Generic Onyx 50 Service Manual

Page 1

Service Manual

Holtvej 8-10, Høruphav, 6470 Sydals Telefon: +45 73 15 11 00 Fax: +45 73 15 11 01 info@scanmi.dk · www.scanmi.dk CVR: 27 73 31 07 www.genericmotor.dk

Juli 2011

ONYX 50

Page 2

ONYX

Service Manual

Generic Motor GmbH

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Contents

Contents................................................................................................................................................ - 1 -

Preface.................................................................................................................................................. - 7 -

Preparing documents....................................................................................................................... - 8 -

Inspection/Adjustment................................................................................................................... - 38 -

Inspection and maintenance of electrical system...................................................................................... - 53 -

1. Battery/charging system.................................................................................................................... - 55 -

1.1 Preparing documents ............................................................................................................... - 55 -

1.2 Failure diagnosis ..................................................................................................................... - 56 -

1.3 Battery ................................................................................................................................... - 57 -

1.4 Charging system...................................................................................................................... - 58 -

1.5 Rectifier ................................................................................................................................. - 59 -

1.6 Magnetor charging coil ............................................................................................................ - 60 -

1.7 Replacement of magnetor......................................................................................................... - 61 -

2. Ignition system................................................................................................................................. - 64 -

2.1 Preparing documents ............................................................................................................... - 64 -

2.2 Failure diagnosis ..................................................................................................................... - 65 -

2.3 Checking the ignition system.................................................................................................... - 66 -

2.4 CDI Group.............................................................................................................................. - 68 -

2.5 Ignition coil ............................................................................................................................ - 69 -

2.6 Trigger ................................................................................................................................... - 70 -

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3. Activation system ............................................................................................................................. - 72 -

3.1 Preparing documents ............................................................................................................... - 72 -

3.2 Failure diagnosis ..................................................................................................................... - 73 -

3.3 Starting motor ......................................................................................................................... - 73 -

3.4 Starting relay .......................................................................................................................... - 75 -

4. Bulbs/Switches/Meters...................................................................................................................... - 79 -

4.1 Preparing documents ............................................................................................................... - 79 -

4.2 Failure diagnosis ..................................................................................................................... - 79 -

4.3 Headlight bulb replacement...................................................................................................... - 79 -

4.4 Front turn signal lamp bulb replacement .................................................................................... - 80 -

4.5 Taillight/Rear turn signal lamp replacement................................................................................ - 80 -

4.6 Meters.................................................................................................................................... - 81 -

4.7 Main switches......................................................................................................................... - 81 -

4.8 Speakers................................................................................................................................. - 81 -

4.9 Combined switch..................................................................................................................... - 82 -

Examination and maintenance of chassis................................................................................................ - 83 -

5. Brake .............................................................................................................................................. - 86 -

5.1 Maintenance instruction ........................................................................................................... - 86 -

5.2 Failure Diagnosis .................................................................................................................... - 87 -

5.3 Front fluid brake...................................................................................................................... - 87 -

5. 4 Rear drum brake..................................................................................................................... - 89 -

6. Body panel ...................................................................................................................................... - 93 -

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7.Front wheel/front suspension.............................................................................................................. - 97 -

7.1 Preparation documents............................................................................................................. - 97 -

7.2 Failure diagnosis ..................................................................................................................... - 98 -

7.3 Front wheel............................................................................................................................. - 98 -

7.4 Steering handle ..................................................................................................................... - 100 -

7.5 Front fork ............................................................................................................................. - 101 -

8.Rearwheel/rear suspension ............................................................................................................... - 106 -

8.1 Preparing documents ............................................................................................................. - 106 -

8.2 Failure diagnosis ................................................................................................................... - 106 -

8.3 Rear wheel............................................................................................................................ - 107 -

8.4 Rear shock absorber............................................................................................................... - 108 -

9.Fuel tank/seat.................................................................................................................................. - 114 -

9.1 Preparation documents........................................................................................................... - 114 -

9.2 Failure diagnosis ................................................................................................................... - 114 -

9.3 Fuel tank/seat........................................................................................................................ - 115 -

10.Removal / installation of motor....................................................................................................... - 117 -

10.1 Preparation documents ......................................................................................................... - 117 -

10.2 Failure diagnosis ................................................................................................................. - 117 -

10.3 Removal of motor................................................................................................................ - 118 -

10.4 Installation of motor............................................................................................................. - 119 -

Inspection and maintenance of motor ................................................................................................... - 120 -

11.Lubricaiton system ........................................................................................................................ - 122 -

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11.1 Preparation documents ......................................................................................................... - 122 -

11.2 Failure diagnosis..................................................................................................................- 122 -

11.3 Machine oil pump................................................................................................................ - 123 -

12.Carburetor .................................................................................................................................... - 127 -

12.1 Preparation documents ......................................................................................................... - 127 -

12.2 Failure diagnosis ................................................................................................................. - 128 -

12.3 Removal of carburetor.......................................................................................................... - 128 -

12.4 Installation and adjustment ................................................................................................... - 130 -

13.Cylinder cap ................................................................................................................................. - 133 -

13.1 Preparation documents ......................................................................................................... - 133 -

13.2 Failure diagnosis ................................................................................................................. - 133 -

13.3 Cylinder cap........................................................................................................................ - 133 -

13.4 Cylinder cap inspection........................................................................................................ - 134 -

13.5 Installation of cylinder cap.................................................................................................... - 134 -

14.Cylinder body and piston................................................................................................................ - 137 -

14.1 Preparation documents ......................................................................................................... - 137 -

14.2 Failure diagnosis ................................................................................................................. - 138 -

14.3 Cylinder body ..................................................................................................................... - 138 -

14.4 Piston ................................................................................................................................. - 139 -

14.5 Installation of piston ............................................................................................................ - 142 -

15.Driving /clutch/driven wheel/foot driving device .............................................................................. - 146 -

15.1 Preparation documents ......................................................................................................... - 146 -

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15.2 Failure diagnosis ................................................................................................................. - 146 -

15.3 Left crankcase cover ............................................................................................................ - 147 -

15.4 Driving disc ........................................................................................................................ - 147 -

15.5 Clutch/driven wheel............................................................................................................. - 149 -

15.6 Detach clutch and driven wheel............................................................................................. - 151 -

15.7 Install ................................................................................................................................. - 155 -

15.8 Foot starting device.............................................................................................................. - 155 -

16.1 Preparation documents ......................................................................................................... - 158 -

16.2 Failure diagnosis ................................................................................................................. - 158 -

16.3 Gear box............................................................................................................................. - 158 -

16.4 Installation.......................................................................................................................... - 159 -

17．Crankcase .................................................................................................................................. - 161 -

17.1 Preparation documents ......................................................................................................... - 161 -

17.2 Failure diagnosis ................................................................................................................. - 161 -

17.3 Crankcase ........................................................................................................................... - 162 -

17.4 Installation.......................................................................................................................... - 164 -

Inspection and maintenance of exhaust gas discharge control system....................................................... - 164 -

18.Exhaust gas discharge control system .............................................................................................. - 166 -

18.1 Exhaust gas discharge control system reconizance................................................................... - 166 -

18.2 Regular maintenance notes ................................................................................................... - 166 -

18.3 Mechanic function of exhaust gas discharge control system ..................................................... - 167 -

18.4 Catalytic transfer system ...................................................................................................... - 167 -

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18.5 Solution for idle discharge value exceeding defined value (two-stroke) ..................................... - 169 -

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Preface

This is maintenance manual for QJ50QT-22D.

Preparing Documents include all necessary instructions and statements. Please

carefully read this manual before operation.

Inspection & Adjustment states how to check and adjust your motorcycle. All

safety rules and maintenance regulations shall be carried out from the beginning of

periodic inspection.

Except for chapter one, the rest chapters explain the disassembly/ assembly/

inspection of engine, entire motorcycle and electrical parts.

Breakdown drawing, systematic drawing, failure analysis and statement are

contained at the first part of each chapter.

Please note that photos, pictures or instructions are for your reference only. The

actual object may differ from these mentioned here. We will not make notification for

any discrepancy.

Generic Motor GmbH

Page 10

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Preparing documents

General safety Maintenance rules

Specification table Failure diagnosis

General Safety

Carbon monoxide

Engine shall be started in a ventilated place, not in a closed area.

Note

Exhaust gas contains poisonous carbon monoxide, which may cause unconsciousness or even death of human

being.

Start engine in an open place. The exhaust cleaning system shall be adopted if engine is started in a closed area.

Petrol

Ventilated place is required for working. Fire is strictly forbidden in work place or where petroleum is stored.

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Maintenance Rules

Metric tools are preferable for the maintenance of this motorcycle. Improper tools may cause damage.

Clean up the surface of parts or assembly parts before removing or opening the shield for maintenance, which can

prevent dirt from falling into the engine, chassis or braking system.

Wash parts and dry with compressed air machine after

disassembly and before measurement of attrition value.

Solvent or oil can easily damage aging rubber articles. Check

rubber before reassembly and replace rubber if necessary.

When releasing assembly parts, please start from outside to inside.

Small assembly parts shall be loosened first.

Complex assembly parts, such as gear box, shall be stored in proper order for facilitating installation in the future.

Please specially note the important connections before

disassembly. Replace parts which will not be in use before

disassembly.

Sheath

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Bolts and screws with different length will be separately used for

assembly parts and shields, and they shall be correctly mounted.

Insert a bolt into a hole to check whether it is proper if you are

confused.

Fill the groove with grease before mounting an oil seal. Check

whether the oil seal is smooth or damaged during assembly.

When installing a hosepipe (fuel, vacuum or cooling agent),

insert its end into the bottom of the connector so that the hose clip

can properly fix the connector. Rubber or plastic dirt-proof boot

shall be mounted according to the original design.

During dismantling ball bearing, one or two (inside & outside)

bearing rollers shall be supported by tools. Ball bearings may be

damaged and have to be replaced if only one roller (either inside

or outside) is imposed with force.

Groove

Clip

Connector

Bearings will be broken under either occasion as mentioned.

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Loose cables threaten electrical safety. Check each cable after they are all clamped to ensure the electrical safety;

Wire clamps are not allowed to bend towards welding point;

Bind cables at the designated place;

Do not deploy cables at the end of frame or at sharp point;

Do not deploy cables at the end of bolts or screws;

Cable deployment shall be far from heat source and where

cables may be clamped during moving;

Cables along the handlebar shall be neither too tight nor too

loose, and do not interface with any neighboring parts at

steering positions;

Cables shall be properly deployed without twist or knot;

Check whether the connector jacket is damaged and whether

the connector is over-stretched before mounting connectors;

Adopt adhesive tape or hosepipe to protect cables if they are

positioned at sharp point or corner;

Bind cables with tape after repairing;

Control cables shall not be bent or twisted. Clumsy operation

may be caused in light of damaged control cables.

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Identification of Motorcycle

1. The identification number of motorcycle frame is

marked at : *LBBB4900?8B?????*. The 9

digital,

10 digital and 11

digital respectively indicate

inspection code, year and supplier code. There are

17-digital in total. The frame sign is nailed at . See

Fig. 1-1.

Fig. 1-1

2. The serial number of engine is printed on the shell of

crankcase of engine and shall be in the format of

KW1E40QMB-4*□□□□□□□□*. Please see fig. 1-2.

Fig. 1-2

Significant Notes

1. Please apply valid Generic parts and accessories. Any part or accessory not in accordance with the design

specification of Generic Company may cause damage to engine.

2. Only metric tools are valid for maintenance and repair. Metric screws, bolts and nuts can not be exchanged with

imperial fasteners.

3. New gaskets, O-rings, cotter pins and locking pieces shall be applied for re-assembly.

4. Bolts with large diameter or positioned inside shall be fastened first and then diagonally screw down until

reaching required torque, otherwise there is special instruction.

5. Wash disassembled parts with cleanser. Lubricate all sliding surface before assembly.

6. Check whether all the parts and accessories are correctly mounted and operated after assembly.

7. Clean and remove oil before measurement. Add recommended lubricant to the lubricating areas during

assembly.

8. Apply lubricant to the surface of engine and driving system if they are dismantled for long-term storage, which

can prevent rust and dirt.

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Special Tools

Special tools refer to tools which are specially designed for assembling or disassembling some motorcycle

parts on special positions. Applicable special tools are necessary for precise adjustment and installation. With

them, parts and accessories can be mounted safely, reliably and rapidly, which improves efficiency and saves

energy.

1．Tools for repairing engine

Special tools are required for properly disassembling/assembling some engine parts.

List and drawing (1-1, 1-2) of special tools for disassembling/assembling engine parts are as follows:

Table 1-1

Name Remark

Special socket spanner

Clutch clamp holder

Flywheel puller

Feeler gauge

Bearing disassembly tools

Bearing assembly tools

Oil seal remover

Handle for dismantling tools

Piston pin pulling device

Piston pin pliers

Socket spanner for spark plug

Clutch thickness measuring device

Cylinder diameter measuring device

Dial indicato

Used for assembling/disassembling bolts for flywheels, Fig. 1-3

Fig. 1-4

Fig. 1-5

Fig. 1-6

Fig. 1-7

Fig. 1-8

Fig. 1-9

Fig. 1-10

Fig. 1-11

Fig. 1-12

Fig. 1-13

Fig. 1-14

Fig. 1-15

Measuring the inner diameter of piston pin, Fig. 1-16

Table 1-2 (continued)

Fig. 1-3 Fig. 1-4

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Fig. 1-5 Fig. 1-6

Fig. 1-7 Fig. 1-8

Fig. 1-9 Fig. 1-10

 handle

Fig. 1-11 Fig. 1-12

Thickness gauge

(feeler gauge)

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 pliers  piston

Fig. 1-13 Fig. 1-14

Fig. 1-15 Fig. 1-16

2．Tools for repairing chassis

List and drawing (1-17, 1-18) of ordinary tools and special tools for disassembling/assembling chassis parts are

as follows:

Tabl e 1-17

Name Remark

Torque spanner

Inner hexagon spanner

Socket spanner

Dial indicator

Magnetic rack, V-block

Micrometer

Vernier calipers

Circlip pliers

Screwdriver with striking cap

Tool for assembling oil seal of front fork

Tool for hammering seal of front fork

Steering nut spanner

Fig. 1-19

Fig. 1-20

Fig. 1-21

Fig. 1-22

Fig. 1-23

Fig. 1-24

Fig. 1-25

Fig. 1-26

Fig. 1-27

Fig. 1-28

Fig. 1-29

Fig. 1-30

(1) Ordinary tools for repairing chassis

Table 1-18 (continued)

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Fig. 1-19 Fig. 1-20

Fig. 1-21 Fig. 1-22

Fig. 1-23 Fig. 1-24

Fig. 1-25 Fig. 1-26

Fig. 1-27 Fig. 1-28

(2) Special tools for repairing chassis: tool for hammering seal of front fork

1. socket head 2. crank handle 3. ratchet spanner

4. connecting rod

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Fig. 1-29

(3) Steering nut spanner

Fig. 1-30

3．Tools for electric parts

List and drawings (1-31, 1-32) of special tools for testing electric parts are as follows:

Tabl e 1-31

Name Remark

Multimeter

Ignition tester

Fig. 1-33

Fig. 1-34

Table 1-32 (continued)

Fig. 1-33

Fig. 1-34

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Specification (QJ50QT-22D)

Model QJ50QT-22D

Engine type

QJ1E40QMB-4

Length mm

1940

Fuel type

Unleaded petrol

(92/95)

Width mm

730

No. of

cylinder

Height mm

1110

ID × stroke

40×39.2

Wheelbase mm

1305

Tota l

displacement

49.2CC

Forward

shaft

Startup

Electric/kick

Backshaft

Cooling

Air cooling

Wei ght kg

(Curb weight)

Tot a l

102

Front outer

tyre

80/80-16

Lubrication

Separate

lubrication

Front rim 16 X 1 .6

Rear outer

tyre

90/80-16

Air filter

AF-B45

Tyre

Size

Rear rim 16 X 1 .8 5

Capacity of

gasoline

tank

5.5 L±0.2L

Clutch

Dry centrifugal

clutch

Variable speed gear

Stepless

Engine

Carburetor

type

PZ19JB-2K

ransmissio

gear

Transmission

Belt transmission

Idle speed

1900±100rpm/min

Max. torque

4.36N.m/5250rpm

Battery

capacity

12V-4AH

Max. Hp

2.60kW/6500rpm

Electromagnetic

motor capacity

90W/5000rpm

Compression

ratio

6.9：1

Spark plug

BR8HSA（ NGK）

Performance

Max. speed

45km/h

Clearance of

spark plug

0.6-0.7mm

Electric devices

Ignition

CDI

Braking

Dia. of fluid

brake disc,

front wheel

φ220mm

Page 21

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system

I.D. of brake

drum, rear

wheel

φ140mm

QJ50QT-22D

Page 22

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N Y

Failure Diagnosis

Diagnosis on failure or difficulty in starting engine

ailure or difficulty in starting engine

Check ignition system

Remove the spark plug and check whether there is

carbon fouling between electrode.

Sparkover test for spark plug Eliminate carbon fouling

Weak spark or no spark between electrode Large blue or bluish purple spark between electrode

Screw off spark plug cap and conduct

sparkover test for high tension line

Check whether ignition is timely conducted with

an ignition timing light

Large blue spark Weak spark or no spark

Check whether spark plug and cap are in

good condition

Check power

supply for

ignition

Check whethe

short circuit o

open circui

occurs to ignition coil

Check whethe

short circuit o

open circuit occurs inside the ignitio

system

Check whether CDI ignition device is in good condition

Check the compressio

ressure of cylinde

with pressure gauge

Check whether there is gasoline in the fuel tank

Normal

compression

pressure

Insufficient

compression

pressure

Add

gasonline

on-contact ignition system

for electromagnetic motor

1. Check whether short

circuit or open circuit occurs to ignition coil

2. Check whether short

circuit or open circuit occurs to trigger coil

1. Check whether CDI

ignition device is in good condition

2. Check whether flywheels

and trigger coil are loosened

Screw off the bolt of carburetor and check whether there is gasoline in the overflow tube

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Y N

Moist electrode of spark plug Dry electrode of spark plug

Check whether there is oil

spillover in the carburetor

Drop a little gasoline into the cylinder for trial startup

1. Check whether the

float needle valve and the valve seat are firmly closed

2. Check whether the

conical surface of float needle valve is abrasive as steps

3. Check whether the float

needle valve is broken

4. Check whether the float

needle valve is too low

Check whether air

filter is blocked

Flameout shortly

after startup

Continue to work

after startup

The carburetor is blocked

inside or the float is too

high

Startup device of

carburetor (startup &

enrichment system)

is at fault

Remove spark

plug and check it

Page 24

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Y N

N Y

Y N

Diagnosis on engine overheating

Engine overheating

Check whether operation is correct

1. Check whether gasoline grade is

roper or stored for a long

time

2. Check whether the engine works

at high speed for a long time or with overload during driving

Check cooling system

Air-cooled engine

Check whether heat sink is spotted or there is too much oil stain

Clean

Check whether cooling fan or air director is damaged (forcedly air-cooled engine)

Inspection & solution

Check whether ignition is timely conducted with a

ignition timing light

1. Check whether

CDI ignition device is in good condition

2. Check whether

flywheels and trigger coil are loosened

Check whether clutch is slipping

Slipping clutch

Solution to

slipping clutch

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Remove the spark plug; check the colors of spark plug insulators and judge the proportion of mixed combustible gas based on abnormity

The spark plug insulators are black; the exhaust muffler emits black smoke or causes backfire if the engine works at low speed;

ad acceleration property; instable idle speed; flameout probability; it works normall

at high speed.

The spark plug insulators are brown

The spark plug insulators are white; the engine may intermit during acceleration; the carburetor generates backfire; insufficient power of engine

Mixed combustible gas

is too dense.

1. Check whether the air filter is

blocked.

2. Check whether the startup device

for carburetor (startup & enrichment system) works normally.

3. Check whether the float needle

valve is too low.

Normal combustible gas mixture

Check whether the cylinder outlet or the exhaust muffler is blocked due to accumulated carbon fouling.

Check the lubrication system

Mixed combustible gas is diluted.

1. Check whether fuel

cock works normally.

2. Check whether the

float needle valve is too high.

3. Check whether the

measuring jets and drill ways in the carburetor are

locked.

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Y N

Diagnosis on power shortage of engine

Power shortage of engine

Raise the main kickstand and lift wheels; rotate

wheels with hands

Flexible rotating of wheels

Inflexible rotating of wheels

Check tyre pressure

1. Check whether there is

braking drag.

2. Check whether wheel bearing

is excessively abraded or damaged.

3. Check whether the spacer

sleeve of hub is missed or too short.

Low pressure

Normal pressure

Check whether air leakage occurs to tyre valve and whether tyre is pierced or broken

Remove the spark plug and block the threaded hole with finger; press the startup button or step on the kick-start lever

Touch with your fingers and you can feel fierce air rushing out with puffing sound.

Touch with your fingers and you can not feel fierce air rushing out.

Normal compression pressure of cylinder

Insufficient compression pressure of cylinder

1. Check whether there is air

leakage in all outer joints of engine.

2. Check whether air supply is

timely conducted.

3. Check whether clearing

between valves is too small.

4. Check whether valve and valve

seat are well sealed.

5. Check whether piston ring is

ruptured, blocked in the groove or lacks elasticity.

6. Check the abrasion of piston

ring and cylinder.

Start the engine and slow accelerate; observe the rotation speed change of engine.

The rotation speed of engine rises as it slowly accelerates.

The rotation speed of engine does not rise as it slowly accelerates.

Check whether ignition is timely conducted with an ignition timing light

1. Check whether the clutch is slipping.

2. Check whether the driving belt is

excessively abraded.

3. Check whether the centrifugal roller of

driving pulley is excessively abraded.

4. Check whether the conical surface of

driving wheels and friction wheels is excessively abraded or abraded as groove.

5. Check whether the conical surface of

driven wheels and moving driven wheels is excessively abraded or abraded as groove.

6. Check whether the roll-away nest on the

inner surface of friction wheels is excessively abraded or pressed into be concave.

1. Check whether the fuel supply system

works normally.

2. Check whether the carburetor, air filter

and exhaust muffler are blocked.

3. Check whether the vacuum diaphragm

of plunger valve of carburetor is cracked or broken.

4. Check whether the height of

carburetor float is proper.

1. Check whether CDI

ignition device is in good condition

2. Check whether

flywheels and trigger coil are loosened

Page 27

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Y N Y N

N Y

Y N

Diagnosis on abnormal idle speed of engine

Abnormal idle speed of engine

High idle speed No idle speed Unstable idle speed

Check compression pressure of cylinder

Check whether the carburetor valve is completely closed with your hand.

Check whether ignition is timely conducted with an ignition timing light

Insufficient compression pressure

Normal compression pressure

1. Check whether there is air leakage in all outer joints of engine.

2. Check whether air supply is timely conducted.

3. Check whether clearing between valves is too small.

4. Check whether valve and valve seat are well sealed.

5. Check whether

iston ring is ruptured,

locked in the groove

or lacks elasticity.

6. Check the abrasion of piston ring and cylinder.

Adjust the idle speed of carburetor.

Check

whether idle

jet is too big.

Check whether the steel wire rope of accelerator control cable is flexible when pulling and whether the throttle valve spring is too soft.

Check whether the electrode clearing of spark

lug is

too small.

1. Check whether

CDI ignition device is in good condition

2. Check whether

flywheels and trigger coil are loosened

Idle speed after adjustment

No idle speed after adjustment

The air adjusting screws or the adjusting screws for throttle valve are improperly adjusted.

Check whether the carburetor idle jet, idle fuel way and air path is blocked.

Clean and clear

Check whether carburetor float is placed at high position.

Adjust the float height to standard value.

1. Check whether the heat insulator of carburetor

is cracked.

2. Check whether the fixing nuts of carburetor

are loosened.

3. Check whether the vacuum tube of fuel cock

is broken.

4. Check whether air leakage occurs to reed

valve.

Adjust the electrode clearing.

Check the proportion of mixed combustible gas.

Page 28

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Y N

Diagnosis on excessive fuel consumption of engine

Check and adjust the carburetor.

Excessive fuel

consumption of engine

Check whether operation is correct

Raise the main kickstand and rotate wheels with hands

1. Check whether motorcycle runs

with overload or not at economical speed or with low gear.

2. Check whether petrol grade is

proper.

Inflexible rotating of wheels

Flexible rotating of wheels

1. Check whether

there is braking drag.

2. Check whether

wheel bearing is seriously abraded or damaged.

3. Check whether the

spacer sleeve of hub is missed or too short.

Check tyre pressure

Low pressure

Normal pressure

Inflate as required

Check whether oil leakage occurs in fuel box, fuel cock, oil pipe and carburetor.

Solve problems based on actual situation

Check the proportion of mixed combustible gas.

Normal combustible gas mixture

Mixed combustible

as is too dense.

Mixed combustible gas is diluted.

Check whether the idle speed of engine is too high.

1. Check whether the air filter

is blocked.

2. Check whether the

carburetor float is too low.

3. Check whether the main

measuring jet of carburetor is too big.

1. Check whether the

carburetor is blocked inside.

2. Check whether the

carburetor float is too

high. Check and adjust the carburetor.

Check whether ignition is timely conducted with an ignition timing light

Check whether the driving belt of clutch is slipping.

Check the ignition system.

Page 29

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N Y

Y N

N Y

Diagnosis on clutch slipping

Diagnosis on transmission gear skip shift

Clutch slipping

Automatic shoe-type centrifugal & dry clutch is slipping.

Check whether the shoe-type friction plate is excessively abraded.

Replace the whole set of clutch shoe blocks

Clean and remove oil stain

Check whether the contact surface between shoe-type friction plate and friction disc is beyond 70%.

Check whether the contact surface between shoe-type friction plate and friction disc is excessively abraded.

修理或更换

Check whether the shoe-type friction plate is spotted with oil stain.

Transmission gear

skip shift

Check whether the spring of positioning wheels is ruptured or lacks elasticity.

Replacement

Disassemble crankcase and check whether the depth in engaging for each gear is in accordance with requirements.

Proper depth in engaging

Insufficient depth in engaging

Check whether the engaging end of the cam claw on the engaged gear face is abraded to be conical or largely circular, and whether the groove on the corresponding gear face is abraded to be trumpet-shaped.

Check whether the shift fork is excessively abraded or deformed.

Replace gear

Check whether the spline teeth of main shaft/countershaft and the spline groove in the clash gear is excessively abraded.

Replace shift fork

1. Check whether shift fork hole and shaft

are abraded.

2. Check whether the clearing between shift

fork pin/gear shift shaft and cam groove is too big.

3. Check whether the installation of

transmission is correct.

Repair or replace clutch shoe blocks.

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N Y

Y N

N Y

Diagnosis on malfunction of hydraulic disc brake

Diagnosis on malfunction of drum brake

Malfunction of hydraulic disc brake

Check the level of brake fluid inside the brake fluid reservoir.

The level of brake fluid is below the lower limit of the reservoir.

The level of brake fluid is beyond the lower limit of the reservoir.

Add brake fluid until it is beyond the lower limit; check whether there is oil leakage in brake caliper, brake hose and hose coupling.

Do you have "sponge" feeling when operating brake lever?

There is air left in the oil passage of brake system.

Check whether the abrasion of brake friction

late reaches limit mark and whether the

brake disc is excessively abraded.

Replace brake friction plate and brake disc.

1. Check whether the piston surface of master brake pump and the wall of oil tank are excessively abraded or damaged.

2. Check whether the piston cup of master brake pump is damaged, cracked or aged.

3. Check whether the seal of brake caliper is damaged, cracked or aged.

4. Check whether the piston surface of brake caliper and the wall of oil tank are excessively abraded or damaged.

Malfunction of drum

brake

Check whether the free stroke of brake lever is within 10mm ~ 20mm or whether the free stroke of brake pedal is within 20mm ~ 30mm.

Readjustment

Separate the brake arm and the steel wire rope of brake control cable; check the brake arm with hands.

The brake arm works flexibly but you can feel resistance when griping the lever.

The brake arm works inflexibly.

The indication arrow on the

rake cam points to or beyond

the sign “▽” on the brake hub

cover.

The indication arrow on the brake cam does not align with the sign “▽” on the

brake hub cover.

The steel wire rope of brake control cable is inflexible when pulling.

1. Check whether the curved surface of brake cam is excessively abraded.

2. Check whether the friction plate of brake shoe is excessively abraded.

3. Check whether the inner diameter of

brake hub is

cessively

abraded.

The moving

art of brake

cam is rusted or

locked by

something.

1. Check whether the friction surface of brake shoe is spotted with oil stain.

2. Check whether the contact surface of the friction plate of brake shoe and the brake hub is less than 70%.

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Riding-style motorcycle

Motorcycle scooter

Y N

Diagnosis on starter motor failure in rotation

The electric horn does not make sound or makes weak sound; the steering lamp emits weak light.

The electric horn makes loud sound and the steering lamp emits bright light.

Battery power shortage or bad

contact of conductor joint

Grip the brake lever (motor scooter), or make the transmission at neutral gear, or grip the clutch lever; press the startup button.

Starter motor failure in

rotation

Turn the ignition switch; press the horn; press or turn

the steering lamp switch.

Press the startup button and there is no joint sound from starting relay.

Press the startup button and there is joint sound from starting relay.

Disassemble the connector of starting relay from the cable assembly; use two lead wires to connect the battery with two down-leads of the starting relay coil.

Use screwdriver or large-diameter lead wire to short-circuit the battery terminal on the starting relay and the starter motor terminal.

The starting relay works normally after connection.

The starter motor works normally after short circuit.

The starter motor does not work after connection, and there is no sound from starting relay.

The starter motor does not work after short circuit.

Open circuit or short circuit of starting relay coil.

Check the inner circuit of the electric starting control system

Contacts of starting relay are burnt or damaged.

Disassemble the starter motor and check:

1. whether the carbon brush is

excessively abraded;

2. whether the carbon brush

spring is ruptured or lacks elasticity;

3. whether the armature

commutator is excessively abraded;

4. whether open circuit or short

circuit occurs to the armature coil.

1. Check whether the

contact of starting

utton is in good

condition.

2. Check whether the

commutation diode is damaged.

3. Check whether the

neutral gear switch works normally.

4. Check whether open

circuit or short circuit occurs to the inner lines of electric starting control system.

Check whether the contact of starting button is bad.

Grip the brake lever and check whether the brake lamp is light.

Bad contact inside the brake lamp switch or open circuit of its auxiliary lines.

Repair or replace starting button

Open circuit or short circuit inside the electric starting control system

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N Y

Y N

Diagnosis on starter motor running weak

Starter motor running weak

Turn the ignition switch; press the horn; press or turn the

steering lamp switch.

The electric horn does not make sound or makes weak sound; the steering lamp emits weak light.

The electric horn makes loud sound and the steering lamp emits bright light.

Battery power shortage or bad contact of conductor joint

Check whether the contact of conductor joint between starting relay and starter motor is bad.

Disassemble the lead wires connecting to starter motor and battery from the starting relay and press the starting

utton. Check whether the resistance between the

attery terminal and the starter motor terminal is normal with ohm meter when the starting relay makes connection sound.

Inspection & elimination

Disassemble the starter motor and check:

1. whether the carbon brush is excessively

abraded;

2. whether the carbon brush spring is

ruptured or lacks elasticity;

3. whether the surface of armature

commutator is stained, burnt or damaged.

4. whether the armature commutator is

excessively abraded;

Contacts of starting relay are burnt or damaged.

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Y N

Diagnosis on motorcycle lamp failure in illumination

Motorcycle lamp failure in illumination

AC power supply system for illumination

DC power supply system for illumination

Remove the connector between the conductor

undle of electromagnetic motor and the cable assembly; check whether there is power supply via the output conductors of the lighting coil with a test lamp.

Press the horn button or turn the steering lamp switch.

The test lamp is not light.

The test lamp is light.

Open circuit or short circuit of lighting coil or output wires

Start the engine and remove the connector between the rectifier regulator and the cable assembly.

The lamp is light

The lamp is not light

Short circuit inside the rectifier regulator.

Dismantle the headlamp assembly and check whether the bulb is burnt.

The horn can make loud sound and the steering lamp is light.

The horn can not make loud sound and the steering lamp is not light.

Normal

attery power

supply

Rapidly strike a lead wire on the negative/positive poles of battery and check spark.

No spark Spark

Power shortage of battery

1. Check whether the

fuse is burnt out.

2. Check whether open

circuit or short circuit occurs

etween the battery

and ignition switch.

3. Check whether open

circuit or short circuit occurs to the ignition switch.

Replace the headlamp bulb and check all the other lamp bulbs.

Check whether there is power output via input wires of illumination switch with a test lamp.

Use a lead wire to short circuit the

ower wire and the output wire of

the illumination switch.

Open circuit or short circuit between the electromagnetic motor/ ignition switch and the illumination switch.

The lamp is light.

The lamp is not light.

Bad contact inside the

illumination switch.

Open circuit or short circuit

etween the illumination switch

and the lamp.

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Diagnosis on burnt-out bulbs

Burnt-out bulbs

Turn the ignition switch; press the horn; turn the steering

lamp switch.

The horn works abnormally or does not make sound; the steering lamp emits weak light.

The horn makes loud sound and the steering lamp emits bright light.

1. Check whether the conductor joint

connecting battery is in good condition.

2. Check whether the electrolyte is

deficient inside the battery.

3. Check whether the electrolyte density

inside the battery is too low.

4. Check whether the battery plate is

sulfurized or short-cut.

Remove the connector between the rectifier regulator and the cable assembly; check whether there is open circuit between the lighting/charging coil of electromagnetic motor and the rectifier regulator with an ohm meter.

Set the multimeter to DC voltage 0V~20V; measure the voltage between the conductor terminal (connector to battery) (normally red wire or red/white wire) and the negative pole.

Connection

No voltage

Voltage available

Open circuit between the connector and the battery

Check whether the rectifier regulator works normally.

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Y N

Diagnosis on weak light from lamps

Weak light from lamps

AC power supply system for illumination

DC power supply system for illumination

Remove the connector between the conductor bundle of electromagnetic motor and the cable assembly; check whether the resistance between the output cable terminals of lighting coil of electromagnetic motor is lower than the standard value with an ohm meter.

Turn the ignition switch; press the horn; turn the steering lamp switch.

Short circuit of lighting coil.

Start the engine and limit the rotation s

eed; remove the connector between the rectifier regulator and the cable assembly; check the brightness of lamps.

The lamp works normally.

Still weak light from the lamp.

Low stable voltage of rectifier regulator.

Check whether there is short circuit in the charging coil of electromagnetic coil and the charging system.

The horn makes loud sound and the steering lamp emits bright light.

The horn makes coarse sound; the steering lamp emits weak light.

Power shortage of battery or bad connection between battery and the ignition switch.

Inspection & elimination

Dismantle the headlamp assembly and check whether the bulb glass is black or yellowish green.

Check whether the bulb power for the illumination system is in accordance with requirements.

Replace headlamp bulb.

1. Check whether the contact inside the illumination switch and dimmer switch is in good condition.

2. Check whether the contact of connector and earth wire is in good condition.

Replace lamp bulb.

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Y N

Diagnosis on steering lamp failure in illumination

Steering lamp failure in

illumination

Steering lamps at one side are partly not light.

Steering lamps at one side are wholly not light.

All the steering lamps are not light.

Remove the lamp covers and check whether the bulbs are burnt.

Replace bulbs

Measure the voltage

etween the contact of the power cord of lamp holder and the negative

ole with a voltage m

eter.

Voltage available

No voltage

Bad earth of lamp holder or bad connection

etween steering lamp bulb and lamp holder.

Open circuit of

ower cord of lamp holder

Remove the lamp covers and check whether the bulbs are burnt.

Replace

bulbs

Remove the connector of steering lamp switch and check whether the switch works normally at the breakdown side with an ohm meter.

Open circuit of output power cord or bad earth of lamp holder at the breakdown side.

Bad contact inside the steering lamp switch.

Press the horn button and check whether the horn works normally.

The horn makes loud sound

The horn can not make or makes coarse sound.

Normal battery power supply

Battery power supply shortage

Remove the steering lamp cover and check whether the bulb is burnt.

Turn the steering lamp switch and use a lead wire or a screwdriver to short-circuit two lugs of flasher.

Replace steering lamp

ulb and check whether

the rectifier regulator works normally.

The steering lamp is not light.

The steering lamp is light.

Remove the connector of steering lamp switch and use a lead wire to short-circuit the output power cord of the switch and the input power cord connecting left/right steering lamp.

The flasher is broken.

The steering lamp is light.

The steering lamp is not light.

Bad contact inside the steering lamp switch.

Check whether there is power supply via the input power cord of steering lamp switch with a test lamp.

The test lamp is light.

The test lamp is not light.

Open circuit or short circuit of power cord of steering lamp.

Open circuit or short circuit between the ignition switch and the flasher or between the flasher and the steering lamp switch.

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Diagnosis on electric horn failure in making sound

Electric horn failure

in making sound

Turn the ignition switch and steering lamp switch; check the work condition of steering lamp.

The steering lamp is not light or emits weak light.

The steering lamp emits bright light.

Battery power supply shortage or open circuit/short circuit between battery and ignition switch.

Normal battery power supply

Remove the power cord from the power-line terminal of the electric horn and strike the power cord with the earth; check the spark

Spark available

No spark

Connect to the power cord of electric horn; use a screwdriver to contact the non-

ower cord terminal (to

button) with the earth.

Short circuit between the ignition switch and electric horn

The electric horn makes sound.

The electric horn does not make sound.

Bad contact inside the horn button or open circuit between the electric horn and the button.

Adjust the volume and tune of the electric horn.

The electric horn does not make sound.

The electric horn works normally.

The electric horn is broken.

Improper adjustment

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Y N

Diagnosis on brake lamp failure in illumination

Diagnosis on power shortage of battery

Brake lamp failure

in illumination

Disassemble the cover of brake lamp and check whether the circuit board is burnt.

Replace the circuit board of brake lamp

Use a lead wire to short-circuit two terminals or two terminal pins of brake lamp switch.

The brake lamp is not light.

The brake lamp is light.

Use a screwdriver or a lead wire to strike the

ower lead of brake lamp with the earth;

check the spark.

Improper adjustment of

rake lamp switch or bad

contact inside.

Spark available

No spark

Short circuit or open circuit between the brake lamp switch and the brake lamp.

Short circuit or open circuit between the ignition switch or brake lamp switch.

Power shortage of

battery

Check whether the brake

lamp is always light.

Adjust or replace the brake lamp switch.

Leakage current is lower than the required value.

Leakage current is higher than the required value. (Normally, the leakage current is required to be no more than 1mA.)

Check whether short circuit occurs to the charging coil of electromagnetic motor.

Short circuit between the rectifier and the rectifier regulator or between the battery and the ignition switch.

Replace charging coil

1. Check whether the electrolyte inside the battery is sufficient.

2. Check whether the electrolyte density inside the battery is too low.

3. Check whether the battery plate is

sulfu

rized or short-

cut.

Turn the ignition switch to “OFF” position; disassemble the negative cable from the battery and connect the negative/positive pen of ampere meter to the negative/positive terminal of battery; check current leakage.

Page 39

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Y N

Diagnosis on battery charging failure

Battery charging

failure

Resistance value lower than standard value.

Short circuit of charging coil

Infinite resistance

value.

Resistance value in accordance with standard value.

Open circuit of charging coil or output conductor.

Set the multimeter to DC voltage 0V~20V; measure the voltage between the conductor terminal (connector to battery) (normally red wire or red/white wire) and the negative pole.

Bad connection or open circuit between the electromagnetic motor and the rectifier or inside the circuit of rectifier regulator

No voltage

Voltage available

Open circuit between the connector and the battery.

Check whether the rectifier or the rectifier regulator is broken down with an ohm meter.

Remove the connector between the conductor bundle of electromagnetic motor and the cable assembly; measure the resistance between the output conductor terminals of charging coil and check whether it is in accordance with the standard.

Connect power to the connector between the conductor

undle of electromagnetic motor and the cable assembly; cut off the connector between the rectifier or rectifier regulator and the cable assembly.

Measure the resistance between the output conductor terminals of charging coil of the connector and check whether it is in accordance with the standard.

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Inspection/Adjustment

Preparing information Cylinder pressure

Periodic Maintenance & Inspection List Gear oil

Engine oil/ Oil filter Replacement of gear oil

Fixing steering stem bearing & handlebar Driving belt

Inspection & adjustment of throttle cable Free stroke of front/rear brake

Air filter Inspection of brake fluid

Spark plug Headlight

Battery Clutch

Carburetor Front/rear suspension system

Ignition timing Bolt/nut/fastener

Rim/tyre Tyre specification

Preparing principles

General

War ning 1

• Make sure that it is well ventilated before starting the engine. It is forbidden to start it in a closed area.

Exhaust gas, which contains monoxide, may cause unconsciousness or even death of human being.

• The petrol is liable to volatile or explode under certain condition. The working area or the oil storage area

shall be kept ventilated and fire is strictly forbidden.

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Specification

Engine

Idle speed

1900±100rpm/min

Clearance of spark plug 0.6-0.7mm

Spec. of spark plug BR 8 HSA (NGK)

Max. power (KW/r) 2.60kW/6500rpm

Max. torque (N﹒m/r)

4.36N.m/5250rpm

Frame

Free stroke of front brake lever 10-20mm

Free stroke of rear brake lever 10-20mm

Tyre Specification

Front wheel 80/80-16

Tyre pressure unit: Kpa

QJ50QT-22D

Rear wheel 90/80-16

Front wheel spindle 55-62 N·m

Torq ue

value

Fixing nut for rear

wheel

100-113 N·m

Certification for Related Parts

Type Name Certificate No.

Front outer tyre E11 75R-001062

Tyr e

Rear outer tyre E11 75R-001063

Front lamp E9-00 1555

Position lamp E9 50R-001555

Tail lamp E9 50R-001556

Front steering lamp E9 50R-001557

Rear steering lamp E9 50R-001558

Lamps

Rear registration plate lamp E11 50R-000066

Rear-view mirror Rear-view mirror E3 001002

Horn Horn e9 1026

Reflector installed at two side of

rear mudguard

E11 020614

Reflector

The rear reflector is combined with

the rear registration plate lamp

E11 023584

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Periodic Maintenance & Inspection List

Per

300

Per

1000

Per

3000

Per

6000

Per

12000

Per

14500

Mileage between

services and time

Inspection item

New

vehicle

One

month

Three

months

Six

months

Twe lve

months

Fifteen

months

Applicable tools

* Air filter I C C R C Ordinary tools

* Petrol filter I I R Ordinary tools

* Oil filter C C C Ordinary tools

Replacement of engine

oil

R Replacement every 1000KM Ordinary tools

Tyre pressure I I I I I I

Tyre pressure

gauge, inflator

Battery inspection I I I I I I

Densimeter,

multimeter

Actuation gap inspection I I I I I I Ordinary tools

Inspection of steering

handle fastening

I I I Ordinary tools

Absorber working

inspection

I I I Ordinary tools

Screw fastening

inspection

I I I I I I Torque spanner

Oil leakage inspection for

gearbox

I I I I I I Ordinary tools

Inspection or replacement

of spark plug

I I R R I Ordinary tools

Replacement of gearbox

oil

I Replacement every 5000KM Ordinary tools

Lubrication of each part L L Lubricator

Muffler I I I I I I Ordinary tools

* Ignition timing I I I I I I Timing lamp

* Carburetor A I A A A A

Exhaust gas inspection at

idle speed

A I A A A A

Tachometer, CO

HC analyzer

* Accelerator inspection I I I I I Ordinary tools

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Fuel pipeline inspection I I I I I Ordinary tools

Lighting/metering/electric

devices

I I I I I I Visual multimeter

Main stand bracket I I I Ordinary tools

Absorber I I I I Ordinary tools

Torque force of engine

bolt

I I I I I Torque spanner

Anticipated inspection

1 Ignition system—obviously continuous ignition abnormality, engine fire or overheating, which requires

inspection and maintenance.

2 Carbon fouling elimination—obviously insufficient horsepower, which requires carbon fouling removal

from cylinder cover, piston head and exhaust system.

3 Piston & cylinder—excessive abrasion; replace cylinder if it is blocked.

Please have your motorcycle inspected and adjusted periodically at Generic distributors for being in best

condition.

The above table is established under the presupposition of 1000 km/month.

I—Inspection A—Adjustment R—Replacement C—Cleaning L—Lubrication

Note: 1. “*” Regulations on exhaust emission made by the State Environmental Protection Agency shall be

complied with. Maintenance must be carried out in accordance with the instruction manual supplied by the

company. We are not responsible for any loss rising from private adjustment or maintenance.

2. Increase frequency of washing air filter if your motorcycle runs on the sandy/gravel road or under heavily

polluted environment so as to extend its service life.

3. Motorcycles which often run at high speed or with high mileage shall be maintained frequently.

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Engine oil/filter

Oil level

*Note

•The motorcycle should be parked on a flat ground when

checking its oil level

•2-3 minutes after the engine running, stop for about 2-3

minutes and then check the oil level.

Check the oil level.

Add oil to the upper limit when alarm is made by sensor at

the oil level.

1. Sump 2. Oil Sensor 3.Rubber mat at the sump mouth

4. Sump cover. 5. Bolt M6×12 6.Nut M6

7. Fixing plate of sump

Oil replacement

*Note

It will be easier to change the oil when the engine is warming

up.

Turn off the engine.

Remove the bolt at the bottom of the crankcase and release

oil.

When the oil leaks completely, you can install the bolt and

packing washer after they are cleaned.

Add oil to proper level.

Check the oil leakage when the engine operates at its idling

speed.

Check the oil capacity again.

Cable accelerator inspection/adjustment

Check whether the cable accelerator is smooth or not.

Check the free travel of accelerator

Free travel: 5-10mm

Adjustment shall be made when improperness exist.

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Adjust the free tavel of accelerator. Fisrt loosen the locked nut ①,

Fix or loosen the adjusting device ②,

Until the free travel meet the standard value,

Then fix the locking nut ①.

Air filter

Filter replacement

Remove the body shield,

Remove the set bolt (13) on the air filter,

Remove the fixing component,

Remove the air filter

Remove the the set bolt （12） on the upper cover of air filter,

Remove the filter element （4） on the filter.

Check weather the filter element is polluted or damaged.

And replace it with a new element if necessary

Remove the pipe clip.

Remove the filter.

Check weather the filter is polluted or damaged.

And replace it with a new one if necessary.

Replacement time

Replace at an early time if the motorcycle is always running

on rainy days.

*Note

•Make sure the air filter cap is well installed before installing

the filter

Spark plug

Disconnect the connecting wire of plug cap

①Lateral electrode ②Central electrode ③Insulator

*Note:

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Clean the spark plug by compressed air, thus to guarantee that no shatter is exist in the firebox.

Remove the spark plug by special spanner or other tools.

（1）Inspection:

Carry out the following inspection, and make replacement when necessary:

．whether the insulator is damaged

．whether the electrode is worn

．Burning condition and color

— Light grey indicates a good burning condition.

— Paleness indicates any error in ignition system, or any diluted air mixture.

—Humidity or black indicates carbon distribution or over rich air mixture.

Visual inspection of spark plug

Replace the spark plug if and crack or wearing is detected.

The following spark plug is recommended:

Standard C5HSA(NGK)

Heat Type C6HSA(NGK)

Cold Type C7HSA(NGK)

（2）Reuse of spark plug:

Clean the electrode of spark plug by scratch brush or special tools.

Check the distance between the central electrode and lateral electrode of spark plug by steel feeler gauge.

If necessary, carefully bend the lateral electrode to adjust the distance.

Distance of spark plugs：0.60～0.70mm

Installed the spark plug onto the cylinder, and fix it to specified torque.

Torque: 18 N·m

Note: Fix the spark plug by hand, and then by special spanner, thus to protect the cylinder cover.

（3）Replacement of spark plug

Adjust the spark plug distance by steel feeler gauge, until it meets the specified value.

Note: Do not fix the spark plug too light.

Install the new spark and sealing cushion, and fix them by

hand.

After contact the spark plug hole, continue fixing by 1/2

circle.

Battery

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Battery removal

Remove the rubber pad (1) of pedal.

Remove the clamp bolt and clamp of battery.

irst remove the negative wire and then

remove the positive wire.

Take the battery (5) from the battery container.

War ning！

The tools for removing the positive electrode should not contact the flame, otherwise it will be very dangerous

that the damaged battery will cause fire.

Install the battery following the opposite sequence.

Do not disconnect the battery during the adjustment of motorcycle, otherwise inner component of the motorcycle

may be damaged.

War ning!

First positive and then negative to prevent short circuit

Charging state（closed circuit voltage）inspection

Open the cushion

Remove the cover of battery container. 。

First remove the negative wire and then

remove the positive wire.

Take out the battery.

Measure the voltage between battery terminals。

Full charge：13.1V

Under charge：12.3V（Keep the battery idle for 1 hour）

* Note

Charge state examination must use a voltmeter operation.

电瓶架：battery bracket 伏特表：voltameter

Charge

Connection method：

Connect the battery charger positive pole and battery

positive pole together.

Connect the battery charger negative pole and battery

Page 48

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negative pole together.

War ning:

• Battery should be far away from fire source

•Turn off the charger switches when starting or completing charging in order to prevent spark of the connections

resulting in explosion.

• You must follow the required current time when charging.

*Note

• Except emergencies, you should not use emergency charge.

• Measure the voltage for every other 30 minutes.

Charging current：standard：0.4A

Rapid：4.0A

Charging time：standard：10-15 hours

Rapid：30 minutes

Charging complete：closed circuit voltage：Above 12.8V

Do not disconnect the battery during the adjustment of motorcycle, otherwise inner component of the motorcycle

may be damaged.

Carburetor

Idle speed adjustment

*Note

Idle adjustment was made in the implementation of the

engine warm-up state.

① and ② refer to adjusting bolts.

Implement after warm-up of the engine.

Connect the engine rotation meter after running the engine.

Adjust the screw of the cable accelerator to rotating velocity.

Idle speed：1900±100rpm/min

Adjust the idling adjusting screw when idle speed

is unstable or unsmooth after oiling lightly.

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Ignition timing inspection

Warm up the engine for 3-5 minutes.

Connect the timing light to the lead of spark plug after the

engine is off.

*Note: carefully read the instruction of timing light before

carry out any operation.

Remove the body shield.

Start the engine and it idle running.

Inspect the ignite timing.

In case the "F" mark and the mark on the right cover of crank

case is in a line, the ignition time is correct.

Speed up the engine, and check out if the "F" mark start to

move.

Idle Speed：1900±100rpm/min

Cylinder pressure

Operate when the engine warm up.

Remove the cushion and body shield.

Remove the spark plug.

Install the cylinder pressure gauge.

At full throttle, measure the cylinder pressure by starting the

engine.

The following items shall be check in case of a low pressure:

—Whether the gasket of cylinder cover is damaged;

—whether piston ring is damaged;

—whether the air inlet and piston ring is worn;

—whether the piston and cylinder is worn When compression pressure is too high, please check the

combustion chamber and carbon distribution at piston head. 测气缸压力：cylinder pressure measuring

Gear oil

Inspection

*Note

Set the middle kickstand on a smooth surface, and keep the

motorcycle upright.

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Remove the oil level gauge (1) after the engine stopped.

The oil level between the upper limit and lower limit of oil level gauge is all right.

Add gear oil when the oil level is below the lower limit.

Install the oil level gauge.

Gear oil replacement

Warm-up the engine

A lacquer tray shall be placed under the engine to hold the

oil.

Remove the release bolt (2) and oil level gauge (1).

Recoil starting the engine for several times, and discharge the

engine oil completely.

Check the oil level gauge when the engine oil is discharged.

Ensure the oil level gauge and O-shape ring is all right, and

then carry out the installation.

Tighten the release bolt.

Fill the crank case with recommended engine oil.

Install the oil level gauge, start the engine, and keep it idle

running for 2-3 minutes.

Stop the engine, and check out whether the oil level is at the upper limit of oil level gauge after several minutes.

The engine shall be kept upright during inspection.

Guarantee that there's no leakage exist.

*Note:

Confirm whether the bolts wear or not.

Drive belt

Remove the cover of left crank case.

Check whether the drive belt is work or damaged.

Periodically maintenance shall be guaranteed, and replace the

drive belt with a new one if necessary.

驱动皮带:driver belt

Free path of front/rear brake

Free path of front brake

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Measure the free path of front brake at the point of the brake lever.

Free path: 10-20mm

Free path of rear brake

Measure the free path of rear brake at the point of the brake

pedal.

Free path: 10-20mm

Inspection of brake fluid level

Use the front brake to the upper limit, and check the oil level thought the oil indicator. In case the brake fluid level

is at or below the arrow in the picture, certain brake fluid (DOT3 or DOT4) shall be added until it reach upper

limit.

Note:

The oil pump component shall be paralleled with the ground during the inspection.

Front light

Remove the left and right rearview mirror components.

Remove the front shield.

Disconnect the lead of front light.

Fix the front light, and rotate the bulb counterclockwise.

Remove the bulb.

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Clutch

Start the engine and increase its speed gradually to check the working condition of the clutch.

If the motorcycle fails to go and the engine stops, you should

check the clutch block. If necessary, change a new one.

摩擦片：friction piece

Front/rear suspension system

Front

Pull the front brake tight and check the absorber.

Check whether the absorber has leakage or loose.

Rear

Check the rear absorber when operating.

Check whether part of the absorber is loose or wear.

Suspend the rear wheel and check it movingly.

Check whether the suspension bushing of the engine is loose or not.

Nuts/bolts/fixed parts

Check whether nuts, bolts, fixed parts are loose or not.

If any, tightening them according to their torque force.

Rim/Tyre

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Check whether the tyre or rim has crack, screw or any other damage.

Check the tyre pressure.

*Note

Check the tyre air pressure when it is cold.

Specification:

Tyre specification

Specification

Check whether the front wheel axle is loose or not.

Check whether the rear wheel nut is loose or not.

In case there is any loosening, tightening them according to

the required torque force value.

Torque force value:

Front wheel axle 55-62 N·m

Rear wheel nut 100-113 N·m

Steering column bearings and handle fix

Swing the handle in order to confirm there is no interference

with wire.

Confirm the handle turn freely when the front wheel turns.

If the handle is loose or unsmooth, you should check the steering column bearings.

Tyre specification

Front Wheel 80/80-16

QJ50QT-22D

Rear Wheel 90/80-16

Front Wheel 80/80-16

QJ50QT-22D

Rear Wheel 90/80-16

Page 54

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Page 55

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Inspection and maintenance of electrical system

Torque force list of fixing parts in electrical system

Position and name of fixing componen

Torque of fixing（N·m）

Rectifier bolt

High tension coil fixing bolt

Flywheel Fixing bolt

Body Shield Bolt

Clutch cover bolt of starting motors

Set screw nut of clutch cover of starting motors

5.0

9.0

5.0

9.0

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Charging System

1 Meters assembly 2 Horn 3 Power locking components 4 Frequency conversion flash apparatus

5 Battery 6Temperature controlled 7 Pressure adjuster 8 Ignition coil

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9 Starting relay 10 Starting switch

1. Battery/charging system

Preparing documents --------1.1 Failure diagnosis -------------1.2

Battery---------------1.3 Charging system -------------1.4

Voltage current adjustor -------1.5 Magnetor charging coil -------1.6

Removal of magnetor ---------1.7

1.1 Preparing documents

Note of work:

*Note

1. Battery charge and discharge can be repeated use, its life span can be shortened and performance decreases after

discharging. Usually its performance decreases 2-3 years later. Battery with performance degradation, the

voltage will resume but sharply drops with load.

2. Battery overcharge：Generally we can judge its overcharge from its body. If the inside of the battery is

short-circuit, it is hard to detect the voltage between its terminals. Adjustment failure: the battery voltage is too

high; battery life span will be shortened.

3. If the battery has been place without using for a long time, it will be self-discharged and its capacity will drop.

Under this condition, it should be charged every 3 months.

4. Check the charging system following the sequence listed on the table.

5. Don’t remove the connector with current flowing through the electrical parts, otherwise the voltage will be too

high and these parts will be broken down. Switch off the main switch and operate.

6. Maintenance free battery (dry cell type) doesn’t have to be checked and added electrolyte and distilled water.

7. Check total electricity load.

8. Emergency charging can only be used in emergent situation.

9. Remove the battery from the motorcycle for emergency charging.

10. Add liquid battery cannot be used when changing the battery.

11. Use the voltage meter for measuring the voltage when charging.

12. Do not disconnect the battery during the adjustment of motorcycle, otherwise inner component of the

motorcycle may be damaged.

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Preparing standards

Item Specifications

Capacity/Type 12V-4AH/dry cell

Full charge 13.1V Voltage

（20℃）

Obligatory

charge

12.3V(not working for 1h)

Charging current

standard：0.4A，rapid：4A

Battery

Charging time

standard：10-15h，rapid：30min

capacity 90W/8000rpm

Lighting coil impedance（20℃）

Green/Red - Black 2.0-2.5Ω

Magnetor

Charging coil impedance(20℃)

White – Black 1.5-2Ω

Type Single-phase semi-wave charge under short circuit

14.0V±0.4V/5000rpm Lighting

Limit

13.5V/5000rpm

Voltage

adjuster

Voltage limit

Charging

limit

14.8V±0.4V/5000rpm

Tightening torque force value Tool

Rectifier bolt 5.0 N·m Multiple fixing spanner

High tension coil fixing bolt 9.0 N·m Flywheel remover

Flywheel Fixing bolt 5.0 N·m Testing instrument

Body Shield Bolt 9.0 N·m Multimeter

1.2 Failure diagnosis

Power supply dead interrupted electric current

Battery overcharge Poor contact of the charging wire

Battery wire isn’t connected Poor contact of the charging system

Fuse blow Poor contact or short circuit of lighting system

Bad power switch

Low voltage Bad charging system

Bad battery charging Poor contact of the wire, short or open circuit

Poor contact Bad voltage current adjustor

Bad charging system Bad magnetor

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Bad voltage current adjustor

1.3 Battery

1.3.1 Battery removing

Rmove the rubber pad of pedal

Remove the clamp bolt and clamp of battery.

irst remove the negative wire and then

remove the positive wire.

Take the battery from the battery container.

War ning！

When removing the positive terminal, the

tools should not be contacted with the

bracket. It is dangerous that spark caused

by short circuit will spark the petrol and

break the battery.

Do not disconnect the battery during the

adjustment of motorcycle, otherwise inner

component of the motorcycle may be

damaged.

Install the battery in an opposite order.

* Note

First positive terminal then negative

terminal to prevent short circuit.

Check the charging situation.

Open the battery cover, and remove the clamp component of battery.

Remove the lead of battery.

Measure the voltage of the terminals

Full charge：13.1V

Insufficient charge：12.3V （not working for 1h）

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* Note

Use voltmeter when charging.

1.3.2 Charging

Connection method：

Connect the positive terminal of the battery charge and the

battery

Connect the negative terminal of the battery charge and the

battery

War ning！

•The battery should be far away from fire

source.

•Turn off the charger when starting

charging or completing charging

•Take the marked current time as a

standard when charging

*Note

•Except emergencies, you should not use

emergency charge

•Measure the voltage for every other 30

minutes

Charging current：standard0.4A

emergency：4.0A

Charging time：standard：10-15h

emergency：30min

Charging completes：open-circuit voltage：above12.8V

1.4 Charging system

1.4.1 Charging system

Remove the batter ground wire, and connect the voltmeter between the negative terminal and ground wire. Turn

off the switch and check whether it is short circuit.

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* Note

Connect the positive terminal of the

multimeter and the negative terminal of

the battery together

Check whether the main switch and main wire are short

circuit under abnormal conditions.

1.4.2 Charging inspection

Use the multimeter to checking the fully charged battery.

Mount the battery after the engine warming up.

Connect the voltmeter between terminals

Remove the fuse and connect the ammeter between its

terminals.

Start the engine slowly and measure the limiting voltage and

current. 万用电表：multimeter

Limiting voltage/rotating speed：14-15V （2500rpm）

If the limiting voltage is not within the required range, check the voltage adjustor.

Check the limiting voltage of the lighting system

* Note

Choose AC voltage of the multimeter

Limiting voltage：13.1(+/-)0.5V/2500rpm

If the limiting voltage is not within the required range, check the current adjustor.

1.5 Rectifier

1.5.1 Main wiring inspection

Remove the 6p plug of the rectifier.

Check the conducting state of the

terminals of the main wiring.

Item（wiring

color）

Judgments

Between Battery With battery voltage

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（red）and GND

of the body

Between GND

wire（black）and

GND of the body

With wiring

Between charging

coil(white) and

the GND of the

body

There is resistance in

the magnetor coil

Between light

wire (green/red)

and the GND

(plug of resistor,

auto side starter

plug, inspect at

OFF position after

the removing of

lighting switch

There is resistance in

the magnetor coil

1.5.2 Voltage and current adjustor

inspection

When the main wiring is completely normal, check

the contact of the adjustor’s plug, and measure the resistance value between the terminals of the adjustor.

* Note

• When checking the metal parts, your

finger should not contact test bar of the

multimeter.

•Different multimeter will show

differently, so use the same multimeter

while checking.

Replace the voltage adjustor when the resistance value between the terminals is abnormal.

1.6 Magnetor charging coil

*Note

Check the magnetor charging coil on the

engine.

Inspection

White

（A）

Green/Red

（L）

Red

（B）

Black

（E）

Multimeter

Unit：MΩ

White（A）

0 6.5 19~21

Green/Red

（L）

1~10 24~25 19~23

Red（B）

10~50 0 19~21

Black（E）

5~15 0 0

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Remove the 6p connector of the magnetor

Measure resistance value between the white coils of magnetor with multimeter

Standard value：0.5-10Ω（20）

Replace the magnetor coil when the measured value exceeds the standard value

1.6.1 Magnetor lighting coil

*Note

Check the magnetor lighting coil on the

engine.

Inspection

Remove the 3p connector of the magnetor

Measure resistance value between the green/red coils of

magnetor and the body GND with multimeter

Standard value：2.0-2.5Ω（20）

Replace the magnetor coil when the measured value exceeds

the standard value. 冷却风扇：cooling fan 螺栓：bolt

1.7 Replacement of magnetor

1.7.1Replacement

Remove the body shield.

Remove the right body cover.

Remove the 2 fixing bolts and 2 screw, and remove the fan cover.

Remove the four fixing bolts of cooling fan, and remove the cooling fan then.

Fix the flywheel using the universal spanner.

Remove the fixing bolt of the flywheel.

万能固定扳手：universal spanner

Remove the flywheel using the flywheel remover.

Remove the solid key.

Remove the connector of the alternator wiring.

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Remove the alternator stator.

飞轮拔取器：flywheel remover

1.7.2 Installation

Install the stator on the body of the engine.

Connect the magnetor terminator.

Clean up the taper part of the bent axle and flywheel.

Install the solid key of the flywheel into the bent axle.

Aim the flywheel groove at the solid key on the axle.

* Note

Ensure the inside of the flywheel do not

have bolts.

Fix the flywheel with the universal spanner and tighten the

fixing screw.

Torque force value：9.0 N·m

Install the right body fender

飞轮：flywheel 冷却风扇：cooling fan 风扇盖：fan cover

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Ignition system

1 Meters assembly 2 Power locking components 3 Horn 4 Battery 5 Starting relay

6 CID DC igniter 7 Frequency conversion flash apparatus 8 Ignition coil

9 Release resistances

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2. Ignition system

Preparation system --------------2.1 CDI Group----------------2.4

Failure diagnosis --------------2.2 Ignition coil --------------2.5

Ignition system checking ----------2.3 Trigger-----------------2.6

2.1 Preparing documents

Note of work:

1. Checking the ignition system following the sequence listed in the table of failure diagnosis.

2. The ignition system is solidified in the CDI group and you don’t have to adjust the ignition time.

3. Checking the ignition system following the sequence listed in the table of failure diagnosis.

4. CDI ignition system cannot subject to strong percussion (which is the main reason for failure), so you need to

pay great attention to that.

5. Check whether the connection is bad or not, because usually the reason for failure is poor contact socket.

6. The heat value of the spark plug should be appropriate. Improper spark plug will cause the engine running

unsmooth and even the spark plug will be burn-out.

7.Inspection in this chapter is based mainly on the maximum voltage，also inspection of the ignition coil

impedance is introduced.

8. Check the main switch according to the table.

9. Remove the alternator and stator according to the instructions.

Preparing standards

Items Standard value

Standard

C5HSA(NGK)

Hot type

C6HSA(NGK)

Spark plug

recommended

Cold type

C7HSA(NGK)

Spark gap

0.6-0.7mm

Primary coil

0.6Ω±10％

With plug cap

5-11KΩ

Ignition coil

impedance

（20）

Secondary coil

Without plug cap

0.5-5.5KΩ

Resistance of trigger（20）

100-500Ω

Measure the maximum voltage after ignition coil

rotates once

95-400V

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Trigger voltage

Above 1.7V

Charging coil voltage 95-400V

Tools

Voltmeter

Multimeter

2.2 Failure diagnosis

Spark plug unable to jump

Error Reason (identify according to the following order)

Ignition

coil

Low voltage

 The inner resistance is too small and it should be tested by required tester  Low rotation speed of the bent axle.  Tester is interfered. (It is normal that several measured voltage is above

the basic standard.)

 Poor contact wire for the ignition system.  Bad ignition coil.  Bad charging coils (measure at maximum voltage).

No or interrupted high voltage electricity

 Wrong connection with the tester.  Bad main switch  Bad connector of the CDI group  Poor contact of the CDI group or GND of the CDI group is short-circuit.  Bad charging coil (measure at maximum voltage)

 Bad trigger（measure at maximum voltage）

 Bad high tension electricity connector  Bad CDI group (when there is no spark for the plug or - is abnormal).

Secondary

Side

voltage

Normal high voltage electricity/no spark

for the plug

 Bad plug or secondary ignition coil leakage  Bad ignition coil

No high voltage electricity

 The inner resistance is too small and should be tested by required tester.  Low rotation speed of the bent axle  Tester is interfered. (It is normal that several measured voltage is above

the basic standard.)

 Bad charging coil（- are normal）

Charging

coil

No or interrupted high tension electricity

 Bad ignition coil  Bad charging coil

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Low high voltage electricity

 The inner resistance is too small and should be tested by required tester.  Low rotation speed of the bent axle (It is normal that several measured

voltage is above the basic standard.)

 Tester is interfered.

 Bad trigger（- are normal）

Trigger

No or interrupted high voltage electricity

 Bad ignition coil  Bad trigger

2.3 Checking the ignition system

*Note

When there is no spark on the spark plug,

check whether there is loose wiring or

poor contact of all components, and make

sure all voltage values are normal.

•There are various kinds of multimeters

with different internal impedances and

different test values.

Connect a high-pressure shunt or an ammeter with

an input impedance above 10MΩ10CV to the multimeter. 万用表：multimeter

2.3.1 Voltage of the ignition

If you replace the original spark plug

with a better one, make ground connection

with the engine.

*Note

Make sure the wire connection is

correct before testing.

Cylinder compression pressure

normally refers to the test value when

the spark plug is installed in the

cylinder head.

万用表

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Remove the intermediate cap.

Connect the wires of ignition coils.

Ground connect the two ends (black/white)

of the primary coil to the car body to

create current divider.

Press the staring motor or step on the

actuating lever to measure the voltage of

the ignition coil at a time.

Minimum voltage：Above 95V.

*Note

Never touch the metal of test prod when

measuring the voltage in case of electric

shock.

2.3.2 Trigger

*Note

Install the spark plug in the cylinder head

and carry out the measuring when the

compression pressure is normal.

Remove the 4p and 2P joints of CDI group,

connect the peak-voltage magnetor

between the trigger with wiring 2p end

(blue / white end) and 4p end (black end).

Press the starting motor or step on the

actuating lever to measuring the peak

voltage of the trigger. CDI组：CDI group 黑：black 蓝：blue 白：white

Method of attachment: Blue/white end to

the positive pole and black end to the

negative pole.

Minimum voltage：Above 1.7V.

*Note

Never touch the metal of test prod when

measuring the voltage in case of electric

shock.

蓝/ 白

白/ 绿

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Remove the adaptor of the alternator when

the peak voltage of the adaptor of CDI 白：white 绿：green 蓝：blue

Group is abnormal.

Connect the magnetor of and the

trigger (blue/white).

·If the obtained voltage of the end of CDI

Group is abnormal while the one of the

end of the alternator is normal, the

problem should be poor contact or wire break.

·If both ends are abnormal, the trigger

may be broken, please refer to the checking

method in the failure diagnosis table.

黑：black 绿：green 蓝：blue 红：red 白： white

2.4 CDI Group

2.4.1 System check

Check the system.

Remove the CDI Group, check the components

concerning the ignition system at the wiring end.

2.4.2 Check

Remove CDI Group, check whether there is loose or corrosion in the adaptor.

Checking item Testing end

Standard value（20）

Main switch Red--red/white Breakover when the main switch is

“OFF”

Trigger

Blue/white – white/green

100-200Ω

Primary coil of the ignition coil Black/white--black

0.6Ω±10％

Secondary coil of the ignition

coil

Black--spark plug cap（without the

spark plug）

0.5-5.5KΩ±10％

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2.5 Ignition coil

2.5.1 Unload

Unload the body shield.

Unload the spark plug cap.

Unload the primary wire of the ignition coil.

Unload the fixed bolt of the ignition coil,

remove the ignition coil.

Carry out the operations in the opposite order

of unloading during installation.

*Note:

Use the black/white end of primary coil

during installation.

2.5.2 Check the primary coil 点火线图：Diagram of ignition wire

Impedance measuring between the ends of the

primary coil

Standard value：0.6Ω（+/-）10％（20）

If the impedance value is within the range

of the standard value, it is fine.

If the impedance is “∞”, there is wire

break in the coil, replace it with a new one.

2.5.3 Secondary coil

With a spark plug attached. Measure the impedance

value between the wire side and the end of

the spark plug cap.

Standard value：5-11KΩ（20）

If the impedance value is within the range

of the standard value, it is fine.

If the impedance is “∞”, there is wire

break in the coil.

Remove the spark plug cap, measure the impedance

value between a side wire and the negative end.

tandard value：0.5-5.5KΩ（+/-）10％（20）

点火线图

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2.6 Trigger

*Note:

Check of the trigger could be carried out on

the engine.

Check

Remove the body shield.

Remove the wire adaptor of the trigger.。白/绿：white/green 蓝/白：blue/white

Measure the impedance value between the

blue/white end of the wire at the engine

side and the ground strap connection of the

body..

磁电机接口：magnetor interface

黑：black 绿/红: green/red 白：white

Standard value：100-500Ω（20）

Change the alternator when the value is

beyond the range of the standard value.

Activation system

磁电机接口

DJ621- 2. 8× 0. 5

DJ7031- 2. 8- 21

白

黑

绿

/ 红

蓝/ 白

白/ 绿

Page 73

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启动示意图

BATT ERY

REL A Y

BRAKE SWITCHBRAKE SWITCH

STARTER SWITCH

STARTOR MOTOR

1 Meters assembly 2 Power locking components 3 Horn 4 Battery 5 Starting relay

6 CID DC igniter 7 Frequency conversion flash apparatus 8 Ignition coil

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3. Activation system

Preparation ---------------3.1

Failure diagnosis ---------------3.2

Starting motor ---------------3.3

Starting relay -------------3.4

3.1 Preparing documents

Notes of working

The unloading of the starting engine could be carried out on the engine.

Refer to the method of unloading when unloading the engine.

Preparation standards

Item Standard value Service limits

Length of the motor brush of the

starting motor

6.2mm 3.0mm

Liner of the starting idler shaft 8.3mm

External diameter of the starting

idler shaft

7.94mm

Torque tightening value

Clutch cover bolt of starting motors 12 N·m

Set screw nut of the clutch cover of starting motors 95 N·m

Instrument

Set screw nut wrench

Universal fixed wrench

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3.2 Failure diagnosis

Activation failure Weak rotating force Starting motor is rotating of the starting motor well while the engine is not

•Burnt out fuse ·Low storage battery •Broken starting clutch

•Low storage battery •Poor contact of connecting line •anticlockwise revolution of the starting motor

•Broken main switch •The gear of the starting motor is •Low storage battery

•Broken starting clutch Blocked by foreign matters.

•Broken brake switch

•Broken stating relay

•poor contact of connecting line

•Broken starting motor

3.3 Starting motor

3.3.1 Unloading

* Attention

Before unloading the starting motor, turn

the main switch to “OFF” first; remove

the bond strap of the storage battery, then

turn the power source on the see if the

starting motor is working to ensure the

security.

Remove the wire clip of the starting motor first.

Remove the fixed bolt of the starting motor and

unload the motor.

Roll up the rubber overshoe and pull down the

adaptor of the starting motor.

3.3.2 Breaking down

Unload the screws in the outer cover, the front cover, the

motor cover and other parts.

转向器：commutator

3.3.3 Check

Check other component assembling.

Replace for a new one when there is wear,

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fragment or burning loss in the surface.

Clean the metal powder on the surface of the

commutators.

Conduction check between all interfaces of

other components

Make sure armature shafts of all interfaces

could not turn on.

Conduction check of the outer cover of

the starting motor

Make sure the conduction terminator and the

outer cover of the starting motor could not

turn on.

Conduction check between conduction terminators

and electric brushes

Change for a new one if there is anything abnormal.

Conduction measuring of the electric brush bracket

Change for a new one if it turns on.

Measuring of the length of electric brushes

Available credit: Change for a new one if the

length value is less than 3.0mm

Check whether the needle bearing in the front

Cover is rotating smoothly and whether there is

any loose when pressed in.

Change for a new one if there is anything abnormal.

Check whether there is any wear or damage of the

oil seal.

3.3.4 Assembling

Oil seal and greasing coating in the front cover.

Install the electric brush on the

Electric brush bracket

Grease coating on movable parts of the two

ends of electric brush.

Press all the electric brushes into the bracket,

then fit on the front cover of the electric motor.

电机外壳：motor sheel 电枢：armature 前盖：front cover

*Note

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• Damage is not allowed in the interface

between the electric brush and the

armature, pay attention please.

The labial part of the oil seal should not

be damaged by the installation shaft, pay

attention please.

Install new O-shape rings on the front cover.

Pair the screw of the motor shell with the

one of the front cover during installation.

Screw up the screw in the outer shell.

*Note

In the assembling of the outer shell and

the front cover, use the magnet to draw

the front cover to make it easy to pull out

the armature, and then press it down

softly.

3.3.5 Installation

Install wires of the starting motor; make sure the soldering cup is properly installed.

Check whether the O-shape ring is damage, and replaced it with a new one when necessary.

Cover the O-shape ring with engine oil, and install it onto the starting motor.

Install the wire clip of the rear brake.

3.4 Starting relay

3.4.1 Actuation examination

Remove the fender of the body.

Ensure there is a “click” when turning on the starting motor

with the main switch remaining “on”.

If there is sound, it is ok.

If no sound appears: ·check the voltage of the starting relay.

·Check the ground loop of the starting relay.

·Actuation examination of the starting relay.

启动继电器：start the relay

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3.4.2 Voltage examination of the starting relay 绿/黄/黑 green/yellow/black

Set up the main stand, measure the voltage between

the negative pole of the green/yellow wire in th

adaptor of the starting motor and the ground strap

connection of the body.

Hold on the brake tension rod with the main switch

remaining “on”, the voltage of the storage battery

must be in accordance with specification.

Continuity check and examination of the wires when

the voltage between the ends of the starting motor is

zero.

3.4.3 Examination of the ground loop of the starting relay

Remove the adaptor of the starting relay.

Conduction examination between the grey wire at the

end of conductor joint and the ground strap connection of

the body.

When pressing on the starting button, the conduction

between the grey wire and the ground strap connection

of the body must be fine.

Examination of the conduction of the starting button and

wires when there is no conduction.

3.4.4 Actuation examination

Remove the storage battery out of the starting

relay, and connect the end of the starting relay

with a multimeter.

Connect the fully charged storage battery between

the black wire and the green/yellow wire of the

relay. The relay will utter a “click” and the electric

impedance the multimeter shows is “zero”.

绿/ 黄

黑

启动继电器

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Bulbs/Switches/Meters

Page 80

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1 Front signal lamp 2 Right rearview mirror 3 Left rearview mirror 4 Front right turn signal lamp

5 Front left turn signal lamp 6 Rear left turn signal lamp 7 Taillight 8 Rear reflector 9 Meters assembly

Certificate No. of front lamp:

E9-00 1555

Certificate No. of front position

lamp:E9 50R-001555

Certificate No. of rear lamp: E9

50R-001556

Certificate No. of front turn light:

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4. Bulbs/Switches/Meters

Preparation --------------4.1 Meters ------------4.6

Failure diagnosis --------------4.2 Main switches --------------4.7

Headlight bulb replacement --------4.3 Speaker----------------4.8

Front turn signal lamp replacement----------4.4 Combined switch------------4.9

Replacement of taillight, rear left/right turn signal lamp -------4.5

4.1 Preparing documents

Notice of work

Conduct examination of the switch (The switch could be removed from the motorcar before being examined)

4.2 Failure diagnosis

The main switch can not be turned "On" Dim light

• The bulb is broken •generator failure

• The switch is broken. •manostat failure

• Poor contact at the adaptor or wire break. •rectifier failure

4.3 Headlight bulb replacement

4.3.1 Unloading

Remove the right/left rearview mirror;

Remove the front shield;

Disconnect the wire of headlight bulb.

Remove the glass lens of the headlight

Keep the headlight in place; rotate the outlet

clockwise to remove the bulb.

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4.3.2 Installation

Install the bulb in the opposite order of removal.

4.4 Front turn signal lamp bulb replacement

4.4.1 Unloading

Unscrew the setscrew of the turn light.

Remove the front turn signal lamp bulb

4.4.2 Installation

Install the bulb in the opposite order of removal.

4.5 Taillight/Rear turn signal lamp

replacement

4.5.1 Unloading

Remove the set screw of taillight to remove the taillight;

Remove the set screw of rear turn signal lamp;

Disconnect the wire of taillight;

Disconnect the wire of turn signal lamp bulb

Remove the taillight and rear turn signal lamp bulb.

4.5.2 Installation

Install the bulb in the opposite order of removal.

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4.6 Meters

Remove the decorative parts of meters

Remove the back protective guard of the handlebar,

Disconnect the wire of meters

Remove the meters

Install the speedometer in the opposite order of removal.

4.7 Main switches

4.7.1 Check

Remove the helmet hook, front basket and rear board.

Remove the added board and foot protective plate of front

basket and rear board.

Remove the conductor joint of the main switch

Conduction examination of the ends of the adaptor

4.7.2 Main switch replacement

Remove the helmet hook, front basket and rear board.

Remove the added board and foot protective plate of front

basket and rear board.

Remove the standing bolt; unload the permanent

seat of the main switch.

Remove the standing bolt to replace the main switch.

4.8 Speakers

Examination

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Remove the wires of the speaker.

Connect the speaker to the storage battery.

If there is sound, it is working.

4.9 Combined switch

Displacement and installation

Remove the rearview mirror component.

Remove the decorative screw of meter.

Remove the meters and back protective guard of the

handlebar.

Remove the set screw of left and right combined switches.

Unscrew the left and right combined switches.

Remove the components of right handle and left handle.

Remove the right and left combined switch.

Install the combined switch in the opposite order of removal.

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Examination and maintenance of chassis

Torque force list of set parts on chassis

Position and name of fixing part

Fixing torque（N·m）

Installing bolt of front fluid brake disc

Bolt component of front absorber

Set bolt of rear brake rocker

Set bolt for welding of handlebar

Front wheel axis

Set bolt of front absorber

Set nut of rear wheel

Top bolt of rear absorber

Bottom bolt of rear absorber

Set bolt of fuel tank

Set bolt of helmet container

Set bolt of fulcrum shaft of motor

5-9 N·m

37-44 N·m

5-9 N·m

40-60 N·m

55-62 N·m

37-44 N·m

100-113 N·m

37-44 N·m

22-29 N·m

5-9 N·m

55-62 N·m

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Front Fluid Brake

Dia of front brake disc: φ 220mm

Thickness of front brake disc: 4.0mm Limit: 3.0

Installing torque of bolt 9 in the picture: 5-9 N·m

Free path of brake handle: 10-20mm

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1 Front brake component 2 Friction piece component 3 Oil pump component 4 Liquid brake handle

5 Brake tube assembly 6 Brake cylinder component 7 Switch assembly 8 Shield 9 Bolt M6×20

10Front brake plate

Rear Drum Brake

Torque of bolt 3 in the picture: 100-113 N·m

Inner dia. Of rear drum brake φ140mm Wearing limit: φ 141mm

Thickness of friction piece of rear brake:4.0mm Limit: 3.0mm

Torque of bolt 10 in the picture: 5-9 N·m

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1 Vacuum tyre 90/80-16 2 Rear wheel component 16×1.85 3Bolt M16X1.5 4 Dust cover 5 nozzle

cap 6 nozzle 7 Brake pad component 8 Rear brake camshaft 9 Drag spring of brake pad \

10Bolt M6X30 11 Rear brake rocker component 12 Bolt M6

5. Brake

Maintenance instruction ------------------------5.1

Failure diagnosis ------------------------5.2

Front fluid brake --------------------------5.3

Rear fluid brake --------------------------5.4

5.1 Maintenance instruction

Note of work

* Note

* Check the brake before riding*

5.1.1Specification

Items Standard value(mm) Available limits (mm)

front brake disc diameter φ220mm -

front brake disc thickness

4.0

3.0

Thickness of friction piece in

front liquid brake

4.0

3.0

Inner diameter of rear drum

brake

φ140mm

Thickness of friction piece in

rear brake pad

4.0 3.0

5.1.2 Torque

Installing bolt of front liquid brake plate 5-9 N·m Set bolt of rear brake rocker 5-9 N·m

Set bolt of rear wheel 100-113 N·m

• Parts of the braking system should not be polluted when installing or removing.

•Use the required cleaner to prevent affecting the function of the braking system.

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5.2 Failure Diagnosis

Brake

Poor performance of the braking system Slow reaction and tight lever

1. Improper adjustments for the brake 1. Improper adjustments for the brake

2. Brake shoe or brake plate wears 2. Brake shoe or brake plate wears

3. Improper installation for the brake shoe 3. Improper installation for the brake shoe

4. Polluted brake plate of brake shoe

Abnormal noise

1. Brake shoe or brake plate wears

2. Polluted brake plate of brake shoe

5.3 Front fluid brake

5.3.1 Remove

* Note

• Replacement of the brake shoe assembly

• Mark the replaced shoe for the next use

Remove the following parts from the right grip and front

absorber

1.Oil pump component（3）

2. Front brake component（10）

3. Brake cylinder component（6）

4. Friction piece component（2）

5.Brake tube assembly（5）

6. Switch（7）

Note: See Fig. 76 for details

*Note

• Oil should not be allowed to pollute the brake shoe during

installing and removing.

• Use the required cleaner to prevent affecting the function of

the braking system.

Loosen the fixed bolt of the brake cylinder.

Remove the brake cylinder from the front absorber.

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Remove the front wheel axis, and dismantle the front wheel。

Remove the brake plate from front wheel.

5.3.2 Check

Check whether the friction piece of front fluid brake is worn，

Replace the shoe when necessary.

Measure the thickness of friction piece of front fluid brake，

Measure the front brake disc and write down the maximum value

Specification:

QJ50QT-22D Dia. O front brake plate φ220mm

Thickness of front brake plate 4.0mm

Thickness of friction piece of front fluid brake 4.0mm

*Note

• Use inside micrometer or caliper only to measure.

Measure the thickness of friction piece of front fluid brake

If the thickness of the brake disc and friction piece is smaller

than the maintenance value or polluted by oil, they should be

replaced.

Available limits

Friction piece of front liquid brake 3.0mm

Front brake plate 3.0mm

Note:

The friction piece of front liquid brake shall be replaced in

pair.

The brake plate can be measured on the motorcycle without being dismantled.

5.3.3 Installation

Install the front brake plate and front wheel components.

Install the friction piece of front liquid brake.

Install the tube assembly and brake cylinder assembly of front brake.

Install the oil pump component and switch component.

The friction piece of front liquid brake and brake plate shall not be polluted by oil stains.

*Note

Any oil stains in the friction piece of front liquid brake may

reduce the performance of brake

Tighten the nuts and bolts according to their torque force

value.

Torque value:

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Installing bolt of front liquid brake: 5-9 N·m

Don’t let oil stains pollute the friction piece of front liquid brake.

If the friction piece of front liquid brake is polluted by oil stains, you should use special cleaner to clean it up.

*Note

Any oil stains in the friction piece of front liquid brake may reduce the performance of brake.

5. 4 Rear drum brake

5.4.1 Remove

Remove the muffle.

Remove the set bolt (3) of rear wheel.

Remove the rear wheel assembly.

Remove the brake pad component (7).

*Note

• Brake shoe replacement.

• Mark the replaced shoe for the next use

Remove the following parts from the rear wheel

Rear brake:

1.Bolt M6X30（10） 7. Brake pad part（4）

2.Rear brake rocker part（11）8. Brake pad spring（5）

3. Nut M6（12） 9. Vacuum tyre 80/80-16（1）

4. Rear wheel component16×1.85（2）

5. Set nut of rear wheel（3）

6. Camshaft of rear brake（8）

Note: See Fig. P77 for details

5.4.2 Check

Check if the brake drum and brake pad are worn.

Replacement shall be made if necessary.

Measure the thickness of friction piece of brake pad.

Measure the inner diameter of brake drum and write down

the maximum value.

*Note

•一 Use micrometer only to measure.

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Measure the inner diameter of brake drum, as well as friction piece of brake shoe.

If the thickness of the brake shoe is smaller than the maintenance value or polluted by oil, they should be replaced.

Note: the brake shoes shall be replaced in pairs.

Inner diameter of rear brake drum φ140mm

Thickness of friction piece in rear brake shoe 4.0mm

Available limit:

Inner diameter of brake drum φ141mm

Friction piece of brake shoe 3.0mm

5.4.3 Installation

Install the brake shoe component.

Install the rear wheel component.

Install the muffle.

* Note

Any oil stains in the friction piece of brake shoe may reduce

the performance of brake.

Tighten the nuts and bolts according to their torque force

value.

Torque value:

Set nut of rear wheel: 100-113N·m

Don’t let oil stains pollute the friction piece of brake shoe.

If the friction piece of brake shoes polluted by oil stains, you

should use special cleaner to clean it up.

Rear brake:

1. Bolt M6X30（10） 7.Brake shoe component（4）

2.Rear brake rocker party（11）8. Brake shoe spring（5）

3. NutM6（12） 9. Vacuum 80/80-16（1）

4. Rear wheel component 16×1.85（2）

5.Set bolt of rear wheel（3）

6. Camshaft of rear brake（8）

*Note

Any oil satins in the friction piece of brake shoe may reduce the performance of brake.

Note: See Fig. P77 for details

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Body Panel

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1Soket head cap screw M8×25 2 gasket 8 3 bolt M8×25 4 rubber cover 5 rear rack assembly 6 cushion assembly 7 headlamp 8 instrument decorative part 9 front handle bar shield 10 rear handle bar shield 11

bolt M6×25 12 gasket Φ6 13 odometer wire clip 14 front mudguard 15 rubber pedal 16 self tapping

screw ST4.2×13 17 gasket Φ5 18 battery cover 19 battery 20 bolt M6×14 21 Black bird crystal 22

Label base 23 Front shield panel 24 Bolt M6×12 25 Bolt M6×16 26 Helmet hook 27 Rear cover of

front box 28 Reinforced board for rear cover of front box 29 Foot protective board 30 lower junction plate I

31 Left decorative plate of front cover 32 Right decorative plate of front cover 33 taillight 34 rear left turn

signal lamp 35 rear right turn signal lamp 36 left decorative part of fender 37 right decorative part of fender

38 left fender 39 right fender 40 front left fender 41 front left fender 42 spark plug cover 43 rear

mudguard 44 rear mudguard rack part 45 bracket for rear license plate 46 reinforced part of rear mudguard

*Note

Do not damage the body

when removing.

Do not damage the hook of

the body.

Do match the grooves for

the panels.

Correctly install the hooks

of each part.

Do not damage the

accessories while installing.

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47 rear mudguard 48 lower junction plate II 49 panel 50 secondary rear mudguard 51 upper cover of front

shield

6. Body panel

Follows the sequence below to tear down the body

Instrument decorative part → Front shield of handle bar → Rear shield of handle bar

→ Front lamp → Cushion assembly → Rear rack assembly → Rear left signal lamp

→ Rear right signal lamp → Taillight → Left decorative part of fender → Right

decorative part of fender → Rubber pedal → Battery cover → Battery → Helmet

hook →Rear cover of front box→ Reinforced board for rear cover of front box→Foot

protective board→ Left decorative plate of front cover→ Right decorative plate of

front cover→ lower junction plate I→ lower junction plate II → Front shield panel →

Front mudguard → Front left fender → Front right fender → Left fender → Right

fender → Spark plug cover →bracket for rear license plate →Reinforced part of rear

mudguard → rear mudguard → bracket part of secondary rear mudguard → Rear

secondary mudguard → Rear mudguard

*Note

Do not damage the body when removing.

Do not damage the hook of the body.

Do match the grooves for the panels.

Correctly install the hooks of each part.

Do not damage the accessories while installing.

Page 96

Front wheel

Front wheel tyre specification: Outer tyre 80/80-16

Item 12(front axle)mounting torque force: 55-62

N·m

Rim tilt limit: Vertical: 2.0mm Horizontal: 2.0mm

Front wheel axle bend limit:

0.2mm

Front outer tyre certificate No.: E11 75R-001062

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1 front rim 16×1.6 2 vacuum tyre 80/80-16 3 front outer bushing 4 front axle oil seal 5 bearing 6201-2RS

6 screw M6×20 7 front brake disc 8 valve cap 9 valve 10 front wheel middle bushing 11 pinion stand

assembly 12 front wheel axle M12×1.5×153.7

Front suspension

Bolt 3 mounting torque

force:22-29

N·m

Bolt 6 mounting torque

force: 37-44

N·m

Ball upper quantity: 21

pcs

Ball lower quantity: 21

pcs

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1 lower connection board welding assembly 2 front left shock absorber assembly 3 bolt M8×30 4socket

head screw M6×20 5 front right shock absorber assembly 6 bolt M10×1.25×30 7 lower bearing lower

steel bow 8 steel ball assembly 9 upper bearing lower steel bowl 10 upper bearing upper steel bowl

11 gasket 12 compression nut

Steering handle

Bolt 9 (steering handle

standing bolt) mounting torque

force: 40-60

N·m

Front brake handle free travel:

10-20mm

Rear brake handle free travel:

10-20mm

Throttle operation handle(fig

3) free travel: 5-10mm

Rearview mirror 4 、 5

ce r t i f i ca t e No . : E3 001002

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1 steering handle welding assembly 2 left handle gloves 3 left nut 4 left rearview mirror assembly 5 right

rearview mirror assembly 6 right nut 7 right handle assembly 8 throttle line assembly 9 bolt

M10X1.25X50 10 handle stand compression block 11 nut M10X1.25 12 left rocker arm support 13 rear

brake cable assembly 14 pin 12 X22 15 regulating nut CM6-12X15 16 rear brake spring 17 cable clamp

assembly 18 front brake switch assembly

7.Front wheel/front suspension

Preparation documents-------------------------7.1

Failure diagnosis-------------------------7.2

Front wheel-------------------------7.3

Steering handle---------------------------7.4

Front fork-------------------------7.5

7.1 Preparation documents

Notes

Before removing the front wheel, you should use jack to let it float above the ground and it cannot be rotated.

Pay attention that no oil stains sticking to the brake shoe, brake shoe assembly and brake disc while operating.

Entire motorcycle standards

Measuring position Item

Standard

value(mm)

Available limits(mm)

Front wheel axle Bow 0.2

vertical 2.0

Front wheel

Rim

shimmy

horizontal Within 1.0 2.0

Torque force Tools

Standing bolt for steering handle welding assembly 40-60 N·m bearing replacing bar

Front wheel axle 55-62 N·m standing bolt spanner

Standing bolt of front shock absorber assembly 37-44 N·m

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7.2 Failure diagnosis

7.2.1 Difficulty of steering

The steering handle bearing has problems

Steering handle bearing is damaged

Low gas pressure for the tyre

Gas leakage of tyre

7.2.2 Unsteady steering

Bearing of the steering handle is broken

Not enough tire gas pressure

Bent front fork and front wheel axle

Deformed or tilting front tyre

7.2.3 Shimmy of front wheel

Deformed tyre

Loose front wheel bearing

Bad tyre

7.2.4 Difficulty of rolling wheel

Trouble of the wheel axle, pinion stand or brake

7.2.5 Abnormal noise of front shock absorber

Friction noise of shock absorber guard plate

Loose bolts of absorber parts

7.3 Front wheel

7.3.1 Removal

Attention：

Prop up motorcycle firmly.

Loose brake cylinder assemble to install bolt④.

Remove brake cylinder assembly ②。