ZIP R3i R3 REPAIR MANUAL

Zip R3i / ZipR3 Service&
Maintenance Manual
Rev no.01/ page 1of 128
VENTO MOTORCYCLES
ILLEGAL COPYING
It is the policy of Vento Motorcycles to actively protect its
copyrights and trademarks. Legal action will be taken against
anyone who unlawfully copies the cover or contents of this manual.
This includes all forms of unauthorised copying including digital,
mechanical and electronic in any form.Illegal copying will also be
reported to the appropriate statutory authorities.
VENTO MOTORCYCLES
This service manual has been specially
prepared to provide all the necessary
information for the proper maintenance and
servicing of VENTO Zip R3i / Zip R3Scooter.
Zip r3i is a new type of scooter that has
many features such as:
• V-belt drive automatic transmission

• Fan air-cooling system
• CDI Ignition system
• Auto Ignition system
• Alarm System
• Light Sensor
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.
VENTO MOTORCYCLES
FORWORD ENGINE 3
INDEX
GENERAL INFORMATION 1
PERIODIC MAINTENANCE PROCEDURE 2
FUEL AND LUBRICATION SYSTEM 4
ELECTRICAL SYSTEM 5
CHASSIS 6
SERVICING INFORMATION 7
VENTO MOTORCYCLES
VENTO MOTORCYCLES
CHAPTER 1
GENERAL INFORMATION
CONTENTS
MODEL IDENTIFICATION………………………………………………
FUEL AND ENGINE OIL…………………………………………………
BREAK-IN PROCEDURES………………………………………………
PRECAUTIONS AND GENERAL INSTRUCTIONS……………………
SPECIFICATIONS ………………………………………………………
VENTO MOTORCYCLES
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 as Shown in figure.
Both FRAME NUBER AND ENGINE NUMBER are designed
specially for registration your scooter and for spare parts
order.
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.
VENTO MOTORCYCLES
PRECAUTIONS AND GENERAL INSTRUCTIONS
GENERAL PRECAUTIONS:
WARNING
o Proper service and repair procedures are important for the safety of the service mechanic and the
reliability of the vehicle.
o When two or more persons are working together, pay attention to the safety of each other.
o When it is necessary to run the engine indoors, make sure that the exhaust gas is forced outwards
and ventilation should be proper.
o 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.
o Don’t use gasoline as a cleaning agent.
o After servicing the motorcycle check all lines i.e. fuel, oil and brake lines for leaks.
o Whenever you remove Oil seals, Gaskets, packings, O-rings, Locking washers, Cotter pins, Circlips,
and certain other parts as specified, be sure to replace them with ones. Also before installing these
new parts be sure to remove any left out material from the mating surfaces.
o 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.
o Do not use self- locking nuts a few times over.
o If parts replacement is necessary, replace the parts with VENTO Genuine parts or their equivalent.
o 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.
o Always use special tools when required.
o Always use specified lubricant, bond& sealant.
o 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.
o During Service to electrical parts, if no need of battery power then please disconnect the Negative
terminal / Cable of the battery.
o 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.
o 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.
VENTO MOTORCYCLES
SPECIFICATIONS
Storage Battery-----------YUASA/YB4L-4
Battery Capacity----------12V-4Ah
Magneto--------------------AC
DIMENSIONS AND NET WEIGHT Fuse------------------------ 10Amp
OVERALL LENGTH---- 1620mm Headlight-------------------12V 35 / 35 Watt
OVERALL WIDTH---- 625mm Turn Indicators (X4)-------12V / 3 Watt
OVERALL HEIGHT--- 1010 mm Tail light/stop light---------12V / 5Watt
WHEELBASE-------------- 1170mm Meter light--------------- ---12V / 3Watt
GROUND CLEARANCE---90mm Oil level Indicator light---12V / 3 Watt
DEAD WEIGHT---------- 78kg Tran signal Indicator light-12V / 3Watt
High beam Indicator light—12V/3 Watt
CHASSIS
Front shock absorber--Telescopic, Coil CAPACITY
spring, without oil damped. Fuel Tank--------------------------5.2L
Rear shock absorber--Swing arm type Coil Engine Lubricating Oil Tank---1.0L
spring, with oil damped. Gear Oil----------------------------0.1L
Steering angle---------48º(toward the
left\toward the right) TRANSMISSION
Front Tire size-----------3.50-10
Rear Tire size------------3.50-10 Clutch System-------Dry shoe, Automatic,
Front brake Disc --------φ160 Centrifugal
Rear brake Drum -------φ110 Type
Gears shifting mechanism ---------Automatic
ENGINE Primary Reduction----------------- 1
Type------------------ Two-stroke, Air Cooled Gear Reduction ratio
The first gear--------------3.692(48/13)
Intake system------- Reed valve The second gear-----------3.000(36/12)
No. of Cylinder------ 1 Drive System --------------V-Belt drive
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--------- 150 at 5000 RPM
Spark Plug-------------- NGK/R/BR8HSA
VENTO MOTORCYCLES
VENTO MOTORCYCLES
CHAPTER 2
PERIODIC MAINTENANCE AND SERVICE
CONTENTS
S
Periodic maintenance and service schedule------------------------------------

Service and adjustment procedures---------------------------------------------
Storage battery---------------------------------------------------------------------
Cylinder head nut and exhaust pipe bolt----------------------------------------
Cylinder head and cylinder-------------------------------------------------------
Spark plug--------------------------------------------------------------------------
Fuel level line-----------------------------------------------------------------------
Air cleaner--------------------------------------------------------------------------
Throttle cable-----------------------------------------------------------------------
Engine idle speed------------------------------------------------------------------
Oil pump-----------------------------------------------------------------------------
Gear oil------------------------------------------------------------------------------
Braking------------------------------------------------------------------------------
Tire ----------------------------------------------------------------------------------
Steering------------------------------------------------------------------------------
Front shock absorber--------------------------------------------------------------
Rear shock absorber----------------------------------------------------------------
Vehicle bolts and nuts--------------------------------------------------------------
VENTO MOTORCYCLES
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
Interval Kilometer 1000 6000 12000 18000 24000
Months. 2 12 24 36 48
Storage battery I I I I I
Cylinder head nut
and exhaust pipe T T T T T
bolt
Cylinder head and
— C C C C
cylinder
Spark plug — C R C R
Inspect & Clean every 3000 Kms (1890 miles)
Air cleaner 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
I I I I I
Brake fluid
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
T T T T T
and nuts
Note:
I=inspect clean adjust lubricate or replace if necessary
A=adjust C=clean R=replace T=tighten
VENTO MOTORCYCLES
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 the
Middle 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.
VENTO MOTORCYCLES
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.
VENTO MOTORCYCLES
IMPORTANT TIPS ON BATTERY
SPECIFIC The Specific Gravity of fully charged battery should be 1.220~1.240
GRAVITY 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 For 2.5 Ah battery the charging current should be Maximum
CURREENT 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 12Volt- 6Ah YTX7A-BS/YUASA
CAPACITY
RECOMMENDED Make: ELAK Model C1/48
BATTERY
CHARGER
RECOMMENDED Make: THIMSON Model: 108
HYDROMETER
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 / Scooter.
VENTO MOTORCYCLES
2-3 PERIODIC MAINTENANCE AND ADJUSTMENT PROCEDURE
Cylinder head nuts and exhaust pipe

bolts
Tighten at Initially 1000 km 630 miles or 2

moths and every 6000 km 3780 miles or 12
months
If cylinder head nuts are not tightened to the

specified torque, may result in leakage of compressed
fuel-air mixture and reduce output, tighten the cylinder
head nuts in the following procedures:
1 Remove the frame lower covers.
2 Remove the cylinder head cover bolt.
3 Remove spark plug Suppressor cap.
4 Tighten the nuts evenly one by one to the their
specified torque. Tighten the nuts in the
Specified order.
Tightening Torque
Cylinder head nut 15-18N.m
Exhaust pipe bolt 15-18N.m
Cylinder and cylinder head

carbon
Remove carbon every 6000 km 3780 miles or 12
months
Carbon deposits in the combustion chamber and

the cylinder head will raise the compression ratio and
may cause preignition and overheating. Carbon
deposition at the exhaust port of the cylinder will
VENTO MOTORCYCLES
prevent the flow of exhaust gases, reducing the output. Remove carbon
deposits periodically as per specified schedule.
VENTO MOTORCYCLES
2-4 Periodic maintenance and adjustment procedures
SPARK PLUG
Neglecting the spark plug maintenance eventually leads to difficult
starting and poor performance. If the spark plug is used for a long time,
the electrode gradually burns away and carbon builds up along the inside
part. In accordance with the periodic table, the plug should be removed
for inspection, cleaning and to reset the gap.
Carbon deposits on the spark plug will prevent good sparking and
cause misfiring. Clean the carbon deposits
periodically.
CARBON DEPOSIT
Check to see the carbon deposit on the Spark Plug. If
the carbon is deposited, remove it with a spark plug
cleaner machine or carefully using a tool with a
pointed end.
Check to see the worn out or burnt condition of the
electrodes. If it is extremely worn or burnt, replace the
plug and also replace the plug if it has a broken insulator, damaged
thread etc.
Thickness gauge
Spark plug gap 0.6~0.7 mm (0.024-0.028 inch)
Check the spark plug for burnt condition. If abnormal replace the
Tighten the spark plug to the specified torque.
Spark plug
Tightening torque:15-18N.m
NOTE:
To check the spark plug, first make sure that the fuel used is
unleaded gasoline.
Confirm the Specification, thread size and reach while replacing
the spark plug.
VENTO MOTORCYCLES
2-5 PERIODIC MAINTENANCE AND ADJUSTMENT PROCEDURE
AIR CLEANER:
Clean every 3000 Kms 1890 miles Replace every
12000 Kms(1750 Miles)
If the air cleaner is clogged with dust, Air Intake resistance will
be increased with a result decrease in power output and will be
increase in fuel consumption. Check and clean the filter element in
the following manner.
Remove clamp and screw take out air cleaner

Unscrew tapping screw remove air cleaner cover Fill a
washing pan of a proper size with
Non-flammable cleaning solvent. Put the air
Cleaner element in the cleaning solvent and wash properly.
Squeeze the cleaning solvent out of the washed element
By pressing it between the palms of both hands: do not twist
or wring the air cleaner element or it will develop tears.
Immerse cleaned filter element in CCI or CCI Super oil and
Squeeze the oil out of the element leaving it slightly wet
With oil. Fit the element to the Air cleaner case properly
Install Air cleaner in the reverse order of removal.

CAUTION
Before and during the cleaning operation, inspect the core for tears. A torn filter element must be
replaced with new one.
Be sure to position the filter element snugly and correctly
So that no incoming air will bypass it. Remember, rapid wear
of piston rings and cylinder bore is often caused by a
defective or poorly fitted filter element .
А- Non-flammable cleaning solvent(Kerosene)
Б- CCI OR CCI Super oil or SAE 80 or90 Gear oil.
VENTO MOTORCYCLES
THROTTLE CABLE
Adjust at initially 1000Kms 630 miles or after 2
months
And after every 6000 Kms 3780 miles or after12
months
thereafter
Loosen locknut and adjust throttle cable play by
turning adjuster in or out to obtain the
following cable play. After adjusting the cable
Play tighten the locknut.
Cable play 0.5-1.0MM 0.02.-0.040 inch
ENGINE IDLE SPEED
Adjust at initially 1000Kms 630 miles or after 2
months and Every 6000 kms (3780 miles or after12
months thereafter.
Adjust the throttle cable play.

warm up the engine at normal running condition
NOTE:
A warm engine means an engine that has been
run for 10 minutes.
Connect an Digital Tachometer to the connecting portion of the magneto lead wire as shown
In the illustration. Use the selector key “C’ position.
Adjust the Idling Screw @ to obtain the Idling RPM as follows:
Idling Speed 1800±100 RPM
Finally adjust the throttle cable play.
FUEL LINE
Inspect at initially 1000 km 630 miles or after 2
months) and Every 6000 km (3780 miles or after12
months), replace after every 4 years.
VENTO MOTORCYCLES
OIL PUMP:
Inspect at Initially 1000 Kms 630 miles 2 months and
every 6000 kms 3780 miles or 12 months there after.
The oil pump to the engine feeds the engine oil. The amount of oil fed to
it is regulated by engine speed and oil pump control lever, which is controlled
by amount of throttle opening.
Check the oil pump in the following manner to confirm correct operation for
Throttle valve full opening position.
Turn the throttle grip full open.

Check whether mark on the oil pump control lever
Is aligned with the index mark when the throttle valve is positioned as above.
If the marks are not aligned, loosen lock nuts and turn the adjuster in or out to align the marks.
After align the marks, tighten the locknuts.
.
Caution
Oil pump cable adjustment must be done after throttle
cable adjustment.
VENTO MOTORCYCLES
GEAR OIL:
Inspect at initially 1000 km 600 miles or 2 months
and every 6000 km 3780 miles or 12 months
thereafter.
Inspect gear oil periodically as follows:

Remove the cover and hose..
Remove the kick-start lever.
Remove clutch cover
Remove oil level bolt and inspect oil level, if oil level is below the
oil hole level, Add oil until oil flows from the level hole.
Tighten oil level bolt to the specified torque.
Tightening torque
9-15N.m(0.9-1.5 kg-m)
BRAKE:
Inspect at initially 1000 km 600 miles 2 months
and every 6000 km 4000 miles 12 months
thereafter, replace brake fluid after every 2 years,
replace brake hose after every 4 years.
Front brake fluid level

Keep the scooter upright and place the handlebar straight.
Check brake fluid level by observing the lower limit line
on the brake fluid reservoir.
When the level is below the lower limit line, replenish with
Brake fluid that meets the following specification.
Specification and classification DOT 3 or DOT4
WARNING
The brake system of this scooter is filled with a glycol-based brake fluid. Do not use or mix different
types of fluid such as silicone-based and petroleum-based. Do not use any brake fluid taken from
old, used or unsealed containers. Never re-use the brake fluid left over from the last servicing or
stored for long periods.
WARNING
Brake fluid, if it leaks, will interfere with safe running and immediately discolor painted
surfaces. Check the brake hoses joints for cracks and oil leakage before riding.
VENTO MOTORCYCLES
BRAKE PADS (FRONT BRAKE)
Observing the limit can check the Wear condition of brake pads
Line marked on the pad. When the wear exceeds the limit mark, replace
The pads with new ones.
CAUTION:
Replace the brake pad as a set, otherwise braking efficiency will be
adversely affected.
AIR BLEEDING FORM THE BRAKE FLUID CIRCUIT(FRONT BRAKE)
Air trapped in the fluid circuit acts like a cushion to absorb a large
proportion of the pressure developed by the master cylinder and thus
interferes with the full braking performance of the brake caliper. The
presence of air is indicated by “sponginess” of the brake lever and
also by lack of braking force. Considering the danger to which such
trapped air exposes the machine and rider, it is essential that, after
remounting the brake and restoring the brake system to the normal
condition, the brake fluid circuit be purged of air in the following manner:
Fill up the master cylinder reservoir to the upper end of the inspection
window. Replace the reservoir cap to prevent entry of dirt.
Attach a pipe to the caliper bleeder valve, and insert the free end of
The pipe into a receptacle.
□ Bleed air from the bleeder valve.
Squeeze and release the brake lever several times in rapid succession. And squeeze the lever
fully without releasing it. loosen the bleeder valve by turning it a quarter of a turn so that the
brake fluid runs into the receptacles: this will remove the tension of the brake lever causing it to
touch the handlebar grip. Then, close the valve, pump and squeeze the lever, and open the
valve. Repeat this process until the fluid flowing into the receptacle no longer contains air
bubbles.
NOTE
When bleeding the braking system, replenish the brake fluid reservoir if necessary.
Make sure that there is always some fluid visible in the reservoir.
Close the bleeder valve, disconnect the pipe. Fill the reservoir with specified brake fluid to the
UPPER end of the inspection window.
TIGHTENING TORQUE BLEEDER VALVE: 6-9N.m(0.6-0.9kg-m, 4.5-6.5lb-ft)

CAUTION
Handle brake fluid with care: The brake fluid reacts chemically with paint, plastics, and
rubber materials, etc.
VENTO MOTORCYCLES
2-9 PERIODIC MAINTENANCE AND ADJUSTMENT PROCEDURE:
@
BRAKELEVR PLAY(REAR BRAKE) : Turn adjusting nut 2 so that
the play @ of Brake lever is 15-25mm(0.6~0.8) as shown.
BRAKE SHOE WEAR:

This vehicle is equipped with the brake lining limit
Indicator on the rear brake.
Inspect brake lining limit as follows
• First check if the brake system is properly
Adjusted.
• When operating the brake, check to see that
the tip of indicator is within the range . ○3
• If the tip of indicator is beyond the range, ○
4
the brake shoe assembly should be replaced with a ○2
new set of shoe.
VENTO MOTORCYCLES
TIRE:
Inspect at initially 1000Kms 630 miles 2 months
and every 6000KM 3780 miles 12 months thereafter
Tire pressure
If the tire pressure is too high, the steering will be
Adversely affected and tire wear increased. Conversely, if tire
pressure is too low, stability will be adversely affected.
Therefore, maintain the correct tire pressure for good
Drivability and to prolong tire life.
CAUTION
The standard tire fitted on the scooter is 3.50-10 for front and rear
The use of other Than standard may cause handling instability. It is highly
recommended to use genuine tire.
Tire treads condition

Operating the scooter with the excessively worn tires will decrease
riding stability and consequently invite dangerous situation. It is highly
Recommended to replace the tire when the remaining depth of tire tread
reaches the following specification.
Tire Tread depth limit: 1.6 mm 0.064 Inch
• Use Tire depth gauge
STEERING
Inspect at initially 1000 kms 630 miles 2

months
and every 6000 kms(3780 miles) thereafter.
Steering should be adjusted properly for smooth turning of handlebars

and safe running. Over tight steering prevents smooth turning
of handlebars and too loose steering will cause poor stability.
Check that there is no play in the front fork assembly by supporting the
machine so that the front wheel is off the ground, with wheel straight
ahead, grasp lower shock absorber near the axle and pull forward. If play is
found, perform steering bearing adjustment.
VENTO MOTORCYCLES
FRONT FORK:
Inspect &Adjust at initially 1000 kms 630 miles 2

months and every 6000 km 3780 miles 12 months
thereafter.
Inspect the front shock absorber for oil leakage or other damage, and replace the defective parts, if necessary.
REAR SHOCK ABSORBER:

thereafter.
Inspect the rear shock absorber for oil leakage and mounting rubbers including engine mounting for wear and
damage, and replace the defective parts, if necessary.
CHASSIS BOLTS AND NUTS:

thereafter.
These bolts and nuts listed below are important safety components. They must be
tightened to the specified torque.
No. Item N•m Kg-m
1 Front axle nut 37-44 3.7-4.4
2 Steering stem locknut 37-44 3.7-4.4
3 Handlebar tightening nut 37-44 3.7-4.4
4 Handlebar positioning bolt 37-44 3.7-4.4
5 Brake hose tightening bolt 22-29 2.2-2.9
6 Brake master cylinder tightening nut 22-29 2.2-2.9
7 Brake caliper tightening bolt 22-29 2.2-2.9
8 Rear wheel tightening nut 85-98 8.5-9.8
9 Rear shock absorber upper tighteing bolt 37-44 3.7-4.4

Rear shock absorber lower tightening
10 22-29 2.2-2.9
bolt
11 Rear brake cam lever tightening bolt 5-9 0.5-0.9
12 Engine mounting bolt/nut 37-44 3.7-4.4
13 Engine mounting bracket nut 37-44 3.7-4.4
VENTO MOTORCYCLES
VENTO MOTORCYCLES
LUBRICATION:
Proper lubrication is important for smooth operation and long life of each working part of the scooter. The
major lubrication points are indicated below
NOTE
• Lubricate exposed parts, which are subject to rust with a rust preventive spray whenever the motorcycle
has been operated under wet or rainy condition.
• Before lubricating each part, clean off any rusty spots and wipe off any grease, oil dirt of grime.
WARNING
Be careful not to apply too much grease to the rear brake camshaft. If grease gets on the linings, brake
slippage will result.
Steering stem bearing

Front wheel bearing
Engine bracket
Rear brake camshaft
Side stand
Rear brake shaft and rear brake cable
Speedometer cable and gear box
Main stand
throttle retainer and throttle Cable.
Α-USE GREASE.
Β-USE ENGINE OIL.
Α Α
Α
Β
Α
Α Α
VENTO MOTORCYCLES
COMPRESSION PRESSURE CHECK
The compression of the cylinder is a good indicator of its internal condition. The
decision to overhaul the cylinder is often based on the results of a Compression test.
Periodic maintenance records kept at your dealership should include compression
readings for each maintenance.
COMPRESSION PRESSURE SPECIFICATION

STANDARD LIMIT
1400 Kpa(14Kg/Cm2,198psi ) 980 Kpa (9.8Kg/Cm2,139psi
LOW COMPRESSION PRESSURE CAN INDICATE ANY OF THE FOLLOWING

CONDITIONS:
• Excessive worn cylinder wall.
• Worn-down piston or piston rings.
• Piston rings stuck in grooves.
• Ruptured or otherwise defective cylinder head gasket.
COMPRESSION PRESSURE TESTING PROCEDURE

NOTE:
• Before testing the engine for compression pressure, make sure that the cylinder
head nuts are tightened to the specified torque values.
• Have the engine warmed up Idling before testing.
• Be sure that the battery used is in fully- charged condition.
Remove the parts concerned and test the compression pressure in the following
manner.
• Support the motorcycle with the center stand.
• Remove the Suppressor cap.
• Remove the spark plug.
• Fit the Compression gauge in plug hole, while taking care that the connection
tight.
• Keep the throttle grip in full open position.
• While cranking the engine a few seconds with the starter, and record the
maximum gauge reading as the compression of that cylinder.
VENTO MOTORCYCLES
AUTOMATIC CLUTCH INSPECTION
This VENTO Zip r3i is equipped with an automatic clutch
and variable ratio belt drive transmission. The
engagement of the clutch is governed by engine RPM
and centrifugal mechanism located in the clutch.
To ensure proper performance and longer lifetime of the
clutch assembly it is essential that the clutch
engagement smoothly and gradually.
The following inspection must be done:
1. INITIAL ENGAGEMENT INSPECTION:

• Warm up the engine to its normal running
temperature.
• Connect the digital tachometer.
• Seated on the motorcycle on the level ground,
increase the engine RPM slowly and note the
RPM at which the motorcycle begins to move
forward.
ENGAGEMENT RPM: 2700~3100 RPM
2. CLUTCH LOCK-UP INSPECTION:

Perform this inspection to determine if the clutch
is engagement and not slipping.
• Apply the rear brake as firm as possible.
• Briefly open the throttle fully and note the maximum engine RPM
Sustained during the test cycle.
LOCK-UP RPM: 4100~4900
Do not apply full power for more than 3seconds, damage may occur to the
clutch or engine.
VENTO MOTORCYCLES
CHAPTER 3
ENGINE
CONTENS
Engine components removal with the engine in place ………….

Engine removal and remounting …………………………………….
Engine removal…………………………………………………….
Engine remounting……………………………………………….
Engine disassembly……………………………………………
Engine components inspection and servicing………………………
Bearings…………………………………………………………….
Oil seals………………………………………………………………….
Crankshaft……………………………………………………………….
Automatic clutch inspection…………………………………………….
Cylinder head……………………………………………………….
Cylinder………………………………………………………………
Piston………………………………………………………………….
Reed valve…………………………………………………………….
Engine remounting………………………………………………….
Oil seals…………………………………………………………….
Bearings………………………………………………………………….
Bushings……………………………………………………………
Crankcase……………………………………………………………….
Rear axle shaft………………………………………………………….
Transmission……………………………………………………………….
Starter pinion and starter gear………………………………………….
Movable driven and clutch…………………………………………….
Movable drive……………………………………………………….
Kicking starter……………………………………………………….
Piston …………………………………………………………….
Oil pump and oil pump driven gear…………………………………
Intake pipe………………………………………………………….
Magneto …………………………………………………………
VENTO MOTORCYCLES
ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE
The parts listed below can be removed and reinstalled without removing the engine from the frame.
Engine left side
• Kick starter lever
• Clutch cover
• Kick starter shaft
• Kick driven gear
• Fixed drive fan
• Fixed drive gear
• B-belt
• Movable drive face
• Starter driven gear
• Starter drive gear
• Clutch housing
• Gear case cover
• Transmission gear
• Clutch shoe
Engine center
• Intake pipe
• Reed valve
• Oil pump
• Oil pump gear
• Cylinder head
• Cylinder
• Piston
Engine right side
• Cooling fan
• Magneto
• Starter motor
VENTO MOTORCYCLES
ENGINE REMOVAL AND REINSTALLATION
ENGINE REMOVAL
• Remove ignition coil

• Remove muffler
• Remove cylinder cover
• Remove cooling fan cover
• Remove cooling fan
Remove magneto rotor nut.
Remove the magneto rotor.
Remove magneto rotor and key
Remove oil pump and retainer
VENTO MOTORCYCLES
Remove oil pump gear
• Remove cylinder head and cylinder
• Place a cloth stopper below the

piston and remove the circlip with a
plier.
• Remove the piston pin and piston.
• Remove the kick-starter lever.

• Remove clutch cover
Remove the kick-starter shaft spring

and kick starter shaft .
VENTO MOTORCYCLES
Remove the retainer after
removing the screws.
Remove spring , gasket and kick
starter gear .
• Remove the kick-starter nut with

the special a tool.
CAUTION
The nut has left-hand thread.
• Remove fan and V-belt .

• Disassemble the movable drive
face .
• Remove the kick-starter shaft.
• Remove starter idle gear cap

and starter pinion.
• Remove starter motor.
• Remove the clutch housing with the special tool.
VENTO MOTORCYCLES
• Drain gear oil
• Remove gear case cover
• Remove starter shaft
• Remove the circlip and final

driven gear .
• Remove the idle gear shaft
assay .
• Remove the rear axle nut.

• Remove the rear wheel.
• Remove brake shoes and rear

axle shaft .
VENTO MOTORCYCLES
• Remove the rear brake cam lever
indicator plate and camshaft .
• Remove spring
• Remove cotter pin and shaft
• Remove main stand
• Remove crankcase securing screws
• Disassemble crankcase with a special

tool.
• Remove crankcase with a special tool.
VENTO MOTORCYCLES
• Loosen the clutch shoe nut with the special
tool.
• Remove the nut while holding down clutch shoe

assy. by both hands as shown in the illustration.
WARNING
Gradually back off the clutch shoe assy. pressed down
by hands to reduce the clutch-sparing load. Releasing
the hand suddenly may cause the following parts to fly
apart.
Clutch shoe nut

Clutch shoe assembly
Spring
CAUTION
Do not attempt to disassemble the clutch
shoe assy. Otherwise the clutch shoe may
be damaged.
• Remove the movable driven face seat with a thin

bared screwdriver.
• Remove the pins , movable driven face and fixed

driven face .
VENTO MOTORCYCLES
• Remove circlip
• Remove bearing with special tool.
CAUTION
Replace the removed bearing with a new one.
Remove bearing with special tool.
CAUTION
Remove the spacer
Remove the oil seal from the gear case

cover with the special tool.
CAUTION
Replace the removed oil seal with a new
one.
Remove the bearing with special tool.
CAUTION
Removing the bearings with special tools.

VENTO MOTORCYCLES
Remove the bearing retainer.
Remove oil seal with the special tools.
CAUTION
Replace the removed oil seal with a new one.
Remove the bearing with special tool.
CAUTION
Replace removed bearing with a new one.
Remove the drive shaft bearing and

idle shaft bearing .
CAUTION:
The removed bearings should be replacing
with
new ones.
Remove the right crankshaft oil seal with
special tool.
CAUTION
The removed oil seal should be replaced with a new one.
Remove the right crankshaft

bearing with the special tool.
VENTO MOTORCYCLES
CAUTION
The removed bearing should be replace with a new one.
Remove the left crankshaft bearing

with special tool.
CAUTION
The removed bearing should be replaced with a new one.
BUSHING INSPECTION:
Inspect the bushing for wear or damage.
If any defects are found, replace the bushing
With a new one.
CRANKCASE BUSHING DISASSEMBLY
Use two steel tubes of appropriate size to press
the engine mounting bushings on a vise as
shown in the illustrations.
VENTO MOTORCYCLES
ENGINE COMPONENTS INSPECTION AND SERVICING
BEARING:
Clear bearing with solvent and lubricate
with engine oil before inspection.
Rotate the bearing inner race by finger to
inspect for abnormal play, noise and
smooth rotation while the bearings are in
the crankcase. Replace the bearing if there
is anything unusual.
OIL SEAL:
Damage to the lip of the oil seal may result in leakage of the
fuel-air mixture or oil. Inspect for damage and be sure to
replace the damaged seal if found.
CRANKSHAFT:
CRANKSHAFT RUN OUT:
Support the crankshaft with“V” blocks as shown, with the
two end journals resting on the blocks.
Position the dial gauge, as shown, and rotate the
crankshaft to read the run out as shown.
Correct or replace the crankshaft if the run out is greater
than the specified limit.
Service limit 0.05mm (0.002in )
Excessive crankshaft run out is often responsible for abnormal engine vibration. Such
vibration reduces the engine life.
VENTO MOTORCYCLES
CONROD DEFLECTION AND CONROD BIG END SIDE CLEARANCE:
Turn the crankshaft with the connecting rod to feel the
smoothness of rotary motion in the big end. Move the rod
up and down while holding the crankshaft rigidly to be sure
that there is no rattle in the big end.
Wear on the big end of the connecting rod can be
estimated by checking the movement of the small end of
the con rod. The method can also check the extent of wear
on the parts of the connecting rod‘s big end. If wear
exceeds the limit, replace connecting rod, crank pin and
crank pin bearing.
Service limit 3.0mm(0.12in)
Instruments: 1.Dial gauge(1/100 mm)
2.V Block and
3. Thickness gauge
Push the big end of the conrod to one side and measure the side clearance with the thickness gauge.
Standard: 0.10~0.45 mm (0.004~0.018 In)
Service Limit : 1.00mm (0.039 In)
CONNECTING ROD SMALL END I.D. :

Measure the connecting rod small end diameter with a
caliper gauge.
Service limit 14.040mm
CLUTCH SHOE INSPECTION:

If the engine RPM doesn’t coincide with the specified
RPM range, then disassemble and inspect the clutch.
Clutch shoe :
Inspect the shoes visually for chips, cracking,
uneven wear and burning, and check the thickness of
Rev no. 01/ Page 44 of 128
VENTO MOTORCYCLES
the shoes with vernier calipers. If the thickness is less than the following service limit,
replace the complete assembly as a set.
Service limit: 2.0mm ( 0.08 In )
CLUTCH HOUSING INSPECTION:

Clutch springs :
Visually inspect the clutch springs for stretched coils or
broken spring coils.
CAUTION
Clutch shoes or springs must be
changed as a set and never separately.
CLUTCH HOUSING INSPECTION:

Inspect visually the condition of the inner surface of
clutch housing, for deep scratches or uneven wear or
discoloration caused by burning. Measure the clutch
housing inside diameter with inside calipers. Measure the
diameter at several points to check for an out-of-round
condition as well as wear. If any defects are found or
measurement exceeds the specified limit, replace the clutch
housing with new one.
Service limit:110.50mm(4.350in)
DRIVE BELT INSPECTION:

Remove the drive belt and check for cracks, abnormal
wear and separation or contamination with oil.
Measure the drive belt width with vernier calipers.
Replace it if the belt width is less than the service limit or
and defect has been found.
CAUTION:
Always keep the drive belt away from any
greasy material.
MOVABLE DRIVE FACE INSPECTION:

Inspect the belt contact surface of the drive face for
wear, scratches or any abnormality. if there is
something unusual, replace the drive face with a
new one.
VENTO MOTORCYCLES
ROLLER AND SLIDING SURFACE
INSPECTION:
Inspect each roller and sliding surface for
wear or damage. Measure the diameter of
roller with vernier calipers. If any defects
are found or measurement exceeds the
specified limit, replace the roller as a
complete set.
DRIVING FACE SPRING INSPECTION:

Measure the free distance of the driven face spring. If
the length is shorter than the service limit, replace the
spring with a new one.
Service limit : 104.5mm (4.11 In)
Driven face pin and oil seal inspection:

Turn the driven face and check to see that the driven
faces turn smoothly. If any stickiness or hitches are
found, visually inspect the lip of oil seal, driven face
sliding surface and sliding pins for wear or damage.
Driven face Inspection:

Inspect the belt-contacting surface of
both
driven faces for any scratches, wear and
Damage.
Replace driven face with a new one if
there is any abnormality.
VENTO MOTORCYCLES
CYLINDER HEAD DISTORTION:
De-carb the combustion chamber.
Check the gasket surface of the cylinder head as shown
in the illustration for distortion with a straightedge and
thickness gauge, taking a clearance reading at several
places. If the largest reading at any places of the
straightedge exceeds the limit, replace the cylinder
head.

If the largest reading at any portion of the straightedge exceeds the limit, rework the surface by
rubbing it against emery paper laid flat on the surface plate in a lapping manner. The surface must be
smooth and perfectly flat in order to secure a tight join a leaky joint can be the cause of reduced
power output and increased fuel consumption.
CYLINDER:
Dearborn exhaust port and upper part of the cylinder, taking care
not to damage the cylinder wall surface. The wear of the cylinder
wall is determined from diameter reading taken at 20mm from the
top of the cylinder with a cylinder gauge. If the wear thus
determined exceeds the limit indicated below, rework the bore to
VENTO MOTORCYCLES
the next oversize by using a boring machine or replace the cylinder with a new one. Oversize
pistons are available in two sizes: 0.5mm and 1.0mm.
Service limit 40.075mm (1.5778 In )
Measuring Instrument : Cylinder Bore gauge
After reworking the bore to an oversize, be sure to chamfer the

edges of ports and smooth the chamfered edges with emery paper.
To chamfer, use a scraper, taking care not to nick the wall surface.
NOTE
Minor surface flaws on the cylinder wall due to seizure or similar
abnormalities can be corrected by grinding the flaws off with
fine-grain emery paper. If the flaws are deep grooves or otherwise
persist, the cylinder must be reworked with a boring machine to the
next oversize.
PISTON:
Cylinder and piston clearance:
Cylinder piston clearance is the difference between piston
diameter and cylinder bore diameter. Be sure to take the marked
diameter at right angles to the piston pin. The value of elevation A
○
is prescribed to be 20mm from the skirt end.
Service limit 39.885mm(1.5703In)
Measuring Instrument : Micrometer
As a result of the above measurement, if the piston-to-cylinder
clearance exceeds the following limit, overhaul the cylinder and
use an oversize piston, replace both cylinder and piston. The
measurement for the bore diameter should be taken in the
intake-to-exhaust port direction and at 20mm from the cylinder
top surface.
Standard Service limit
Cylinder 40.005-40.020 mm 40.075 mm
Piston 39.94-39.955 mm 39.885 mm
Cylinder to piston 0.06-0.07 mm 0.120 mm
VENTO MOTORCYCLES
De-carb:
De-carb the piston and piston ring grooves, as illustration.
After cleaning the grooves, fit the rings and rotate them in
their respective grooves to be sure that they move
smoothly. Carbon in groove is liable to cause the piston
ring to get stuck in the groove, and the condition will lead
to reduce engine power output.
Grind piston surface evenly with emery paper
A piston whose sliding surface is badly grooved or seized

due to overheating must be replaced. Shallow grooves or
minor scuff can be removed by grinding with emery paper
of about #400
Piston pin bore:
Use a caliper gauge to measure the piston pin bore inside diameter; if
reading exceeds the following service limit, replace it with a new one.
Service Limit: 12.30mm(0.48 In)
Piston pin outside diameter

Use a micrometer to measure the piston pin outside diameter at
three positions.
Service limit 11.980mm(0.4717 In)
PISTON RINGS:
Check each ring for end gap, reading the gap with a thickness gauge
shown in the illustration. If the end gap is found to exceed the specified limit,
indicated below, replace it with a new one.
The end gap of each ring is to be measured with the ring fitted squarely
into the cylinder bore and held at the least worn part near the cylinder
bottom, as shown in the illustration.
Service limit 0.75mm(0.0296 In)
As the piston ring wears, its end gap increases reducing engine power
output because of the resultant blow by through the enlarged gap. Here lies
the importance of using piston rings with end gaps with the limit. Measure
the piston ring free end gap to check the spring tension.
Service limit 3.6mm(0.142In)
VENTO MOTORCYCLES
Fix the piston ring in the piston ring groove, measure the ringside clearance with the
thickness gauge while matching the sliding surface of piston and ring.
Standard clearance:
1st 0.04-0.06mm(0.0016-0.0024in)
2nd 0.02-0.04mm(0.0008-0.0016in)
Reed Valve:
Check the clearance ○ A between reed valve and its seat and the dimension ○ B . If the
clearance A is noted to exceed 0.2mm, replace the reed valve assembly. The dimension
○
B is at least 1mm.
ENGINE REASSEMBLY:
Reassembly is generally performed in the

reverse order of disassembly, but there are a
number of reassembly steps that demand
detailed explanation. These steps will be taken
up for respective parts and components.
Oil seals:
Fit the oil seals into the crankcase following the
procedure below. Replace removed oil seals with new ones.
Apply special multipurpose grease to the lip of the oil
seals.
Be sure to apply THREAD LOCK “1342” to outer
surfaces of right and left crankshaft oil seals to prevent
them from moving.
When fitting the oil seal into the crankcase, insert it

slowly with the special tools.
NOTE:
Align the oil seal with edge ○
A of the crankcase as
shown in the illustration.
VENTO MOTORCYCLES
BEARINGS:
Install the new bearings with a set of the special
tools.
Install the new bearing and oil seals into the gear
case cover with the special tools.
ENGINE MOUNTING BEARING PRESSING:
Using two steel tubes of appropriate size and a

vise, press the mounting bushings and into
the crankcase holes as shown in the illustration.
NOTE:
Knurled end should face inside, Position ○
A
and○
B should be in the same direction.
VENTO MOTORCYCLES
CRANK SHAFT: Bushing
Bushing
Crankcase
crankcase
• Decide the length between the webs refer the figure

at right when assembling the crankshaft.
Standard width between webs:
38±0.1mm(1.496±0.004in)
• When mounting the crankshaft into crankcase, it is
necessary to pull its left end into the crankcase with
the special tool.
CAUTION:
Never fit the crankshaft into the the crankcase by driving
VENTO MOTORCYCLES
it with a plastic hammer. Always use the special tool, otherwise
crankshaft alignment accuracy will be affected.
CRANKCASE
• Wipe the crankcase mating surfaces with
cleaning solvent.
• Apply specified liquid gasket evenly to
the mating surface of the left half of the
crankcase, and install the dowel pins
• Install the two dowel pins
• Tighten the crankcase bolts securely with
torque wrench at specified torque.
Torque:12 Nm (1.2 Kgm)
• Check crankshaft rotation should be smooth.
VENTO MOTORCYCLES
VENTO MOTORCYCLES
• Install the rear axle shaft into the crankcase by tapping its end lightly.
• Apply engine oil on the left end of the rear axle shaft being inserted later in
the reduction gear box cover.
• Apply grease lightly on the rear brake cam

pivot part and install it to the crankcase.
• Turn to position the cam where the punched

mark○A on the end face is directed toward the
axis of the rear axle shaft.
• Aligning the tang on the wear indicator plate

with a cutaway on the rear brake cam
serrated end; slide the indicator plate over
the cam serration.
Rev no.01/ Page 76 of 128
VENTO MOTORCYCLES
Wear indicator plate Cutaway
Tang
• When installing the cam lever to the cam,

Line on the
align the line on the cam with the slit of
cam
cam lever.
Slit
• Tighten the cam lever nut to the specified

torque.
Tightening Torque
6~8N.m(0.6~0.8kgm)
• Install the brake shoes.

• Install the rear wheel
TRANSMISSION
VENTO MOTORCYCLES
NOTE:
When using a new circlip, pay attention to the direction of
the cir-clip between its two faces; one with sharp corners and
the other with rounded corners. When installing, determine the Thrust
direction of thrust being applied and position the cir-clip so that
it supports the thrust with it sharp corner securely pressing the
shaft groove as shown in the illustration.
Sharp corner
• Assemble the idle shaft subassembly using the idle
VENTO MOTORCYCLES
shaft , cir-clip and thrust washer○ , and then
install the subassembly on the gear case.
• Install the final driven gear○ on the rear

axle shaft using the cir-clip○.
• Install washer ○ , new gasket ○ and dowel

pin○ .
• Install the drive shaft ○ to the gear case
cover.
• Install the retainer○
Tighten gearbox cover to the specified torque.

Tighten the oil drain bolt○
11
Tightening Torque
10~12 N.m(1.0~1.2Kgm)
• Fill the gearbox with engine oil up to the oil level
hole.
Oil Capacity:100ml (SAE 10W/40)
Starter pinion and starter gear:

• Apply grease on the pinion shaft and install the
starter pinion subassembly.
• Assemble the starter pinion subassembly .

• Insert the two dowel pins bushing on the
crankcase and install the starter idle gear cap .
VENTO MOTORCYCLES
• Install the starter gear over the left
crankshaft end.
• Install the new O-RING .
Install the starter motor . When tightening the

attachment screws, secure the clamp together with
the upper front screw.
VENTO MOTORCYCLES
MOVABLE DRIVEN AND CLUTCH
Install the bearing in the fixed driven face with the

special tools.
Install needle bearing
VENTO MOTORCYCLES
Install the bearing with special tool
Install the spacer and cir-clip .
• install the new oil seals and to

the movable driven face with the special
tool.
• Apply grease to the lip of oil seals and
groove of inside of movable driven face.
NOTE:
When reinstalling the movable face to the fixed
face, make sure that the oil seal is positioned
properly.
• Install the pin at three places on the

driven face hub.
• Apply grease lightly to the cam part where
the pins are placed.
• Install two O-Rings .
VENTO MOTORCYCLES
VENTO MOTORCYCLES
• Install the movable driven face seat .
• Install the clutch shoe assembly and

nut .
• Tighten the nut to the specified torque

with the special tool.
Tightening torque
50-60 Nm(4.0-6.0kg.m)
• Insert the V-belt between the driven faces as deep inside

possible while pulling the movable driven face all the way
outside to provide the maximum belt clearance.
CAUTION:
The belt should be positioned so that the arrows on the
belt periphery points the normal turning direction.
The V-belt contact face on the driven faces should be
thoroughly cleaned to be free from oil.
• Thoroughly clean the clutch housing to be free from oil and position
it over the clutch shoe assembly.
• Tighten the clutch-housing nut to the specified torque with the
special tool.
Torque
50-60 N.M (5.0~6.0 kg.m)
VENTO MOTORCYCLES
MOVABLE DRIVE
• Apply grease to all the sliding and rolling surfaces

for six roller weights. For each weight,
approximately 1.5g of grease should be used.
• Mount the three dampers on the movable drive

plate and install it on the movable drive face.
• Position the O-RING on the movable drive face.
• Install the movable drive face cover .

NOTE:
Make sure that the movable drive plate is fully
positioned inside, otherwise the rollers may come out.
Insert the spacer

Position the movable drive face subassembly on the
crankshaft as shown in illustration.
NOTE
Thoroughly clean the belt contact to be free from oil.
VENTO MOTORCYCLES
Install the fixed drive fan .
Tighten the nut to the specified torque with
special tool.
Tightening torque
50-60N.M(5.0-6.0kg-m)
• Fill grease in the groove provided inside

sliding surface of the kick driven gear and
install ○ on the end of the crankshaft. Wipe
off excess grease. Install washer ○ and
spring○.
NOTE:
When installing washer face the resin
surface of washer to outside.
• Install the retainer .
• Continue turning the fixed drive face○ by

hand until the belt is seated in and both the
drive and driven faces○ will move together
smoothly without slip.
• Fill the final gearbox with engine oil

up to the level hole.
Oil capacity 100 m l
Tighten the oil level bolt to the specified
torque.
Tightening torque
9-15N.M (0.9~1.5 Kg.m)
VENTO MOTORCYCLES
KICK STARTER
Apply grease on inside surface of the kick-starter shaft spacer.
Position the kick-starter shaft return spring and hook the

spring end ○ on the clutch cover boss○.
Install the dowel pins

Install the new gaskets( and )
VENTO MOTORCYCLES
• Fix the gasket to the clutch cover as shown in the
illustration.
NOTE: Install the kick starter lever as shown in the illustration.

Tightening Torque
8~12N.M (0.8-1.2kg-m)
VENTO MOTORCYCLES
PISTON
• Install the piston rings on the piston.
The first and the second ring.
NOTE:
Position the ring so that the marking is on upside.
• it is extremely important that, when the piston is fed

into the cylinder, each ring in place should be so
positioned as to hug the locating pin as shown in
illustration.
• Apply CCI oil on the piston and install the piston to the connecting
rod.
NOTE
The arrow mark on the piston head should point the exhaust side.
• The cir-clip should be mounted in such a position that the mating
ends of the cir-clip do not coincide with the grove portion of the piston.
• Position the cylinder base gasket.
• Apply CCI oil on the position and cylinder wall surfaces and install the
cylinder over the piston carefully.
OUTSIDE
• Tighten the cylinder head nut to the specification.
VENTO MOTORCYCLES
Tightening torque
18-28Nm (1.8~2.8 Kgm
OIL PUMP DRIVEN GEAR AND OIL PUMP

• Apply grease to the oil pump driven gear
and install it to the crankcase.
• Install the oil pump and retainer and

tighten them to the specified torque.
Tightening Torque
3~5N.m(0.3~0.5 kgm)
INTAKE PIPE
N ip p le
• Install the nipples to the intake pipe as shown in N ip p le
the illustration.
A not equipped check valve
Nipple○
B equipped check valve
Nipple○
VENTO MOTORCYCLES
• Install the gasket and intake pipe with reed
valve to the crankcase.
• Install the clamps( , , ).
• Install the oil hoses.
MAGNETO
Degrease the tapered portion of the crankshaft
and also the magneto rotor.
Install the pin .
Install the stator and retainer and tighten them.
Apply thread lock super “1322”to the rotor nut

and tighten it to the specified torque with the
special tool.
Tightening torque
40-45N.m (4.0-4.5kg.m)
• Install the fan case and cooling fan .
VENTO MOTORCYCLES
• Install the magneto lead wire and starter motor lead
wire correctly.
• Install the cooling fan cover .

• Tighten the exhaust pipe bolts and muffler
mounting bolts to the specified torque.
TIGHTENING TORQUE:
8~12N.m(0.8-1.2kg.m)
18~28N.m(1.8-2.8kg.m)
VENTO MOTORCYCLES
CHAPTER 4
FUEL AND LUBRICATION SYSTEM
CONTENTS
FUEL SWITCH……………………………………………….
CARBURETOR……………………………………………….
OIL PUMP ………………………………………………….
VENTO MOTORCYCLES
FUEL SWITCH
When turning the starter motor, a negative pressure is generated in the combustion
chamber. This negative pressure draws on the fuel tap diaphragm,(through a
passage way in the carburetor intake pipe) and vacuum hose. Due to this, the
negative pressure increases behind the fuel tap diaphragm, until it is higher than this
valves spring pressure. The fuel valve in the fuel is then forced to open(due to this
diaphragm operation) and allows fuel to flow into the carburetor float chamber.
Fuel switch
Carburetor Type
Identification code Side Draught
Throat tube diameter PZ19JB
CARBURETOR 19mm
Main jet size
Idle needle jet size 80
Fuel needle clamp position 57.5
Idle air adjusting screw 3rd groove from top
extrude 1 1 ± 1 turnout
2 2
Float height 13±1mm
Throttle cable play 3~6 mm (0.1~0.2 In)
VENTO MOTORCYCLES
Comment:
CARBURETOR
CARBURETION
Proper carburetion is determined according to the results of various tests, mainly
concerning engine power, fuel consumption and cooling effect of fuel on engine,
and jet settings are made so as to satisfy and balance all of these conditions.
Therefore, the jet should not be replaced with a size other than the original. And
the positions of adjustable parts should not be changed except when
compensation for the mixture ratio due to altitude differences or other climatic
conditions. When adjustment is necessary, refer to the following.
VENTO MOTORCYCLES
VENTO MOTORCYCLES
AIR –FUEL SYSTEM
AIR-FUEL FLOW CIRCUIT
Fuel is being supplied to the carburetor from fuel tank by controlled fuel cock assy. Air filter box
is fitted on the left side of the motorcycle. Fuel gets atomized and mixes with clean air in right
proportion in the carburetor and then air fuel mixture is supplied to the combustion chamber of
the engine. In engine this air fuel mixture is controlled by the intake valve and camshaft rocker
arm mechanism.
AIR- FUEL FLOW CHART
AIR FUEL
Atmosphere Fuel tank
Air cleaner assy. Strainer fuel cock
Filters Sedimentation bowl
Fuel Tap Filter
Venturi Inlet Floater Chamber
Diffuser of Jet
Venturi outlet
Combustion chamber
VENTO MOTORCYCLES
AIR FUEL MIXTURE RATIO
• Starting ------------------------------------ 7~8: 1
• Idling speed--------------------------------------- 10~12: 1
• Slow speed ------------------------------------- 12~14: 1
• Medium speed------------------------------------- 15~17: 1
• High speed--------------------------------------- 13~15:1
CARBURETTOR CIRCUITS :
ZIP r3i CARBURETOR HAS FOLLOWING 6 MAIN CIRCUITS
1. Fuel Intake circuit
2. Choke circuit
3. Idling speed circuit
4. Slow speed circuit
5. Medium speed circuit
6. High speed circuit
VENTO MOTORCYCLES
CARBURETTOR CIRCUITS
1. FUEL INTAKE CIRCUIT:
From fuel tank fuel comes into
float chamber of carburetor by
controlled fuel cock assy. Separate
vent is provided at LH side of
carburetor body to maintain inside
atmospheric pressure. When fuel
starts filling the float chamber, float
rises up words along with the float
pin and after a certain level it stops
further flow of fuel.
2. CHOKE CIRCUIT:
Choke is provided for easy starting,
since it requires rich mixture. Hence
choke knob is being operated from the
carburetor. Due to this an air stopper
(Butterfly valve) comes on the way to
the venturi (Air filter side) of the
carburetor, thus reducing the amount of
air being mixed with fuel. Excessive fuel
is being sucked from the slow jet and
less quantity of air enters from the choke
valve and from the small opening below
the throttle valve.
When the motorcycle engine starts, a
spring loaded window is provided in the
choke actuating lever itself so as provide
in the choke actuating knob itself so as
provide extra air as required to run the
engine in rich mixture.
VENTO MOTORCYCLES
3. IDLING CIRCUIT:
After starting operation choke is
released, more air starts flowing thru the
venturi. From slow jet fuel is sucked due
to venturi effect. A separate passage
from the air filter side is coming at the
diffuser of the slow jet for the
atomization of fuel in slow jet. This
atomized fuel is sucked into the venturi
as started above from the slow jet (As
shown in figure). The amount of air for
atomization is regulated by airscrew
located at bottom side of the carburetor
body.
4. SLOW SPEEDCIRUIT
Slow speed requires very less
acceleration. Air fuel mixture is being
supplied by slow jet and also from main
jet. This is due to partial opening of
throttle valve, lifts needle jet upwards.
Hence some quantity of air fuel mixture
coming out from main jet diffuser also
mixes along with slow jet mixture to
increase the mixture quantity as required
by engine.
5.MEDIUM SPEED CIRCUIT

(Economy speed range)
Further acceleration the air fuel
mixture supplied to engine only from
main jet. During this slow jet stops
supplying air fuel mixture due to
venturi effect. Hence air is drawn to
main jet through metered air jet (Brass
tube) for better mixing of fuel with air
in the main jet diffuser. Main jet started
supplying air fuel mixture in economy
range i.e. more air with less quantity of
fuel as per engine requirement.
VENTO MOTORCYCLES
1. HIGH SPEED CIRCUIT
During acceleration the throttle
valve (piston) is fully raised, more
air is being supplied due to higher
velocity. Hence pressure drops at the
opening of throttle jet needle. Where
as more fuel is sucked from the main
jet due to tapperness of jet needle. A
jet holder is provided to the main jet
to avoid fuel flow strain (turbulence)
effect in the float chamber created
during the very high speed to
diffuser (As shown in the figure)
CARBURETOR
CARBURETTOR REMOVAL/INSTALLATION FROM MOTORCYCLE
REMOVAL:
1. Turn fuel switch “ OFF” position.
2. Disconnect fuel pipe from carburettor by pressing clip.
3. Loosen the clamp over air cleaner connecting tube (Air duct).
4. Drain the fuel from carburettor float chamber in a separate pan loosening drains screw.
5. Remove insulator clamp screw.
6. Pull out the carburetor assy. Along with insulator from air duct.
7. Open the carburetor top cap, pull out the throttle valve along with needle, clip, and
spring & throttle cable.
8.Remove the overflow/drain pipe.
INSTALLATION:
FOLLOW THE REVERSE ORDER OF REMOVAL
NOTE:
• After installation check for any fuel leakage from the carburetor or fuel line.
• Check for the throttle smooth movement, if necessary adjust throttle grip free play 3 to 6 mm.
VENTO MOTORCYCLES
CARBURETTOR ASSEMBLY
DISASSEMBLY PROCEDURE FOR CARBURETTOR CLEANING:
• Remove the throttle valve from the accelerator cable by compressing the spring up from
the seat in long slit. Remove the tip of the cable from the slot of the valve.
• Remove the jet needle from the throttle valve along with clip and plate.
• Remove the airscrew with spring.
• Remove the Idling screw with spring.
• Remove the float chamber by unscrewing three screws.
• Pull out the float arm pin to remove the float.
• Remove the main jet along with jet holder and needle.
• Remove the slow jet.
• Now clean all the carburetor components and apply compressed dry air in all passages
(galleries)
NOTE:
• Don’t remove clip from the jet needle groove.
• Ensure that float and float valve is being removed before carrying out any other jobs on
carburetor. So that these components will not get damage.
ASSEMBLY PROCEDURE OF CARBURETTOR:
• Screw the slow jet (Ensure that all holes are clearly visible on the slow jet body).
• Fix needle jet from main jet hole (Ensure that the smaller dia face towards carburetor body
hole).
• Tighten the needle jet holder (Ensure that all holes clearly visible on the needle jet holder
body).
• Screw the main jet along with jet holder.
• Insert the float arm pin through the pivot and the float.
• Check float height (Specified13±1mm) adjust, if necessary this will avoid overflow.
• Fix the float chamber.
• Fix idle screw and airscrew along with spring (Initial airscrew setting one and half turn
out).
• Insert the jet needle along with clip and plate into the throttle valve (Ensure that needle
lock clip is in 3rd groove position from top).
• Connect the throttle valve to the accelerator cable first compress the spring into the cap,
Insert the tip of the cable through the slot in the throttle valve base and fix cable in long
slit rest position.
• Align the groove on the side of the throttle valve with the guide pin in the carburetor body.
Check for its smooth movement.
• Tighten the top cap over carburetor body.
VENTO MOTORCYCLES
CARBURETTOR TUNING OR ADJUSTMENT PROCEDURE
After installation the carburetor in the engine as per above said procedure,
follow the following steps:
1. Warming up the engine to the normal running temperature.
2. Adjust Idling speed to 1800±100 RPM by throttle stop (Idle) screw.
3. Turn the airscrew all the way inside until seats lightly in the carburetor body.
1. If engine stops then… OK (Incase does not stop, check for air leakage from insulator “O” ring
and rectify).
2. Readjust airscrew position to 1 1 ± 1 turns out.
2 2
3. Start the engine and increase the Idling speed by turning the Idle (stop) screw in anticlockwise
direction, till the engine speed increases to the range of 2000 to 2500 RPM.
4. Open the airscrew outwards (anticlockwise) slowly till engine RPM increases to the
peak/highest speed position while setting. Now stop adjusting air screw (Maximum
recommended air screw opening position 1¾ turns out).
5. Readjust Idling speed to 1800±100 RPM by the throttle stop screw & ensure that exhaust
emission Carbon Monoxide CO % 1.5 to 2.0 %.
6. After adjusting Idling speed, check for its stability/flat spot/missing if any, by accelerating
few times. Repeat above said steps until engine speed increases smoothly.
NOTE:
• Do not apply force or over tight the airscrew. Damage may occur incase the air screw is being
tightened against the airscrew seat.
• Incase the Idling speed is too low engine will stop; if it is too high will cause fuel
consumption.
WARNING
While running engine in Idling speed turn the handle bar to the extreme left or
right hand side, if any change in idling speed noticed, the accelerator cable may be
wrongly routed or improperly adjusted. Correct the same before test ride.
VENTO MOTORCYCLES
CHAPTER 5
ELECTRICAL SYSTEM
CONTETNS
• IGNITION SYSTEM -------------------------------
• CHARGING AND LIGHTING SYSTEM………..
• STARTER SYSTEM………………………………..
• FUEL GAUGE……………………………………..
• OIL LEVEL CHECK LIGHT AND TURN SIGNAL
• INDICATOR-----------------------------------------------------------
• SWITCHS -------------------------------------------
• BARTTERY. ----------------------------
VENTO MOTORCYCLES
IGNITION SYSTEM
CDI&Ignition coil unit

MAGNETO
Spark plug
The ignition system consists of a flywheel magneto, a CDI&Ignition coil unit and
a spark plug. As the rotor generates, an AC current is induced in the coil. Then
current induced in the A
○ direction charges up the capacitor.
As the rotor rotates further, the current is induced in the reverse direction. The
current causes a voltage applied through the ground to the gate of SCR. As the
SCR conducts, the energy, which has been charged in the capacitor, is
instantaneously discharged through the primary winding of the ignition coil.
CDI UNIT AND IGNITION COIL INSPECTION
CHECKING WITH ELECTRO TESTER
Connect the CDI test lead to the coil’s primary
connector.
Switch Black
Connect the high-tension leads, red○+ lead to
red
— lead to the
the spark plug cord and the black○ CDI test lead
black lead of the test lead.

Set the test selector knob to “P.E.I”.
Connect the power lead to the appropriate
AC source.
Switch the power on.
VENTO MOTORCYCLES
NOTE:
The spark in the spark gap window. It should be strong and
continuous, not intermittent, across a preset 8mm(0.32in) gap. Allow
the spark to jump the test gap for at least five minutes continuously.
To insure proper operation under the temperature of actual riding.
MAGNETO EXCITING COIL

• Remove the right frame side cover.
• Disconnect the exciting coil lead wire (black
with red tracer).
• Using a Multimeter, measure the resistance
between the B/R lead wire and ground. If the
resistance checked is incorrect, replace the coil.
Exciting coil restance 140-220Ω
VENTO MOTORCYCLES
CHARGING AND LIGHTING SYSTEM
VENTO MOTORCYCLES
The charging system uses the flywheel magneto shown in the figure. The charging
and lighting coils are mounted on the magneto stator and generate AC as the flywheel
rotor turns. AC generated in the charging coil flows to the regulator/rectifier, which
changes AC to DC. The DC Then charges the battery.
R e g u la to r /r e c tif ie r
M agnet F u se
o
B a tte r
H e a d lig h t T a illig h t L ig h t
On the other hand, lighting coil supplies AC current to the headlight, taillight, and
meter light under the regulated condition.
VENTO MOTORCYCLES
CHARGING OUTPUT CHECKING:
Start the engine and keep it running at

Fuse
5000 RPM with light switch turned on
Battery
condition.
NOTE:
When making the test, be sure that the battery is fully charged condition.
Digital Tachometer: For measuring engine RPM
Specified charging output Voltage 12~14 Volt at 5000 RPM
VENTO MOTORCYCLES
NO-LOAD PERFORMANCE
Disconnect the magneto lead wire coupler.

Start the engine and keep it running at 5000 RPM.
Using a Multimeter, measure the AC voltage between the
white and red tracer lead wire and ground. If the tester
reading is as follows, magneto is in good condition.
Specified no-load Voltage:

More than 65Volt (AC) AT 5000 RPM.
STATOR COILS RESISTANCE VALUE
S no Coil Description Resistance

Value
1. Charging Coil 285 to 375
Ω
2. Pick-up Coil 120±20 Ω
at 20oC
3. Light Coil Less
than 2 Ω
4. Battery Charging Coil Less than 2 Ω
Use Multimeter tester to measure the resistance between the lead wire and ground.
If the resistance checked is not correct, replace the coil.
Regulator/rectifier
Disconnect the lead wire coupler.
Using the Multimeter ×1 Ω Range , measure the
resistance between the terminals as shown in the
following table. If the resistance checked is
incorrect, replace the regulator/rectifier.
UNIT: Ω
VENTO MOTORCYCLES
STARTER SYSTEM
DESCRIPTION
The starter system is shown in the diagram below namely, the Starter Motor,
Relay, Starter switch and Battery. Depressing the starter button while squeezing the
front or rear brake lever energizes the relay, causing the contact points to close, which
connects the starter motor to the battery.
Starter relay
Fuse
Battery
Starter motor
Starter button
Front brake switch
Ignition switch
Rear brake switch
Starter motor removal and disassembly:

Remove the starter motor; disassemble the starter motor as shown in the
illustration
VENTO MOTORCYCLES
STARTER MOTOR INSPECITION
CARBON BRUSHES
When the brushes are worn, the motor will be
unable to produce sufficient torque, and the engine
will be difficult to turn over. To prevent the,
periodically inspect the length of the brushes and
replace them when they are too short or chipping.
Service Limit 3.5mm (0.14in)
Segment
Commutator
If the commutator surface is dirty, starting
performance will decrease. Polish the commutator Mica
with #400 or similar fine emery paper when it is
dirty.
Service Limit 0.2mm (0.008in)
VENTO MOTORCYCLES
ARMATURE COIL
Using the Multimeter, check the coil for open and

ground by placing probe pins on each commutator
segment and rotor core and on any two segments at
various places. With the brushes lifted off the
commutator surface. If the coil is found
open-circuited or grounded, replace the armature.
STARTER RELAY INSPECTION

Disconnect lead wire (R/W) of the starter motor.
Turn on the ignition switch and squeeze the front
or rear brake lever, then inspect the continuity
between the Red and Red/White lead wires at the
starter relay when pushing the starter button.
If the starter relay is in sound condition,
continuity is found.
● Disconnect the starter relay lead wire coupler. Check the coil for “open”,
“ground” and ohmic resistance. The coil is in good condition, if the resistance is as
follows:
STANDARD RESTANCE: 80~150 Ω
VENTO MOTORCYCLES
FUEL LEVEL GAUGE
INSPECTION OF FUEL LEVEL GAUGE
The two different checks to be used for inspection of fuel level gauge.
The first, and simplest test will tell if the meter is Operating but will not indicate the meters accuracy
throughout the range. To perform the test, lift the seat and remove the
right frame cover, then disconnect the B/W and Y/B lead Connector of the fuel gauge-sending unit.
Connect a jumper Wire between B/M and Y/B wires coming from the main wiring harness, the
ignition switched ON, the fuel meter should indicate“F”.
The second test will check the accuracy of the meter in the full and empty positions.Connect a
90-ohm resistor between the Y/B and B/W lead wires.The fuel meter is normal if its pointer
indicates the E(empty) position when the
specified voltage is applied to the circuit and if its pointer indicates the F(full) position when the
resistor is changed to 10 ohms.If either one or both indications are
abnormal,replace the fuel meter with a new one.
FUEL GAUGE SENDING UNIT INSPECTION

Disconnect the lead wires coming out of the fuel gauge and check resistance of each position. If the
resistance measured is incorrect, replace the fuel gauge assembly with a new one.
Resistance is shown in the following table:
FLOAT POSITION RESISTANCE

F FULL Approx.33 Ω
(HALF) Approx.200 Ω
E EMPTY Approx.300 Ω
OIL LEVEL SWITCH INSPECTION
Check the oil level switch for continuity between the lead wires. If the tester does not show the value
of 1 ohm when the switch ring is in bottom position, file the contact surface or replace the unit.
VENTO MOTORCYCLES
SIGNAL SYSTEM:
The same bulb is used for both oil levels check light and turn signal indicator light. The circuit
diagram is shown below. When the oil level has fallen to a certain level (the remaining amount of oil
has become approximately 160 ml, the oil level check light turns on and remains lit. When the turn
signal switch is turned on and the turn signal light flashes, the turn signal indicator light (oil level
check light) also flashes, both being not concurrently but alternatively as one being lit white the other
unit. (Pl refer electric diagram on next page)
VENTO MOTORCYCLES
VENTO MOTORCYCLES
SWITCHES
VENTO MOTORCYCLES
BATTERY
SPECIFICATIONS
Type designation YUASA/YB4L-B
Capacity 12V-4Ah
Specific gravity (Fully charged) 1.24~1.28 at 27 0C
Needs Charging Below 1.220
INITIAL CHARGING
FILLNG ELECTROLYTE
Remove the aluminum tape sealing the battery electrolyte filler holes.
Remove the caps .

NOTE
After filling the electrolyte completely, use the removed
Cap as the sealed caps of battery-filler holes.
Do not remove or pierce the sealed areas of the
electrolyte container.
Insert the nozzles of the electrolyte container into the

battery’s electrolyte filler holes, holding the container
firmly so that it does not fall. Take precaution not to allow
any of the fluid to spill.
Make sure air bubbles are coming up each electrolyte container, and
leave in the position for about more than 20 minutes.
NOTE:
If no air bubbles are coming up from a filter port, tap the
bottom of the two or three times.
Never remove the container from the battery.
VENTO MOTORCYCLES
After confirming that the electrolyte has entered the battery completely, remove the electrolyte
containers from the battery, wait for around 25 minuets.
Insert the caps into the filler holes, pressing in firmly so that the top of the caps does not protrude
above the upper surface of the battery’s top cover.
CAUTION:
• Always use specified things of the battery.
• Once install the caps to the battery; do not remove the caps.
• Check battery voltage by multimeter if battery voltage less than the specified voltage
(12.5~12.6 Volt). Charge the battery with a battery charger.
SERVICING:
Visually inspect the surface of the battery container. If any sign of cracking or
electrolyte leakage from the sides of the battery have occurred, replace the battery
with a new one. If the battery terminals are found to be coated with rust or an acidic
white powdery substance, then this can be cleaned away with sandpaper.
VENTO MOTORCYCLES
RECHARGING OPERATION
Apply multimeter to measure the voltage of battery. If the reading is below 12.0V it should be
recharge with a battery charger.
NOTE: When recharging, remove the battery form the vehicle.
NOTE: When recharging, don’t remove the sealing caps from the battery.
Recharging Current &Time
0.4Amp charging current for 5 hours OR 4.0Amp charging current for 1 hour.
NOTE: The charging current should be not more than 4Amp at any time.
CAUTION:
• After recharging, wait for more than 30 minutes and re-check battery voltage by
multimeter.
• If the battery voltage is less than12.5 Volt, please recharge the battery again.
• If battery voltage is still less than 12.5Volt please replace the battery with a
new one.
• When the motorcycle is not used for a long period, check the battery every
one-month to prevent the battery discharge.
VENTO MOTORCYCLES
CHAPTER 6
CHASSIS
CONTENTS
LEG SHIELD AND FRAME SIDE COVERS··
LEG SHIELD REMOVAL··
LEG SHIELD REMOUNTING··
FARME SIDE COVER REMOVAL··
FARME SIDE COVER REMOUNTING··
HANDLEBAR COVERS··
REMOVAL··
REMORNTING··
FRONT WHEEL ·
REMORAL··
INSPECTION AND DISASSEMBLY··
REASSEMBLY AND REMOUNTING··
FRONT BRAKE··
BRAKE PAD REPLACEMENT··
CALIPER REMOVAL AND DISASSEMBLY··
CALIPER AND DISC INSPECTION··
CALIPER REASSEMBLY··
MASTER CYLINDER REMOVAL AND DISASSEMBLY··
MASTER CYLINDER INSPECTION··
MASTER CYLINDER REASSEMBLY AND REMOUNTING··
STEERING STEM AND FRONT SUSPENSION··
REMOVAL AND DISASSEMBLY··
INSPECTION··
IGNITION SWITCH··
REAR WHEEL AND BRAKE··
REMOVAL AND DISASSEMBLY··
INSPECTION··
VENTO MOTORCYCLES
LEG SHIELD AND FRAME SIDE COVERS
Front cover
VENTO MOTORCYCLES Front leg shied
Rear leg shield

Frame no. cover Right rear cover
Right front cover Connecting board

Front luggage box
Fuel lighting board

Left rear fender
Under connecting board I Pedal cover Rear fender
Under connecting board II

Left front cover
Pedal
SIDE COVER REMOVAL
1. Open seat and remove rear cap
2. Remove decorating cover , inner hex head screw and rear
Carrier .
3. Open seat, remove seat , helmet barrel and rear carrier by

Loosing tightening screw .
4. Remove tapping screw and then remove side covers .
Side cover installation:

5. The installation sequence is essentially the reverse of removal.
VENTO MOTORCYCLES
LEGSHIELD REMOVAL
1.Open front cover, remove front luggage box

by loosening bolt and screw .
2. Remove pedal and front cover by loosening

Screw and bolt .
3. Remove front cover I by loosing screw .
VENTO MOTORCYCLES
4. Remove leg shield by loosing bolt .
LEGSHIELD INSTALLATION
The installation sequence is essentially
the reverse of removal.
HANDLEBAR COVER
Handle front cover

Right switch
Left switch
Handle rear cover
VENTO MOTORCYCLES
HANDLE COVER REMOVAL
1. Remove handlebar front cover by
loosening bolt .
2. Remove handlebar rear cover by loosing bolt .
HANDLEBAR COVER INSTALLATION

The installation sequence is essentially the reverse of removal.
VENTO MOTORCYCLES
FRONT WHEEL
1. Front axle shaft

2. Screw GB820 M5X16
3. Gear seat
4. Roller bearing GB6200
5. Bearing spacer
6. Inner tire 3.50-10
7. Outside tire 3.50-10
8. Roller bearing GB6200
9. Oil seal
10. Brake disc
11. Bushing
12. NutGB5789 M10Χ1.25
13. Bolt
REMOVAL: 2
• Remove the front brake caliper by removing the
mounting bolts .
CAUTION
Do not operate the front brake lever while dismounting
1
the caliper.
2
• Remove mounting bolt .
• Remove left decorating cover and right

one of front fork.
5
• Remove screw
• Remove front fender
• Support the scooter by jack

or wood shelf.
• Remove front wheel by

removing front axle shaft.
VENTO MOTORCYCLES
INSPECTION AND DISASSEMBLY
WHEEL BEARING
• Inspect the play of bearing inner race by hand while mounted in the
wheel.
• Rotate the inner race by hand to inspect if any abnormal noise occurs
or rotating smoothly,
• Replace the bearing if there is anything unusual.
• Remove the dust seal.
CAUTION:
The removed dust seal and bearing should be replaced with new ones.
AXLE SHAFT:
Check the axle shaft run out and replace it if the run out exceeds the
limit.
Service limit: 0.25mm (0.010 in)
WHEEL RIM:
Make sure that the wheel rim run out does not exceed the service
limit when checked as shown.
An excessive run out is usually due to worn or loose wheel bearings
and can be reduced by replacing the bearings. If bearing replacement fails to reduce
the runout,replace the wheel.
Service Limit: 2.0mm (0.08 in )
VENTO MOTORCYCLES
Reassembly and remounting
Reassemble the front wheel in the reverse order of removal, and also carry out the
following steps:
1. Install this wheel bearing with the special tools.
2. Install the brake disc as shown in picture.
3. When installing this speedometer gearbox, align the two

driving pawls with the two recesses of the wheel hub.
Tighten the nut with special tool to the specified
torque value.
VENTO MOTORCYCLES
FRONT BRAKE SYSTEM
1. Disc brake assy.

2. Disc brake handle lever
3. Tightening bolt
4. Nut M6
5. Master cylinder
6. Tightening seat
7. Bolt M6X20
8. Brake hose assy.
9. Brake caliper
10. Connecting board tightening bolt
11. Hose mounting bolt
12. Seal gasket
13. Front gasket
14. Rear gasket
15. Brake pad 1
16. Brake pad 2
17. Master cylinder rubber
bushing
18. Front brake switch
BRAKE PAD REPLACEMENT

Remove the calliper by removing the mounting bolts
NOTE:
Do not operate the front brake lever while dismounting the calliper.
Remove the brake pads.

CAUTION:
Replace the brake pads as a set, otherwise braking efficiency
will be adversely affected.
Reassemble and remount the calliper.
CALIPER
VENTO MOTORCYCLES
REMOVAL AND DISASSEMBLY
Remove the brake hose and collect the brake fluid in a suitable
receptacle.
CAUTION:
Never re-use the brake fluid left over from the last servicing
and stored for long periods.
·Remove the calliper.

·Remove the brake pads.
·Remove the spring and pad holder.
·Place a rag over the piston to prevent popping up & push out the
piston with an air gun.
CAUTION:
Do not use high-pressure air to prevent piston damage.
• Remove the dust seal ○ and piston seal ○.
CALIPER AND DISC INSPECTION

• Inspect the calliper cylinder bore wall or nicks,
scratches or other damage.
• Inspect piston for damage and wear.
• The removed rubber parts should be replaced
with new ones.
VENTO MOTORCYCLES
BRAKE DISC INSPECTION
• Visually check the brake disc for damage or cracks.
• Check the disc for wear with a micrometer.
• Its thickness can be checked with disc and wheel
in place. Replace the disc if the thickness is less than
the specified service limit.
Service Limit: 3.5 mm (0.14 in)
Check the disc for face run out with a dial gauge as shown.
Replace the disc if the run out exceeds the service limit.
Service Limit:0. 3 mm (0.012 in)
VENTO MOTORCYCLES
BRAKE CALIPER REASSEMBLY
Reassemble and remount the calliper in the reverse order of
removal and disassembly, and also carry out the following steps.
CAUTION:
• Wash the calliper components with fresh brake fluid before
reassembly. Never use cleaning solvent or gasoline to wash them.
Apply brake fluid to the calliper bore and piston to be inserted into
the bore.
• Do not wipe components with a rag.
Reassemble and remount the calliper. (refer to above pages)
WARNING:
Bleed air after remounting the calliper. (Refer to above pages)
MASTER CYLINDER REMOVAL AND DISASSEMBLY

• Remove the handlebar cover. (Refer to above page)
• Disconnect the front brake light switch lead wires.
Place a cloth underneath the union bolt on the master cylinder

to catch spilled drops of brake fluid. Unscrew the union bolt
and disconnect the brake hose master cylinder joint.
CAUTION:
Completely wipe off any brake fluid contact of any parts of motorcycle.
The fluid reacts chemically with paint, plastics, rubber materials, etc.
• Remove the master cylinder.
VENTO MOTORCYCLES
• Remove the brake lever and brake switch.
• Remove the dust boot.
• Remove the circlip with the special tool.
• Remove the piston /primary cup with return spring.

• Remove the reservoir cap and diaphragm.
• Drain brake fluid.
MASTER CYLINDER INSPECTION

• Inspect the master cylinder bore for any scratches or other damage.
• Inspect the piston surface for scratches or other damage.

• Inspect the primary cup and dust boot for wear or damage.
VENTO MOTORCYCLES
MASTER CYLINDER REASSEMBLY AND ERMOUNTING
Reassemble and remount the master cylinder in the reverse order of the
Removal and disassembly, and also carry out the following steps.
CAUTION:
Wash the master cylinder components with fresh brake fluids before
reassembly. Never use cleaning solvent or gasoline to wash them.
Apply brake fluid to the cylinder bore and all the internals to be
inserted into the bore.
Reassemble and remount the master cylinder, when remounting the master cylinder on the handlebar,
first tighten the clamp bolt for upside.
CAUTION:
Bleed air after remounting the master cylinder.
VENTO MOTORCYCLES
STEERING STEM AND FRONT SUSPENSION
1. Steer shaft
2. Locknut
3. Stopper
4. Upper outer race
5. Steel ballφ3.969
6. Upper outer race
7. Lower inner race
8. Steel ballφ4.763
9. Lower outer race
10. Buffer
11. Shock absorber spring
12. Right inner tube
13. Guide tube II
14. Shock absorber spring
15. Guide tube I
16. Spring circle for hole
17. Anti-dust cover
18. Left inner tube
19. Handle cover mounting
board
20. Tapping screw ST4.2X13
21. Bolt GB5789 M10X1.25X45
22. Screw GB819 M8×35
23. Gasket GB97 Φ10
24. Nut GB6187 M10X1.25
25. Handlebar
REMOVAL AND DISASSEMBLY:
□ Remove the handle cover refer to previous page

□ Remove under decorating cover refer to previous page
□ Remove leg shield refer to previous page
□ Remove front wheel refer to previous page
□ Disconnect the front and rear brake light switch lead
Wires .
□ Remove the rear brake cable .
□ Remove throttle grip case .

□ Remove throttle cable .
□ Remove disc brake system.
VENTO MOTORCYCLES
□ Remove tightening bolt and tightening screw and
remove handlebar.
□ Loosen the steering stem locknut with special tool.

universal tightening wrench
□ Remove steering upper outside race and remove front fork

assembly.
NOTE:
Check should not drop the steering stem balls.
□ Remove front shock absorber
□ Remove bearing lower race by chisel.

□ Remove steel balls.
Number of steel balls
Upper 25 (Φ 3.969)
Lower 21 (Φ 4.763)
□ Remove the upper and lower bearing inner races with a
appropriate bar.
VENTO MOTORCYCLES
INSPECTION OF STEERING RACE & BALLS:
□ Inspect the removed parts for the following abnormalities.
Bearing race wear and corrosions.
Worn and damaged steel balls.
Distortion of steering stem or handlebar.
NOTE:
If any abnormalities noticed on the race, replace the balls and races as a set.
□ Inspect the suspension and rubber bush for

damage.
REASSEMBLY AND REMOUNTING

Reassemble and remount the steering stem, handlebar
and front fork in the reverse order of disassembly
and removal, and also carry out the following steps.
□ Install the right left suspension arms.
Steel ball:
Apply grease when installing the upper and lower steel balls.
Number of steel balls
Upper 25 (Φ 3.969)
Lower 21 (Φ 4.763)
• Tighten the steering outer race with special tool, then loosen it
1/8-1/4round.
NOTE
Adjustment will vary from scooter to scooter.
Be sure that the steering turns smoothly and easily, left to right.
VENTO MOTORCYCLES
□ Install the washer
□ Tighten locknut with special tool.
□ Install handlebar and tighten the screw and bolt
to the specified torque.
NOTE:
After performing the adjustment and installing the handlebar,
check the front wheel forward and backward to ensure that there
Is no play and that the procedure is accomplished correctly. If
play is noticed, readjust the steering outer race nut again.
VENTO MOTORCYCLES
REAR WHEEL AND BRAKE
1.Outer tire 3.5-10

2.rear rim
3.brake shoe
4.rear brake shoe spring
5.spring
6.rear indicator plate
7.nut M6
8rear brake camshaft
9.bolt M6Χ30
10.inner tire3.50-10
11.nut M14Χ1.5
12.rea brake arm
13.valve cap
VENTO MOTORCYCLES
REMOVAL
□ Place the scooter on level ground.
□ Remove muffler.
□ Remove rear small fender.
□ Remove locknut and rear wheel.
□ Remove brake shoes.
INSPECTION REAR RIM
Measure inner diameter of rear rim hub with micrometer,

if measured diameter exceeds its limit; replace it with a new one.
BRAKE SHOES:
Check the brake shoe lining wear out it should be replaced, if wear out is more than specified limit.
Service limit 1.5mm (0.06in)
VENTO MOTORCYCLES
REASSEMBLY AND REMOUNTING
Reassemble and remount the rear wheel and brake in
the reverse order of removal, and also carry out
the following steps:
□ Turn the punched mark on the camshaft to the

rear axle shaft side.
□ Install the protrusion of indicator plate to the groove

of Camshaft.
□ When installing the brake cam shaft, align the groove of camshaft
with the slit of on cam lever.
• When installing brake shoes, apply grease to the camshaft and

pin before installing the brake shoes.
CAUTION:
Please don’t apply too much grease to the camshaft and pin. If grease gets on the lining, braking
efficiency will be lost.
VENTO MOTORCYCLES
CHAPTER 7
SERVICING INFORAMTION
CONTENTS
1.Trobule shooting …………………………………

2.Wiringd diagram……………………………………
3.Wire, cable and hose routing………………………
4.Special tools ………………………………………
5.Tightening torque……………………
6.Service data……………………………………………
VENTO MOTORCYCLES
1.TROUBLE SHOOTING
ENGINE
Complaint Symptom and possible causes Remedy
Engine does not start, Compression too low
or is hard to start. 1. Excessively worn cylinder or piston & piston rings. Replace.
2. Sticky piston rings in groove. Repair or replace.
3. Compression leaks from the joint in crankcase, cylinder Repair or replace.
or cylinder head.
4. Damaged reed valve. Replace.
5. Spark plug too loose or poor seating. Retighten
6. Worn-out cylinder bore. Replace or rebore.
7. Too slowly starter cranking starter motor See electrical section.
Plug not sparking Replace.
1. Damaged spark plug or suppressor cap. Replace.
2. Dirty or fouled spark plug. Clean.
3. Defective CDI & ignition coil unit or stator coil. Replace.
4. Open or short in high-tension cord. Replace.
5. Defective ignition switch. Replace
No fuel reaching to the carburetor
1. Clogged hole in the fuel tank cap. Clean or replace.
2. Clogged or defective fuel cock. Clean or replace.
3. Defective carburetor float valve. Replace.
4. Clogged fuel hose or defective vacuum hose. Clean or replace.
Engine not starts 1. Carbon deposited on the spark plug. Clean.
easily. 2. Defective CDI & ignition coil unit. Replace.
3. Clogged fuel hose. Clean.
4. Clogged jets in carburetor. Clean.
5. Clogged exhaust pipe. Clean.
Noisy engine. Noise appears to come from piston
1. Piston or cylinder worn-out. Replace.
2. Combustion chamber fouled with carbon. Clean.
3. Piston pin, bearing or piston pin bore worn. Replace.
4. Piston rings or ring grooves worn. Replace.
Noise seems to come from crankshaft
1. Worn or burnt crankshaft bearings. Replace.
2. Worn or burnt conrod big-end bearings. Replace.
Noise seems to come from final gear box
1. Gears worn or rubbing. Replace.

2. Badly worn splines. Replace.
3. Worn or damaged bearing of drive shaft or rear axle Replace.
shaft.
Slipping clutch 1. Worn or damaged clutch shoes. Replace.
2. Worn clutch drum. Replace.
Engine idles poorly. 1. Excessively worn cylinder or piston rings. Replace.
2. Sticky piston rings in grooves. Replace or clean.
3. Compression leaks from crankshaft oil seal. Replace.
4. Spark plug gaps too wide. Adjust or replace.
5. Defective CDI & ignition coil unit. Replace.
6. Defective magneto stator coil. Replace.
7. Float-chamber fuel level out of adjustment in carburetor. Replace.
8. Clogged jets in carburetor. Clean or adjust.
9. Broken or damaged reed valve. Replace.
VENTO MOTORCYCLES
Engine runs 1. Excessively worn cylinder or piston rings. Replace.
poorly in 2. Sticky piston ring in grooves. Replace or clean.
high-speed 3. Spark plug gaps too less. Adjust.
range. 4. Ignition not advanced sufficiently due to poorly working Replace.
CDI & ignition coil unit.
6. Float-chamber fuel level too low. Adjust or replace.
7. Clogged air cleaner element. Clean.
8. Clogged fuel hose, resulting in inadequate fuel supply to Clean and prime.
carburetor.
9. Clogged fuel cock vacuum pipe. Clean.
Dirty or heavy 1. Too much “2T” oil into the engine. Check oil pump.
exhaust smoke. 2. Use of incorrect “2T” oil. Change or specified oil.
Engine lacks 1. Excessively worn cylinder or piston rings. Replace.
power. 2. Sticky piston ring in grooves. Replace.
3. Compression leaks from crankshaft oil seals & gaskets. Replace.
4. Spark plug gaps incorrect. Adjust or replace.
5. Clogged air cleaner element. Clean.
6. Float-chamber fuel level out of adjustment. Adjust or replace.
7. Fouled spark plug, Clean.
8. Sucking air from intake pipe. Clean or replace the
9. Slipping or worn V-belt. gaskets.
10. Damaged/worn rollers in the movable drive face. Replace.
11. Weak movable driven face spring. Replace.
12. Too rich fuel/air mixture due to defective starter system. Replace.
Replace.
Engine 1. Heavy carbon deposits on piston crown. Clean.

overheats. 2. Defective oil pump or clogged oil circuit. Replace and clean.
3. Fuel level too low in float chamber. Adjust or replace.
4. Air leakage from intake pipe. Retighten/replace gaskets.
5. Use of incorrect engine oil. Change & use specified oil.
6. Use of incorrect spark plug. Change & use specified.
7. Clogged exhaust pipe/muffler. Clean or replace.
CARBURETOR
Trouble with 1. Starter jet is clogged. Clean.
starting. 2. Air leaking from a joint between starter body and carburetor. Check starter body and
carburetor for tightness,
and replace gasket.
3. Air leaking from carburetor′s joint or vacuum hose joint. Check and replace.
4. Starter plunger is not operating properly. Check and replace.
VENTO MOTORCYCLES
Idling or 1. Pilot jet, pilot air jet are clogged or loose. Check and clean.
low-speed 2. Air leaking from carburetor′s joint, vacuum pipe joint, or Check and replace.
troubles. starter.
3. Pilot outlet is clogged. Check and clean.
4. Starter plunger is not fully close. Check and replace.

Medium- or 1. Main jet or main air jet is clogged. Check and clean.
high-speed 2. Needle jet is clogged. Check and clean.
trouble. 3. Fuel level is improperly set. Check and replace.
4. Throttle valve is not operating Check throttle valve for operation.
properly.
5. Fuel filter is clogged. Check and clean.
Overflow and 1. Needle valve is worn or damaged. Replace.
fuel level 2. Spring in needle valve is broken. Replace.
fluctuations. 3. Float is not working properly. Check and adjust.
4. Foreign material has stucked to Clean.
needle valve.
5. Fuel level is too high or low. Adjust and replace.
ELECTRICAL
No sparking or 1. Defective CDI & ignition coil unit. Replace.
poor sparking. 2. Defective spark plug. Replace.
4. Loose connection of lead wire. Connect/tighten.
Spark plug soon 5. Mixture too rich. Adjust carburetor.
becomes fouled 6. Idling speed too high. Adjust carburetor.
with carbon. 7. Incorrect gasoline. Change & use specified gasoline.
8. Dirty element in air cleaner. Clean.
9. Spark plug loose. use specified plug.
10. Incorrect “2T” oil. Replace & use specified “2T” oil.
Spark plug 1. Spark plug too hot. Replace & use specified plug.
electrodes 2. The engine overheats. Tune up.
overheat or burn. 3. Spark plug loose. Retighten.
4. Mixtures too lean. Adjust carburetor.
5. Not enough engine lubricating oil. Check oil pump.
Magneto does not 1. Open or short in lead wires, or loose lead Repair or retighten.
charge the connections.
battery. 2. Shorted, grounded or open magneto coil. Replace.
3. Shorted or open regulator/rectifier. Replace.
Magneto charge, 1. Lead wires tend to get shorted or open-circuited or Repair or retighten.
but charging rate loosely connected at terminal.
is below the 2. Grounded or open-circuited stator coils of magneto. Replace.
specifications. 3. Defective regulator/rectifier. Replace.
4. Defective cell plates in the battery, Replace the battery.
Magneto 1. Internal short-circuit in the battery. Replace the battery.
overcharges. 2. Resistor element in the regulator/rectifier damaged Replace.
or defective.
3. Regulator/rectifier unit poorly grounded. Clean and tighten ground connection.
VENTO MOTORCYCLES
Unstable 1. Defective regulator/rectifier. Repair or replace.
charging. 2. Lead wire insulation frayed due to Replace.
vibration, resulting in intermittent shorting.
3. Magneto coil internally shorted.
Replace.
Starter button is 1. Run down Battery. Repair or replace.

not effective. 2. Defective switch contacts. Replace.
3. Brushes not seating properly on commutator Repair or replace.
in starter motor.
4. Defective starter relay. Replace.
5. Defective starter pinion gears Replace.
6. Defective front or rear brake light switch Repair or replace.
circuit.
BATTERY
Complaint Remedy
Symptom and possible causes
Battery runs 1. The charging system is not correct. Check the magneto and regulator/rectifier circuit
down quickly. connections, and make necessary adjustments to
obtain specified charging operation.
2. Cell plates have lost much of their active Replace the battery, and correct the charging
material as a result of over-charging. system.
3. A short-circuit condition exists within the
battery due to excessive accumulation of Replace the battery.
sediments caused by the incorrect electrolyte.
4. Battery is too old.
Replace the battery.
VENTO MOTORCYCLES
Reversed battery 1. The battery has been connected the wrong way Replace the battery and be sure to connect the battery
polarity. round in the system, so that it is being charged properly.
in the reverse direction.
Battery 1. Dirty container top and sides. Clean.
discharges too 2. Battery is too old. Replace.
rapidly.
“Sulfation”acidic 1.Cracked battery case Replace the battery.

White powdery
substance or 2.Battery has left in a run-down condition for Replace the battery.
spots on surface a long time.
of cells
Battery 1.Too low or high charging rate. (When battery is not Replace the battery.
“Sulfation” in use should be checked at least once a month to
avoid “Sulfation”.
2.Left unused the battery for too long in cold climate. Replace the battery if badly “Sulfated”.
CHASSIS
Complaint
Remedy
Symptom and possible causes
Handling feels 1. Steering stem nut over tightened. Adjust.
too heavy. 2. Broken bearing/ball/race in steering stem. Replace.
3. Distorted steering stem. Replace.
4. Not enough pressure in tires. Adjust tire pressure.
Wobbly 1. Loss of balance between right and left front Replace.
handlebars. suspension.
2. Distorted front axle or crooked tire. Replace.
Wobbly front
1. Distorted wheel rim. Replace.
wheel.
2. Worn front wheel bearings. Replace.
3. Defective or incorrect tire. Replace.
4. Loose nut on axle. Retighten.
5. Loose nuts on the rear shock. Retighten.
6. Worn engine mounting bushing. Replace.
7. Loose nuts or bolts for engine mounting. Tighten.
Front
1. Weakened springs. Replace.
suspension too
2. Oil leakage of shock absorber, Replace.
soft.
Front
1. Not enough grease, Refill.
suspension too
2. Worn suspension arm spacer, Replace.
stiff.
Noisy front 1. Not enough grease. Refill.
suspension. 2. Loose nuts on suspension. Retighten.
Wobbly rear 1. Distorted wheel rim. Replace.

wheel. 2. Defective or incorrect tire. Replace.
3. Loose nuts on the rear shock absorber. Replace.
4. Worn engine mounting bushing. Replace.
5. Loose nuts or bolts for engine mounting. Retighten.
VENTO MOTORCYCLES
Rear suspension
1. Weakened spring.
too soft. Replace.
2. Oil leakage of rear shock absorber.
Replace.
BRAKES
Insufficient 1. Leakage of brake fluid from hydraulic Repair or replace.
brake power. system.
2. Worn pads. Replace.
3. Oil adhesion on engaging surface of pads. Clean disc and pads.
4. Worn disc. Replace.
5. Air entered into hydraulic system. Bleed air.
6. Worn shoe. Replace.
7. Friction surfaces of shoes are dirty with oil. Replace.
8. Excessively worn drum. Replace.
9. Too much brake lever play. Adjust.
Brake 1. Carbon adhesion on pad surface. Repair surface with sandpaper.
squeaking. 2. Tilted pad. Modify pad fitting or replace.
3. Damaged wheel bearing. Replace.
4. Worn pad or disc. Replace.
5. Foreign material entered into brake fluid. Replace brake fluid.
6. Clogged return port of master cylinder. Disassemble and clean master cylinder.
7. Brake shoe surface glazed. Repair surface with sandpaper,
8. Loose front-wheel axle or rear-wheel axle Tighten to specified torque.
nut. Replace.
9. Worn shoe.
Excessive brake
lever stroke. 1. Air entered into hydraulic system. Bleed air
2. Insufficient brake fluid. Replenish fluid to specified level; bleed air.
3. Improper quality of brake fluid. Replace with specified fluid.
4. Worn brake cam lever. Replace
5. Excessively worn shoes and/or drum. Replace
Leakage of 1. Insufficient tightening of connection joints. Tighten to specified torque.

brake fluid. 2. Cracked hose. Replace.
3. Worn piston seal. Replace piston and/or cup.
VENTO MOTORCYCLES
2.WIRING DIAGRAM OF Zip r3i
VENTO MOTORCYCLES
VENTO MOTORCYCLES
3. WIRE, CABLE AND BRAKE HOSE ROUTING
VENTO MOTORCYCLES
VENTO MOTORCYCLES
4. SPECIAL TOOLS LISTED BELOW FOR REMOVAL AND
REINSTALLATION
DESCRIPTION
NO. TOOL NUMBER
1 T01 “T”shape of sleeve
2 T02 Sleeve tools 7mm,8mm,10mm,12mm,13mm
3 T03 Flywheel remover
4 T04 Sleeve (18mm, 24mm)
5 T05 Screw remover

6 T07 Cylinder pressure gauge
7 T08 Piston pin remover
8 T09 Spark plug remover
9 T10 Flywheel lock bolt remover
10 Clutch clamp
VENTO MOTORCYCLES
VENTO MOTORCYCLES
5. TIGHTENTING TORQUE O F SCREW THREAD PARTS
ENGINE
ITEM N M
Cylinder guide cover tapping screw 1-4
Fan guide cover lock bolt 10-12
Cylinder cover locknut 15-18
Spark plug 15-18
Inlet pipe lock bolt 10-12
Cooling fan impeller lock screw 10-12
Flywheel lock bolt 45-50
Magneto stator coil lock screw 10-12
Magneto exciting lock screw 3-5
Oil pump lock screw 5-9
Right crankcase lock bolt 10-12
Bearing press board lock bolt 10-12
Cylinder double head bolt 15-18
Motor tightening bolt 10-12
Left crankcase cover lock screw 10-12
Left crankcase cover lock bolt 10-12
Main drive wheel face locknut 35-38
Driven wheel face locknut 35-38
Driven wheel face clutch locknut 55-60
Exceeding clutch outside lock screw 10-12
Electrical start idle press board screw 10-12
Gear case lock bolt 10-12
Left crankcase discharging oil hole lock bolt 22-25
Left crankcase positioning pin shaft locknut 18-22
VENTO MOTORCYCLES
6. SERVICE DATA
CYLINDER+PISTON+PISTON RING
Unit mm (inch)
ITEM STANDARD LIMIT
Piston to cylinder clearance 0.06-0.07 0.120
(0.0024-0.0028) (0.0047)
Cylinder bore 40.005-40.020 40.075
(1.5750-1.5756) (1.5778)
Cylinder diameter 39.94-39.955 39.885
(1.5724-1.5746) (1.5703)
Cylinder distortion 0.04
(0.0016)
Cylinder head distortion 0.04
(0.0016)
st
Piston ring free cotter end 1 ring 0.02~0.06mm
nd
clearance 2 ring 0.02~0.06mm
Piston ring close end 0.15-0.35 0.8
clearance (0.0059-0.0138) (0.0315)
st
Piston ring to groove 1 ring 0.02~0.06(0.0008~0.0024)
nd
clearance 2 ring 0.02~0.06(0.0008~0.0024)
Piston pin bore 10.002-10.008 10.030
(0.3938-0.3940) (0.3949)
Piston pin outside diameter 9.994-10.000 9.98
(0.3935-0.3937) (0.3929)
CONNECTING ROD+CRANKSHAFT
ITEM STANDARD LIMIT
Conrod small end 13.995-14.006(0.5510-0.5514) 14.040(0.5528)
Conrod deflection 3.0(0.12)
Conrod web to web width 38-38.1(1.496-1.500)
Crankshaft run out 0.05(0.002)
OIL PUMP
ITEM SPECIFICATION
Pump reduction ratio 30.000(30/1)
VENTO MOTORCYCLES
CCI pump discharge ratio 1.1-1.3ml/5min(working pressure is 0.06Mpa and rotating
(full open) Speed 118 RPM)
VENTO MOTORCYCLES
CLUTCH Unit: mm(inch)
ITEM STANDARD LIMIT

Clutch wheel inner diameter 112.00-112.15(4.410-4.415) 112.5(4.429)
Clutch shoe thickness 1.8(0.071) 1.2(0.005)
Clutch engagement 3000±300 RPM
Clutch lock-up 6000±300 RPM
TRANSMISSION+DRIVE CHAIN UNIT mm(inch) Except Ratio

Item Standard Limit
Final reduction ratio 11.076(48/13×36/12)
Gear reduction ratio (Variable) 2.64~0.86
Drive belt width 16.8-17.2(0.6614-0.6772) 16.4(0.6457)
Driven face spring free 69(2.72) 64.5(2.54)
length
CARBURETOR
Type Side draught vacuum type
Identification code PZ19JB
Throat tube diameter 19mm
Main jet size #80
Pilot jet size #57.5
Needle clamp position 3rd groove from top
Idle air adjusting screw
11 ±1 turnout
2 2
Float height 13±1mm
ELECTRICAL UNIT mm (inch)
ITEM SPECIFICATION NOTE
0
Ignition timing 15 at 5000RPM
Spark plug Type NGK/R/BR8HSA
Gap 0.5~0.7mm 0.020~0.028
Spark performance Over 8 (0.3) at 1 atm
Ignition coil resistance Secondary 12-18KΩ Plug cap-ground
Primary 0.09~0.13 Ω
Magneto coil resistance Lighting <2Ω Green/Red GROUND

Charging <2Ω White Ground
Exciting 200±20Ω at 20 Blue White or Green
White Ground
Generator no-load voltage More than 52 Volt at 5000 RPM
Regulated voltage More than 12-14Volt at 5000 RPM
VENTO MOTORCYCLES
WATTAGE
ITEM STANDARD
Headlight 12V 35W/35W
Low beam 12V 35W/35W
Taillight 12V 21W/5W
Front turn light 12V 5W×2
Rear turn light 12V 5W×2
Turning signal indicator light 12V 3W
High beam indicator light 12V 3W
Meter indicator light 12V 3W
Alarm indicator light Light diode
Light sensor Light diode
Brake and rim

Item Specification Limit
Brake lever play Rear 15-20mm
Hub diameter Rear φ110 mm φ110.7 mm
Brake shoe thickness Rear 1.5 mm
Brake disc thickness Front 4.0±0.2 3.5 mm
Tire size Front/rear 3.50-10
Tire surface thickness Front/rear 1.6 mm
SUSPENSION
Front fork stroke 66 mm Rear shock absorber stroke 45 mm
Tire Pressure
Front tire air pressure 150kpa Rear tire air pressure 200kpa
Fuel and Engine oil

Fuel type Gasoline applied should be graded 85-95 octane or higher.
Unleaded gasoline is recommended.
Fuel tank capacity 5.2L
Engine gear oil GL-5, graded 85W/90
Oil capacity 0.1L
Brake fluid type DOT3 or DOT4
VENTO MOTORCYCLES
VENTO MOTORCYCLES
VENTO MOTORCYCLES
VENTO MOTORCYCLES

ZIP R3i R3 REPAIR MANUAL

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Zip R3i / ZipR3 Service&

Rev no.01/ page 1of 128

Rev no.01/ page 2of 128

• V-belt drive automatic transmission

This manual contains an introductory

Rev no.01/ page 3of 128

PERIODIC MAINTENANCE PROCEDURE 2

FUEL AND LUBRICATION SYSTEM 4

Rev no.01/ page 4of 128

Rev no.01/ page 6of 128

FUEL AND ENGINE OIL RECOMMENDATION

Rev no.01/ page 7of 128

Rev no.01/ page 8of 128

Periodic maintenance and service schedule------------------------------------

Rev no.01/ page 11of 128

PERIODIC MAINTENANCE CHART

Idle speed (rpm) I I I I I

Rev no.01/ page 12of 128

Rev no.01/ page 13of 128

BATTERY CHARGING CIRCUIT TEST

Rev no.01/ page 14of 128

Rev no.01/ page 15of 128

Cylinder head nuts and exhaust pipe

Tighten at Initially 1000 km 630 miles or 2

If cylinder head nuts are not tightened to the

Cylinder head nut 15-18N.m

Exhaust pipe bolt 15-18N.m

Cylinder and cylinder head

Carbon deposits in the combustion chamber and

Rev no.01/ page 17of 128

Rev no.01/ page 18of 128

Remove clamp and screw take out air cleaner

Install Air cleaner in the reverse order of removal.

Rev no.01/ page 19of 128

Adjust the throttle cable play.

Adjust the Idling Screw @ to obtain the Idling RPM as follows:

Idling Speed 1800±100 RPM

Finally adjust the throttle cable play.

Rev no.01/ page 20of 128

Turn the throttle grip full open.

Rev no.01/ page 21of 128

Inspect gear oil periodically as follows:

Front brake fluid level

Specification and classification DOT 3 or DOT4

Rev no.01/ page 22of 128

AIR BLEEDING FORM THE BRAKE FLUID CIRCUIT(FRONT BRAKE)

TIGHTENING TORQUE BLEEDER VALVE: 6-9N.m(0.6-0.9kg-m, 4.5-6.5lb-ft)

BRAKE SHOE WEAR:

Rev no.01/ page 24of 128

Tire treads condition

Inspect at initially 1000 kms 630 miles 2

Steering should be adjusted properly for smooth turning of handlebars

Rev no.01/ page 25of 128

Inspect &Adjust at initially 1000 kms 630 miles 2

REAR SHOCK ABSORBER:

Inspect &Adjust at initially 1000 kms 630 miles 2

CHASSIS BOLTS AND NUTS:

Inspect &Adjust at initially 1000 kms 630 miles 2

1 Front axle nut 37-44 3.7-4.4

2 Steering stem locknut 37-44 3.7-4.4