BLATA B1 ORIGAMI MINI Bike Service Manual

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MINIBIKE – ORIGAMI B1 SERVICE MANUAL FOR USE AND MAINTENANCE AND SPARE PARTS LIST For your own safety and the safety of others Follow these recommendations in order to use your MINIBIKE safely and correctly. Read the instructions CAREFULLY, failure to do so may place yourself and others in extreme and or ultimate DANGER. If you do not understand the instructions and Data then, you are not to attempt to operate this Minibike under any circumstances. It may be used for show purposes only! CONTENTS PAGE INTRODUCTION .............................................................................................................. 2 TECHNICAL DATA .......................................................................................................... 2 UNPACKING AND SETTING UP BEFORE RIDING ....................................................... 3 SAFETY ............................................................................................................................ 3 BEFORE STARTING........................................................................................................ 3 STARTING THE ENGINE - FIG. 2 ................................................................................... 4 CARBURETOR - FIG. 3 ................................................................................................... 4 RIDING ............................................................................................................................ 4 PERIODIC MAINTENANCE ............................................................................................. 5 CHAIN SETTING AND MAINTENANCE ......................................................................... 5 CENTRIFUGAL CLUTCH REPAIR OR REPLACEMENT…............................................ 5 BRAKES ADJUSTING - FIG. 4 ........................................................................................ 6 FRONT BRAKES PADS REPLACEMENT - FIG. 7 ......................................................... 6 REAR BRAKES PADS REPLACEMENT - FIG. 7. ......................................................... 6 REMOVE AND REFIT THE FRONT WHEEL – FIG. 5 ……………................................... 7 REMOVE AND REFIT THE REAR WHEEL - FIG. 5 ................................................ ....... 7 REPLACEMENT OF SPROCKET - FIG. 9 ..................................................................... 7 MINIBIKE ORIGAMI B1 - FIG. 5 ………………………………………………….................... 8,9 PARTS LIST ……………………………………………………………………....................... 10,11 ENGINE - BLATA …………………………………………………………………................ 12 CLUTCH COMPLETE - FIG. 6…………………………………………………..................... 13 FRONT AND REAR BRAKES - FIG. 7 …………………………………………................. 14 REPLACEMENT OF TIRE – FIG. 5 ................................................................................. 15 REMOVE AND REFIT AIR FILTER .................................................................................. 15 CLUTCH ADJUSTMENT – FIG. 8 ………………………………………………................... 15 MAINTENANCE OF COOLING SYSTEM ………………………………………................. 16 TORQUE SETTINGS ......................................................................................................... 17 STORAGE PROCEEDURES …………………………………………………………............. 18 Downloaded from www.Manualslib.com manuals search engine

INTRODUCTION The Minibike Origami B1 is designed and built for use on a paved closed circuit track. The track should be clean and without obstacles of any kind. Qualified adults and younger persons can drive the minibike. Children can drive the minibike only under the supervision of a responsible adult person. The minibike is constructed especially for racing competitions on special racing tracks. The minibike uses a single-cylinder two-stroke, Gasoline combustion engine, and has an air filter and exhaust silencer. Transfer of power to the rear wheel is through a drive chain. The the overall drive ratio to the rear wheel can be changed by the replacement of chain sprockets. The front and rear wheel is equipped with disk brakes. The rear brake is controlled with the left lever and the front brake is controlled with the right lever on the handlebars. BASIC TECHNICAL DATA ENGINE : BLATA…………………………….………………………TWO-STROKE NUMBER OF CYLINDERS ................................................................. 1 CYLINDER CAPACITY …………………………….. .........39,8 cc ENGINE COOLING SYSTEM………………………..LIQUID COOLED POWER OUTPUT ........................................... 10,5 kW at 12 300 rpm TORQUE ………………………………................8,1 Nm at 12 000 rpm CARBURETOR ........................................... PHVA 17,5 DELL’ ORTO FUEL ADMISION …………REED VALVE DIRECT TO CRANKCASE IGNITION................................................................... CONTACT-LESS SPARK PLUG……………………..................................... NGK B9ES STARTING ........................................... HAND PULL TYPE, MANUAL CLUTCH ............................................... CENTRIFUGAL AUTOMATIC FRAME : ENHANCED TRELLIS…………….. SUPPORTING STRUCTURES MADE OF LIGHT ALLOYS BRAKES : FRONT WHEEL ... DISC BRAKE – DISC DIAMETER 162mm ( 6,3”) REAR WHEEL ........ DISC BRAKE-DISC DIAMETER 119 mm ( 4,7”) WHEELS : FRONT ............................................ OF LIGHT ALLOY 2,1”x 6,5”- 99 REAR ............................................ OF LIGHT ALLOY 2,1”x 6,5”- 130 TIRE : FRONT ...................................................................... SIZE 90/65 - 6,5” REAR .......................................................... 110/50 - 6,5”, 90/65 - 6,5” FUEL : .........MIXTURE OF PETROL 92 OR HIGHER OCTANE +2 STROKE SYNTHETIC OIL MIXING RATIO (after break in period) ....................................... 50: 1 TANK CAPACITY ............................................1,7 Liter 0,44 US gal. ) UNLOADED WEIGHT : ..................................................................... 25 kg ( 55 lb. ) CARRYING CAPACITY : ............................................................... 110 kg ( 242 lb. ) BASIC DIMENSIONS: LENGTH .................................................................... 1 100 mm ( 41” ) WIDTH ......................................................................... 560 mm ( 22 “ ) HEIGHT ..................................................................... 550 mm ( 21,6” ) Downloaded from www.Manualslib.com manuals search engine

UNPACKING AND SETTING UP BEFORE RIDING The minibike is delivered in a cardboard carton and packed with folded handlebars and brake levers. After unpacking, set up the handlebars into the position, that suits the best for driving. The maximum pulled brake lever position should not touch on the handlebar grip. After setting up, tighten the handlebar sleeve (clip-on) nuts 1; tighten the brake lever bolts and the throttle assembly 3. See, Fig.1. By loosening the nut M8 (P/N 920.010.01) on the foot peg bracket, the rider can adjust the foot peg position in a forward or rear direction. The foot rest can be moved to the front or back position. It is recommended to try and check the position of handlebars and foot rests individually. While tightening the bolts and nuts, do not use an excessive force as to not damage the threads, or distort the tubes and other parts. Verify the smooth and perfect function of the Bowden cables to throttle and both brakes. Fill the cooling system with coolant and vent the system (follow the instructions in chapter MAINTENANCE OF COOLER SYSTEM). Fill the fuel tank with fuel mixture. Failure to use the proper oil mix ratio will result in Engine damage for which you will be responsible. Fig. 1 Operating controls: 1. Handlebar bolts 2. Brake lever bolts 3. Throttle Assy. bolts 4. Stop switch 5. Front brake lever 6. Rear brake lever 7. Balance tank for coolant Range of adjusting handlebars function position SAFETY The minibike is unsuitable for public road use. It does not comply with valid Safety Standards. Unsafe and careless use of a minibike can result in serious injuries. The driver can minimize the potential risks by wearing the Safety Equipment. The driver must wear safety helmet, goggles, gloves, elbow pads, kneepads, and firm footwear. The minibike cannot be used on wet, icy or oily surfaces. Avoid uneven surfaces and obstacles. Drive with two hands on the handlebars. BEFORE STARTING It is strongly recommended to follow all the instructions about the break-in period to promote engine reliability and long life. Break-in period of the minibike is complete after the consumption of five full fuel tanks. It is important to use mixture of petrol 92 or higher Octane with 2-stroke synthetic oil in the ratio 30:1 and after break-in period a ratio of 50:1. Mix the petrol and oil completely before putting it into the fuel tank. During the break-in period do not run the engine at maximum RPM and do not allow the engine to overheat. 1 6 4 2 7 3 5 Downloaded from www.Manualslib.com manuals search engine

Check the tire inflation – 200 kPa (2 bars) or (28 to 30psi) to be commensurate with the driver’s weight. The Tyre pressure should never exceed 2,5 bars, (38psi) in either the front or rear wheel. IMPORTANT NOTICE: If the coolant level rises in the balance tank, switch off the engine immediately! Check the drive of the coolant pump and sealing of the cooling system. After these steps, execute the ventilation of the Radiator. The raised level of coolant is an indicator of a overheated engine, which can result in seizing the piston in the cylinder. STARTING THE ENGINE Engine starting should be done only on the stand - Fig. 2. Fill the fuel tank and close it with the filler cap. Open the Gas petcock. Set the petrol supply cock. Set the choke lever into position “C”, Fig. 3. Without turning the accelerating handle, pull gently twice the starting wire and by next guick pull start the engine. It is not allowed to pull the starting wire up to full winding off. The choke lever will turn back to the position “A” automaticaly by turning the accelerating lever after a short engine run . Let the engine run about 1 min. Leave the minibike on the stand with running engine and if necessary adjust the revolutions so the rear wheel is not turning. For adjustment use the adjustment screw No. 3 on the carburetor Fig. 3. Fig. 2 CARBURETOR 1. Air filter 2. Carburetor body 3. Idle speed adjusting screw 4. Float chamber A – Cock position for riding C – Cock position for cold starting Fig. 3 RIDING Remove the minibike from the stand to sit on the seat. When seated, then slowly rotate the throttle grip to start riding. Before braking, rotate the Throttle grip to the off or idle position and lightly depress the rear brake lever with left hand and then the front brake lever with right hand. Beware to not skid the wheels. The minibike engine is switched off by pushing the red button (Engine stop switch) on the handlebars. It is necessary to check the tightness of bolts and nuts, especially of the engine, and the brake settings after the first ride and often during the break in period. 1 2 4 3 C A Downloaded from www.Manualslib.com manuals search engine

PERIODIC MAINTENANCE Periodic maintenance is the best way to help the machine perform well, give longevity and provide safety and low cost operation. In addition, you will be spared from many worries from self caused problems, resulting from poor maintinence or no maintinence. A - Before every ride: 1. Check the Cables and efficiency of brakes. 2. Check the lubrication and chain tension settings. The chain free play should be (5 mm) (.200in) After every ride clean the minibike carefully and keep it clean. Do not use aggressive cleaning detergents. 3. After 1-hour of use, wash the air filter in air drying spirits and lubricate it with special oil for air filters. 4. After 1- hour of use, check the state of the clutch pads. Review the clutch adlustment. B. After every 5 hours of riding: Check the tightness of all bolts and nuts. Tighten with a properly adjusted torque wrench only! For torque settings see tables on page 17. 5. Wash the air filter in gas and lubricate it with special oil for an air filters to better catch the dust. 6. Clean carefully the carburetor float chamber. 7. Check the brake pads, the thickness of brake lining cannot be less than 1 mm (.039 in). Review the basic brake adjustment. 8. Check the state of the clutch pads - the thickness cannot be less than 1 mm (.039in). Review the clutch adjustment. C - Every time after 10 hours of riding: 9. Check the state of the clutch pads - the thickness cannot be less than 1 mm (.039in). CHAIN SETTING AND MAINTENANCE To set the chain tension, loosen the Nut (920.011.01) of the axel thru the rear wheel and the nut (914.021.01) of the rear Caliper anchor plate. The required chain tension (chain free play ) is (5 mm) (.200in) and is performed by equal movement of the Axel adjustor plate (920.009.01) on the both sides of the rear wheel. When the adjustment is correct, tighten the Axel nuts and the Caliper holding nut. Tighten the adjustor plate nuts both sides an extra nip, just to set them firmly. It is important to lubricate the chain regularly, to avoid excess wear and prolong effective lifetime. The lubrication is important after every ride on a wet surface. It is recommended to lubricate the minibike with special chain spray. If chain replacement is necessary, check both chain Sprockets and if there is a need to change them do it together with the chain. CENTRIFUGAL CLUTCH PARTS, REPLACEMENT Remove the chain guard by loosing two bolts M6 (916.020.01), Fig. 5. Loosen the chain and remove it from the sprocket. Next, loosen three bolts holding the aluminum clutch housing. Remove it together with steel clutch basket, and dismantle it. Loosen the bolt from the carrier and remove the clutch from the engine. Loosen and remove the adjustable bolts and springs. Then dismantle the safety rings from pins. When all this is done, replace with new clutch slipper shoes and springs (if required), at this time. During the reassembly process follow these steps: 1. put the plate with the springs on the slipper shoes. 2. Put the plate against the carrier and mount it on the fixed pins. Fit it with the safety rings and install the adjustable bolts. Downloaded from www.Manualslib.com manuals search engine

ADJUSTING THE BRAKES Small incremental brake adjustment Free play at the handlebar lever is effected by turning the knurled end on the cable adjustor. This will allow the lever to be set at the nominal to ¼ inch of free lever movement. Basic brake adjusting: Screw in the knurled cable adjustor at the brake lever so the cable is in it’s most slack starting position.. At the caliper, loosen the nut, No. 3 and tighten the adjustable bolt No. 4 , so the wheel cannot turn. Back off bolt No. 4 about ¼ to ½ of a turn and fix it with lock nut No. 3 . Do not use the cable retainer No. 5 for adjusting the brakes! Fig. 4 FRONT BRAKE PADS REPLACEMENT - FIG. 7 First screw in the knurled cable adjustor at the right brake lever (122.002.00) on the handlebars to the starting position (slackened cabled). Loosen the nut (920.001.01) and turn the adjustable bolt (512.015.00) in the way that by pressing the front brake lever, the lever (312.017.00) will be over the bolt head M5 (312.018.00), which protects brake pads and spring of pads (312.020.00). Unbolt this bolt and replace the old brake pads with new ones. When mounting the brake pads place the brake spring against both pads, so they are pressed into the front direction. While replacing the brake pads do not loosen bolts M5 (914.001.01) on the driving pins and do not loosen the cable retainer! REAR BRAKE PADS REPLACEMENT - FIG. 7 First screw in the knurled cable adjustor at the left brake lever (122.001.00) on the handlebars to the starting position (slackended cable). Loosen the nut (920.001.01) and turn the adjustable bolt (512.015.00) all the way out. Unbolt the nut M10 (920.001.01) of the back axel, push it out and dismantle the rear wheel from the Swingarm. Push out the brake from driving pins, that will loosen the brake pads and replace the old ones at this time. While replacing the brake pads do not loosen bolts M5 (914.001.01) on the driving pins and do not loosen the cable retainer! During the mounting follow all these instructions in the reverse direction and then perform basic adjusting of the brakes. 4 3 Downloaded from www.Manualslib.com manuals search engine

REMOVE AND REPLACE THE FRONT WHEEL - FIG. 5 Before dismantling the front wheel it is necessary to remove the front brake pads from the front brake, so it is possible to move the brake caliper from the wheel and be able to draw out the wheel and tire. Remove the front axel nut. M10 (920.011.01) Draw out the axel from the fork and wheel. Remove the wheel by an easy pull downwards from the forks. CAUTION! Two 3mm spacers will fall out when the wheel is being removed! Insert one spacer between the brake rotor and the brake mounting bracket, and the other spacer between the wheel and the right fork (P/N 315.011.00) when re-assembling. Return the brake pads with the spring and tighten up the axel nut. Perform the basic brake adjusting. Double check your work. This is important! REMOVE AND REPLACE THE REAR WHEEL - FIG. 5 Loosen and remove nut M10 on the rear axle. Safely (hold) keep the rear wheel from falling out while pulling out the axel. Caution, note the location of both spacer tubes and one spacer washer (between caliper mount plate and rotor) while removing wheel. When refitting the wheel, make sure to slide the brake rotor into the caliper between the pads. Hold the wheel in place and fit the wheel spacers in proper order. . Insert one 3mm spacer between the brake rotor and brake mounting bracket and than insert the 9.5mm spacer between the brake and the rear swing arm. Adjust chain tension and tighten axel nut. Tighten the caliper holder plate nut and set and tighten both chain adjustor plate M6 nuts. At this time check the brake operation. Recheck all your work. This is important ! REPLACEMENT OF PINION - FIG. 9 First dismantle the front chain guard and chain guard.Loosen the nut of rear wheel axle and the nut of chain tightener ,remove chain. Insert carefully a larger screw driver or steel rod into the hole of clutch drum, Fig. 9, to avoid a turning over the clutch drum at releasing the pinion. Using the pinion wrench P/ N 319.050.00, release the new pinion to be carried out by reverse way. FIG. 9 Downloaded from www.Manualslib.com manuals search engine

REPLACEMENT OF TIRE – FIG. 5 Remove the wheel from the minibike. For the front wheel unbolt the brake disk and for the rear wheel, the brake disk and sprocket. Deflate the tire, by removing the valve stem. Place the wheel on a hard surface and press the tire bead from the wheel rim in to the middle relief at centre of rim. Tire is ready to be removed from the rim at this time and is done in the conventional manner. After fitting new Tire and Tube (if necessary) to the rim, you can inflate 28 to 30 psi. Take care to check that the tire bead is fully seated in the rim bead edge. You can now refit the wheel to the bike in reverse order to removing it. Use Caution and recheck your work always. DISMANTLING AND MOUNTING OF AIR FILTER - FIG. 3 Remove the bolt from the sleeve, which connects the rubber holder of the air filter to the carburetor. When the air filter is loosened, take it out and very carefully wash it in air drying solvent, lubricate it when dry and spray with air filter oil and reassemble, following the steps in the reverse order. CLUTCH ADJUSTMENT – FIG. 8 After first hour of use, check the state of the clutch pads. Review the clutch adjustment – engaged with 8 000 – 8 500 rpm. Basic adjustment: After every clutch slipper shoe replacement it is necessary to adjust the clutch springs. To increase the revolutions, and feel the clutch working, tighten up the adjusting bolts and to engage shoes at lower revolutions,loosen the bolt. It is important to adjust all the springs to the same level, so the clutch lining wearing is even. The index for adjusting is the length of the spring, which should be 21,00 mm. The length is measured from the bearing surface of the clutch shoe to the spring plate. FIG. 8 Downloaded from www.Manualslib.com manuals search engine

MAINTENANCE OF COOLER SYSTEM 1. Liquid filling: Place the minibike on the stand. Dismantle the seat and very carefully check all the joints on the hose. For older minibikes do not forget to check for holes and other damages to the hose. To fill the cooler system, 0.5 liters of the coolant is needed. In case the minibike will be used during the wintertime, do not forget to use the anti-freeze coolant. Pour the coolant into the balance tank, which is placed between the handlebars, until it is filled to ¾ of capacity. Unbolt vent bolt M5 (P/N 914.006.01), which is inserted in the hose (P/N 349.) between the bottom part of the radiator and the engine block. Tighten the bolt only after all air has been bled and only coolant is coming out of the vent plug hole. Always hold the hose in order not to pull out the air escape valve. It is important to have more than ½ capacity of the coolant in the balance tank. The same procedure applies to the venting hose (P/N 349.) between the cylinder head and the radiator. Once more vent the system while loosening the air bleed screws until all air is expelled. Close the tank and pull the start T’handle two or three times. This will circulate the coolent in the system. Once more vent the system while loosening the air bleed screw. Only now it is possible to start the minibike, and leave it to run on the stand for one minute. Turn of the motor, and vent it again. Then the minibike is ready for use. 2. Check up of cooler system: Before every ride check the amount of coolant in the balance tank! After every 10 hours of riding, remove the pull starter cover and check the Gilmer type belt, which runs the coolant pump. Important notice: If the coolant level rises in the balance tank switch of the engine immediately! Check the drive of the coolant pump and sealing of the cooler system. After these steps vent the air bleed screw. The raised level of coolant is an indicator of a warmed up engine, which can result in seizing of the piston in the cylinder. 3. Draining the Coolant: Dismantle the hose on the bottom of the cooler system and eliminate the liquid. Unbolt the drain plug in the balance tank. Downloaded from www.Manualslib.com manuals search engine

BLATA B1 ORIGAMI MINI Bike Service Manual

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