GENERIC TRIGGER 50 QJ50 Scooter Workshop Repair Manual

REPAIR MANUAL D01 - TRIGGER 50 Vers. 2015_01

It is important that you read this repair manual carefully before the start of work. Only use GENERIC/ KSR spare parts. KSR Motot Motorcycles is a registered brand by KSR Group GmbH. This vehicle can only fulfil the demands placed on it if the service work is made by qualified experts and in accordance with the service schedule. The repair manual was written to correspond to the current state of this model. We reserve the right to make changes in this manuals in the interest of technical advancements and improvements without a notice. It is recommended that repair work will be done by a fully educated mechanic. We will not provide descriptions of general workshop methods, safety rules that necessary in a workshop. All specifications refers to the current state and are nonbinding. KSR Group GmbH specifically reserves the right to modify the information in this manual without notice and without specifying reasons. KSR Group GmbH accepts no liability deviations from illustrations and descriptions or misprints and other errors. The models in this manual partly contain special equipment that does not belong to the regular scope of delivery fur- ther the illustrations and pictures are symbolic images, and may differ from the actual components. © 2012 by KSR Group GmbH, Krems Austria All rights reserved Reproduction of this manual is permitted only with the express written permission of the copyright owner. Within the meaning of the international quality management standard ISO 9001, KSR Group GmbH uses quality as- surance processes that lead to the maximum possible quality of the products. KSR Group GmbH A-3500 Krems, Austria INTRODUCTION 2

IMPORTANT NOTES 6 LOCATION OF SERIAL NUMBERS VIN (VEHICLE IDENTIFICATION NUMBER) AND FRAME PLATE 7 ANTI TEMPERING LABEL 7 ENGINE NUMBER 7 DECRYPTING THE VEHICLE IDENTIFICATION NUMBER 7 GENERAL SPECIFICATIONS VEHICLE SPECIFICATION 8 SPECIFIC TIGHTENING TORQUE 10 GENERAL TIGHTENING TORQUE 11 SPECIAL TOOLS SPECIAL TOOLS 12 1. PERIODIC MAINTENANCE PERIODIC MAINTENANCE CHART CHECKLIST OF CONSTANT MAINTENANCE 15 IMPORTANT PREPARATION REFERENCES IMPORTANT PREPARATION REFERENCES 18 FUEL SYSTEM AIR CLEANER 21 CHANGING INTERVALS 21 THROTTLE WIRE INSPECTION/ ADJUSTMENT 21 IDLE ADJUSTMENT 22 CARBURETTOR ADJUSTMENT 22 FUEL HOSE INSPECTION 22 FUEL FILTERS CLEANING 23 ENGINE ENGINE OIL LEVEL INSPECTION 23 ENGINE OIL LEVEL SENSOR INSPECTION 24 OIL PUMP INSPECTION 24 OIL PUMP ADJUSTMENT 26 TRANSMISSION OIL LEVEL INSPECTION 27 SPARK PLUG INSPECTION 27 SPARKPLUG IMAGES AND ANALYSIS 28 SPARK PLUG REPLACEMENT 28 CYLINDER PRESSURE INSPECTION 28 CLUTCH CLUTCH CABLE FREE PLAY ADJUSTMENT 29 ADJUSTING THE CLUTCH CABLE FREE PLAY ON THE ENGINE SIDE 29 CLUTCH ADJUSTMENT 30 WHEELS AIR PRESSURE INSPECTION 30 WHEEL BEARING AND WHEEL AXLE DAMAGE INSPECTION 31 BRAKES BRAKE FLUID LEAK INSPECTION FRONT 31 BRAKE FLUID LEAK INSPECTION REAR 31 BREAK OPERATION INSPECTION FRONT 31 BREAK OPERATION INSPECTION REAR 32 BRAKE FLUID LEVEL INSPECTION FRONT 32 BRAKE FLUID LEVEL INSPECTION REAR 32 FRONT BRAKE PADS INSPECTION 33 REAR BRAKE PADS INSPECTION 33 FRONT BRAKE DISC INSPECTION 34 REAR BRAKE DISC INSPECTION 35 FRONT BRAKE LEVER/ MASTER BRAKE CYLINDER REPLACEMENT 35 FOOT BRAKE LEVER/ MASTER BRAKE CYLINDER REPLACEMENT 36 FRONT BRAKE CALLIPER REPLACEMENT 36 REAR BRAKE CALLIPER REPLACEMENT 36 FRONT BRAKE HOSE REPLACEMENT 37 REAR BRAKE HOSE REPLACEMENT 37 FRONT BRAKE LEVER ADJUSTMENT 38 REAR BRAKE LEVER ADJUSTMENT 38 DRIVE CHAIN DRIVE CHAIN SLACK INSPECTION 39 DRIVE CHAIN SLACK ADJUSTMENT 39 DRIVE CHAIN LUBRICATION 39 DRIVE CHAIN WEAR INSPECTION 40 SUSPENSION FRONT FORK OPERATION INSPECTION 40 FRONT FORK OIL LEAK INSPECTION 40 REAR SHOCK OPERATION INSPECTION 41 REAR SHOCK OIL LEAK INSPECTION 41 STEERING STEERING PLAY INSPECTION 41 STEERING BEARING LUBRICATION 42 ELECTRICAL SYSTEM BATTERY INSPECTION/ CHARGING 43 FUSES 44 LIGHT AND SWITCHES OPERATION INSPECTION 44 HEADLIGHT AIMING INSPECTION 45 2. REPAIR AND DIAGNOSTIC CHASSIS EXPLODED VIEW / PART LOCATION - FRAME 47 EXPLODED VIEW / PART LOCATION - REAR SWING ARM 48 EXPLODED VIEW / PART LOCATION - SEAT 48 FUEL SYSTEM EXPLODED VIEW / PART LOCATION - FUEL SYSTEM 50 SPECIFICATION 51 CARBURETTOR EXPLODED VIEW / PART LOCATION - CARBURETTOR 52 CARBURETTOR REMOVAL 53 CHOKE/ CABLE REMOVAL 53 CARBURETTOR UPPER COVER REMOVAL 54 CARBURETTOR ADJUSTMENT 54 FUEL SUPPLY FUEL SUPPLY INSPECTION 54 FUEL TANK REMOVAL 55 FUEL COCK 56 ENGINE EXPLODED VIEW / PART LOCATION - CYLINDER/ CYLINDER COVER 57 EXPLODED VIEW / PART LOCATION - CRANK ASSEMBLY 58 EXPLODED VIEW / PART LOCATION - CRANKCASE 59 SPECIFICATION 60 TROUBLESHOOTING 61 ENGINE OVERHAUL/ REMOVAL 62 ENGINE PREPARATION 62 ENGINE REMOVAL 62 ENGINE TOP END CYLINDER COVER REMOVAL 63 CYLINDER REMOVAL 63 PISTON REMOVAL 63 OIL PUMP REMOVAL 64 WATER PUMP REMOVAL 64 CRANKCASE (RIGHT) REMOVAL 64 CLUTCH REMOVAL 65 CRANKSHAFT GEAR AND MAIN SHAFT GEAR REMOVAL 66 MEMBRANE 66 SPROCKET REMOVAL 66 CRANKCASE COVER (LEFT) REMOVAL 67 INDEX 3

INDEX 4 STARTER REMOVAL 67 STARTER GEAR REMOVAL 67 STATOR REMOVAL 67 CRANKCASE SEPARATION 68 CRANKSHAFT REMOVAL 68 TRANSMISSION DISASSEMBLY 69 INPECTION OF TRANSMISSION AND GEAR SHIFT MECHANISM 70 EXPLODED VIEW / PART LOCATION - PRIMARY SHAFT ASSY/ SECONDARY SHAFT ASSY 71 EXPLODED VIEW / PART LOCATION - SHIFT MECHANISM 72 EXPLODED VIEW / PART LOCATION - REDUCTION GEAR 73 INSPECTION OF TRANSMISSION AND SHIFT MECHANISM 74 TRANSMISSION ASSEMBLING 75 CRANKSHAFT INSPECTION 76 TOP END PARTS INSPECTION 78 PISTON INSTALLATION 80 CYLINDER INSTALLATION 81 CYLINDER COVER INSTALLATION 81 LEFT CRANKCASE ASSEMBLING 82 SPROCKET INSTALLATION 83 MEMBRANE INSPECTION 83 MEMBRANE INSTALLATION RIGHT CRANKECASE ASSEMBLING 83 CLUTCH INSPECTION 84 EXPLODED VIEW / PART LOCATION CLUTCH 85 CLUTCH ASSEMBLING 86 OUTWARD RELEASE LEVER ADJUSTMENT 87 ACTUATING LEVER INSPECTION 87 ACTUATING LEER ASSEMBLING 87 RIGHT CRANKCASE ASSEMBLING 87 ACTUATING LEVER ADJUSTMENT 88 EXPLODED VIEW / PART LOCATION - OIL PUMP 89 INSPECTION OF THE OIL PUMP 89 OIL PUMP ASSEMBLING 89 LUBRICATION SCHEME 90 COOLING SYSTEM SCHEME 91 WATER PUMP INSPECTION 91 WATER PUMP ASSEMBLING 91 WHEELS AND TIRES EXPLODED VIEW / PART LOCATION - FRONT WHEEL 92 EXPLODED VIEW / PART LOCATION - REAR WHEEL 93 WHEELS (RIMS) 94 TIRES 94 WHEEL BEARING REPLACEMENT FRONT WHEEL 94 WHEEL BEARING REPLACEMENT REAR WHEEL 95 WHEEL BEARING INSPECTION 95 WHEEL AXLE INSPECTION 95 RIM INSPECTION 95 BRAKES EXPLODED VIEW / PARTLOCATION - FRONT BRAKE 96 EXPLODED VIEW / PART LOCATION - REAR BRAKE 97 BRAKE LEVERS / FRONT BRAKE LEVER 98 BRAKE LEVERS / REAR BRAKE PEDAL 98 BRAKE FLUID 99 BRAKE HOSE 99 REAR BRAKE PAD WEAR INSPECTION 99 BRAKE PEDAL REPLACEMENT 100 SUSPENSION EXPLODED VIEW / PART LOCATION - FRONT SUSPENSION 101 EXPLODED VIEW / PART LOCATION - ADJUSTABLE REAR-SUSPENSION 103 FRONT SUSPENSION REPLACEMENT 104 FRONT SUSPENSION WHOLE FORK REPLACEMENT 105 REAR SUSPENSION REPLACEMENT 105 REAR SWING ARM REPLACEMENT 106 STEERING EXPLODED VIEW - PART LOCATION / STERRING 107 HANDLEBAR REPLACEMENT 108 CLUTCH LEVER REPLACEMENT 109 BRAKE LEVER REPLACEMENT 110 EXHAUST EXHAUST REPLACEMENT 110 SECONDARY AIR SYSTEM SECONDARY AIR SYSTEM INSPECTION 112 ELECTRICAL SYSTEM WIRING DIAGRAM 114 LOCATION - ELECTRICAL SYSTEM 115 LOCATION - LIGHTS / INSTRUMENTS SWITCHES 116 SPECIFICATION 117 FUSES FUSE REPLACEMENT 118 SPECIFICATION 118 TROUBLESHOOTING 118 BATTERY BATTERY GENERAL INFORMATION 118 BATTERY REMOVAL 119 BATTERY AND CHARGING SYSTEM 119 CHARGING SYSTEM CHARGING SCHEME 120 CHARGING PERFORMANCE TEST 120 REGULATOR - RECTIFIER INSPECTION 121 GENERATOR CHARGING COIL 121 IGNITION SYSTEM IGNITION SYSTEM 122 PREPARATORY DATA 122 SPECIFICATION 123 FAULT DIAGNOSIS 123 IGNITION SYSTEM INSPECTION 124 PRIMARY VOLTAGE OF IGNITION COIL 124 TRIGGER (PICK UP) 124 TRIGGER INSPECTION 125 CDI ASSEMBLY 125 IGNITION COIL REMOVAL 125 PRIMARY COIL INSPECTION 125 SECONDARY COIL INSPECTION 126 STARTING SYSTEM STARTING DIAGRAM 126 FAULT DIAGNOSIS 127 STARTING MOTOR 127 STARTING MOTOR INSPECTION 127 STARTING RELAY 127 STARTING RELAY ACTUATION INSPECTION 127 STARTING RELAY VOLTAGE INSPECTION 128 LIGHTNING SYSTEM BULBS REPLACEMENT GENERAL INFORMATION 129 HEADLAMP BULB REPLACEMENT 129 POSITION LIGHT BULB REPLACEMENT 130 WHOLE HEADLIGHT REPLACEMENT 130 REAR WINKER REPLACEMENT 131 FRONT WINKER REPLACEMENT 131 BULB WINKER REPLACEMENT 132 BULB TAILLIGHT REPLACEMENT 132 TAILLIGHT REPLACEMENT 133 LICENSE PLATE BULB REPLACEMENT 133 SPEEDOMETER SPEEDOMETER DESCRIPTION 134 SPEEDOMETER REPLACEMENT 134

INDEX 5 SWITCHES AND SENSORS IGNITION SWITCH INSPECTION 134 IGNITION SWITCH REPLACEMENT 134 STEERING LOCK 134 ELECTRIC HORN INSPECTION 135 ELECTRIC HORN REPLACEMENT 135 LEFT HANDLE SWITCH 135 RIGHT HANDLE SWITCH 135 LEFT HANDLE SWITCH INSPECTION 136 LEFT HANDLE SWITCH REPLACEMENT 136 RIGHT HANDLE SWITCH INSPECTION 136 RIGHT HANDLE SWITCH REPLACEMENT 137 FRONT BRAKE LIGHT SWITCH INSPECTION / REPLACEMENT 137 REAR BRAKE LIGHT SWITCH INSPECTION 138 REAR BRAKE LIGHT SWITCH REPLACEMENT 138 NEUTRAL SENSOR INSPECTION 139 NEUTRAL SENSOR REPLACEMENT 139 SPEED SENSOR INSPECTION 140 SPEED SENSOR REPLACEMENT 140 FAULT DIAGNOSIS 142 CHASSIS SEAT REMOVAL 143 LEFT / RIGHT SIDE COVER REMOVAL 143 LEFT / RIGHT LOWER SIDE COVER REMOVAL 143 LEFT / RIGHT TANK SIDE COVER REMOVAL 144 REAR BODY PANEL REMOVAL 144 REAR SIDE COVER REMOVAL 145 REAR FENDER REMOVAL 145 FRONT FENDER REMOVAL 146 HEADLIGHT COVER REMOVAL 146 COVER FRONT SHOCK ABSORBER LEFT REMOVAL 147 COVER FRONT SHOCK ABSORBER RIGHT REMOVAL 148 MIRROW BACK VIEW MIRROWS 149 BACK VIEW MIRROWS REMOVAL 149 SECOND SPEEDOMETER SECOND SPEEDOMETER 150 SWITCH BUTTON FUNCTION LIST 150 REMOVAL OF POWER LIMITATION REMOVAL OF POWER LIMITATION 151 LEVEL 1 151 LEVEL 2 151

WARRANTY The work prescribed in the service schedule must be carried out in an authorized workshop and confirmed in the customer‘s service card, otherwise no warranty claims will be recognized. No warranty claims can be considered for damage resulting from manipulations and/or alterations to the vehicle. NOTES AND WARNINGS Pay attention to the notes/warnings in this manual. • Identifies dangers that will lead to environmental damage if the measures are not taken. • Identifies dangers that is likely to lead to fatal or serious injury if the measures are not taken. • Identifies dangers that will lead to considerable machine and material damage if the measures are not taken. • Identifies dangers that will immediately lead to fatal or serious permanent injury if the appropriate measures are not taken. REPAIR MANUAL It is important that you read this manual completely before the start of work. It contains useful information how to repair and maintain the vehicle. FUEL AND LUBRICANTS Use only the fuels, oils and lubricants according to specifications as listed in this manual. Please consider that KSR Group GmbH give no approval for Bio- Ethanol (E 10 or higher) fuel. SPARE PARTS AND ACCESSORIES Only use spare parts and accessory that have been approved or recommended by KSR Group GmbH. PRACTICE Special tools are required for some work but mostly professional work shop equipment is enough for service, repair and maintenance of the vehicle. Special tools mentioned inside of this manual. When thread locker is used on connections (e.g., Loctite®), follow the instructions for use from the manufacturer. After disassembly, clean the parts that are to be reused and check them for damage and wear. Replace damaged or worn parts. IMPORTANT • After each repair or maintenance work security check and a test drive must be done. • Before you delivery the vehicle to the customer a road safety test must be done. ! WARNING IMPORTANT NOTES 6

VIN (CHASSIS NUMBER) AND FRAME PLATE The vehicle identiﬁcation number (VIN) (1) is punched into the right side of the steering tube. The frame plate (2) is located on the right side in front of the frame. ANTI TEMPERING LABEL The anti tempering label (3) is ﬁxed on the inner side of the seat bench. ENGINE NUMBER The engine number (4) is stamped into the left side of the engine case. DECRYPTING THE VEHICLE IDENTIFICATION NUMBER EXAMPLE: VA4D0115XDB775449 VA4 - WORLD MANUFACTURER INDEX (NAME OF MANUFACTURER) D01 - MODEL TYPE 1 - VARIANT OF MODEL 5 - VERSION OF MODEL X - RANDOM NUMBER D - YEAR OF PRODUCTION (CB = 2012/ DB = 2013,.........) B - ASSEMBLING PLANT (LOCATION OF FACTORY) 775449 SERIAL NUMBER LOCATION OF SERIAL NUMBERS 7 1 2 3 4

ENGINE Engine type: Liquid cooled 2 - stroke Cylinder arrangement: Horizontal (+60°) single cylinder Displacement: 49.6 cm³ Compression ratio: 7.0:1 Max. output (kw/rpm): 2.2 kW/ 6500 rpm Max. torque (Nm/rpm): 3.6 Nm/ 5500 rpm Starting system: Electric starter and Kick starter Lubrication system: Fresh oil lubrication ENGINE OIL QUANTITIY Capacity: 1 L Recommended type: CASTROL Power 1-Racing 2T Fully Synthetic TRANSMISSION OIL Quantity 0.5 L for disassemble/ 0.4 for replacement Recommended type: CASTROL Power 1-Racing 4T 10W-40 AIR FILTER ELEMENT Foam ﬁlter FUEL Recommended fuel: Unleaded gasoline only ≥ 95 Oct Do not use Bio-Ethanol fuel - E10 is not permitted Fuel tank capacity: 10 L ± 0.2 L CARBURETTOR Type/ Manufacturer: PZ19JB JB-4/ LEADER or QJ Main jet: 95 Idle jet: 22.5 SPARK PLUG Manufacturer/ model: NGK/BR8ES CLUTCH Clutch type: Multi-disc in oil bath TRANSMISSION TYPE Manual, 5 speed CHASSIS Frame type: Steel tube TIRES (Version 0 = Trigger X) Front tire Type: Tubeless/ Pressure on cold tire: 2.25 bar Size: Rim: 1.6*21 Tire: 3.00-21 Rear tire Type: Tubeless/ Pressure on cold tire: 2.25-2.5 bar Size: Rim: 1.85*18 Tire: 4.10-18 TIRES (Version 1 = Trigger SM) Front tire Type: Tubeless/ Pressure on cold tire: 2.25 bar Size: Rim: 2.5*17 Tire: 100/80-17 Rear tire Type: Tubeless/ Pressure on cold tire: 2.25-2.5 bar Size: Rim: 3.00*17 Tire: 130/80-17 Version 0 Version 1 GENERAL SPECIFICATION 8

GENERAL SPECIFICATION 9 BRAKES Front brake Type: Single Hydraulic disc brake (280 mm)/ Right hand operation Brake fluid: DOT4 Recommended brake fluid: (CASTROL SUPER DISK BRAKE FLUID DOT 4.) Rear brake Type: Hydraulic disc brake (220 mm)/ Right foot operation Brake fluid: DOT4 Recommended brake fluid: (CASTROL SUPER DISK BRAKE FLUID DOT 4.) FRONT SUSPENSION Type: Telescopic fork Spring/shock absorber type: Coil spring/oil damper REAR SUSPENSION Type: Unit swing Spring/shock absorber type: Coil spring/oil damper ELECTRICAL SYSTEM Ignition system: CDI Charging system: Magneto BATTERY Model: YT4L-BS/ 12V, 3 Ah LIGHT AND BULBS Headlight : 12 V , 35.0 W Tail/brake light: 12 V , 21.0 W / 5.0W Position light 12 V, 35.0 W Front turn signal light: 12 V, 10.0 W Rear turn signal light: 12 V, 10.0 W License plate light: 12 V, 5.0 W High beam indicator light: 12 V, 2 W Turn signal indicator lights: 12 V, 3 W N signal indicator light: 12V, 3 W Instrument lights (2x): 12V, 3 W MAIN FUSES 10.0 A

SPECIFIC TIGHTENING TORQUES 10 MODULE PART TORQUE / Nm Electrical System Starting motor clutch cover bolt 12 Starting motor clutch locknut 95 Rectifier bolt 5 Fixing bolt of ignition coil 9 Fixing bolt of flywheel 35-40 Wheel Axles Front wheel spindle 55 - 62 Rear wheel spindle nut 85 - 98 Fuel tank Fixing bolt for fuel tank 5-9 Cushion mounting bolt 9-10 Front brake system Fixing bolt of brake disc 22-29 Mounting bolt of brake caliper 22-29 Fixing bolt of hand brake lever braket 5-9 Rear brake system Fixing bolt of brake disc 22-29 Mounting bolt of brake caliper 22-29 Fixing bolt of hand brake lever braket 5-9 Rear shock absorber Top nut of rear shock absorber 37-44 Bottom nut of rear shock absorber 37-44 Front fork Front shock absorber mounting bolt 37-44 Handlebar Upper bracket assembly mounting bolt 40-60 Muffler Mounting bolt for muffler 5-9 Combined screw for muffler protecting plate 5-9 Engine Cylinder cover nut 18-22 Fixing nut in the power gear of clutch 50-60 Stud bolt of air cylinder 18-22 Clutch locknut 50-60 Spark plug 10-15 Limiting screw of the feet starter lever 35-40 Shift positioned bolt 10-16 Mould assembling bolt 10-12 Bolts on the right and left crankcase cover 10-12 Loop bolt 10-12 Motor fixing bolt 10-12 Seperating disk bolt of clutch 10-16 Fixing bolt of inlet valve 10-12 Setscrew of shift display 4-7 Setscrew of constant temperature set 4-7 Setscrew of electric wire clamp 4-7 Fixing bolt of water pump 10-12 Frame Rear swing arm shaft nut 70-83

GENERIC TRIGGER 50 QJ50 Scooter Workshop Repair Manual

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