Installing the A35 70cc Performance Kit

A basic metric tool kit is required including a 10lb.ft torque wrench.

Turn off the gas valve.

Remove right side cover, exhaust and foot peg.

Loosen the throttle cable screw.

Disconnect fuel line.

Remove the air filter.

Loosen the clamp and remove carb.

Remove the two screws in the top of carb.

Lift cover and remove throttle plate.

Disconnect throttle cable.

Remove head bolt nuts and washers.

Remove head.

Gently pry cylinder away from crankcase.

Remove cylinder.

Remove circlip from piston and slide out piston pin.

Place a rag into the hole to collect debris as you clean the mating surfaces.

Oil the piston pin bearing.

70cc piston<<< >>>49cc piston.

The arrow on the piston points DOWN!

Note: The engine will run with the arrow up albeit very poorly.

Install the new ring on the new piston.

LINE UP THE RING GAP WITH THE PIN IN THE RING GROOVE!!!!

Install circlip in away side of piston.

Place new piston on rod.

Oil piston pin and insert.

Install circlip in near side of piston.

Inspect both circlips to ensure they are seated in the groove.

Place gasket on cylinder.

Oil cylinder and piston.

Squeeze ring together with fingers.

RING GAP MUST BE LINED UP WITH PIN IN RING GROOVE!!!!

Gently slide piston into cylinder.

Gently push cylinder toward crankcase.

Install head gasket onto studs.

Install head, tighten head nuts EVENLY!

Torque head nuts to 10lb.ft.

Install oil injection banjo onto new intake manifold.

Install manifold to head with new gasket.

Good time to change your transmission oil.

Remove filler plug, level plug and drain plug.

Reinstall drain plug.

Fill transmission until oil runs out of level plug hole.

Reinstall level plug and filler plug.

SAE Type F (Ford ATF) = sharp quick shift.

SAE 30 = higher smoother shift.

You can experiment with these oils or mix them to get the shift you want.

Install new exhaust.

High temp silicone will help seal two piece exhaust systems.

This step is not required however should you desire to check the main jet size this is the procedure.

Throttle cable connection.

Choke cable connection.

Carb installed.

Use a dremmel tool to cut the side cover to fit.

Reinstall foot peg.

Add two full caps of two stroke oil to the gas tank.

Start the engine.

Check the oil injection system for proper operation.

Adjust the carb as required.

City Moped 2010 June, 2010