SCOOTDAWG GY6 User manual

THE SCOOTDAWG
COMPLETE OWNER S
MANUAL
FOR GY6 SCOOTERS
This is the manual that should have come with
your scooter!
For Engines 139QMB and157QMJ
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©2005 ScootDawg.com

2
Introduction
This manual is intended as a real world manual for all GY6 scooters. This is
only a supplement to the manual provided by your dealer or manufacturer. Most
of the manuals provided with Chinese scooters are very difficult to understand
and most do not have the information you need to properly care for your scooter.
Within these pages you will find instructions for common maintenance
procedures. You will also find many specifications that you wont find in common
owner s manuals, such as valve gap settings, etc. These values have been
obtained from what are believed to be reliable sources but cannot be guaranteed
to be correct.
A complete shop manual for the 50cc GY6 can be downloaded at
www.ScootDawg.com The vast majority of information also applies to the 125cc
and 150cc GY6.
Safety Warning
Please refer to your original manual for recommended safety precautions. It is
up to you to comply with all federal, state and local laws and regulations. Do not
operate or work on your scooter under the influence of mind - altering substances.
Always wear proper protective gear when riding or working on your scooter. It is
recommended that you take a motorcycle safety course if you are a new rider.
This is copyrighted material. Scootdawg will pursue violators!
Table of Contents
Page
3 Pre - Delivery Instructions
4 Gauges and Controls
6 Starting/Break - in Procedures
7 Changing the Oil
9 Changing Gear Oil
10 Air Filter
11 Spark Plug
12 Idle Adjustment
13 Carburetor Tuning
14 Brakes
16 Caring for and Storing
17 Maintenance Schedule
18 Torque Settings
21 Valve Adjustment
22 Body Panels
23 Reading Spark Plugs
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3
Pre - Delivery Inspection (P.D.I.)
If you purchased y our scooter from a local dealer, they should have
already performed a P.D.I. If you purchased it on the internet, you must perform
your own. Not doing this can result in malfunction of your scooter and could
re sult in serious injury or death . The follow ing is a typical P.D.I. checklist.
*Check all nuts & bolts for tightness
* Check fuel lines for kinks and proper
connect ion .
* Fully charge the battery before
installing. Battery location under the
floor
========================
* Check spark plug gap. G ap to .035 .
* Check tire pressure (Improper tire
pressure will greatly reduce
performance and safety).
* Check functioning of all switches and electrical components
* Check brake fluid level
* Check oil level
* Check brake levers for proper free play
* Check su spension for proper functioning
* Check wheels for alignment, free rotation and proper tightening
* Check headlight aim
* Check for fuel and oil leakage
*Although not common, you may want to consider bleeding your disc
brakes. Some owners of less expensive Chinese scooters have reported
improperly bled brake lines out of the factory. The easiest and most
effective way to do this is to
purchase an inexpensive brake
bleeding kit at an auto parts
store. Follow the instructions
with the kit.
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4
Gauges and Controls
With so many body styles available, the location of your controls may differ and
you may have
some not
included here
but this will give
a good generic
indication of the
gauges and
cont rols found
on a scooter.
Your controls
function as
illustrated.
Ignition Switch:
On Position - Electrical Circuits are
on, scooter can be started, key
cannot be removed.
Off Position - Electrical circuits are
off, engine is off, key can be
removed.
To lock steering, turn the
handlebars to the left, push the key
in and turn it to the lock position.

5
To accelerate, twist the throttle in a counterclockwise motion. When braking,
both brake levers should be depressed with even pressure.

6
S tarting your Scooter
T he left brake lever must be held in to start the scooter . Some scooters also
come with a safety switch built into the
side kickstand and will not start with the
side stand in the down position. Make
sure the ignition switch is fully on and
that the kill switch is in running position.
Never leave your sc ooter running on the
side stand. T he back wheel could turn
and dump your scooter onto the ground.
Never operate the electric ignition more
than a few seconds at a time or you will
burn the unit out. If you have made more than five repeated attempts to start
your scooter, stop and let the starter cool down for a couple minutes.
Use the kick starter if the battery is
dead. Make sure to return th e foot peg
to the original position after using.
To use the kick, the ignition must be on.
Some scooters require that the brake be
held in.
Engine Break - In
Most manu facturers recommend that you not run your scooter at more than 2/3
throttle before i t is broken in (around 6 00 - 1000 miles). A new school of thought
has emerged that many enthusiast now follow. You can read about the hard
break - in method and make your own decision.
http://ww w.mototuneusa.com/break_in_secrets.htm
The main rule you need to follow is to NOT maintain a constant engine speed for
extended periods of time.
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7
Changing the Oil
The oil should at a minim um be changed after the first 300km (180 miles) and
every 1000km (600 miles) after
that. It doesn t hurt to change it
after the first 50 miles. New
engines can produce small
shavings in the first few miles
that can be abrasive to the
internal parts.
It helps for the engine to be
warmed (not hot) at the time of
change.
Place a drain pan under the
drain plug. Remove the filler cap, then
remove the drain plug .
When you remove the drain , these parts will come out
5=screen filter , 6=spring, 7=gasket, 8=plug .
Blow out the screen with compressed air to clean.
Gently depressing the kick starter five or six times
will flush out remaining oil that does not drain freely.
Make sure the ignition switch is in the off position
while doing this .
After oil is thoroughly drained, replace plug
components in the configuration shown.

8
Fill oil as shown using a funnel . Use high quality 10w40 or 5w30 synthetic oil.
Capacity is approximately 0 .9 liter. Check the level using the dipstick. Do not
screw the dipstick in while check ing the level. Do not overfill.
Replace filler cap. Check for leaks.
Take a short ride and check the
level and for leaks again.
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9
How to Chang e Gear Oil
Tools you will need
1. 10 mm wrench
2. Pistol grip oil can
3. 75w90 gear oil 110cc (3.7 oz.)
4. Measuring cup.
Do the following
while the scooter
is warmed (not
hot). Measure
110cc (3.7 oz) of
gear oil into a
measuring cup.
Pour the oil into
the pist ol grip oil
gun. Spread a
towel under the
drain plug and
place measuring
cup under drain
screw. Remove
the drain screw
and fill screw and
let oil flow out into
the measuring cup. Removing the fill screw at this time helps the oil drain more
freely. Usi ng the measuring cup lets you know if you ve lost some oil. Once the
oil is fully drained, replace the
drain screw.
Insert the tube of the oil gun
toward the rear of the oil box
and squirt the oil gently into the
box. Dont squirt so fast that the
oil doesn t have time to flow into
the box. Once you have
emptied the can, replace the fill
screw. Wipe everything down
and observe for leaks. Take a
short ride and observe for leaks
again.

10
Air Filter
The air filter on the GY6 scooters is usually found in one of two places. One is
on the side next to the kick start.
Some models have it located
under the seat. Some of the
newer models may have it located
somewhere else but it should be
easy to find.
Cleaning the air filter is important.
A dirty filt er will cause poor
performance and decreased fuel
economy.
L ocate the screws to the plastic cover and
remove. The filter is most likely a foam filter
which can be cleaned. Some models, such
as United Motors, are equipped with filters
that need to be r eplaced.
Clean the filter in a pan of kerosene or
mineral spirits.
Squeeze out excess solvent. Dont twist or tear the filter. Apply oil to the filter
and squeeze out excess oil. The filter
should be damp but not wet.