT 88
EXPLODED VIEW / PART LOCATION - OIL PUMP 89
INSPECTION OF THE OIL PUMP 89
OIL PUMP ASSEMBLING 89
LUBRICATION SCHEME 90
COOLING SYSTEM SCHEME 91
WATER PUMP INSPECTION 91
WATER PUMP ASSEMBLING 91
WHEELS AND TIRES
EXPLODED VIEW / PART LOCATION - FRONT WHEEL 92
EXPLODED VIEW / PART LOCATION - REAR WHEEL 93
WHEELS (RIMS) 94
TIRES 94
WHEEL BEARING REPLACEMENT FRONT WHEEL 94
WHEEL BEARING REPLACEMENT REAR WHEEL 95
WHEEL BEARING INSPECTION 95
WHEEL AXLE INSPECTION 95
RIM INSPECTION 95
BRAKES
EXPLODED VIEW / PARTLOCATION - FRONT BRAKE 96
EXPLODED VIEW / PART LOCATION - REAR BRAKE 97
BRAKE LEVERS / FRONT BRAKE LEVER 98
BRAKE LEVERS / REAR BRAKE PEDAL 98
BRAKE FLUID 99
BRAKE HOSE 99
REAR BRAKE PAD WEAR INSPECTION 99
BRAKE PEDAL REPLACEMENT 100
SUSPENSION
EXPLODED VIEW / PART LOCATION - FRONT
SUSPENSION 101
EXPLODED VIEW / PART LOCATION -ADJUSTABLE
REAR-SUSPENSION 103
FRONT SUSPENSION REPLACEMENT 104
FRONT SUSPENSION WHOLE FORK REPLACEMENT 105
REAR SUSPENSION REPLACEMENT 105
REAR SWING ARM REPLACEMENT 106
STEERING
EXPLODED VIEW - PART LOCATION / STERRING 107
HANDLEBAR REPLACEMENT 108
CLUTCH LEVER REPLACEMENT 109
BRAKE LEVER REPLACEMENT 110
EXHAUST
EXHAUST REPLACEMENT 110
SECONDARY AIR SYSTEM
SECONDARYAIR SYSTEM INSPECTION 112
ELECTRICAL SYSTEM
WIRING DIAGRAM 114
LOCATION - ELECTRICAL SYSTEM 115
LOCATION - LIGHTS / INSTRUMENTS SWITCHES 116
SPECIFICATION 117
FUSES
FUSE REPLACEMENT 118
SPECIFICATION 118
TROUBLESHOOTING 118
BATTERY
BATTERY GENERAL INFORMATION 118
BATTERY REMOVAL 119
BATTERY AND CHARGING SYSTEM 119
CHARGING SYSTEM
CHARGING SCHEME 120
CHARGING PERFORMANCE TEST 120
REGULATOR - RECTIFIER INSPECTION 121
GENERATOR CHARGING COIL 121
IGNITION SYSTEM
IGNITION SYSTEM 122
PREPARATORY DATA 122
SPECIFICATION 123
FAULT DIAGNOSIS 123
IGNITION SYSTEM INSPECTION 124
PRIMARY VOLTAGE OF IGNITION COIL 124
TRIGGER (PICK UP) 124
TRIGGER INSPECTION 125
CDI ASSEMBLY 125
IGNITION COIL REMOVAL 125
PRIMARY COIL INSPECTION 125
SECONDARY COIL INSPECTION 126
STARTING SYSTEM
STARTING DIAGRAM 126
FAULT DIAGNOSIS 127
STARTING MOTOR 127
STARTING MOTOR INSPECTION 127
STARTING RELAY 127
STARTING RELAYACTUATION INSPECTION 127
STARTING RELAY VOLTAGE INSPECTION 128
LIGHTNING SYSTEM
BULBS REPLACEMENT GENERAL INFORMATION 129
HEADLAMP BULB REPLACEMENT 129
POSITION LIGHT BULB REPLACEMENT 130
WHOLE HEADLIGHT REPLACEMENT 130
REAR WINKER REPLACEMENT 131
FRONT WINKER REPLACEMENT 131
BULB WINKER REPLACEMENT 132
BULB TAILLIGHT REPLACEMENT 132
TAILLIGHT REPLACEMENT 133
LICENSE PLATE BULB REPLACEMENT 133
SPEEDOMETER
SPEEDOMETER DESCRIPTION 134
SPEEDOMETER REPLACEMENT 134
INDEX 5
SWITCHES AND SENSORS
IGNITION SWITCH INSPECTION 134
IGNITION SWITCH REPLACEMENT 134
STEERING LOCK 134
ELECTRIC HORN INSPECTION 135
ELECTRIC HORN REPLACEMENT 135
LEFT HANDLE SWITCH 135
RIGHT HANDLE SWITCH 135
LEFT HANDLE SWITCH INSPECTION 136
LEFT HANDLE SWITCH REPLACEMENT 136
RIGHT HANDLE SWITCH INSPECTION 136
RIGHT HANDLE SWITCH REPLACEMENT 137
FRONT BRAKE LIGHT SWITCH
INSPECTION / REPLACEMENT 137
REAR BRAKE LIGHT SWITCH INSPECTION 138
REAR BRAKE LIGHT SWITCH REPLACEMENT 138
NEUTRAL SENSOR INSPECTION 139
NEUTRAL SENSOR REPLACEMENT 139
SPEED SENSOR INSPECTION 140
SPEED SENSOR REPLACEMENT 140
FAULT DIAGNOSIS 142
CHASSIS
SEAT REMOVAL 143
LEFT / RIGHT SIDE COVER REMOVAL 143
LEFT / RIGHT LOWER SIDE COVER REMOVAL 143
LEFT / RIGHT TANK SIDE COVER REMOVAL 144
REAR BODY PANEL REMOVAL 144
REAR SIDE COVER REMOVAL 145
REAR FENDER REMOVAL 145
FRONT FENDER REMOVAL 146
HEADLIGHT COVER REMOVAL 146
COVER FRONT SHOCKABSORBER LEFT REMOVAL 147
COVER FRONT SHOCKABSORBER RIGHT REMOVAL 148
MIRROW
BACK VIEW MIRROWS 149
BACK VIEW MIRROWS REMOVAL 149
SECOND SPEEDOMETER
SECOND SPEEDOMETER 150
SWITCH BUTTON FUNCTION LIST 150
REMOVAL OF POWER LIMITATION
REMOVAL OF POWER LIMITATION 151
LEVEL 1 151
LEVEL 2 151
WARRANTY
The work prescribed in the service schedule must be carried out in an authorized workshop and conrmed in the cus-
tomer‘s service card, otherwise no warranty claims will be recognized. No warranty claims can be considered for dam-
age resulting from manipulations and/or alterations to the vehicle.
NOTES AND WARNINGS
Pay attention to the notes/warnings in this manual.
• Identies dangers that will lead to environmental damage if the measures are not taken.
• Identies dangers that is likely to lead to fatal or serious injury if the measures are not taken.
• Identies dangers that will lead to considerable machine and material damage if the measures are not taken.
• Identies dangers that will immediately lead to fatal or serious permanent injury if the appropriate measures are not
taken.
REPAIR MANUAL
It is important that you read this manual completely before the start of work. It contains useful information how to
repair and maintain the vehicle.
FUEL AND LUBRICANTS
Use only the fuels, oils and lubricants according to specications as listed in this manual.
Please consider that KSR Group GmbH give no approval for Bio- Ethanol (E 10 or higher) fuel.
SPARE PARTS AND ACCESSORIES
Only use spare parts and accessory that have been approved or recommended by KSR Group GmbH.
PRACTICE
Special tools are required for some work but mostly professional work shop equipment is enough for service, repair and
maintenance of the vehicle. Special tools mentioned inside of this manual.
When thread locker is used on connections (e.g., Loctite®), follow the instructions for use from the manufacturer.
After disassembly, clean the parts that are to be reused and check them for damage and wear. Replace damaged or
worn parts.
IMPORTANT
• After each repair or maintenance work security check and a test drive must be done.
• Before you delivery the vehicle to the customer a road safety test must be done.
!WARNING
IMPORTANT NOTES 6
VIN (CHASSIS NUMBER) AND FRAME PLATE
The vehicle identication number (VIN) (1) is punched into the
right side of the steering tube. The frame plate (2) is located
on the right side in front of the frame.
ANTI TEMPERING LABEL
The anti tempering label (3) is xed on the inner side of the
seat bench.
ENGINE NUMBER
The engine number (4) is stamped into the left side of the
engine case.
DECRYPTING THE VEHICLE IDENTIFICATION NUMBER
EXAMPLE: VA4D0115XDB775449
VA4 - WORLD MANUFACTURER INDEX (NAME OF MANUFACTURER)
D01 - MODEL TYPE
1 - VARIANT OF MODEL
5 - VERSION OF MODEL
X - RANDOM NUMBER
D - YEAR OF PRODUCTION (CB = 2012/ DB = 2013,.........)
B - ASSEMBLING PLANT (LOCATION OF FACTORY)
775449 SERIAL NUMBER
LOCATION OF SERIAL NUMBERS 7
1
2
3
4
ENGINE
Engine type: Liquid cooled 2 - stroke
Cylinder arrangement: Horizontal (+60°) single cylinder
Displacement: 49.6 cm³
Compression ratio: 7.0:1
Max. output (kw/rpm): 2.2 kW/ 6500 rpm
Max. torque (Nm/rpm): 3.6 Nm/ 5500 rpm
Starting system: Electric starter and Kick starter
Lubrication system: Fresh oil lubrication
ENGINE OIL QUANTITIY
Capacity: 1 L
Recommended type: CASTROL Power 1-Racing 2T Fully Synthetic
TRANSMISSION OIL
Quantity 0.5 L for disassemble/ 0.4 for replacement
Recommended type: CASTROL Power 1-Racing 4T 10W-40
AIR FILTER ELEMENT
Foam lter
FUEL
Recommended fuel: Unleaded gasoline only ≥ 95 Oct
Do not use Bio-Ethanol fuel - E10 is not permitted
Fuel tank capacity: 10 L ± 0.2 L
CARBURETTOR
Type/ Manufacturer: PZ19JB JB-4/ LEADER or QJ
Main jet: 95
Idle jet: 22.5
SPARK PLUG
Manufacturer/ model: NGK/BR8ES
CLUTCH
Clutch type: Multi-disc in oil bath
TRANSMISSION TYPE
Manual, 5 speed
CHASSIS
Frame type: Steel tube
TIRES (Version 0 = Trigger X)
Front tire
Type: Tubeless/ Pressure on cold tire: 2.25 bar
Size: Rim: 1.6*21
Tire: 3.00-21
Rear tire
Type: Tubeless/ Pressure on cold tire: 2.25-2.5 bar
Size: Rim: 1.85*18
Tire: 4.10-18
TIRES (Version 1 = Trigger SM)
Front tire
Type: Tubeless/ Pressure on cold tire: 2.25 bar
Size: Rim: 2.5*17
Tire: 100/80-17
Rear tire
Type: Tubeless/ Pressure on cold tire: 2.25-2.5 bar
Size: Rim: 3.00*17
Tire: 130/80-17
Version 0
Version 1
GENERAL SPECIFICATION 8
GENERAL SPECIFICATION 9
BRAKES
Front brake
Type: Single Hydraulic disc brake (280 mm)/ Right hand operation
Brake uid: DOT4
Recommended brake uid: (CASTROL SUPER DISK BRAKE
FLUID DOT 4.)
Rear brake
Type: Hydraulic disc brake (220 mm)/ Right foot operation
Brake uid: DOT4
Recommended brake uid: (CASTROL SUPER DISK BRAKE
FLUID DOT 4.)
FRONT SUSPENSION
Type: Telescopic fork
Spring/shock absorber type: Coil spring/oil damper
REAR SUSPENSION
Type: Unit swing
Spring/shock absorber type: Coil spring/oil damper
ELECTRICAL SYSTEM
Ignition system: CDI
Charging system: Magneto
BATTERY
Model: YT4L-BS/ 12V, 3 Ah
LIGHT AND BULBS
Headlight : 12 V , 35.0 W
Tail/brake light: 12 V , 21.0 W / 5.0W
Position light 12 V, 35.0 W
Front turn signal light: 12 V, 10.0 W
Rear turn signal light: 12 V, 10.0 W
License plate light: 12 V, 5.0 W
High beam indicator light: 12 V, 2 W
Turn signal indicator lights: 12 V, 3 W
N signal indicator light: 12V, 3 W
Instrument lights (2x): 12V, 3 W
MAIN FUSES
10.0 A
SPECIFIC TIGHTENING TORQUES 10
MODULE PART TORQUE / Nm
Electrical System
Starting motor clutch cover bolt 12
Starting motor clutch locknut 95
Rectier bolt 5
Fixing bolt of ignition coil 9
Fixing bolt of ywheel 35-40
Wheel Axles Front wheel spindle 55 - 62
Rear wheel spindle nut 85 - 98
Fuel tank Fixing bolt for fuel tank 5-9
Cushion mounting bolt 9-10
Front brake system
Fixing bolt of brake disc 22-29
Mounting bolt of brake caliper 22-29
Fixing bolt of hand brake lever braket 5-9
Rear brake system
Fixing bolt of brake disc 22-29
Mounting bolt of brake caliper 22-29
Fixing bolt of hand brake lever braket 5-9
Rear shock absorber Top nut of rear shock absorber 37-44
Bottom nut of rear shock absorber 37-44
Front fork Front shock absorber mounting bolt 37-44
Handlebar Upper bracket assembly mounting bolt 40-60
Mufer Mounting bolt for mufer 5-9
Combined screw for mufer protecting plate 5-9
Engine
Cylinder cover nut 18-22
Fixing nut in the power gear of clutch 50-60
Stud bolt of air cylinder 18-22
Clutch locknut 50-60
Spark plug 10-15
Limiting screw of the feet starter lever 35-40
Shift positioned bolt 10-16
Mould assembling bolt 10-12
Bolts on the right and left crankcase cover 10-12
Loop bolt 10-12
Motor xing bolt 10-12
Seperating disk bolt of clutch 10-16
Fixing bolt of inlet valve 10-12
Setscrew of shift display 4-7
Setscrew of constant temperature set 4-7
Setscrew of electric wire clamp 4-7
Fixing bolt of water pump 10-12
Frame Rear swing arm shaft nut 70-83
If no specic torque is given for a bolted assembling use the table below to tighten the screws. If you release a bolted
and glued assembling it must be glued in assembling again. For the bonding of screws use Loctite ® 243 ™, follow
the instructions for use from the manufacturer.
*The value R (strength) indicates the material property. The lower the value of R is the lower the torque of the bolts.
MAXIMUM TORQUE IN NM REFERRING ISO 898/1 FOR METRIC
FASTENERS/ COEFFICIENT OF FRICTION 0.12
Size *Strength (R) 3.6 *Strength (R) 8.8 *Strength (R) 12.9
M1.6 0.047 Nm 0.169 Nm 0.285 Nm
M 2 0.10 Nm 0.35 Nm 0.60 Nm
M 2.5 0.21 Nm 0.73 Nm 0.12 Nm
M 3 0.36 Nm 0.12 Nm 0.21 Nm
M 4 0.82 Nm 3.0 Nm 5.1 Nm
M 5 1.6 Nm 5.9 Nm 10.0 Nm
M 6 2.8 Nm 10.1 Nm 17.4 Nm
M 8 6.8 Nm 24.6 Nm 42.2 Nm
M 10 13.7 Nm 48 Nm 83 Nm
M 12 23 Nm 84 Nm 144 Nm
M 14 37 Nm 133 Nm 229 Nm
M 16 57 Nm 206 Nm 354 Nm
M 18 80 Nm 295 Nm 492 Nm
M 20 112 Nm 415 Nm 692 Nm
GENERAL TIGHTENING TORQUES 11
SPECIAL TOOLS 12
Special tools are required for some work but mostly professional work shop equipment is enough for service, repair and
maintenance of the vehicle. After disassembly, clean the parts that are to be reused and check them for damage and
wear. Replace damaged or worn parts.
NAME REMARKS
Flywheel extractor Figure 1
Spacer gauge Figure 2
Dismounting tools for bearing Figure 3
Assembling tools for bearing Figure 4
Oil-seal dismounting tool Figure 5
Handle of dismounting tools Figure 6
Piston pin exhaustion apparatus Figure 7
Piston ring opening pincer Figure 8
Spark plug circular wrench Figure 9
Dial dictator (subito) - Measure inner bore Figure 10
Cylinder diameter tester Figure 11
Inner hexagon wrench Figure 12
Rest wrench Figure 13
Micrometer Figure 14
Circular wrench Figure 15
Dial indicator Figure 16
Magnetic stand, V-shape block Figure 17
Square caliper Figure 18
Whack-type screw drive Figure 19
Front fork oil seal dismounting tools Figure 20
Front part seal element driving-in tools Figure 21
Steering nut wrench Figure 22
Universal meter Figure 23
Spring clip-ring clipper Figure 24
Ignition tester Figure 25
Clutch holder Figure 26
Valve guide remover Figure 27
Valve guide installer Figure 28
Valve clearance adjuster Figure 29
Valve spring remover Figure 30
Valve guide reamer Figure 31
Crankcase remover Figure 32
Dial gauge, V-block Figure 33
Brake bleeder device no picture
Fig. 1 Fig. 2
Fig. 3
Fig. 7
Fig. 11
Fig. 5
Fig. 9
Fig. 13
Fig. 4
Fig. 8
Fig. 12
Fig. 6
Fig. 10
Fig. 14
SPECIAL TOOLS 13
SPECIAL TOOLS 14
1. Bush-head 2.Shake-handle
3.Ratchet type wrench 4.Connecting-rod
Fig. 15
Fig. 19
Fig. 22a
Fig. 17
Fig. 21a
Fig. 23a
Fig. 16
Fig. 20
Fig. 22b
Fig. 18
Fig. 21b
Fig. 23b
SPECIAL TOOLS 15
Fig. 24
Fig. 28
Fig. 32
Fig. 26
Fig. 30
Fig. 25
Fig. 29
Fig. 33
Fig. 27
Fig. 31
Following special tools are not used for 2-stroke engines:
-> Fig. 27, Fig. 28, Fig. 29, Fig. 30, Fig. 31, Fig.32, Fig. 33
1. PERIODIC MAINTENANCE
Important maintenance work have to be carried out by an authorized workshop.
PERIODIC MAINTENANCE CHART 17
CHECKLIST OF CONSTANT MAINTENANCE
The inspection intervals are required, otherwise, no guaran-
tee can be granted. 1000 km or
1. month 4.000 km or
6. month 7.000 km or
12. month 10.000 km or
18. month 13.000 km or
24. month
PART TO DO
Air lter Clean / exchange √ √ exchange √ √
Wheels, rims Control √ √ √ √ √
Tires Control / tire pressure √ √ √ √
Wheel bearing Control / exchange √ √ √ √
Steering bearing Control / clean / lubricate √ √ √ lubricate √
Screws Coverparts Control / tighten √ √ √ √
Brake system Control / clean / exchange √ √ √ √
Main stand Control / clean / lubricate √ √ √ √
Front fork Control √ √ √ √
Rear suspension Control √ √ √ √
Oil lter Clean √ √ √
Engine oil Control / exchange exchange √ exchange √ exchange
Valves (Engine) Control / adjust √ √ √ √ √
Transmission oil* Exchange exchange exchange exchange
Variomatic belt* Control / exchange √ exchange √
Fly wheels* Control / exchange √ exchange √
Driven chain / sprokets* Control / clean / exchange √ √ √ √ √
Clutch Control √ √ √ √ √
Cable / bowden Control / clean / lubricate √ √ √ √ √
Throttle Control / adjust / lubricate √ √ √ √
Lights / switches Control / adjust √ √ √ √ √
Fuel line / fuel lter Control / exchange √ exchange √ √
Idle speed Control / adjust √ √ √ √ √
Exhaust system Control / tighten √ √ √ √
Coolant* Control √ √ √ √ √
CAUTION: Variomatic belt, y wheels respectively drive chain/sproket, spark pluge, fuel lter and air lter element
have to be exchanged every 7000km. Only use duration coolant. Brake lines have to be exchanged at least every
4 years. From 13.000km or 24th month the inspection should be made every 7000km. The vehicle is constantly
checked for rust. The owner is responsible for rust prevention.
* Model specic deviations are possible
ENGINE
Oil/ Oil pump
Item Standard Service Limit
Transmission oil
capacitiy Oil for replacement 0.4+/- 0.1 L --
Oil for disassemble 0.5+/- 0.1 L --
Engine oil capacity Engine oil 1 L
Oil pump Outer diameter of the piston -- 2.45 mm
Cylinder/ Piston
Item Standard value [mm] Allowable limit [mm]
Air cylinder
Bore diameter 40.27 - 40.28 40.3
Bend --- 0.05
Cylindricity --- 0.05
Roundness --- 0.05
Piston and
piston ring
Clearance between the piston
ring and the pinston ring groove Top ring 0.015 - 0.05 0.09
Second ring 0.015 - 0.05 0.09
Interface clearance Top ring 0.1 - 0.25 0.5
Second ring 0.1 - 0.25 0.5
Outer diameter of piston 40.22 - 40.23 40.2
Clearance of piston and air cylinder 0.04 - 0.06 0.1
Bore diameter of piston pin hole 12.002 - 12.008 12.04
Outer diameter of piston pin 11.994 - 12 11.96
Clearance of piston pin hole and piston 0.002 - 0.014 0.08
Bore diameter of connectin rod small end 14.995 - 15.006 15.06
Carburettor
Item Standard value
Carburettor
Throat diameter 17.5
Main nozzle B03
Main jet 95
Idle jet 22.5
Needle valve B05-Z
Fuel tank
Item Standard Tolerance
Fuel tank capacity 10 L +/- 0.2 L
IMPORTANT PREPARATION REFERENCES 18
IMPORTANT PREPARATION REFERENCES 19
TRANSMISSION
Item Standard value [mm] Allowable limit [mm]
Crankshaft
Clearance of connecting rod big end in right
and left direction 0.1 - 0.35 0.55
Axial clearance of connecting rod big end in
vertical angle 0 - 0.008 0.005
Vibration --- 0.1
Clutch Thickness of wearing plate 2.9 - 3 2.6
Length of pressure spring 29.4 - 30.6 29.0
Shift mechanism
Bore diameter of shift fork 7.825 - 7.845 7.91
Thickness of shift fork 3.95 - 4.05 3.9
Outer diameter of shift drum 41.8 - 42 41.75
Locked groove width of shift drum 6.05 - 6.15 6.3
ELECTRICAL SYSTEM
Item Specication
Battery
Capacity 12 V / 3 AH
Voltage
(20°C) Fully recharged 13.1 V
Must be recharged 12.3 V
Charging current Standard 0.4 A
Quick 1.5 A
Charging period Standard 5-10 h
Quick 1 h
Magneto Max. capacity 80W / 1500 rpm
Coil impedance value (20°C) Between white and black 3.3 - 3.5 Ω
Voltage regulator Type single-phase semi wave SCR charge,
SCR semi wave short circuit mode
Battery recharging voltage 14-15 V / 5000 rpm
IGNITION
Item Standard value
Spark plug NGK/BR8ES
Spark plug gap 0.6 - 0.7 mm
Ignition coil impedance value (20°C)
Primary coil 0.4 Ω±10% (bl/w-bl)
Secundary coil With spark plug cover 8-11 KΩ
Without spark plug
cover 4.5-5.5 KΩ
Resistance value of trigger (20°C) 100-200 Ω (bl/w-gr/w)
Trigger voltage Above 1.7 V
IMPORTANT PREPARATION REFERENCES 20
STARTER MOTOR
Item Standard value Allowable limit
Brush length of startup motor 12.5 mm 8.5 mm
Liner of startup idler shaft 8.3 mm
Outer diameter of startup idler shaft 7.94 mm
WHEELS
Item Specication Tire pressure (bar)
Tire pressure unit
Front wheel of inside 3.00-21 2.25
Rear wheel of inside 4.10-18 2.25
Front wheel 100/80-17 2.25
Rear wheel 130/80-17 2.25
Measuring position Item Standard value (mm) Service limit (mm)
Front wheel shaft Curvature 0.2
Front wheel Wheel
shimmy Longitudinal 2.0
Transversal Within 1.0 2.0
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