Panterra Fusion User manual

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NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL
FORWARD
This manual is intended to serve as an
introduction to the PanTerra motor scooter
and to provide basic material and information
about the maintenance and servicing of this
vehicle.
Chapter 1 covers the product specifications
and technical data as well as basic
adjustments and maintenance of the scooter.
Also included is a section on maintenance
techniques, troubleshooting and problem
solving.
Chapter 2 covers disassembly and servicing
of the body panels for the scooter.
Chapter 3 covers all of the technical
information necessary to perform routine
maintenance on the scooter along with
diagrams that will help you in this process. A
scheduled maintenance chart is included to
help keep track of important maintenance
requirements.
Chapter 4 covers the operation and repair of
the lubrication system for the scooter engine.
Chapter 5 covers the operation and repair of
the fuel system including the carburetor.
Chapter 6 covers the removal and installation
of the engine to the scooter.
Chapter 7 covers diagnostic procedures and
repair methods for the cylinder head and
valve train of the engine.
Chapter 8 covers service and repairs of the
cylinder, piston and rings of the engine.
Chapter 9 covers diagnostic procedures,
service and repairs of the primary drive
system and the kick-starting system.
Chapter 10 covers service and repair of the
final transmission drive assembly.
Chapter 11 covers service and repair of the
crankcase and crankshaft assembly.
Chapter 12 covers the service and repairs for
the steering system, front suspension and
front braking system.
Chapter 13 covers the service and repair for
the rear suspension and brake systems.
Chapter 14 covers service and repair to the
charging system.
Chapter 15 covers service and repair to the
ignition system.
Chapter 16 covers service and repair to the
electric start system.
Chapter 17 covers service and repair to the
lighting and general electric systems.
If you cannot find the information that you
require in this manual, or for further help with
the servicing or repair of this scooter, contact
PanTerra Customer Service at 626 336 1128
Between the hours of 8am & 5pm PST

Table of Contents
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TABLE OF CONTENTS
Chapter Topic Page
CHAPTER 1: Introduction 2
CHAPTER 2: Body Cover and Exhaust System 28
CHAPTER 3: Scheduled Maintenance 33
CHAPTER 4: Lubricating System 45
CHAPTER 5: Fuel System 52
CHAPTER 6: Engine Removal and Installation 67
CHAPTER 7: Cylinder Head Valve 71
CHAPTER 8: Body Cover and Exhaust System 88
CHAPTER 9: Driving Belt Device & The Starting Lever 96
CHAPTER 10: The Final Transmission Assembly 110
CHAPTER 11: The Crankcase and the Crankshaft 116
CHAPTER 12: The Front Wheel, Front Brake, 124
Front Buffer and the Front Fork
CHAPTER 13: The Rear Wheel, the Rear Brake & Rear Shock 140
CHAPTER 14: The Battery and the Charging System 146
CHAPTER 15: Ignition System 160
CHAPTER 16: Starter System 166
CHAPTER 17: Meters, Switches and Lighting System 173
INDEX 180

1. General Information
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NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL
CHAPTER 1: INTRODUCTION
FRAME NUMBER CUT POSITION
ENGINE NUMBER CUT POSITION
Topic Page
Engine and Frame Number Positions 1-1
Product Specifications 1-2
and Technical Data
Technical Tips 1-3
Torque Settings 1-11
Topic Page
Tools 1-12
Oil and Grease Supply Chart 1-13
Control Cables and Wiring Diagram 1-14
Failure Diagnostics 1-21
Location for: Engine Number/Frame Number

1. General Information
Product Specifications and Technical Data
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CHAPTER 1: INTRODUCTION
Scooter Model Retro
Fusion
Freedom
Length 1685mm (66.5 inches)
Width 660mm (26 inches)
Height 1070mm (42 inches)
Wheel base 1195mm (47 inches)
Engine type 4-stroke OHC
Displacement 49.5cc
Fuel requirements Lead-free gasoline
Dry weight
Front 35kgs (77 lbs)
Rear 56kgs (123 lbs)
Total 91kgs (200 lbs)
Curb weight
Front 37kgs (81.5 lbs)
Rear 60kgs (132 lbs)
Total 97kgs (213.5 lbs)
Tire size
Front 3.00 x 10
Rear 3.00 x 10
Ground clearance 80mm (3.25 inches)
Stopping distance 4m from 30km/hr
16 ft from 18 mph.
Turning radius 1.65m (5.5 ft)
Engine Specs
Type 4-stroke SI
Starting Electric/kick start
Cylinders Single
Combustion chamber Hemispherical
Valve train Single OHC
Bore 39mm (13.34 inches)
Stroke 41.4mm (1.63 inches)
Displacement 49.5cc
Compression ratio 10.5:1
Compression pressure 15kg/cm
215psi
Power 2.2 HP @ 8000 RPM
Torque 4.5 ft lbs @ 6000 RPM
Intake timing 6˚ BTDC-28˚ ATDC
Exhaust timing 38˚ BBDC-6˚ BTDC
Valve lash .05mm
Idle speed 1850-1900RPM
Oil system Pressure/splash
Oil pump Internal gear
Oil filter Full-flow filter and screen
Oil capacity .8L (32 oz)
Cooling Ducted forced air
Air cleaner Foam and paper
Carburetor type CVK 50
Venturi 18mm
Throttle mechanism Butterfly type
Ignition system CDI type
13˚BTDC @ 2000 RPM
Spark plug NGK C7HSA Champion
Z9Y
Gap .5-.6mm (.022-.024 inch)
Battery 12V 4AH
Drive system
Clutch Dry multi plate
Transmission CVT
Shifting Automatic
Final Drive Double reduction
1st step 3.2:1
2nd step 3.4:1
Steer tube angle 64˚
Steering angle 45˚
Tire pressure front 1.75kg/cm (26psi)
Tire pressure rear 2.25kg/cm (35psi)
Front brake Hydraulic disc
Rear brake Mechanical drum
Suspension front Telescopic
Suspension rear Trailing arm
Shock absorber front Coil spring/hydraulic
Shock absorber rear Coil over hydraulic shock
Frame type Tubular space frame

1. General Information
•Replace all gaskets, o-rings, circlips
and cotter pins when performing
maintenance on the scooter. Nuts and
bolts on all engine covers should be
tightened in a diagonal pattern to
uniformly distribute clamp
force.
•Use lubricants recommended in this
manual at all times to assure peak
performance from the scooter.
•Use only genuine replacement parts
when performing repairs to the scooter.
•Special service tools may be required
to perform maintenance and repairs on
this scooter. Always use the proper tools
to prevent damage to the scooter.
•Clean and lubricate all engine parts
during the disassembly and reassembly
process to prevent damage to the
engine.
Technical Tips
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CHAPTER 1: INTRODUCTION

1. General Information
•When performing maintenance on the
scooter, make sure that all moving parts
and controls move freely and return to
their proper position.
•When connecting the battery, always
connect the positive terminal first.
•When disconnecting the battery, always
disconnect the negative terminal first.
•Make sure that tools and service
equipment do not come in contact with
both battery terminals.
•Cover both battery terminals with a
light coat of grease to prevent
corrosion.
Technical Tips (continued)
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CHAPTER 1: INTRODUCTION

1. General Information
Technical Tips (continued)
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NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL
CHAPTER 1: INTRODUCTION
•When replacing fuses, always use an
exact replacement. Do not use fuses of
a higher amp rating!
•Replace all rubber caps on wire
connectors after performing
maintenance.
•When disconnecting wire connectors,
press firmly on the locking tab and pull
the body of the connectors. Never pull
on the wires
•When assembling wire connectors,
press firmly to assure the lock tab fully
engages.
•Make sure that all wire terminals are
properly in place before attempting to
assemble any wire connector.
YES
NO

1. General Information
Technical Tips (continued)
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CHAPTER 1: INTRODUCTION
•Make sure that all wiring connectors are fully
seated and lock tubs engaged.
•Check if almuce of connector is covered and
fixation is tight.
•Make sure that all protective covers are
properly in place over the wiring connectors.
•Never reuse damaged wire terminals or
connectors.
•Never reuse damaged wire terminals or
connectors.
•Replace all rubber covers on wire connectors
to prevent water from getting into the
connector.
•Strip of main wire must be fixed on assigned
position.
•Insulator of aluminum strip must be affixed to
wires.
•Make sure that all wiring harness retainers are
properly placed.
•Do not over tighten wiring ties to prevent
pinching of wires.
•Do not allow wiring harness to hang in loose
loops.

1. General Information
Technical Tips (continued)
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NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL
CHAPTER 1: INTRODUCTION
•Make sure that all wire clips are
properly attached.
•Make sure that the wiring harness and
all wires do not contact moving or
rotating parts of the scooter.
•Make sure that the wiring harness and
all wires do not contact hot components
or surface parts of the scooter.
•Make sure that the wiring harness and
all wires do not contact sharp edges or
parts of the scooter. Use tape to prevent
damage to wires on sharp edges.
YES
YES YES
NO
NO NO
NO

1. General Information
Technical Tips (continued)
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CHAPTER 1: INTRODUCTION
•Do not pull wires too tightly.
•Use tape to protect against sharp edges.
•Make sure that all rubber grommets are in
place to protect the wiring harness.
•Do not reuse broken or frayed wires.
•Repair or replace wires as necessary.

1. General Information
Technical Tips (continued)
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NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL
CHAPTER 1: INTRODUCTION
•Do not twist or knot wires when
performing maintenance on the scooter.
•Make sure the wiring harnesses to the
handlebars are not too tight or too loose
by turning the handlebars both right and
left while making sure there is no pinching
or pulling of the wires.
•Make sure that you understand the proper
use of test equipment to perform
maintenance on the scooter. This will
prevent accidental damage to the
electrical system of the scooter.
•Use electrical contact cleaner and
abrasive paper to clean corrosion from any
wire terminals.
•Take care to prevent inadvertent damage
to wiring and cables.
YES
NO
NO

1. General Information
Technical Tips (continued)
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CHAPTER 1: INTRODUCTION
Definitions of diagrams
The following icons are used to highlight important
operations in the service of the scooter.
Lubricating oil required.
Grease required.
Engine oil required.
Special tools required.
Special attention required.
Dangerous and important,
special care required.

1. General Information
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NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL
CHAPTER 1: INTRODUCTION
Torque Settings
Torque
Standard Torque Settings
5mm Cap Screw
6mm Cap Screw
8mm Cap Screw
10mm Cap Screw
12mm Cap Screw
.5 kg/cm
1 kg/cm
2.2 kg/cm
3.5 kg/cm
5.5 kg/cm
TorqueFastener TypeFastener Type
5mm Socket Head Screw
6mm Socket Head Screw
8mm Flange Head Screw
10mm Flange Head Screw
12mm Flange Head Screw
.4 kg/cm
.9 kg/cm
1.2 kg/cm
2.7 kg/cm
4.0 kg/cm
General Torque Requirements for Standard Fasteners
Number
Used
Special Torque Settings
Cylinder Bolt A
Cylinder Bolt B
Oil Filter Screen Cap
Exhaust Pipe Flange Bolt
Flange Screw Belt Pulley
Valve Adjusters
Cam Chain Adjuster
Guide Plate Screw
Oil Fill Screw
Clutch Cover Screw
Clutch Driven Unit
Mounting Screw
Starter Motor Mounting Screw
Oil Pump Mounting Screw
Clutch Driver Mounting Screw
ACG coil Mounting Screw
Cam Chain Adjuster Screw
Spark Plug
2
2
1
2
4
2
1
1
1
1
2
3
1
3
1
1
Torque
kg m (in. lbs) Comments
Dia.
(mm)
Fastener Type
8
8
30
6
8
5
6
8
12
12
6
6
12
6
6
10
.9
.9
1.5
.9
2.0
.9
1.0
1.3
5.5
5.5
1.0
1.2
5.5
1.0
.5
1.2
Lubricate with Engine Oil
Lubricate with Engine Oil
Torque Requirements for Engine Fasteners
Number
Used
Cylinder Bolt A
Cylinder Bolt B
Oil Filter Screen Cap
Exhaust Pipe Flange Bolt
Flange Screw Belt Pulley
Valve Adjusters
1
1
1
1
1
1
Torque
kg m (in. lbs) Comments
Dia.
(mm)
Fastener Type
25.4
10
14
10
8
5
8-12
4-5
8-10
3-4
2-3
.5
Use Soft Set Lock Tite
Torque Requirements for Frame Fasteners

1. General Information
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CHAPTER 1: INTRODUCTION
For general maintenance and repair of the
scooter, a complete basic set of metric sized
tools is required. This should include; Open-end
wrenches, sockets and ratchet, hex keys, straight
and Philips screw drivers, standard pliers,
needle-nosed pliers, wire cutters, wire strippers,
scraper, pin punch, hammer and soft faced mallet.
For a more extensive tear down and rebuild of the
scooter, there are a variety of special tools that
will be required. These include the following:
•Valve spring compressor
•Valve guide reamer
•Feeler gage set
•Slide hammer bearing and seal remover
•Bearing press
•Torque wrench
•Ring compressor
•Clutch spring compressor
•Fly wheel puller
•Electronic multi meter
Tool Requirements

1. General Information
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NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL
CHAPTER 1: INTRODUCTION
Lubrication Requirements: Engine
valve guide valve stem moving part
cam shaft lug surface
valve rocking arm friction surface
camshaft drive chain
cylinder fixed screw bolts and nuts
around piston and piston ring groove
around piston pin
cylinder surface
connecting rod, piston pin bore
connecting rod big end
crankshaft R, L side oil seal
starter reduction rear engaging (mating) part
coundershaft gear engaging part
final gear engaging part
each bearing rotational part
o-ring surface
oil seal lip
starter idle gear
friction spring moving part, shaft moving part
shaft moving groove part
starter drive axle
AC-generator connector
Item Location Recommended Lubricant
SAE 5W 30 Engine Oil
API-SG Grade Engine Oil
oil
grease
oil
oil
oil
oil
oil
oil
oil
oil
oil
grease
oil
oil
oil
grease
oil
grease
adhesive

1. General Information
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CHAPTER 1: INTRODUCTION
ENGINE OIL:
•SPEEDOMETER
DRIVE
GREASE:
•SPEED METER FLEXIBLE SHAFT
•FRONT WHEEL BEARING
•BRAKE CAM
•FIXED PIN
•FRONT SHOCK ABSORBER BASE
GREASE:
•CENTER STAND PIVOT
GREASE:
•REAR WHEEL BEARING
GREASE:
•REAR BRAKE LEVER PIVOT
GREASE:
•SEAT LATCH
GREASE:
•REAR BRAKE
GUIDE LINE
GREASE:
•BRAKE CAM
AND PIN
•Apply oil to the following parts.
•Use grease in the parts other than specified
ones.
•Apply engine oil or grease to the moving parts to
prevent abnormal noise and to raise durability.
Chassis

1. General Information
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NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL
CHAPTER 1: INTRODUCTION
Cable Routing Diagram
AUTOMATIC BY-PASS
STARTER RESISTANCE
FLASHER
HORN
MAIN SWITCH
THROTTLE CABLE
FRONT BRAKE
SWITCH LEAD
FRONT BRAKE CABLE
REAR BRAKE SWITCH LEAD
SPEEDOMETER CABLE
REAR BRAKE CABLE
HEADLIGHT LEAD CONNECTOR
HEADLIGHT RESISTANCE
VOLTAGE REGULATION/RECTIFIER

1. General Information
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CHAPTER 1: INTRODUCTION
SPEEDOMETER CABLE
FRONT DISC BRAKE HOSE
REAR BRAKE CABLE
THROTTLE CABLE
AUTOMATIC
ENRICHMENT
RESISTANCE
HEADLIGHT
RESISTANCE
VOLTAGE REGULATION RECTIFIER
MAIN HARNESS
THROTTLE CABLE

RED BATTERY CABLE POSITIVE
FUSE
GREEN BATTERY CABLE NEGATIVE
1. General Information
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NIKOTA USA: PANTERRA SCOOTER SERVICE MANUAL
CHAPTER 1: INTRODUCTION