User manual

REPLACEMENT OF THE CENTRIFUGAL CLUTCH LEVERS
REPLACEMENT OF THE TIRE
REMOVAL AND MOUNTING OF THE AIR FILTER
Loosen the chain, remove the bearing housing and take the chain off the pinion. Uns-
crew the 3 bolts holding the clutch housing together with the clutch basket and remove
the clutch housing. Loosen the nut of the catch driver by placing a pipe between the
engine block and the catch driver and then loosen the nut. Use the puller puller MP-1
(159.019.00) to remove the clutch set from the motor g. 19. Unscrew the adjustment
bolts of the springs and remove the lock rings from the pegs. Then replace the clutch
levers with new ones. We recommend to also replace the springs. During assembly,
rst place on the spring with the cup onto the lever and mount them together so that the
spring cup is pushed against the catch driver and place the lever onto the peg. Secure
it by the lock ring and mount the adjustment bolts. Perform the basic adjustment accor-
ding to chap. ADJUSTMENT OF THE CENTRIFUGAL CLUTCH page 18.
First remove the wheel from the minibike. For the front wheel unscrew the brake disc,
and for the rear wheel unscrew the brake disc and the sprocket-wheel. Release the
air from the tires, preferably by unscrewing the valve out. Place the wheel on a solid
pad and push the tire bead from the edge of the rim towards the middle of the rim’s
span area. Use one assembly lever to slip the tire bead, at the valve, across the edge
of the rim and hold it there. Insert another assembly lever right beside and slip over
the remaining part of the tire across the edge of the rim.
Place the second tire bead into the middle of the rim’s span areas and slip it across
the edge of the rim without using assembly levers. Perform the mounting in the rever-
se procedure. The assembling of the tire onto the rim is always started on the opposi-
te side of the valve. Perform the air inating of the tire according to the weight of the
rider, with a maximum of 250 kPa (2.5 bars) and mount the wheel into the minibike.
During the removal of the lter, rst loosen the screws of the strap, which is securing
the rubber extension of the lter on the carburetor. This will release the lter, which is
then removed and carefully washed in gasoline and smeared with oil for air lters and
is mounted using reverse procedure.
g. 19
ADJUSTMENT OF THE CENTRIFUGAL CLUTCH
After the rst hour of riding perform the inspection of the adjustment of the clutch
jaws. The clutch should engage at 8000 - 8 500 RPM according to the weight of the
rider. Adjust it to the higher prescribed revolutions when the rider is of the heavier
weight.
basic adjustment:
The basis for the adjustment is the length of the spring, which is measured from the
seating area on the clutch lever to the spring cup g. 20. For a new clutch (following
the replacement of the clutch lining) and with a clutch drum with an inside diameter
of 80 mm, set this length to 21.00 mm. During this setting the clutch starts to grab at
8000 RPM. The grabbing RPM increase as a result of the operational wear of the clutch
lining and the drum. Therefore continually inspect the grabbing RPM (inspection after
every ride) and loosen or possibly tighten the adjustment bolts, in order to maintain
the grabbing RPM at a value of 7000 - 9000 RPM. The tightening of the adjustment
bolts increases the grabbing RPM and loosening them decreases the grabbing RPM.
The grabbing RPM can differ in relation to the power of the motor, the weight of the
rider and the character of the track. In no case may the clutch continue to further slip
after gripping (during higher RPM than the gripping RPM). This would result in a quick
wearing of the clutch lining and possibly also in irreversible damage to the entire
clutch. Pay attention to always set all the springs evenly, to prevent uneven wear of
the clutch lining. Every time following the replacement of the clutch levers there must
be performed the basic adjustment of the clutch springs to the measurement of 21.00
mm and 8000 RPM. For the setting of the gripping RPM of the centrifugal clutch, we
recommend to use an RPM gauge connected to the high voltage spark plug cable.
g. 20
19 20