0421 220 goes SERVICE MANUAL.doc

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SERVICE MANUAL

 

CONTENTS

1.

INFORMATION………………………………………...

2

2.

MAINTENANCE…………………….…………………

6

3.

ENGINE REMOVAL AND INSTALLATION…………

17

4.

LUBRICATION…………………………………………

19

5.

CYLINDER HEAD / VALVES………………………..

29

6.

CYLINDER & PISTON………………………………...

40

7.

TRANSMISSION & KICKSTARTER…………………

49

8.

FRONT WHEEL, SUSPENSION AND STEERING..

61

9.

REAR WHEEL SYSTEM………………………………

80

10.

FENDERS AND EXHAUST PIPE……………………..

91

11.

ELECTRICAL SYSTEM……………………………….

94

12.

TROUBLE SHOOTING………………………………..

100

 

1.        INFORMATION

1.1        Safety

1.2        Notes

1.3        Specifications

1.4        Serial number

1.5     Torque valve

 

1.1  SAFETY

 

GASOLINE

Gasoline is extremely flammable and is explosive under certain condition. Do not smoke or allow sparks or flames in your work area.

 

CARBON MONOXIDE

Never run the engine in a closed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death.

 

BATTERY ELECTROLYTE

The battery electrolyte contains sulfuric acid. Protect your eyes, skin and clothing. If you come into contact with the electrolyte, flush the area thoroughly with water. If you get the electrolyte in your eyes, flush with water and contact a doctor immediately.

 

HOT PARTS

Engine and exhaust pipe become very hot and remain hot for one hour after the engine is run. Wear insulated gloves before handling these parts.

 

USED ENGINE /GEAR OIL

Used engine oil and gear oil may cause skin disease after repeated contact with the skin for long periods. Keep out of reach of children.

 

1.2  NOTES

All information, illustrations, directions and specifications included in this publication are base on the latest product information available at the time of approval for printing.

 

No part of this publication may be reproduced without written permission.

 

 

1.3 SPECIFICATION

Air-cooled 4-stroke , vertical cylinder

195.8 cc

65×59mm

9.6:1

1.45 N-m @ 5000 rpm

Mikuni

C.D.I Electronic

Electrical & Kick-Start

Wet Sump

 

AE-9

Automatic(C.V.T sysetm with reverse gear)

68.5 inches (1740mm)

41.3 inches (1050mm)

49.6 inches (1260mm)

31.1 inches (790mm)

44.9 inches (1140mm)

7.0 inches (178mm)

175kg (385.8lb)

8.5 liter 

 

Double Wishbone

Swing Arm

 

Disc

Disc

 

21 × 7 - 10

20 × 10 - 9”

 

ENGINE

Type                  

                    

Displacement       

Bore and Stroke     

Compression        

Maximum Torque     

Carburetor          

Ignition              

Starting               

Lubrication          

 

Air Cleaner

Transmission

CHASSIS

Overall Length

Overall Width

Overall Height

Seat Height

Wheel Base

Ground Clearance

Dry Weight

Fuel Tank Capacity

SUSPENSION

Front

Rear

BRAKES

Front

Rear

TIRES

Front

Rear

 

 

 

 

*Specifications subject to change without notice.

1.4 SERIAL NUMBER

The frame serial number is stamped on the front frame.

And stick a bar code paper to cover it.

The engine number is stamped under the crankcase.

1.5 TORQUE VALVES

5 N.m (3.5 lbs.ft)

10 N.m (7.2 lbs.ft)

22 N.m (16 lbs.ft)

35 N.m (25 lbs.ft)

55 N.m (40 lbs.ft)

 

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