Chinese GY6 150cc Scooter Service & Repair Manual

CHINESE GY6 150cc SERVICE & REPAIR MANUAL

Servicing information 1 Vehicle bodymuffler 2 Inspection & Adjustment 3 Lubricating system 4 Carburetor air filter 5 Cooling system 6 Disassembly of engine 7 Cylinder head covercylinder head cylinder bodyvalve 8 CVT system 9 Gearbox 10 Right side covermagnetowater pump 11 Crankcase bodycrankshaftpiston set 12 Front wheel front brake front suspension steering system 13 Rear wheelrear brakerear suspension system 14 Batterycharging system 15 Ignition system 16 Electric starting systemoverriding clutch 17 Lightinginstruments & metersswitch 18 Circuit diagramwiring diagram 19 Troubleshooting FOREWORD This manual contains an introductory descrip- tion of procedures for inspectionmaintenance, overhaul disassembly & assemblyremoval and installation of components and parts, troubleshooting and service data together with illustra- tions of our scooters Chapter 1general service information, tools  vehicle structure and technical data. Chapter 2 inspection and adjusting key points service guideline  Chapter 3: and later disassembly of parts and components installation overhaul and troubleshooting. The manufacturer reserves the right to make improvements or modifications to the products without prior notice. Overhaul and maintenance should be done according to the actual state and condition of the cooters. INDEX

Conversion Table Item Example Conversion Pressure 200Kpa (2.00lgf/cm 2 ) 33kpa(250mmHg) 1kgf/cm 2 =98.0665kpa 1kpa=1000pa 1mmHg=133.322Pa=0.133322Kps Torque 18  N(1.8kgf-m) 1kgf  m=9.80665N  m Volume 419ml 1ml=1cm 3 =1cc 1l=1000cm 3 Force 12N (1.2kgf) 1kgf=9.80665N

 1 Overhaul Information Cautions…………………………………1-1 Special Tools…….……….……….1-16 Cautions for Disassembling and Assembling..1-3 Lubricant, Sealing Agent …………. 1-18 VIN Number & Engine Number.. …………1-6 Cable Routing….……….……… .1-20 Main Data Table ……….…………….…...1-7 Protecting Device for Hazardous Overhaul Data Table.. ……………….……..1-9 Gas Proliferation………….……… 1-27 Tightening Torque …………….……… 1-14 Secondary Air Intake Device ……….1-28 Cautions for Operation Safety Cautions Warning: Hazardous components in exhaust. Warning: Do not touch the engine Do not run the engine in a enclosed or or muffler with bare hands after the engine poorly ventilated place for long time. has just stopped to avoid scalding. Wear long-sleeve work clothes and gloves for operation. Caution: Battery liquid(dilute sulfuric acid) Warning: Coolant is poisonous. Do not is highly causitic and may cause burns to drink or splash to skin, eyes or clothes. skin and eyes. Flush with water if splashed Flush with plenty of soap water if splashed to to skin and get immediate medical skin. Flush with water and consult the doctor. attention. Flush with water if splashed to If drinking the coolant, induce vomiting and clothes to avoid burns. Keep battery and consult doctor. Keep coolant away from reach liquid away from reach of children of children. Caution: Wear proper work clothes, Warning: Gasoline is highly flammable. No cap and boots. If necessary, were dust- smoking or fire. Also keep against sparks. glass,gloves and mask if necessary. Vaporized gasoline is also explosive. Operate in a well-ventilated place.

 Caution: When charged, Battery may Warning: The asbestos dust on the brake generate hydrogen which is explosive. drum is carcinogenic is breathed in. Charge the battery in a well-ventilated Do not clean off the dust with compressed air. place. Use cleaning detergent to avoid dust proliferation. Warning: Be careful not to get clamped Warning: When more than two people are by the turning parts like wheels and operating, keep reminding each other for clutch. safety purpose.

 1 Overhaul Information Cautions for Disassembling and Assembling Use genuine CMSI parts, Clean the mud, dust before over hauling lubricants and grease Place and store the disassembled parts  Replace the disassembled washers, o-rings, Separately in order for correct assemble.  Piston pin circlip, cotter pin with new ones. Elastic circlips might get distorted after Disassembled. Do not use the loosed circlips.  Clean and blow off the detergent Measure the data during disassembly for after disassembling the parts. Apply correct assembling. lubricants on the surface of moving parts.  If not knowing the length of screws, Pre-tighten the bolts, nuts and screws, then install the screws one by one and tighten tighten according to the specified torque, with same torque. From big to small and from inner side to outer side.

  Check if the disassembled rubber parts Apply or inject recommended lubricant to are aged and replace if necessary. Keep the the specified parts. rubber parts away from grease.  Use special tools wherever necessary If the disassembling of pressed ball bearing is done by pressing the balls, do not use the disassembled bearing.  Turn the ball bearing with hands to Install the one-side dust-proof bearing in make sure the bearing will turn smoothly. The right direction. When assembling the .Replace if the axial or radial play is too big. open type or double-side dustproof bearing, .If the surface is uneven, clean with oil install with manufacturer#s mark outward. and replace if the cleaning does not help. .When pressing the bearing into the machine or to the shaft, replace the bearing if it could not be pressed tight.  Keep the bearing block still when blowing Install the elastic circlip properly. dry the bearing after washing clean. Apply Turn the circlip after assembling to make oil or lubricant before assembling. Sure is has been installed into the slot.

 1 Overhaul Information  After assembling, check if all the tightened Brake fluid and coolant may damage parts are properly tightened and can move coating, plastic and rubber parts. Flush smoothly. these parts with water if splashed. Install oil seal with the side of When installing pipes, insert the pipe till manufacturer#s mark outward. the end. Fit the pipe clip, if any, into the .do not fold or scratch the oil seal lip groove. Replace the pipes that cannot be .apply grease to the oil seal lip tightened. before assembling Do not mix mud or dust into engine Clean the gaskets and washers of the engine or the hydraulic brake system. cases before assembling. Remove the scratches on the contact surfaces by polishing evenly with an oilstone. Do not twist or bend the cables too When assembling the parts of caps, insert the much. Distorted or damaged cables caps to the grooves, if any. may cause poor operation.

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Chinese GY6 150cc Scooter Service & Repair Manual

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