Explorer GT 50 - SERVICING INFORMATION

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SERVICING INFORAMTION

Troubleshooting

Battery

Vehicle

Wiring diagram

Wire, cable and brake hose routing

Special tools

Thread parts tightening torque

Service data

CONTENTS

Main Page

General Information4
Contents4
Type Identification5
Engine Number5
Fuel and Engine Oil5
Break-In Time5
Precautions and General Instructions6
Replacement Components6
Specifications7
Dimension and Net Weight7
Engine7
Periodic Maintenance and Service8
Periodic Maintenance and Service Schedule9
Periodic Maintenance Table9
Maintenance and Adjustment Procedures10
Storage Battery10
Cylinder and Cylinder Head11
Cylinder Head Nuts and Exhaust Pipe Bolts11
Thickness Gauge12
Spark Plug12
Fuel Line12
Air Cleaner13
Throttle Cable13
Engine Idle Speed13
Tachometer14
Oil Pump14
Front Brake Fluid Level15
Gear Oil15
Brakes15
Brake Pads16
Bleeding Air from the Brake Fluid Circuit16
Bleeder Valve17
Rear Brake17
Brake Shoe Wear17
Steering18
Tire18
Tire Tread Condition18
Tire Pressure18
Front Shock Absorber19
Rear Shock Absorber19
Lubrication21
Engine Assy.24
Remove Worm Wheel and Oil Seal Press Board25
Unscrew Clutch Shoe Nut with Special Tools30
Remove Circlip31
Engine Components Inspection and Servicing34
Bearings34
Oil Seal35
Crankshaft35
Crankshaft Runout35
Condition of Big End Bearing35
Lock-Up R/Min36
Inspect Initial Engagement36
Clutch “LOCK-UP” Inspection36
Automatic Clutch Inspection36
Drive Belt37
Clutch Wheel37
Drive Face37
Roller and Sliding Surface38
Driving Face Spring38
Driven Face Pin and Oil Seal38
Driven Face38
Cylinder39
Piston39
Cylinder and Piston Clearance39
Piston Pin Bore40
Piston Rings40
Piston Pin Outside Diameter40
Standard Clearance41
Reed Valve41
ENGINE Reassembly42
Oil Seals42
Install Bearing42
Oil Seal Installation42
Shock Absorber Bushing43
Positon43
Install Crankshaft (Without Bearings)43
Crankcase44
Install Gearcase Bearing44
Install Output Axle45
Gearshift45
Movable Driven and Clutch46
Install the Bearing with Special Tool47
GENERIC Special Super Grease47
Movable Drive49
Starter Assy.51
Oil Pump53
Magneto54
Intake Pipe54
Fuel and Lubrication System56
Fuel Switch57
Carburetor58
Carburetion59
OIL LEAKAGE Throughout59
Electrical System60
Checking with Electro Tester61
Ignition System61
CDI&Ignition Coil Unit61
Electronic Tester62
Ignition Coil Testing Lead62
Magneto Exciting Coil62
Charging and Lighting System63
Charging Output Check63
Rregulator/Rectifier64
Stator Coils64
Inducing Coils64
No-Load Performance64
Starter System65
Starter Motor Removal and Disassembly65
Starter Motor Inspecition66
Carbon Brushes66
Commutator66
Armature Coil66
Fuel Level Meter/Gauge67
Fuel Guage Sending Unit Inspection67
Fuel Meter Inspection67
Signal System68
Oil Level Switch Inspection68
Main Switch69
Light Control Switch69
Break Switch69
Horn Switch69
Fillng Electrolyte70
Battery70
Initial Charging70
Recharging Operation71
Table of Contents72
Chassis72
Side Cover Removal73
Under Cover Removal74
Under Cover Installation74
Front Cover Removal74
Legshield and Pedal Removal75
Legshield and Pedal Installation75
Handle Cover Removal76
Handle Cover Unstallation78
Front Wheel79
- Inspection and Disassembly80
- Reassembly and Remounting81
- Caliper Removal and Disassembly83
- Caliper and Disc Inspection84
- Brake Caliper Reassembly85
- Master Cylinder Removal and Disassembly85
- Master Cylinder Inspection86
- Master Cylinder Reassembly and Remounting87
Steering Stem and Front Suspension88
- Removal and Disassembly88
- Inspection90
- Reassembly and Remounting91
- Install Handlebar and Tighten the Screw92
Rear Wheel and Brake93
- Inspection94
- Reassembly and Remounting95
- Servicing Inforamtion96
- Troubleshooting97
- Battery100
- Wire, Cable and Brake Hose Routing103
  - Special Tools Listed below for Removal and Reinstallation107
  - Tightenting Torque O F Screw Thread Parts109
- Service Data110

Explorer GT 50 - SERVICING INFORMATION

Table of Contents