Free workshop printables
Sheets you can print, take to the garage, and use with no signal
Every one of these is a PDF, free, with no account, no email and no download wall. They are built for the machine in front of you rather than for a catalogue that does not cover it — record sheets, true-size gauges, diagnostic chains and checklists.
- Sheets
- 81
- Printed pages
- 342
- Formats
- Letter + A4
- Price
- Free
The packs
Several sheets assembled into one PDF, for a job that takes a whole day or a machine you are driving across a county to see. Everything inside them is also free on its own.
- The Used Scooter Inspection PackEverything for buying a used Chinese scooter, from the first phone call to the first week of ownership. Five sheets, one print job.5 sheets · 15 pp
- The GY6 Workshop PackIdentification, transmission measurement, service records and the two diagnostic chains that cover most no-start faults. Seven sheets.7 sheets · 21 pp
- The Part Measurement PackEverything for identifying and measuring a part you cannot name, and checking the replacement before you fit it. Six sheets with true-size scales throughout.6 sheets · 17 pp
- The Electrical Fault-Finding PackBattery, charging, starter, fuses and wiring, in the order that finds the fault cheapest first. Four sheets and a meter.4 sheets · 12 pp
- The CVT Overhaul PackDiagnose it, measure everything that comes out, and record what goes back in. Four sheets for the system that wears fastest.4 sheets · 13 pp
- The Brake Service PackMeasure the pads, identify the shoes, find out why it drags, and keep the record. Four sheets with true-size instruments throughout.4 sheets · 13 pp
- The Complete Owner's Workshop PackFifteen sheets covering the whole arc of owning one of these machines — identify it, measure it, record it, diagnose it, buy for it. One print job.15 sheets · 44 pp
Start here
If you only ever print two single sheets, print these two.
Before you order a scooter part: checklistTwelve checks that take ten minutes and prevent the single most common expensive mistake these machines produce.
What scooter do I actually have?A one-sheet record of every number that identifies your machine — badge, VIN, engine number, engine family and factory. Fill it in once, photograph it, and never hunt for it again.Identify your machine
Work out what you actually own when the badge is meaningless and the paperwork has gone. All 11 sheets
- What scooter do I actually have?A one-sheet record of every number that identifies your machine — badge, VIN, engine number, engine family and factory. Fill it in once, photograph it, and never hunt for it again.PDF · 6 pp · Letter & A4
- Where is the VIN on a Chinese scooter?A search checklist for the VIN, frame number, engine number and emission label — including the places people look last and should look first.PDF · 3 pp · Letter & A4
- GY6 engine identification chart and worksheetThe measurements and observations that tell you which engine you have when the label is gone — recorded in the order a parts supplier will ask for them.PDF · 3 pp · Letter & A4
- Short case or long case? How to tell, and why it decides everythingOne measurement and one count decide which drive belt, which wheel and which brake your engine takes. Take them before you shop, not after.PDF · 3 pp · Letter & A4
- How to read a Chinese scooter VIN, character by characterWhat each of the seventeen characters means under US federal rules, and the two traps that make a motorcycle VIN harder to read than a car one.PDF · 3 pp · Letter & A4
- What the engine code on your crankcase meansEvery character in the code stamped on your crankcase, what it means, and why 139QMB and 1P39QMB are the same engine.PDF · 3 pp · Letter & A4
- What size engine do I actually have?The speedometer, the sticker and the title can all be wrong. The crankcase is not. How to settle displacement from physical evidence.PDF · 3 pp · Letter & A4
- Where is the emission label? Sorted by body styleThe most useful label on the machine, organised by what shape your machine is rather than by what it says on the bodywork.PDF · 3 pp · Letter & A4
- How to take a rubbing of a frame or engine numberWhen a stamping will not photograph and will not read, take a rubbing. It works when your eyes and your phone both fail.PDF · 3 pp · Letter & A4
- Badge twins: the other names your scooter was sold underThe same machine was sold under other names. Those names are extra search terms, and this is where you write them down.PDF · 2 pp · Letter & A4
- Is my scooter a two-stroke or a four-stroke?The question everything else depends on, settled from six things you can see without tools. Plus air-cooled or liquid-cooled while you are there.PDF · 2 pp · Letter & A4
Measure parts
True-size gauges and record sheets for the measurements a seller will ask you for. All 22 sheets
- Mystery part measurement sheetYou are holding a part. Nobody knows what it is called. This sheet records everything a supplier needs in order to find it for you.PDF · 3 pp · Letter & A4
- GY6 belt size chart and measuring sheetHow to read the three numbers printed on a scooter drive belt, how to measure a belt that has no readable markings left, and a record sheet for the one you have.PDF · 3 pp · Letter & A4
- Variator roller size chart and measuring sheetDiameter, width and weight are three separate things, and a roller set is only interchangeable on all three. A record sheet with true-size circles and a weighing block.PDF · 3 pp · Letter & A4
- Scooter brake pad measurement and tracing cardChinese scooter pads are sold by shape, not by model. Trace yours, measure four dimensions, and compare against the listing photograph before you buy.PDF · 3 pp · Letter & A4
- Chinese scooter bolt, thread and spanner cardWhy an 8mm bolt sometimes takes a 12mm spanner and sometimes a 13mm, how to identify a thread without a gauge, and a true-size thread pitch scale.PDF · 2 pp · Letter & A4
- Scooter tyre size decoder and record sheetEvery field on a scooter tyre sidewall, what it means, and a record block for the sizes currently fitted to your machine.PDF · 3 pp · Letter & A4
- Wheel bolt pattern measuring templateMeasure a bolt circle without a special tool, including the odd-numbered patterns where measuring across two holes does not work.PDF · 3 pp · Letter & A4
- Old part vs new part comparison sheetThe five minutes that stop a return. Check the new part against the old one before you fit anything, while it is still returnable.PDF · 3 pp · Letter & A4
- Wheel bearing size chart and reverse lookupMeasure bore, outside diameter and width, read the bearing number off the table. Works without knowing what the machine is.PDF · 3 pp · Letter & A4
- How to measure and identify a Chinese scooter carburettorCarburettors are sold by a bore size and a family name that nobody explains. Measure yours and record the fittings before you order one.PDF · 3 pp · Letter & A4
- How to measure ATV and go-kart chain and sprocketsChain pitch is a real published standard, so this one can be measured exactly. Count, measure and record before you order.PDF · 2 pp · Letter & A4
- How to measure a scooter throttle or brake cableTwo numbers, not one. The community disagrees about correct lengths, so this sheet teaches the measurement instead of quoting a figure.PDF · 2 pp · Letter & A4
- Brake pad measuring board — read all four dimensions at oncePush the pad into the corner and read all four dimensions off the page. Built because look-alike pads differ by millimetres and no photograph shows it.PDF · 3 pp · Letter & A4
- Brake shoe arc template — which drum size do you have?True-size arcs at the two drum diameters the owner community reports. Lay the shoe on the page and see which one it belongs to.PDF · 3 pp · Letter & A4
- Oil seal size reverse lookup for scooters and ATVsSeals are described by three numbers and nothing else. Measure them and buy from a bearing factor rather than a scooter shop.PDF · 2 pp · Letter & A4
- How to measure a scooter or ATV air filterFilters are sold by shape and dimension, never by model. Four measurements and a fitting type settle it.PDF · 2 pp · Letter & A4
- Measuring exhaust stud spacing and port sizeStud spacing and port bore decide whether an exhaust bolts on. Measure both against a true-size grid before ordering.PDF · 3 pp · Letter & A4
- How to measure a scooter intake manifoldThe rubber part between the carburettor and the head, and the four dimensions that decide whether a replacement will do the job.PDF · 2 pp · Letter & A4
- How to measure a spark plug's thread, reach and seatThread diameter, reach and seat type decide whether a plug is safe to fit. All three are measurable, and none of them is the heat range.PDF · 2 pp · Letter & A4
- How to measure a scooter clutch and clutch bellThe half of the CVT that gets blamed on the belt. Four measurements and a wear inspection, with true-size circles for the bell.PDF · 3 pp · Letter & A4
- How to measure a scooter shock absorber and forksEye to eye, mount type and fork dimensions. Four numbers that let you order suspension without a model number.PDF · 3 pp · Letter & A4
- Scooter mirror thread size and the reverse-thread trapTwo common sizes, and one trap that catches everybody. A five-second test settles which you have.PDF · 2 pp · Letter & A4
Maintenance and records
Logs and checklists that turn a machine with no history into one with a history. All 13 sheets
- GY6 maintenance schedule and service logA service record you build yourself from what your machine actually needs, rather than from a schedule invented for a machine nobody can identify.PDF · 6 pp · Letter & A4
- Chinese scooter storage and recommissioning checklistPutting a machine away for months, and getting it back out again. The second list is the one people forget they need.PDF · 3 pp · Letter & A4
- Spark plug record and reading logThe plug is the cheapest diagnostic instrument on the machine. A record of what it looked like each time turns it into a trend rather than a guess.PDF · 3 pp · Letter & A4
- Pre-ride check card for a Chinese scooter or mopedSixty seconds before you set off, on a card small enough to leave in the storage bin. Written for the faults these machines actually develop.PDF · 3 pp · Letter & A4
- CVT service record for a GY6 or Chinese scooterThe transmission is the highest-wear system on a scooter and the least documented. One sheet for everything that goes in it, with the measurements taken each time.PDF · 3 pp · Letter & A4
- Parts that fitted: the log worth keeping for a Chinese scooterThe single most valuable page you can keep for one of these machines. What you bought, from where, and whether it actually went on.PDF · 3 pp · Letter & A4
- GY6 valve clearance check and recordThe check the most experienced owners do first when one of these runs badly — recorded, without a target figure we cannot source.PDF · 2 pp · Letter & A4
- Scooter compression test logOne reading tells you little. Four over a year tell you whether the engine is going backwards, and how fast.PDF · 2 pp · Letter & A4
- Scooter brake service recordWhat was fitted, what it measured when it came off, and how long it lasted. For the system where guessing is least acceptable.PDF · 3 pp · Letter & A4
- Scooter tyre record and pressure logSmall tyres hide low pressure well, and low pressure costs speed and eats fuel. One page, checked monthly.PDF · 2 pp · Letter & A4
- Scooter coolant system record and checksFor liquid-cooled machines only. Level, condition, and the fan test almost nobody does until it is too late.PDF · 2 pp · Letter & A4
- Scooter seasonal maintenance plannerA year on one page, built from your own intervals rather than from a schedule invented for a machine nobody can identify.PDF · 3 pp · Letter & A4
- Scooter fastener torque recordPublished torque figures for these machines conflict. This records what you set, and where the figure came from, so the next person is not guessing.PDF · 2 pp · Letter & A4
Troubleshooting
Structured diagnostic sheets that end at an observation you can make, not a part to buy. All 13 sheets
- Chinese scooter won't start: diagnostic chartA structured way through the four things an engine needs, ending at an observation you can make rather than a part you should buy.PDF · 3 pp · Letter & A4
- GY6 no spark diagnostic chartWorking back along the ignition circuit from the plug, one component at a time, without replacing anything on spec.PDF · 3 pp · Letter & A4
- Chinese scooter vacuum hose and fuel line worksheetDraw your own routing before you take it apart. There is no single correct diagram for these machines, and the only one that matters is yours.PDF · 3 pp · Letter & A4
- GY6 starts then dies, or will not idleIt fires, runs for a few seconds and stops. Or it only idles with the throttle cracked open. Four causes account for most of it.PDF · 3 pp · Letter & A4
- GY6 poor acceleration and no top speedIt runs, but it will not pull. The first question separates a transmission fault from an engine fault, and almost nobody asks it.PDF · 3 pp · Letter & A4
- GY6 CVT slipping, juddering and squealingThree different noises from the same case, and they mean different things. What to look at with the cover off, in order.PDF · 3 pp · Letter & A4
- Chinese scooter overheating and running hotAir-cooled engines depend on shrouding and oil more than owners expect. A relative test, because the published temperature figures contradict each other.PDF · 3 pp · Letter & A4
- GY6 belt keeps breaking — what is destroying itA belt that fails repeatedly is not a bad belt. Something is destroying it, and it is usually one of six things.PDF · 3 pp · Letter & A4
- Scooter smoking: what blue, white and black each meanThree colours, three quite different faults. And on a two-stroke, some smoke is meant to be there.PDF · 3 pp · Letter & A4
- Scooter fault log — the record that makes diagnosis possibleThe sheet that makes every other diagnostic better. What happened, under what conditions, and what had changed just before.PDF · 3 pp · Letter & A4
- Scooter brakes dragging or bindingA wheel that will not spin freely costs speed and fuel and makes heat. Six causes, each ending at something you can feel or see.PDF · 3 pp · Letter & A4
- Scooter runs then dies after a few minutesIt starts, runs beautifully, and stops. One free test finds the commonest cause, and almost nobody knows to do it.PDF · 3 pp · Letter & A4
- GY6 backfiring and popping on the overrunA pop in the exhaust and a bang through the carburettor are two different faults. Which one you have narrows it immediately.PDF · 3 pp · Letter & A4
Electrical and wiring
Meter readings, connector maps and wire traces, recorded on paper where they belong. All 8 sheets
- GY6 wiring colour and continuity notes sheetThere is no universal wiring colour standard on these machines. This sheet records the one your machine actually uses.PDF · 3 pp · Letter & A4
- Battery and charging system test sheetThree voltage readings diagnose most electrical faults on these machines. Two thresholds are sourced; the rest is direction of change.PDF · 3 pp · Letter & A4
- Scooter starter clicks but will not turn overOne mechanical check first, then three electrical ones. The click itself tells you more than most people realise.PDF · 2 pp · Letter & A4
- Scooter fuse record and circuit mapWhat fuse protects what, on a machine whose wiring diagram does not match anybody else's. Plus the blade fuse colours, from the manufacturers' datasheets.PDF · 3 pp · Letter & A4
- GY6 CDI connector pinout — map your ownMap your own connector with a meter, because there is no universal pinout and every chart you will find contradicts another.PDF · 3 pp · Letter & A4
- Scooter earth and ground connection checklistA corroded earth produces the same symptoms as a dead ignition component, and costs nothing to fix. Check these before buying anything.PDF · 3 pp · Letter & A4
- Testing a scooter stator and regulator without a spec sheetOpen, shorted, or plausible. Three states that need no reference figure and catch most real failures.PDF · 2 pp · Letter & A4
- Scooter lights not workingOne light or all of them is the first question, and it splits the fault before you touch anything.PDF · 3 pp · Letter & A4
Complete packs
The sheets that belong together, assembled into a single PDF for a job that takes a whole day. All 7 sheets
- The Used Scooter Inspection PackEverything for buying a used Chinese scooter, from the first phone call to the first week of ownership. Five sheets, one print job.PDF · 15 pp · Letter & A4
- The GY6 Workshop PackIdentification, transmission measurement, service records and the two diagnostic chains that cover most no-start faults. Seven sheets.PDF · 21 pp · Letter & A4
- The Part Measurement PackEverything for identifying and measuring a part you cannot name, and checking the replacement before you fit it. Six sheets with true-size scales throughout.PDF · 17 pp · Letter & A4
- The Electrical Fault-Finding PackBattery, charging, starter, fuses and wiring, in the order that finds the fault cheapest first. Four sheets and a meter.PDF · 12 pp · Letter & A4
- The CVT Overhaul PackDiagnose it, measure everything that comes out, and record what goes back in. Four sheets for the system that wears fastest.PDF · 13 pp · Letter & A4
- The Brake Service PackMeasure the pads, identify the shoes, find out why it drags, and keep the record. Four sheets with true-size instruments throughout.PDF · 13 pp · Letter & A4
- The Complete Owner's Workshop PackFifteen sheets covering the whole arc of owning one of these machines — identify it, measure it, record it, diagnose it, buy for it. One print job.PDF · 44 pp · Letter & A4
Buying and ordering
What to check before you hand money over, and before you click buy on a part. All 7 sheets
- Used Chinese scooter inspection checklistWhat to check before handing over money, in the order you can check it, including the paperwork problems specific to these machines.PDF · 3 pp · Letter & A4
- Before you order a scooter part: checklistTwelve checks that take ten minutes and prevent the single most common expensive mistake these machines produce.PDF · 2 pp · Letter & A4
- First day with a used Chinese scooterWhat to do in the first hours, before spending money on anything. Most of it costs nothing and all of it saves money later.PDF · 2 pp · Letter & A4
- What to ask a seller before you go and look at a scooterTwelve questions and one photo request that decide whether a machine is worth driving across the county to see.PDF · 3 pp · Letter & A4
- Comparing scooter parts suppliersPrice is the least important column. Whether they will answer a dimension question is the most important one.PDF · 2 pp · Letter & A4
- Scooter parts order and returns recordWhat you ordered, when the window closes, and where the evidence is if it has to go back.PDF · 2 pp · Letter & A4
- Selling a Chinese scooter: preparation and handoverWhat to gather, what to hand over, and what to remove. A machine with a documented history sells for more and argues less.PDF · 3 pp · Letter & A4
What is cited, and how firmly
Three tiers appear on these sheets, and the wording on the page always tells you which one you are reading. Regulation is quoted. A published standard is stated with the standard named. Anything that could only be traced to trade and owner-community usage is labelled as a convention, never as a specification.
- Regulation49 CFR Part 565 — Vehicle Identification Number Requirements
- VIN structure, check digit, excluded characters, model-year cycle, low-volume manufacturers
- Regulation49 CFR 567.4 — Content and location of the certification label
- Where the certification label carrying the VIN must be fitted on a motorcycle
- Regulation49 CFR 571.3 — Definitions
- The federal definition of a motorcycle, and the absence of any federal definition of a moped
- StandardISO 15 — Rolling bearings, radial bearings, boundary dimensions
- Bore, outside diameter and width of the 6000, 6200 and 6300 deep-groove series
- StandardISO 261 — ISO general purpose metric screw threads, general plan
- Coarse thread pitches for M5 to M14
- StandardDIN 933 / ISO 4014 and JIS B1180
- The two hex head across-flats conventions, and why they differ on M8 and above
- Single expert authorThe 49ccScoot FAQ
- The rich-versus-lean symptom split, cranking compression benchmarks, slow-launch diagnosis and the parasitic draw figure. The most internally consistent single source we found for these engines — but one author's experience, not a manufacturer document, and labelled as such wherever it appears.
- ManufacturerRolls Battery — voltage readings and state of charge
- Rested lead-acid voltage. Only the fully-charged row is an open-circuit figure, which is why the sheet prints two thresholds rather than a percentage table.
- ManufacturerLittelfuse ATO and Eaton Bussmann ATC datasheets
- Blade fuse rating-to-colour, built to SAE J1284 / ISO 8820-3 / JASO 612. Ratings above 25A are omitted from the sheet because their colours could not be verified to a datasheet.
- ConventionOwner community consensus
- Engine designation scheme, the P prefix, the short-case and long-case split, belt and roller marking conventions. Consistent across multiple independent owner forums and retailers, but with no standards document behind it — labelled as convention wherever it appears.
Elsewhere on the registry
- Printable measuring gaugesBelts, rollers, carburettor spigots, bolt patterns
- Identify your machineFrom an engine family, a VIN prefix or a badge
- Identification guidesHow to read the numbers you have found
- BlogWhat the certification record shows