Pit Bike Repair/Parts Manuals / Exploded views

[sean01]

Ok this seems to be happening a lot lately.
Many users are asking for manuals and exploded views of engines. And since pbk inspired me lol, i thought id start a thread so we can list all the engines manuals and what not..

I've included some of the wiring diagrams, carby and suspension manuals too.

please note that most these links are online PDF's so give them time to load

most of this info available here - Video/Downloads - DHZ Mini Moto here Manuals and Guides : Elstar Products, Factory-tuned Racing Motorbikes ATV (Quad Bikes), aftersale support, spare parts and accessories. An agent for Apollo motorbikes, Orion, Elstar Motorbikes Shineray. High-quality parts by FastAce, Motul, RK, Ariet and here Pitbike - Reservdelar & manualer
the DHZ link even includes some of the DHZ bike assembly manuals
but for those can cant search for this stuff, here it is again.

SERVICE MANUALS

THUMPSTAR manual - Thumpstar 125cc Engine Parts list

Kawasaki KLX110 - http://boss.csteam.free.fr/Moto/SM_KLX110-A1.PDF

ENGINES

Zongshen Z155 Manual / Exploded View - http://www.dhz.com.au/assets/usermanual/ZS-155CC-engine-diagram.pdf

Zongshen z160HO Manual / Exploded view - http://www.dhz.com.au/assets/usermanual/OUTLAW160R_z160HO_Engine_Diagram.pdf
PITSTER 150 HO ENGINE BREAKDOWN

Zongshen 140 Manual / Exploded view - http://www.dhz.com.au/assets/usermanual/ZS_ENGINE_DIAGRAM.pdf (same as yx140)

Lifan 140 Manual / Exploded view - http://www.dhz.com.au/assets/usermanual/1P55FMJ.pdf
wiring diagram - http://www.dhz.com.au/assets/usermanual/Wiring_Diagrams.jpg

Lifan 150 Manual / Exploded view - http://www.scribd.com/doc/45930284/Lifan-150cc-parts-list

Lifan / Ducar (Shineray) / Loncin 125 (including lifan type R) kick start only crank mounted clutch engines Manual / Exploded view - http://www.dhz.com.au/assets/usermanual/1P52FMI.pdf (should be same for all crank mounted clutch engines)

YX / GPX 125 manual / exploded view - http://www.scribd.com/doc/45930485/YX-125-140-parts-list

Daytona 115 / 125 Manual / Exploded view - http://www.scribd.com/doc/45930278/Daytona-115-125-119cc-Engines-parts-list

Daytona 150 Manual / Exploded view - owners manualhttp://daytona-global.com/products/pdf/84346.pdf

Jialing 125 Manual / Exploded view (same as most 125 engines) - http://www.scribd.com/doc/45930295/PITPRO-125cc-parts-list

Jialing 107 (110) 3 Valve manual / exploded view - http://www.scribd.com/doc/45930290/PITPRO-107cc-3-valve-Parts-list

Honda crf50 manual / exploded view - HONDA CRF50 Technical Drawings

WIRING

Genuine KLX wiring diagram (extracted from the manual) - http://img413.imageshack.us/img413/9641/genklxwiring.jpg
2010/2011 models http://www.tradebit.com/usr/ridered-atc-atv/pub/9003/10-11klx110_wiring.pdf

Zongshen z160HO wiring diagram - http://www.dhz.com.au/assets/usermanual/wiring_diagram_z160.pdf

Lifan 150 ORK / outer rotor kit - TBolt USA, LLC

Inner rotor / IRK diagram - http://www.elstars.com.au/products/images/large/rk-in_02.jpg

Several wiring diagrams (bottom image for most bikes) - Hopper Wiring Diagrams Hooper Imports Experts on Chinese Motorcycles and Parts, Engines

Standard 110 / 125 / 138 wiring diagram - http://www.dhz.com.au/assets/usermanual/Wiring_Diagrams.jpg

CARB

Keihin PWK (99% same as OKO) parts list / exploded view - http://keihin-us.com/am/_media/pdf/pwk_parts.pdf
http://scootrs.com/images/pwk-type.png

Keihin PE series parts list / exploded view - http://www.sudco.com/Diagrams123/exppe.gif

Mikuni VM series (similar to chinese mikuni carb) manual / parts list / exploded view - http://www.mikuni.com/pdf/vmmanual.pdf

Mikuni TM series parts list / exploded view - Sudco - Mikuni TM Carburetor Parts
http://www.sudco.com/Diagrams323728/exptm.gif

SUSPENSION

FASTACE Catalog 2008 - http://www.elstars.com.au/pdf/manual/auth/fastace_catalog-2008.pdf

FASTACE Catalog 2009 - http://www.elstars.com.au/pdf/manual/auth/fastace_catalog-2009.pdf

FASTACE AS02 / AS-02 USD forks manual - http://www.scribd.com/doc/45930621/FastAce-Forks-AS02-Service-Manual

ELKA MiniSeries 50 manual - http://www.scribd.com/doc/45930736/ELKA-Suspension-MiniSeries-50-Owners-Service-Manual

Marzocchi Shiver 35mmm manual / exploded view - http://www.scribd.com/doc/45931099/Marzocchi-Shiver-35-Factory-Works-Exploded-diagramf
parts list - http://www.scribd.com/doc/45931013/Marzocchi-Shiver-35-Forks-parts-list

for anything your looking for or maybe links above have gone dead check this scribd page out that someone has compiled.. http://www.scribd.com/MinibikeTech

im still adding to the list, as its hard to locate all the diagrams/manuals.

if anyone has anything they'd like to add, PM me or post it up and ill include it..

also iv tried to make it site search friendly with certain wording/spacing..

also id like to thank ken from DHZ for updating his site and including some of the information. i'm actually going to email him requesting for a couple more of the much needed manuals/exploded views..(mainly suspension).

 

[cbinvb]

Kudos.

Top of my bookmark list.

 

[pbk]

thanks for the mention lol

yes indeed a freakin good thread, this should be stickied ASAP!

 

[MuckUte]

Definately worth a sticky :clap:

 

[I_THUMP]

Top job putting all those links in one place.

+Reps and a sticky for you :grinning-smiley-003

 

[jordancurrie]

yeah definately +reps mate, top job, just goes to show the commitment of the members in this community, no one HAS TO do a review, or do a tutorial, or anything... but they take the time and do stuff like this! Great stuff mate.
________
OUTDOOR TUBES

 

[sean01]

yep well i spose it was another topic that was well over due..

cheers for the replies and the sticky

 

[JTS]

Thanks for the Parts Books they have been helpful

 

[ben.a.]

"The document 'YX.GPX engine exploded diagram' has been deleted"

If someone else has this stored localled, I'd be happy to host it so everyone else can access it.

 

[sean01]

"The document 'YX.GPX engine exploded diagram' has been deleted"

If someone else has this stored localled, I'd be happy to host it so everyone else can access it.

iv updated it with an alternative... these engines are 99% the same from style to style..

grabbed it from here MinibikeTech on Scribd | Scribd

 

[Shearer]

thats great always handy to have manuel to SERVICE MANUALS. to keep ya minibike running sweet!

 

[youbet5]

i cant get the Jialing 107 (110) 3 Valve manual exploded view to load. is there any other way to get to it?

 

[sean01]

i cant get the Jialing 107 (110) 3 Valve manual exploded view to load. is there any other way to get to it?

yeah ill have to try and find another one
what part of the 3 valve engine are you working on?? from the barrel down should be same as a 125 engine in the same style

 

[youbet5]

im working on the transmission. and i cant get the 125 to pop up either.

 

[sean01]

im working on the transmission. and i cant get the 125 to pop up either.

ok iv fixed a lot of the dead links now, even the 107 3 valve one is back alive...
but for the record, pretty much all these gearboxs are the same with the exception of shaft sizes and gear drum configuration..

 

[themountain]

FASTACE AS02 / AS-02 USD forks manual - FastAce Forks AS02 Manual
.

Thats deleted:thumbdown:

 

[sean01]

Thats deleted:thumbdown:

fixed ....................

 

[themountain]

You´re the man!!

 

[wogtaz ryder]

Awesome thread , really needed this today lol..

 

[Hillz]

real men dont need instructions