Service manual

MAINTENANCE OF COOLING SYSTEM

1. Liquid filling:

Place the minibike on the stand. Dismantle the seat and very carefully check all

the joints on the hose. For older minibikes do not forget to check for holes and

other damages to the hose. To fill the cooler system, 0.5 liters of the coolant is

needed. In case the minibike will be used during the wintertime, do not forget

to use the anti-freeze coolant. Pour the coolant into the balance tank, which is

placed between the handlebars, until it is filled to ¾ of capacity. Unbolt vent

bolt M5 (P/N 914.018.01), which is inserted in the hose (P/N 349.) between the

bottom part of the radiator and the engine block. Tighten the bolt only after all

air has been bled and only coolant is coming out of the vent plug hole. Always

hold the hose in order not to pull out the air escape valve. It is important to

have more than ½ capacity of the coolant in the balance tank. The same

procedure applies to the venting hose (P/N 349.) between the cylinder head and

the radiator. Once more vent the system while loosening the air bleed screws

until all air is expelled.

Close the tank and pull the start T’handle two or three times. This will circulate

the coolant in the system. Once more vent the system while loosening the air

bleed screw.

Only now it is possible to start the minibike, and leave it to run on the stand for

one minute. Turn of the motor, and vent it again. Then the minibike is ready for

use.

2. Check up of cooling system:

Before every ride check the amount of coolant in the balance tank! After every

10 hours of riding, remove the pull starter cover and check the Gilmer type belt,

which runs the coolant pump.

Important notice: If the coolant level rises in the balance tank switch of the

engine immediately! Check the drive of the coolant pump and sealing of the

cooling system. After these steps vent the air bleed screw. The raised level of

coolant is an indicator of a warmed up engine, which can result in seizing of

the piston in the cylinder.

3. Draining the Coolant:

Dismantle the hose on the bottom of the cooler system and eliminate the

liquid. Unbolt the drain plug in the balance tank.