Generic Race 50 - Page 2

Generic Race 50

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1

User's operation and maintenance manual for

double-wheel motorcycle RACE 50

Table of Contents

Service Manual1
Table of Contents3
Contents3
Preface6
- Documents to be Prepared7
  - Important Notices13
  - Troubleshooting24
- Inspection/Adjustment44
Inspection and Service of Electrical System65
Battery/Charging System69
- Preparation Data69
- Fault Diagnosis69
- Battery72
- Charging System73
- Voltage and Current Regulator74
- Charge Coil of the Alternator75
- Disassembly of Alternator75
- Preparation Data80
II. Ignition System80
- Fault Diagnosis82
- Ignition System Inspection84
- CDI Group85
- Ignition Coil87
- Trigger87
- Preparation Data92
III. Startup System92
- Fault Diagnosis94
- Start Electric Machinery94
- Start Relay97
- Preparation Data100
- Fault Diagnosis100
- IV. Bulbs/ Switch/Instrument100
- Replace the Head Light Bulb100
- Replace Bulb of the Front Turning Light101
- Disassembly/Replace the Bulb of the Taillight and Rear-Right Turning Light101
- Instrument102
- Main Switch102
- Horn103
- Handle Switch103
Inspection and Service of Chassis105
Brake108
- Maintenance Instruction108
- Fault Diagnosis109
- Front Hydraulic Brake109
- Rear Drum Brake111
Body Cover115
Front Wheel/ Front Suspension 90 7.1 Preparation Data116
- Front Suspension118
- Fault Diagnosis120
- Front Wheel120
- VII. Front Wheel/ Front Suspension120
- Steering Bar124
- Front Fork125
- Fault Diagnosis129
- Preparation Data129
VIII. Rear Wheel/Rear Suspension129
- Real Wheel130
- Rear Shock Absorber131
  - Rear Shock Absorber132
  - Fuel Tank135
Fuel Tank/Seat Mat137
- Lubrication System143
- Fault Diagnosis144
- Preparation Data144
X. Lubrication System144
- Fault Diagnosis145
- Oil Pump145
- Preparation Data150
XI. Carburetor150
- Fault Diagnosis151
- Disassembly of Carburetor151
- Installation & Adjustment156
- Preparation Data158
- Fault Diagnosis158
XII. Cylinder Cover158
- Cylinder Head158
- Examination on Cylinder Head160
- Cylinder Head Installation160
- Preparation Data163
XIII. Air Cylinder/Piston163
- Fault Diagnosis164
- Cylinder Body164
- Piston166
- Installation of Piston170
  - Installation of Piston171
  - XIV. Drive Disk/Clutch/Driven Wheel / Foot Start Mechanism175
Drive Disk/Clutch/Driven Wheel / Foot Start Mechanism 174 14.1 Preparation Data176
- Left Crankcase Cover176
- Clutch/Driven Wheel179
- Disassemble the Clutch and the Driven Wheel181
- Installation187
- Foot Start Mechanism187
- Preparation Data190
- Fault Diagnosis190
XV. Decelerator190
- Gear Case190
- Installation192
- Crankcase193
- Installation200
Exhaust Emission System Inspection and Maintenance201
Exhaust Emission and Control System202
- Warranty of Exhaust Emission and Control System202
- Regular Maintenance Guideline203
- Mechanical Function of the Exhaust Control System204
- Catalyst Converter System206

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