KYMCO ZING 150 - Page 79

8. STARTER MOTOR/GENERATOR/LEFT CRANK-
CASE COVER/STARTER CLUTCH/CAMSHAFT
8
-
1
SERVICE INFORMATION
GENERAL INSTRUCTIONS
• The starter motor, generator, left crankcase and starter clutch can be serviced in the frame.
• Do not install the starter clutch forcedly.
• Install the generator by aligning the groove in the flywheel with the key on the crankshaft.
• Install the starter motor reduction gear shaft by aligning the shaft pin with the shaft seat groove.
SPECIFICATIONS
Item
Standard (mm)
Service Limit (mm)
Reduction gear shaft O.D. 9.972～9.987 9.932
Reduction gear shaft hole I.D. 10.031～10.056 10.096
Camshaft O.D. 13.966～13.984 13.926
Cam gear shaft hole I.D. 14.06～14.078 14.118
Roller O.D. 9.99～10.005 9.95
Starter gear shaft I.D. 22.01～22.022 22.062
Starter gear shaft O.D. 42.574～42.6 42.534
TORQUE VALUES
Flywheel lock bolt 0.8～1.2kg-m
SPECIAL TOOLS
Flywheel holder
Flywheel puller
TROUBLESHOOTING
Hard starting and poor performance at high speed
• Improperly tightened flywheel lock bolt Starting noise
• Worn reduction gear
Starter clutch slips • Worn starter gear
• Worn starter clutch roller • Worn starter clutch roller
• Faulty starter clutch roller or spring • Faulty reduction gear shaft bearing
• Worn starter gear shaft O.D.
SERVICE INFORMATION .......................8-1 CAMSHAFT REMOVAL.............................8-4
TROUBLESHOOTING..............................8-1 CAMSHAFT INSTALLATION....................8-5
STARTER MOTOR ...................................8-2 STARTER GEAR INSTALLATION............8-5
LEFT CRANKCASE COVER REMOVAL........8-2 GENERATOR INSTALLATION .................8-5
GENERATOR REMOVAL........................8-2 LEFT CRANKCASE COVER INSTALLATION...8-6
STARTER CLUTCH REMOVAL.............8-3 STARTER MOTOR INSTALLATION ........8-6