How to fix EVERYTHING on a 150cc GY6 Chinese scooter 2014 Tao Tao BWS (Yamaha Zuma clone)

Introduction

This tutorial provides a comprehensive guide on inspecting, repairing, and maintaining a 150cc GY6 Chinese scooter, specifically the 2014 Tao Tao BWS model. Whether you’re a beginner or an experienced mechanic, this step-by-step guide will help you understand the common issues and necessary repairs to get your scooter running smoothly.

Chapter 1: Inspection

Start with a thorough inspection of your scooter to identify any existing issues.

• Tires: Check the front and rear tires for tread wear. The front tire should be a Michelin reggae (130/90-10) while the rear may be a Kenda K-413 (also 130/90-10). Replace if worn out.
• Suspension: Look for torn rubber boots on the suspension; they can be replaced easily.
• Brakes: Inspect brake pads and levers. Ensure they have about 50% life left and feel solid when engaged.
• Throttle: Test the throttle by turning it. If it doesn’t snap back, replace the throttle cable.
• Battery: If the scooter didn’t come with a battery, purchase a new one (approx. $28).
• Oil Check: Measure oil level with the dipstick, ensuring the scooter is upright. It should be three-quarters full.

Chapter 2: Replacing the Battery

Replacing the battery is straightforward:

1. Remove the old battery (if applicable).
2. Insert a piece of cardboard under the battery nut for better contact.
3. Connect the new battery’s terminals securely.

Chapter 3: Testing the Scooter

After replacing the battery, check if the scooter runs:

• Start the engine and listen for any unusual sounds (i.e., exhaust leaks).
• Check all lights, including headlights and turn signals.
• Ensure the brake lights work properly.

Chapter 4: Charging System Test

Test the charging system:

1. Measure the battery voltage with the engine off; it should read around 12.6 volts.
2. Rev the engine and check for output between 13-14 volts. If not, further investigation is needed.

Chapter 5: Remove Body Plastic

To access internal components, remove the body plastic:

1. Unscrew the seat and remove the seat compartment.
2. Carefully detach body panels, noting the locations of all screws.

Chapter 6: Carburetor Inspection

Inspect the carburetor for proper function:

• Check the throttle cable connection; if it’s stuck, replace it.
• Clean and inspect the carburetor jets for clogs.
• Ensure all hoses are connected properly, especially the vacuum hoses.

Chapter 7: CVT Inspection

Inspect the continuously variable transmission (CVT):

1. Remove the CVT cover and inspect the belt for wear (cracks or glazing).
2. Check the variator and rollers for damage; replace if necessary.

Chapter 8: Replace Drive Belt and Variator

If the drive belt or variator needs replacement:

1. Remove the old belt and variator.
2. Install the new variator and belt, ensuring correct alignment.
3. Use Loctite on the variator nut and torque to 36 foot-pounds.

Chapter 9: Adjust Valves

Ensure the valves are properly adjusted:

1. Remove the valve cover and check the gap using a feeler gauge.
2. Adjust the clearance to 0.004 inches for intake and 0.005 inches for exhaust.

Chapter 10: Brake System Maintenance

Maintain the brake system:

1. Bleed the front brake to remove air bubbles.
2. Inspect and replace worn brake pads as necessary.

Chapter 11: Replace Headlight Bulbs

If your headlights are dim or burnt out:

1. Remove the headlight assembly and replace bulbs.
2. Consider upgrading to LED bulbs for better performance.

Chapter 12: Final Assembly

Reassemble the scooter:

1. Replace all body panels, ensuring all screws are tight.
2. Double-check all connections, especially electrical ones.

Conclusion

By following these steps, you can effectively inspect and repair your 150cc GY6 Chinese scooter, ensuring it runs efficiently. Remember to keep a log of all repairs and maintenance for future reference. If issues persist, consider consulting a professional for further diagnosis. Happy riding!