Generic Race 50 Service Manual

Service Manual

Holtvej 8-10, Høruphav, 6470 Sydals
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E-mail: [e-mail] · www.scanmi.dk
CVR: 27 73 31 07

November 2010

Race 50

1

User's operation and maintenance manual for

double-wheel motorcycle RACE 50

2

Zhejiang Qianjiang Motorcycle Co., Ltd.

Contents

Contents 2
Preface 4

Documents to be prepared ...................................................................................................................................5

Inspection/adjustment ..........................................................................................................................................6

Inspection and Service of Electrical System 63
I. Battery/ Charging system 67

1.1 Preparation data ...........................................................................................................................................53

1.2 Fault diagnosis.............................................................................................................................................53

1.3 Battery .........................................................................................................................................................71

1.4 Charging system ..........................................................................................................................................72

1.5 Voltage and current regulator....................................................................................................................... 73

1.6 Charge coil of the alternator ........................................................................................................................74

1.7 Disassembly of alternator ............................................................................................................................74

II.

Ignition system 61

2.1 Preparation data ...........................................................................................................................................61

2.2 Fault diagnosis.............................................................................................................................................79

2.3 Ignition system inspection ...........................................................................................................................83

2.4 CDI group .................................................................................................................................................... 84

2.5 Ignition coil..................................................................................................................................................86

2.6 Trigger .........................................................................................................................................................86

III. Startup system 90

3.1 Preparation data ...........................................................................................................................................91

3.2 Fault diagnosis.............................................................................................................................................93

3.3 Start electric machinery ............................................................................................................................... 93

3.4 Start relay..................................................................................................................................................... 96

IV. Bulbs/ switch/instrument 73

4.1 Preparation data ...........................................................................................................................................99

4.2 Fault diagnosis.............................................................................................................................................99

3

4.3 Replace the head light bulb..........................................................................................................................99

4.4 Replace bulb of the front turning light.......................................................................................................100

4.5 Disassembly/replace the bulb of the taillight and rear-right turning light .................................................100

4.6 Instrument..................................................................................................................................................101

4.7 Main switch ...............................................................................................................................................101

4.8 Horn ........................................................................................................................................................... 102

4.9 Handle switch ............................................................................................................................................102

Inspection and Service of Chassis 103
V. Brake 80

5.1 Maintenance instruction............................................................................................................................. 107

5.2 Fault diagnosis...........................................................................................................................................108

5.3 Front hydraulic brake................................................................................................................................. 108

5.4 Rear drum brake ........................................................................................................................................110

VI．Body cover 86
VII. Front wheel/ front suspension 90

7.1 Preparation data ......................................................................................................................................... 119

7.2 Fault diagnosis........................................................................................................................................... 119

7.3 Front wheel ................................................................................................................................................ 120

7.4 Steering bar................................................................................................................................................123

7.5 Front fork...................................................................................................................................................124

VIII. Rear wheel/rear suspension 97

8.1 Preparation data .........................................................................................................................................128

8.2 Fault diagnosis...........................................................................................................................................128

8.3 Real wheel .................................................................................................................................................129

8.4Rear shock absorber.................................................................................................................................... 130

IX. Fuel tank/seat mat 136

9.1 Preparation data .........................................................................................................................................136

9.2 Fault diagnosis...........................................................................................................................................136

9.3 Fuel tank/seat mat......................................................................................................................................137

Inspection and maintenance of engine 139
X. Lubrication system 107

10.1 Preparation data .......................................................................................................................................143

10.2 Fault diagnosis.........................................................................................................................................144

10.3 Oil pump .................................................................................................................................................. 144

XI. Carburetor 111

11.1 Preparation data .......................................................................................................................................149

11.2 Fault diagnosis.........................................................................................................................................150

11.3 Disassembly of carburetor ....................................................................................................................... 150

11.4 Installation & adjustment......................................................................................................................... 155

XII. Cylinder cover 116

12.1 Preparation data .......................................................................................................................................157

12.2 Fault diagnosis.........................................................................................................................................157

12.3 Cylinder head........................................................................................................................................... 157

12.4 Examination on cylinder head .................................................................................................................159

12.5 Cylinder head installation ........................................................................................................................ 159

XIII. Air cylinder/piston 120

4

13.1 Preparation data .......................................................................................................................................162

13.2 Fault diagnosis.........................................................................................................................................163

13.3 Cylinder body ..........................................................................................................................................163

13.4 Piston .......................................................................................................................................................165

13.5 Installation of piston ................................................................................................................................170

XIV. Drive disk/Clutch/Driven Wheel / Foot start mechanism 174

14.1 Preparation data .......................................................................................................................................174

14.2 Fault diagnosis.........................................................................................................................................174

14.3 Left crankcase cover................................................................................................................................ 175

14.4 Drive disk.................................................................................................................................................175

14.5 Clutch/driven wheel................................................................................................................................. 178

14.6 Disassemble the clutch and the driven wheel .......................................................................................... 180

14.7 Installation ...............................................................................................................................................186

14.8 Foot start mechanism...............................................................................................................................186

XV. Decelerator 137

15.1 Preparation data .......................................................................................................................................189

15.2 Fault diagnosis.........................................................................................................................................189

15.3 Gear Case................................................................................................................................................. 189

15.4 Installation ...............................................................................................................................................191

XVI. Crankcase 140

16.1 Preparation data .......................................................................................................................................194

16.2 Fault diagnosis.........................................................................................................................................195

16.3 Crankcase................................................................................................................................................. 195

16.4 Installation ...............................................................................................................................................199

Exhaust emission system inspection and maintenance 144
XVII. Exhaust emission and control system 145

17.1 Warranty of Exhaust emission and control system.................................................................................. 201

17.2 Regular maintenance guideline................................................................................................................ 202

17.3 Mechanical function of the exhaust control system.................................................................................203

17.4 Catalyst converter system ........................................................................................................................205

17.5Countermeasure of idle speed emission exceeding specified value（Two -stroke）................................ 206

5

Preface

This Manual explains the maintenance of Qianjiang RACE 50.

The documents to be prepared are the maintenance manual and all the operations are included in, please read

the manual prior to operation.

Inspection and Adjustment explains the gist of inspection and adjustment; the maintenance of safety of vehicle

and the performance of each part should come into force since regular inspection.

After Chapter I is the explanation of the gist of disassembly, assembly and inspection of engine, entire vehicle

and electric fittings.

There are exploded view, system diagram, maintenance, fault diagnosis and explanation before each chapter.

Notice：

There is no prior individual notification on the alteration of mode or structure of motorcycle and the actual

product shall prevail if there is discrepancy between the photos, pictures or explanation contained in this Manual

and the actual product.

Zhejiang Qianjiang Motorcycle Co., Ltd.

6

Documents to be prepared

General safety Maintenance regulation

Specififcation sheet Troubleshooting

General safety

Carbon monoxide

If the engine must be activated, make sure that the workplace is well ventilated. The engine can not be running in a

confined place.

Attention

The exhaust contains toxic gas, carbon monoxide, which can numb people and may result in death.

The engine should be started in an open area and the exhaust scavenging system should be applied if the engine has

to be started in a closed area.

Gasoline

The operation should be made in a ventilated area and smoking or lighting fires should be strictly forbidden in
working space or the place stored gasoline.

Battery

Battery could give off explosive gases, so, keep it away from incineration area or open flame or where smoking is

permissible. When charging, keep it well-ventilated.

Battery contains sulphuric acid (electrolyte) which could result in burn if contacting your skin or eye, so, wear

protective clothing and faceshield.

-If electrolyte spatters on your skin, use fresh water to flush immediately.

-If electrolyte spatters in your eye, use fresh water to flush for more than 15 minutes and see a doctor

immediately.

Electrolyte is toxic. In case you drink some electrolyte inadvertently, drink a large volume of fresh water, milk and

milk of magnesia (a kind of laxative antiacid) or vegetable oil and see a doctor immediately. Keep it at a place
where is beyond reach of children.

7

Maintenance regulation

As maintaining this vehicle, the instrument of metric system should be applied as possible for the reason that the

application of incorrect instrument may demage this vehicle.

Before dismantling from or frame cover of vehicle to maintain the dirt of parts or external subassembly should be

purged in order to prevent that falling into engine , chasis or braking system.

After dismantling and before measuring attrition value, please
clean parts and purge it with compressor.

The rubber parts will be deteriorated due to aging which is prone to be damaged by solvent or oil and it should be

inspected (if necessary, it should be replaced) before

reinstallation.

Sleeve

8

Loosen the parts with multiple assemblies that should be made

from outside to inside and started from small one.

The complicated assembly, transmission case, for instance, should
be stored according to proper assembly sequence in order to
facilitate the assembly in the future.

9

For the important assembly position, it should be given special

attention before dismantling. The parts out of use should be
replaced before dismantling in time.

The length of bolts to assemblies and frame cover are different

which should be installed in correct position and the bolts may

placed in the hole to find out whether they are suitable if they are
mixed.

For the installation of oil seal, the grease should be filled in oil

seal groove; as installing oil seal, it should check the smoothness
of oil seal whether it will likely damage the oil seal.

For the installation of rubber hose (fuel, vacuum or coolant), the

ends of which should plug into the bottom of the joint in order to

ensure that there is enough space for hose clamp to clamp the

joint. The rubber or plastic soldering cup should restore its

Grove

Clamp

Joint

10

original design position.

As dismantling ball bearing, please use the tool to withstand one

or two (internal and external) bearing runners. If the strength is

only applied onto a rolling ring (no matter internal or external),

the bearing may be damaged as dismantling and has to be

replaced.

In both instances, the bearings will be broken

11

Loose cable is a hidden trouble to electrical safety. After

clamped, check each cable to ensure electrical safety;

It is not allowed to leave any wire clip bending towards

bonding points;

Bind each cable to its designated position;

It is not allowed to lay a cable to end or a sharp corner on

frame;

It is not allowed to lay a cable to end of a bolt or screw;

When laying a cable, keep it away from any heat source or

any place where may bite it when it is moving;

When laying a cable along a handle, avoid it being strained

too tightly or loosely and it can not interfere with any

adjacent part at any turning point;

All cables should be laid smoothly without twist or knot;

Before butt-jointing a connector, check if its sheath has been

damaged and if it is overstretched;

If a cable is at a sharp corner or outer corner, use tape or hose

to protect it;

After a cable is repaired, use tape to bind it securely;

Keep all control cables from bend or twist because dumb
control will result in case any control cable is damaged.

12

Motorcycle Identification

1. The vehicle identification number (VIN) is inscribed at

① on the frame. See Figure 1-1. Identification number:

LBBB9212?????????. On the VIN, the 10

th

digit shows the year

of manufacture and the 11

th

digit shows the code of the

manufacture plant. The anti-refit name plate is stuck inside the

helmet bucket; the frame name plate is riveted to ② on the

frame.

Figure 1-1

2. The engine series number ① is inscribed on the

crankcase housing. See Figure 1-2.

Figure 1-2

Important Notices

1. Please use genuine parts of Qianjiang Motorcycle. Use of the parts that fail the design specifications of

Qianjiang Motorcycle may cause damage to engine.

13

2. During servicing, use metric tools only. Do not interchange a metric bolt, nut or screw and an English system

fastener.

3. During reassembly, replace with new washers, O-rings, cotter pins and locking pieces.

4. When tightening bolts or nuts, tighten the ones with larger diameters or comparatively located at inside first, and

then tighten all bolts or nuts diagonally to specified torques step by step unless described otherwise.

5. Clean the removed parts with washing fluid. Before assembly, lubricate all sliding planes.

6. After assembly, check all parts for proper installation and correct operation.

7. Before measurement, remove dirt and oil; during assembly, add recommended lubricants to oil sites.

8. When engine and driveline require a long-term storage after dismounted, please apply lubricant to surfaces of
parts to prevent rust and dust accumulation.

14

Specific tools

The so-called specific tools refer to those specifically designed for assemble or dismantle of certain

components of the motorcycle. These tools are usually used in specific locations. Appropriate specific tools are

indispensable in the complete and accurate adjustment as well as in the assembly operations. By taking advantage

of specific tools, the components can be safely, reliably and quickly assemble or dismantle, thus enhancing the

work efficiency and saving lots of efforts.

1．tools used for the engine-overhaul

When assembling or dismantling the engine, specifically designed tools should be used for some certain

components to guarantee a smooth dismounting.

The list of specific tools for the assembly and dismantling of engine components and the figure of real objects

can be seen in table 1-1 and table 1-2.

Table 1-1

Name Remarks

Specialized circular wrench

Clutch holder

Flywheel extractor

Spacer gauge

Dismounting tools for bearing

Assembling tools for bearing

Oil-seal dismounting tool

Handle of dismounting tools

Piston pin exhaustion apparatus

Piston ring opening pincer

Heating plug circular wrench

Measure the thickness of clutch

Cylinder diameter tester

Dial dictator

Used for the assembly and dismantle of flywheel

bolt ,figure 1-3

Figure 1-4
Figure 1-5
Figure 1-6
Figure 1-7
Figure 1-8

Figure 1-9
Figure 1-10
Figure 1-11
Figure 1-12
Figure 1-13
Figure 1-14
Figure 1-15

Measure the inner canon of piston pin,Figure 1-16

Successive table 1-2

Figure 1-3 Figure 1-4

15

Figure 1-5 Figure 1-6

Figure 1-7 Figure 1-8

Figure 1-9 Figure 1-10

①Handle

Figure 1-11 Figure 1-12

Thickness gauge (clearance gauge)

16

① opening pincer ② piston

Figure 1-13 Figure 1-14

Figure 1-15 Figure 1-16

2．Tools used for the underpan-overhaul

The list of general tolls and specific tools for the dismounting of underpan components as well as the figure of

real objects can be seen in table 1-17 and table 1-18.

Figure 1-17

Name Remarks

rest wrench

inner hexagon wrench

circular wrench

micrometer

magnetic stand, V-shape block

dial indicator

square caliper

spring clip-ring clipper

whack-type screw drive

front fork oil seal dismounting tools

front part seal element driving-in tools

steering nut wrench

Figure 1-19
Figure 1-20
Figure 1-21
Figure 1-22
Figure 1-23
Figure 1-24
Figure 1-25
Figure 1-26
Figure 1-27
Figure 1-28
Figure 1-29
Figure 1-30

（1）General tools for the underpan-overhaul

Successive table 1-18

17

Figure 1-19 Figure 1-20

Figure 1-21 Figure 1-22

Figure 1-23 Figure 1-24

Figure 1-25 Figure 1-26

Figure 1-27 Figure 1-28

1. Bush-head 2.Shake-handle

3.Ratchet type wrench 4.Connecting-rod

18

（2）Specific tools for underpan-overhaul: front fork seal element driving-in tools

Figure 1-29

（3）Steering nut wrench

Figure 1-30

3．Tools used for electric apparatus components

The list of specific tools for the testing of electric apparatus components, as well as the figure of real objects

can be seen in table 1-31 and table 1-32.

Table 1- 3 1

Name Remarks

universal meter

ignition tester

Figure 1-33

Figure 1-34

Successive table 1-32

Figure 1-33

19

Figure 1-34

20

Specififcation Sheet (RACE 50)

Model RACE 50 Engine Type QJ1E40QMB-4

Full length mm 1820 Fuel type

Unleaded gasoline

（92/95）

Full width mm 695

Number of

cylinders

1

Full height mm 1140

Inside measure

* stroke

40×39.2

Wheelbase mm 1280 Total flow rate 49.2

Front axle 37 Start mode

Start by electricity

Foot start

mechanism

Rear axle 55 Cooling mode Wind-cooling

Vehicle weight kg

(serving quality)

To ta l

92

Outer

cover of

front wheel

120/70-12

Lubrication

Lubricate

separatly

Front rim

3.50×12

Outer

cover of

rear wheel

130/70-12

Air cleaner

3XG

Tyre specification

Rear rim 3.50×12

Petrol capacity 5±0.2L

Clutch type

Dry-centrifugal type

Engine

Carburetor type IIF-45

Transmission Stepless shift

Idling speed -

rpm

1750±100rpm/min

Gearing

Driving mode Belt drive

Maximum

torque

4.3 N.m/5500rpm

Battery

capacity/type

12V-4AH/

dry-charged type

Maximum

torque

2.50kW/6000 rpm

Capacity of

alternator

90W/8000rpm

Compression

ratio

6.9：1

Spark plug

NGK/TORCH，

BR7ES

Perform

ance

Maximum speed 45km/h

Spark plug 0.6-0.7mm

Diameter of

front brake

disk（mm）

φ190mm

Electrical
installation

Ignition mode CDI

Brake

Inner diameter

of rear brake

drum

（mm）

φ110mm

21

RACE 50

22

23

N Y

N Y

Y N

Y N

Troubleshooting

Trouble diagnosis program for engine start failure or difficulty

Engine fails or is difficult to
start

Check ignition

s

y

ste

m

Remove spark plug to check between its
electrodes for carbon connection

Perform spark over test of
s

p

ark plug

Clear carbon deposit

Sparks between electrodes weak or
none at all

Strong blue or purple blue sparks can jump out
from between electrodes

Screw off spark plug cap to perform
s

p

ark over test of ignition coil

Use an ignition timing light to detect if engine
i

g

nition timing is correct

Strong blue sparks can

jump

out

Sparks weak or none at
all

Check spark plug and its cap for
malfunction

Check
supply of
ignition
power

Check
ignition coil
for short
circuit or
open circuit

Check internal
wiring of
ignition system
for short circuit
or open circuit

Check CDI
igniter for
malfunction

Use a cylinder
pressure gauge to
check and measure
com

p

ression

Check
inside of
fuel tank
for
presence
of

Com
press
ion
press
ure
of
cylin

Com
press
ion
press
ure
of
cylin

Fill
gasol
ine

No-contact magneto
i

g

nition system

1. Check ignition power
coil for short circuit or
open circuit

2. Check trigger coil for
short circuit or open
circuit

1. Check CDI igniter for
malfunction

2. Check magneto flywheel
and trigger coil for
looseness

Loosen drain screw
on carburetor to
check if gasoline
flows out from
overflow pipe on
carburetor

24

Y N

Spark plug electrode wet Spark plug electrode dry

Check carburetor for flooding

Drip a little gasoline into cylinder to
perform experimental starting

1. Check between needle
valve and valve seat of
carburetor float for ajar
position caused by foreign
materials

2. Check cone of float
needle valve of carburetor
for steps caused by wear

3. Check for broken
carburetor float

4. Check carburetor float
for insufficient height

Check air cleaner
for clogging

Engine shuts down
in a very short time
after start

Engine can
continue to work
after start

Inside of carburetor
clogged or float
height excessive

Carburetor
starting device
(i.e. starting
richer system)
malfunctioning

1. Check all joints outside
engine for air leak

2. Check for the piston ring
locked in groove or having
insufficient elastic force

3. Check piston ring and
cylinder for wear

1. Check breather on
fuel tank cap for
clogging

2. Check fuel filter and
fuel cock for clogging

3. Check fuel cock for
proper operation

4. Check oil inlet on
carburetor for clogging

5. Check carburetor
float for height excess

Remove spark
plug for
inspection

25

Y N

Y N

Y N

N Y

Y N

Trouble diagnosis program for engine overheat

Engine
overheats

Check for improper method of
o

p

eration and usage

1. Check gasoline for inferior
brand or extended storage

2. Check if engine has ever run at
high speed or worked under
overload during running

Check cooling
s

y

ste

m

Air cooling
en

g

ine

Check radiating fins for sticking mud
and sand or excessive oil stains

Clea
n

Check cooling fan and its
cowl for damage (forced air
cooling engine)

Check and
troublesho

Use an ignition timing
light to detect if engine
ignition timing is
correct

1. Check CDI
igniter for
malfunction

2. Check magneto
flywheel and trigger
coil for looseness

Check for clutch slip

Clutch slips

Refer to
handling of
clutch slip

26

Remove spark plug, observe
color of spark plug insulator
skirt and determine mixture
ratio of combustible mixture
according to various abnormal
situations.

Spark plug insulator skirt
renders black; in addition,
exhaust muffler gives off black
fume or blasts, accelerating
ability is poor or idle speed is
instable and engine is liable to
shutdown when it is running
under medium low speed
(comparatively normal when it is

Spark plug insulator skirt
renders chocolate-

b

rown

Spark plug insulator skirt
renders white; in addition,
intermittent engine stop,
carburetor backfire, or power
lack of engine, etc. occurs
during acceleration.

Combustible
mixture too rich

1. Check air cleaner for clogging

2. Check carburetor starting device
(i.e. starting richer system) for
proper operation

3. Check carburetor float for
insufficient height

Mixture ratio of
combustible mixture
normal

Check exhaust port of
cylinder block and
exhaust muffler for
clogging caused by
excessive carbon
de

p

osit

Check
lubrication
s

y

ste

m

Combustible
mixture too thin

Lubrication system
on 2/4 stroke engine

1. Check fuel cock for
proper operation

2. Check carburetor
float for height excess

3. Check all orifices
and tunnels on
carburetor for clogging

1. Check if volume of engine oil
in crankcase is sufficient

2. Check if viscosity of engine
oil in crankcase is too low or
engine oil is too dirty

3. Check oil filter for clogging

4. Check oil pump for proper
operation

5. Check lubricant ducts for
clogging

27

Y N

Trouble diagnosis program for engine power lack

Engine power lacks

Erect main jiffy stand to enable wheels to be lifted
off

g

round and then rotate them by han

d

Wheels rotate
freel

y

Wheels rotate
dull

y

Check tire

p

ressure

1. Check brake for retard

2. Check wheel bearing for
excessive wear or damage

3. Check for missing or
comparatively short intermediate
spacer of wheel hub

Air pressure
too low

Air pressure
normal

Check tire valve core for air
leak and check for pierced
or cracked tire

Remove spark plug, block its threaded
hole by finger, and then depress start
button or rapidly depress starting lever.

Fingers feel that gas dashes out
making “pow…pow” sounds

Fingers do not feel that gas dashes out

Compression pressure of
c

y

linder normal

Compression pressure of
c

y

linder insufficient

1. Check all joints outside
engine for air leak

2. Check for the piston ring
broken or locked in groove or
having insufficient elastic
force

3. Check piston ring and
cylinder for wear

Start engine, increase throttle opening
slowly and observe for speed change of
engine

Engine speed rises with increase of
throttle o

p

ening

Engine speed can not rise with increase
of throttle o

p

enin

g

Use an ignition timing light to
detect if engine ignition
timing is correct

1. Check for clutch slip

2. Check drive belt for excessive wear

3. Check centrifugal rollers on head
pulley for excessive wear

4. Check cones on driving wheels and
moving friction wheels for excessive
wear or grooves caused by wear

5. Check cones on driven wheels and
moving driven wheels for excessive
wear or grooves caused by wear

6. Check raceway on inner end face of
moving friction wheel for excessive
wear or pits caused by extrusion

1. Check fuel supply system for
unobstructed fuel supply

2. Check carburetor, air cleaner and
exhaust muffler for clogging

3. Check vacuum diaphragm on
plunger valve of carburetor for map
cracking or breakage

4. Check carburetor float for
improper height

1. Check CDI igniter
for malfunction

2. Check magneto
flywheel and trigger
coil for looseness

28

Y N Y N

N Y

Y N

Y

N

Trouble diagnosis program for poor engine idle speed

Engine idle speed is

poor

Engine idle speed
too hi

g

h

Engine idle
s

p

eed disable

d

Engine idle speed
unstable

Check compression

p

ressure of cylinder

Pull carburetor throttle valve
by hand to check if it has been
completely closed

Use an ignition timing
light to detect if engine
ignition timing is correct

Compression pressure
of c

y

linder insufficient

Compression pressure
of c

y

linder normal

1. Check all joints
outside engine for
air leak

2.

5. Check for the
piston ring broken
or locked in groove
or having
insufficient elastic
force

6. Check piston ring
and cylinder for
wear

Readjust idle speed of
carbureto

r

Check for
oversize
idling jet

Check if cable
wire of throttle
control cable
can be pulled
to move
smartly in
cable jacket
and if throttle
valve spring is
too soft

Chec
k for
under
size
clear
ance
betw
een
spark
plug
electr
odes

1. Check CDI
igniter for
malfunction

2. Check magneto
flywheel and
trigger coil for
looseness

Engine idle
speed is
enabled after
ad

j

ustment

Engine idle
speed is still
disabled after
ad

j

ustment

Air adjust
screw on
carburetor or
adjusting screw
on throttle
valve adjusted
improperly

Check idling jet, fuel
way and air way on
carburetor for clogging

Clean and
dred

g

e

Check carburetor float for height
excess

Adjust float
height to
standard value

1. Check insulating body on carburetor for
cracks

2. Check connecting and fixing nut on
carburetor for looseness

3. Check negative pressure pipe of fuel cock
for breakage

4. Check leaf valve for air leak

Adjust
clearance
between
electrodes

Check mixture
ratio of
combustible
mixture

29

Y N

Y N

Y N

Y N

Trouble diagnosis program for excessive fuel consumption

Engine fuel consumption
is excessive

Check for correct method of
o

p

eration and usage

Erect main jiffy stand and rotate
wheels b

y

hand

1. Check if motorcycle has ever run
under overload, at non economical
vehicle speed, or in low gear

2. Check if brand of the gasoline
used is correct

Wheels rotate
dull

y

Wheels rotate
freel

y

1. Check brake for
retard

2. Check wheel
bearing for excessive
wear

3. Check for missing
or comparatively short
intermediate spacer of
wheel hub

Check tire

p

ressure

Air pressure
too low

Air pressure
normal

Inflate until
full as re

q

uire

d

Check fuel tank, fuel cock, oil
delivery pipe, carburetor, etc.
for oil leak

Troubleshoot as
a

pprop

riate

Check mixture ratio of
combustible mixture

Mixture ratio of combustible
mixture normal

Combustible
mixture too rich

Combustible
mixture too thin

Check engine for too high
idle s

peed

1. Check air cleaner for
clogging

2. Check carburetor float for
insufficient height

3. Check for oversize main jet
on carburetor

1. Check inside of
carburetor for clogging

2. Check carburetor float
for height excess

Check and adjust
carbureto

r

Use an ignition timing
light to detect if engine
ignition timing is
correct

Check for clutch
drive belt slip

Check ignition
s

y

ste

m

30

Y N

Y N

Y N

N Y

Y N

Trouble diagnosis program for the malfunction that exhaust muffler on a 2 stroke engine gives off strong

blue-white smoke

Trouble diagnosis program for shift difficulty of transmission

Exhaust muffler on 2 stroke engine gives off
stron

g

blue-white smoke

Check if engine oil level in crankcase exceeds the
u

pp

er scale line marke

d

If crankcase is overfilled with engine
oil, drain redundant engine oil until
engine oil level does not exceed the
u

pp

er scale line.

1. Check cylinder, piston and piston ring
for excessive wear

2. Check for the piston ring having
insufficient elastic force or locked in ring
groove

3. Check if gaps on piston rings stagger
each other

Start engine and then screw off oil
dipstick with engine running under high
speed to check if engine oil filler port
smokes

Transmission shift is
difficult

Start engine and check it for too high idle
s

peed

Readjust

Check for harmonious
o

p

erations during shift

Check for halfway release of
clutch

Improve method of
o

p

eration

Check shift shaft for deformation and shift arm for
deformation or excessive wea

r

1. Check if free stroke of clutch grip
is within 10mm~20mm

2. Check clutch springs for even
elastic force

3. Check gullets on driving and
driven hubs of clutch for saw teeth
caused by wear

4. Check clutch driven disc for
warpage

5. Check clutch operating device
parts for excessive wear

Replace

1. Check inside of cam slot on shift
camshaft for excessive wear or
damage

2. Check shift fork hole for excessive
wear

3. Check shift fork for deformation

4. Check declutch shift shaft for
deformation or excessive wear

31

N Y

N Y

N Y

Y N

Y N

N Y

Trouble diagnosis for trip stop of transmission

Trouble diagnosis program for clutch slip

Clutch slips

Automatic centrifugal dry type
shoe clutch sli

p

s

Check clutch shoe
plate for excessive
wear

Replace clutch shoe as
a set

Clear oil
stains

Check if contact area
percent of clutch shoe
plate and clutch friction
disc is less than 70%

Check contact surface of
clutch friction disc and shoe
plate for excessive wear

Repair or
replace
clutch shoe

Check clutch shoe plate for oil stains

Trip stop of
transmission

Check for the spring of stationary wheel

b

roken or having insufficient elastic

Repl
ace

Disassemble crankcase to check if approach depths of

g

ears are satisfactor

y

Approach depths of

g

ears sufficient

Approach depths of

g

ears insufficient

Check if approach end of cam claw on end face of meshing
gear has been worn to a taper or larger roundness and if groove
on corresponding gear end face has been worn to bell mouth

Check shift fork for excessive
wear or defo

r

mation

Replace

gear

Check spline teeth on main
shaft and countershaft and
spline groove on sliding gear
for excessive wea

r

1. Check shift fork hole and declutch
shift shaft for excessive wear

2. Check for oversize fit clearance
between shift fork pin and cam slot on
shift camshaft

3. Check transmission for proper
installation

Replace
shift for

k

32

N Y

Y N

N Y

Trouble diagnosis program for hydraulic disc brake failure

Trouble diagnosis program for drum brake failure

Hydraulic disc brake
fails

Check brake fluid level in fluid
reservoir of brake master c

y

linde

r

Brake fluid level is below lower
limit line on fluid reservoi

r

Brake fluid level is above lower
limit line on fluid reservoi

r

Refill brake fluid
to upper limit line
on fluid reservoir;
also, check brake
caliper, brake
hose and hose
connector for oil
leak

If you have a sponge-like
feel when operating brake
grip

Residual air
exists in brake
line

Check if brake lining has been
worn to limit mark and if brake
disc is excessively worn

Replace brake
lining and brake
disc

1. Check surface of brake master cylinder piston and that of oil
cylinder wall for excessive wear or damage

2. Check brake master cylinder piston cup for damage, map
cracking and aging.

3. Check brake caliper gasket for damage, map cracking and aging.

4. Check surface of brake caliper piston and that of oil cylinder wall
for excessive wear or damage

Drum brake fails

Check if free stroke of brake grip is within
10mm~20mm or if that of brake pedal is within
20mm~30mm

Readjust

Separate brake rocker arm from cable wire of brake control cable and then

p

ull brake rocker arm by hand to chec

k

Brake rocker arm
rotates smartly but a
resistance is felt
when grasping
brake handle

Brake
rocker
arm
rotates
dully

Arrow on indicator board of
brake cam aligns with or
has exceeded “▽” mark on
brake hub cap

Arrow on indicator board of brake
cam does not align with “▽” mark
on brake hub cap

Cable wire
of brake
control cable
moves dully
in its jacket
when pulled

Movable
part on
brake cam
rusted or
locked by
foreign
material

1. Check arc surface on brake cam for
excessive wear

2. Check brake shoe plate for excessive
wear

3. Check bore of brake hub for
excessive wear

1. Check surface of brake shoe
plate for oil stains

2. Check if contact area percent
of brake shoe plate and brake
hub is less than 70%

33

Y N

Trouble diagnosis program for charge failure of battery

Battery can not

b

e charge

d

Resistance is less
than standard value

Charge coil
shorte

d

Resistance is
infinite

Resistance conforms
to standard value

Charge coil or its
output conductor
opened

Set a multimeter to 0V~20V DC Voltage
range and then measure voltage between
conductor end (generally, red wire or
red/white wire) from connector to battery
and negative.

Circuit from magneto to rectifier
or rectification regulator contacts
poorly or opened

No voltage
dis

play

Voltage display
available

Conductor from
connector to
battery opened

Use an ohm meter to check
and measure rectifier or
rectification regulator for
malfunction

Disconnect bundle conductor of
magneto from connector of complete
vehicle cable and then use an ohm meter
to measure if resistance between output
conductor ends of charge coil conforms
to standard value

Connect bundle conductor of magneto with
connector of complete vehicle cable and
disconnect rectifier or rectification regulator from
connector of com

p

lete vehicle cable

Use an ohm meter to measure resistance between
output conductor ends of charge coil in connector
to see if it corresponds to self-resistance of charge
coil

34

Y N

Y N

Trouble diagnosis program for undercharge of battery

Battery is
underchar

ged

Check if brake lamp
kee

p

s illuminatin

g

Adjust or replace brake
lam

p

switch

Leakage current is less than
s

p

ecified value

Leakage current is greater than
specified value (generally, it is
required that leakage current is not

g

reater than 1mA).

Check charge coil of magneto for
short circuit

Circuit between rectifier,
rectification regulator or battery
and ignition switch shorted

Replace charge
coil

1. Check if electrolyte inside battery is
insufficient

2. Check if density of electrolyte in battery
is too low

3. Check for sulphated or shorted pole

p

late in batter

y

Set ignition switch to “OFF” position, remove negative cable from battery,
connect negative meter pen of an ammeter to negative terminal of battery and
positive meter pen to negative cable, and then detect and measure leakage
current.

35

Ride-on
motorc

y

cle

Sit-on
motorc

y

cle

Y N

Y N

Trouble diagnosis program for rotation failure of starting motor

Electric horn does not
sound or only makes low
sound and turn signal lamp
li

g

ht is di

m

Electric horn can make loud and
clear sound and turn signal lamp
can give off bright light

Battery level is low or conductor
joint connecting battery contacts
poorly

Grasp brake grip (sit-on motorcycle) or set
transmission to neutral position or grasp clutch
grip, and then depress start button.

Starting motor does
not rotate

Turn on ignition switch, depress horn button, or
to

gg

le turn signal lamp switch.

After start button is depressed, engaging sound
of start rela

y

it not heard.

After start button is depressed, engaging sound
of start rela

y

can be heard.

Remove connector of start relay from complete
vehicle cable and then connect positive and
negative of battery with two lead wires of start
relay coil using two conductors.

Short battery terminal on start
relay and starting motor terminal
with a screwdriver or thick
conductor

After connection,
starting motor rotates
normally

After shorted,
starting motor can
rotate normally.

After connection,
starting motor does not
rotate yet and no
engaging sound of
start relay is heard

After shorted,
starting motor
does not rotate

y

et.

Start relay coil
opened or
shorted

Check internal wiring of
electric start control s

y

ste

m

Start relay contact
burned through or
damaged

Disassemble starting motor
and perform the following
checks:

1. Check carbon brush for
excessive wear.

2. Check for the carbon brush
spring broken or having
insufficient elastic force

3. Check armature
commutator for excessive
wear

4. Check armature coil for
open circuit or short circuit

1. Check start button
contact for poor
contact

2. Check rectifier
diode for damage

3. Check neutral
switch for improper
operation

4. Check internal
wiring of electric start
control system for
open circuit or short
circuit

Check start button
contact for poor
contact

Grasp brake grip to check if brake lamp
will come on

Internal contact of brake
lamp switch contacts poorly
or its supporting circuit is
o

p

ene

d

Repair or
replace start
button

Internal wiring of electric
start control system
opened or shorted

36

N Y

Y N

Trouble diagnosis program for weak rotation of starting motor

Turn on ignition switch, depress horn button, or toggle
turn si

g

nal lamp switch.

Electric horn does not
sound or only makes low
sound and turn signal lamp
li

g

ht is dim

Electric horn can make loud and
clear sound and turn signal lamp
can give off bright light

Battery level is low or
conductor joint connecting
battery contacts poorly

Check conductor joint between
start relay and starting motor for
poor contact

Remove connecting conductors of starting motor and
battery from start relay, depress start button, and
then use an ohm meter to measure if resistor between
battery terminal and starting motor terminal on start
relay is conductive when start relay makes engaging
sound.

Check and
troubleshoot

Disassemble starting motor and perform
the following checks:

1. Check carbon brush for excessive
wear

2. Check for the carbon brush spring
broken or having insufficient elastic
force

3. Check surface of armature
commutator for sticking dirt or burn
through and damage

4. Check armature commutator for
excessive wear

Start relay contact
burned through or
damaged

Starting motor
rotates weakl

y

37

Y N

Y N

Trouble diagnosis program for the malfunction that none of illuminating lamps comes on

None of
illuminatin

g

AC power supply
li

g

hting system

DC power supply
li

g

hting syste

m

Disconnect bundle conductor of
magneto from connector of complete
vehicle cable and then use test lamp
method to check if electric power is
output from output conductor of
li

g

hting coil of magneto.

Depress horn button
or toggle turn signal
lamp switch

Tes t lamp
does not

Tes t lamp
comes on

Lighting coil of
magneto or its
output conductor
opened or shorted

Start engine and disconnect
rectification regulator from
connector of complete
vehicle cable

Illuminating
lam

p

comes on

Illuminating
lam

p

does not

Internal short circuit of
rectification re

g

ulator

Disconnect head lamp
unit to check if head
lamp bulb has been

b

urned out

Electric horn makes
loud and clear sound
and turn signal lamp
comes on

Electric horn does
not make sound
and turn signal
lam

p

does not

Power
supply
from

b

attery is

Score and touch positive
and negative of battery
instantly with a
conductor to view status
of sparks

No sparks are

g

enerated

Sparks are

g

enerated

No
electricit

y

in

1. Check for blown
fuse

2. Check for opened
or shorted circuit
between battery and
ignition switch

3. Check ignition
switch for open
circuit or short
circuit

Replace head lamp bulb and check
other illuminating lamp bulbs one
by one for burn-out

Use test lamp method to check
power input conductor of
lighting switch for electric

p

ower output

Short power supply conductor
and output conductor of lighting
switch with a conductor

Circuit between magneto or
ignition switch and lighting
switch opened or shorted

After shorted,
illuminatin

g

lamp

After shorted,
illuminatin

g

lamp does

Internal contact of
lighting switch
contacts poorly

Circuit between lighting
switch and illuminating lamp
opened or shorted

38

N

Y

Trouble diagnosis program for the malfunction that illuminating lamp bulb is liable to burn-out

Illuminating lamp is
liable to burn-out

Turn on ignition switch, depress horn button, or toggle
turn si

g

nal lamp switch.

Electric horn is hoarse
or does not make any
sound and turn signal
lam

p

light is dim

Electric horn can make loud and
clear sound and turn signal lamp
can give off bright light

1. Check conductor joint connecting
battery for poor contact

2. Check if electrolyte inside battery is
insufficient

3. Check if density of electrolyte in
battery is too low

4. Check for sulphated or shorted pole
plate in battery

Disconnect rectification regulator from
connector of complete vehicle cable and
then use an ohm meter to measure if
circuits between lighting and charge
coils of magneto and rectification
re

g

ulator are opene

d

Set a multimeter to 0V~20V DC Voltage
range and then measure voltage between
conductor end (generally, red wire or
red/white wire) from connector to battery
and negative.

On

No voltage
dis

play

Voltage display
available

Conductor from connector to

b

attery opened

Check rectification regulator for
malfunction

39

Y N

Y N

Y N

Y

N

Trouble diagnosis program for weak illuminating lamp light

Illuminating lamp
li

g

ht is di

m

AC power supply
li

g

hting system

DC power supply
li

g

hting syste

m

Disconnect bundle conductor of magneto
from connector of complete vehicle cable
and then use an ohm meter to measure if
resistance between output conductor ends
of lighting coil of magneto is less than
standard value

Turn on ignition switch, depress horn button, or
to

gg

le turn signal lamp switch.

Lighting coil
shorte

d

Start engine and restrict its
speed, disconnect rectification
regulator from connector of
complete vehicle cable, and then
check brightness of illuminating
lam

p

light.

After disconnection,
illuminating lamp
light is set right.

After disconnection, illuminating
lamp light is still comparatively
dim.

Flat voltage of
rectification
regulator too low

Check charge coil and
internal wiring of charging
system of magneto for short
circuit

Electric horn
can make loud
and clear sound
and turn signal
lamp can give
off bright light

Electric horn is hoarse and turn signal
lam

p

light is dim

Battery level runs low or joint
between battery and ignition
switch contacts poorly

Check and
troubleshoot

Disconnect head lamp unit and
then check if head lamp bulb
glass renders black or

y

ellow-green

Check if power of bulb used
in lighting system is
satisfactory

Replace head
lam

p

bulb

1. Check internal contacts of
lighting switch and dimmer
switch for poor contact

2. Check connectors and
ground wires in system for
poor contact

Replace illuminating
lam

p

bulb

40

Y

N

Y

N

Y N

N

Y

Trouble diagnosis program for the malfunction that turn signal lamp does not come on

Turn signal lamp
does not come on

Part of turn signal lamps at
one side does not come on

None of turn signal lamps at
one side comes on

None of turn signal
lam

p

s comes on

Remove turn signal lamp
shade to check turn signal
lamp bulb for burn-out

Repl
ace
turn
signa
l
lamp
bulb

Use a voltmeter
to measure
voltage between
power cord
contact on lamp
holder and

Voltage display
available

No voltage
dis

play

Lamp holder
ground poor
or poor
contact
between turn
signal lamp
bulb and

Power
cord of
lamp
holder
opened

Remove turn signal lamp
shade to check turn
signal lamp bulb for

b

urn-out

Replace
turn signal
lamp bulb

Disconnect connector
of turn signal lamp
switch and then use
an ohm meter to
detect if turn signal
lamp switch is
conductive at

Output
power cord
at
malfunctioni
ng side
opened or
lamp holder

Internal contact
of turn signal
lamp switch
contacts

p

oorl

y

Depress horn button to check operation
of electric horn

Electric horn
can make loud
and clear sound

Electric horn does
not make any
sound or is hoarse

Power supply
from battery is
normal

Battery level runs
low

Remove turn signal lamp
shade to check turn
signal lamp bulb for

b

urn-out

Toggle turn signal lamp switch and
short two terminal lugs on flasher
with a conductor or screwdriver

Replace turn signal
lamp bulb,
meanwhile, check
rectification
regulator for
im

prop

er operation.

After shorted, turn signal lamp
does not come on

y

et.

After shorted, turn signal
lam

p

comes on.

Disconnect connector of turn signal lamp switch and then
short power input conductor of turn signal lamp switch and
power supply conductors of left and right turn signal lamps
res

p

ectively with a conductor

Flasher has

b

een damaged

After shorted, turn
si

g

nal lamp comes on.

After shorted, turn signal
lam

p

does not come on yet.

Internal contact of turn
si

g

nal lamp switch poo

r

Use test lamp method to check power input conductor of turn
si

g

nal lamp switch for power output

Tes t lamp
comes on

Test lamp does
not come on

Power supply conductor of turn
si

g

nal lamp opened or shorte

d

Circuit between ignition switch and
flasher or flasher and turn signal
lamp switch shorted or opened

41

Trouble diagnosis program for the malfunction that electric horn does not sound

Electric horn
does not soun

d

Turn on ignition switch and
toggle turn signal lamp switch
to check operation of turn
si

g

nal lam

p

Turn signal lamp does not come on or
onl

y g

ives off dim light

Turn signal lamp can give
off bri

g

ht light

Battery level runs low or circuit
between battery and ignition
switch opened or shorted

Power supply from

b

attery is normal

Pull off power supply conductor from power line
terminal of electric horn and then score and touch
power supply conductor and ground instantly to
check status of s

p

arks

Sparks are generated
durin

g

scoring and touch

No sparks are generated
durin

g

scoring and touch

Connect power supply conductor of electric horn and
then make non power line terminal (to terminal of
button) of electric horn contact with ground with a
screwdrive

r

Power cord between
ignition switch and
electric horn opened

After contact,
electric horn sounds.

After contact, electric
horn does not sound.

Internal contact of horn button
contacts poorly or conductor
between electric horn and button

b

roken

Adjust volume and tone of electric
horn

After adjustment, electric
horn does not sound

y

et.

After adjustment, electric horn
sound is set ri

g

ht.

Electric horn has been
dama

ged

Electric horn adjusted
im

prop

erly

42

Y N

Y N

Trouble diagnosis program for the malfunction that brake lamp does not come on

Trouble diagnosis program for undercharge of battery

Brake lamp does not
come on

Remove brake lamp shade to check circuit board
of brake lam

p

for burn-out

Replace circuit

b

oard of brake lamp

Short plugs on two terminals or lead wires of brake lamp
switch with a conducto

r

After shorted, brake lamp
does not come on

y

et.

After shorted, brake
lam

p

comes on.

Score and touch power supply conductor
and ground of brake lamp switch with a
screwdriver or conductor to check status of
s

p

arks

Brake lamp switch is
adjusted improperly or its
internal contact contacts

p

oorly

Sparks are generated
durin

g

scoring and touch

No sparks are generated
durin

g

scoring and touch

Conductor between brake lamp switch and brake
lam

p

shorted or opene

d

Power supply conductor between ignition switch and

b

rake lamp switch opened or shorted

Battery is
underchar

ged

Check if brake lamp
kee

p

s illuminatin

g

Adjust or replace brake
lam

p

switch

Leakage current is less than
s

p

ecified value

Leakage current is greater than
specified value (generally, it is
required that leakage current is not

g

reater than 1mA).

Check charge coil of magneto for
short circuit

Circuit between rectifier,
rectification regulator or battery
and ignition switch shorted

Replace charge
coil

1. Check if electrolyte inside battery is
insufficient

2. Check if density of electrolyte in battery
is too low

3. Check for sulphated or shorted pole

p

late in batter

y

Set ignition switch to “OFF” position, remove negative cable from battery,
connect negative meter pen of an ammeter to negative terminal of battery and
positive meter pen to negative cable, and then detect and measure leakage
current.

43

Inspection/adjustment

Preparation of documents Cylinder pressure

Check list of constant maintenance Gear mobile oil

Engine mobile oil/oil filter Changing gear oil

direction column bearing and handle fixing Diving belt

Inspection/adjustment of accelerator's pull wire Front/back brake free displacement

Air cleaner

The liquid volume examination of break fluid

Spark plug Head lamp

Battery Clutch

Carburator Front/rear suspension system

Ignition timing Bolt/nut/fixture

Rim/tyre Tyre specification

Preparation requirement

General

War ning!

•Before starting engine, please confirm whether there is favorable ventilation and do not start engine in a

closed location for that the exhaust gas contains carbon monoxide which may numb or kill people.

•Under certain condition, gasoline is prone to volatilize and explode so that the working place should be
ventilated and kill the engine and should be free from smoking and lighting in the working area or oil storage.

Please do not disconnect battery when you perform overall lineup; otherwise, internal damage of complete
vehicle components may result.

44

45

Specification

Engine

Gyration speed at idle speed

1750±100rpm/min

Spark plug gap

0.6-0.7mm

Spark plug specification

BR7ES (NGK/TORCH)

Carriage

Free stroke of front brake drawbar 10-20mm

Free stroke of rear brake drawbar 10-20mm

Specification Tire pressure

Outer cover of front

wheel

120/70-12

Front rim 3.50×12

145-170kpa

Outer cover of rear wheel

130/70-12

Tire pressure unit：Kpa

RACE 50

Rear rim 3.50×12

170-195kpa

front wheel-axle

clamping nut

100-113 N·m Torque

force

value

rear wheel fixed nut 100-113 N·m

Certification of related components

Sort Name Certification number

Outer cover of front wheel

E11 75R 000210

Tire

Outer cover of rear wheel

E11 75R 000216

Head lamp

E4 0012026

Tail lamp

E11 000054

Light fitting

Front turn signal lamp

E3 001024

46

Rear turn signal lamp

E3 001024

Rear-view mirror Rear-view mirror

E3 001002

Horn Horn

E4 000066

Side reflector

E11 020614

Reflector

Rear reflector

E11 020613

Muffler Muffler

EUR02-CAT

47

Check list of constant maintenance

Every

300
KM

Ever

y

1000

KM

Every

3000

KM

Every

6000

KM

Every

12000

KM

Every

14500

KM

Mileage and time

of maintenance

Inspection items

New

motor

cycle

One

mont

h

3

mont

hs

6

mont

hs

A year

15

months

Tools

* Air cleaner I C C R C

General purpose

tool

* Gasoline filter I I R

General purpose

tool

* Oil cleaner C C C

General purpose

tool

Changing engine mobile

oil

R Changed every 1000KM

General purpose

tool

Tire pressure I I I I I I

Pressure meter,

inflator

Battery inspection I I I I I I

Gravimeter,

universal meter

Clearance inspection I I I I I I

General purpose

tool

examination on the

tightness of direction

handle

I I I

General purpose

tool

Shock absorber

inspection

I I I

General purpose

tool

Bolt inspection I I I I I I Torque spanner

Oil leak inspection of gear

case

I I I I I I

General purpose

tool

*

Spark plug inspection or

replacement

I I R R I

General purpose

tool

*

Replacement of gear case

oil

I Changed every 5000KM

General purpose

tool

Lubrication of each part L L Lubrication filler

Muffler I I I I I I

General purpose

tool

* Ignition timing I I I I I I Timing lamp
* Carburator A I A A A A

*

Inspection of idle speed

and exhaust gas

A I A A A A

Tachometer, CO

HC analyser

* Accelerator inspection I I I I I

General purpose

tool

Fuel line inspection I I I I I

General purpose

tool

Lamplight, instruments,

electric installations

I I I I I I

Visual universal

meter

Main rack, side rack I I I

General purpose

tool

Shock absorber I I I I

General purpose

tool

*

Torque force of engine

bolt

I I I I I Torque spanner

48

Pre-inspection

1 Ignition system - maintenance and inspection of ignition malfunction of distinct continuity, engine failed

to start and superheat of afterburning.

2 Carbon laydown purging - purging the carbon laydown in the head of air cylinder, piston head and exhaust

air system when the horsepower is in distinct deficiency.

3 Piston, air cylinder - excessive wear of air cylinder and cylinder smoothness, please replace.

Please be inspected at the dealer in Qianjiang regularly in order to keep motorcycle under its optimized condition.

The said table is based on that the motorcycle runs 1000km per month.

I - inspection, A - adjustment, R - replacement, C - clean, L - lubrication

Remarks:

1. "*" for the project of exhaust emission, according to the provisions of State Environmental Protection
Administration of China, the maintenance should be implemented according to the specifications of the Instruction
Manual of the Company and should not be adjusted or repaired without permission, otherwise the company will
not take any responsibility.

2. If the motorcycle is driven on the sandstone road or under the environment of severe contamination, the times of
purging air filtrator should be increased to prolong the service life.

3. For the motorcycle which is frequently driven at high speed or the milage is large the frequency of maintenance
should be increased.

Engine mobile oil/filtrator

Mobile oil level
*Attention

•The motorcycle of which the mobile oil is to be inspected
should be done on the flat floor.

•After running 2-3 minutes, the engine should be stopped for
2-3 minutes for inspecting mobile oil level.
Inspect mobile oil level.
When the mobile oil level is below the lower limit, please
supplement it up to the upper limit position.

1. Sump module 2. Sump cap module 3. Bolt M6×16

4. Oil sensor module 5. Clip 8

Changing mobile oil

*Attention

Change the mobile oil when the engine is warm for that it is
easy to be effuse.

Kill the engine.
Dismantle the mobile oil drain bolt under the crankcase and
discharge the mobile oil.
When the mobile oil is completely discharged, reinstall the
mobile oil drain bolt and joint washer after cleaning.

Add mobile oil to specified volume.

Check mobile oil leakage; start engine at idle speed for several
minutes.

49

Reinspect mobile oil level.

50

Inspection/adjustmentof accelerator's pull

wire

Check the smoothness of accelerator pull wire.

Examination of the free replacement of accelerator stayguy

Free displacement：5-10mm

The main adjusting position is on the carburator side.
Loosen the fixing nut and adjust by turning adjusting nut.

Air cleaner

Replacement of the filtrator
Remove body fender.
Remove fixing bolt (3) of air cleaner cover.
Remove pipe clip (4).

Remove the air filter.

Dismantle the clamping screw of the cover of air filter.

Take down the upper-cover of the filter.
Dismantle the filter element from the filter.

Check to see if the filter element is polluted or damaged.
If it is polluted or damaged, please replace with new one.

Dismantle the clamp component.
Remove the filter.
Check whether the filtrator is polluted or damaged.
If it is polluted or damaged, please replace with new one.

Changing time

If the motorcycle is frequently driven on bad road or in rain,
it should be replaced early.

Mounting bolt M6x20

51

*Attention

•Please confirm whether the air cleaner is installed as installing air cleaner cover.

52

Spark plug

Dismantle spark plug.

Check the overburning, pollution and carbon laydown of
spark plug.

If there is the said problem, please purge it with cleaner of
spark plug or steel brush.

Inspection of spark plug gap

Clearance：0.6-0.7mm

*Attention

As installing spark plug, pleae install it with hands and tighten by spark-plug socket.

Battery

Dismantle battery

Open the battery-cell lid.
Dismantle the clamping bar components of battery cell.

Dismantle the negative lead of prior to the positive lead.
Take out battery.

War ning!

As dismantling positive pole, the tools should not contact the

carriage in order to avoid short-circuit spark and igniting

gasoline and the battery will be damaged that will be

Spark plug gap

53

extremely dangerous.

The installtion is in the reverse order of dismantling.

War ning!

In order to prevent short circuit, please connect positive pole prior to the negative one.

Please do not disconnect battery when you perform overall lineup; otherwise, internal damage of complete vehicle
components may result.

Inspection of charging state (CCU)

Open the battery-cell lid.

Dismantle the clamping bar components of battery cell.

Remove the negative pole wire first, and then the positive

pole wire.
Take out battery.

Measure the voltage between the battery terminals.

Fully charged: 13.1V

Undercharge：12.3V

*Attention

The inspection of charging state should be made by voltage meter.

Charging

Connecting method:

Connect the positive pole of charger to that of battery.

The negative pole of charge connects to that of battery.

War ning!

•Fire should be strictly prohibited around battery.

•As starting to charge or upon the completion of charge, the

switch of charger should be turned off first in order to

prevent the sparkle of connecting position from explosion

hazard.

•The current time specified on the battery should be the
reference for charging.

Voltmeter

54

*Attention

• If the storage cell is rapidly charged, it can not be used generally except in emergency.

•The voltage should be measured every 30 minutes after charging.

Charging current： standard：0.4 A

Quick：4.0A

Charging period: standard：10 - 15 hours

Quick：30 minutes

Completion of charge: open-circuit voltage: above 12.8V

55

Carburator

Idle adjustment

*Attention

The idle adjustment should be made when the engine is
warm.

It should be conducted after the warm-up of engine.

Start engine and connect the turnmeter of engine.

Adjust the accelerator pull wire and bolt stopper to specifiy

the winding number.

Winding number at idle speed ：1750±100rpm/min

Readjust the idle adjustment bolt (2) when the gyration at idle
speed is instable or there is dificulty of slight acceleration.

Ignition timing

*Attention

Warm up engine for 3~5 minutes.
Shut down engine and connect timing lamp to spark plug
conductor.
*Notice: Please refer to instructions for timing lamp before
any operation.
Remove fender (1).
Start engine and idle it.
Check ignition timing.
If symbol “F” aligns with the mark symbol on right crankcase
cover, it indicates that the ignition timing is correct.
Raise engine speed and check if symbol “F” starts to move.

Idle speed：1750±100rpm/min

Cylinder pressure

It should be made when the engine is warm.
Remove the guard plate of car body.
Dismantle spark plug.
Install cylinder pressure meter.
Full throttle, press "Start" to run motor and measure the
cylinder pressure.

Check the following items if the compression pressure is too
low:
—Cylinder head gasket is damaged
—Damage of piston ring
—Ring wear
—Piston，cylinder , valve wear

Check the combustion chamber and the carbon laydown on the top of pistion if the compression pressure is too

Measure the
cylinder’s pressure

56

high.

57

Gear mobile oil

Inspection
*Attention

Fuel check, let down the middle supporter to be
perpendicular to motorcycle on the flat floor.

Dismantle the inspection bolt of gear oil after stopping

engine.（1）.

The oil level is below the lower limit of bolt hole is good.
Please supplement gear oil when the oil level is too low.
Install the inspection bolt of gear oil.

*Attention

Confirm the airtightness of bolt and whether it is out of clutch and damage.

Changing gear oil

Dismantle the inspection bolt of gear oil.

Dismantle the oil drain bolt（1），the gear oil will effuse.

Install the oil drain bolt.

*Attention

Confirm the airtightness of bolt and whether it is out of clutch and damage.

Supplement gear oil.

Check the oil leak of each position after operation.
Install the inspection bolt of gear oil.

Driving chain

Dismantle the left crankcase lid.

58

Check to see if the driving belt is broken or worn out.
Replace for new products when necessary or periodically.

Free displacement of the front/rear brake

Free displacement of the front brake

Measure the free displacement of the front brake handle at

the tip of the brake handle.

Free displacement: 10-20mm

Free

displacement of the rear brake

Measure the free displacement of the rear brake handle at the

tip of the brake handle.

Free displacement: 10-20mm

59

Examination on the liquid amount of the brake liquid

When braking to its end, check up the oil amount through the

oil lens. If the liquid level of the brake fluid is vertical to or is

lower than the graphic arrow, brake liquid should be injected

in till the ceiling level.

Note:

During the examination, the oil pump body should be parallel
with the surface.

Head lamp

Remove the front cover.

Cut off the switch connecter of the head lamp.
Remove the head lamp.

60

Clutch

Start engine and increase the winding number slowly to

inspect the actuation of clutch and check the clutch block if

the motorcycle does not move or the engine misses.
Replace the new part if necessary.

Front/rear suspension system

Front

Strain the front brake and compress the front shock absorber up

and down to check the actuation.

Check whether the front shock absorber is leak and each part is loosened.

Compress up
and down

61

Rear

Compress the rear shock absorber up and down to check the

actuation.

Check whether each part of the rear shock absorber is

damaged or loosened.

Suspense the rear wheel and swing it to check whether the
engine suspension bush is loosened.

Nut/bolt/fixture

Check whether the bolt, nut and fixture of the motorcycle is
loosened.
If so, please tighten to specified torque force value.

Rim/tyre

Check whether there is crack, nail or other damage of the tyre.
Check the tire pressure.

*Attention

The tire pressure should be measured under cold condition.

Compress up
and down

62

Specified pressure Unit：Kpa

Tyre specification

Outer cover of front wheel

120/70-12

Front rim

3.50×12

Outer cover of rear wheel

130/70-12

RACE 50

Rear rim

3.50×12

Check whether the front wheel spindle is loosened.

Check whether the nuts of rear wheel are loosened.
If so, please tighten to specified torque force value.

Torque force value：front wheel-axle clamping nut 100-113 N·m

rear wheel fixed nut 100-113 N·m

Direction column bearing and handle

fixing

Swing the handle to check and confirm whether the leads are

interfered.

Turn the front wheel and swing the handle freely to confirm.

Check the steering post bearing if the handle is not smooth
and loosened.

Specification

Tire

pressure

Outer cover of

front wheel

120/70-12

Front rim

3.50×12

145-170

Outer cover of

rear wheel

130/70-12

RACE 50

Rear rim

3.50×12

170-195

63

64

Inspection and Service of Electrical System

Table of Torques for Fasteners in Electrical System

Fastening location and name of fastener Tightening torque (N·m)

Starting motor clutch cover bolt

Fixing nut of starting motor clutch cover

Rectifier bolt

Fixing bolt of ignition coil

Fixing nut of flywheel

Body fender bolt

12

95

5.0

9.0

5.0

9.0

65

66

Charging system

67

1. Battery 12V, 4AH 2. Cushion lock module 3. Horn 4. Rectifier 5. Power lock module 6. Igniter

7. Relay 8. Release resistor

68

I. Battery/charging system

Preparation data ----------------------1.1 Fault diagnosis -------------------1.2

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

Voltage and current regulator -------1.5 Charge coil of the alternator ---1.6

Disassembly of alternator -----------1.7

1.1 Preparation data

Matters needing attention in operation
* Note

1. The battery can be charged and discharged over again. If the battery is unused after discharge, the service life
will shorten and the performance will degrade. Generally, performance of the battery used for 2 or 3 years will
degrade. Such battery（capacity declined）may restore its voltage after charging but the voltage will drop off rapidly
when loaded.

2.Surcharge of battery：generally surcharge can be observed from the battery proper. If the battery is cut short
inside, no voltage can be tested at the terminal of the battery or the voltage is very low. Invalidation of the
regulator：the battery will have too high voltage, which may shorten its service life.

3. Long rest of the battery will result in self discharge and the electric capacity will reduce, therefore, it must be
charged every 3 months.

4. Inspect the charging system in accordance with the order stipulated in the fault diagnosis table.

5. If there is electric current passes through an electrical unit, do not disassemble the connector, otherwise,
overtension will occur which can damage the electronic parts inside the voltage regulator. The main switch must
be pushed to "off" before any operation.

6. Maintenance free（dry charged type）battery does not need inspection, replenish of electrolyte solution or
distilled water.

7. Inspect the entire power load.

8. Emergency charging cannot be used except in contingency situations.

9.In emergency charging of the battery，it must be unloaded from the motorcycle before charging.

10. Please do not use liquid type battery when exchanging batterys.

11. A voltage meter must be used when inspecting the charging conditions.

69

Preparation reference

Item Specification

Capacity/ type 12V-4AH/ charge type

Fully charged 13.1V Voltage

（20℃）

Must be charge

12.3V(not work for an hour)

Charging current

Standard：0.4A，Fast：4A

Battery

Charging time

Standard：10-15h，Fast：30m

Capacity 90W/8000rpm

Impedance value of lighting

coil (20)

Between green/red and black 2.0-2.5Ω

Magneto

Impedance value of charge coil

(20)

Between white and black 1.5-2Ω

Typ e

Single-phase half-wave SCR charge; SCR half-wave

short circuit method

14.0V±0.4V/5000rpm Lighting

limit

13.5V/5000rpm

Voltage

regulator

Voltage limit

Charge limit 14.8V±0.4V/5000rpm

Torque value Tools

Rectifier bolt 5.0 N·m Multiple-use fixing spanner

Fixing bolt of high tension coil 9.0 N·m Flywheel dissembler

Flywheel fixed nut 5.0 N·m Testing instrument
Car body guard plate bolt 9.0 N·m Avometer

1.2 Fault diagnosis

No power supply Discontinuous current

Over-discharge of battery Poor wiring contact of battery

Battery wire not connected Poor contact of discharge system

Fuse blown Poor contact or short circuit in lighting system
Bad act of power switch

Low voltage Bad act of charging system

Battery badly charged Poor contact， short line or short circuit of wire terminal

Poor contact Bad act of voltage and current regulator

Bad act of charging system Bad act of alternator

70

Bad act of voltage and current regulator

71

1.3 Battery

1.3.1 Disassembly of the battery

Open the battery-cell lid.
Dismantle the clamping bar components of battery cell.
Disassemble the negative wire and then the positive wire.

Take out the battery.

War ning!

In the disassembly of positive pole the tools mustn't contact

the frame because the short-circuit spark will ignite gasoline
and damage the battery.

Installation is conducted in the reverse order of disassembly.

*Attention

In order to prevent short circuit, connect positive pole first before the negative pole.

Please do not disconnect battery when you perform overall lineup; otherwise, internal damage of complete vehicle
components may result.

Inspect the charging state（open-circuit voltage）.

Open the battery-cell lid. Dismantle the clamping bar components of battery cell.

Remove the joint wire of storage cell.

Measure the voltage between battery terminals.

Fully charged：13.1V

Undercharged ：12.3V （The battery does not work for an hour）

*Attention

Inspection of charging state must be performed with a
voltage meter.

72

1.3.2 Charge

Connecting method：

Connecting the positive pole of charger and the positive pole of
battery.
Connecting the negative pole of charger and the negative pole
of battery.

War ning！

•Keep the battery away from ignition sources.

•Shut off the charger first once charge is started or finished so as to prevent explosion hazard caused by flashes at
the interconnecting part.

•Charge operation must follow the marked time on the battery.

*Attention

•Fast charging cannot be used except in contingency situations.

•Do not measure the voltage until 30 minutes after the charge.

Charging current ：Standard：0.４A

Fast：４.0A

Charging time ： Standard：10-15h

Fast：30m

Charge completed：open-circuit voltage：12.8V or above

1.4 Charging system

1.4.1Short circuit test

Remove the ground wire off the battery, connect the voltmeter between the battery negative pole and ground wire
with the switch at OFF and inspect whether there is short circuit.

*Attention

Connect the positive pole of avometer with the negative pole of battery.

If there is any disorder, please inspect whether the main
switch and main wire are in short circuit condition.

1.4.2 Inspect the charging state

Test with an avometer when the battery is fully charged.
Mount the fully charged battery after the engine warms up.
Connect a voltage meter between the battery terminals.
Connect an amperemeter at the position where two terminals

Avomete

r

73

are disassembled to the main fuse.
Start the engine and measure the clamping voltage and current when the rotation speed gradually increases.

Clamping voltage/rotation speed ：14-15V （2500rpm）

If the clamping voltage exceeds the specified value range,
inspect the voltage regulator.

Inspect the clamping voltage of the lighting system.

*Attention

Set the avometer at the alternating voltage position.

Clamping voltage ：13.1±0.5V/2500rpm

If the clamping voltage exceeds the specified value range, inspect the voltage and current regulator.

1.5 Voltage and current regulator

1.5.1 Inspect the main wire circuit

Disassemble the 4P plug of the voltage and current regulator.

Inspect the conduction between main wire terminals with the

following methods.

Item（wire color） Judging method

between the battery（red）and

body ground

there being battery

voltage

between the ground wire（black）

and body ground

there being wire

between the charge coil（white）

and body ground

there being

resistance in

alternator coil

After checking that the main
wiring end between illuminating
line (green/red) and body ground

(resistor plug; plug of automatic

side starter; remove lighting

switchboard and check in OFF

position) is completely normal.

there being

resistance in

alternator coil

White

（A）

Green/re

d

（L）

Red

（B）

Black

（E）

Multiteste

r

Multitester

+

_

Unit：MΩ

White（A）

0 6.5 19~21

Green/red 1~10 24~25 19~23

74

1.5.2 Inspect the voltage and current

regulator

Check plug of voltage and current regulator for poor contact

and measure impedance values between terminals on voltage
and current regulator body.

*Attention

•The metal area of the avometer prod mustn't be touched by
fingers during inspection.

•Inspect with an avometer. Different avometers will give

different resistance values, and the inspection result is
incorrect.

If the resistance value between terminals is abnormal, the
voltage regulator should be replaced.

1.6 Charge coil of the alternator

*Attention

Inspection of the charge coil of alternator may be conducted
on the engine.

Inspection

Disassemble the 6P joint of alternator.

Measure the resistance value between the white coil of

alternator and the motorcycle frame with an avometer.

Standard value ：1.5-2Ω（20℃）

If the measured value exceeds the standard value, replace the
alternator coil.

1.7 Disassembly of alternator

*Attention

Inspection to lighting coil of magneto can be performed on
engine.

1.7.1 Inspection

Remove 3P joint of magneto.

（L）

Green（B）

10~50 0 19~21

Black（E）

5~15 0 0

Fixing spanner

Cooling fan

Bolt

Flywheel

p

ulle

r

75

Use a multimeter to measure the impedance value between green/red wire on magneto and body ground.

Standard value ：2.0-2.5Ω（20℃）

When the measured value exceeds the standard value, replace the magneto coil.

1.7.2 Disassembly

Disassemble the body guard.

Remove right body fender.
Remove fixing bolts and screws and take off fan cover.

Remove 4 fixing bolts of cooling fan to take the latter off.

Fix the flywheel with a multiple use fixing spanner.

Disassemble the flywheel fixing bolt.

Remove the flywheel with a flywheel puller.

Disassemble the retaining key.

Disassemble the lead connector of the alternator.
Disassemble the alternator stator.

76

1.7.3 Installation

Install magneto stator on engine case.
Connect wire terminals of magneto.

Clean the tapered part of the crankshaft and flywheel.

Install the retaining key of flywheel in the key groove on the

crankshaft and confirm.
Align the flywheel groove with the retaining key of the shaft.

*Attention

Confirm no bolts are on the inner face of the flywheel because
of magnetism of the inner face.

Fix the flywheel with a multiple use fixing spanner and screw

the fixing nut.

Torque value ：9.0 N·m

Install the left body guard.

螺钉

Bolt

Flywheel

Cooling fan

Fan cover

77

Ignition system

78

点火系统

1. Battery 12, 4AH 2. Ignition coil assembly 3. Rectifier 4. Power lock module 5. Igniter 6. Relay 7.
Cushion lock module 8. Horn

Ignition system

79

II.Ignition system

Preparation data ----------------- 2.1 CDI group ----------------------2.4

Fault diagnosis ------------------ 2.2 Ignition coil ------------------- 2.5

Ignition system inspection ----- 2.3 Trigger ------------------------- 2.6

2.1 Preparation data

Matters needing attention in operation

1. Inspect the ignition system in accordance with the order stipulated in the fault diagnosis table.

2. The ignition system is an electronic auto-advance device integrated in the CDI group, therefore the ignition time

needs no adjustment.

3. Inspect the ignition system in accordance with the order stipulated in the fault diagnosis table.

4.Take particular care in disassembly that the CDI group of ignition system should not fall off and drop down or

should not stricken with might（which is the main cause of fault）

5. Bad socket contact is the main cause of the ignition system fault, so inspect whether the joint of each part is in

poor contact or not.

6. Inspect whether the spark plug is utilized at a proper thermal value. Improper spark plug may lead to unsmooth

operation of engine or burn-out of the spark plug.

7. Inspection in the chapter is based on explanation of peak voltage and the judgment whether the resistance value

of ignition coil is OK or not according to records after the inspection.

8. Inspection of the main switch should be performed in accordance with the conduction table.

9. The disassembly of the alternator and stator should be conducted in accordance with the disassembly
explanation.

Preparation reference

Item Standard value

Standard

C5HSA(NGK)

Hard plug

C6HSA(NGK)

Recommended

spark plug

Soft plug C7HSA(NGK)

Spark plug gap 0.6-0.7mm

Primary coil 0.6Ω±10％

With spark plug

cover

5-11KΩ

Resistance
value of
ignition coil

（20）

Secondary coil

Without spark

plug cover

0.5-5.5KΩ

Resistance value of the trigger（20℃） 100-500Ω

Measured peak voltage of ignition coil at one go 95-400V

Trigger voltage Above 1.7V

Voltage of charge coil 95-400V

To ol s

Accessory of peak voltage meter

80

Avometer

81

2.2 Fault diagnosis

No flashover in spark plug

Abnormal circumstance Cause of badness（confirm in order from 1）

ignition
coil

high voltage too low

 The interior resistance is too low and test it with a
designated tester.
The cranking speed is too low.
The tester is disturbed（if the voltage measured for several
times is above standard, then the value is normal）.
 poor contact of ignition system wire
bad act of the ignition coil
bad act of the charge coil（peak voltage test)

no high voltage，off-and-on

high voltage

connecting error in tester
bad act of the main switch
 poor contact of CDI joint
 short circuit or poor contact of CDI ground wire
bad act of charge coil（peak voltage test）
bad act of trigger （peak voltage test）.
 bad act of connector for high voltage wire
bad act of CDI group（when item- is abnormal or when
there is no spark in the sparkplug）

side
voltage

Normal high voltage, no spark

bad act of spark plug or power leak in secondary coil
bad act of ignition coil

no high voltage

The interior resistance is too low. Test it with a designated
tester.
The cranking speed is too low.
The tester is disturbed（if the voltage measured for several
times is above standard, then the value is normal）.
bad act of the charge coil（no abnormality in Item -）

charge coil

no high voltage，off-and-on

high voltage

bad act of the ignition coil
bad act of the charge coil

high voltage too low

The interior resistance is too low and tests it with a
designated tester.
The cranking speed is too low.
The tester is disturbed（if the voltage measured for several
times is above standard, then the value is normal）.
bad act of the charge coil（no abnormality in Item -）

trigger

no high voltage，off-and-on

high voltage

bad act of the ignition coil
bad act of the trigger

82

83

2.3 Ignition system inspection

*Attention

•When there is no spark in the spark plug， inspect whether
the wire or part is loosen or in poor contact and confirm
whether each voltage value is normal.

•Since there are a great many of avometer brands with

different interior resistance, the values tested will differ
accordingly.

Connect the avometer with a high voltage diverter or an
electric meter with input resistance above 10MΩ10CV.

2.3.1 Primary voltage of ignition coil

Replace the spark plug with a good one and connect it with the engine.

*Attention

Correctly connect each circuit before the test.

Normal compression pressure of the air cylinder is

achieved in the test when the spark plug is installed on
the cylinder head.

Connect the wire of ignition coil and connect the primary
coil terminal（black / white） with the diverter at the Ground.
Press the startup electrical machinery or step on the
actuating lever to measure the primary peak voltage of the
ignition coil.

Minimum voltage：95 V or above.

*Attention

The metal area of the avometer prod mustn't be touched
by fingers to prevent electroshock.

Remove the 4P and 2P joint of CDI group, and connect a
High Voltage diverter between the charge coil of the 2P joint
（red / white terminal）to the wire and the 4P joint（black
terminal）.
Press the startup motor or step on the actuating lever to
measure the peak voltage of the charge coil.

万用表

Multimeter

点火线圈

万用表

Multimeter

Ignition coil

Blac

k

CDI Group

Blue/white

84

2.3.2 Trigger

*Attention

Install the spark plug on the air cylinder head and inspect with normal compression pressure.

Remove the 6P joint of CDI group, and connect a peak

voltage diverter between the trigger of 6P joint （blue/white

terminal）to the wire and the 4P joint（black terminal）. Press

the startup electrical machinery or step on the actuating lever
to measure the peak voltage of the trigger.

Connecting method: positive pole connected with blue/white

line, and negative pole connected with black line.

Minimum voltage：1.7V or above.

*Attention

The metal area of the avometer prod mustn't be touched by
fingers to prevent electroshock.

If the peak voltage of the CDI terminal has an abnormal value,

disassemble the right body guard and the alternator joint.

Connect the trigger（blue / white） with the diverter.

•If the tested voltage of CDI is abnormal whereas the tested

voltage at the alternator is normal, poor contact or broken line

can be determined.

•If both are abnormal, bad act of the trigger can be determined. Please refer to inspection of the troubleshooting
table.

2.4 CDI group

2.4.1 System inspection

System inspection.

Disassemble the CDI group and inspect the parts related
with the ignition system at the wire terminal.

蓝/ 白

Ω

白/ 绿

Black

Black/white

Green/white

Dark green

Blue/white

Blac

k

/

red

White/green

Blue/White

85

2.4.2 Inspection

Disassemble the CDI group and inspect whether the joint is
loosen or eroded.

Inspection item Testing terminal Standard value （20）

Main switch red—red/white Conducted when main switch at "

OFF "

Trigger Blue/white—white green 100-500Ω

primary ignition coil black/white—black 0.6Ω±10％

Secondary ignition coil black—spark plug cover（spark

plug not included）

0.5-5.5KΩ

86

2.5 Ignition coil

2.5.1 Disassembly

Disassemble the body guard.
Disassemble the spark plug cover.
Disassemble the primary ignition coil.
Disassemble the ignition coil fixing bolts and unload the
ignition coil.

Installation is conducted in the reverse order of disassembly.

*Attention

The primary coil is installed in accordance with the black/
white wire.

2.5.2 Inspect the primary coil

Measure the resistance between terminals of primary coil.

Standard value ：0.6Ω±10％（20℃）

If the resistance value is within standard value range,

the primary coil is good.

The resistance value "∞" stands for broken line in the coil，so replace with a new product.

2.5.3 Secondary coil

Measure the resistance value between the wire of spark plug
cover (with the spark plug) and the terminal.

Standard value ：5-11KΩ（20℃）

If the resistance value is within standard value range, the
primary coil is good.
The resistance value "∞" stands for broken line in the coil.
Remove the spark plug cover and measure the resistance
value between the primary wire of ignition coil and the
negative terminal.

Standard value ：0.5-5.5KΩ±10％（20℃）

2.6 Trigger

*Attention

Inspection of the trigger can be conducted on the engine.

Inspection

Ω

点火线圈

Ignition line figure

点火线圈

Ω

蓝/ 白

Ω

白/ 绿

Ignition line figure

White/green

Blue/white

87

Disassemble the body guard.
Disassemble the lead connector of the trigger.

88

Measure the resistance value between the blue/white terminal
at the engine side and the body ground.

Standard value ：100-500Ω（20℃）

If the measured value exceeds the standard value, replace the
alternator.

磁电机接口

DJ621- 2. 8× 0. 5

DJ7031- 2. 8- 21

白

黑

绿

/

红

Interface of magnetor

Blac

k

Green/re

d

Blac

k

89

启动示意图

BATTERY

REL AY

BRAKE SWITCHBRAKE SWITCH

STARTER SWITCH

STARTOR MOTOR

Startup system

Startup diagram

90

1. Battery 12V, 4AH 2. Cushion lock module 3. Horn 4. Rectifier 5. Power lock module 6. Igniter

7. Relay 8. Release resistor

91

III. Startup system

Preparation data --------------------------3.1

Fault diagnosis ---------------------------3.2

Start electrical machinery ---------------3.3

Start relay ---------------------------------3.4

3.1 Preparation data

Matters needing attention in operation

Disassembly of the start electrical machinery may be conducted on the engine.
Please refer to disassembly operation in disassembly.

Preparation reference

Item Standard value Allowable limit

Brush length of startup motor

6.2mm 3mm

Liner of startup idler shaft

8.3mm

Outer diameter of startup idler

shaft

7.94mm

Torque value

Bolt in the clutch cover of the startup electrical machinery 12 N·m
Fixing nut in the clutch of the startup electrical machinery 95 N·m

To ol s

Fixing nut spanner
Multiple-use fixing spanner

92

93

3.2 Fault diagnosis

Unable to startup Rotating force of start machinery too weak No revolution in the RE Rotary Engine

•Fuse blown •Power shortage in battery •Bad act of startup clutch

•Power shortage in battery •Poor contact of connecting wire

•Reverse revolution of startup electrical machinery

•Bad acts of main switch •

Gear of the startup machinery jammed with foreign body

•Power shortage in battery

•Bad act of startup clutch

•Bad act of brake switch

•Bad act of start relay

•Poor contact of connecting wire

•Bad act of startup electrical machinery

3.3 Start electric machinery

3.3.1 Disassembly

*Attention

The main switch must be switched to "OFF" before

disassembly of the startup electrical machinery. Dismantle

the bonding strip of the battery and turn on the power supply

to see whether the startup electrical machinery will run so as
to confirm security.

First take down the wire clamp of the startup electrical
machinery dismantle the fixed bolt of starting motor.
Separate the front end cover and the rear one. Remove the starting motor.
Roll up the rubber waterproof jacket and disassemble the joint of startup electrical machinery.

3.3.2 Dismantling

Disassemble the housing bolts, front cover, motor housing
and others.

3.3.3 Inspection

Inspect other spare parts.

If uneven wear, damage or burning is detected on the surface,
replace it with a new one.

The adhesive metal powder between commuator surfaces

Commutator

94

must be cleaned away.
Inspect conduction of contact surfaces between other assemblies.

Confirm the armature shafts between each surface of the
commutator cannot be connected.
Inspect conduction of the housing of startup.

Confirm the terminal and housing of the startup electric
machinery cannot be connected. .
Inspect conduction of the terminal and electric brush.

If there is disorder, replace is with a new one.
Inspect conduction of the brush holder. If there is
conduction, replace is with a new one.
Measure the length of the electric brush.

Allowable limit：3mm(under the value, replace it)

Inspect whether the needle shaft in the front cover is flexible
in rotation and whether it is loosen when pressed in.
If there is disorder, replace is with a new one.
Inspect whether the oil seal is worn out or damaged.

3.3.4 Assembly

Oil seal in the front cover and coating of grease.
Mount the electric brush on the brush holder.
Spread grease on the active parts of the electric brush ends.

Press all brushes in bracket and then install front cover of
electrode.

*Attention

•Take particular care that the contact surface of the electric
brush and armature can not be damaged.

•Take care in case the mounting shaft of the armature should damage the oil seal lip.

Put a new O-ring on front cover.
Install with the boss on motor casing engaging with the recess on front cover.
Screw the housing bolts.

*Attention

When the housing and front cover is assembled together, the

armature is easy to pull up with a magnet attracting the front
cover and can be put together with slight press down by hand.

3.3.5 Installation

Mount the wire of the startup electrical machinery and

Motor casing

O-ring

O-ring

Front cover

95

confirm the soldering cup is installed.

Check the O-ring for damage. If abnormal situation is found, replace it with a new one.
Apply engine oil to the O-ring and then fit it on the starting motor.
Install the wire clamp of the rear brake.

96

3.4 Start relay

3.4.1 Actuation inspection

Disassemble the body guard.

Push the main switch to "ON" and press the startup electrical
machinery with a "click ".
Sound means normal.

No sound： •Inspect voltage of the start relay

•Inspect the earth line of the start relay.

•Inspect actuation of the start relay

3.4.2 Inspect voltage of the start relay

Erect the main stand and measure the voltage between the

earth line of the frame and the negative polar of the
green/yellow line of the starting relay connector.

Push the main switch to "ON" to pick up the brake rod. The
battery voltage should conform to regulations.

If there is no voltage on the starting relay line, inspect the
wire and conduction of the brake switch.

3.4.3 Inspect the earth line of the start

relay

Remove the connector of start relay.

Inspect conduction between the gray line at the lead
connector terminal and the body ground.
When pressing the start button, the gray line of the connector
and the body ground are in good conduction.
If no conduction occurs, inspect the wire and conduction

performance of the start button.

3.4.4 Actuation inspection

Connect the starting relay with the battery and connect the
terminal of startup electric machinery with the avometer.
Connect the fully charged battery between the black line and

green/ yellow line of the relay. At this point, the relay

should give out a "Click" sound and the avometer resistance

Start relay

Green-yellow/line

97

reads "0".

98

Bulbs/ switch/instrument

A

Certification number of head lamp:

E4 0012026

B

Certification number of front turn

signal lamp:

E3 001024

C

Certification number of tail lamp:

E11 000054

D

Certification number of rear turn

signal lamp:

E3 001024

E

Certification number of rear reflector:

E11 020613

99

1. Head lamp 2. Turn signal lamp (FL) 3. Turn signal lamp (RL) 4. Side reflector 5. Turn signal lamp
(RR) 6. Meter 7. Tail lamp 8. Turn signal lamp (FR) 9. Rear reflector

IV. Bulbs/ switch/instrument

Preparation data -------------------------------4.1 Instrument----------------4.6

Fault diagnosis --------------------------------4.2 Main switch --------------4.7

Replace the head light bulb -----------------4.3 Horn-----------------------4.8

Replace bulb of the front turning light-----4.4 Handle switch ------------4.9

Replace the bulb of the taillight ------------4.5

4.1 Preparation data

Matters needing attention in operation

The conduction of switches may be measured after
disassembled from the motorcycle.

4.2 Fault diagnosis

Main switch is pushed to "ON" but the light doesn't work.

•Bad act of the bulb

•Bad act of the switch

•Poor contact of the connector or broken line

4.3 Replace the head light bulb

4.3.1 Disassembly

Dismantle the front cover.

Disassemble the fixing bolts so that the head light could be

disassembled.

Cut off the switch connecter of the head lamp.

Remove the head lamp.

Disassemble the air guide sleeve.

Disassemble the glass sheet on the head light.
Fix the head light and turn the socket clockwise so that the bulb can be removed.

4.3.2 Installation

Install the bulb back to the original position in the reverse order of disassembly.