PANTERRA 50cc & 90cc DIRT Bike Workshop Service Manual

Introduction NIKOTA USA: PANTERRA 50-90CC DIRT BIKE SERVICE MANUAL 1 INTRODUCTION PanTerra I 49cc & 90cc Dirt Bikes by Nikota USA

Introduction NIKOTA USA: PANTERRA 50-90CC DIRT BIKE SERVICE MANUAL 2 INTRODUCTION Important Safety Notice This manual does not contain detailed descriptions of standard workshop procedures, safety principles, and service operations. It is important to note that this manual contains some warnings and cautions against some specific service methods that could cause PERSONAL INJURY to service personnel or that could damage a vehicle or render it unsafe. Please understand that those warnings could not cover all conceivable ways in which service (whether or not recommended by PanTerra Motorworks) might be done or of the possibly hazardous consequences of each conceivable way, nor could PanTerra Motorworks investigate all such ways. It is the responsibility of the individual performing the work to ensure her or his own safety when servicing the vehicle and following any of the recommendations in this manual. Furthermore, when servicing the vehicle, the individual performing the work must use appropriate discretion when deciding which tools and procedures to use. WARNING! WARNINGS INDICATE A STRONG POSSIBILITY OF SEVERE PERSONAL INJURY OR DEATH IF INSTRUCTIONS ARE NOT FOLLOWED CAUTION: CAUTIONS INDICATE A POSSIBILITY OF EQUIPMENT DAMAGE IF INSTRUCTIONS ARE NOT FOLLOWED. Note: Notes give helpful information. II

Introduction NIKOTA USA: PANTERRA 50-90CC DIRT BIKE SERVICE MANUAL 3 INTRODUCTION Introduction This service manual describes the service procedures for the PanTerra 50/90cc dirt bike. This Model Specific Manual includes every service procedure that is of a specific nature to this particular model. Basic service procedures that are common to other PanTerra Motorcycle/ Motor Scooter/ATVs can be found in the Common Service Manual. This Model Specific Service Manual should be used together with the Common Service Manual in order to provide complete service information on all aspects of this motorcycle. Follow the Maintenance Schedule (Section 3) recommendations to ensure that the vehicle is in peak operating condition. Performing the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the break-in period. Sections 1 and 3 apply to the whole ATV. Section 2 illustrates procedures for removal/installation of components that may be required to perform service described in the following sections. Sections 4 through 13 describe parts of the motorcycle, grouped according to locations. Find the section you want on this page, then turn to the table of contents on the first page of the section. Most sections describe the service procedure through system illustration. Refer to the next page for details on how to use this manual. If you don’t know the source of the trouble, go to section 16 Troubleshooting. All information, illustration, direction and specifications included in this publication are based on the latest product information available at the time of approval for printing. PanTerra Motorworks and Nikota USA reserve the right to make changes at any time without incurring any obligation whatsoever. No part of this publication may be reproduced without written permission. This manual is written for persons who have acquired basic knowledge of maintenance on PanTerra motorcycles, motor Scooters or ATVs. PanTerra Motorworks Nikota USA Technical Communications office July, 2004 III

Introduction NIKOTA USA: PANTERRA 50-90CC DIRT BIKE SERVICE MANUAL 4 INTRODUCTION Table of Contents Chapter Topic Page CHAPTER 1: General Information 7 CHAPTER 2: Frame/ Body Panels/ Exhaust System 39 CHAPTER 3: Maintenance 55 CHAPTER 4: Lubrication System 83 CHAPTER 5: Fuel System 91 CHAPTER 6: Engine Remove/Install 103 CHAPTER 7: Cylinder Head/Valves 109 CHAPTER 8: Cylinder/Piston 129 CHAPTER 9: Clutch/Gearshift Linkage 141 CHAPTER 10: Alternator/Cam Chain Tensioner 153 CHAPTER 11: Crankshaft/Transmission/Kick Starter 161 CHAPTER 12: Front Wheel/Brake/Suspension 173 CHAPTER 13: Rear Wheel/Brake/Suspension 193 CHAPTER 14: Ignition System 215 CHAPTER 15: Wiring Diagram 223 CHAPTER 16: Troubleshooting 225 APPENDIX: 50cc & 90cc Diagrams 235 INDEX: Index 241 IV

Introduction NIKOTA USA: PANTERRA 50-90CC DIRT BIKE SERVICE MANUAL 5 INTRODUCTION How To Use This Manual Finding Information You Need This manual is divided into sections that cover each of the major components of the vehicle. To quickly find the section you are interested in, use the manual page numbers and chapter page number for quick access and reference. The first page of each section lists the table of contents within the section. Read the service information and troubleshooting related to the section before you begin working. The last chapter contains an index of the entire book so you can directly locate the information you need. About the Illustrations Part removal and installation is usually illustrated by large and clear illustrations that should provide the reader with visual aid in understanding the major point for servicing. The system illustrations are augmented by callouts whose numbers or letters indicate the order in which the parts should be removed or installed. The sequences of steps represented numerically are differentiated from the ones represented alphabetically to notify the reader that they must perform these steps separately. For example, if the steps prior to camshaft removal are performed with the engine installed, but the subsequent steps like cylinder head removal require engine removal, the callouts are grouped in numerical and alphabetical orders. The illustrations may contain symbol marks to indicate necessary service procedures and precautions that need to be taken. Refer to the next page for the meaning of each symbol mark. Illustration also contain charts that list information such as the order in which the part is removed/ installed, the name of the part, and some extra notes that may be needed. Step by step instructions are provided to supplement the illustrations when a detailed explanation of the procedure is necessary or illustrations alone would not suffice. Service procedures required before or after the procedure described on that particular page, or inspection/adjustment procedures required following the installation of parts, are described under the heading “Requisite Service” within each chapter. Standard workshop procedures and knowledge covered in the Common Service Manual are abbreviated in this manual as follows: Symbol mark System illustration Detailed description of the procedure Step sequence (numerals or alphabets) Part name Number of parts V

Introduction NIKOTA USA: PANTERRA 50-90CC DIRT BIKE SERVICE MANUAL 6 INTRODUCTION How To Use This Manual (cont’d) Extra notes or precautions related to the service procedure Symbols The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols, it will be explained specifically in the text without the use of the symbols. Replace the part(s) with new one(s) before assembly. Use recommended engine oil, unless otherwise specified. Use molybdenum oil solution (mixture of the engine oil and molybdenum grease with the ratio 1:1). Use multi-purpose grease (Lithium based multi-purpose grease NLGI #2 or equivalent). Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or equivalent). For example: - Molykote® BR-2 Plus manufactured by Dow Corning, U.S.A. Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or equivalent). For example: - Molykote G-n Paste manufactured by Dow Corning, U.S.A. Use silicone grease. Apply a locking agent. Use the agent of the middle strength, unless otherwise specified. Apply sealant. Use brake fluid, DOT 3 or DOT 4. Use the recommended brake fluid, unless otherwise specified. Use Fork or Suspension Fluid. VI

Introduction NIKOTA USA: PANTERRA 50-90CC DIRT BIKE SERVICE MANUAL 7 INTRODUCTION

Introduction NIKOTA USA: PANTERRA 50-90CC DIRT BIKE SERVICE MANUAL 8 INTRODUCTION

Section 1 NIKOTA USA: PANTERRA 50-90CC DIRT BIKE SERVICE MANUAL 7 SECTION 1: GENERAL INFORMATION General Information 1-1

PANTERRA 50cc & 90cc DIRT Bike Workshop Service Manual

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