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GT 50
Page 29
Explorer GT 50 - Page 29
112 pages
Manual
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31
z
Remove crankcase fixing shaft
z
disassemble crankcase with special tools
z
first rem
ove right crankcase cover
.
z
Remove crankcase with special tools
z
Remove crankshaft bearing with special tools
SLIDING
SHOAFT
W
arning use a new sliding shaft.
28
30
Table of Contents
Main Page
General Information
4
Contents
4
Type Identification
5
Engine Number
5
Fuel and Engine Oil
5
Break-In Time
5
Precautions and General Instructions
6
Replacement Components
6
Specifications
7
Dimension and Net Weight
7
Engine
7
Periodic Maintenance and Service
8
Periodic Maintenance and Service Schedule
9
Periodic Maintenance Table
9
Maintenance and Adjustment Procedures
10
Storage Battery
10
Cylinder and Cylinder Head
11
Cylinder Head Nuts and Exhaust Pipe Bolts
11
Thickness Gauge
12
Spark Plug
12
Fuel Line
12
Air Cleaner
13
Throttle Cable
13
Engine Idle Speed
13
Tachometer
14
Oil Pump
14
Front Brake Fluid Level
15
Gear Oil
15
Brakes
15
Brake Pads
16
Bleeding Air from the Brake Fluid Circuit
16
Bleeder Valve
17
Rear Brake
17
Brake Shoe Wear
17
Steering
18
Tire
18
Tire Tread Condition
18
Tire Pressure
18
Front Shock Absorber
19
Rear Shock Absorber
19
Lubrication
21
Engine Assy.
24
Remove Worm Wheel and Oil Seal Press Board
25
Unscrew Clutch Shoe Nut with Special Tools
30
Remove Circlip
31
Engine Components Inspection and Servicing
34
Bearings
34
Oil Seal
35
Crankshaft
35
Crankshaft Runout
35
Condition of Big End Bearing
35
Lock-Up R/Min
36
Inspect Initial Engagement
36
Clutch “LOCK-UP” Inspection
36
Automatic Clutch Inspection
36
Drive Belt
37
Clutch Wheel
37
Drive Face
37
Roller and Sliding Surface
38
Driving Face Spring
38
Driven Face Pin and Oil Seal
38
Driven Face
38
Cylinder
39
Piston
39
Cylinder and Piston Clearance
39
Piston Pin Bore
40
Piston Rings
40
Piston Pin Outside Diameter
40
Standard Clearance
41
Reed Valve
41
ENGINE Reassembly
42
Oil Seals
42
Install Bearing
42
Oil Seal Installation
42
Shock Absorber Bushing
43
Positon
43
Install Crankshaft (Without Bearings)
43
Crankcase
44
Install Gearcase Bearing
44
Install Output Axle
45
Gearshift
45
Movable Driven and Clutch
46
Install the Bearing with Special Tool
47
GENERIC Special Super Grease
47
Movable Drive
49
Starter Assy.
51
Oil Pump
53
Magneto
54
Intake Pipe
54
Fuel and Lubrication System
56
Fuel Switch
57
Carburetor
58
Carburetion
59
OIL LEAKAGE Throughout
59
Electrical System
60
Checking with Electro Tester
61
Ignition System
61
CDI&Ignition Coil Unit
61
Electronic Tester
62
Ignition Coil Testing Lead
62
Magneto Exciting Coil
62
Charging and Lighting System
63
Charging Output Check
63
Rregulator/Rectifier
64
Stator Coils
64
Inducing Coils
64
No-Load Performance
64
Starter System
65
Starter Motor Removal and Disassembly
65
Starter Motor Inspecition
66
Carbon Brushes
66
Commutator
66
Armature Coil
66
Fuel Level Meter/Gauge
67
Fuel Guage Sending Unit Inspection
67
Fuel Meter Inspection
67
Signal System
68
Oil Level Switch Inspection
68
Main Switch
69
Light Control Switch
69
Break Switch
69
Horn Switch
69
Fillng Electrolyte
70
Battery
70
Initial Charging
70
Recharging Operation
71
Table of Contents
72
Chassis
72
Side Cover Removal
73
Under Cover Removal
74
Under Cover Installation
74
Front Cover Removal
74
Legshield and Pedal Removal
75
Legshield and Pedal Installation
75
Handle Cover Removal
76
Handle Cover Unstallation
78
Front Wheel
79
Inspection and Disassembly
80
Wheel Bearing
80
Axle Shaft
80
Wheel Rim
80
Reassembly and Remounting
81
Front Brake System
82
Rake Pad Replacement
82
Remove the Brake Pads
83
Caliper Removal and Disassembly
83
Caliper and Disc Inspection
84
Brake Caliper Reassembly
85
Master Cylinder Removal and Disassembly
85
Master Cylinder Inspection
86
Master Cylinder Reassembly and Remounting
87
Steering Stem and Front Suspension
88
Removal and Disassembly
88
Inspection
90
Reassembly and Remounting
91
Install Handlebar and Tighten the Screw
92
Rear Wheel and Brake
93
Inspection
94
Reassembly and Remounting
95
Servicing Inforamtion
96
Troubleshooting
97
Engine Does Not Start, or Is Hard to Start
97
Compression too Low
97
Plug Not Sparking
97
Battery
100
Wire, Cable and Brake Hose Routing
103
Special Tools Listed below for Removal and Reinstallation
107
Tightenting Torque O F Screw Thread Parts
109
Service Data
110
Cylinder+Piston+Piston Ring
110
Connecting Rod+Crankshaft
110
Clutch
111
Transmission System+Driving Chain
111
Electrical
111
Wattage
112
Brake and Rim
112
Suspension
112
Tire Air Pressure
112
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