Vento ZIP R3I Scooter Full Service & Repair Manual 2004-Onwards

Chapter 1. General Information.........................Page 1 2. Periodic maintance and service.......Page 4 3. Engine..............................................Page 23 4. Fuel and Lubrication System...........Page 37 5. Electrical System.............................Page 48 6. Servicing Information........................Page 62 This service manual has been specially prepared to provide all the necessary information for the proper maintenance and servicing of VENTO Zip r3i Scooter. This manual contains an introductory description on VENTO Zip r3i and procedures for Inspection/Service and overhaul of its main components. This Manual is intended those who have enough knowledge and skills for servicing of VENTO vehicles. Without such knowledge and skills you should not attempt servicing by relying on this manual only. Instead, please contact your nearly authorized VENTO motorcycle dealer. Service Manual Table of Contents Rev. 1 Date 01/05/2004

CHAPTER 1 1-1 GENERAL INFORMATION TYPE & IDENTIFICATION FRAME NUMBER FRAME NUMBER is Engraving on the steel tube of frame as shown in figure. ENGINE NUMBER ENGINE NUMBER is Engraving on rear side Crankcase Shown figure. Both FRAME NUBER AND ENGINE NUMBER are designed Specially for registration your scooter and for spare part Orders. FUEL AND ENGINE OIL RECOMMENDATION Be sure to use specified fuel and engine oil. Some specifications are as follows: FUEL Gasoline should be Unleaded, the octane number must be 85 ~95 or more. ENGINE OIL For engine lubrication, you can use specified high quality two-stroke engine oil (without being diluted). GEAR OIL Use high quality, all-purpose SAE10W/40 Gear oil for this scooter. Make sure that the Engine oil/Gear oil what you are using should come under API classification. BREAK-IN PROCEDURES During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to BREK-IN before subjecting the engine to maximum stresses. The future performance and reliability of the engine depends on the care and restraint during its early life. General requirements are as follows Limit break-in speed At the first 1000 ms (630 miles mileage use throttle opening less than 1/2. Up to 1600 Kms 1000 miles mileage use throttle opening less than 3/4. Upon reaching an odometer reading of 1600 kms (1000 miles) you can subject the motorcycle to full throttle operation. Do not maintain constant engine speed for on extended time period during any portion of the BREAK-IN period, try to vary the throttle position.

1-2 GENERAL INFORMATION PRECAUTIONS AND GENERAL INSTRUCTIONS GENERAL PRECAUTIONS: WARNING Proper service and repair procedures are important for the safety of the service mechanic and the reliability of the vehicle. When two or more persons are working together, pay attention to the safety of each other. When it is necessary to run the engine indoors, make sure that the exhaust gas is forced outwards and ventilation should be proper. When working with toxic or flammable materials, make sure that the area you work in is well ventilated and that you follow all off the material manufacturer s instructions. Don t use gasoline as a cleaning agent. After servicing the motorcycle check all lines i.e. fuel, oil and brake lines for leaks. Whenever you remove Oil seals, Gaskets, packing, O-rings, Locking washers, Cotter pins, Circlips, and certain other parts as specified, are sure to replace them with ones. Also before installing these new parts be sure to remove any left out material from the mating surfaces. Never reuse a circlip, when installing a new circlip, take care not to expand the end gap larger than required to slip the circlip the shaft. After installing a circlip, always ensure that it is completely seated in its groove and securely fitted. Do not use self- locking nuts a few times over. If parts replacement is necessary, replace the parts with VENTO Genuine parts or their equivalent. When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstall in proper order and orientation. Always use special tools when required. Always use specified lubricant, bond& sealant. While removing the battery, disconnect the Negative terminal / Cable first then Positive terminal / Cable and when reconnecting the battery, connect the Positive terminal / Cable first then Negative terminal / Cable. During Service to electrical parts, if no need of battery power then, please disconnect the Negative terminal / Cable of the battery. During tightening of Cylinder head and crank case bolts and nuts start with larger diameter and ending with smaller diameter, from inside to outside diagonally, with the specified tightening torque values. After reassembly, recheck parts for tightness and operation. REPLACEMENT COMPONENTS Be sure to use genuine VENTO spare parts or their equivalent. Genuine VENTO components are high quality parts, which are designed specially for VENTO vehicles. CAUTION Scooter/motorcycle may damage by using non genuine parts or parts that is not equivalent to VENTO parts and will be affecting performance also.

1-3 GENERAL INFORMATION SPECIFICATIONS DIMENSIONS AND NET WEIGHT Overall Length.......................1620mm Overall Width...........................625mm Overall Height.......................1010 mm Wheelbase.............................1170mm Ground Clearance......................90mm Dead Weight................................78kg CHASSIS Front shock absorber Telescopic, Coil spring, without oil damped. Rear shock absorber Swing arm type Coil spring, with oil damped. Steering angle 48º (toward the left\toward the right) Front Tire size................................3.50-10 Rear Tire size.................................3.50-10 Front brake Disc................................. 160 Rear brake Drum................................ 110 ENGINE Type.....................Two-stroke, Air Cooled Intake system.........................Reed valve No. of Cylinder........................................1 Bore.............................................40.0mm Stroke..........................................39.6mm Displacement........................................49.8CC Compression Ratio............................6.9:1 Carburetor.................................Side draft Air cleaner..........Dual polyurethane foam Starting System Electric start & Kick pedal for Manual Start. Lubricating System Auto lubrication, by Oil Pump ELECTRICAL Ignition System.......................Electronic CDI Ignition Timing......................15 0 at 5000 RPM Spark Plug.........................NGK/R/BR8HSA Storage Battery....................YUASA/YB4L-4 Battery Capacity.............................12V-4Ah Magneto..................................................AC Fuse..................................................10Amp Headlight............................12V 35 / 35 Watt Turn Indicators (X4)...................12V / 3 Watt Tail light/stop light.......................12V / 5Watt Meter light..................................12V / 3Watt Oil level Indicator light...............12V / 3 Watt Tran signal Indicator light...........12V / 3Watt High beam Indicator light............12V/3 Watt CAPACITY Fuel Tank........................................5.2L Engine Lubricating Oil Tank............1.0L Gear Oil...........................................0.1L TRANSMISSION Clutch System Dry shoe, Automatic, Centrifugal Type Gears shifting mechanism Automatic Primary Reduction 1 Gear Reduction ratio The first gear ...................3.692(48/13) The second gear .............3.000(36/12) Drive System...................V-Belt driv

Rev no.01/ page 6of 128 CHAPTER 2 PERIODIC MAINTENANCE AND SERVICE Contents Periodic maintenance and service schedule................................5 Storage battery.............................................................................7 Service and adjustment procedures.............................................9 Cylinder head nut and exhaust pipe bolt .....................................9 Cylinder head and cylinder ..........................................................9 Spark plug ...................................................................................10 Air cleaner....................................................................................11 Fuel level line...............................................................................12 Throttle cable...............................................................................12 Engine idle speed.........................................................................12 Oil pump.......................................................................................13 Gear oil.........................................................................................14 Braking..........................................................................................15 Tire................................................................................................17 Steering ........................................................................................17 Front shock absorber ...................................................................18 Rear shock absorber ....................................................................18 Vehicle bolts and nuts ...................................................................18

Rev no.01/ page 7of 128 2-1 PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Mileages are expressed in terms of Kilometer, Miles and time for your convenience. Note: More frequent servicing may be performed on motorcycles that are used under bad road condition. PERIODIC MAINTENANCE CHART Miles 630 3780 7560 11340 15120 Kilometer 1000 6000 12000 18000 24000 Interval Months. 2 12 24 36 48 Storage battery I I I I I Cylinder head nut and exhaust pipe bolt T T T T T Cylinder head and cylinder C C C C Spark plug C R C R Air cleaner Inspect & Clean every 3000 Kms (1890 miles) Replace every 12000 Kms(1750 Miles) Idle speed (rpm) I I I I I Throttle cable play I I I I I Oil pump I I I I I Gear oil I R R I I I I I Fuel line Replace every 4 years Brake I I I I I I I I I I Brake hose Replace every 4 years I I I I I Brake fluid Replace every 2 years Steering I I I I I Front fork I I I I I Rear shock absorber I I I I I Tire I I I I I Vehicle body bolts and nuts T T T T T Note: I=inspect clean adjust lubricate or replace if necessary A=adjust C=clean R=replace T=tighten

Rev no.01/ page 8of 128 2-2 PERIODIC MAINTENANCE PROCEDURE BATTERY INSPECTION AND CHECKING PROCEDURE Storage Battery Inspect at initially 1000Kms 630 miles 2 months and every 6000 Kms 3780 miles 12 months. Open seat, and then remove the battery box cap in theMiddle of helmet box. Disconnect Negative terminal / Cable first then Positive terminal / Cable of Battery. Measure the voltage between the +ve and ve terminal of Battery charge the Battery if the voltage is below the specified limit.

Rev no.01/ page 9of 128 BATTERY TESTING PROCEDURE Remove the battery from the Motorcycle/Scooter. Connect the battery on load tester ensuring Red lead of tester to (+ve) and Black lead to (-ve) terminal of battery. Check the terminal voltage of battery. It should be 12~14.5 Volts. Press the push button on the tester and watch the voltmeter reading on load. The battery voltage should not drop down less than 9 volts; this indicates that the battery is perfect to take load of self-starter motor. Check the specific gravity of each cell should not be less than 1.220.Put the battery on charge, if required and carry out load test. Diagnose the nature of failure as under: BATTERY CELL DEAD TEST: On load if battery voltage is found less than 9.5Volt and one or more cell shows specific gravity less than 1.220 then change the battery. OPEN CIRCUIT: During the charging of battery does not pickup the charge. In any of the above case, replace the battery. RECOMDED BATTERY LOAD TESTER: MAKE ELAK, MODEL: ---BCT7 CAUTION: During Inspection, if the battery on the vehicle is found defective, before replacing with a new battery, it is important to check the battery charging circuit. BATTERY CHARGING CIRCUIT TEST The MAGNETO generated AC current, which is rectified into DC current by Voltage Regulator .It, is automatically charging the battery depending upon condition of the battery, load and engine rpm. Regulator is connected in parallel to the circuit. Hence this type of system is called PARALLEL LOAD REGULATOR . Connect DC Voltmeter and DC Ammeter, start the engine with fully charged good battery. The Voltage Regulator output is as follows. Battery charging current range in between 0.6 Amp to 2Amp. The engine speed @ 5000 rpm with headlamp on condition. Battery terminal charging voltage > 11.5 V at any load condition (depending upon the condition of battery) NOTE 1 Incase charging output is less than 0.6 Amp or more than 2.0Amp then replace the Voltage Regulator with new one and recheck. NOTE 2 AMMETER: ------Series connection inline with positive battery wire to measure DC Amp. VOLTMETER: ---Parallel connection between positive & negative terminal of the battery to measure DC- Volts.

Rev no.01/ page 10of 128 IMPORTANT TIPS ON BATTERY SPECIFIC GRAVITY The Specific Gravity of fully charged battery should be 1.220~1.240 Use Hydrometer to check each cell of battery. WARNING Remove negative terminal first, then positive terminal. If the battery is corroded by sulfur. Please exchange it. If the terminal of the battery has too much precipitate, please exchange it. CHARGING Charging is necessary at less than 1.220 Specific Gravity for old battery. It changes according to electrolyte temperature. Connect positive terminal of charger to positive battery wire & negative terminal of charger to negative battery wire. CHARGING CURREENT For 2.5 Ah battery the charging current should be Maximum 0.25Amp. For 6.0 Ah battery the charging current should be Maximum 0.6Amp. CHARGING TIME For new battery 8-12 hrs. For old battery 12-14 hrs. WARNING Always open all the caps of battery before charging. Keep flames & sparks away from the battery. Turn ON or OFF Switch at charger & not at battery terminal Don t charge the battery, if electrolyte temperature is more than 45ºC. Do not quick charge the battery. INSTALLATION Connect positive terminal first, then negative terminal. BATTERY CAPACITY 12Volt- 6Ah YTX7A-BS/YUASA RECOMMENDED BATTERY CHARGER Make: ELAK Model C1/48 RECOMMENDED HYDROMETER Make: THIMSON Model: 108 NOTE Always top up battery with the distilled water up to the maximum level (Never use Acid to top up the old battery). Always ensure new battery is being charged in cold condition after filling with the electrolyte. Always ensure that battery breather tube is not clogged, crimped or bent. Breather tube should be properly routed. Incase if Motorcycle/ Scooter is not being used for longer period, then first charge the battery fully & then connect only positive terminal to Motorcycle /

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Vento ZIP R3I Scooter Full Service & Repair Manual 2004-Onwards

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