Performance Kit - Absolutely Scootersabsolutelyscooters.net/PerformanceKitOperation.pdf · 2016....

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Performance Kit

Operation Manual

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For meeting the perfect effect of the upgrade operation, the

following parts must be changed

No Ref

No.

Description Function No. Remarks

1 Cylinder Head Comp ∮47

2 Cylinder 12100-SCB0-0000 ∮47

3 Gasket, Cylinder Head 12251-SCB0-0000 ∮47

4 Piston 13101-SCB0-0000 ∮47

5 Piston Pin 13111-SCB0-0000 37

6 Piston Ring Comp. 13011-SCB0-0000 ∮47

7 Oil Pump 15100-SCB0-0000 Rotor’s thickness is 10mm

8 Roller of Drive Sprocket Assy.

22019-SCB0-0000 Roller’s weight is 8 gram

Note:

I. Cylinder head comp include intake valve, exhaust valve,

spring for inner and outer valve, valve outer spring

retainer, cotter valve, valve seal stem, studs for Intake and

outer valve.

II. The Roller’s weight is 8 gram.

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1.Operation Notice I. During the operation, the cylinder gasket, right

crankcase cover gasket, tensioner gasket and fasteners

may be subject to effect. All the gaskets mentioned

above must be changed, and other parts was determined

by technician for being changed.

II. For the perfect upgrade, we suggest to cancel the

function of limited speed, therefore, pull out the thrum

according to the picture.

III. Concrete methods should be carried out in accordance

with assembling technology and service manual.

2.Tools I. T-model wrench (T8, T10, T12, T14) II. Open spanner 8, 9, 10,17 III. Cross screwdriver IV. Pneumatic gun V. Gun head 14, 17 VI. Valve adjust tool VII. Special tool for disassemble flywheel. VIII. Snipe-nose cutting pliers IX. Spark-plug socket

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Catalog

1. Disassembly engine

………………………………………………1

2. Drain engine oil

………………………………………………13

3. Disassembly cylinder head, case and right cover

………………………………………………15

4. Cleaning& replacing parts

……………………………………………… 28

5. Assembly cylinder head, case, right cover

……………………………………………… 31

6. Replace the roller of the drive sprocket Assy.

……………………………………………… 45

7. Reinstall engine

……………………………………………… 50

8. Adjustments

……………………………………………… 59

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Chapter 1: Disassembly engine

1

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1.1 Remove storage box

TOOLS: T-model wrench 10

2

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1.2 Remove fuel line

TOOLS: open spanner 10, 12

3

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1.3 Remove vacuum tube

TOOLS: snipe-nose cutting pliers

4

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1.4 Remove ignition coil

TOOLS: -------

5

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1.5 Remove generator line, starter valve set wire, starter motor line

TOOLS: T- model wrench 10

6

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1.6 Remove rear break cable

TOOLS: snipe-nose cutting pliers , T-model wrench 14

7

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1.7 Remove air cleaner intake pipe, cooling pipe(left)


8

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1.8 Remove air cleaner

TOOLS: T- model wrench 10 , cross screwdriver

9

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1.9 Remove engine mount front & rear

TOOLS: T- model wrench 12,13 , open spanner 14

10

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1.10 Remove muffler

TOOLS: T- model wrench 10,12

11

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1.11 Remove carburetor TOOLS: cross screwdriver

1.12 Disassembly work can be done without removal of rear tire.

12

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Chapter2: Drain engine oil

13

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2.1 Loosing the oil plug and engine oil

TOOLS: double ring ended spanner 17

2.2

After draining all content oil, reinstall shim and tighten oil plug

TOOLS: double ring ended spanner 17

14

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Chapter3: Disassembly cylinder head, case and right cover

15

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3.1 Remove 2 M6 nut, intake pipe, insulator carburetor. TOOLS: T- model wrench 10

3.2 Remove 2 screw ST5*16, one M6*16 blot, 3 M6*25 blot, fan cover, shroud A, shroud B, seal of shroud A TOOLS: cross screwdriver , T- model wrench 8

16

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3.3 Remove 4 bolts M6*25, clamper breather drain tube, cylinder head cover


17

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3.4 Remove 2 bolts M6*16, lifter assy. tensioner, gasket tensioner lifter.

TOOLS: T- model wrench 8,10

18

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3.5 Remove 4 nets M7, four gaskets 7, camshaft holder, dowel pin 10*14


19

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3.6 Remove camshaft, 2 bolt M6*85 on cylinderhead


20

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3.7 Remove cylinder head assy. Cylinder head gasket, 2 dowel pin 10*14, cam chain guide comp

TOOLS: --------

21

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3.8 Remove cylinder head body, cylinder body gasket, 2 dowel pins 10*14

TOOLS: -------------

22

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3.9 Remove piston pin clip, piston pin, piston.


23

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3.10 Remove 4 bolts M6*18, cooling fan


24

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3.11 Remove M10 lock nut, flywheel

TOOLS: pneumatic gun or electric gun ,gun head 14, special tool for disassemble flywheel

25

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3.12 Remove 2 nuts M5*12 of generator pulse TOOLS: T- model wrench 8

3.13 Remove 4 M6*100, 4 M6*85 TOOLS: T- model wrench 8

3.14 Remove right cover assy., right cover gasket, 2 dowel pin 8*14

26

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3.15 Remove one nut M6,drive gear of oil pump TOOLS: T- model wrench 10

3.16 Remove two bolt M6*20, one bolt M6*25, oil pump, 2 O-ring 9*1.6, dowel pin 8*10 TOOLS: T- model wrench 8

27

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Chapter4: Cleaning & replacing parts

28

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4.1 Remove spark plug from disassembled cylinder head TOOLS: spark-plug socket , cross screwdriver

4.2 Clean and dry the removed parts TOOLS: ---------

4.3 Select the disassembled parts Note: During the operation, there may be some impact

on cylinder body gasket, R cover gasket, lifter tensioner gasket and locks. Among them, cylinder body gasket, R cover gasket and lifter tensioner must be changed. Other parts are determined by technician for being changed.

TOOLS: --------

29

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4.4 Replace the different parts of between GY6-80 and GY6-50

TOOLS: -----------

4.5 Install the removed spark plug in the new cylinder head, install Inlet/outlet valve double head bolt

TOOLS: spark-plug socket , cross screwdriver

30

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Chapter5: Assembly of cylinder

head, case, right cover

31

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5.1 Install 2 O-ring 9*16, dowel pin 8*10, oil pump, 2 bolts M6*20, 1 bolt M6*25 in turn


5.2 Install oil pump driven gear, 1 nut M6 in turn


32

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5.3 Install dowel pin 8*14, right cover gasket, right cover, 4 bolts M6*100, 4 bolts M6*85.


5.4 Install 2 bolts M5*12, trigger coil.


33

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5.5 Install flywheel, lock nut M10 in turn

TOOLS: pneumatic gun or electric gun ,gun head 14

34

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5.6 Install cooling fan, 4 bolts M6*18


35

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5.7 Install piston, piston pin, piston clip


36

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5.8 Install cylinder body gasket, 2 dowel pins 10*14, cylinder body

TOOLS: -----------

37

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5.9 Install guide comp. Cam chain, cylinder head gasket, 2 dowel pins 10*14, cylinder head assy.

TOOLS: ------------- 38

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5.10 Timing, install camshaft assy

TOOLS: ------------- 39

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5.11 Install 2 dowel pins 10*14, camshaft holder, 4 gaskets 7, 4 nuts M7

TOOLS: T- model wrench 10 40

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5.12 Install tensioner gasket, lifter tensioner, 2 bolts M6*18 TOOLS: T- model wrench 8,10 5.13 Install 2 bolts M6*85 on cylinder head. TOOLS: T- model wrench 8 5.14 Timing, adjust valve clearance TOOLS: Valve special tool ,open spanner 9

41

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5.15 Install cylinder head cover, clamper breather drain tube , 4 bolts M6*25


42

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5.16 Install shroud seal, shroud A, shroud B, 2 screws ST5*16, 1 bolt M6*16, 3 bolts M6*25

TOOLS: cross screwdriver, T- model wrench 8

43

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5.17 Install pipe comp in insulator carburetor, pipe comp in, 2 nuts M6.


44

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Chapter6: Replace the roller of the drive sprocket

45

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6.1 Remove clamper throttle, clamper brake cable, 8 flange bolts M6*35, left cover assy. TOOLS: T- model wrench 8

6.2 Remove left cover gasket, 2 dowel pins 8*14TOOLS: ----------------

46

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6.3 Remove nut M12, gasket 12, driven ratchet wheel gear, driven sprocket assy.

TOOLS: pneumatic gun or electric gun, gun head 17

47

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6.4 Replace weight rollers

TOOLS: ---------------

48

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6.5 Install driven sprocket assy., driven ratchet wheel gear, gasket 12, nut M12 TOOLS: pneumatic gun or electric gun, gun head 17

6.6 Install 2 dowel pins 8*14, left cover gasket TOOLS: ---------- 6.7 Install clamper throttle, clamper brake cable, 8 flange bolts M6*35, left cover assy. TOOLS: T- model wrench 8

49

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Chapter 7: Reinstall engine

50

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7.1 Install muffle TOOLS: T- model wrench 10,12 7.2 Install carburetor TOOLS: cross screwdriver 7.3 Place the engine assembly on proper position of crack

51

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7.4 Lock front, rear hanger bolts

TOOLS: T- model wrench 12,13 , open spanner 14

52

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7.5 Install real brake line

TOOLS: T- model wrench 14 , snipe-nose cutting pliers

53

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7.6 Install air filter

TOOLS: cross screwdriver, T- model wrench10

54

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7.7 Install air filter pipe comp. in, left cover cooling pipe


55

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7.8 Install generator, start valve set wire，motor line


56

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7.9 Insert ignition coil, vacuum tube TOOLS: snipe-nose cutting pliers

7.10 Install fuel line TOOLS: T- model wrench 10,12

57

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7.11 Install luggage box.


58

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Chapter 8: Adjustments

59

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8.1 Add oil.

8.2 Adjust motorcycle

------------ End --------------

60

Performance Kit - Absolutely Scootersabsolutelyscooters.net/PerformanceKitOperation.pdf · 2016....

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Transcript of Performance Kit - Absolutely Scootersabsolutelyscooters.net/PerformanceKitOperation.pdf · 2016....