Service info
Running in and service info
NO OIL IN ENGINE WHEN IT ARRIVES PLEASE NOTE
Starting info
Never kick on compression will kick back and will set off kick start sheer gears or will fracture cases "excluded from warranty as its rider error"
Never use choke! See starting video here
Warm up
2 valve engines need at least 3 minutes warm up time before riding
4 valve engines need 5 minutes minimum warm up time before riding with no more than 4000 rpm
Engine oil
Manual engines: 20/50 Summer 10/40 Winter mineral oil
Semi Auto and fully Auto: 10/40 mineral
First oil change 50 miles
Change the oil every 300 miles there after
Clutch cover magnet
Found on Charger and Phase 5 engines only
Remove cover to access magnet, clean in situ 100 miles from new and every 500 miles there after
Also clean out oil strainer below oil pump
Head torque
Check head torque after the first running session when cold
YX/Charger 150/160/170 2V & 4V 18 ft-lbs 24.4 NM
YX/Phase 5 125/140/149 2V 12 ft-lbs
Flywheel/Drive gear/Clutch nut torque
40 ft-lbs 55NM with dab of locktite all engines
Valve clearance
2 valve engine Inlet 4 thou/0.10mm. Exhaust 6 thou/0.15mm. Check every 300-500 miles. All engines 50 to 210cc
4 valve engine Inlet 4 thou/0.10mm. Exhaust 4 thou/0.10mm. Check every 500 miles.
Wiring from stator
Blue/white = trigger pulse coil stator to CDI
Black/red = source coil feed stator to CDI
Green = common earth
2 x Yellow = Single phase
3 x Yellow = 3 phase
1 x Yellow 1 x White = Split phase
Neutral switch
Blue = N
Green = 1
Yellow = 2
White = 3
Red = 4
CDI
Black/white = Kill switch, earth out to stop
Black/yellow = Feed to coil
2 x Spare wires Black/white or 2 x White are for Rev switch control, open = Full reves Closed = Rev control via brass screw on unit.
Running issues
Below piston image is of one that was run on a way to big carb and resulted in a major melt down, wasn’t a lack of oil as it would look like at first, first singe of low/lack of oil is camshaft and rocker failure. So if you are using a carb of your choice make sure ist the right size for CC and Valve size.
Flywheel issues
Always use the recommended weighted flywheel we supply with the engine. Using the incorrect weight can result is crankshaft taper sheering off.
Also make sure you are running the right gearing so that the engine is not over revving when cruising, common issues are running i.e 50cc gearing when you up grade to a 70 or bigger engine, doing that’s will result in the flywheel working its self lose and sheering off the woodruff key.
