Generic XOR 50 ccm Service Manual
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Generic XOR 50 ccm, 82 Remove the brake lever and brake switch. Remove the dust boot. Remove the circlip with the special tool. Remove the piston/primary cup with return spring. Remove the reservoir cap and diaphragn. Drain brake fluid. MASTER CYLINDER INSPECTION Inspect the master cylinder bore for any scratches or other damage.
Generic XOR 50 ccm, 12 AIR CLEANER Clean every 3000KM(2000 miles) If the air cleaner is clogged with dust, intake resistance will, be increased with a resultant decrease in power output and an increase in fuel consumption. Check and clean the element in the following manner. Remove screw 1 and screw 2,take down air cleaner Unscrew tapping screw 3,remove air cleaner cap 4 Fill a washing pan of a proper size with Non-flammable cleaning solvent. Immerse the air Cleaner in the cleaning solvent and wash them clean. Squeeze the cleaning solvent out of the washed element By pressing it between the palms of both hands: do not tw
Generic XOR 50 ccm, 51 z install cooling fan z install guiding cover z install fan guiding cover z install pipe screw and screw for tightening muffler to their specified torque. :8-12Nm (0.8-1.2kg.m,6.0-8.5Ib-ft) :18-28Nm (1.8-2.8kg.m,13.0-20.0Ib-ft) z lubricate brake cam shaft with GENERIC grease.
Generic XOR 50 ccm, 68 CHAPTER 6 CHASSIS CONTENTS LEG SHIELD AND FRAME SIDE COVERS LEG SHIELD REMOVAL LEG SHIELD REMOUNTING FARME SIDE COVER REMOVAL FARME SIDE COVER REMOUNTING HANDLEBAR COVERS REMOVAL REMORNTING FRONT WHEEL REMORAL INSPECTION AND DISASSEMBLY REASSEMBLY AND REMOUNTING FRONT BRAKE BRAKE PAD REPLACEMENT CALIPER REMOVAL AND DISASSEMBLY CALIPER AND DISC INSPECTION CALIPER REASSEMBLY MASTER CYLINDER REMOVAL AND DISASSEMBLY MASTER CYLINDER INSPECTION MASTER CYLINDER REASSEMBLY AND REMOUNTING STEERING STEM AND FRONT SUSPENSION REMOVAL AND DISASSEMBLY INSPECTION REASSEMBLY AND REMOUNTING IGNITION SWITCH REAR WHEEL AND BRAKE
10 Cylinder head nuts and exhaust pipe bolts Tighten at 500 km, and each service. If cylinder head nuts are not tightened to the specified torque, may result in leakage of compressed fuel-air mixture and reduce output, tighten the cylinder head nuts in the following procedures:: 1. Remove the frame lower covers. 2. Remove the cylinder head cover bolt. 3. R
Generic XOR 50 ccm, 43 z Install the bearing with special tool z install the spacer and circlip: z install the new oil seals and to the movable driven face with the special tool. z apply grease to the lip of oil seals and groove of inside of movable driven face. GENERIC special super grease NOTE: When reinstalling the movable face to the fixed face, make sure that the oil seal is positoned properly. z install the pin at three places on the driven face hub. z Apply grease lightly to the cam part where the pins are placed. z Inst
55 CARBURETION Proper carburetion is determined according to the results of various tests, mainly concerning engine poer, fuel consumption and cooling effect of feul on engine, and jet settings ard made so as to satisfy and balance all of these conditions. Therefore, the jet should not be replaced with a size other than the original. And the positions of adjustable pa
Generic XOR 50 ccm, 16 NOTE:when bleeding the braking system, replenish the brake fluid reservoir if necessary. Make sure that there is always some fluid visible in the reservoir. Close the bleeder vavle, disconnect the pipe. Fill the reservoir with brake fluid to the upper end of the inspection window. BLEEDER VALVE TIGHTENING TORQUE: 6-9N.m(0.6-0.9kg-m,4.5-6.5lb-ft) CAUTION: Handle brake fluid with care: the fluid reacts chemically with paint, plastics, rubber materials, etc. Rear brake Turn adjusting nut so that the the play of the brake lever is 15-25MM as shown in the illustration. Brake shoe wear: The vehicle is equipp
Generic XOR 50 ccm, 23 ENGINE ASSY. z Remove the muffler z Remove cooling fan cover z Remove cylinder cover z Remove cooling fan z Remove magneto nut with special tools. z remove magneto rotor and half circle key with special tools. z remove magneto stator and paper gasket z remove oil pump
Generic XOR 50 ccm, 20 LUBRICATION Proper lubrication is important for smooth operation and long life of each working part of the scooter. The major lubrication points are indicated below: NOTE: 1. Lubricate exposed parts which aare subject to ruse with engine oil. 2. Before lubricating each part, clean off any rusty spots and wipe off any grease, oil dirt of grime. WARNING:Be careful not to apply too much grease to the rear brake camshaft, otherwise brake slippage will result from the presence of grease in brake drum. steering stem bearing
Generic XOR 50 ccm, 60 NO-LOAD PERFORMANCE z Disconnect the magneto lead wire coupler. z Start the engine and keep it running at 5000r/min. z Using a pocket tester, measure the AC voltage between the white and red tracer lead wire and ground. If the tester reading is as follows, magneto is in good condition. Standard no-load performance: more than 65v(AC)AT 5000R/MIN. STATOR COILS Inducing coils Use procket tester to measure the resistance between the lead wire and ground. If the resistance checked is not correct, replace the coil. Rregulator/rectifier Disconnect the lead wire couple. Using the pocket tester( × 1K
Generic XOR 50 ccm, 98 BATTERY Complaint Symptom and possible causes Remedy Battery runs down quickly. The charging method is not correct. Cell plates have lost much of their active material as a result of over-charging. A short-circuit condition exists within the battery due to excessive accumulation of sediments caused by the incorrect electrolyte. Battery is too old. Check the magneto and regulator/rectifier circuit connections, and make necessary adjustments to obtain specified charging operation. Replace the battery, and
35 Roller and sliding surface Inspect each roller and sliding surface for wear or damage. Driving face spring Measure the free distance of the driven face spring. If the length is shoter than the service limit, replace the spring with a new one. service limit: 104.5mm(4.11in) Driven face pin and oil seal Turn the driven face and check to see that the driven faces turn
Generic XOR 50 ccm, 18 Front shock absorber Adjust at initially 500km and each service. Inspect the front shock absorber for oil leakage or other damage, and replace the defective parts, if necessary. Rear shock absorber Adjust at initially 500km and each service. Inspect front shock absorber for oil leakage and other damage, and replace the defective parts if necessary. No. Item N•m Kg-m 1 Front axle nut 55-60 5.5-6 2 Handle tightenging nut 37-44 3.7-4.4 3 Steering sterm locknut 37-44 3.7-4.4 4 Disc brake caliper fixing bolt 22-29 2.2-2.9 5 Disc brake master cylinder hose fixing bolt 22-29 2.2-2.9 6 Disc brake fixing bolt 5-9 0.5-0.9 7 Front
Generic XOR 50 ccm, 105 SPECIAL TOOLS LISTED BELOW FOR REMOVAL AND REINSTALLATION NO. TOOL NUMBER DESCRIPTION 1 2 3 4 5 6 7 8 9 10 T01 T02 T03 T04 T05 T07 T08 T09 T10 “T”shape of sleeve sleeve tools(7mm,8mm,10mm,12mm,13mm) flywheel remover sleeve (18mm,24mm) screw remover cylinder pressure gauge piston pin remover spark plug remover flywheel lockbolt remover clutch clamp
Generic XOR 50 ccm, 31 ENGINE COMPONENTS INSPECTION AND SERVICING BEARINGS Clear bears with solvent and lubricate with engine oil before inspecting. Turn the inner ring and check to see that the inner rieng turns smoothly. If it does not turn lightly, quietly and smoothly, or if noise is heard, the bearing is defective and must be replaced with a new one. OIL SEAL Damage to the lip of the oil seal may result in leakage of the fuel-air mixture or oil. Inspect for damage and be sure to replace the damaged seal if found. CRANKSHAFT CRANKSHAFT RUNOUT Support crankshaft by“V” block, with the dial gauge rigged to read the runout as shown. Service limit:
Generic XOR 50 ccm, 2 PREFACE The service manual has been specially prepared to provide all the necessary information for the proper maintenance and servicing. You have now a new type of scooter that has many techinal features such as: V-belt drive automatic transmission Forced air-cooling system CDI ignition system Electric starter system Those who will be servicing the scooter should carefully review the manual before performing any repair or services. Major modifications and changes incorporated later will be advised to G
Generic XOR 50 ccm, 66 BATTERY SPECIFICATIONS Type designation YB4L-B Capacity 12V 4Ah Standard electrolyte 1.28(20) INITIAL CHARGING FILLNG ELECTROLYTE Remove the aluminum tape sealing the battery electrolyte filler holes. Remove the caps . NOTE: * After filling the electrolyte completely,use the removed cap as the sealed caps of battery-filler holes. * Do not remove or pierce the sealed areas of the electrolyte container. Insert the nozzles of the electrolyte container into the battery`
Generic XOR 50 ccm, 84 STEERING STEM AND FRONT SUSPENSION REMOVAL AND DISASSEMBLY (Refer to preceding page) □ remove the handle cover(refer to preceding page) □ remove under decorating cover(refer to the preceding page) □ remove legshield(refer to preceding page) □ remove front wheel(refer to preceding page) □ disconnect the front and rear brake light switch lead wires . □ Remove the rear brake cable . □ Remove throttle grip case
Generic XOR 50 ccm, 48 z Install the dowel pins z install the new gaskets( and ) z apply GENERIC bond no. 1215 to the clutch cover as shown in the illustration. GENERIC bond no. 1215 NOTE: Install the kick starter lever as shown in the illustration. Tightening toque:8-12Nm (0.8-1.2kg-m, 6.0-8.5Ib-ft) PISTON z install the piston rings on the piston. The first and the second ring: keystone ring. NOTE: Position the ring so that the marking is on upside. z it is extremely important that, when the piston is fed into the cylinder, each ring in place should be so pos
62 STARTER MOTOR INSPECITION CARBON BRUSHES When the brushes are worn, the motor will be unable to produce sufficient torque, and the engine will be difficult to turn over. To prevent the , periodically inspect the length of the brushes and replace them when they are too short or chipping. Service limit:3.5mm(0.14in) Commutator If the commutator surface is dirty, st
Generic XOR 50 ccm, 53 FUEL SWITCH When the engine has started, a negative pressure (vacuum) is generated at the intake port. The negative pressure acts upon the diaphragm of the fuel switch and it pressed down the spring which supports the diaphragm so that the fuel passageway is opened and fuel is fed to the carburetor. When the engine has stopped, the spring presses the valve, the fuel passageway is closed, and no fuel flows to the engine. Fuel switch
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